Offset Liquid Influx Mixing for Homogeneity and Waste Reduction
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Solution Overview
Problem
Traditional industry-scale methods for forming liquid consumer products lack flexibility and generate significant waste, as they require cleaning or purging the production line when switching between different products, leading to inefficient use of raw materials and suboptimal mixing results.
Innovation Solution
The method involves in situ mixing of two or more liquid raw materials directly inside a container by using liquid influxes offset from the longitudinal axis of the container by an angle between 5° to 50°, which enhances the kinetic energy and homogeneity of the final product, reducing waste and allowing for maximum raw material utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional batch mixing or continuous in-line mixing methods are used to form liquid consumer products, then high throughput and satisfactory mixing homogeneity are achieved, but the production line lacks flexibility and generates significant waste liquid when switching between different products
Solution Approach 1:
The invention divides the mixing process into two distinct stages: (1) preliminary mixing of most components in a storage tank, and (2) final mixing inside the container during filling. This segmentation allows the production line to maintain high throughput for the bulk mixing operation while enabling flexibility in the final product formulation by adjusting the composition of the second liquid introduced during container filling.
Solution Approach 2:
The majority of the mixing operation is performed in advance in a storage tank before filling, with only the final mixing step occurring inside the container. This preliminary action enables the production line to be optimized for high-volume mixing while the container-based final mixing provides product-specific flexibility without requiring full production line reconfiguration.
2Manufacturing precision
If traditional batch mixing or continuous in-line mixing methods are used, then satisfactory mixing homogeneity is achieved, but extensive cleaning or purging is required when switching products, resulting in waste liquid generation
Solution Approach 1:
The invention extracts the final mixing operation from the main production line and relocates it to the container during the filling process. This separation allows the production line to be dedicated to bulk mixing operations that require thorough cleaning, while the final product-specific mixing occurs in disposable or easily cleaned containers, significantly reducing waste liquid generation during product transitions.
Solution Approach 2:
The second liquid introduced during container filling serves as a disposable medium that enables product switching without requiring cleaning of the main production line. The container and its contents can be discarded or easily replaced, eliminating the need for extensive purging operations and reducing waste liquid generation.
3Ease of operation
If liquid influx is applied along the longitudinal axis of the container, then simple filling is achieved, but insufficient mixing homogeneity and stability are obtained
Solution Approach 1:
The invention introduces the second liquid at an offset position from the container's longitudinal axis, creating an asymmetric flow pattern. This asymmetric influx generates rotational motion and turbulence within the container, significantly enhancing mixing homogeneity and product stability while maintaining operational simplicity through a single filling operation.
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 improves the homogeneity and stability of the final product while minimizing waste and enabling the use of the same production line for different products without the need for extensive cleaning, thus optimizing raw material usage and production efficiency.
Implementation Method 1
Such offset or angled liquid influxes function to increase the impact of available kinetic energy on the mixing result and in turn improve homogeneity and stability of the finished liquid consumer product so formed
Data Source
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AI summary
Methods for in situ mixing of two or more different liquid compositions in a container by employing one or more liquid influxes that are offset by 1-50° from a longitudinal axis of such container. Such offset or angled liquid influxes function to increase the impact of available kinetic energy on the mixing result and in turn improve homogeneity and stability of the finished liquid consumer product so formed.