Aseptic Filler Fitment Plug Assembly for Pressure Maintenance
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Solution Overview
Problem
Current aseptic packaging methods for flexible bags with standard fitments face challenges in maintaining positive pressure within the fill chamber without the use of sterile gas and chemicals, which is necessary to prevent contamination and meet regulatory requirements.
Innovation Solution
An aseptic filler apparatus that utilizes steam to maintain positive pressure in the fill chamber, featuring a fitment plug assembly and cap removal system to ensure sterile conditions during the filling process, allowing for the use of standard fitments without sterile gas or chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sterile gas and chemicals are used to maintain overpressure in the fill chamber, then contamination is prevented and regulatory requirements are met, but the system complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the sterile gas and chemical components from the overpressure maintenance system, replacing them with a mechanical plug system that physically isolates the fill chamber while maintaining simplicity
Solution Approach 2:
The fitment plug assembly acts as an intermediary component between the fill chamber and the bag, providing a mechanical means to maintain overpressure without requiring complex sterile gas control systems or chemical agents
2Productivity
If the fitment cap is removed to allow filling, then the bag can be filled through the fitment, but the fill chamber pressure dramatically decreases due to bag expansion
Solution Approach 1:
The fitment plug is positioned and sealed in advance before the cap is removed, ensuring that when the filling operation begins, the overpressure is already maintained and will not dramatically decrease due to bag expansion
Solution Approach 2:
The fitment plug serves as a mediator that allows the cap to be removed for filling while simultaneously maintaining the pressure seal, enabling both filling capability and pressure maintenance
3Reliability
If customized fitments with center membranes are used to maintain overpressure, then contamination is prevented, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the complex center membrane structure from the fitment design, replacing it with a simple plug assembly that can be manufactured using standard processes and works with conventional fitments
Solution Approach 2:
The fitment plug assembly is designed to work with standard fitments universally, eliminating the need for customized fitments with special membrane structures while maintaining contamination prevention capabilities
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 system effectively maintains aseptic conditions and meets regulatory pressure requirements by using steam to sterilize and maintain positive pressure within the fill chamber, preventing contamination and ensuring the integrity of the packaging process.
Implementation Method 1
steam from a steam source is directed to the fitment chamber for sterilizing the fitment
Implementation Method 2
a fitment plug assembly that is moveable between an actuated position to bear against the fitment collar to block food flow communication between the fitment collar and the bag
Data Source
AI summary
An aseptic filler apparatus (30) includes an actuatable fitment plug assembly (500) that may be placed against the bottom of a fitment collar, which is in communication with a flexible bag to be filled with flowable food products, thereby to prevent steam or other gasses or liquids from entering the fill bag when undesirable to do so. The plug assembly (500) includes a plug (502) mounted on a distal end portion of a pivot arm (504). The opposite end of the pivot arm is rotatably axled on a cross pin. A linear actuator (518) is connected to the distal end of a lug (512) projecting transversely from the pivot arm. The opposite end of the linear actuator (518) is pinned to a stationary location, enabling the actuator to pivot the plug (502) from an engaged position against the fitment collar and a retracted position away from the fitment collar.