Gas Replacement System for Beverage Containers
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Solution Overview
Problem
Conventional beverage manufacturing facilities face inefficiencies in gas replacement due to leakage of carbon dioxide gas during transfer from filling to sealing machines, leading to excessive use and increased costs, environmental impact, and safety concerns.
Innovation Solution
A gas replacement system that collects and recycles leaked carbon dioxide gas by introducing it back into the container within a chamber maintained at a higher concentration of the gas, reducing the need for additional gas supply and enhancing the concentration of replacement gas in the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional gassing methods are used to replace air with carbon dioxide gas in containers, then the oxygen concentration in the container is reduced to acceptable levels, but excessive amounts of carbon dioxide gas are consumed and leaked into the atmosphere
Solution Approach 1:
The patent applies the inert atmosphere principle by creating a controlled chamber environment filled with carbon dioxide gas. The chamber serves as an inert atmosphere that prevents oxygen from entering the container during transfer operations. By maintaining the entire transfer path within a CO2-filled chamber, the system eliminates the need for excessive gassing to compensate for leakage, as the chamber atmosphere itself prevents oxygen contamination throughout the process.
2Quantity of substance
If carbon dioxide gas is supplied in excess to compensate for leakage during transfer, then the requested oxygen gas concentration is maintained, but cost and environmental impact increase
Solution Approach 1:
The patent converts the harmful leakage of carbon dioxide gas into a beneficial effect by designing a chamber that captures and utilizes the leaked gas. Instead of allowing CO2 to escape wastefully, the chamber contains the gas and maintains it as the atmospheric environment. The leaked gas that would otherwise be wasted now serves as the chamber atmosphere, preventing oxygen ingress during transfer while eliminating the need for additional gas supply.
3Quantity of substance
If conventional gassing procedures are used during filling and sealing operations, then air is replaced in the container, but carbon dioxide gas leaks into the atmosphere during multiple process steps
Solution Approach 1:
The patent merges multiple separate gassing operations into a single integrated chamber environment. Instead of performing gassing at discrete steps (filling, transfer, sealing) with separate gas supplies, the system combines all these operations within one continuous CO2 atmosphere. The chamber unifies the entire process space, allowing gas replacement to occur once when the chamber is pressurized, rather than requiring repeated gassing operations that would cause additional leakage.
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 significantly reduces the amount of carbon dioxide gas used, minimizing costs and environmental impact while maintaining the desired oxygen gas concentration in the container, thus improving operational safety and efficiency.
Implementation Method 1
a chamber 14 that covers the filling machine 12 and the sealing machine 13 and contains a replacement gas
Data Source
Figure 1
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AI summary
To reduce an amount of use of a replacement gas used for replacing air in a container. A gas replacement system 10 includes: a washing machine 11 that washes the container 1 with water; a filling machine 12 that fills the container 1 with a content fluid; a sealing machine 13 that seals the container 1 transferred from the filling machine 12; a chamber 14 that covers the filling machine 12 and the sealing machine 13, and contains a replacement gas; and a water discharge mechanism (washing machine 11) that discharges the water in the container 1 having been carried into the chamber 14 while containing the water out of the container 1 in the chamber 14. The water in the container 1 is replaced with an ambient gas in the chamber 14 along with the discharge of the water.