In-line Packaging Forming Filling Sealing System
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Solution Overview
Problem
Existing Bag In Box (BIB) package production is costly and complex, with high logistical requirements and limited capacity for large-volume packages due to vertical distribution of filling equipment, which leads to high tension in packaging material and potential splitting, restricting production to small volumes and single-use packages.
Innovation Solution
A system for online forming, filling, and sealing that includes a sterilization apparatus, forming apparatus, inclined conveyor belt, and filling apparatus to support packaging material, allowing for large-volume package production without the need for additional filling interfaces, using sterile hot air and a hot filling process to maintain sterility and reduce material tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If vertical distribution of filling equipment is used, then small-volume packages can be produced, but large-volume packages cannot be produced due to high tension in packaging material
Solution Approach 1:
The patent transitions from vertical distribution of filling equipment to horizontal in-line distribution, changing the spatial arrangement from one dimension (vertical) to another (horizontal). This allows the packaging material to be supported along its length rather than bearing full weight through tension, enabling large-volume packages to be produced without material splitting.
2Volume of moving object
If premade bags are used for large-volume packages, then large-volume packaging is achieved, but production cost and supply chain complexity increase significantly
Solution Approach 1:
The patent merges the forming, filling, and sealing operations into a single integrated in-line system. The packaging material is formed into a bag, filled with product, and sealed continuously in one production line, eliminating the need for separate premade bag production, sterilization, and filling processes. This consolidation reduces supply chain complexity and production costs while enabling large-volume packages.
3Reliability
If sterile conditions are maintained throughout the process, then product quality is ensured, but production cost increases
Solution Approach 1:
The patent applies preliminary sterilization to the packaging material before it enters the filling process. The material is sterilized in advance, then maintained in a controlled environment during forming and filling. This preliminary action ensures product quality while reducing the need for continuous expensive sterilization measures throughout the entire process.
4Productivity
If filling interface is made large for high-speed filling, then filling speed is improved, but additional interfaces and sterilization steps are required
Solution Approach 1:
The patent designs a single filling interface that serves multiple functions: it allows high-speed filling through its adequate size, maintains sterility through the integrated design, and eliminates the need for separate dispensing interfaces. The interface is built into the packaging material structure itself, making it multi-functional and reducing overall system complexity.
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 production costs by 30-50% and simplifies the supply chain, enabling efficient production of large-volume packages while maintaining product quality and shelf life, and eliminating the need for additional dispensing interfaces and sterilization steps.
Implementation Method 1
the sterilized premade bag is transported to a filling plant under sterile storage conditions
Implementation Method 2
once the interior of the space formed, it is filled with sterile hot air which is used to resist air from the outside and thereby ensure that the packaging material interior and the product are sterile
Implementation Method 3
a filling apparatus, for filling the space for holding the product to be dispensed in the packaging material with the product to be dispensed using a hot filling process
Data Source
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Figure 3a~4c
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AI summary
Disclosed is a system of in-line shaping, filling and enclosing to form product packaging, said system comprising: a sterilisation device, a shaping device, a conveyor belt, a filling device and a first sealing device. Also disclosed is a method of in-line shaping, filling and enclosing to form product packaging. The method integrates the production and filling of large-capacity packaging, significantly shortens the supply chain, and increases the production efficiency.