Plasma Treatment of Thermoplastic Preforms for Residue Removal
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Solution Overview
Problem
The existing methods for decontaminating thermoplastic containers using hydrogen peroxide result in residual concentrations that can alter packaged products and exceed regulatory limits, particularly in small-capacity containers, due to incomplete removal of hydrogen peroxide residues.
Innovation Solution
A process involving the sequential treatment of thermoplastic hollow bodies with hydrogen peroxide deposition, thermal activation, and plasma treatment to reduce hydrogen peroxide residues, where the plasma is introduced into the hollow body to break down the hydrogen peroxide into harmless components, thereby reducing concentrations below regulatory limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrogen peroxide is used for decontamination of thermoplastic containers, then microbial contaminants are eliminated, but hydrogen peroxide residues remain that can alter packaged products and exceed regulatory limits
Solution Approach 1:
The patent extracts and removes hydrogen peroxide residues from the container interior using a purification system that introduces inert gas to displace and vent the residues outside, separating the harmful substance from the final product
Solution Approach 2:
The patent changes the physical and chemical parameters of the treatment process by controlling temperature, gas flow rates, and purification duration to optimize the removal of hydrogen peroxide residues while maintaining decontamination efficacy
2Reliability
If thermal activation is used to activate hydrogen peroxide for decontamination, then microbial elimination is enhanced, but hydrogen peroxide decomposition is incomplete leaving residues
Solution Approach 1:
The patent implements continuous purging with inert gas after thermal activation to continuously remove decomposed hydrogen peroxide residues and byproducts from the container, ensuring complete elimination without interrupting the protective atmosphere
Solution Approach 2:
The patent introduces inert gas as an intermediary substance that facilitates the removal of hydrogen peroxide residues by creating a displacement flow that carries residues out of the container without reacting with them
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
The process effectively minimizes hydrogen peroxide residues in containers, ensuring compliance with regulatory standards and preventing product alterations, while maintaining decontamination efficacy.
Implementation Method 1
the sterilizing agent consisting of hydrogen peroxide is deposited by condensation on the inner wall of the preform, in the form of a uniform film of mist
Implementation Method 2
The preform is then thermally conditioned in an oven to be softened with the aim of then undergoing a transformation into a container by blow molding or by stretch blow molding, the heating of the preform then also having the function of thermally activating the hydrogen peroxide
Implementation Method 3
At least a portion of the hydrogen peroxide is then evaporated under the effect of the heating, going from the liquid state, in which it is found after having been deposited by condensation, to the gaseous state
Implementation Method 4
treating the hollow body with plasma to reduce the concentration of hydrogen peroxide residue there
Data Source
AI summary
Disclosed is a process for treating at least one hollow body made of thermoplastic material, such as a preform or a cap, the treatment process successively including at least the following steps: a first step, consisting in treating at least the inside of the hollow body using hydrogen peroxide; a second step, consisting in heating the hollow body; a third step, consisting in treating the hollow body with plasma in order to reduce the concentration of hydrogen peroxide residues. Also disclosed is a plant for manufacturing containers in which the process is carried out in particular by way of a unit for the plasma treatment of the preforms.