Sterilization Line Segmentation for Compact CIP Design
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Solution Overview
Problem
Conventional product liquid sterilization treatment lines require extensive space and high costs due to dual piping lines, consume excessive chemical liquids and energy, and prolong treatment times.
Innovation Solution
Implementing a sterilization treatment line with only certain intermediate piping lines in parallel, allowing for downsizing and compact design, where CIP treatment is focused on the intermediate piping line prone to burning, using less chemical agents and reducing treatment time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dual piping lines are arranged in parallel for sterilization treatment, then reliability is improved (continuous production can be maintained), but device complexity and space requirements increase
Solution Approach 1:
The piping system is segmented into three functional sections: heating section, sterilization section, and cooling section. Only the heating and cooling sections are arranged in parallel with switching capability, while the sterilization section remains single-line. This segmentation allows redundancy where needed (heating/cooling) while avoiding unnecessary complexity in the critical sterilization path.
Solution Approach 2:
Different parts of the piping system have different quality requirements. The heating and cooling sections are designed with parallel configuration and switching capability for reliability, while the sterilization section uses a simplified single-line design. This local differentiation optimizes the system by applying complexity only where necessary.
2Manufacturing precision
If CIP treatment is performed on the entire piping line, then cleaning effectiveness is improved, but chemical liquid consumption and treatment time increase
Solution Approach 1:
The CIP treatment system is segmented to target only the heating and cooling sections that require cleaning, excluding the sterilization section from routine CIP cycles. This is achieved through selective connection of the CIP system to specific piping sections, reducing chemical consumption while maintaining cleaning effectiveness where needed.
Solution Approach 2:
Instead of performing CIP treatment on the entire piping line, the system applies partial action by treating only the heating and cooling sections. This partial approach is sufficient because the sterilization section undergoes thermal sterilization that inherently cleanses it, avoiding unnecessary chemical treatment.
3Reliability
If extensive CIP and SIP treatments are performed on dual piping lines, then reliability is improved, but energy consumption and treatment time increase
Solution Approach 1:
The sterilization process is segmented into thermal sterilization (SIP) of the single-line sterilization section and chemical sterilization (CIP) of the parallel heating/cooling sections. This segmentation allows each section to receive appropriate sterilization treatment, reducing overall energy consumption by avoiding redundant SIP cycles on sections that don't require them.
Solution Approach 2:
The system changes the sterilization parameter approach by using thermal parameters (SIP with steam) for the sterilization section and chemical parameters (CIP with cleaning solutions) for the heating/cooling sections. This parameter differentiation optimizes energy usage by applying high-energy thermal treatment only where necessary.
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 results in a more economical and efficient sterilization process with reduced chemical usage and energy consumption, enabling continuous production while maintaining aseptic conditions.
Implementation Method 1
the product liquid is heated in the first stage heating unit from the normal temperature to a temperature of about 65°C, heated in the second stage heating unit from about 65°C to about 140°C
Implementation Method 2
maintained in the third stage heating unit at about 140°C for about 30 to 60 seconds to thereby subjected to the sterilization treatment
Implementation Method 3
the product liquid is cooled in the first stage cooling unit from about 140°C to about 90°C, cooled in the second stage cooling unit from about 90°C to about 45°C, and cooled in the third stage cooling unit from about 45°C to about 30°C
Data Source
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AI summary
In a sterilization treatment line in which an upstream side tank 16 in which product liquid is stored and a downstream side tank 17 are connected to each other through a conduit 18 through which the product liquid is transferred, a high-temperature heating unit 21 for sterilizing the product liquid is provided at an intermediate portion of the conduit, one or more stages of heating units 22, 23 heating the product conduit in a stepwise manner are provided for the conduit at portions between the upstream side tank and the high-temperature heating unit, and one or more stages of cooling units 24, 25, 26 cooling the product conduit in a stepwise manner are provided for the conduit at portions between the high-temperature heating unit and the downstream side tank, a plurality of intermediate piping lines P, Q are arranged in parallel with each other at portions between a heating stage of the heating unit 23 disposed in a temperature range at which the product liquid is burnt and between a cooling stage of the cooling unit 24 disposed in a temperature range at which the product liquid is burnt, and a sterilization treatment, a CIP treatment and a positive pressure keeping treatment with respect to the product liquid to be transferred from the upstream side tank to the downstream side tank are performed by switching the plural intermediate piping lines arranged in parallel with each other.