Reciprocating Filling Units for Continuous Container Cleaning
Solution Overview
Problem
Conventional filling apparatuses experience reduced productivity due to the need for machine stops during Clean-Out-of-Place (COP) maintenance and cleaning operations, which disrupt the continuous filling process and lead to inefficiencies in container filling rates.
Innovation Solution
The apparatus features a design with a filling area and a separate rest area, allowing for Clean-In-Place (CIP) and COP operations to be performed without stopping the machine, utilizing reciprocally movable filling units and actuating means to maintain continuous operation, ensuring that one unit can be cleaned or maintained while the other continues filling containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Clean-Out-of-Place (COP) cleaning operations are performed on filling units, then hygiene standards and cleaning thoroughness are improved, but the apparatus must be stopped and productivity decreases
Solution Approach 1:
The filling apparatus is divided into two independent filling units (first filling unit and second filling unit) that can operate independently. This segmentation allows one unit to undergo COP cleaning operations while the other continues filling containers, eliminating the need to stop the entire apparatus for maintenance.
Solution Approach 2:
The apparatus maintains continuous filling operation by switching between two filling units. When one unit is cleaned using COP method, the other unit continues to fill containers without interruption. This ensures uninterrupted production flow and maintains high productivity while still performing thorough cleaning operations.
2Productivity
If Clean-In-Place (CIP) cleaning operations are performed on filling units, then cleaning efficiency is improved, but access for thorough maintenance and COP operations becomes difficult
Solution Approach 1:
The apparatus separates the two filling units spatially, with the second filling unit positioned in a rest area that is accessible from the outside of the apparatus. This segmentation allows operators to access the second unit for COP cleaning and maintenance without disrupting CIP operations on the first unit or stopping the filling process.
Solution Approach 2:
The rest area acts as an intermediary space that provides external access to the second filling unit. This intermediate zone allows operators to perform COP cleaning and maintenance operations on the second unit without entering the filling area during operation, thus maintaining both safety and operational efficiency.
3Object-affected harmful factors
If safety barriers are installed to prevent operator access during filling operations, then operator safety is improved, but access for maintenance and cleaning operations becomes restricted
Solution Approach 1:
The apparatus divides the working space into a filling area with safety barriers and a rest area accessible from outside. This segmentation allows the second filling unit to be positioned in the rest area where it can be accessed for maintenance without compromising operator safety during filling operations in the first area.
Solution Approach 2:
Maintenance and cleaning operations on the second filling unit can be performed continuously without stopping the filling operation in the first area. The safety barriers remain in place during filling operations while the second unit in the rest area is accessed and maintained, ensuring both safety and continuous maintenance capability.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The present invention relates to a filling apparatus (1; 2) for filling containers (101) with fluid products, and to the respective method, wherein the apparatus (1; 2) comprises a rest area (1"; 2") arranged outside of a filling path and of a filling area (1'; 2'), the rest area (1"; 2") is accessible to the operator without interrupting the filling of the containers (1) and actuating means to reciprocally move a first (111; 122) and a second (211; 222) filling unit from an operating condition to a rest condition; wherein in an operating condition one between a first (111; 122) and second (211; 222) filling unit is arranged in the filling area (1'; 2') and able to be in fluid communication with the containers (1) to be filled; and wherein in the rest condition the other between the first (111; 122) and second (211; 222) filling unit is arranged in the rest area (1"; 2") accessible to the operator without interrupting the filling of the containers (1) in the filling area (1') .