Steam Infusion Sterilization for Preservative-Free Dermo-Cosmetic Emulsions
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Solution Overview
Problem
Current sterilization methods for preservative-free dermo-cosmetic emulsions are inadequate, as they either break the emulsion or require preservatives, and existing ultra-high temperature processes are difficult to control and not suitable for industrial-scale production of high-volume viscous products.
Innovation Solution
A continuous sterilization process involving gradual preheating, steam infusion, maintaining at a specific temperature, and progressive cooling to achieve a sterilizing value of F0=22 minutes, ensuring the emulsion's stability and sterility without breaking it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal sterilization treatment is applied to reduce viscosity, then microbial sterilization is improved, but emulsion stability deteriorates due to breaking
Solution Approach 1:
The invention applies parameter changes by precisely controlling temperature and time parameters during sterilization. The process uses a sterilizing value F0 of 22 minutes (higher than the standard 15 minutes) with specific temperature-time combinations that achieve complete sterilization while limiting thermal exposure duration to prevent emulsion breaking. This resolves the contradiction by optimizing the parameter combination rather than simply increasing temperature.
Solution Approach 2:
The invention applies preliminary action through pre-heating the emulsion to a controlled temperature before the main sterilization phase. This gradual pre-heating prepares the emulsion for the subsequent high-temperature treatment, reducing thermal shock and minimizing emulsion breaking while ensuring uniform temperature distribution for effective sterilization.
2Reliability
If preservative adjuvants are added to ensure preservation, then microbial growth prevention is improved, but product tolerance deteriorates due to poor toleration by users
Solution Approach 1:
The invention applies the extraction principle by completely removing preservative adjuvants from the formulation. Instead of relying on chemical preservatives that cause user intolerance, the process achieves preservation through enhanced physical sterilization (F0=22 minutes) that eliminates the need for any preservative substances, thus resolving the contradiction between preservation effectiveness and user tolerance.
3Reliability
If ultra-high temperature process is applied for sterilization, then sterilizing value is improved, but process control difficulty increases due to viscosity changes
Solution Approach 1:
The invention applies feedback control by implementing continuous monitoring and adjustment of temperature and flow rate parameters during the sterilization process. The system measures actual process conditions and adjusts operational parameters in real-time to maintain the target sterilizing value F0=22 minutes despite viscosity changes, resolving the control complexity issue through closed-loop feedback mechanisms.
Solution Approach 2:
The invention applies dynamics by allowing process parameters such as flow rate and temperature to vary dynamically during sterilization rather than maintaining static conditions. The system adapts parameters in response to changing emulsion viscosity and thermal conditions, enabling effective control of the ultra-high temperature process while achieving the required sterilizing value.
4Productivity
If existing UHT process is used for industrial production, then productivity is improved, but manufacturing precision deteriorates due to difficulty in controlling heating and cooling times
Solution Approach 1:
The invention applies segmentation by dividing the sterilization process into distinct phases: pre-heating, main sterilization, and cooling. Each phase has specifically controlled duration and temperature parameters, with the total process optimized to achieve F0=22 minutes. This segmented approach enables precise control of heating and cooling times while maintaining high industrial production capacity, resolving the contradiction between productivity and manufacturing 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
This process effectively sterilizes dermo-cosmetic emulsions to a high standard (F0=22 minutes) without using preservatives, maintaining emulsion stability and allowing for industrial-scale production, ensuring long conservation and tolerance of active ingredients.
Implementation Method 1
a ii. bring the preheated emulsion to a temperature T2 by steam infusion
Implementation Method 2
heating step by infusion of value
Implementation Method 3
b iii. cool the emulsion under vacuum to a temperature T3 less than T1 by 5K
Data Source
Figure 1~2
Figure 3~3C
AI summary
The invention relates to the use, for the continuous sterilization of a preservative-free emulsion suitable for dermo-cosmetic applications, of a process comprising a heating step by steam infusion and including the steps of: a. gradually preheating (120) the emulsion to a preheating temperature, T1, the limiting temperature of stability of said emulsion; bi. raising the preheated emulsion to a temperature T2 by steam infusion; bii. maintaining the emulsion at temperature T2 for a time t; biiii. cooling the emulsion under vacuum to a temperature T3 5K (5°C) lower than T1; c. gradually cooling the sterilized emulsion with stirring to a storage temperature T4, the temperature difference between two stages being at most 15K (15°C); characterized in that the combination of temperature T2 and holding time t provides a sterilizing value F0 of 22 minutes.