Packed Product Sterilization via Inert Gas Atmosphere
Solution Overview
Problem
Packed products face issues with uncontrolled condensation of steam in containers, leading to negative pressure and potential bacterial growth due to moisture, which affects product quality and stability.
Innovation Solution
Replacing part of the superheated steam atmosphere in packing containers with an inert gas, such as nitrogen or carbon dioxide, before sealing, to prevent condensation and maintain a stable atmosphere, thereby eliminating unwanted pressure and moisture issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the packing container is filled in a superheated steam atmosphere and sealed, then the product achieves sterilization and preservation, but uncontrolled condensation of steam occurs after cooling causing negative pressure and potential bacterial growth
Solution Approach 1:
The patent replaces part of the steam atmosphere in the packing container with an inert gas (nitrogen or carbon dioxide) before sealing. This creates a controlled gas mixture that prevents uncontrolled condensation while maintaining the sterilization benefits of steam. The inert gas displaces oxygen and controls the condensation behavior of remaining steam, eliminating negative pressure issues and preventing bacterial growth.
Solution Approach 2:
The patent modifies the composition parameters of the gas atmosphere by introducing inert gas at specific concentrations (at least 10 vol.-%, preferably at least 20 vol.-%). This parameter change transforms the purely steam-based atmosphere into a controlled mixture, fundamentally altering the condensation characteristics and pressure behavior during cooling while preserving sterilization efficacy.
2Reliability
If steam atmosphere is used for filling, then product sterilization is achieved, but substantial negative pressure develops after cooling affecting rigid containers
Solution Approach 1:
By introducing inert gas into the steam atmosphere before sealing, the patent creates a gas mixture where the inert component does not condense during cooling. This prevents the substantial negative pressure that would otherwise develop in rigid containers due to complete steam condensation, while maintaining the sterilization function of the steam portion.
Solution Approach 2:
The inert gas acts as an intermediary substance between the steam and the container environment. It mediates the pressure changes during cooling by providing a non-condensing gas phase that maintains pressure equilibrium, preventing the vacuum effect that would occur with pure steam condensation in rigid containers.
3Temperature
If steam condenses on container walls during cooling, then product moisture increases creating favorable conditions for bacterial growth
Solution Approach 1:
The inert gas creates an oxygen-displaced atmosphere that fundamentally changes the condensation behavior. While steam may still condense on container walls during cooling, the absence of oxygen and the presence of inert gas prevents the condensed moisture from creating favorable conditions for aerobic bacterial growth, thus allowing efficient cooling without compromising product safety.
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 ensures controlled condensation of gases, preventing negative pressure and bacterial growth, ensuring the product's durability and quality by maintaining a stable environment within the container.
Implementation Method 1
more or less uncontrolled condensation of steam remaining in the packing container after sealing which may affect quality and long term stability of the product
Implementation Method 2
a product is brought into a superheated steam atmosphere and filled in the steam atmosphere into a packing container
Implementation Method 3
CA 2 898 643 A1 discloses a method for auto manufacture of a packed product in a superheated steam atmosphere with an O 2 content of max. 3 % and a temperature of at least 120 °C
Data Source
Figure 1
AI summary
Method for manufacturing a packed product, comprising the steps of: a) bringing a product into a superheated steam atmosphere with an O2 content of maximum 10 vol.-%, a pressure of between 950 mbar and 1100 mbar and a temperature of minimmn 100°C, b) making available a packing container in the steam atmosphere and filling the packing container with a predetermined quantity of the product, wherein a residual volume of the packing container not filled with product is filled with the steam atmosphere, c) replacing at least 50% of the residual volume of steam atmosphere in the packing container by a sterile inert gas, d) sealing the packing container, and e) cooling the packing container and the product contained therein to a temperature of between 10°C and 25°C.