Sterilization Gassing Zone Segmentation for Concentration Stability
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Solution Overview
Problem
Existing sterilization devices for packages, such as carton bottles, face challenges in maintaining a stable high concentration of gaseous sterilization agents while minimizing emissions and consumption, often resulting in inadequate sterilization and increased costs due to significant outflows of sterilization agents.
Innovation Solution
The device divides the gassing zone into sub-zones using physical separation means with gaseous sterilization agent flows, ensuring a high and stable concentration throughout the zone by counteracting flow between sub-zones, and incorporates inlet and outlet means to control the flow effectively, reducing recontamination and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single gassing zone is used for sterilization, then the device structure is simple, but the sterilization agent concentration is unstable and emissions are high
Solution Approach 1:
The gassing zone is divided into multiple sub-zones (first gassing zone and second gassing zone) separated by a partition. Each sub-zone has its own inlet means for introducing sterilization agent, allowing independent concentration control. This segmentation stabilizes the overall sterilization agent concentration while reducing fluctuations that would occur in a single large zone.
2Reliability
If strong inflow of sterilization agent is maintained to compensate for outflow, then the sterilization agent concentration in the zone is sufficient, but emissions and consumption increase significantly
Solution Approach 1:
The partition with controlled opening creates a feedback mechanism where the sterilization agent flow between sub-zones is regulated. The opening size and position control the exchange rate, allowing the system to maintain sufficient concentration without excessive inflow, thereby reducing emissions and consumption.
Solution Approach 2:
The partition extracts the sterilization agent flow control function from the main gassing zone, creating a separate controlled interface. This allows precise management of agent distribution and reduces uncontrolled emissions to the external environment.
3Reliability
If partitionings are used to separate zones, then zone conditions can be maintained, but the device complexity and sterilization agent consumption increase
Solution Approach 1:
The partition is strategically positioned to divide only the critical portion of the gassing zone where concentration stability is most needed. The partition includes a controlled opening that allows selective interaction between sub-zones, maintaining zone integrity where required while minimizing overall structural complexity.
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 configuration achieves stable and safe sterilization of packages with reduced emissions and consumption of sterilization agents, maintaining aseptic conditions and ensuring commercial sterility of both internal and external surfaces.
Implementation Method 1
chemical sterilization can be used for sterilizing open carton bottles before filling. One sterilization apparatus for gas phase sterilization of carton bottles is described
Implementation Method 2
the carton bottles are heated up in the heating zone to a temperature above the dew point of the hydrogen peroxide gas
Implementation Method 3
In the venting zone, the carton bottles are subjected to sterile hot air in order to vent off hydrogen peroxide which remains in and on the carton bottles
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A device (1) for sterilization of packages (17) and a method of sterilizing packages are provided. The device comprises a gassing zone (7) for exposing the packages to a gaseous sterilization agent, inlet means (43) for introducing the gaseous sterilization agent into the gassing zone and a conveyor (15) for transporting the packages through the gassing zone in a transport direction (T). The device is characterized in further comprising separation means (49) arranged inside the gassing zone to divide at least an upper part (53) of the gassing zone into sub gassing zones (7a, 7b, 7c...), each of said separation means having an opening (61) for passage of the packages, each of at least a number of the inlet means being arranged to provide a flow of the gaseous sterilization agent at the opening of a respective one of the separation means.