Multi-Manifold Gas Rail for Controlled Container Atmosphere
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Solution Overview
Problem
Existing packaging methods for products sensitive to air, such as bakery goods and fruits, face challenges with limited shelf life due to atmospheric conditions, and current controlled environment systems are often expensive, bulky, and impractical for use in many facilities, as they fail to efficiently remove oxygen and prevent contamination.
Innovation Solution
An apparatus featuring an elongated rail with aligned manifolds and a nozzle system that provides a composite gas stream to penetrate and maintain a controlled environment within containers, using regulated gas flows to ensure deep penetration and prevent outside air from entering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high velocity gas jets are used to penetrate into food products for oxygen removal, then oxygen removal efficiency is improved, but air is pulled in and re-contaminates the product
Solution Approach 1:
The gas delivery system is segmented into multiple manifolds (first, second, and third manifolds) positioned in substantial alignment with the container, each serving distinct functions in the gas delivery sequence to prevent air entrainment while maintaining oxygen removal efficiency
Solution Approach 2:
A preliminary low velocity gas flow is delivered through the first manifold to prepare the container environment before the high velocity penetration flow is introduced through the second manifold, preventing air re-contamination by establishing a protective gas barrier in advance
2Duration of action of stationary object
If existing controlled environment systems are used to package products, then product shelf life is extended, but the systems are expensive, bulky, and require three phase power
Solution Approach 1:
The invention employs a simplified, portable apparatus that can be easily deployed and removed, replacing complex permanent controlled environment systems. The system uses standard electrical outlets and disposable or reusable gas cartridges, eliminating the need for expensive three-phase power infrastructure
Solution Approach 2:
The controlled environment function is extracted from bulky permanent installations and embodied in a portable, self-contained apparatus that can be positioned directly at the packaging location, reducing system complexity and infrastructure requirements while maintaining shelf life extension benefits
3Speed
If high velocity flushing gas jets are used to purge containers, then oxygen removal speed is improved, but turbulence pulls in outside air
Solution Approach 1:
The gas delivery occurs in periodic sequences: low velocity flow through the first manifold, followed by high velocity penetration through the second manifold, then low velocity flow through the third manifold. This periodic alternation maintains high oxygen removal speed while preventing outside air entrainment by resetting the flow conditions between high velocity pulses
4Productivity
If perpendicular rows of high velocity jets are used to flush containers, then oxygen removal is achieved, but the process is time-consuming and allows air re-entry
Solution Approach 1:
The three manifolds are positioned in substantial alignment with the container, enabling continuous gas delivery through sequential activation along the same path. This eliminates the time loss associated with moving between perpendicular rows of jets, maintaining continuous oxygen removal effectiveness while reducing total purging time
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 solution effectively extends the shelf life of products by ensuring a controlled environment within containers, reducing oxygen levels and preventing contamination, while being more practical and cost-effective for use in various facilities.
Implementation Method 1
A composite gas stream including substreams flowing at different speeds is provided through the nozzle to penetrate and maintain controlled environment within containers
Implementation Method 2
At least one gas flow regulator is operably attached to the first, second, and third manifolds to ensure regulated gas flows
Data Source
AI summary
An apparatus and method for exposing a container to a controlled environment. The apparatus includes an elongated rail with first, second, and third manifolds positioned in substantial alignment with the container. The first, second, and third manifolds are adapted for providing flow of a gas therethrough. At least one gas flow regulator is operably attached to the first, second, and third manifolds. At least one nozzle is positioned adjacent the second manifold. The at least one nozzle is adapted for providing a composite gas stream exiting through the second manifold. The method includes providing an elongated rail with first, second, and third manifolds positioned in substantial alignment with the container. A flow of a gas is regulated through the first, second, and third manifolds. A composite gas stream is provided exiting through the second manifold.