Monochromatic UV Sterilization for Heat-Sensitive Containers
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Solution Overview
Problem
Current sterilization techniques, such as steam sterilization and ethylene oxide, are inefficient and can damage certain materials, are costly, and generate waste, while existing UV light sterilization methods using incoherent, polychromatic light are ineffective for certain applications.
Innovation Solution
The use of monochromatic UV light sterilization systems with continuous wave, high-intensity, incoherent light in multiple light source configurations, which operate at ambient temperature and can be integrated into an in-line process, reducing energy costs and waste, and effectively sterilizing heat-sensitive products without damaging packaging or products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam sterilization is used, then sterilization effectiveness is improved, but material damage and energy consumption increase
Solution Approach 1:
The patent replaces the mechanical/thermal sterilization system (steam autoclave) with a photonic sterilization system using monochromatic UV light. This substitution eliminates the need for high temperature and pressure, thereby preventing damage to heat-sensitive materials while maintaining sterilization effectiveness through targeted UV irradiation at specific wavelengths that destroy microbial DNA without thermal effects.
Solution Approach 2:
The patent changes the sterilization parameter from thermal energy (steam at high temperature and pressure) to electromagnetic radiation energy (monochromatic UV light at specific wavelengths). This parameter change allows sterilization of materials that cannot withstand thermal conditions, as the UV light delivers germicidal effect without thermal damage.
2Reliability
If steam sterilization is used, then sterilization effectiveness is improved, but energy costs and waste generation increase
Solution Approach 1:
The patent replaces the energy-intensive steam generation and pressure maintenance system with a more efficient photonic system. The UV light sources (excimer lamps or LEDs) convert electrical energy directly to germicidal radiation with higher efficiency, eliminating the need for large amounts of water heating, steam generation, and pressure control, thereby reducing overall energy consumption and waste.
3Reliability
If ethylene oxide gas sterilization is used, then sterilization effectiveness is improved, but safety hazards and aeration requirements increase
Solution Approach 1:
The patent replaces the chemical sterilization method (ethylene oxide gas) with a physical photonic method (UV light irradiation). This substitution eliminates the use of toxic carcinogenic gases entirely, removing all associated safety hazards, aeration requirements, and residual gas concerns, while achieving equivalent or superior sterilization through DNA damage by UV photons.
4Adaptability or versatility
If incoherent, polychromatic light sterilization is used, then broad spectrum coverage is achieved, but sterilization effectiveness for certain applications is reduced
Solution Approach 1:
The patent applies the principle of local quality by using monochromatic UV light at specific wavelengths (222 nm, 248 nm, 254 nm, 282 nm, 308 nm, 354 nm, or 361 nm) that are locally optimized for maximum germicidal effectiveness. Rather than using broad-spectrum polychromatic light, the system concentrates energy at specific wavelengths where microbial DNA absorbs most strongly, achieving superior sterilization effectiveness for parenteral and enteral solutions while maintaining adaptability through wavelength selection.
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
Achieves a desired sterilization level without affecting the physical properties of container systems or product efficacy, reducing non-sterile hold times and energy costs, and effectively inactivating microorganisms in a continuous or semi-continuous process.
Implementation Method 1
The container system receives monochromatic light energy from each light source while in the treatment zone to achieve a sterilization effect of the container system
Data Source
AI summary
The present disclosure provides for methods, systems and apparatus for monochromatic UV light sterilization of container systems and/or container-packaged products. More particularly, the present disclosure provides for improved methods, systems and apparatus for monochromatic UV light sterilization of liquid and/or solid products/solutions and/or packaging/container systems for liquid and/or solid products/solutions (e.g., parenteral pharmaceutical products/solutions and/or packaging/container systems for parenteral pharmaceutical products/solutions). In exemplary embodiments, the present disclosure provides for improved systems and methods for the sterilization of container systems and/or container-packaged products using monochromatic, continuous wave, high-intensity, incoherent light in multiple light source configurations, wherein such sterilization regimen achieves a desired sterilization level without negatively affecting the physical properties of the package/container systems and/or the efficacy of the underlying products/systems.