Powder Packaging System Vacuum Deaeration Dosing
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Solution Overview
Problem
The packaging of powders faces challenges in achieving precise dosing due to variations in flow rate caused by non-homogeneous powder compaction and air entrapment, which affects the weight and organoleptic properties of the product.
Innovation Solution
A system with a vacuum area inside the tube and hopper, utilizing a screw conveyor and filtering material, where air is suctioned from the gap between tubes to compact the powder uniformly, maintaining a constant flow rate and allowing precise dosing control through a pressure sensor and vacuum pump adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If deaerators are used to remove air from powder, then the volume of powder is reduced and organoleptic properties are preserved, but the flow rate of powders becomes non-homogeneous and dosing precision deteriorates
Solution Approach 1:
The system divides the powder handling into two distinct zones: a deaeration zone where air is removed from the powder in the hopper, and a dosing zone where the screw conveyor delivers compacted powder. This segmentation allows air removal without disrupting the homogeneity needed for precise dosing.
Solution Approach 2:
The screw conveyor acts as an intermediary device that receives deaerated powder from the hopper and compacts it into homogeneous blocks before delivery. This intermediary action transforms the non-homogeneous deaerated powder into dosable units with consistent flow characteristics.
2Quantity of substance
If vacuum is applied to convey powder, then air is extracted and powder compaction is achieved, but the flow rate varies due to discontinuous powder blocks
Solution Approach 1:
The system performs preliminary deaeration and compaction of powder in the hopper and first tube before the powder enters the conveying stage. This preliminary action ensures that powder is pre-compacted into homogeneous blocks, which then flow more consistently through the vacuum conveyor.
Solution Approach 2:
The system changes the physical parameters of powder (density, compaction level, air content) in the initial zones before conveyance. By adjusting these parameters through vacuum deaeration and screw compaction, the powder transforms from a loose, non-homogeneous state to a compacted, consistent state that flows more uniformly.
3Manufacturing precision
If powder is compacted to increase density, then volume is reduced and dosing precision improves, but air entrapment increases and flow homogeneity worsens
Solution Approach 1:
The screw conveyor operates continuously to compact powder into homogeneous blocks while maintaining steady flow. This continuous action ensures consistent compaction levels and uniform block formation, preventing air entrapment that would occur with intermittent or variable compaction.
Solution Approach 2:
The system replaces simple gravitational flow with mechanically-driven screw compaction and vacuum-assisted conveyance. This mechanical substitution allows precise control over compaction levels and flow characteristics, achieving both density and homogeneity that gravity alone cannot provide.
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 enables precise control of powder dosing, reduces air content, and extends product shelf life by preventing oxidation, while being adaptable for various powder types and quantities.
Implementation Method 1
the second tube comprises a first opening configured to be able to suck air from the gap and from the hopper
Implementation Method 2
making a vacuum area inside the tube where the powder is transported and inside the hopper
Implementation Method 3
the first tube is made of filtering material and is arranged inside a second tube
Data Source
AI summary
The present document presents a system and a method for packaging powders in containers (S) through a hopper (T) and a first tube (TC) connected to the hopper (T). Air is sucked both in the area of the first tube and in the area of the hopper. The powder is then drawn directly from inside the hopper thus keeping the flow rate and the degree of compacting of the system constant. Moreover, the powder sucked inside the first tube is thus compacted and can be conveyed compacted towards the outlet. In this way it is possible to control the dosing of the product exiting from the system with high precision.