Drink Filling Line Cleaning Programs for Faster Product Changeovers
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Solution Overview
Problem
Conventional drink filling systems require extensive and inefficient cleaning and sterilization processes when switching between different types of drinks, leading to prolonged downtime and reduced production efficiency, especially in facilities producing small lots of various products.
Innovation Solution
A method for a drink filling system that selectively executes specific cleaning and sterilization programs based on the type of drink, including CIP, SIP, COP, and SOP treatments, tailored for aseptic carbonated, high acidic, and low acidic drinks, allowing for customized cleaning approaches to reduce unnecessary processes and improve efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all CIP, SIP, COP, and SOP treatments are always performed when changing drink types, then sterilization reliability is improved, but production efficiency deteriorates due to prolonged downtime
Solution Approach 1:
The patent applies parameter changes by adjusting the cleaning and sterilization process parameters based on the specific drink type being produced. Different drink types (carbonated, high acidic, low acidic) have different pH levels and chemical properties, so the cleaning program selectively applies appropriate treatments. For example, high acidic drinks may require different sterilization intensity compared to carbonated drinks, allowing optimization of both reliability and productivity by matching process parameters to product requirements.
Solution Approach 2:
The patent implements dynamics by making the cleaning and sterilization process adaptive rather than static. The system dynamically selects and adjusts cleaning programs based on real-time production requirements and drink type changes. This dynamic approach allows the system to perform only necessary treatments, reducing unnecessary downtime while maintaining required sterilization standards for each specific product type.
2Reliability
If extensive cleaning and sterilization treatments are performed for all drink types, then aseptic condition is improved, but manufacturing time increases
Solution Approach 1:
The patent applies partial action by performing only the necessary cleaning and sterilization treatments required for each specific drink type rather than applying all possible treatments universally. The system assesses the specific requirements of each drink type (carbonated, high acidic, low acidic) and applies appropriate partial treatments, eliminating excessive cleaning steps that would waste time while still maintaining adequate aseptic conditions for product safety.
3Reliability
If multiple cleaning programs are implemented for different drink types, then cleaning effectiveness is improved, but system complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the cleaning and sterilization system into distinct modular programs tailored for different drink types (carbonated, high acidic, low acidic). Each segment handles specific cleaning requirements, making the overall complex system manageable through modular organization. This segmentation allows effective cleaning for each drink type while simplifying control through clear program separation and selection logic.
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 approach allows for the elimination of excessive cleaning processes, reducing manufacturing time and enhancing production efficiency by selecting appropriate cleaning methods for each type of drink, thereby improving overall productivity.
Implementation Method 1
The CIP treatment is performed, for example, by flowing a cleaning liquid prepared with water to which alkaline chemical agent such as caustic soda is added in a flow path from an inside of a pipe line of a drink filling path to a filling nozzle of a filling machine
Implementation Method 2
The SIP treatment is performed, for example, by circulating steam or heated water through the drink filling path cleaned by the CIP treatment mentioned above
Implementation Method 3
The COP treatment is performed, for example, by atomizing water into the aseptic chamber in a state of shower
Implementation Method 4
The SOP treatment is performed in a manner such that hydrogen peroxide water, for example, in a state of mist or shower, is supplied into the aseptic chamber
Implementation Method 5
thereafter, hot air is blasted into the aseptic chamber to thereby dry remaining hydrogen peroxide
Data Source
AI summary
An object of the present invention is to make short a manufacturing time at a time of switching a kind of a filling drink. In a cleaning method of a drink filling system provided with a drink supply pipe line for supplying a drink to a filling machine (2) and an aseptic chamber (3) surrounding at least the filling machine, the cleaning method is performed by executing program including at least two of first, second and third programs, wherein the first program corresponds to an aseptic carbonated drink and executes a COP treatment performed for an interior of the aseptic chamber and a CIP treatment performed for an interior of the drink supply pipe line, the second program corresponds to a high acidic drink and executes the COP treatment and an SOP treatment performed for the interior of the aseptic chamber and a CIP treatment and an SIP treatment performed in the interior of the drink supply pipe line, and the third program corresponds to a low acidic drink and executes the COP treatment and the SOP treatment performed for the interior of the aseptic chamber and the CIP treatment and the SIP treatment performed in the interior of the drink supply pipe line, and wherein either one of the three programs is enabled to be selectively executed, and in a case where the drink is an aseptic carbonated drink, the first program is selected, in a case where the drink is a high acidic drink, the second program is selected, and in a case where the drink is a low acidic drink, the third program is selected, to thereby clean the interiors of the aseptic chamber and the drink supply pipe line before filling of the drink in accordance with the selected program.