Preform Sterilization via Hydrogen Peroxide Mist and Temperature Control
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Solution Overview
Problem
Conventional aseptic drink filling methods face issues with incomplete sterilization due to inadequate hydrogen peroxide treatment, leading to potential bacterial contamination and defective molding, especially in preforms with low heat-resisting properties, requiring extensive sterilization equipment and high hydrogen peroxide usage.
Innovation Solution
A drink filling method involving preheating and preliminary sterilization of preforms with low-density hydrogen peroxide mist, followed by main sterilization after molding, using a continuous conveying system with integrated heating and sterilization processes to reduce hydrogen peroxide usage and prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If much amount of hydrogen peroxide mist is blasted to the preform, then sterilization effectiveness is improved, but molding defects such as whitening, strain, and unevenness occur
Solution Approach 1:
The preform is preheated to a predetermined temperature before hydrogen peroxide mist is blasted onto it. This preliminary heating action activates the sterilizing agent and enhances sterilization effectiveness while allowing the use of lower amounts of hydrogen peroxide, thereby preventing molding defects such as whitening and strain during the subsequent blow-molding process.
2Reliability
If the mouth portion of the preform is heated to a high temperature for sterilization, then sterilization effectiveness is improved, but the mouth portion is deformed and sealing performance is damaged
Solution Approach 1:
The heating process is designed to create a temperature gradient where the body portion of the preform is heated to a high temperature (90-130°C) for effective sterilization, while the mouth portion is maintained at a lower temperature (40-50°C) to prevent deformation. This localized temperature control ensures both sterilization effectiveness and preservation of the mouth portion's sealing performance.
3Reliability
If sterilization equipment is added to sterilize all components and conveying areas, then sterilization completeness is improved, but device complexity and initial investment increase
Solution Approach 1:
The preform is preheated and sterilized with hydrogen peroxide mist before being conveyed to the blow-molding machine. This preliminary sterilization action ensures that the preform is already sterile when it enters the molding process, eliminating the need for additional sterilization equipment for the molding machine and conveying areas, thereby reducing device complexity and initial investment.
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 method enhances sterilization effectiveness against bacteria and fungi, reduces hydrogen peroxide consumption, and minimizes molding defects, allowing for efficient production of aseptic packages with improved sterilization and reduced equipment costs.
Implementation Method 1
blasting hydrogen peroxide mist (M) or gas to the preheated preform (1) so as to perform the preliminary sterilization thereof
Implementation Method 2
preheating a preform (1), blasting hydrogen peroxide mist (M) or gas to the preheated preform (1), and further heating the preform (1) to a temperature suitable for molding the preform
Data Source
AI summary
Bottles are appropriately sterilized in an inline system. While continuously traveling preheated preforms (1), the preform is preliminarily heated, hydrogen peroxide mist (M) or gas is blasted to the preheated preform, the preform is heated to a temperature suitable for molding the preform, the preform is molded in a blow-molding mold (4), which is continuously traveling together with the preform, into a container (2), the container taken out of the mold is filled with drink while being continuously traveled and then applied with a lid to seal the container.