Aseptic Pouch Filler Assembly With Zoned Vacuum Sterilization

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Solution Overview

Problem

Existing filler assemblies face challenges in filling pouches with flowable materials in an aseptic environment while minimizing contamination and improving sterilization efficiency, fluid circulation, and pouch handling.

Innovation Solution

A filler assembly with sequential zones for preheating, sterilization, and flushing, utilizing nozzle assemblies with vacuum systems and a pouch movement mechanism to enhance aseptic filling, including preheat, sterilization, and flush zones with multiple nozzle assemblies and a helical screw-based movement system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sterilization steps are implemented in the filler assembly, then aseptic filling is achieved, but fluid removal efficiency decreases and contamination risk increases

Engineering Contradiction:

Improveaseptic fillingVSAvoidfluid removal efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The filler assembly is divided into distinct functional zones: a sterilization zone with sterilization nozzles and vacuum nozzles, and a separate flush zone with flush nozzles and vacuum nozzles. This segmentation allows independent optimization of each zone's fluid removal efficiency while maintaining overall aseptic integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Vacuum is applied continuously through multiple stages: during sterilization to remove sterilization fluids, then during flush to remove flush fluids. The vacuum system operates continuously without interruption, ensuring efficient fluid removal at each stage while maintaining aseptic conditions.

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If multiple vacuum nozzles are used in each zone, then fluid removal improves, but device complexity increases

Engineering Contradiction:

Improvefluid removal efficiencyVSAvoidnumber of nozzle assemblies

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Each zone contains both sterilization nozzles and flush nozzles that can operate independently or in coordination. The vacuum nozzles are designed to work with both sterilization and flush operations, providing multi-functionality that reduces the need for separate dedicated vacuum systems for each fluid type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The sterilization and flush zones are integrated into a single filler assembly structure, sharing common support elements and vacuum systems. This merging approach consolidates multiple functions into a unified device while maintaining the distinct operational zones required for effective fluid removal.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If pouch assemblies are moved through multiple zones sequentially, then aseptic filling is achieved, but handling complexity increases

Engineering Contradiction:

Improveaseptic fillingVSAvoidpouch handling mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

A support element acts as an intermediary carrier that holds multiple pouch assemblies and moves them sequentially through the sterilization zone, flush zone, and filling zone. This intermediary mechanism simplifies the handling of multiple pouches by providing a single coordinated movement system rather than individual handling for each pouch.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enhances aseptic filling by improving sterilization efficiency, reducing contamination, and optimizing fluid circulation and pouch handling, ensuring high-quality filling of pouches with flowable materials.

Implementation Method 1

a vacuum is pulled on the pouch assembly in the preheat zone with the preheat vacuum nozzle prior to attachment of the pouch assembly to the at least one sterilization nozzle assembly

Methodology Applied

Scientific EffectVacuum suction: Suction

Implementation Method 2

The pouch preheat zone includes at least one preheat nozzle assembly having an inlet and an outlet, wherein the outlet engageable with a pouch assembly

Methodology Applied

Scientific EffectThermal heating: Heating

Implementation Method 3

The pouch sterilization zone is positioned after the pouch preheat zone and includes at least one sterilization nozzle assembly having an inlet and an outlet, wherein, the outlet engageable with a pouch assembly

Methodology Applied

Scientific EffectChemical sterilization: Oxidation

Data Source

PatentUS20260035117A1Filler assembly and method of filling a pouch

Publication Date: 2026.02.05 SCHOLLE IPN CORP

AI summary

A filler assembly comprising a pouch preheat zone, a pouch sterilization zone, and a pouch flush zone. The preheat zone includes a preheat nozzle assembly having an inlet and an outlet, the outlet engageable with a pouch assembly, and a preheat vacuum nozzle assembly having an inlet engageable with a pouch assembly and an outlet attachable to a vacuum. The pouch sterilization zone includes a sterilization nozzle assembly having an inlet and an outlet, the outlet engageable with a pouch assembly, and, a sterilization vacuum nozzle assembly having an inlet engageable with a pouch assembly and an outlet attachable to a vacuum. The pouch flush zone includes a pouch flush nozzle assembly having an inlet and an outlet, the outlet engageable with a pouch assembly, and, a pouch flush vacuum nozzle assembly having an inlet engageable with a pouch assembly and an outlet attachable to a vacuum.