Packaging Machine Scrubber for Peroxide Residue Removal
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Solution Overview
Problem
Peroxide residues often pass through the seal in packaging machines, reducing the effectiveness of the seal and increasing wear on mechanical components, and posing health risks to operators due to high concentrations in accessible areas.
Innovation Solution
A packaging machine with a fluidic conveying system that includes a scrubber to remove peroxide residues from the air and sterilizing agent, using a scrubbing solution to increase solubility and separate the residues from cleaned air, which is then pumped away, reducing exposure to the forming and folding units and operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seal is used to separate the aseptic chamber from the forming unit, then the sterilizing agent can be contained, but peroxide residues still pass through the seal and contact mechanical components
Solution Approach 1:
A fluid conveying system is introduced as an intermediary between the seal and the forming unit to capture and remove peroxide residues that pass through the seal, preventing direct contact with mechanical components while maintaining the seal's containment function
Solution Approach 2:
The harmful peroxide residues are extracted from the air stream using a scrubber that separates and removes the residues from the cleaned air, concentrating the harmful substance for removal while preserving the beneficial cleaned air
2Adaptability or versatility
If opening devices are applied directly onto the web by injecting plastic material, then closable opening devices are provided, but the seal effectiveness is reduced and peroxide residues pass through more easily
Solution Approach 1:
The fluid conveying system acts as an intermediary that compensates for the reduced seal effectiveness caused by opening devices, capturing peroxide residues that pass through the compromised seal and preventing them from reaching downstream components
3Productivity
If the tube is fed at high speed, then productivity is increased, but the seal has less time to press against the tube and peroxide residues pass through more easily
Solution Approach 1:
The fluid conveying system serves as a backup protective measure that ensures peroxide removal even when the high-speed operation compromises the seal's ability to maintain continuous contact with the tube
4Reliability
If peroxide residues are present in accessible areas, then the sterilization function is maintained, but operator health is at risk and regulatory compliance is compromised
Solution Approach 1:
The scrubber extracts peroxide residues from the air in accessible areas, separating the harmful substance from the breathable air to protect operators while maintaining the sterilization function in the aseptic chamber
Solution Approach 2:
The fluid conveying system and scrubber together form an intermediary protection layer between the sterilization process and operators, allowing sterilization to proceed while removing harmful residues from operator-exposed zones
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
Significantly reduces peroxide concentrations in accessible areas, minimizing wear on mechanical components and ensuring compliance with European regulations by maintaining low hydrogen peroxide levels, with air cleaned to less than 0.4 ppm near operators and 1 ppm in non-accessible zones.
Implementation Method 1
A packaging machine with a fluidic conveying system that includes a scrubber to remove peroxide residues from the air and sterilizing agent, using a scrubbing solution to increase solubility and separate the residues from cleaned air
Data Source
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AI summary
There is described a packaging machine (1) for producing sealed packages (9) of pourable food products from a web (3) of packaging material, comprising: an aseptic chamber (21) through which web (3) is fed and within which a sterilizing agent is applied onto web (3); a station (22) which is arranged downstream from said aseptic chamber (21) and in which a tube (10) formed by web (3) is, in use, fed; and sealing means (25) which separate chamber and station (22); packaging machine (1) also comprise conveying means (30) fluidically connected with station (22) and adapted to convey away residues of sterilizing agent from station (22).