Filling Machine Conveyor Belt Cleaning for Aseptic Production
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Solution Overview
Problem
Existing filling machines require time-consuming and expensive cleaning of conveyor belts due to the need for maintaining sterile conditions, particularly when filling food products, which disrupts production and increases operational costs.
Innovation Solution
A cleaning station is integrated into the return section of the conveyor belts within the filling machine to clean and sterilize the belts using a cleaning fluid, ensuring minimal disruption to the production process and maintaining aseptic conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conveyor belts are cleaned manually or stopped for cleaning, then sterility of the aseptic zone is maintained, but production downtime increases and operational costs rise
Solution Approach 1:
The cleaning station is positioned in the return section to perform cleaning actions before the conveyor belts re-enter the aseptic zone. This preliminary cleaning ensures that any contaminants are removed in advance, maintaining sterility without requiring interruption of the filling operation. The conveyor belts are cleaned while still in motion during their return journey.
Solution Approach 2:
A cleaning fluid is introduced as an intermediary substance to facilitate the cleaning process. The cleaning fluid is applied to the conveyor belts in the return section through cleaning nozzles, allowing effective cleaning to occur without direct human intervention in the aseptic zone and without stopping production. The fluid acts as a mediator between the cleaning requirement and the continuous operation requirement.
2Ease of manufacture
If cleaning station is added to the filling machine, then conveyor belts can be cleaned efficiently, but machine footprint expands
Solution Approach 1:
The cleaning function is integrated into the vertical dimension by positioning the cleaning station above or below the return section, utilizing the vertical space within the existing machine envelope. The cleaning nozzles are arranged to spray downward or upward onto the conveyor belts as they pass through the return section, adding cleaning capability without extending the horizontal footprint of the machine.
Solution Approach 2:
The return section of the conveyor belt system serves multiple functions: it returns the belts to the transport section, provides a pathway for cleaning operations, and maintains separation between clean and dirty sides of the belts. By making the return section multi-functional, the design avoids adding separate dedicated cleaning infrastructure that would increase footprint.
3Ease of manufacture
If cleaning is performed in the transport section, then conveyor belts are cleaned, but package bodies may be contaminated by cleaning fluid
Solution Approach 1:
The cleaning operation is extracted from the transport section and relocated to the return section. This separation removes the harmful cleaning fluid application away from the package bodies that are being transported through the aseptic zone. The cleaning function is isolated to a specific area (return section) where it cannot interfere with the filled packages.
Solution Approach 2:
The conveyor belt system is segmented into distinct functional zones: a transport section for moving package bodies through the aseptic zone, and a return section for belt circulation and cleaning. This segmentation allows independent operation of cleaning and transport functions, enabling cleaning to occur without affecting package body sterility while maintaining clear functional separation between clean and dirty areas.
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 allows for efficient and cost-effective cleaning of conveyor belts without significantly expanding the machine's footprint, ensuring continuous operation and maintaining the sterility of the aseptic zone, thereby reducing downtime and operational costs.
Implementation Method 1
A cleaning station is integrated into the return section of the conveyor belts within the filling machine to clean and sterilize the belts using a cleaning fluid
Data Source
Figure 1A~1B
Figure 1C
Figure 1D~1E
AI summary
Described and shown is a filling machine (20) for filling package bodies (12) open on one side with products, the filling machine (20) having a filling station (35) for filling the package bodies (12) open on one side, a head closure station (37) for closing the head of the filled package bodies (12) open on one side and a transport device (26) for transporting at least the package bodies (12) open on one side at least from the filling station (35) to the head closure station (37) through the filling machine (20), wherein the transport device (26) has at least one pair of conveyor belts (27) for holding the package bodies (12) on opposite side walls and for moving the package bodies (12) in a transport direction (T), wherein the conveyor belts (27) have, between at least two pulleys (44) for deflecting the conveyor belts (27), an at least substantially straight transport section (45) for transporting the package bodies (12) and an at least substantially straight return section (47) for returning the conveyor belts (27) aligned at least substantially parallel to the transport section (45). In order to simplify the method and the design without having to accept functional limitations is provided that a cleaning station (52) for cleaning the conveyor belts (27) with a cleaning fluid is assigned to the transport section (45) and/or the return section (47) of the conveyor belts (27).