Container Filling Return Gas Flow Path Design
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Solution Overview
Problem
Existing filling systems experience significant vortex formation and alcohol losses during the recirculation of filling material and gases, particularly with products having high alcohol content, due to the return of filling goods and gases into the filling material boiler, leading to inefficient filling and potential contamination.
Innovation Solution
Implementing a flow path with a sensor to monitor the return gas and filling material, directing it to a collecting space below the filling material level, which prevents disturbance in the liquid space and allows for reliable detection of defective filling points, ensuring tightness and preventing alcohol losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the return gas and filling material are recirculated into the filling material boiler, then the filling material is reused and filling efficiency is improved, but vortex formation occurs and volatile components such as alcohol are lost
Solution Approach 1:
The patent extracts the harmful gaseous components from the recirculation flow by introducing the return gas into the gas space above the filling material level rather than directly into the liquid filling material. This separation prevents the gaseous components carrying volatile substances like alcohol from disturbing the liquid filling material and causing losses.
Solution Approach 2:
The patent uses the gas space as an intermediary medium between the return gas and the liquid filling material. The return gas is directed into the gas space where it can mix with gaseous components without directly contacting the liquid filling material, thus preventing vortex formation and alcohol losses while still achieving recirculation.
2Productivity
If the return gas is introduced into the liquid space of the filling material boiler, then the filling material recirculation is achieved, but considerable disturbance and vortex formation occur in the filling material
Solution Approach 1:
The patent extracts the return gas flow from the liquid space and redirects it into the gas space above the filling material level. This eliminates the direct contact between the return gas and liquid filling material, preventing vortex formation and maintaining filling material stability while still achieving recirculation through the gas phase.
Solution Approach 2:
The patent uses pneumatic principles by introducing the return gas into the gas space where it can be managed as a gas phase flow rather than a liquid phase flow. This allows for better control of the gas flow and prevents the hydraulic disturbances that would occur if the same flow were introduced directly into the liquid filling material.
3Reliability
If a sensor is added to monitor the return gas flow, then defective filling points can be reliably detected, but the device complexity increases
Solution Approach 1:
The patent employs a flow sensor that automatically monitors the return gas flow and provides feedback to the control system. The sensor enables the system to self-diagnose filling defects by detecting abnormal flow patterns, reducing the need for manual inspection and improving reliability without requiring complex additional machinery.
Solution Approach 2:
The patent implements a feedback mechanism where the flow sensor continuously monitors the return gas flow and communicates this information to the control system. This feedback loop enables real-time detection of filling defects and allows for immediate corrective action, enhancing system reliability while keeping the added complexity manageable through automated control.
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 method enables safe and reliable filling with minimal structural changes, effectively preventing alcohol losses and contamination by monitoring the flow of return gases and materials, ensuring accurate detection of defective filling points and maintaining product integrity.
Implementation Method 1
the flow of the return gas displaced from the interior of the container during filling and/or the flow of the filling material displaced from the interior of the container is monitored, specifically in that flow path via which the return of the return gas and/or the filling material is carried out to a collecting space
Implementation Method 2
the headspace not occupied by the filling material is first applied to the filled container with a Trinox gas under pressure, so that filling material via the return gas or Trinox tube is pressed or pushed out of the container
Data Source
Figure 1
Figure 2
AI summary
A method for filling containers with a liquid filling medium supplied from a filling medium tank, wherein during filling the container is sealingly arranged against a filling element and during filling the interior of the container is connected to a flow duct in the filling element, via which gaseous and/or vaporous medium, preferably pressurizing gas, displaced from the interior of the container by the flow of filling medium is discharged as a return gas during filling, and via which, at the end of the filling phase, filling medium displaced from the interior of the container is channelled to a collection chamber.