Steam Valve Control for Aseptic Heat Exchanger Temperature Stability

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Solution Overview

Problem

Aseptic food processing systems face inefficiencies and quality issues due to sudden temperature changes during the transition from recirculating water to a food product, leading to potential loss of sterility and unacceptable product quality.

Innovation Solution

A system with a computer-controlled steam valve that adjusts its position based on calculated parameters to maintain optimal temperature and prevent sudden changes, using a software program to manage the heating medium's temperature during the transition, ensuring sterility and preventing overheating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the system transitions from recirculating water to food product during aseptic processing, then the food product can be processed, but the temperature drops suddenly causing loss of sterility

Engineering Contradiction:

Improvefood product processing capabilityVSAvoidsterility maintenance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The control system detects the approach of the water/food product interface and preemptively adjusts the steam valve position before the temperature drop occurs. By calculating the interface arrival time based on flow rate and distance, the system prepares the heating medium temperature in advance to compensate for the incoming cooler food product, preventing sterility loss.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors the temperature of the heating medium and adjusts the steam valve position dynamically based on real-time temperature data. When the temperature approaches the minimum sterility threshold, the control system increases steam flow to maintain the required temperature, creating a closed-loop control that ensures sterility is maintained throughout the transition.

Inventive Principle:

Principle #23Feedback

2Reliability

If the steam valve opens fully to maintain temperature, then sterility is maintained, but the food product may overheat and degrade quality

Engineering Contradiction:

Improvesterility maintenanceVSAvoidproduct quality

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The control system dynamically adjusts the steam valve position based on the real-time temperature of the heating medium and the detected position of the water/food product interface. Rather than using a fixed valve position, the system continuously modulates the steam flow to match the actual thermal conditions, allowing precise control that responds to changing temperatures as the interface moves through the heat exchanger.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the steam valve position parameter dynamically during the processing transition. By adjusting this key parameter based on temperature feedback and interface position, the system optimizes heat transfer to maintain sterility while preventing overheating of the food product, thereby controlling both temperature and quality outcomes.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If the system uses manual monitoring and adjustment of temperature, then flexibility is maintained, but response time is insufficient to prevent sterility loss

Engineering Contradiction:

Improvetemperature control flexibilityVSAvoidresponse time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The control system autonomously monitors temperature, detects the water/food product interface position, and adjusts the steam valve without human intervention. The system calculates the interface arrival time based on flow rate and distance, then automatically implements the necessary valve adjustments, eliminating the time delay associated with manual detection and response while maintaining operational flexibility.

Inventive Principle:

Principle #25Self-service

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 system effectively minimizes temperature fluctuations, maintaining sterility and improving product quality by automatically controlling the steam valve's position, reducing the risk of loss of sterility and overheating.

Implementation Method 1

a steam source (144) having a steam valve (144c)

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

at least one heat exchanger (142) comprising a heating medium

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentEP2951657B1Systems and methods for mitigating undesired temperature changes during food processing

Publication Date: 2018.10.17 SOCIETE DES PRODUITS NESTLE SA

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AI summary

The present disclosure provides systems and methods for manufacturing food products. In a general embodiment, a system for manufacturing a food product is provided and includes at least one heat exchanger, at least one food product tank, at least one steam source having a steam valve, a computer having a computer processor, and a computer-readable medium accessible to the computer and containing a software program therein that is programmed to cause the computer processor to automatically control the steam valve to move from a first position to a second, calculated position to maintain a temperature of a heating medium that is sufficient to maintain sterility of the food product during a recirculating water-to-food product transition in the heat exchanger. Methods for manufacturing food products are also provided.