Isolator Sterilization via Temper Fluid and VHP
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Solution Overview
Problem
Current dry aseptic processes in beverage bottling systems require complete shutdown for intermediate sterilization, leading to production interruptions and increased costs due to the need for a full cleaning and sterilization cycle.
Innovation Solution
A method for intermediate sterilization that involves applying a temperature control fluid to temper surfaces, followed by the application and removal of a dry sterilizing agent like vaporized hydrogen peroxide, allowing for rapid resumption of production without full system shutdown, using existing dry aseptic system components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complete cleaning and sterilization cycle is performed after production shutdown, then system sterility is restored, but production time is lost and productivity decreases
Solution Approach 1:
The patent applies preliminary action by performing sterilization during brief operational interruptions rather than waiting for complete production shutdown. The isolator is sterilized using vaporized hydrogen peroxide while the system is in a stopped state but before full production restart, allowing quick restoration of sterility without complete production cessation. This resolves the contradiction by enabling sterility restoration during minimal interruption rather than requiring full production stoppage.
2Ease of operation
If the isolator is opened for intervention during operation, then system accessibility is improved, but sterility is compromised and requires full shutdown for re-sterilization
Solution Approach 1:
The patent enables preliminary sterilization action to be taken after isolator opening and before production restart. The system allows the isolator to be opened for interventions, then quickly re-sterilized using vaporized hydrogen peroxide during the interruption period, restoring sterility without requiring complete production shutdown. This resolves the contradiction by decoupling accessibility from sterility loss consequences.
Solution Approach 2:
The patent introduces vaporized hydrogen peroxide as an intermediary sterilizing agent that can quickly restore sterility after isolator opening. This intermediary chemical agent enables rapid sterility restoration during operational interruptions, avoiding the need for complete production shutdown and full cleaning cycles. The hydrogen peroxide vapor penetrates the isolator and surfaces, restoring sterility efficiently.
3Reliability
If wet aseptic process is used for sterilization, then sterilization effectiveness is improved, but condensation forms and may contaminate the filling product
Solution Approach 1:
The patent applies parameter changes by using vaporized hydrogen peroxide instead of liquid or aerosolized forms. The sterilizing agent is delivered as vapor that does not condense on surfaces, eliminating the harmful condensation effect while maintaining sterilization effectiveness. This parameter change from liquid/aerosol to vapor phase resolves the contradiction between sterilization effectiveness and condensation contamination risk.
Solution Approach 2:
The patent utilizes phase transitions by employing hydrogen peroxide in vapor phase for sterilization. The vaporized form prevents condensation on isolator surfaces and filling products, avoiding contamination while achieving effective sterilization. The phase transition from liquid to vapor eliminates the condensation problem inherent in wet aseptic processes.
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
Enables sterilization of surfaces during operational interruptions without stopping production, maintaining system sterility and reducing maintenance and investment costs by utilizing existing infrastructure and minimizing the need for additional design measures.
Implementation Method 1
applying a tempering fluid to at least one surface of the insulator in order to temper it
Implementation Method 2
vaporized hydrogen peroxide is blown into the heated isolator to sterilize all accessible surfaces
Implementation Method 3
at least partially removing the tempering fluid from the insulator
Data Source
AI summary
Method for intermediate sterilization of an isolator (1) of a container treatment system, the method comprising: introducing a temperature control fluid having a higher temperature than the isolator (1) into the isolator (1), thereby tempering the isolator (1); at least partially removing the temperature control fluid from the isolator (1); and introducing a dry sterilizing agent into the isolator (1).