Sterile Preform Blow-Fill Layout for Compact Container Lines
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Solution Overview
Problem
Existing systems for manufacturing filled plastic containers require a large installation space due to the significant distance between the forming and filling devices, leading to increased costs and space inefficiency.
Innovation Solution
A system and method that reduces the distance between the forming and filling devices by using a transport device with multiple transport units, a rotatable forming device, and a filling device with a movable carrier, allowing for a more compact design with a maximum distance of 5.5-6.0 meters between their central axes, while maintaining sterilization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the distance between the forming device and the filling device is reduced to minimize installation space, then the system footprint and costs are reduced, but the transport path for sterilized containers becomes shorter which may compromise sterilization effectiveness
Solution Approach 1:
The patent transforms the traditional linear arrangement of devices into a spatial configuration where the filling device is positioned above the forming device. The container transport path extends vertically from the forming device upward to the filling device, utilizing the third dimension (height) rather than only horizontal space. This dimensional change allows the system to achieve a compact footprint while maintaining an adequate sterilization path length through vertical transport.
2Reliability
If sterilization is performed on fully formed containers, then the container interior is sterilized, but the surface area requiring sterilization is large leading to high energy and media consumption
Solution Approach 1:
The patent implements preliminary sterilization of the preforms before the forming process. The preforms are sterilized while they still have a small surface area, prior to being transformed into large containers. This preliminary action ensures that when the containers are later formed and filled, their interiors are already sterile, eliminating the need for subsequent sterilization of the large container surfaces and significantly reducing energy and media consumption.
3Area of stationary object
If the distance between forming and filling devices is reduced, then installation space and costs are saved, but the system requires more complex transport device coordination
Solution Approach 1:
The transport device serving between the forming and filling devices is designed with multi-functionality. It not only transports containers vertically between these two devices but also maintains the sterile environment, coordinates the timing of container transfer, and integrates with both the forming device output and filling device input. This universal design reduces the need for separate specialized transport mechanisms, thereby managing complexity while achieving compact spatial arrangement.
Data Source
Figure 1
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AI summary
Plant and method for operating a plant for producing filled plastic containers (10) from sterile plastic preforms. Plant for producing filled plastic containers (10) from sterilized plastic preforms, with a transport device (2) for transporting the plastic preforms (11) and plastic containers formed from the plastic preforms by forming along a predetermined transport path through the plant, with a forming device (8) for forming the sterilized plastic preforms (11) into plastic containers, wherein the transport device (2) is suitable and intended for feeding the sterilized plastic preforms (11) to the forming device (8), wherein the forming device (8) has a transport carrier movable about a central axis.a forming device (8) is arranged with a plurality of forming stations for forming each plastic preform into a plastic container by applying a flowable medium, and with a filling device (12) for filling the plastic containers during their transport, at least in sections, essentially along a circular path around a central axis of the filling device (12). According to the invention, the forming device (8) and the filling device (12) have a maximum distance from each other with respect to their respective central axes of - 5.5 m, preferably (H2O2) 5.3 m, and the forming device (8) has a maximum of 24 forming stations or - 6.0 m, preferably (H2O2) 5.6 m, and the forming device (8) has more than 24 forming stations.