Two-Stage Liquid Blow Molding for Heat-Sensitive Ingredients
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Solution Overview
Problem
Conventional liquid blow molding methods are challenging for containers holding heat-sensitive ingredients, as they can lead to deterioration of such ingredients due to heat, and for mixed liquids like seasoning dressings, where maintaining a uniform mixed state is difficult during the molding process.
Innovation Solution
A two-step liquid blow molding method where a first liquid is supplied at a predetermined pressure to shape the preform, followed by a second liquid, with the option of equal or higher pressure, and including a cleaning step to remove the second liquid, ensuring the heat-sensitive ingredient is protected and the mixed state is maintained.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the preform is heated to the temperature at which stretchability is achieved and liquid is supplied into the preform, then the container can be molded efficiently with content liquid filled simultaneously, but the heat-sensitive ingredient in the content liquid undergoes deterioration such as denaturation and deactivation
Solution Approach 1:
The liquid supply process is segmented into two distinct stages: first supplying a heat-resistant liquid (water or alcohol) to mold the container, then subsequently supplying the heat-sensitive content liquid. This segmentation allows the molding process to proceed at high temperature without damaging the heat-sensitive ingredients, as they are introduced only after the preform has cooled down.
Solution Approach 2:
The heat-resistant liquid is supplied first as a preliminary action to complete the molding process. This preliminary molding step prepares the container shape while the preform is still hot, and only after this preliminary action is complete does the system proceed to supply the heat-sensitive content liquid, ensuring the ingredients are not exposed to damaging temperatures.
2Productivity
If the liquid is supplied into the heated preform through the nozzle, then the container is molded with content liquid filled, but it is difficult to maintain the uniform mixed state of the liquid
Solution Approach 1:
The liquid supply is segmented into sequential steps rather than simultaneous mixing. First the heat-resistant liquid is supplied and used for molding, then the content liquid is supplied separately. This eliminates the problem of maintaining uniform mixing during the high-temperature molding process, as the heat-sensitive content liquid is introduced only after molding is complete and temperatures have decreased.
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 allows for the production of containers holding heat-sensitive ingredients and mixed liquids without deterioration, ensuring the quality and uniformity of the content liquid, simplifying the production process and configuration.
Implementation Method 1
supplying, into the preform that has been heated to a predetermined temperature, a first liquid at a predetermined pressure through a nozzle
Implementation Method 2
supplying a second liquid into the preform at a predetermined pressure through the nozzle
Implementation Method 3
in a case where a liquid-containing container holding, as the content liquid, an enzyme liquid detergent containing the heat-sensitive ingredient is molded. In this case, when the liquid detergent is supplied into the heated preform, enzyme contained in the liquid detergent undergoes denaturation or deactivation (deterioration) due to the heat of the preform
Data Source
AI summary
A liquid blow molding method molds a bottomed tubular-shaped preform into a liquid-containing container in which a content liquid is held. The liquid blow molding method includes: a first molding step of liquid blow molding the preform into a halfway shape by supplying, into the preform that has been heated to a predetermined temperature, a first liquid at a predetermined pressure through a nozzle unit; and a second molding step, performed after the first molding step, of liquid blow molding the preform by supplying a second liquid into the preform at a predetermined pressure through the nozzle unit.