Plasma Mist Sterilization for Flexible Packaging Tubes
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Solution Overview
Problem
Current methods for sterilizing packaging materials for fluent products require extensive sterile environments, leading to significant downtime and space constraints due to the need for prolonged immersion in sterilizing baths or electron beam irradiation, and plasma mist technology is primarily used for large-scale sterilization rather than in-line packaging processes.
Innovation Solution
A packaging machine with a filling head that injects a plasma mist into the interior of forming laminate tubes or sachets and extracts it, allowing for in-line sterilization without the need for a fully sterile environment, using a cylindrical pipe with apertures to ensure the mist sterilizes the interior surfaces before product contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If immersion sterilization is used for laminate material, then sterility is achieved, but substantial space is required for the sterilizing bath
Solution Approach 1:
The patent replaces the mechanical immersion sterilization system with a plasma-based sterilization system. The plasma is generated by passing a gas (such as nitrogen or air) through an electromagnetic field to create reactive species that sterilize the laminate material as it passes through the treatment zone, eliminating the need for large immersion baths
Solution Approach 2:
The patent uses a gas flow system to deliver plasma to the laminate material. A gas is fed through a nozzle or channel adjacent to the moving laminate, and the plasma generated from this gas contacts the material surface for sterilization, replacing liquid-based immersion with a gaseous plasma delivery system
2Reliability
If prolonged immersion in sterilizing bath is used, then satisfactory sterility is achieved, but production speed is reduced
Solution Approach 1:
The plasma sterilization system operates continuously as the laminate material moves through the treatment zone. The plasma is generated continuously and contacts the material surface in real-time during transit, allowing sterilization to occur without stopping the production line or requiring prolonged exposure times
Solution Approach 2:
The plasma treatment is applied as a periodic pulse or continuous stream along the path of the moving laminate, ensuring that each section of the material receives adequate sterilization exposure as it passes through the treatment zone, maintaining sterility while accommodating production speed requirements
3Reliability
If a sterile enclosure is created for filling machinery, then sterility is maintained, but access for operators requires re-sterilization and causes downtime
Solution Approach 1:
The patent extracts the sterilization function from a separate pre-treatment stage and integrates it directly into the filling head where the laminate is formed into tubes. This allows the critical sterilization to occur at the point of need, reducing or eliminating the requirement for large sterile enclosures and associated downtime
Solution Approach 2:
The plasma sterilization is applied to the laminate material immediately before it is formed into the final tube structure and filled with product. This preliminary sterilization at the critical moment ensures sterility is achieved when most needed, without requiring extended sterile enclosure periods
4Reliability
If electron beam irradiation is used for sterilization, then sterility is achieved, but the equipment complexity and space requirements increase
Solution Approach 1:
The patent changes the sterilization parameter from high-energy electron beams to low-energy plasma generated from common gases. This plasma can be generated using simpler electromagnetic fields and gas flow systems, reducing equipment complexity while maintaining effective sterilization through reactive oxygen and nitrogen species
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 enables efficient, continuous production of sterile packaging without the need for a fully sterile environment, as the plasma mist breaks down into harmless components upon contact with the product, reducing equipment sterilization requirements and maintaining optimal sterilization conditions through controlled mist flow and composition.
Implementation Method 1
passes the solution through an atmospheric cold plasma arc, which produces a highly reactive oxygen species. This species, which is commonly known as ozone, kills and inactivates bacteria, viruses and mould spores
Implementation Method 2
produces a highly reactive oxygen species. This species, which is commonly known as ozone, kills and inactivates bacteria, viruses and mould spores by lysis of proteins, carbohydrates and lipids
Data Source
AI summary
Described herein is a method of forming individual tubes or sachets containing fluent material, and a packaging machine for doing so, are described. The side of the foil which will be in contact with the fluent material when the package is formed is exposed to plasma in mist or aerosol form as the tube or sachet is formed from a strip of laminate material (1), which is folded about a former (2) into a closed tube or sachet which passes over the open end of a dispensing tube (3) from which the fluent material is dispensed. A mist of plasma is injected into the interior of the material tube as it is formed, extracted from the area once it has passed over the interior walls of the laminate tube.