Low-Temperature Hydrogen Peroxide Sterilization for Plastic Packaging
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Solution Overview
Problem
Current methods for sterilizing food and medicinal packaging using hydrogen peroxide require high temperatures, which can deform plastic containers and make it difficult to achieve the required residue limit of 0.5 ppm, necessitating a need for a low-temperature sterilization process that is expedited and cost-effective.
Innovation Solution
A two-component solution involving a hydrogen peroxide solution applied at low temperatures, followed by an alkaline solution with a pH of 10-14, which reacts to generate active oxygen species to destroy microorganisms, allowing for sterilization at temperatures ranging from 35° C to 100° C, and subsequent rinsing with sterile water to remove residues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature sterilization is used to kill microorganisms, then sterilization effectiveness is improved, but plastic containers deform and become fluid
Solution Approach 1:
The patent changes the temperature parameter from high (120-135°C) to low (below 65°C) and introduces a chemical catalyst (metal ion or enzyme) to accelerate the hydrogen peroxide reaction, enabling effective sterilization without thermal deformation of plastic containers
Solution Approach 2:
The patent introduces an intermediary substance (metal ion catalyst or enzyme catalyst) that mediates the sterilization process by catalyzing hydrogen peroxide decomposition to generate hydroxyl radicals, enabling low-temperature effective sterilization
2Loss of substance
If extended drying process is used to evaporate peroxide residue, then residue removal is improved, but processing time increases
Solution Approach 1:
The patent uses a catalyst to rapidly decompose residual hydrogen peroxide into water and oxygen, skipping the extended thermal drying process and reducing residue removal time from minutes to seconds
Solution Approach 2:
The patent changes the residue removal mechanism from thermal evaporation to catalytic decomposition, enabling rapid breakdown of peroxide residues without extended heating or drying time
3Reliability
If plastic bottles are sterilized at elevated temperatures, then microorganisms are killed, but bottles deform and become fluid
Solution Approach 1:
The patent changes the temperature parameter from elevated (120-135°C) to low (below 65°C) and introduces a chemical catalyst to accelerate the sterilization reaction, maintaining bottle structural stability while achieving effective microorganism kill
Solution Approach 2:
The patent replaces the thermal-mechanical sterilization system with a chemical-catalytic system using hydrogen peroxide and catalysts, eliminating the need for high temperatures that cause plastic softening and deformation
4Reliability
If PET bottles are sterilized with hydrogen peroxide, then sterilization is achieved, but peroxide absorption makes residue limit difficult to meet
Solution Approach 1:
The patent introduces a catalyst as an intermediary that promotes complete decomposition of hydrogen peroxide, reducing absorbed peroxide residues to below detectable levels and meeting the 0.5 ppm FDA limit
Solution Approach 2:
The patent changes the chemical reaction parameters by introducing catalysts that accelerate peroxide decomposition, enabling complete breakdown of absorbed hydrogen peroxide and achieving residue levels below 0.5 ppm
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 effectively sterilizes packaging at lower temperatures, reducing the sterilization time, minimizing hydrogen peroxide absorption, and enabling the use of thinner wall containers, while achieving aseptic conditions and meeting FDA residue limits.
Implementation Method 1
an alkaline solution... which reacts to generate active oxygen species including hydroxyl radicals to destroy microorganisms
Implementation Method 2
generate active oxygen species including hydroxyl radicals from the hydrogen peroxide
Data Source
AI summary
A method (20) and apparatus (100) for sterilizing packaging (102) is disclosed herein. The method (20) applies a solution of hydrogen peroxide onto the packaging (102) and an alkaline solution to react with the hydrogen peroxide to generate hydroxyl radicals to kill microorganism. The use of an alkaline solution allows the sterilization process to proceed at a lower temperature and a faster rate. A solution of sodium hydroxide is the preferred alkaline solution. The temperature of the process is preferably below 100° C.