Sterilization Filter Unit F-Value Control for Lower Heat Load
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Solution Overview
Problem
Sterilization filter units in aseptic filling machines deteriorate due to high heat exposure from steam or hydrogen peroxide gas, reducing their service life, and there is a need for a method to minimize heat load and extend their lifespan.
Innovation Solution
Implement F-value control for sterilization using heated steam, combined with targeted use of hydrogen peroxide gas, to manage sterilization time and temperature effectively, reducing exposure to high heat and extending the service life of the filter units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sterilization filter unit is sterilized by heated steam or gasified hydrogen peroxide, then sterilization effect is achieved, but resin parts deteriorate due to high heat exposure and service life decreases
Solution Approach 1:
The patent applies F-value control to precisely manage sterilization parameters (temperature and time) by calculating and controlling the integral of log(killing rate) over time. This allows achieving effective sterilization while minimizing heat exposure duration, thereby protecting resin components from thermal deterioration and extending filter unit service life.
Solution Approach 2:
The patent implements feedback control by measuring temperature at multiple locations during sterilization and using these measurements to calculate F-values. The system adjusts sterilization parameters based on actual temperature data to ensure sterilization effectiveness while preventing excessive heat exposure that would damage resin parts.
2Reliability
If sterilization time and temperature are increased to ensure sterilization effectiveness, then sterilization reliability improves, but heat load on resin parts increases and service life decreases
Solution Approach 1:
The patent uses F-value control to optimize the sterilization parameter combination (temperature-time profile) to achieve the minimum necessary sterilization effectiveness. By precisely controlling parameters rather than using excessive values, the system reduces heat load on resin components while maintaining sterilization reliability.
Solution Approach 2:
The patent applies partial action by using F-value control to determine the minimum necessary sterilization exposure. Instead of applying excessive heat and time, the system calculates and applies only the necessary sterilization dose (F-value) to achieve effectiveness, thereby reducing harmful heat exposure on resin parts.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method reduces sterilization time and heat exposure, thereby prolonging the service life of sterilization filter units and maintaining aseptic conditions in aseptic filling machines.
Implementation Method 1
The piping for the compressed aseptic air and the sterilization filter unit are typically sterilized by heated steam
Implementation Method 2
a hydrogen peroxide solution is sprayed and then heated for gasification, and the resulting hydrogen peroxide gas is fed to a sterilization filter unit
Implementation Method 3
hydrogen peroxide is supplied into air piping, and the hydrogen peroxide deposited in the piping is evaporated and fed to a filter by heated air
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
To sterilize a sterilization filter unit with heated steam, minimize the heat load on the sterilization filter unit and extend the service life of the sterilization filter unit. Heated steam is supplied to a sterilization filter unit that sterilizes supplied air, the temperature of the heated steam discharged from the sterilization filter unit is measured at predetermined time intervals, the F value is calculated from the measured temperature, and sterilization of the sterilization filter unit is ended when the F value reaches a target value.