Pulsed Light Sterilization for Thermoplastic Containers
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Solution Overview
Problem
Current methods for sterilizing thermoplastic material containers, such as PET bottles, are inefficient, costly, and leave chemical residue, with high maintenance requirements and lengthy processing times, making them unsuitable for aseptic packaging of sensitive products.
Innovation Solution
A system comprising an extruder, molding apparatus, thermal conditioning apparatus, blow molding apparatus, pulsed light irradiation apparatus, and aseptic filling and capping apparatus, where pulsed light is used to sterilize bottles after production, reducing contamination levels and eliminating the need for additional sterilization means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chemical sterilization methods (hydrogen peroxide or peroxyacetic acid) are used, then sterilization effectiveness is achieved, but chemical compound residues remain and processing time increases
Solution Approach 1:
The patent replaces chemical sterilization systems with a physical sterilization system using pulsed light irradiation. The light irradiation apparatus emits pulsed light to sterilize containers without introducing chemical residues, directly substituting the chemical mechanism with a physical one.
Solution Approach 2:
The patent changes the sterilization parameter from chemical concentration to light energy parameters (pulsed light intensity and duration). By controlling the energy parameters of pulsed light, effective sterilization is achieved without chemical residue issues.
2Reliability
If chemical sterilization methods are used, then sterilization is achieved, but processing time becomes relatively lengthy
Solution Approach 1:
The patent employs periodic pulsed light action instead of continuous chemical exposure. The pulsed light delivers sterilization energy in short, intense bursts, significantly reducing the time required compared to prolonged chemical sterilization processes.
3Reliability
If particular sterilization systems are used to maintain sterility, then sterility is maintained, but system cost and maintenance requirements increase
Solution Approach 1:
The patent extracts the sterilization function from complex maintained systems and integrates it directly into the production line through a pulsed light irradiation apparatus. This eliminates the need for separate, expensive sterilization systems and their associated maintenance requirements.
4Reliability
If conventional sterilization methods are used, then sterilization is achieved, but operational costs increase due to consumables
Solution Approach 1:
The patent replaces expensive consumable chemicals with a reusable pulsed light irradiation system. The light source, while having a finite lifespan, eliminates the need for continuous purchase of costly sterilization chemicals like hydrogen peroxide and peroxyacetic acid.
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 system achieves effective sterilization of thermoplastic containers with reduced contamination and operational costs, ensuring the sterility required for food, pharmaceutical, and cosmetic products while maintaining efficiency and affordability.
Implementation Method 1
a pulsed light irradiation apparatus; irradiating the containers by means of a pulsed light irradiation apparatus
Data Source
AI summary
A system (1) for producing thermoplastic material bottles (5),the system (1) comprising in sequence:an extruder (10);a molding apparatus (20) for producing preforms;a thermal conditioning apparatus (30) for thermally conditioning the preforms;a blowing apparatus (40) for producing bottles (5) from the preforms;a pulsed light irradiation apparatus (50, 55, 60, 70);an aseptic filling and capping apparatus (80).