Filling Element Distribution Device for Beverage Plants
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Solution Overview
Problem
In beverage bottling plants, highly viscous or particle-like components in filling products tend to settle in product tanks and filling valves during system downtime, leading to uncontrolled filling and product loss when the system is restarted, resulting in contamination and equipment issues.
Innovation Solution
A device with a distribution device that introduces a distribution medium into the product storage section to mix the filling product, preventing phase separation and ensuring components remain suspended, using a carrier medium such as water or gas to maintain a well-defined filling jet and minimize product loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the plant operates for prolonged periods, then productivity is improved, but phase separation occurs in the filling valves leading to uncontrolled filling
Solution Approach 1:
The distribution device is activated before filling operations resume after a pause, performing preliminary mixing action to prevent phase separation from occurring in the first place. This anticipatory measure ensures that when filling restarts, the product in the filling valves remains homogeneous and controllable.
Solution Approach 2:
A distribution medium (gas or liquid) is introduced as an intermediary substance to mix the filling product in the holding section. This intermediary agent disrupts the settled layers and redistributes the product components, preventing phase separation without requiring direct mechanical intervention in the filling valve.
2Productivity
If the filling valve is opened after prolonged shutdown, then filling operation resumes, but product splashing and uncontrolled filling jet occur
Solution Approach 1:
Mixing action is performed in advance through the distribution device before the filling valve is opened. This preliminary homogenization prevents the formation of settled layers that would otherwise cause splashing and uncontrolled filling jets when the valve opens, ensuring smooth product flow from the start of the filling operation.
Solution Approach 2:
The distribution device applies a counteracting mixing force to prevent the harmful settling effect that would otherwise lead to splashing. By actively disrupting the separation of product components before filling begins, the system counteracts the gravitational settling that causes the harmful splashing phenomenon.
3Reliability
If product is directed into isolator after interruption, then filling valve is cleared, but significant product loss occurs
Solution Approach 1:
A distribution medium serves as an intermediary to mix and clear the filling valve without requiring product disposal. The gas or liquid medium flows through the holding section, disrupting settled layers and clearing the valve internally, thereby maintaining valve reliability while preserving the filling product for use.
Solution Approach 2:
The distribution device enables the filling system to self-clear the valve using a distributed medium rather than requiring external intervention or product disposal. The system uses the distribution medium to perform the cleaning function that would otherwise require discarding product into the isolator.
4Stability of the object's composition
If product circulation is created in product tank, then settling is prevented, but filling valves remain affected during shutdown
Solution Approach 1:
The mixing function is segmented into two distinct zones: the product tank with its circulation system for bulk suspension, and the filling valve holding section with the distribution device for localized mixing. This segmentation allows each zone to be optimized independently, ensuring both tank stability and valve reliability during shutdown periods.
Solution Approach 2:
The distribution device provides localized mixing quality specifically in the filling valve holding section, where phase separation would directly impact filling operation. While the tank circulation maintains general product suspension, the distribution device ensures homogeneous product distribution at the critical filling point, addressing the specific local quality requirement.
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 solution effectively prevents phase separation in filling elements, ensuring a clean and controlled filling process, reducing product loss and equipment contamination, and improving the reliability and efficiency of the filling process.
Implementation Method 1
The distribution device is configured to introduce a distribution medium into the filling element via the distribution inlet in such a way that the product in the product holding section is thoroughly mixed
Data Source
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AI summary
Device (1) and method for filling a container with a filling product, preferably in a beverage filling plant, wherein the device (1) comprises: at least one filling element (20) with a product line (22) and a product holding section (23) in fluid communication with the product line (22), in which at least a part of the filling product that can be supplied via the product line (22) can be received, wherein the filling element (20) is configured to introduce the filling product from the product holding section (23) into the container; and a distribution device (200) with a distribution inlet (201) that is in fluid communication with the product holding section (23), wherein the distribution device (200) is configured to introduce a distribution medium via the distribution inlet (201) into the filling element (20) in such a way that the filling product is mixed in the product holding section (23).