Preform Sterilization With Preheating for Residue Control

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Solution Overview

Problem

Existing aseptic bottling processes using hydrogen peroxide sterilization face challenges such as residue buildup, condensation, and reduced throughput due to the slower evaporation and decomposition of hydrogen peroxide at cooler temperatures, which can lead to microbial contamination and inefficient production.

Innovation Solution

Pre-heating the preforms before hydrogen peroxide sterilization to accelerate evaporation and decomposition, utilizing systems with dedicated heating elements and airflow to maintain optimal temperatures for hydrogen peroxide application, thereby reducing residue and enhancing throughput.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If preforms are sterilized with hydrogen peroxide at cooler temperatures, then energy consumption is reduced, but evaporation and decomposition rates slow down causing residue buildup and reduced throughput

Engineering Contradiction:

Improveenergy consumptionVSAvoidthroughput

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

The system pre-heats preforms before hydrogen peroxide application to accelerate evaporation and decomposition rates, ensuring complete sterilization without residue buildup. This preliminary heating action enables faster processing cycles and maintains high throughput while using lower energy during the actual sterilization phase

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts temperature parameters throughout the sterilization process - heating preforms to optimal temperatures before H2O2 application, then maintaining controlled temperature during decomposition. This parameter optimization ensures rapid evaporation and decomposition without excessive energy consumption, resolving the contradiction between energy efficiency and productivity

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If hydrogen peroxide is applied to cooler preforms, then the sterilization process is simpler, but condensation forms on the preform surface leading to contamination risks

Engineering Contradiction:

Improvesterilization process complexityVSAvoidcontamination prevention

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The system pre-heats preforms to temperatures above the dew point before hydrogen peroxide vapor application. This preliminary heating prevents condensation formation during sterilization, eliminating contamination risks while maintaining process simplicity through automated temperature control

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses temperature sensors and control systems to monitor preform temperature and adjust heating accordingly. This feedback mechanism ensures preforms remain at optimal temperatures throughout sterilization, preventing condensation while automating the process to maintain simplicity despite added reliability measures

Inventive Principle:

Principle #23Feedback

3Object-affected harmful factors

If hydrogen peroxide decomposition is slower at cooler temperatures, then safety is improved, but residence time increases causing potential product contamination

Engineering Contradiction:

ImprovesafetyVSAvoidresidence time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The system pre-heats preforms before hydrogen peroxide application, creating optimal conditions for rapid decomposition. This preliminary heating reduces residence time significantly, preventing product contamination while the controlled heating process maintains safety by preventing overheating and decomposition runaway

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system optimizes temperature parameters to balance safety and residence time - using sufficient heat to accelerate decomposition and reduce exposure time, but controlling maximum temperatures to prevent safety issues. This parameter optimization resolves the contradiction between safety and time loss

Inventive Principle:

Principle #35Parameter changes

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

The pre-heating process minimizes hydrogen peroxide residue, accelerates decomposition, and increases the efficiency of microbial sterilization, allowing for higher production rates and reduced contamination risks in aseptic bottling lines.

Implementation Method 1

pre-heating the preform increases the surface temperature of the preform. When hydrogen peroxide is applied to a warmer surface, it tends to evaporate more quickly

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

hydrogen peroxide decomposes into water and oxygen in the presence of heat, pre-heating the preform accelerates the decomposition

Methodology Applied

Scientific EffectDecomposition: Decomposition (biological)

Implementation Method 3

Pre-heating the preform may also reduce the likelihood of hydrogen peroxide vapor condensing on the surface of the preform

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS20250303630A1Systems and methods for preform sterilization

Publication Date: 2025.10.02 NIAGARA BOTTLING LLC

AI summary

A method for manufacturing a bottle may including preheating a preform to an internal temperature with an airflow directed within a deduster unit. A method for manufacturing a bottle may also include sterilizing the preheated preform with a hydrogen peroxide solution. A method for manufacturing a bottle may further include forming a bottle from the preheated preform using a blow molding process.