Sensor-Guided CIP Cleaning for Food Dosing Units
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Solution Overview
Problem
Existing dosing devices require time-based cleaning processes that are resource-intensive and often over-clean certain components, leading to inefficiencies and resource waste, without precise detection of contamination within the device.
Innovation Solution
A dosing device with a sensor unit to detect contamination characteristics of the cleaning medium, allowing for individual and flexible adjustment of the cleaning process based on contamination levels, optimizing resource use and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If time-based cleaning processes are used for dosing devices, then cleaning thoroughness is improved, but resource consumption (energy and cleaning agents) increases and production downtime extends
Solution Approach 1:
The patent implements a sensor unit that continuously monitors contamination characteristics of the cleaning medium during the cleaning process. This feedback mechanism allows the system to detect when cleaning is complete based on actual contamination levels rather than predetermined time intervals, enabling dynamic adjustment of cleaning duration to optimize resource consumption while maintaining thoroughness.
Solution Approach 2:
The cleaning process transitions from a static time-based approach to a dynamic contamination-based approach. The sensor unit enables real-time monitoring and adjustment of cleaning parameters based on actual contamination levels, allowing the system to adapt cleaning intensity and duration to specific needs of different dosing device components.
2Reliability
If time-based cleaning processes are used for dosing devices, then cleaning thoroughness is improved, but production downtime increases
Solution Approach 1:
The sensor unit provides real-time feedback on contamination levels in the cleaning medium, allowing the system to terminate cleaning operations as soon as cleaning objectives are achieved. This eliminates unnecessary extended cleaning time and reduces production downtime while maintaining required cleaning thoroughness.
Solution Approach 2:
The cleaning process duration becomes dynamic rather than fixed, adjusting based on actual contamination conditions detected by the sensor unit. This enables shorter cleaning cycles when contamination is low and extended cycles when needed, optimizing the balance between cleaning quality and production continuity.
3Reliability
If uniform cleaning is applied to all dosing device components, then overall cleanliness is improved, but resource efficiency deteriorates due to over-cleaning
Solution Approach 1:
The dosing device is divided into multiple cleaning zones with individual sensor elements monitoring each zone. This segmentation allows the control unit to identify which specific components require cleaning and apply cleaning agents only to those areas, eliminating over-cleaning of already clean components and reducing cleaning agent consumption.
Solution Approach 2:
The cleaning process transitions from uniform application to localized targeted cleaning. Sensor elements detect contamination in specific zones, and the control unit directs cleaning agents only to contaminated areas, providing locally optimized cleaning that maintains overall cleanliness while reducing resource waste.
4Measurement precision
If sensor elements are added to monitor cleaning medium contamination, then cleaning precision is improved, but device complexity increases
Solution Approach 1:
Sensor elements are integrated into the cleaning medium flow path to provide continuous contamination monitoring. The sensor data feeds back to the control unit, which automatically adjusts cleaning operations based on detected contamination levels, achieving precise measurement without requiring complex manual monitoring systems.
Solution Approach 2:
The sensor unit serves multiple functions: detecting contamination characteristics, providing feedback to the control unit, and enabling automated cleaning adjustments. This multi-functionality reduces the need for separate monitoring and control systems, minimizing the increase in device complexity while achieving high measurement precision.
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
Enhances cleaning efficiency by adapting the process to specific needs, reducing resource consumption, and minimizing production downtime.
Implementation Method 1
a sensor unit for sensing at least one contamination characteristic of the cleaning medium in the cleaning process
Data Source
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AI summary
The invention relates to a dosing device (12), in particular a food dosing device, with at least one filling unit (16) for conveying at least liquid or pasty products and with an interface to a CIP system (14) for cleaning the filling unit (16) by means of a cleaning medium in at least one cleaning process, and with a sensor unit (18) for sensing at least one contamination parameter of the cleaning medium in the cleaning process, wherein the filling unit (16) has a dosing unit (20) and a first sensor element (30) of the sensor unit (18) is arranged fluidically downstream of a product outlet (26) of the dosing unit (20). It is proposed that the dosing device (12) includes a receiving unit (50) for receiving the cleaning medium after cleaning at least the dosing unit (20), on which the first sensor element (30) is arranged.