Liquid Filling System with Circulation Loop for Air Evacuation
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Solution Overview
Problem
Inefficient startup of liquid food processing systems leads to product losses and potential machine failures due to air entrapment and microbiological growth, especially during unplanned stops, which affects food safety and increases operational costs.
Innovation Solution
A method and system for efficiently filling and circulating liquid products through a network of pipes and valves, incorporating a level switch and diversion valves to prevent air entrapment and maintain product flow, using sterile water and air flushing to ensure cleanliness and temperature control, and an inline cooler to keep products chilled, thereby reducing waste and contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the system is filled by opening both flow paths simultaneously, then filling speed is improved, but air entrapment occurs causing product loss and machine failure
Solution Approach 1:
The filling process is segmented into two distinct phases: first filling the second flow path (tank to inlet) with the first valve closed, then filling the first flow path (inlet to tank) with the first valve opened. This segmentation prevents air entrapment by ensuring systematic air evacuation through the pump before product introduction, resolving the contradiction between filling speed and machine failure risk.
Solution Approach 2:
The system performs preliminary action by first filling the second flow path and priming the pump before opening the first valve to fill the first flow path. This preliminary priming ensures that air is evacuated through the pump beforehand, preventing air entrapment in the product flow path and eliminating machine failure risks while maintaining efficient filling.
2Loss of substance
If the system is filled efficiently with proper circulation, then product loss is reduced, but device complexity increases due to additional valves and control mechanisms
Solution Approach 1:
The circulation system serves multiple functions: it fills the pipes, primes the pump, evacuates air, and maintains product flow. By making the circulation path multi-functional, the system reduces product loss without requiring separate dedicated systems for each function, thereby limiting the increase in device complexity.
Solution Approach 2:
The filling and circulation functions are merged into a single integrated process using the same pipes and valves. The first valve controls both filling operations, and the second flow path serves both as a fill path and a circulation path, reducing the number of separate components needed while minimizing product loss.
3Productivity
If air is entrapped during system filling, then filling speed is improved by simultaneous filling, but harmful effects occur including product loss and microbiological growth
Solution Approach 1:
The system extracts air from the product flow path by directing the initial product flow through the pump in the second flow path, which acts as an air evacuation route. This extraction of air before product introduction eliminates harmful effects like air entrapment and microbiological growth while maintaining filling efficiency through the systematic two-phase approach.
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 approach minimizes product losses and ensures food safety by preventing microbiological growth and machine failures, reducing operational costs and environmental impact by optimizing system startup and operation.
Implementation Method 1
a first pipe connecting said inlet to said tank forming a first flow path, wherein said first pipe is provided with said first valve such that said first flow path is closed or open, a second pipe connecting said tank to said inlet forming a second flow path, such that said first flow path and said second flow path provide a circulation flow path
Implementation Method 2
The second pipe may be provided with a pump, and said pump may be filled when said second pipe is filled with liquid product
Implementation Method 3
The first pipe or said second pipe may be provided with a cooling device
Data Source
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AI summary
A method for filling an empty system with a liquid product is provided. The system comprising an inlet, a first valve, a tank, a first pipe connecting said inlet to said tank forming a first flow path, wherein said first pipe is provided with said first valve such that said first flow path is closed or open, a second pipe connecting said tank to said inlet forming a second flow path, such that said first flow path and said second flow path provide a circulation flow path. The method comprises closing said first valve such that said first flow path is closed, feeding in said liquid product via said inlet such that said second pipe is filled with said liquid product, opening said first valve such that said first flow path is opened, and feeding in said liquid product via said inlet such that said first pipe is filled with said liquid product.