Sterilization Agent Diversion for Aseptic Container Deformation
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Solution Overview
Problem
In aseptic container sterilization processes, machine failures or discontinuities lead to overtreatment and potential deformation of containers due to continuous high-temperature sterilization media flow, which cannot be immediately switched off without disrupting the overall air balance in clean rooms.
Innovation Solution
A method and device that includes a switching device to interrupt the sterilization agent supply to containers while maintaining production, using a diverting mechanism to redirect the sterilization medium away from containers during machine stoppages, thus preventing overtreatment and maintaining air balance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sterilization medium flow is continuously maintained to keep air balance constant, then the air balance in clean room is maintained, but the containers are overtreated and may be deformed when machine stops
Solution Approach 1:
The system divides the sterilization medium flow into two separate controllable paths: one for maintaining air balance in the clean room and another for actual container treatment. This segmentation allows independent control of each function, enabling the air balance to be maintained while preventing harmful flow to containers during stoppages.
Solution Approach 2:
A switching device acts as an intermediary between the sterilization medium source and the containers. This intermediary can redirect the medium flow away from containers when machine stoppage is detected, while still allowing controlled flow to maintain air balance, thus mediating between the conflicting requirements.
2Object-affected harmful factors
If the sterilization medium is immediately switched off when fault occurs, then container overtreatment is prevented, but the air balance in clean room is disrupted and restart time increases
Solution Approach 1:
By segmenting the sterilization medium flow into separate controllable paths, the system can selectively maintain flow for air balance purposes while stopping treatment flow to containers. This allows the sterilization system to remain in a ready state without overtreating containers, enabling rapid restart after fault clearance.
Solution Approach 2:
The switching device serves as an intermediary that can quickly redirect flow paths without requiring complete system shutdown. When faults occur, it immediately prevents treatment flow to containers while maintaining overall system readiness, minimizing restart time while preventing harm.
3Productivity
If the treatment temperature is increased to reduce treatment time, then treatment efficiency is improved, but container shrinkage and deformation occur
Solution Approach 1:
The system uses periodic or pulsed sterilization medium flow rather than continuous high-temperature exposure. The switching device enables intermittent treatment cycles that achieve sterilization effectiveness while allowing containers to cool between exposures, preventing cumulative thermal deformation while maintaining treatment efficiency.
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
Enables continuous operation and immediate restart after errors, preventing container deformation and maintaining air balance in clean rooms by diverting sterilization medium away from containers during machine stoppages.
Implementation Method 1
The sterilization of the packaging materials, the filling of the product and the capping of the bottles usually take place in this machine unit. The entire space in which sterilization and filling takes place is referred to as an isolator, if available.
Implementation Method 2
a vaporized sterilization agent, which can be hydrogen peroxide or peracetic acid, for example
Implementation Method 3
After the plastic containers have been sterilized with this sterilization medium for a certain period of time, they can be blown out with hot air several times in order to reduce the residues of sterilization medium in these containers
Data Source
Figure 1~2
Figure 3a~4b
Figure 5~6b
AI summary
The sterilization device (1) has a transport device to transport a container (10) along a transportation path and a sterilizing agent generator (2) to generate the sterilizing agent. A feed device (4) is provided to supply the sterilizing agent to the container. A switching unit (20) is provided to interrupt the supply of sterilization agent to the container. A derivative device (22) is set to derive the sterilizing agent such that the sterilizing agent is not supplied directly to the container. An independent claim is included for a method for sterilizing container.