Filling Valve Plunger Throttle Position for Sterilization
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Solution Overview
Problem
Current filling valve sterilization methods in the food and pharmaceutical industries require complex and costly designs to maintain high hygiene standards, involving multiple SIP caps and mechanical movements, which are inefficient and labor-intensive.
Innovation Solution
The method involves the filling material valve stamp being adjusted to a throttle position to allow sterilization gas to flow through the channel, eliminating the need for separate SIP caps and using the valve itself to maintain vapor pressure, followed by a second sterilization step with hydrogen peroxide introduced via the valve outlet to ensure thorough sterilization, including the use of sterile air for drying and residue removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a SIP cap is used to maintain steam pressure during sterilization, then sterilization effectiveness is improved, but device complexity and mechanical effort increase significantly
Solution Approach 1:
The invention extracts and eliminates the SIP cap component from the sterilization system. Instead of using a separate cap to maintain steam pressure, the system uses the filling valve's own plug in a throttled position to achieve the same pressure-maintaining function, thereby removing unnecessary mechanical complexity while preserving sterilization effectiveness
Solution Approach 2:
The filling valve plug is given a dual function: it serves both as the closing element for the filling valve and as a throttle element to maintain steam pressure during sterilization. This eliminates the need for a separate SIP cap, reducing device complexity while maintaining the required sterilization function
2Reliability
If multiple SIP caps are used for multiple filling valves, then sterilization coverage is improved, but manufacturing cost and design effort increase
Solution Approach 1:
The filling valve plug performs multiple functions including closing the valve and throttling steam flow during sterilization. This multi-functionality eliminates the need for separate SIP caps for each valve, reducing manufacturing costs and design effort while maintaining complete sterilization coverage
Solution Approach 2:
The invention merges the function of the SIP cap with the filling valve plug. By combining these functions into a single component, the system reduces the number of parts needed, lowering manufacturing costs and simplifying design while ensuring all filling valves can be sterilized effectively
3Reliability
If the valve is kept in the open position for steam flow, then sterilization reach is improved, but steam pressure drops due to lack of throttling
Solution Approach 1:
The filling valve plug can dynamically adjust its position between fully open and throttled positions. During sterilization, it is positioned in a throttled state to maintain pressure while still allowing steam flow. This dynamic positioning capability enables the system to maintain both adequate steam pressure and sterilization reach simultaneously
4Reliability
If separate SIP caps with mechanical movements are used, then sterilization completeness is improved, but ease of operation deteriorates due to labor-intensive procedures
Solution Approach 1:
The filling valve plug automatically maintains steam pressure during sterilization through its throttled position, eliminating the need for separate SIP cap operations. This self-service capability simplifies the sterilization process, making it easier to operate while maintaining complete sterilization of all filling valves
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 simplifies the sterilization process, reduces mechanical complexity and costs, while ensuring effective sterilization of the filling valve and container, maintaining product hygiene without contaminating the filling material.
Implementation Method 1
a sufficiently high resistance is generated which serves to build up a suitably high vapor pressure
Implementation Method 2
a small opening hole that ensures that the condensed steam can be discharged while at the same time ensuring a sufficiently high steam pressure so that the steam can maintain its gaseous form
Data Source
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AI summary
The invention relates to a method for sterilizing a filling valve (1) with a filling valve plunger (7) arranged in a filling channel (2), which is movably configured to move between an open and a closed position. According to the invention, at least in a first sterilization step, the filling valve plunger (7) is moved into a throttle position and a first sterilization gas (5) then flows through the filling channel (2).