Packaging Material Sterilization with Two-Stage Hydrogen Peroxide and UV
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Solution Overview
Problem
Existing methods for producing packaging containers with low microbiological loads struggle to effectively exterminate mould spores, which can contaminate the packaging material and limit shelf-life, especially when stored in certain environments.
Innovation Solution
A method involving the application of a chemical sterilization agent, such as hydrogen peroxide, in two stages: a first partial quantity applied before UV-light irradiation to allow sufficient absorption time for microorganisms, and a second partial quantity applied in a sterile chamber just before irradiation, maximizing exposure time and ensuring effective extermination of mould spores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a chemical sterilization agent is applied to exterminate mould spores on packaging material, then the microbiological load is reduced, but the shelf-life is still limited due to insufficient extermination of mould spores
Solution Approach 1:
The patent applies the first partial quantity of chemical sterilization agent in advance, sufficiently long before UV irradiation, to allow mould spores to absorb the agent. This preliminary action ensures that when UV irradiation occurs, the spores have already taken up enough sterilization agent to be effectively exterminated, thereby extending shelf-life by addressing the insufficiency of conventional single-stage treatment.
2Reliability
If the concentration of chemical sterilization agent is increased to ensure thorough extermination of microorganisms, then the microbiological load is reduced, but the cost and environmental impact increase
Solution Approach 1:
The patent divides the chemical sterilization agent application into two distinct stages: a first partial quantity applied in advance to allow absorption by microorganisms, and a second partial quantity applied immediately before UV irradiation. This segmentation enables effective sterilization at lower overall concentrations, reducing cost and environmental impact while maintaining thorough extermination of microorganisms including mould spores.
3Productivity
If UV-light irradiation is applied immediately after chemical sterilization agent application, then the process is rapid, but mould spores do not have sufficient time to absorb the sterilization agent
Solution Approach 1:
The patent implements a time-delayed two-stage application where the first partial quantity of sterilization agent is applied sufficiently long before UV irradiation to allow mould spores to absorb the agent. This preliminary absorption phase ensures that when irradiation occurs, the spores contain enough sterilization agent for effective extermination, resolving the contradiction between rapid processing and effective sterilization.
4Device complexity
If a single stage application of chemical sterilization agent is used, then the process is simple, but it is ineffective against mould spores which take longer to absorb the agent
Solution Approach 1:
The patent segments the chemical sterilization agent application into two distinct stages with different timing and purposes. The first partial quantity is applied in advance to allow absorption by mould spores, while the second partial quantity is applied immediately before UV irradiation. This segmentation overcomes the limitation of single-stage application against mould spores while maintaining reasonable process complexity.
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 significantly increases the shelf-life of packaged products by ensuring thorough extermination of microorganisms, including mould spores, while maintaining a low concentration of chemical sterilization agent, allowing for non-refrigerated distribution in some cases.
Implementation Method 1
a first partial quantity of a chemical sterilization agent is applied on the packaging material a sufficiently long time before the packaging material is irradiated with UV-light in order that a predetermined portion of expected microorganisms will have time to absorb a sufficient amount of the chemical sterilization agent
Implementation Method 2
the packaging material is irradiated with UV-light
Data Source
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AI summary
The invention relates to a method of producing a packaging container with low microbiological load by treating the packaging material with a combination of a chemical sterilization agent and UV-light. The invention is characterised in that a first partial quantity of the chemical sterilization agent is applied on the packaging material a sufficiently long time before the packaging material is irradiated with UV-light in order for a predetermined portion of expected microorganisms to have time to absorb a sufficient amount of the chemical sterilization agent in order to be exterminated on being irradiated with UV-light, and that a second partial quantity of the chemical sterilization agent is applied on the packaging material in a sterile chamber before the packaging material is irradiated with UV-light. The invention also relates to a device for realising the method, and a filling machine provided with the device.