Rigid Container Deep Vacuum Sealing via Steam Condensation
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Solution Overview
Problem
Existing food packaging methods, such as canning and vacuum metal packaging, face challenges in achieving deep vacuum conditions, leading to over-cooking and deterioration of food products due to slow cooling and residual oxygen, which results in organoleptic and nutritional losses.
Innovation Solution
A method and system for continuous pasteurization or sterilization of foodstuffs followed by deep vacuum sealing of rigid containers, utilizing a container design with an elastic seal and a process involving superheated steam injection and cold water shower to create a deep vacuum, ensuring rapid cooling and preservation of food quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional canning sterilization is used, then food safety is ensured, but cooling time is too slow causing over-cooking and deterioration of organoleptic and nutritional quality
Solution Approach 1:
The patent utilizes the phase transition of water from liquid to vapor and back. During sterilization, water in the food converts to steam. During rapid cooling, this steam condenses back to liquid, absorbing latent heat and dramatically accelerating the cooling process while ensuring food safety is maintained through controlled temperature profiles
Solution Approach 2:
The invention changes the thermal parameters by using superheated steam injection to create a temperature differential. The superheated steam (at temperatures above 100°C) is injected into the container, then rapidly cooled by cold water injection, creating a controlled thermal shock that accelerates cooling while maintaining sterility through the initial high-temperature exposure
2Quantity of substance
If vacuum packaging is applied after sterilization, then oxygen removal is improved, but deep vacuum conditions are not achieved and residual oxygen remains causing product deterioration
Solution Approach 1:
The patent performs preliminary degassing by injecting superheated steam into the container before sealing. The steam displaces air and creates a steam-filled environment. When the steam is subsequently condensed during cooling, it creates a deep vacuum condition, removing oxygen before the packaging is sealed, thus preventing oxidation and product deterioration
Solution Approach 2:
The invention exploits the phase transition of steam to create vacuum. Superheated steam is injected to displace air, then cold water is injected to rapidly condense the steam into liquid water. This phase change from vapor to liquid creates a deep vacuum condition (less than 24 mbar) that effectively removes oxygen from the container before sealing
3Quantity of substance
If steam injection is used for vacuum creation, then deep vacuum is achieved, but residual air and heterogeneous temperature distribution occur during sterilization
Solution Approach 1:
The patent employs continuous rotation of the container during steam injection and cooling processes. This continuous rotational movement ensures uniform exposure of all container surfaces to the superheated steam and subsequent cold water, eliminating temperature gradients and ensuring homogeneous heating and cooling throughout the food product
Solution Approach 2:
The invention uses mechanical agitation in the form of container rotation during the steam injection and cooling phases. This rotational movement creates dynamic fluid circulation patterns that promote uniform temperature distribution throughout the food, preventing localized overheating or cooling while maintaining the deep vacuum condition
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 method achieves a deep vacuum of less than 24 mbar, significantly reducing cooling times and preserving the nutritional and organoleptic qualities of food, preventing caramelization and vitamin destruction, and allowing for the packaging of sensitive products like purees in larger quantities.
Implementation Method 1
injection of steam overheated, hermetically sealed
Implementation Method 2
pasteurization or sterilization of foodstuffs
Implementation Method 3
cold shower applied to a sterile filled container
Implementation Method 4
uniform rapid cooling
Implementation Method 5
the condensation of the steam located in the container causes a depression in the container compared to atmospheric pressure, depression sufficient to ensure that the container and the lid are firmly joined
Implementation Method 6
achieves a deep vacuum of less than 24 mbar
Implementation Method 7
provided with an elastic seal which ensures a connection between the container and the lid thanks to the vacuum
Data Source
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AI summary
The invention relates to the field of vacuum packaging of foodstuffs. It concerns a method, a system of devices for the continuous sterilization or pasteurization of foodstuffs contained in specific rigid containers, followed by the continuous deep vacuum sealing of said containers, vacuum achieved by rotary injection of steam between the lids and the containers followed by sealing the containers and a cold shower causing the steam to condense inside the container and consequently a deep vacuum, for long-term deep vacuum preservation of food under exceptional organoleptic and nutritional quality conditions, thanks to a drastic reduction in the cooling time of the containers after sterilization or pasteurization, a reduction in time achieved by low-temperature vacuum boiling, with boiling distributed homogeneously throughout the entire container.It is particularly suitable for pasty or liquid products, or products in pieces, included in a liquid or pasty mixture. It requires the use of an exceptionally rigid container, designed to be sealed under deep vacuum, with a lid free of any means of attachment and equipped with an elastic seal. This lid is held in place solely by the vacuum and can be opened using a vacuum-breaking system.