Beverage Filling Device Emergency Pulse Flushing
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Solution Overview
Problem
Existing methods for filling glass bottles with oxygen-sensitive beverages in beverage bottling plants are hindered by the reliance on vacuum pumps for negative pressure, leading to production interruptions when pumps fail, as they require sufficient negative pressure for normal operation.
Innovation Solution
A method and device that determine the parameter of negative pressure in the container, allowing for either normal operation flushing or emergency operation pulse flushing, ensuring continuous filling even with reduced negative pressure by adjusting the flushing protocol based on the parameter, which includes the vacuum pump's status, power consumption, and actual pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum pumps are used to provide negative pressure for container evacuation, then oxygen removal efficiency is improved, but production continuity deteriorates when pumps fail
Solution Approach 1:
The system dynamically adjusts the flushing mode based on real-time vacuum degree monitoring. When vacuum pumps are functioning normally, the system operates in normal evacuation mode for efficient oxygen removal. When vacuum degree drops below threshold indicating pump failure, the system automatically switches to emergency pulse flushing mode, maintaining production continuity without manual intervention.
Solution Approach 2:
The control unit continuously monitors the vacuum degree parameter and uses this feedback to determine the appropriate flushing operation mode. This closed-loop control ensures that the system responds appropriately to changing vacuum conditions, automatically selecting normal or emergency flushing based on actual pump performance rather than requiring manual assessment.
2Manufacturing precision
If normal evacuation procedure is used, then filling quality is improved, but production stoppage occurs when vacuum pump fails
Solution Approach 1:
The system provides two distinct evacuation procedures that can be dynamically selected: normal evacuation for high-quality filling when pumps are functional, and emergency pulse flushing when pump failure occurs. The control unit automatically selects the appropriate procedure based on monitored vacuum degree, ensuring both filling quality and production continuity are maintained under different operating conditions.
Solution Approach 2:
The system changes operational parameters (flushing mode, pulse timing, gas flow rates) based on vacuum degree conditions. Normal evacuation uses continuous vacuum application with standard flushing parameters, while emergency pulse flushing uses pulsed gas introduction with adjusted timing and flow rates, allowing the system to adapt to degraded vacuum conditions while maintaining acceptable filling quality.
3Reliability
If multiple evacuation and rinsing loops are performed, then residual oxygen content is reduced, but processing time increases
Solution Approach 1:
The emergency pulse flushing mode employs periodic gas pulses instead of continuous flushing. The control unit introduces purge gas in multiple discrete pulses with specific timing intervals, achieving effective oxygen removal through repeated exposure cycles. This periodic action is more time-efficient than traditional multiple evacuation-rinsing loops while maintaining oxygen removal effectiveness under emergency conditions.
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
Enables uninterrupted filling operations by switching to emergency pulse flushing when normal operation negative pressure is insufficient, effectively reducing residual oxygen content through controlled flushing gas pulses, thereby minimizing production losses due to vacuum pump failures.
Implementation Method 1
initiating a vacuum in the interior of the container
Implementation Method 2
purge the interior of the container with a purge gas
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a method for filling a container (4) with a filling product (20), preferably for filling a glass bottle with an oxygen-sensitive beverage in a beverage filling plant, comprising sealingly connecting a filling element to the interior of the container (4) to be filled, and initiating a vacuum in the interior of the container (4), wherein a parameter quantifying the vacuum in the container (4) to be filled is determined, wherein, depending on the determined parameter, either a normal operation flush of the interior of the container (4) or an emergency operation pulse flush of the interior of the container (4) is carried out; and a device designed for carrying out the aforementioned method.