Sanitizing Device for Food Containers Using Circuitous Path
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Solution Overview
Problem
Food and feed products are susceptible to recontamination after the initial pathogen kill step during processing, leading to potential pathogen-infected products and increased risks of factory shutdowns, recalls, and legal liabilities.
Innovation Solution
A sanitizing device that maintains pre-quantified units of flowable products in enclosed containers, exposing them to one or more sanitizing agents along a path before packaging, ensuring continuous sanitization and minimizing recontamination risks by using compatible agents like heat, chemicals, or irradiation, and allowing for container sterilization between uses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an initial extrusion-based sanitizing step is used to destroy pathogenic microorganisms, then pathogen levels are reduced, but the product becomes susceptible to recontamination during subsequent processing and packaging
Solution Approach 1:
The patent applies a second sanitizing step immediately before packaging to preemptively eliminate pathogens that may have been introduced during handling and processing. This preliminary action ensures that any recontamination occurring during intermediate steps is eliminated right before the product enters the packaging stage, maintaining the reliability achieved by the initial extrusion sanitizing step.
Solution Approach 2:
The patent implements continuous sanitization by maintaining the product in enclosed containers throughout the process and applying sanitizing agents continuously from the initial extrusion step through to the final pre-packaging sanitizing step. This continuous action prevents interruption in the sanitizing effect, ensuring that pathogen destruction is maintained throughout the entire processing sequence without allowing recontamination to take hold.
2Reliability
If multiple sanitizing agents are used to prevent pathogen resistance, then sanitizing efficacy is improved, but the complexity of the sanitizing system increases
Solution Approach 1:
The patent divides the sanitizing process into distinct segments, with different sanitizing agents applied at different stages. The initial extrusion-based sanitizing step uses heat, followed by a second sanitizing step using chemical agents or irradiation immediately before packaging. This segmentation allows each agent to target specific pathogens without requiring all agents to be applied simultaneously, reducing system complexity while maintaining high sanitizing efficacy.
Solution Approach 2:
The patent maintains continuous sanitization action by seamlessly transitioning between different sanitizing agents throughout the processing sequence. The product remains in enclosed containers that facilitate continuous exposure to sanitizing agents from extrusion through to final packaging, ensuring uninterrupted sanitizing effect without requiring complex intermittent switching mechanisms.
3Reliability
If the path is extended to increase residence time with sanitizing agent, then sanitizing effectiveness is improved, but the facility requires more space or equipment reconfiguration
Solution Approach 1:
The patent nests the sanitizing process within the existing production facility layout by integrating sanitizing stations along the current product flow path. The enclosed containers move through compact sanitizing zones that are nested within the existing facility footprint, allowing extended residence time for effective sanitization without requiring significant expansion of the facility space or major reconfiguration of equipment.
Solution Approach 2:
The patent utilizes the vertical dimension and three-dimensional space within enclosed containers to achieve extended sanitizing exposure without increasing horizontal facility footprint. The containers are designed to allow thorough penetration of sanitizing agents throughout the product volume, effectively creating a compact sanitizing chamber that provides extended residence time within the existing facility constraints.
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
This solution effectively reduces pathogen levels immediately before packaging, preventing recontamination and maintaining product safety while being compatible with existing production facilities, allowing for seamless integration without significant equipment changes.
Implementation Method 1
an ultraviolet light source is provided to generate an ultraviolet radiation as the first sanitizing agent
Implementation Method 2
the first container is flooded with a fluid sanitizing agent at a second sanitizing station disposed along the path
Implementation Method 3
a drag chain conveyor configured to move the containers through the stations
Data Source
AI summary
A method for sanitizing pre-measured units of a pre-sanitized flowable food product in a sanitizing device installed into an existing food production system without substantially increasing the head height requirement of the feed production system. A plurality of containers are moved about a path with increased retention time through a plurality of stations: a receiving station, one or more sanitizing stations, and a dispensing station, and a container cleaning station. A pre-measured unit measured for packaging is received at the receiving station into a container. The pre-measured unit is exposed to one or more sanitizing agents at one or more sanitizing stations. The pre-measured unit is immediately packaged after sanitization. The pre-measured unit is dispensed into a packaging device at the dispensing station. The containers are then cleaned at the container cleaning station to prepare each container to receive a subsequent pre-measured unit of the pre-sanitized flowable feed product.