Two-Phase Beverage Filling for Hot Container Deformation
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Solution Overview
Problem
Beverage bottle filling machines face challenges in precisely adjusting the carbon dioxide content in carbonated beverages, especially when filling hot containers, which can lead to deformation and increased costs due to the need for cooling segments and complex filling processes.
Innovation Solution
A method involving a two-phase filling process where containers are initially filled at ambient pressure with a first product component, followed by a second phase at a higher pressure with a second product component, allowing for precise adjustment of carbon dioxide content without deformation, reducing spatial and energy costs, and eliminating the need for intermediate cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If containers are filled immediately after stretch-blowing without cooling, then productivity increases and space requirements are reduced, but container deformation occurs due to high temperature
Solution Approach 1:
The filling process is divided into two distinct phases: a first filling phase at ambient pressure to cool the container, and a second filling phase at elevated pressure to achieve proper carbonation. This segmentation allows the container to be cooled sufficiently during the first phase to prevent deformation during the pressurized second phase, while maintaining high overall productivity.
Solution Approach 2:
The first filling phase acts as a preliminary cooling step before the main carbonation process. By filling a portion of the container at ambient pressure first, the container walls are cooled below the deformation temperature, preparing them to withstand the pressure of the second filling phase without deforming.
2Shape
If a cooling segment is added between stretch-blowing and filling, then container deformation is prevented, but productivity decreases and space requirements increase
Solution Approach 1:
The cooling function is merged with the filling process itself. The first filling phase serves dual purposes: it fills the container with beverage while simultaneously cooling the container walls. This eliminates the need for a separate cooling segment, maintaining productivity while preventing deformation.
Solution Approach 2:
The filling process itself provides the cooling effect needed to prevent deformation. The beverage introduced during the first filling phase acts as a cooling medium, allowing the container to cool itself without requiring external cooling equipment or separate cooling steps.
3Measurement precision
If a two-phase filling process is implemented, then carbon dioxide content is precisely adjusted, but device complexity increases
Solution Approach 1:
The filling element is designed with dynamic pressure control, allowing it to operate at ambient pressure during the first filling phase and then increase to elevated pressure for the second phase. This dynamic pressure adjustment enables precise carbonation control while using a single, integrated filling element rather than multiple separate devices.
Solution Approach 2:
A single filling element performs multiple functions: it fills the container during the first phase, cools the container walls, and then provides pressurized carbonation during the second phase. This multi-functionality achieves precise carbon dioxide control without requiring separate filling devices for each phase.
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 method ensures precise carbon dioxide content in filled beverages, prevents container deformation, and reduces production costs and space requirements by integrating both filling phases in a single machine, allowing for direct filling of hot containers without intermediate cooling.
Implementation Method 1
the first liquid product component reaches a fill level that is at least 1.5 mm above said injection point, in order to cover said injection point with the first liquid product component and to cool, with the first liquid product component, the container base
Implementation Method 2
performing a first beverage filling phase by dispensing a first amount of a first beverage component into said beverage bottle under a first beverage filling pressure in said container; and performing a second beverage filling phase by dispensing a second amount of a second beverage component into said beverage bottle under a second beverage filling pressure in said container
Data Source
AI summary
A beverage bottle filling machine and a method of filling beverage bottles and similar containers.