Process Gas Line Sterilization in Beverage Filling Devices
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Solution Overview
Problem
Existing filling systems in beverage bottling plants face contamination risks due to undefined states of process gas lines when not in use, particularly in operating modes without process gas treatment, which can lead to germ growth and product damage.
Innovation Solution
A device with a process gas line that includes a sterile medium inlet and shut-off valves to maintain a defined, sterile state during operating modes without process gas treatment, using sterile media like air, water, or steam to isolate and pressurize the lines, minimizing contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the filling system uses process gas lines for carbonated beverage filling, then the containers can be purged and pressurized properly, but the lines remain in an undefined state when not in use, creating contamination risks
Solution Approach 1:
The system performs preliminary sterilization of the process gas lines by filling them with sterile medium before switching to operating mode without process gas treatment. This preliminary action ensures that the lines are in a defined sterile state, preventing contamination from developing during unused periods.
Solution Approach 2:
The patent creates an inert sterile environment within the process gas lines by introducing sterile medium (inert gas or sterilized liquid). This inert atmosphere prevents microbial growth and contamination in the lines when they are not actively being used for carbonated beverage filling.
2Ease of operation
If the system operates in mode without process gas treatment for non-carbonated beverages, then the filling process is simplified, but the process gas lines are left in an undefined state, posing contamination risks
Solution Approach 1:
Before switching to the simplified operating mode without process gas treatment, the system automatically performs a preliminary sterilization action by introducing sterile medium into the process gas lines. This ensures that the lines are in a defined sterile state, maintaining hygiene reliability while keeping the operating mode simple.
Solution Approach 2:
The system uses its own existing process gas line infrastructure to deliver sterile medium, eliminating the need for separate sterilization equipment. The sterile medium is introduced through the same lines that would normally carry process gas, allowing the system to sterilize itself without adding complex external components.
3Reliability
If sterile medium is continuously supplied to the process gas line, then the lines remain in a defined sterile state, but the system complexity increases due to additional valves and control mechanisms
Solution Approach 1:
The process gas line serves multiple functions: it carries process gas during carbonated beverage filling, and it serves as the delivery pathway for sterile medium during sterilization mode. The shut-off valves enable the same line to be used for both purposes, eliminating the need for separate dedicated sterilization lines and reducing overall system complexity.
Solution Approach 2:
Shut-off valves are introduced as intermediary components that control the flow of sterile medium into the process gas line. These valves act as mediators that allow the system to switch between operating modes, enabling sterile medium to be introduced only when needed while maintaining simplicity in the overall system architecture.
4Ease of operation
If the process gas line is left open to the environment, then the system is simpler to operate, but microorganisms can ingress and grow in the lines over time
Solution Approach 1:
The patent fills the process gas lines with sterile medium (inert atmosphere) when not in use for carbonated beverage filling. This creates a protective inert environment that prevents microorganisms from ingressing and growing in the lines, while the system remains operationally simple through the use of shut-off valves that can be easily controlled.
Solution Approach 2:
The patent converts the potentially harmful open connection to the environment into a beneficial controlled connection by using shut-off valves. When closed, the valves create a sealed sterile environment that prevents contamination. When opened, they allow controlled introduction of sterile medium. This transforms a weakness (open connection) into a strength (controlled access).
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 solution ensures process gas-carrying components are kept in a sterile, defined state, reducing contamination and germ formation, thereby enhancing the reliability and safety of the filling process for various beverage types.
Implementation Method 1
introducing the sterile medium into the process gas line... so that the sterile medium remains in the process gas line
Data Source
Figure 1
AI summary
Device (1) for filling containers with a filling product, preferably in a beverage filling plant, wherein the device (1) is operable in an operating mode with process gas treatment and an operating mode without process gas treatment and comprises: at least one process gas line (50) which is configured to supply the containers with a process gas in the operating mode with process gas treatment, preferably to purge and/or pre-pressurize them; at least one sterile medium inlet which is configured to introduce a sterile medium into the process gas line (50); and one or more shut-off valves (58, 59) which are configured to shut off the process gas line (50) in the operating mode without process gas treatment in such a way that the sterile medium introduced via the sterile medium inlet remains in the process gas line (50).