Viscous Product Sterilization via Segmented Heat Treatment
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Solution Overview
Problem
The challenge is to sterilize cosmetic products containing temperature-sensitive compounds without denaturing them, as traditional heat treatment methods can alter the properties of these compounds, and existing methods are limited by the high viscosity of the products, which prohibits the use of filters and raises concerns about the safety of preservatives used for preservation.
Innovation Solution
An apparatus and method for preparing and sterilizing a viscous fluid with a temperature-sensitive compound, involving a heat treatment unit for sterilizing the viscous matrix, a sterilizing device for the compound, and a mixing unit to incorporate the compound into the matrix, using direct or indirect heating and evaporative cooling to maintain the compound's integrity, with a dosing pump to control the flow rate of the compound.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional heat treatment methods are used to sterilize cosmetic products, then sterilization effectiveness is improved, but the properties of temperature-sensitive compounds are deteriorated
Solution Approach 1:
The sterilization process is segmented into two independent stages: (1) sterilizing the viscous matrix separately using heat treatment, and (2) adding the temperature-sensitive compound after the matrix has cooled down. This segmentation allows the matrix to receive full sterilization treatment while the sensitive compound is exposed to minimal heat, preventing denaturation.
Solution Approach 2:
The viscous matrix is sterilized in advance before the temperature-sensitive compound is added. By completing the sterilization process beforehand and allowing the matrix to cool, the subsequent addition of the compound does not require re-heating, thus preserving the compound's thermal sensitivity while ensuring the product is already sterilized.
2Reliability
If filters are used to sterilize viscous products, then sterilization is achieved, but the high viscosity of the products prohibits filter usage
Solution Approach 1:
The sterilization function is extracted from the mixing process. Instead of attempting to filter the final viscous product containing the temperature-sensitive compound, the sterilization is performed separately on the viscous matrix alone before the compound is added. This extraction allows sterilization to occur when the product is still processable, avoiding the need to force viscous material through filters.
3Duration of action of stationary object
If preservatives are added to extend shelf life, then product preservation is improved, but harmful preservatives are banned by regulations
Solution Approach 1:
The chemical preservation method is replaced with a physical sterilization method. Instead of using chemical preservatives to prevent microbial growth during storage, the product is physically sterilized through heat treatment of the matrix before use. This substitution eliminates the need for harmful chemical additives while achieving the same goal of extending safe shelf life.
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 approach effectively extends the shelf life of cosmetic products while preserving the properties of temperature-sensitive compounds, avoiding the use of harmful preservatives and ensuring efficient sterilization without denaturation.
Implementation Method 1
Heat treatment of liquid food products for the purpose of sterilization is a commonly used industrial process. To achieve rapid heating up to high temperatures, typically exceeding 100°C, steam is employed.
Implementation Method 2
This normally takes place by evaporative cooling, commonly referred as flash-cooling, in a vacuum chamber. During the process, the steam is released and condensed at the same time as the product is cooled down to a similar temperature it had before the heat treatment.
Implementation Method 3
a sterilizing device (27), fed with a temperature sensitive compound (11), ensuring the sterilization of the temperature sensitive compound (11)
Data Source
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AI summary
The invention relates to an apparatus for the preparation and sterilization of a viscous fluid (10) containing a temperature sensitive compound (11) diluted into a viscous matrix (12), characterized in that it comprises: - a heat treatment unit (15), fed with the viscous matrix (12), wherein the viscous matrix (12) is sterilized, - a mixing unit (17), fed with the sterilized viscous matrix (12) and the sterile temperature sensitive compound (11), wherein the temperature sensitive compound (11) is incorporated into the sterilized viscous matrix (12) to form the viscous fluid (10).