Continuous Surfactant Composition Filling via Segmented Injection
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Solution Overview
Problem
Current methods for producing liquid surfactant-containing compositions face challenges such as high space requirements, inefficiencies in batch processes, and difficulties in adding solid ingredients in continuous processes, leading to incompatibilities and storage issues in multi-chamber containers.
Innovation Solution
A continuous sequential process for producing multiple liquid surfactant-containing compositions by adding different additives to a basic mixture, allowing for precise filling of multi-chamber containers without parallel system requirements, enabling efficient production and storage of diverse compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If batch processes are used to produce liquid surfactant-containing compositions, then formulation adjustment and quality control are improved, but space requirements and production efficiency deteriorate
Solution Approach 1:
The production system is segmented into multiple independent injection points along the continuous flow line, allowing different formulations to be produced simultaneously in separate chambers while using a single continuous reactor system. This maintains formulation precision while improving productivity.
Solution Approach 2:
The process transitions from time-based batch production to spatial-based continuous production with multiple parallel streams. By adding the dimension of multiple simultaneous injection points along the flow path, the system achieves both formulation flexibility and continuous operation.
2Productivity
If continuous processes are used to produce liquid surfactant-containing compositions, then productivity and space utilization are improved, but the ability to add solid components and adjust formulations deteriorates
Solution Approach 1:
The system employs dynamic control of injection timing and dosage at multiple points along the continuous flow line. This allows the formulation to be adjusted dynamically during production, enabling both continuous operation and formulation flexibility.
Solution Approach 2:
Multiple independent injection points are segmented along the continuous flow path, allowing different solid and liquid components to be added at specific locations. This maintains adaptability while preserving continuous production capabilities.
3Adaptability or versatility
If multi-chamber containers are filled with different compositions, then product versatility and storage stability are improved, but the complexity of the filling system and synchronization requirements deteriorate
Solution Approach 1:
Multiple filling operations are merged into a single continuous process. The reactor system produces different formulations simultaneously in different chambers using one continuous flow line, eliminating the need for separate filling systems and reducing overall complexity.
Solution Approach 2:
The different compositions are prepared and separated into different chambers before final filling. By pre-preparing the formulations in separate streams within the continuous system, the filling process becomes simpler and more synchronized.
4Productivity
If large quantities of product are produced in each batch, then production efficiency is improved, but storage space requirements and handling complexity deteriorate
Solution Approach 1:
The system eliminates interruptions between production batches by maintaining continuous operation. Multiple chambers are filled continuously with different formulations, eliminating the need for large storage spaces for finished goods and reducing handling complexity.
Solution Approach 2:
The continuous production is segmented into multiple parallel streams that fill different chambers simultaneously. This allows continuous production of multiple products without requiring large storage spaces for any single formulation, as they are produced and stored separately in dedicated chambers.
Data Source
Figure 1
AI summary
The present invention relates to a method for producing liquid surfactant-containing compositions in a sequential, continuous process, which makes it possible to fill multi-chamber containers simultaneously with different compositions.