Continuous Sterilizing System Thermal Zone Segmentation
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Solution Overview
Problem
Existing continuous sterilization systems lack suitable thermal insulation between zones, leading to inefficient energy consumption and prolonged processing times for products with higher solids loads, as temperature differences are not effectively managed, and equipment must be repeatedly depressurized and reheated for each batch.
Innovation Solution
A continuous sterilizing equipment with thermally isolated sterilization zones, each with independent thermal fluid supply and receptacles featuring a thermal insulation layer, allowing for optimized energy consumption and reduced processing time by maintaining distinct temperature zones and minimizing the need for frequent equipment reconditioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If discontinuous sterilization systems are used, then products can be sterilized in batches, but the equipment must be depressurized and cooled for each new batch, causing time loss and energy expenditure
Solution Approach 1:
The sterilization chamber is divided into multiple independent zones with separate thermal fluid circuits, allowing each zone to maintain different temperature and pressure conditions simultaneously. This enables continuous batch processing without requiring the entire system to be reconditioned between batches.
Solution Approach 2:
Each sterilization zone has independent thermal control, allowing localized temperature and pressure optimization for different product types or sterilization stages without affecting other zones, thereby eliminating downtime between batches.
2Adaptability or versatility
If discontinuous sterilization systems are used, then batch processing is enabled, but energy expenditure increases due to repeated heating and pressurizing
Solution Approach 1:
The system divides the sterilization chamber into independent zones with separate thermal fluid circuits, allowing each zone to maintain its own temperature and pressure conditions. This segmentation enables continuous operation without energy-intensive reconditioning cycles.
Solution Approach 2:
While one zone is being reconditioned, other zones continue sterilization operations, ensuring continuous productive action. The independent thermal circuits allow overlapping of reconditioning and sterilization processes across different zones.
3Productivity
If continuous sterilization systems with vertical towers or large horizontal autoclaves are used, then large series of products can be sterilized optimizing time and energy, but the systems are complex and require significant space
Solution Approach 1:
The sterilization chamber is divided into multiple independent zones that can operate simultaneously with different parameters, enabling continuous high-volume processing without requiring a single large complex autoclave.
Solution Approach 2:
The system uses multiple zones arranged in a compact configuration, utilizing spatial arrangement to achieve continuous processing capacity comparable to large towers or horizontal autoclaves while reducing overall system complexity and footprint.
4Temperature
If deflectors are used to distribute thermal fluid in sterilizing chambers, then temperature zones can be established, but the temperature difference between zones is limited and thermal insulation between zones is insufficient
Solution Approach 1:
The sterilization chamber is divided into independent zones with separate thermal fluid circuits, allowing each zone to maintain distinct temperature levels without thermal interference from adjacent zones.
Solution Approach 2:
Thermal insulation barriers are positioned between zones to prevent unwanted heat transmission, while separate thermal fluid circuits act as independent mediators for temperature control in each zone.
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
The equipment achieves efficient energy use and reduced processing time by maintaining independent temperature zones within the sterilizing body, optimizing energy consumption and enabling continuous operation without the need for frequent equipment reconditioning.
Implementation Method 1
the receptacles (2) incorporate a thermal insulation layer (17) which is arranged at least in the front part of the receptacles (2) in the direction of forward movement of the receptacles (2) inside the sterilizing body (1)
Data Source
AI summary
The invention relates to a continuous sterilizing system comprising a sterilizing body into which a thermal fluid is introduced for sterilizing products, the products to be sterilized being arranged in containers that circulate inside the sterilizing body, said sterilizing body being divided into different sterilization zones by means of dividing walls, and each of said dividing walls having a through-opening that is substantially the same shape as a container, such that the containers close the through-openings of the dividing walls, rendering the sterilization zones thermally isolated from one another.