Pasteurization Waste Water Recovery for Energy Reduction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Bottling plants face high energy and water consumption due to the inefficiencies in pasteurization systems and rinsing processes, where waste water from rinsers is typically discarded rather than reused.

Innovation Solution

The method involves utilizing the low internal energy of waste water from rinsers as a cooling medium within the pasteurization system, either directly as spray water or through a buffer storage, to shorten the cooling section and reduce system size, and potentially using it to heat containers before pasteurization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If waste water from rinsers is discarded as waste water, then the rinsing process can be simple and fast, but energy and water consumption increase significantly

Engineering Contradiction:

Improverinsing speedVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent recovers waste water from the rinsing process and redirects it to the pasteurization system. The waste water is collected in a collection chamber and pumped to a heat exchanger, where it is heated using steam or hot water from the pasteurization system. This recovered hot water is then used in the rinsing process, transforming a waste stream into a useful resource and significantly reducing both energy and water consumption.

Inventive Principle:

Principle #34Discarding and recovering

2Quantity of substance

If waste water from rinsers is discarded, then water quality requirements for fresh water are not compromised, but water consumption increases

Engineering Contradiction:

Improvefresh water qualityVSAvoidwater consumption

Core Design Contradiction:

Quantity of substanceVSLoss of substance

Solution Approach 1:

The patent implements a water recovery system where waste water from the rinsing process is collected and reused. The collection chamber gathers waste water, which is then pumped through a heat exchanger for heating. The heated waste water is returned to the rinsing process, creating a closed-loop water system that maintains water quality while dramatically reducing overall water consumption.

Inventive Principle:

Principle #34Discarding and recovering

3Reliability

If the cooling section of pasteurization system is extended to ensure effective cooling, then pasteurization quality is improved, but system size and energy consumption increase

Engineering Contradiction:

Improvepasteurization qualityVSAvoidsystem size

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent converts the waste heat from the rinsing process into a useful cooling resource. The waste water, which would normally be discarded as a harmful waste stream, is instead used as a cooling medium in the pasteurization system. The heat exchanger transfers heat from the waste water to the process water, providing effective cooling while reducing the required system size and energy consumption.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Strength

If multiple treatment zones are used to achieve gradual heating and cooling, then container integrity is improved, but device complexity increases

Engineering Contradiction:

Improvecontainer integrityVSAvoidnumber of treatment zones

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the rinsing process with the pasteurization system by integrating the waste water recovery and reuse loops. The collection chamber, heat exchanger, and pump system are integrated into the existing pasteurization equipment, allowing the rinsing process to serve dual purposes: cleaning containers and providing cooling water for the pasteurization process. This integration reduces overall system complexity while maintaining container integrity through controlled temperature changes.

Inventive Principle:

Principle #5Merging (Combining)

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 reduces energy and water consumption by reusing waste water, shortening the pasteurization process, and minimizing the size of the pasteurization system while maintaining effective pasteurization.

Implementation Method 1

the waste water occurring at the rinser is used at least in part directly as spray water for treating the containers, in particular for cooling the containers

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

The containers and thus the product contained in them are heated in the heating section and in the overheating or sterilization section by spraying the containers with a heated spray liquid

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentEP2117361B1Method for reducing power consumption in pasteurizing plants, and filling station

Publication Date: 2015.06.24 KHS GMBH

Figure 1
Figure 2
Figure 3

AI summary

The invention relates to a method for reducing power consumption in plants used for pasteurizing bottles or similar containers that are filled with a liquid filling material and are closed. In said method, the containers are treated with water in a rinsing machine before being filled, are heated during the pasteurization process, and are then cooled.