Aseptic Filling Device Deodorization via Steam Condensation
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Solution Overview
Problem
The filling device in aseptic filling systems has a complex shape and large liquid contact area, leading to residual smells from previous liquid products contaminating new products, and existing CIP techniques are inefficient in deodorization, either extending downtime or using strong agents that can damage rubber packings.
Innovation Solution
A purifying method using steam for deodorization, where steam is supplied to the filling device to desorb residual liquid and smells, which are then discharged, followed by a sterilization step with steam, and a preliminary cleaning solution is used to eliminate cleaning agent odors, allowing for simultaneous deodorization and sterilization without additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the CIP technique is extended to improve deodorization, then the smell removal effect is improved, but the manufacturing efficiency deteriorates due to extended downtime
Solution Approach 1:
The patent changes the parameter of the cleaning solution by adjusting its temperature to optimize deodorization effectiveness. By controlling the temperature parameter of the cleaning solution during the CIP process, the system achieves better smell removal without extending the cleaning time, thus maintaining manufacturing efficiency.
Solution Approach 2:
The patent utilizes phase transition of water by incorporating a steam blowing step before the CIP process. The steam (gas phase) condenses on the filling device surfaces (liquid phase), effectively removing residual liquid products and odors. This phase transition enhances deodorization efficiency, allowing shorter CIP cycles and maintaining productivity.
2Object-generated harmful factors
If strong cleaning agents are used to improve deodorization, then the smell removal effect is improved, but the rubber packings deteriorate due to chemical damage
Solution Approach 1:
The patent replaces chemical cleaning agents with a physical cleaning mechanism using steam blowing followed by water-based CIP. The steam and water physically remove residual liquid products through condensation and flushing, eliminating the need for strong chemical agents that would damage rubber packings while still achieving effective deodorization.
Solution Approach 2:
The patent introduces steam as an intermediary substance between the residual liquid products and the cleaning process. The steam condenses on the filling device surfaces, carrying away odor-causing residues without requiring direct contact with harsh chemicals, thus protecting rubber packings while achieving deodorization.
3Object-generated harmful factors
If the CIP process time is extended to improve deodorization, then the smell removal effect is improved, but the cleaning cost increases due to longer operation time
Solution Approach 1:
The patent performs a preliminary steam blowing action before the main CIP process. This preliminary step pre-cleans the filling device surfaces by condensing steam that carries away residual liquid products and odors. As a result, the subsequent CIP process requires less time to achieve complete deodorization, reducing both time loss and operational costs.
Solution Approach 2:
The patent creates a continuous cleaning action by combining steam blowing with the CIP process in sequence. The steam blowing continuously removes residues during the transition between liquid products, and the CIP process continues this cleaning action with water flushing. This continuous useful action ensures thorough deodorization without requiring excessive extension of the overall cleaning time.
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
This method effectively reduces deodorization time, maintains manufacturing efficiency, and prevents smell transfer between products, while avoiding damage to rubber packings and reducing the need for separate sterilization methods.
Implementation Method 1
steam for deodorization, where steam is supplied to the filling device to desorb residual liquid and smells
Implementation Method 2
steam is supplied to the filling device to desorb residual liquid and smells, which are then discharged
Implementation Method 3
a portion of the steam will condense within the passage, the smell component will be entrapped in this condensate
Data Source
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AI summary
Provided is a purifying method capable of deodorizing a filling device in a shorter period than the conventional purifying method. The purifying method has a sterilizing step for sterilizing at least a filling device either periodically or each time when a kind of a liquid product to be filled thereby is to be changed in an aseptic filling system having the filling device configured to fill a predetermined unit filling amount of such liquid product in an individual container. The method includes an air supplying step #3 for supplying steam to the filling device which has been emptied of the liquid product, prior to or simultaneously with the sterilizing step #5 and a liquid supplying step #4 for supplying, after the air supplying step #3, a rinsing solution or a new liquid product after product change to the filling device.