Sterile Gas Cushion Control in Partially-Filled Package Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing packaging apparatuses for producing partially-filled packages with a sterile gas space face challenges such as foam formation during filling, limited sterile gas volume, precision issues in gas volume control, and clogging risks, which hinder efficient production of packages that require a controlled gas environment for maintaining product quality and consumer experience.
Innovation Solution
A packaging apparatus that includes a tube forming and sealing device, a filling device, and a gas feeding device with a pressure and flow control system to precisely control the volume of sterile gas within the package, preventing foam formation and allowing for a larger gas space while minimizing clogging risks, using a multilayer packaging material structure and an isolation chamber for sterile conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If sterile gas is introduced into the pourable product during filling, then a gas space is formed within the package, but foam formation occurs during the filling process
Solution Approach 1:
The patent introduces sterile gas into the isolation chamber before the filling process begins, creating a pressurized sterile gas environment in advance. This preliminary action allows the gas to be readily available when needed during filling, enabling quick gas space formation without prolonged exposure that would cause foam formation in the pourable product.
Solution Approach 2:
The patent employs periodic or controlled introduction of sterile gas during the filling process rather than continuous introduction. The gas feeding device operates in a controlled manner, introducing gas at specific moments or at controlled rates, which prevents excessive gas incorporation that would lead to foam formation while still achieving the desired gas space volume.
2Quantity of substance
If a larger volume of sterile gas is introduced, then a larger gas space is formed, but the risk of clogging in the gas feeding device increases
Solution Approach 1:
The isolation chamber is pre-filled with sterile gas before the actual packaging process. This preliminary action ensures that the gas feeding device does not need to draw large volumes of gas through long conduits during operation, reducing the risk of clogging while still achieving the desired large gas space volumes in the final packages.
Solution Approach 2:
The isolation chamber acts as an intermediary reservoir between the sterile gas source and the filling process. It buffers and regulates the gas flow, allowing large volumes of sterile gas to be stored in a controlled environment and then introduced into packages in a manner that minimizes clogging risks in the feeding device.
3Manufacturing precision
If precise control of gas volume is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent incorporates a control system that monitors and regulates the volume of sterile gas introduced into packages. This feedback mechanism adjusts gas flow based on actual conditions, achieving precise gas volume control. The system uses sensors and controllers to maintain the desired gas space volume while managing the complexity through automated regulation rather than manual control.
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 apparatus enables high-precision control of the gas space volume, reduces foam formation, minimizes clogging, and allows for a larger gas space, ensuring product quality and consumer experience by maintaining a controlled gas environment within the packages.
Implementation Method 1
gas feeding device (9) configured to introduce a sterile gas into the pourable product to a controlled extent... controlling the pressure of the sterile gas within the gas cushion (10) such that the pressure ranges between 5 kPa to 40 kPa
Implementation Method 2
chemical sterilization (e.g. by applying a chemical sterilizing agent, such as a hydrogen peroxide solution)
Implementation Method 3
physical sterilization (e.g. by means of an electron beam)
Implementation Method 4
the packaging material also comprises a layer of heat-seal plastic material... covered with another layer of heat-seal plastic material forming the inner face of the package eventually contacting the food product
Data Source
AI summary
A method for forming sealed partially-filled packages filled with a pourable product comprises at least forming a tube from a web of packaging material, filling the pourable product into the tube for forming a product column within the tube, directing a sterile gas into the product column for forming and/or maintaining a gas cushion within the product column, and forming and transversally sealing the tube, for obtaining the packages containing the pourable product and a gas space formed from a defined volume of the sterile gas originating from the gas cushion.