Container Filling Machine Pressure-Regulated Vessel Foam Reduction
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Solution Overview
Problem
Existing methods for filling containers with liquid, such as those using vacuum or pressure-regulated vessels, often result in aerated or foamed liquids, lengthy filling operations, and excessive recirculation, which affect the quality and efficiency of the filling process.
Innovation Solution
A method and machine for filling containers using a pressure-regulated vessel with a filler tube and discharge cannula, where the filling mode transitions from a 'stream' to a 'gravity' mode to minimize recirculation and foam formation, utilizing controlled shutters and vents to manage the flow and pressure equilibrium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If vacuum is used to fill containers, then liquid flows from the filler tube, but the liquid becomes aerated and quality deteriorates
Solution Approach 1:
The harmful vacuum condition is extracted and replaced by atmospheric pressure filling. The system removes the vacuum environment that causes aeration and substitutes it with a controlled atmospheric pressure system where liquid flows under gravity and pressure differential without creating harmful bubbles in the liquid.
Solution Approach 2:
The pressure parameter is changed from negative (vacuum) to positive/controlled atmospheric pressure. This parameter change eliminates the aeration effect while maintaining liquid flow capability through the filler tube.
2Duration of action of stationary object
If recirculation is allowed during filling, then filling continues, but excessive recirculation affects liquid quality
Solution Approach 1:
A feedback control system monitors the filling process and detects when the container reaches the desired fill level. This feedback signal automatically stops the filling operation, preventing excessive recirculation and maintaining liquid quality by ending the process at the optimal moment.
Solution Approach 2:
The system allows partial recirculation necessary for complete filling but stops before excessive recirculation occurs. The feedback mechanism ensures the process terminates at the precise point where sufficient filling is achieved, avoiding the harmful effects of prolonged recirculation.
3Manufacturing precision
If filling continues to set level, then liquid level is achieved, but bubbles or foam are created making level setting difficult
Solution Approach 1:
The system performs preliminary filling action that anticipates the point where foam formation begins. By using feedback control to detect approaching fill level and terminate filling before foam becomes problematic, the system prevents the harmful effect rather than correcting it after occurrence.
4Productivity
If controlled shutters and vents are used, then filling mode can transition, but device complexity increases
Solution Approach 1:
The system uses dynamic control of shutters and vents that adjust their state based on the filling phase. The shutters open/close and vents activate/deactivate in response to real-time process conditions, enabling transition between filling modes (initial rapid filling vs. final precision filling) to optimize productivity throughout the process.
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 enables quick and efficient filling without vacuum, reduces recirculation, and minimizes foam formation, thereby improving the quality and speed of the filling process while maintaining precise control over the filling level.
Implementation Method 1
filler liquid stored in a pressure regulated vessel and delivered using at least one filler head
Implementation Method 2
creating both a vent for the container and also a vent for the cannula
Implementation Method 3
putting the discharge cannula into communication with the vessel in order to fill the container with the liquid in gravity mode
Data Source
AI summary
A method of filling containers with the help of a filler liquid stored in a pressure regulated vessel and delivered using at least one filler head comprises a filler tube and provided with a main shutter, the filler tube including internally a discharge cannula. After engaging the filler tube inside the container, the main shutter of the tube is opened and a vent is created for the container and for the cannula, communication between the cannula and the vessel being closed. Before the end of filling, the vent is closed and the cannula is put into communication with the vessel. At the end of filling, when the liquid reaches a determined level of the tube, the shutter of the tube is closed, and communication between the discharge cannula and the vessel is closed.