Granule Beverage Sterilization via Volumetric Cup and Cyclic Water
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Solution Overview
Problem
The high production cost of granule-containing liquid beverages due to expensive granule flow meters and incomplete sterilization of granules, which can lead to breakage and reduced taste, as well as increased production time and cost from repeated sterilization cycles.
Innovation Solution
A preparation and sterilization device with a heating mechanism using preheating and sterilization heat exchange pipes, temperature sensors, and controllers to ensure complete sterilization, and a system where pure water replaces the beverage for cyclic sterilization when filling equipment fails, avoiding granule breakage and maintaining sterile conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a granule flow meter is used to measure granules in the preparation process, then the measurement precision of granules is improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent replaces the expensive granule flow meter with a disposable volumetric cup that has a predetermined volume. This cup is used to measure granules by volume displacement in the liquid, providing adequate measurement precision without the high cost of electronic flow meters. The cup is simple, inexpensive, and can be easily replaced or cleaned.
Solution Approach 2:
The patent introduces a liquid medium as an intermediary to facilitate granule measurement. Instead of directly measuring granule flow with an expensive meter, the granules are suspended in liquid and the liquid level rise in a graduated cylinder or volumetric cup is measured. This indirect measurement method achieves sufficient precision at low cost.
2Reliability
If the sterilization temperature is increased to ensure complete sterilization of granules, then the sterilization effectiveness is improved, but the granule breakage increases and product quality deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-heating the granule-liquid mixture to a moderate temperature (e.g., 60-80°C) for a extended period (15-30 minutes) before final sterilization. This preliminary heating gradually raises the granule temperature, allowing thermal penetration to the center without sudden thermal shock that would cause breakage. The granules are also pre-cooked or pre-sterilized separately before being mixed with the liquid, reducing the thermal stress during final sterilization.
Solution Approach 2:
The patent employs dynamic temperature control during sterilization, using multiple heating stages with different temperatures and durations. The system dynamically adjusts heating power based on temperature sensors monitoring both the liquid and granule temperatures. This dynamic approach ensures the granule center reaches the required sterilization temperature (e.g., 121°C) while preventing excessive temperature that would cause breakage. The heating rate is controlled to be optimal for thermal penetration without causing thermal stress.
3Reliability
If the UHT system performs repeated CIP/SIP processes to ensure sterile conditions after back-end filling equipment failure, then the sterile condition reliability is improved, but the production time and manufacturing cost increase significantly
Solution Approach 1:
The patent applies preliminary action by maintaining the entire preparation system (including tanks, pipes, and heat exchangers) in a continuously sterile state through ongoing circulation of sterile liquid or periodic sterilization. This preliminary maintenance of sterile conditions means that when back-end filling equipment fails, the system is already sterile and does not require repeated CIP/SIP processes. The granules are pre-sterilized and stored in sterile containers, and the liquid is continuously sterilized or filtered, so the system remains ready for production without needing time-consuming re-sterilization cycles after failures.
4Reliability
If the granule-containing beverage is cyclically sterilized to maintain sterile conditions in the equipment, then the sterile condition reliability is improved, but the granule breakage increases and product quality deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-sterilizing the granules separately before mixing with the liquid, and by maintaining the liquid and equipment in a sterile state through continuous circulation or filtration. This preliminary sterilization means that cyclic re-sterilization of the final product is not needed, or if needed, the granules are already protected by being suspended in sterile liquid at controlled temperatures that prevent breakage during any necessary re-sterilization cycles.
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
Reduces preparation costs, ensures complete sterilization of granules, prevents breakage, and maintains sterile conditions by using a controlled heating and sterilization process and cyclic sterilization with pure water, thereby improving the efficiency and quality of granule-containing beverages.
Implementation Method 1
a preheating heat exchange pipe and a preheating thermal insulation pipe successively communicating with each other
Implementation Method 2
heating mechanism comprises a preheating heat exchange pipe
Implementation Method 3
a sterilization heat exchange pipe and a sterilization thermal insulation pipe successively communicating with each other
Implementation Method 4
sterilization mechanism comprises a sterilization heat exchange pipe
Implementation Method 5
a cooling heat exchange pipe and an outlet cooling pipe successively communicating with each other
Implementation Method 6
cooling mechanism comprises a cooling heat exchange pipe
Data Source
Figure 1
AI summary
A preparation and sterilization device and a preparation method for a granule-containing liquid beverage, the device comprises a storage container, a batching mechanism, a pure water container, a discharge pipeline, the discharge pipeline comprises a first switch valve disposed at a feed end and a second switch valve disposed at a discharge end; the first switch valve is used to communicate the pure water container and the feed end or to communicate the storage container and the feed end; the second switch valve is used to communicate the discharge end and the pure water container or to communicate the discharge end and the storage container; the batching mechanism comprises a batching container communicating with the storage container, a liquid inlet pipeline, a flow meter disposed on the liquid inlet pipeline, a granule inlet pipeline, and a liquid level sensor; the liquid level sensor is used to determine whether the granules entering the batching container raises the liquid level in the batching container to a set height.