Container Filling Method Using Nitrogen Pressurization to Suppress Foam
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Solution Overview
Problem
Existing container handling systems in the beverage industry face challenges in filling and closing containers without using CO2, which is environmentally harmful and expensive, especially when filling carbonated beverages at high speeds, leading to excessive foaming and greenhouse gas emissions.
Innovation Solution
A method that involves evacuating the container interior to a negative pressure, flushing with steam to raise the pressure to atmospheric levels, filling with liquid filling material, and then pressurizing with nitrogen to the CO2 saturation pressure or above, followed by closing the container under controlled pressure conditions, eliminating the need for CO2 and minimizing foam formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CO2 is used for filling and closing containers at high speed, then filling speed is improved, but excessive foaming and environmental harm occur
Solution Approach 1:
The patent changes the gas composition parameter from CO2 to nitrogen, and adjusts pressure parameters dynamically during the filling process. The system uses negative pressure during filling to prevent foaming, then applies positive pressure with nitrogen for closing, thereby eliminating harmful CO2 emissions while maintaining high filling speeds.
Solution Approach 2:
The patent creates an inert atmosphere by using nitrogen instead of CO2 in the container headspace during the closing phase. This inert environment prevents unwanted chemical reactions and foam formation while allowing the container to be closed at high speed without environmental harm.
2Reliability
If CO2 is used to maintain pressure during closing, then closing effectiveness is improved, but environmental impact and cost increase
Solution Approach 1:
The patent changes the gas type parameter from CO2 to nitrogen for maintaining pressure during closing. This substitution maintains the necessary pressure for effective closing while eliminating the environmental harm and cost associated with CO2, as nitrogen is more environmentally friendly and often more economical.
Solution Approach 2:
The patent uses nitrogen, which is often more economical and environmentally benign compared to CO2. The system temporarily introduces nitrogen to maintain pressure during closing, then releases it, making the process cost-effective and environmentally sustainable without requiring expensive or harmful gases.
3Productivity
If rapid filling is performed without pressure control, then filling speed is improved, but foam formation increases
Solution Approach 1:
The patent applies preliminary negative pressure to the container before and during the filling process. This preliminary action prevents foam formation by creating a pressure differential that suppresses bubble formation, allowing rapid filling without loss of substance to foam while maintaining high productivity.
Solution Approach 2:
The patent uses pneumatic pressure control, switching between negative and positive pressure states to manage the filling process. By applying negative pressure during filling and then positive pressure with nitrogen for closing, the system achieves rapid filling without excessive foam formation while maintaining container integrity.
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 method allows for rapid and efficient filling of containers without CO2, reducing environmental impact by using nitrogen instead, preventing excessive foaming, and ensuring precise control over pressure conditions for effective container closure.
Implementation Method 1
evacuating the container interior to a negative pressure
Implementation Method 2
flushing with steam to raise the pressure to atmospheric levels
Implementation Method 3
pressurizing with nitrogen to the CO2 saturation pressure or above
Data Source
AI summary
A method for filling and closing containers at a filling and closing unit of a handling station. After the completion of a filling phase, a handling phase is carried out at the filling and closing unit of the handling station, in which the process chamber is pre-loaded, in particular above the container opening of the corresponding container, by way of nitrogen to a pressure which is at or above the saturation pressure of the CO2 contained in the filling material.