Sterile Container Blow Molding Preform Sterilization

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Solution Overview

Problem

Existing methods for sterilizing blow-molded containers require significant apparatus and control expenditure due to the need for complex lifting devices and low pressures/temperatures, and often result in contamination during the filling process due to the handling of multiple components.

Innovation Solution

The method involves a main sterilization treatment of preforms using high-temperature and high-pressure gaseous or liquid media, followed by a simpler post-sterilization treatment to remove any residual contamination, with the use of electron beams as an alternative for aggressive sterilization, and a clean room environment to minimize contamination risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sterilization treatment is carried out on containers after blow molding, then containers can be sterilized, but contamination occurs during filling due to contact with many components

Engineering Contradiction:

Improvesterility of containersVSAvoidcontamination during filling

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary sterilization to preforms before blow molding, ensuring they are sterilized in advance. This preliminary action maintains sterility through the subsequent blowing and filling processes, preventing contamination rather than attempting to sterilize after potential contamination has occurred.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If aggressive sterilization treatment is used on containers, then sterilization efficiency increases, but apparatus expenditure and control complexity increase due to complex lifting devices

Engineering Contradiction:

Improvesterilization efficiencyVSAvoidapparatus and control expenditure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical lifting devices with a horizontal transport system where sterilization occurs in a linear flow. Preforms are transported horizontally through the sterilization zone using simple conveyance mechanisms, eliminating the need for complex vertical lifting and positioning apparatus while maintaining effective sterilization.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If low pressure and temperature are used for sterilization, then thin-walled containers are not damaged, but sterilization effectiveness is reduced

Engineering Contradiction:

Improveintegrity of thin-walled containersVSAvoidsterilization effectiveness

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs parameter changes by using high temperature for a short duration in a controlled horizontal flow system. The brief exposure time and continuous movement through the sterilization zone allow aggressive parameters to be used without damaging thin-walled containers, achieving both effectiveness and safety.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If multiple sterilization treatments are carried out on preforms and containers, then sterility is improved, but transport distance and time increase

Engineering Contradiction:

Improvesterility levelVSAvoidtransport time and distance

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent merges the sterilization function into the existing horizontal transport flow between blowing and filling operations. Rather than adding separate sterilization stages that extend transport distance, the sterilization treatment is integrated into the continuous horizontal movement, eliminating additional time and distance while maintaining sterility.

Inventive Principle:

Principle #5Merging (Combining)

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 approach reduces the apparatus and control requirements, ensures sterile containers with minimal residual contamination, and allows for efficient sterilization with reduced space and time, maintaining high hygiene standards.

Implementation Method 1

a main sterilization treatment of preforms using high-temperature and high-pressure gaseous or liquid media

Methodology Applied

Scientific EffectThermal sterilization: Heating

Implementation Method 2

with the use of electron beams as an alternative for aggressive sterilization

Methodology Applied

Scientific EffectElectron beam sterilization: Electron Beam

Data Source

PatentEP2295324B1Method and device for stretch blow moulding or blow moulding and filling of sterile containers

Publication Date: 2013.04.24 KRONES AG

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AI summary

In a process for blow molding and filling sterile containers (T) from preforms (P) in a container handling device (V) containing a blow molding module (B), wherein the preforms (P) are transferred from a heating device (H) to the blow molding module via transport devices (3), and the containers (T) are transported to a filling machine and filled, with a sterilization treatment being carried out on both the preforms (P) and the containers (T), a primary sterilization treatment is carried out on the preforms (P) between the heating device (H) and the blow molding module (B), and only a secondary sterilization treatment is carried out on the containers (T) during transport to the filling machine (F). The device suitable for carrying out the process has a primary sterilization module (PS) between the heating device (H) and the blow molding module (B) and a secondary sterilization module (PS) between the blow molding module (B) and the filling machine (F).