Pharmaceutical Container Washing Circuit Recirculation for Sterile Restart
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Solution Overview
Problem
When a washing system for pharmaceutical containers is temporarily stopped, the pipes cool down, causing the fluid to lose sterility and prolonging the time required to restart the system due to the need to reheat both the fluid and pipes.
Innovation Solution
A method and system that involves recirculating heated fluid within the pre-washing circuit during a temporary stop to maintain pipe temperature and sterility, allowing immediate restart of pre-washing operations, and heating the washing circuit during restart to ensure sterility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the washing system is temporarily stopped, then energy consumption is reduced by interrupting fluid supply, but the pipes cool down causing loss of sterility and prolonging restart time
Solution Approach 1:
The fluid circulation system is segmented into two independent circuits: a washing circuit that can be interrupted during temporary stops, and a pre-washing circuit that maintains continuous circulation to preserve pipe temperature and sterility. This segmentation allows energy-saving interruption in the washing circuit while maintaining temperature in the pre-washing circuit.
Solution Approach 2:
The pre-washing circuit is prepared in advance by maintaining continuous fluid circulation and heating during temporary stops, so that when restart is needed, the pipes are already at the required temperature and sterility level, eliminating the need for time-consuming reheating of pre-washing pipes.
2Temperature
If heated fluid is circulated through cold pipes during restart, then pipes are brought up to temperature, but the fluid cools down losing sterility and requiring reheating
Solution Approach 1:
The system separates the heating function into two independent circuits: the washing circuit handles heating of cold pipes during restart, while the pre-washing circuit maintains its own temperature through continuous circulation. This prevents the pre-washing fluid from cooling down while still allowing washing pipes to be heated.
Solution Approach 2:
The pre-washing circuit maintains continuous fluid circulation and heating even during temporary stops and restart phases, ensuring that the fluid always remains at sterilizing temperature and sterile, ready for immediate use when containers need pre-washing.
3Temperature
If the recovery tank heater is kept active during temporary stops, then fluid temperature is maintained, but energy is wasted when fluid is not being used
Solution Approach 1:
The heating function is segmented between the recovery tank heater (for washing fluid) and the pre-washing circuit heater (for pre-washing fluid). During temporary stops, only the pre-washing circuit heater remains active with continuous circulation, while the recovery tank heater can be interrupted, reducing energy waste while maintaining necessary temperature.
Solution Approach 2:
The pre-washing circuit serves itself by maintaining continuous circulation and heating through its own dedicated heater, ensuring temperature maintenance without requiring the recovery tank heater to remain active during temporary stops.
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
Facilitates quick restart of the washing system by maintaining pipe sterility and reducing energy consumption by minimizing the need for recirculating hot fluid during temporary stops.
Implementation Method 1
The recovery tank comprises a heater, usually an electric resistor, placed at the bottom of the tank to heat the recovered fluid
Implementation Method 2
recirculating fluid between the recovery tank, the pre-washing delivery branch and the recirculation branch, and heating said fluid while it recirculates
Implementation Method 3
heating the pipes can be performed simply by running heated fluid through the pipes until the fluid releases sufficient heat to the pipes to bring them to a predetermined temperature
Data Source
AI summary
A method for washing containers for pharmaceutical use includes the steps of sending heated fluid to washing nozzles of a washing station through a washing circuit; sending fluid dispensed by the washing nozzles to a recovery tank through the washing circuit; sending fluid from the recovery tank to pre-washing nozzles of a pre-washing station through a pre-washing delivery branch of a pre-washing circuit. If the washing system temporarily stops, further steps include interrupting fluid delivery to the pre-washing nozzles; connecting a recirculation branch of the pre-washing circuit with the pre-washing delivery branch and with the recovery tank; recirculating fluid among the recovery tank, the pre-washing delivery branch and the recirculation branch; and heating the fluid while it recirculates. A washing system associated with the method is also presented.