Container Neck Sterilization Using Plasma Isolation
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Solution Overview
Problem
Aseptic bottling lines face challenges with substantial sterilization volumes, complex structures, and difficulty in maintaining sterility, leading to lengthy and costly procedures, as well as practical limitations during format changes and maintenance due to the risk of contamination.
Innovation Solution
An apparatus with a rotating carousel and individual treatment volumes for each container neck, using tubular elements and plasma generators to create sterile environments, allowing for efficient sterilization and reduced downtime by isolating the neck from the external environment and maintaining continuous fluid flow to prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cleanroom is used to contain all filling apparatus, then sterility is maintained, but the volume becomes substantial and sterilisation procedures become lengthy and expensive
Solution Approach 1:
The patent divides the cleanroom into separate isolators, each containing a specific filling machine (first filling machine, second filling machine). This segmentation allows each isolator to be sterilized independently and reduces the total volume requiring sterilization compared to a single large cleanroom, while maintaining sterility for each filling operation.
Solution Approach 2:
The patent extracts the filling machines from the main cleanroom environment by placing them within dedicated isolators. This allows the main cleanroom volume to be reduced while maintaining sterile conditions only in the specific zones where filling occurs, eliminating the need to sterilize the entire large cleanroom volume.
2Reliability
If a cleanroom is used to contain all filling apparatus, then sterility is maintained, but operating fluid wastage increases
Solution Approach 1:
By segmenting the cleanroom into separate isolators for each filling machine, the patent reduces the volume of sterile environment required. This decreases the amount of sterile air and sanitization liquids needed to maintain sterility, thereby reducing operating fluid wastage while maintaining sterility where it is most critical.
3Reliability
If a cleanroom is used to contain all filling apparatus, then sterility is maintained, but access for maintenance and format change becomes difficult
Solution Approach 1:
The patent segments the filling system into separate isolators, each housing a specific filling machine. This allows maintenance personnel to access individual isolators for maintenance and format changes without needing to enter or contaminate a large entire cleanroom, making maintenance easier while maintaining sterility in the operational zones.
Solution Approach 2:
By extracting each filling machine into its own isolator, the patent enables maintenance operations to be performed on individual units without affecting the entire cleanroom environment. This simplifies access for maintenance and format changes while preserving sterility in the remaining operational areas.
4Reliability
If isolators are used to protect process zones, then sterility is maintained, but structural complexity increases
Solution Approach 1:
The patent uses segmentation to create separate, modular isolators for each filling machine rather than one large complex cleanroom. This modular approach simplifies the overall structure by breaking down the system into manageable, standardized units that are easier to construct and maintain, while still providing the necessary sterility protection.
5Reliability
If isolators are used to protect process zones, then sterility is maintained, but the volumes to be sterilised remain considerable
Solution Approach 1:
The patent segments the sterile environment into separate isolators, each with a smaller volume than a comprehensive cleanroom would require. This reduces the total volume needing sterilization while maintaining sterility in the critical process zones where containers are filled and capped.
Solution Approach 2:
The patent extracts only the essential process zones (filling and capping areas) into isolators, excluding non-critical areas from the sterile environment. This minimizes the volume requiring sterilization while ensuring sterility is maintained where it is most needed for 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 solution reduces sterilization volumes and time, enhances practicality and safety by allowing individual container maintenance, and reduces downtime through focused sterilization of only necessary container surfaces, ensuring efficient and flexible operation.
Implementation Method 1
said second means comprises a plasma generator configured to generate plasma
Implementation Method 2
means for separating a treatment volume of the individual neck of each container from an external environment
Data Source
AI summary
A method for filling a container (2) with a filling product, comprising the steps of: positioning the container (2) in a filling station (1) so that its mouth (2b) is below the filling valve (9); separating a treatment volume (40) of the neck (2a) comprised between the filling valve (9) and at least one part of the neck (2a) of the container (2) from an external environment (6) containing the body (2d) of the container (2); dispensing plasma into the treatment volume (40) so that it flows over the neck (2a) of the container (2); enabling the filling valve (9) to dispense the filling product into the container (2).