Pouch Residual Air Reduction Device Using Gravity Drainage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for reducing residual air in pouch packaged products are complex, costly, and labor-intensive, with limited success in achieving the desired low air levels, which can lead to product appearance issues due to oxidation.
Innovation Solution
A device with a bump surface and alignment sides, adjustable bump angle, and attachment flange is integrated into the manufacturing line to contact pouches and effectively reduce residual air by releasing trapped air into the head space, allowing for customizable dimensions and angles to suit various products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical devices such as vibratory or squeezing stations are used to reduce residual air, then residual air reduction is achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The invention extracts the air removal function from complex mechanical vibration or squeezing systems and implements it through a simple gravity-based drainage structure. The pouch is oriented vertically with the opening at the bottom, allowing air to naturally drain out through the opening without requiring active mechanical intervention, thus achieving air removal while dramatically simplifying the device complexity.
Solution Approach 2:
The invention replaces complex mechanical vibration or squeezing systems with a passive gravity-based system. By simply orienting the pouch vertically and allowing air to drain through the opening under gravity, the need for vibratory motors, squeezing mechanisms, or complex mechanical actuators is eliminated, substituting a mechanical system with a gravity-based passive system.
2Manufacturing precision
If complex mechanical devices are deployed for air removal, then some residual air reduction is achieved, but manufacturing cost and labor intensity increase
Solution Approach 1:
The invention enables the pouch filling system to be self-servicing for air removal. By orienting the pouch vertically with the opening at the bottom during filling, the system uses its own structure and gravity to automatically drain air without requiring external mechanical assistance, complex control systems, or additional energy input, making the air removal process self-service and cost-effective.
Solution Approach 2:
The invention extracts the air removal function from expensive mechanical devices and implements it through a simple structural modification - vertical pouch orientation with bottom opening. This extraction eliminates the need for costly vibratory stations, squeezing mechanisms, or vacuum systems, achieving air removal through a simple gravitational drainage approach that is easy to manufacture and implement.
3Productivity
If traditional filling processes are used, then manufacturing speed is maintained, but residual air causes product oxidation and appearance deterioration
Solution Approach 1:
The invention performs preliminary air removal action during the filling process itself by orienting the pouch vertically with the opening at the bottom, allowing air to drain out before the product is fully enclosed. This preliminary action prevents oxygen from remaining in the pouch, thereby preventing subsequent oxidation and appearance deterioration without requiring separate post-filling air removal steps, thus maintaining manufacturing speed while improving product quality.
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 solution significantly reduces residual air in pouches by up to 40% compared to traditional methods, minimizing oxidation-related product appearance issues and improving manufacturing efficiency.
Implementation Method 1
contacting the package with a device at a specific contact point to maximize residual air reduction
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The present disclosure relates to removing residual air in a packaged product. In particular, the present disclosure is directed to a residual air reduction device and to methods of using such device to reduce the amount of residual air in a packaged product. Such a device is employed during the manufacturing process to release air trapped in a product matrix and/or in a head space of the package as the package contacts the device. In some embodiments, the device and methods of the disclosure are useful in reducing residual air in a pouch package by at least 5% in comparison to a pouch package manufactured without use of the device and/or methods described herein.