Preform Sterilization via Hydrogen Peroxide Spray and Superheated Steam
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Solution Overview
Problem
Conventional methods for sterilizing preforms are costly, complex, and inefficient, requiring expensive equipment and chemicals, and can lead to residual steam issues and bacterial survival, especially when using hydrogen peroxide or steam sterilization.
Innovation Solution
A method and apparatus where preforms are loaded on a conveyor in a scraggly overturned manner, sprayed with hydrogen peroxide water from both sides, and then blasted with superheated steam at 200° C to 500° C to ensure thorough sterilization, reducing the need for expensive equipment and aligning devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrogen peroxide water is sprayed to sterilize preforms, then sterilization effect is improved, but equipment cost increases due to need for expensive mist generator
Solution Approach 1:
The patent replaces expensive mist generation equipment with a simple spray system using conventional hydrogen peroxide water. Instead of generating expensive mist, the system uses affordable spray nozzles to apply the sterilizing agent directly, achieving effective sterilization without the need for costly mist generators.
2Reliability
If preforms are conveyed in vertically aligned state for chemical agent jetting, then sterilization uniformity is improved, but system complexity and size increase
Solution Approach 1:
Instead of conveying preforms in a vertical aligned state as in conventional methods, the patent inverts the approach by conveying preforms horizontally in an overturned state. The spray nozzles are positioned to spray from above, allowing the preforms to be sterilized uniformly without requiring complex vertical alignment mechanisms.
3Measurement precision
If hydrogen peroxide solution is dropped into each preform with predetermined quantity, then sterilization precision is improved, but device cost increases due to need for expensive measuring device
Solution Approach 1:
The patent replaces expensive predetermined quantity discharge devices with simple spray nozzles that apply hydrogen peroxide water through spraying. This approach achieves sufficient sterilization precision without requiring costly equipment to measure and dispense exact quantities of the chemical agent into each preform.
4Reliability
If steam is blasted into preform to heat above glass-transition point, then sterilization effect is improved, but residual steam remains causing whitening during molding
Solution Approach 1:
The patent extracts the steam blasting step from the sterilization process and replaces it with hydrogen peroxide water spraying. This eliminates the source of residual steam that causes whitening during molding, while maintaining effective sterilization through the chemical action of hydrogen peroxide on the preform surfaces.
5Reliability
If steam is applied to mouth portion for long time, then sterilization completeness is improved, but mouth portion deformation occurs reducing sealing performance
Solution Approach 1:
The patent replaces prolonged steam application with brief hydrogen peroxide water spraying. The hydrogen peroxide spray achieves complete sterilization in a short duration, preventing thermal deformation of the mouth portion while ensuring thorough sterilization of all preform surfaces including the heat-sensitive mouth area.
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 allows for efficient, cost-effective sterilization of preforms with reduced residual steam issues and enhanced bacterial kill rates, ensuring aseptic conditions without deforming the preform's mouth portion.
Implementation Method 1
hydrogen peroxide water is sprayed within the chamber (5) from both sides of the conveyer (4) in a direction crossing the conveyer (4), thereby adhering the hydrogen peroxide water to inner and outer surfaces of each of the preforms (1)
Implementation Method 2
superheated steam having a temperature of 200° C. to 500° C. made from water is blasted to at least the inner surface of all surfaces of the preform including a mouth portion thereof
Data Source
AI summary
A preform is easily and speedily sterilized. A number of preforms (1), each having a bottomed tubular shape, are laid on a conveyer (4) in a scraggly overturned manner, these preforms passes inside a chamber (5) together with the conveyer, and hydrogen peroxide water mist is sprayed from both sides of the conveyer in a direction crossing the conveyer in the chamber, thereby adhering the sprayed hydrogen peroxide water to inner and outer surfaces of the preforms (1) on the conveyer (4).