Packaging Machine Gas Circuit Cleaning Configuration
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Solution Overview
Problem
Existing packaging machines for pourable food products face challenges in efficiently cleaning and sterilizing the filling and gas feeding devices, which can lead to contamination and reduced production efficiency.
Innovation Solution
The packaging machine incorporates a control unit that allows for configuration changes between production, cleaning, and sterilization modes, enabling facilitated cleaning of the gas delivery circuit and product circuit, and ensuring thorough sterilization of all components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cleaning operations are executed on the filling device and gas feeding device, then contamination risks are reduced, but production time is lost and productivity decreases
Solution Approach 1:
The patent implements automatic cleaning operations that are performed preliminarily before sterilization and before production resumes. The cleaning device activates automatically to clean the filling device and gas feeding device, ensuring contamination is removed in advance, thus preventing contamination risks without requiring manual intervention that would extend downtime.
Solution Approach 2:
The cleaning device is configured to automatically clean the filling device and gas feeding device without requiring manual operation. The system performs self-service cleaning by circulating cleaning solutions through the circuits, reducing the time workers need to spend on cleaning tasks and minimizing production interruptions while maintaining reliability.
2Reliability
If sterilization operations are executed after cleaning, then product quality is ensured, but additional time is consumed and production efficiency is reduced
Solution Approach 1:
The system performs cleaning as a preliminary action before sterilization, ensuring that organic contaminants are removed first. This preliminary cleaning step prepares the surfaces for more effective sterilization, reducing the time and intensity required for the sterilization process itself, thus maintaining product quality while minimizing time loss.
Solution Approach 2:
The cleaning and sterilization operations are integrated into a continuous automated sequence without interruption to the overall process. The cleaning device and sterilization system work in succession without manual intervention between steps, eliminating idle time and ensuring that the transition from cleaning to sterilization is seamless, thereby reducing total time loss while ensuring product quality.
3Reliability
If manual cleaning operations are performed by workers, then cleaning effectiveness is achieved, but worker exposure to contaminants increases and safety risks arise
Solution Approach 1:
The cleaning device automatically performs cleaning operations on the filling device and gas feeding device without requiring workers to manually handle contaminated surfaces. The system circulates cleaning solutions through the circuits and uses automated mechanisms to remove contaminants, maintaining cleaning effectiveness while eliminating worker exposure to harmful contaminants.
Solution Approach 2:
The cleaning device acts as an intermediary between the contaminated components and the cleaning agents. It handles the circulation of cleaning solutions and the removal of contaminants through automated processes, shielding workers from direct contact with contaminants while ensuring thorough cleaning effectiveness through controlled application of cleaning agents.
4Productivity
If the packaging machine operates continuously without cleaning, then productivity is maintained, but contamination risks increase and product quality deteriorates
Solution Approach 1:
The system implements periodic cleaning and sterilization cycles during operation. The control unit schedules automatic cleaning operations at predetermined intervals or based on production volume thresholds, allowing the machine to maintain continuous productivity while periodically interrupting for brief automated cleaning cycles that prevent contamination buildup and ensure ongoing product quality without prolonged stoppages.
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 enables efficient cleaning and sterilization processes, reducing contamination risks and improving production efficiency by allowing for easy maintenance and ensuring the quality of packaged products.
Implementation Method 1
a flow of sterile gas into the tube for obtaining a gas pressure within the tube providing a correct forming pressure. In such a way, the required hydrostatic pressure provided by the product column is reduced.
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
There is described a packaging machine (1) comprising a conveying device (5), an isolation chamber (7), a tube forming and sealing device (10) being configured to form and longitudinally seal a tube (3), a gas feeding device (14) configured to direct gas into the tube (3), a cleaning device (19) and a control unit (11) configured to set the packaging machine (1) into a production configuration and a cleaning configuration. The gas feeding device (14) comprises a gas delivery circuit (20) and a gas delivery source (21) configured to deliver the sterile gas to the gas delivery circuit (20). The gas delivery circuit (20) comprises a connection element (24) configured to be arranged in a production position and a cleaning position with the packaging machine (1) being controlled into, respectively, the production configuration and the cleaning configuration; The connection element (24) is fluidically connected to the gas delivery source (21) when being in the production position and to the cleaning device (19) when being in the cleaning position.