Sterilization Machine Post-Heating Unit Dew Point Control
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Solution Overview
Problem
Existing container sterilization machines face challenges in maintaining effective sterilization performance, particularly with high flow rates of hydrogen peroxide, where vapor condensation occurs, leading to reduced sterilization effectiveness and increased downtime due to the need for re-heating systems after prolonged stops.
Innovation Solution
A machine with a rotary carousel and isolator for container treatment, incorporating a vaporization device that generates a mixture of air, water vapor, and hydrogen peroxide, and a post-heating unit to maintain the temperature above the dew point, ensuring the hydrogen peroxide remains in a gaseous state and preventing condensation, with the post-heating unit located proximal to the sterilization area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydrogen peroxide is vaporized at high flow rates, then sterilization coverage is improved, but vapor condensation occurs reducing sterilization effectiveness
Solution Approach 1:
The system pre-heats the hydrogen peroxide vapor in a dedicated heating section before it reaches the sterilization zone. This preliminary heating action ensures the vapor maintains sufficient temperature to prevent condensation even at high flow rates, thereby maintaining sterilization effectiveness while achieving broad coverage
Solution Approach 2:
A heating section acts as an intermediary between the vaporization source and the sterilization zone. This intermediate heating zone compensates for temperature drops during transport, ensuring the vapor arrives at the correct temperature for effective sterilization without condensing
2Loss of energy
If the system is stopped for prolonged periods, then energy consumption is reduced, but re-heating is required increasing downtime
Solution Approach 1:
The heating function is localized to specific sections where needed most - the vaporization zone and the transport conduit. This localized heating approach minimizes overall energy consumption while maintaining vapor temperature in critical areas, allowing faster restart after stops
3Device complexity
If vaporization device is placed far from sterilization zone, then structural complexity is reduced, but temperature drop causes condensation
Solution Approach 1:
A heated transport conduit serves as an intermediary element between the remotely placed vaporization device and the sterilization zone. This intermediate heating mechanism allows the system to maintain simplicity in overall layout while ensuring temperature maintenance during transport, preventing condensation despite the distance
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 ensures consistent and effective sterilization performance over time, reducing downtime and maintaining the desired sterility level without increasing structural complexity, by keeping the hydrogen peroxide vapors above the minimum temperature required for sterilization.
Implementation Method 1
a post-heating unit (7) operatively active on said mixture to keep its temperature above the dew point
Implementation Method 2
a vaporisation device (2) configured to generate a mixture comprising air, water vapour and an evaporated sterilising agent
Implementation Method 3
an aqueous solution of hydrogen peroxide is brought from the liquid phase to the gaseous phase, known as VHP (Vapour Hydrogen Peroxide)
Data Source
Figure 1
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Figure 3
AI summary
Machine (200) for sterilising containers (100), comprising: a rotary carousel (201) provided with a plurality of treatment stations of the containers (100), in each of said treatment station being arranged a dispensing nozzle; an isolator (202) configured for separating the rotary carousel (201) from the external environment; a vaporisation device (2) configured to generate a mixture comprising air, water vapour and an evaporated sterilising agent; a post-heating unit (7) operatively active on said mixture so as to maintain the temperature thereof above a dew point temperature; a rotary distributor arranged inside the isolator (202) and configured to receive the mixture form the post-heating unit (7) and to distribute the mixture towards the dispensing nozzles of the treatment stations, characterised in that said vaporisation device (2) is arranged in a lateral zone of the rotary carousel (201) and the post-heating unit (7) is located in proximity of the rotary carousel (201).