Preform Sterilization with Low-Concentration Hydrogen Peroxide
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Solution Overview
Problem
Conventional aseptic filling machines require excessive hydrogen peroxide for sterilizing preforms, leading to residual hydrogen peroxide in bottles, which can contaminate drinks and cause molding defects due to non-uniform sterilization and high temperatures.
Innovation Solution
A method involving gasification of a sterilizer containing 30% or less hydrogen peroxide and a solvent with a boiling point of 85°C or lower, combined with ultraviolet light irradiation, to reduce residual hydrogen peroxide and ensure uniform sterilization of preforms before blow-molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high concentration of hydrogen peroxide sterilizer is applied to the preform, then sterilization effectiveness is improved, but residual hydrogen peroxide in the bottle increases which can contaminate drinks
Solution Approach 1:
The patent introduces an intermediary substance (solvent with low boiling point) that facilitates the sterilization process by allowing controlled decomposition of hydrogen peroxide. The solvent acts as a carrier that enables the sterilizer to function effectively while being easily removable, thus reducing residual contamination in the final product
Solution Approach 2:
The patent changes the concentration parameter of hydrogen peroxide in the sterilizer composition, using a lower concentration (30% or less) combined with a solvent. This parameter change allows achieving sufficient sterilization effectiveness while reducing the amount of residual hydrogen peroxide that could contaminate the drink
2Reliability
If high temperature heating is applied to the preform for sterilization, then sterilization effectiveness is improved, but molding defects occur due to non-uniform heating
Solution Approach 1:
The patent changes the temperature parameter by using a lower concentration sterilizer that can effectively sterilize at lower temperatures. This avoids the non-uniform heating problems associated with high temperature processing while maintaining sterilization effectiveness
Solution Approach 2:
The patent uses a composite sterilizer composition consisting of hydrogen peroxide combined with a solvent having specific properties (boiling point of 85°C or lower). This composite formulation enables effective sterilization through chemical action rather than relying solely on high temperature, thus preventing molding defects
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 approach effectively reduces hydrogen peroxide residues in bottles, enhances sterilization efficiency, and prevents molding defects by ensuring uniform heating and thorough sterilization, particularly for the mouth portion of the preform.
Implementation Method 1
a sterilizer gas blasting step of gasifying a sterilizer at least containing 30% by mass or less of hydrogen peroxide and a solvent having a boiling point of 85°C or lower and blasting the sterilizer gas to the preform
Implementation Method 2
the preform is then introduced into a heating furnace and heated in the heating furnace to a temperature suitable for molding the preform into a container
Implementation Method 3
a sterilizer containing 25% by mass of hydrogen peroxide and ethanol... a solvent having a boiling point lower than 100°C
Implementation Method 4
gasifying a sterilizer at least containing 30% by mass or less of hydrogen peroxide and a solvent having a boiling point of 85°C or lower
Data Source
Figure 1
Figure 2(A)~2(D)
Figure 3(E)~3(H)
AI summary
To provide a method and an apparatus for sterilizing a preform that can reduce the amount of the remaining hydrogen peroxide in sterilization of a preform. A sterilizer at least containing 30% by mass or less of hydrogen peroxide and a solvent having a boiling point of 85°C or lower is gasified, the sterilizer gas is blasted to the preform, and the preform to which the sterilizer has been blasted is heated to a temperature suitable for molding by blasting hot air or without blasting hot air. Alternatively, after the preform is irradiated with light containing ultraviolet rays, the sterilizer gas is blasted to the preform, and the preform is heated to a temperature suitable for molding.