Filling Machine Sterilization Station Clean Air Supply
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Solution Overview
Problem
The existing filling machines face issues with excessive condensation and evaporation of gaseous sterilizing agents like H2O2 during the sterilization process, leading to corrosion and reduced machine lifetime, as well as delays due to ventilation requirements after machine stops.
Innovation Solution
A filling machine configuration that includes a sterilization station with a clean air supply system, using filtered or sterile air jets directed towards the packaging containers to reduce condensation on the transport system and exterior surfaces, while maintaining a high concentration of sterilizing agent inside the packages, utilizing distribution pipes with outlet holes and baffle plates to create a planar jet of clean air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gaseous sterilizing agent (H2O2) is used to sterilize packages, then sterilization effectiveness is improved, but condensation occurs on transport system and package surfaces leading to corrosion and machine downtime
Solution Approach 1:
A clean air supply system is introduced as an intermediary substance to counteract the harmful condensation effects of H2O2 gas. The clean air flows over the transport system and package surfaces, preventing condensation while allowing the H2O2 sterilization to proceed effectively inside the packages.
Solution Approach 2:
The solution applies different conditions to different locations: H2O2 gas is maintained at high concentration inside the packages for sterilization, while clean air is supplied at the transport system and exterior surfaces to prevent condensation. This local differentiation resolves the contradiction between sterilization effectiveness and corrosion prevention.
2Reliability
If H2O2 gas is supplied for sterilization, then package sterilization is improved, but evaporation occurs from filling machine openings causing safety and hygiene issues
Solution Approach 1:
Clean air acts as a mediator that prevents H2O2 evaporation from filling machine openings. The clean air flow creates a protective atmosphere that contains the sterilizing agent within the packages while preventing its escape through openings, thus eliminating the harmful evaporation effect.
3Object-affected harmful factors
If machine stops for ventilation after sterilization, then H2O2 evaporation and ventilation are improved, but productivity is reduced due to downtime
Solution Approach 1:
The clean air supply operates continuously during the sterilization process, preventing condensation and evaporation issues in real-time. This eliminates the need for stopping the machine for ventilation, allowing continuous operation and maintaining productivity while still achieving effective sterilization.
Solution Approach 2:
Clean air is supplied preliminarily during the sterilization process to prevent condensation and evaporation issues before they occur. This preliminary action eliminates the need for subsequent ventilation stops, ensuring continuous operation and maintaining productivity.
4Object-affected harmful factors
If clean air is supplied to reduce condensation, then corrosion prevention is improved, but device complexity increases due to additional air supply system
Solution Approach 1:
The clean air supply system serves multiple functions: it prevents condensation on the transport system, prevents evaporation from openings, and maintains hygienic conditions throughout the filling machine. This multi-functionality justifies the added complexity by providing comprehensive protection against multiple harmful effects simultaneously.
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 solution effectively reduces undesired condensation and evaporation of sterilizing agents, minimizing corrosion risks and machine downtime, while ensuring thorough sterilization and maintaining hygienic conditions within the filling machine.
Implementation Method 1
As the condensed film is slowly evaporating along the movement around the entire transport system, emissions of H2O2 will occur from the filling machine openings
Implementation Method 2
the dew point of the H2O2 gas needs to be very high to secure condensation of the H2O2 on the entire inside surface of the ready-to-fill package
Data Source
AI summary
A filling machine configured to form, fill, and seal individual packages is provided. The filling machine comprises a sterilization station configured to provide a flow of gaseous sterilizing agent towards open ends of ready-to-fill packaging containers passing through said sterilization station. The filling machine comprises at least one clean air supply and at least one baffle plate arranged above the at least one clean air supply, wherein the air supply is configured to direct a stream of clean air towards the ready-to-fill packaging containers. The clean air supply in turn comprises at least one distribution pipe and wherein the distribution pipe extends in a horizontal direction, the horizontal direction being in the direction of the flow of packages through the filling machine.