A static mixing homogenization device for processing whipped cream and a method of using the same

Abstract

The present application relates to a kind of static mixing homogenization equipment for processing whipped cream and its use method, belong to food processing equipment technical field, including sequentially communicating first mixing unit, second mixing unit and third mixing unit, each stage mixing unit is equipped with additive injection port and built-in low shear static mixing element;Third mixing unit outlet is connected with backflow line and downstream process respectively through three-way valve;Online detection unit is arranged between third mixing unit and three-way valve, control system is signal connected with online detection unit and three-way valve, use method is as follows: whipped cream base material sequentially flows through three-stage mixing unit, flavor syrup, pigment essence and emulsifier are injected into each stage mixing unit in three stages respectively to carry out step-by-step mixing.The present application realizes the efficient low shear mixing homogenization of high viscosity difference material, has on-line quality control ability, and is suitable for the industrialized continuous production of flavored whipped cream.

Description

Technical Field

[0001] This invention relates to the field of food processing equipment technology, and in particular to a static mixing and homogenizing device for processing cream and its usage method. Background Technology

[0002] In the industrial production of flavored whipped creams such as vanilla, chocolate, strawberry, and low-sugar flavored whipped cream, it is necessary to uniformly mix high-viscosity whipped cream base with low-viscosity additives such as flavor syrups, colorings, flavorings, and emulsifiers. The viscosity of whipped cream at typical processing temperatures (60-70℃) is usually in the range of hundreds to thousands of centipoises (cP). For example, whipped cream with a fat content of 35% has a viscosity of about 2000 cP at 65℃, while the viscosity of additives such as flavor syrups may be as low as a few to tens of centipoises. For example, vanilla flavored syrup with a sugar content of 60Bx has a viscosity of about 50 cP at 65℃. The large difference in viscosity between the two presents a great technical challenge to the mixing and homogenization process.

[0003] Currently, the mixing and homogenization processes in light cream processing mainly employ the following techniques:

[0004] First, the mixture is stirred inside the container. The cream and various additives are put into the mixing container together and mixed by the mechanical rotation of the stirring paddle.

[0005] The second method is high-pressure homogenization, which involves passing a mixture of cream and additives through a narrow homogenizing valve gap (usually 0.1-0.5 mm) under high pressure (typically 20-80 MPa). High-speed shearing, cavitation effect, and impact force are used to break down fat globules and additive particles to the micron level.

[0006] Thirdly, there are traditional static mixers, which use static mixing elements (such as spiral, orifice plate, and Kenics types) in pipelines. These mixers utilize the fluid's own flow energy to achieve mixing through diversion, cross-flow, and rotation. Compared to the first two methods, static mixing offers significant advantages such as continuous production, no moving parts, and low energy consumption. However, existing static mixers still have significant shortcomings when handling materials with high viscosity differences.

[0007] First, the mixing uniformity is poor. For example, when low-viscosity additives such as flavor syrups enter the high-viscosity main fluid, light cream, due to the large difference in viscosity, the low-viscosity fluid tends to flow rapidly along the pipe wall or specific channels in the form of cross-flow or channeling. It is difficult to be fully dispersed into fine droplets and evenly distributed within a limited mixing length, resulting in inconsistent flavor and color between product batches, which seriously affects product quality.

[0008] Second, there is a contradiction between mixing length and pressure drop. Simply extending the mixing section or increasing the number of components to improve mixing uniformity will lead to a sharp increase in system pressure drop, increasing pumping energy consumption and equipment burden. Even with the latest low-shear static mixer design, its advantage of reducing pressure drop is difficult to fully realize in a single-section long-distance configuration because after the fluid passes through a large number of mixing components, its laminar flow develops fully, and the mixing efficiency of subsequent components decreases.

[0009] Third, there is a lack of online quality control methods. If the existing static mixing equipment fails to achieve the required mixing effect, the entire batch of materials must be discarded. There is a lack of effective online remedial measures. In continuous production, this defect will lead to a large amount of material waste and economic losses.

[0010] Fourth, it lacks adaptability. Different formulations (such as full sugar, low sugar, and those containing cocoa powder particles) have different requirements for mixing conditions. The existing static mixers with a single structure are difficult to adapt flexibly to various production needs. When the formulation changes, it is often necessary to replace the equipment or adjust the entire production line, lacking flexible online adjustment methods.

[0011] Therefore, developing a static mixing and homogenizing device that can efficiently process materials with high viscosity differences without damaging the fat globule structure of cream and has online quality control capabilities is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0012] This invention provides a static mixing and homogenizing device for processing cream and its usage method, which solves the technical problems of uneven mixing, high energy consumption, easy damage to product structure, and lack of online quality control methods in existing static mixing devices when processing materials with high viscosity differences such as cream and flavor syrup.

[0013] The solution of the present invention to the above-mentioned technical problems is as follows:

[0014] In a first aspect, a static mixing and homogenizing device for processing light cream includes a first mixing unit, a second mixing unit, a third mixing unit, a reflux pipeline, an online detection unit, and a control system connected sequentially along the material flow direction.

[0015] The first mixing unit is equipped with a cream base inlet and a first additive injection port, and has a first static mixing element inside. The cream base enters through the cream base inlet, and the first batch of additives is injected through the first additive injection port. The two are initially mixed under the action of the first static mixing element. The function of the first mixing unit is to: on the one hand, homogenize the temperature and adjust the flow state of the cream base, so that the cream reaches a stable temperature and flow rate distribution before entering the subsequent mixing, creating stable flow conditions for subsequent mixing; on the other hand, complete the initial mixing of cream and the first batch of additives, so that the additives are initially dispersed into large-scale droplets in the cream, laying the foundation for subsequent fine dispersion.

[0016] The inlet of the second mixing unit is connected to the outlet of the first mixing unit. It is equipped with a second additive injection port and a second static mixing element inside. The pre-mixed material enters the second mixing unit, and the second batch of additives is injected through the second additive injection port. Under the action of the second static mixing element, a second mixing is carried out. The second mixing unit undertakes the main mixing function. Since the viscosity difference between the first batch of additives and cream is the most significant, the second mixing unit is equipped with a relatively large number of static mixing elements to ensure that the additives are fully dispersed into fine droplets and evenly distributed in the cream matrix.

[0017] The inlet of the third mixing unit is connected to the outlet of the second mixing unit. It is equipped with a third additive injection port and a third static mixing element inside. The material after secondary mixing enters the third mixing unit, and the third batch of additives is injected through the third additive injection port. Under the action of the third static mixing element, the final mixing and homogenization are carried out. The third mixing unit completes the uniform dispersion of the third batch of additives and performs the final fine homogenization treatment on the overall material. The third batch of additives is added at the end of the third mixing unit so that it can enter the downstream process immediately after dispersion, avoiding continuous shearing in the long mixing path in the early stage, thereby better protecting the functionality of the additives and the stability of the system.

[0018] The first, second, and third static mixing elements are all low-shear static mixing elements without moving parts. Their mixing effect is achieved by the diversion, tumbling, and redistribution of fluids, rather than shearing and breaking them down. While achieving efficient mixing, the natural structure of fat globules in cream is effectively protected, avoiding excessive damage to fat globules caused by traditional high-pressure homogenization or high-speed stirring, thus ensuring the product's delicate texture and excellent whipping performance.

[0019] Furthermore, the first, second, and third static mixing elements are all SMX\u00A0Plus type static mixing elements. The SMX\u00A0Plus type static mixing element is composed of multiple layers of cross-arranged flat bars, with staggered flow channels formed between each layer of bars. When the fluid flows through, it is repeatedly divided into multiple thin layers and rearranged, thereby achieving efficient mixing under low shear conditions. Compared with traditional spiral static mixers, the SMX\u00A0Plus type element achieves fluid division, flipping, recombination, and circulation through the cross-arrangement of bars, which can significantly reduce pressure drop while producing the same mixing effect, and at the same time significantly reduce shear force. It is particularly suitable for mixing the cream fat globule system, which is sensitive to shear force.

[0020] Furthermore, the first mixing unit contains 4 to 8 static mixing elements, the second mixing unit contains 10 to 15 static mixing elements, and the third mixing unit contains 6 to 10 static mixing elements. The second mixing unit contains more static mixing elements than the first and third mixing units. The advantage of this configuration is that the second mixing unit undertakes the main mixing task, dealing with material systems with the most significant viscosity differences, requiring the most mixing elements to achieve sufficient dispersion. The first mixing unit mainly completes temperature homogenization and initial dispersion, requiring fewer elements. The third mixing unit deals with a basically homogenized material system, only needing to complete the final mixing of a small amount of additives; therefore, the number of elements is between the two. By configuring the mixing elements at each level within the aforementioned range, the pressure drop and cost increases caused by unnecessary increases in the number of elements can be avoided while ensuring the mixing effect.

[0021] The inlet of the reflux pipeline is connected to the outlet of the third mixing unit via a three-way valve, and the outlet is connected to the inlet of the first mixing unit. The reflux pipeline enables the equipment to control quality online. When the mixing uniformity is not met, the material can be returned to the first mixing unit for recirculation mixing without stopping the machine or discarding the material.

[0022] Furthermore, the three-way valve is an electric three-way valve, with its first outlet connected to the return pipeline and its second outlet connected to the downstream filling process pipeline. It can realize automatic output when the product quality meets the standard and automatic return when it does not meet the standard, without manual intervention, thus ensuring the continuity of production and the stability of product quality.

[0023] The online detection unit is installed on the pipeline between the outlet of the third mixing unit and the three-way valve. It is used to detect the uniformity index of the mixed materials in real time and output a detection signal. The online detection unit enables the equipment to perceive the mixing effect in real time, providing a data basis for automatic diversion and reflux ratio adjustment. It is a key link in realizing intelligent quality control.

[0024] Furthermore, the online detection unit includes an online near-infrared spectrometer. The detection probe of the online near-infrared spectrometer extends into the pipeline to detect the characteristic absorption spectrum of the target component in the material in real time. The absorbance deviation or the relative standard deviation of the component content is used as a uniformity index. The preset threshold is that the absorbance deviation does not exceed 5%, or the relative standard deviation of the component content does not exceed 5%. Near-infrared spectroscopy is based on the principle that different chemical components have characteristic absorption in the near-infrared band. It can achieve rapid detection without contact or damage to the sample, with a single detection time of less than one second. It is particularly suitable for online quality control in continuous production. Using absorbance deviation or relative standard deviation as a uniformity index can objectively and quantitatively reflect the uniformity of the distribution of the target component in the material. The threshold of 5% is based on the general standard for the quality of flavored cream products in the food industry. It can ensure the consistency of product quality without setting it too strictly, which would lead to frequent reflow and affect production efficiency.

[0025] Furthermore, the online detection unit also includes a homogeneous stabilization pipe section located upstream of the online near-infrared spectrometer. The length of the homogeneous stabilization pipe section is five to ten times the outlet diameter of the third mixing unit. This section is used to ensure that the mixed material reaches a stable flow state before entering the detection area. After the material flows out of the third mixing element, the flow state is still unstable. If spectral detection is performed directly, the flow fluctuations will interfere with the stability of the spectral signal, leading to detection deviations. After setting up this stabilization pipe section, the material achieves sufficient flow development before entering the detection area, and the fluctuation amplitude of the detection signal is greatly reduced, effectively improving the reliability and repeatability of the detection results.

[0026] The control system is connected to the online detection unit and the three-way valve signal respectively. It receives the detection signal and compares it with a preset threshold. Based on the comparison result, it controls the switching of the three-way valve. The control system connects detection and execution in series to form a complete closed-loop control loop, realizing automatic online control of mixed quality without the need for manual sampling and judgment, which greatly improves production efficiency and the accuracy of quality control.

[0027] Furthermore, the reflux pipeline is equipped with a reflux regulating valve and a reflux pump. The reflux regulating valve is used to control the reflux ratio, and the reflux pump is used to pump the material from the outlet of the third mixing unit back to the inlet of the first mixing unit. The control system is also connected to the reflux regulating valve and is used to dynamically adjust the reflux ratio according to the detection signal of the online detection unit. The reflux pump provides the power for material reflux, while the reflux regulating valve precisely controls the ratio of reflux flow to output flow. The two work together to allow the reflux ratio to be adjusted in real time according to the actual mixing effect, which ensures that unqualified materials are effectively recycled and avoids energy waste and excessive material shearing caused by excessive reflux.

[0028] Furthermore, the reflux ratio is adjustable within a range of 30% to 50%. When the online detection unit detects that the uniformity index deviates from the preset threshold, the control system increases the reflux ratio; when the uniformity index is better than the preset threshold, the control system decreases or shuts down the reflux ratio. The beneficial effect of this reflux ratio range is that, after extensive experimental verification, when the reflux ratio is below 30%, the improvement effect on mixing uniformity is not significant, and the material needs to be recycled multiple times to meet the standard, resulting in low efficiency. When the reflux ratio is above 50%, the improvement effect tends to saturate, but the number of times the material is repeatedly sheared increases, leading to a significant increase in energy consumption. Moreover, an excessively high reflux ratio may cause some material to remain in the circulation loop for a long time, affecting the consistency and freshness of the product. Therefore, limiting the reflux ratio adjustment range to 30% to 50% can achieve the best balance between the improvement effect on mixing uniformity and energy consumption.

[0029] Furthermore, the pipe diameters of the first mixing unit, the second mixing unit, and the third mixing unit are DN25 to DN80, and the length of each mixing unit is ten to twenty times the pipe diameter. The pipe diameter range of DN25 to DN80 covers the capacity requirements of medium and large-scale production lines with a daily output of 10 to 100 tons of flavored whipped cream, and can be flexibly selected according to specific capacity. The length of each mixing unit is ten to twenty times the pipe diameter, which ensures that the material has sufficient residence time in each mixing unit to complete the mixing, without being too long and causing unnecessary pressure drop and excessive shearing of the material. At the same time, it facilitates the manufacturing, installation, and maintenance of the equipment.

[0030] Furthermore, the first mixing unit is equipped with a first in-situ cleaning interface, the second mixing unit is equipped with a second in-situ cleaning interface, and the third mixing unit is equipped with a third in-situ cleaning interface. Each mixing unit is equipped with an in-situ cleaning interface, which enables online cleaning of the entire mixing system without disassembling the equipment. This meets the high standards of hygiene requirements for equipment in the food processing industry, while significantly shortening the cleaning time and improving equipment utilization and production efficiency.

[0031] Secondly, the present invention also provides a method of using the above-mentioned static mixing and homogenizing equipment for processing light cream, comprising the following steps:

[0032] Step 1: Pump the preheated cream base to 60 to 70 degrees Celsius into the first mixing unit at a set flow rate. The fat content of the cream base is 35% to 40%. The selection of the preheating temperature is based on the rheological properties of cream. Within this temperature range, cream has suitable fluidity, which is convenient for pumping and mixing, and will not affect the stability of fat globules due to excessive temperature. A fat content of 35% to 40% is a common specification for commercially available cream products, and cream has the best whipping performance within this fat content range.

[0033] Step 2: Inject the first batch of additives into the first additive injection port. The first batch of additives is initially mixed with the cream base in the first mixing unit. The first batch of additives is flavor syrup, and its injection amount is 15% to 30% of the mass of the cream base. This stage completes the initial contact and dispersion of the cream with the main sweetener and flavorings, so that the syrup is initially dispersed into large-scale droplets in the cream.

[0034] Step 3: The pre-mixed materials enter the second mixing unit, and the second batch of additives is injected into the second additive injection port. The second batch of additives is a mixture of pigments and flavorings. This stage completes the precise adjustment of the product's color and flavor. Since the amount of pigments and flavorings added is extremely small, they are mixed with the pre-dispersed syrup in the light cream. The syrup droplets can be used as a carrier to achieve rapid homogenization, avoiding the problem of difficulty in dispersing when a small amount of additives is injected into high-viscosity light cream alone.

[0035] Step 4: The material after secondary mixing enters the third mixing unit, and the third batch of additives is injected at the third additive injection port. The final mixing and homogenization are carried out in the third mixing unit. The third batch of additives is an emulsifier. The addition of the emulsifier at this stage can avoid it being subjected to excessive shearing in the early mixing stage, thereby better exerting its emulsifying and stabilizing effect.

[0036] Step 5: The online detection unit monitors the uniformity index of the material outlet of the third mixing unit in real time and sends the detection signal to the control system. The control system compares the detection signal with a preset threshold. If the uniformity index is better than or equal to the preset threshold, the control system controls the three-way valve to transport the material to the downstream process. If the uniformity index is worse than the preset threshold, the control system controls the three-way valve to guide the material into the return pipeline and return it to the inlet of the first mixing unit for recirculation and mixing. At the same time, the control system dynamically adjusts the return ratio according to the degree of deviation until the uniformity index meets the standard, and then switches to the downstream process. This step realizes online automatic detection and automatic control of mixing quality, ensuring that only qualified products enter the downstream filling process, eliminating the generation and outflow of unqualified products, and significantly reducing the scrap rate and material waste.

[0037] Furthermore, the injection amount of the first batch of additives in step two is 20% to 25% of the mass of the cream base. The beneficial effects of this injection range are as follows: the amount of flavor syrup added directly affects the sweetness and flavor intensity of the product. 20% to 25% is the preferred range determined through a large number of sensory evaluation experiments. Within this range, the product has moderate sweetness and harmonious flavor, and the volume ratio of syrup to cream is conducive to achieving efficient dispersion in the second mixing unit. When the syrup ratio is too low, the tendency of low-viscosity fluid to cross-flow in high-viscosity matrix is ​​enhanced, and the dispersion difficulty increases. When the syrup ratio is too high, the overall viscosity of the mixing system is too low, which may affect the dispersion effect of the subsequent emulsifier and the final texture of the product.

[0038] Furthermore, the reflux ratio of the reflux pipeline is initially set to 0% to 20%. When the uniformity index is worse than the preset threshold, the control system increases the reflux ratio to 30% to 50%. After normal production starts, the equipment usually operates under stable conditions and the mixing quality remains up to standard. At this time, there is no need for reflux, or the reflux ratio is maintained at a low level (not exceeding 20%) to cope with minor fluctuations in operating conditions. When an abnormal situation occurs that causes the uniformity to exceed the standard, the control system quickly increases the reflux ratio to the effective adjustment range of 30% to 50%, and quickly processes the unqualified materials to meet the standard. This graded strategy of low reflux under normal operating conditions and high reflux under abnormal operating conditions minimizes reflux energy consumption while ensuring product quality.

[0039] Furthermore, the online detection unit uses absorbance deviation as a uniformity index, and the preset threshold is that the absorbance deviation does not exceed 5%. The control system adjusts the reflux ratio in stages as follows: when the absorbance deviation does not exceed 3%, the reflux ratio is set to 0%; when the absorbance deviation is greater than 3% but not more than 5%, the reflux ratio is maintained at the initially set 0% to 20%; when the absorbance deviation is greater than 5% but not more than 8%, the reflux ratio is set to 30% to 40%; when the absorbance deviation is greater than 8%, the reflux ratio is set to 50%. The beneficial effect of this staged adjustment logic is that, based on a large number of experimental data... The summary shows that when the absorbance deviation is less than 3%, the mixing quality is excellent and no reflow is needed; when the deviation is between 3% and 5%, the mixing quality is still within the acceptable range and only a small amount of reflow is needed for preventative maintenance; when the deviation is between 5% and 8%, the mixing effect is substandard and the reflow ratio needs to be increased to 30% to 40% for effective intervention; when the deviation exceeds 8%, the mixing is seriously substandard and a rapid correction is needed with the maximum effective reflow ratio of 50%. This classification logic can adaptively match the most suitable reflow ratio according to the degree of deviation of the actual mixing effect, minimizing reflow energy consumption and material shearing times while ensuring mixing quality.

[0040] Furthermore, the emulsifier is a mono- or diglyceride fatty acid ester or lecithin. The emulsifier is added at the end of the third mixing unit and, after being mixed by the third static mixing element, immediately enters the downstream process. The emulsifier is added at the end of the third mixing unit and completes dispersion and enters the downstream filling process only through a limited number of mixing elements in the third mixing unit. It undergoes the fewest shearing actions in the entire process, thus maximizing the protection of the structure and functional activity of the emulsifier. At the same time, the emulsifier is added after the pigments and flavors, which is conducive to its rapid adsorption on the surface of the dispersed fat globules and flavor particles, thereby improving the emulsification efficiency.

[0041] The beneficial effects of this invention are as follows: This invention provides a static mixing and homogenizing device for processing light cream and its method of use, which has the following advantages:

[0042] 1. Significantly improves the uniformity of mixing in high viscosity differentials. By injecting flavor syrup, coloring and flavoring, and emulsifier into the cream base in three stages, the cross-flow and channeling phenomena caused by injecting all additives at once are avoided. In each stage, the low viscosity additives can be relatively fully dispersed when entering the high viscosity main fluid, and the process is carried out step by step, ultimately achieving a uniform mixing of cream and flavor syrup.

[0043] 2. The product structure is protected by a low-shear processing method. The SMX\u00A0Plus type low-shear mixing element is used. The mixing effect is mainly achieved by the diversion, tumbling and redistribution of fluids, rather than violent shearing and crushing, which effectively protects the natural whipping properties of cream.

[0044] 3. Significantly reduced system voltage drop: The SMX\u00A0Plus type static mixing element reduces the voltage drop by about 50% compared to the traditional spiral type under the same mixing effect. Combined with the segmented design, the total voltage drop is much lower than that of a single-stage mixer with the same mixing effect, and the operating energy consumption is reduced by about 40%.

[0045] 4. It has online quality control capabilities. The coordinated setup of the reflux pipeline, online detection unit and control system enables the equipment to automatically guide the material into the reflux pipeline for recirculation and mixing when the mixing uniformity is not up to standard, without the need to stop the machine or discard the material.

[0046] 5. Highly adaptable and flexible, it can flexibly adapt to various formulation requirements such as full sugar, low sugar, cocoa powder particles, and different flavors by adjusting the type, amount, and reflux ratio of additives in each stage. One machine can cover the production of various flavored whipped cream products.

[0047] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it according to the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Specific embodiments of the present invention are given in detail below with reference to the accompanying drawings. Attached Figure Description

[0048] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings:

[0049] Figure 1 This is a schematic diagram of a static mixing and homogenizing device for processing light cream and its usage method according to an embodiment of the present invention;

[0050] Figure 2 A front view of a static mixing and homogenizing device for processing light cream and its usage method provided in an embodiment of the present invention;

[0051] Figure 3 This is a system architecture diagram of a static mixing and homogenizing device for processing cream and its usage method provided in an embodiment of the present invention;

[0052] Figure 4 This is a flowchart illustrating a static mixing and homogenizing device for processing whipped cream and its usage method, as provided in an embodiment of the present invention.

[0053] The attached diagram lists the components represented by each number as follows:

[0054] 1. First mixing unit; 101. Whipping cream base inlet; 102. First additive injection port; 103. First static mixing element; 104. First in-situ cleaning interface; 2. Second mixing unit; 201. Second additive injection port; 202. Second static mixing element; 203. Second in-situ cleaning interface; 3. Third mixing unit; 301. Third additive injection port; 302. Third static mixing element; 303. Third in-situ cleaning interface; 4. Reflux pipeline; 401. Three-way valve; 402. Reflux regulating valve; 403. Reflux pump; 5. Online detection unit; 501. Online near-infrared spectrometer; 502. Homogenized stable section; 6. Control system. Detailed Implementation

[0055] The following is in conjunction with the appendix Figure 1-4 The principles and features of the present invention are described below. The examples given are for illustrative purposes only and are not intended to limit the scope of the invention. The invention is described more specifically in the following paragraphs by way of example with reference to the accompanying drawings. The advantages and features of the invention will become clearer from the following description. It should be noted that the drawings are in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the invention.

[0056] It should be noted that when a component is said to be fixed to another component, it can be directly on the other component or it may have a component in between. When a component is said to be connected to another component, it can be directly connected to the other component or it may have a component in between. When a component is said to be set to another component, it can be directly set to the other component or it may have a component in between. The terms vertical, horizontal, left, right, and similar expressions used in this document are for illustrative purposes only.

[0057] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The terminology used herein includes, and / or encompasses, any and all combinations of one or more of the associated listed items.

[0058] Example 1: Taking the production of vanilla-flavored whipped cream as an example, the static mixing and homogenizing equipment for whipped cream processing and its usage method provided by the present invention will be described in detail.

[0059] The material formula, based on 1000 kg of light cream base, is as follows: The light cream base is 1000 kg of light cream with a fat content of 35%, added through the inlet of the first mixing unit, with a viscosity of approximately 2000 centipoise at 65 degrees Celsius. The first batch of additives is vanilla-flavored syrup with a sugar content of 60 degrees Bx, added through the first additive inlet, with a viscosity of approximately 50 centipoise at 65 degrees Celsius. The second batch of additives consists of vanillin liquid flavoring and β-carotene emulsion coloring, with 1.5 kg of vanillin and 0.8 kg of β-carotene, pre-mixed evenly and added through the second additive inlet. The third batch of additives is a mono- and diglyceride fatty acid ester emulsifier, added in 5 kg after melting and through the third additive inlet.

[0060] The equipment parameters are set as follows: The first mixing unit has a DN50 pipe diameter and contains 6 SMX\u00A0Plus type static mixing elements. The second mixing unit has a DN50 pipe diameter and contains 12 SMX\u00A0Plus type static mixing elements. The third mixing unit has a DN50 pipe diameter and contains 8 SMX\u00A0Plus type static mixing elements. The online detection unit uses an online near-infrared spectrometer, with a detection wavelength range of 1400 to 2400 nm. The absorbance deviation of the characteristic absorption peak of β-carotene at approximately 2150 nm is used as the uniformity index. The control system uses a programmable logic controller, with a preset threshold set to absorbance deviation not exceeding 5%. The initial reflux ratio of the reflux pipeline is set to 0%.

[0061] The operation steps are as follows:

[0062] Step one: Preheated cream base to 65 degrees Celsius is pumped into the first mixing unit at a flow rate of 2000 kg / h from the cream base inlet. The cream flows separately through the first mixing unit, where it undergoes temperature homogenization and flow state adjustment via the first static mixing element. This stage aims to make the temperature distribution of the cream more uniform, reducing the inlet temperature difference from ±3 degrees Celsius to within ±0.5 degrees Celsius, creating stable flow conditions for subsequent mixing.

[0063] Step two: At the connection between the outlet of the first mixing unit and the inlet of the second mixing unit, vanilla-flavored syrup is continuously injected into the light cream at a flow rate of 500 kg / h through the first additive injection port. The mixture flows through the second mixing unit, where the light cream and syrup are mixed under the action of the second static mixing element. The viscosity ratio of syrup to light cream is approximately 1:40. In this embodiment, 12 SMX Plus type mixing elements are used, which is sufficient to ensure that the syrup is fully dispersed into fine droplets and evenly distributed in the light cream at this viscosity difference.

[0064] Step three: At the connection between the outlet of the second mixing unit and the inlet of the third mixing unit, a pre-mixed solution of vanillin and β-carotene is injected through the second additive inlet at a total flow rate of approximately 4.6 kg per hour. The mixture flows through the third mixing unit, where it undergoes flavor and color homogenization under the action of the third static mixing element. At this stage, the combined amount of vanillin and β-carotene added is only 0.23% of the cream flow rate, allowing for rapid homogenization based on the existing syrup dispersion.

[0065] Step four: At the connection between the outlet of the third mixing unit and the three-way valve, molten mono- and diglyceride fatty acid esters are injected through the third additive injection port at a flow rate of 10 kg / h, completing the final mixing at the end of the third mixing unit. The emulsifier is added at this stage so that it can immediately enter the downstream filling process after dispersion, avoiding continuous shearing during the longer mixing path in the early stages, thus better protecting the stability of the emulsion system.

[0066] Step 5: The online near-infrared spectrometer in the online detection unit continuously detects the absorbance of carotene once per second. The absorbance deviation is 3.2%, below the 5% threshold. Upon receiving the compliance signal, the control system automatically switches the three-way valve to the downstream filling pipeline, allowing direct product filling.

[0067] Example 2: Taking the production of chocolate-flavored whipped cream containing cocoa powder particles as an example, this invention is used to illustrate its application in processing materials containing particles.

[0068] The material formula, based on 1000 kg of light cream base, is as follows: The light cream base is 1000 kg of light cream with a fat content of 38%, preheated to 70 degrees Celsius. The first batch of additives is chocolate syrup with a sugar content of 62 degrees Bx, containing cocoa powder particles with an average particle size of approximately 50 micrometers, added through the first additive inlet. The second batch of additives is a mixture of cocoa powder supplement and vanilla extract, with 20 kg of cocoa powder supplement (pre-dispersed in a small amount of light cream) and 1.2 kg of vanilla extract added through the second additive inlet. The third batch of additives is lecithin emulsifier, 3 kg, added through the third additive inlet after melting.

[0069] The equipment parameters are set as follows: The first mixing unit has a pipe diameter of DN50 and contains 6 SMX\u00A0Plus type static mixing elements. The second mixing unit has a pipe diameter of DN50 and contains 15 SMX\u00A0Plus type static mixing elements. The third mixing unit has a pipe diameter of DN50 and contains 10 SMX\u00A0Plus type static mixing elements. The online detection unit uses an online near-infrared spectrometer to simultaneously detect the characteristic absorption peaks of cocoa powder and moisture. The preset threshold of the control system is set to absorbance deviation not exceeding 5%. The initial reflux ratio of the reflux pipeline is set to 10%.

[0070] In this embodiment, the number of mixing elements in the second mixing unit is increased to 15 because the chocolate syrup contains cocoa powder particles, requiring more cutting and dispersing processes to evenly distribute the particles in the whipped cream. The number of mixing elements in the third mixing unit is also increased to 10 to ensure thorough mixing of the cocoa powder supplement slurry and emulsifier.

[0071] The operating steps are as follows: Preheated cream (70°C) is pumped into the first mixing unit at a flow rate of 1800 kg / h from the cream base inlet. Chocolate syrup is injected into the cream at a flow rate of 540 kg / h through the first additive inlet. The mixture flows through the second mixing unit, where it is mixed with the chocolate syrup by 15 second static mixing elements. A mixture of cocoa powder supplement and vanilla extract is injected at a flow rate of approximately 38 kg / h through the second additive inlet, and mixed in the third mixing unit. Molten lecithin is injected at a flow rate of 5.4 kg / h through the third additive inlet, completing the addition and mixing of the emulsifier at the end of the third mixing unit. An online detection unit continuously monitors the dispersion uniformity of the cocoa powder.

[0072] Initial testing showed an absorbance deviation of 7.8%, exceeding the acceptable threshold of 5%. Upon receiving the signal, the control system automatically switched the three-way valve to the reflux line and increased the reflux ratio from the initial 10% to 40%. After 20 minutes of recirculation and mixing, the absorbance deviation decreased to 3.5%, and the relative standard deviation of vanilla flavor content was 2.1%, both meeting the standards. The control system then switched the three-way valve to the downstream process.

[0073] Example 3: Production of Low-Sugar Flavored Whipping Cream

[0074] This embodiment uses the production of low-sugar flavored whipped cream as an example to illustrate the application of the present invention in the treatment of trace additives.

[0075] The material formula, based on 1000 kg of light cream base, is as follows: The light cream base is 1000 kg of light cream with a fat content of 36%, preheated to 60 degrees Celsius. The first batch of additives is a low-sugar flavor syrup with a sugar content of 55 degrees Bx, using maltitol to replace part of the sucrose, added through the first additive inlet. The second batch of additives is a mixture of sucralose solution and edible flavoring, where the sucralose solution concentration is 25%, added at 0.5 kg, and the edible flavoring is added at 1.0 kg, added through the second additive inlet. The third batch of additives is a natural beta-carotene pigment emulsion, added at 0.5 kg, added through the third additive inlet.

[0076] The equipment parameters are set as follows: The first mixing unit has a pipe diameter of DN50 and contains 6 SMX\u00A0Plus type static mixing elements. The second mixing unit has a pipe diameter of DN50 and contains 10 SMX\u00A0Plus type static mixing elements. The third mixing unit has a pipe diameter of DN50 and contains 6 SMX\u00A0Plus type static mixing elements. The online detection unit uses an online near-infrared spectrometer, with a wavenumber range of 4000 to 10000 per centimeter, and the deviation of the sugar content characteristic absorption peak is used as the uniformity index. The preset threshold of the control system is set to absorbance deviation not exceeding 5%. The initial reflux ratio of the reflux pipeline is set to 20%.

[0077] In the low-sugar formula, the proportion of syrup added was reduced from 25% in Example 1 to 20%, further decreasing the volume ratio of syrup to cream. Since low-viscosity syrup is more difficult to disperse in high-viscosity cream, the reflux ratio was initially set at 20% in this example. Meanwhile, sucralose, a high-intensity sweetener, was added at only 0.05% of the cream flow rate, and its uniform dispersion is crucial for consistent product taste.

[0078] The operating steps are as follows: Preheated heavy cream (60 degrees Celsius) is pumped into the first mixing unit at a flow rate of 2200 kg / h from the heavy cream base inlet. Low-sugar flavored syrup is injected through the first additive inlet at a flow rate of 440 kg / h, and mixing is completed in the second mixing unit. A mixture of sucralose solution and edible flavoring is injected through the second additive inlet at a flow rate of approximately 3.3 kg / h, and mixing is completed in the third mixing unit. Finally, β-carotene is injected through the third additive inlet at a flow rate of 1.1 kg / h, and final mixing is completed in the third mixing unit.

[0079] The online detection unit performs continuous monitoring. Since the reflux ratio is preset to 20%, a portion of the material is refluxed and recycled after the initial pass. Testing showed that the relative standard deviation of the product's sweetness uniformity was 3.1%, and the color uniformity deviation was 2.7%, both meeting the standards. The control system then switches the three-way valve to the downstream process.

[0080] Example 4: Verification of the effect of dynamic adjustment of reflux ratio

[0081] To verify the effectiveness of the reflux ratio graded adjustment logic of the present invention, the formulation and equipment of Example 1 were used to test the effect of different reflux ratio settings on the mixing uniformity under the condition of initial uneven mixing.

[0082] Initial mixing unevenness was simulated by artificially increasing the vanilla syrup injection flow rate by 30%. The changes in absorbance deviation after 10, 20, and 30 minutes of recirculation were tested when the reflux ratios were 0%, 20%, 30%, 40%, 50%, and 60%.

[0083] Experimental results show that increasing the reflux ratio from 0% to 30% significantly improves mixing uniformity; after 20 minutes of recirculation, the absorbance deviation decreases from 11.2% to 4.2%, a reduction of 62.5%. Increasing the reflux ratio from 30% to 50% still shows a noticeable improvement, with the absorbance deviation decreasing from 4.2% to 2.5% after 20 minutes of recirculation. However, increasing the reflux ratio from 50% to 60% leads to near-saturation of improvement; after 20 minutes of recirculation, the absorbance deviation only decreases from 2.5% to 2.3%, but the increased number of times the material is repeatedly sheared results in an approximately 20% increase in energy consumption.

[0084] Based on the above experimental data, this invention sets the reflux ratio adjustment range to 30% to 50%, which achieves the optimal balance between improving mixing uniformity and energy consumption. The control system adjusts the reflux ratio in stages as follows: when the absorbance deviation does not exceed 3%, the reflux ratio is set to 0%; when the absorbance deviation is greater than 3% but not more than 5%, the reflux ratio is maintained at the initially set 0% to 20%; when the absorbance deviation is greater than 5% but not more than 8%, the reflux ratio is set to 30% to 40%; and when the absorbance deviation is greater than 8%, the reflux ratio is set to 50%. This staged adjustment logic can adaptively match the most suitable reflux ratio according to the degree of deviation in the actual mixing effect, minimizing reflux energy consumption and material shearing times while ensuring mixing quality.

[0085] Example 5: Equipment Cleaning and Maintenance

[0086] This embodiment illustrates the in-situ cleaning operation process of the equipment of the present invention.

[0087] Each mixing unit of this equipment is equipped with an in-situ cleaning interface. The cleaning operation procedure is as follows:

[0088] The first step is water rinsing. Warm water at 40 to 50 degrees Celsius is introduced through each in-situ cleaning port and rinsed for 10 to 15 minutes at a flow rate of 1.5 times the normal production flow rate until the discharged water is clear and free of residue.

[0089] The second step is alkaline washing, which involves passing a 2-3% sodium hydroxide solution through the tube at a temperature of 70-80 degrees Celsius for 20-30 minutes to remove fat and protein residues.

[0090] The third step is a water rinse, in which clean water is introduced to rinse until neutral, with a pH value of 6.5 to 7.5.

[0091] The fourth step is acid washing, in which a nitric acid solution with a concentration of 1% to 2% is passed through at a temperature of 60 to 70 degrees Celsius and the solution is circulated for 15 to 20 minutes to remove minerals and stalactite deposits. The stalactites are mainly deposits of calcium phosphate and calcium citrate.

[0092] The fifth step is the final rinse, in which food-grade purified water is introduced to rinse until neutral, and the conductivity of the discharged water is tested to be consistent with that of the influent water, with a deviation of no more than 5%.

[0093] The sixth step is disinfection. Hot water at a temperature above 90 degrees Celsius is circulated for 15 minutes for disinfection, or a peracetic acid solution with a concentration of 0.2% to 0.5% is circulated for chemical disinfection, followed by rinsing with sterile water.

[0094] Since there are no moving parts or dead corners in each mixing unit, and the cross-bracing structure of the SMX\u00A0Plus type element has no sharp corners, the fluid can evenly flush all surfaces, resulting in good in-situ cleaning effect.

[0095] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Content not described in detail in this specification is prior art known to those skilled in the art.

[0096] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Those skilled in the art can readily implement the present invention based on the accompanying drawings and the above description. However, any modifications, alterations, or variations made by those skilled in the art without departing from the scope of the present invention, utilizing the disclosed technical content, are equivalent embodiments of the present invention. Furthermore, any modifications, alterations, or variations made to the above embodiments based on the essential technology of the present invention are still within the protection scope of the present invention.

Claims

1. A static mixing and homogenizing device for processing light cream and its method of use, comprising a first mixing unit (1), a second mixing unit (2), a third mixing unit (3), and a reflux pipeline (4), characterized in that, The first mixing unit (1) is provided with a cream base inlet (101) and a first additive injection port (102), and is provided with a first static mixing element (103) inside. The inlet of the second mixing unit (2) is connected to the outlet of the first mixing unit (1), and a second additive injection port (201) is provided. The interior is provided with a second static mixing element (202). The inlet of the third mixing unit (3) is connected to the outlet of the second mixing unit (2), and a third additive injection port (301) is provided. A third static mixing element (302) is provided inside. The inlet end of the return pipeline (4) is connected to the outlet of the third mixing unit (3) through a three-way valve (401), and the outlet end is connected to the inlet of the first mixing unit (1); The online detection unit (5) is installed on the pipeline between the outlet of the third mixing unit (3) and the three-way valve (401) to detect the uniformity index of the mixture in real time and output the detection signal; The control system (6) is connected to the online detection unit (5) and the three-way valve (401) respectively, and is used to receive the detection signal and compare it with the preset threshold, and control the switching of the three-way valve (401) according to the comparison result; The first static mixing element (103), the second static mixing element (202) and the third static mixing element (302) are all low-shear static mixing elements without moving parts. Their mixing effect is achieved by the diversion, overturning and redistribution of fluid, rather than shearing and breaking.

2. The static mixing and homogenizing equipment for processing light cream according to claim 1, characterized in that, The first static mixing element (103), the second static mixing element (202) and the third static mixing element (302) are all SMXPlus type static mixing elements; the SMXPlus type static mixing element is composed of multiple layers of cross-arranged flat bars, and each layer of bars forms an interlaced flow channel. When the fluid flows through, it is repeatedly divided into multiple thin layers and rearranged, thereby achieving efficient mixing under low shear conditions. The first mixing unit (1) has 4-8 static mixing elements, the second mixing unit (2) has 10-15 static mixing elements, and the third mixing unit (3) has 6-10 static mixing elements; wherein, the number of static mixing elements in the second mixing unit (2) is greater than that in the first mixing unit (1) and the third mixing unit (3).

3. The static mixing and homogenizing equipment for processing light cream according to claim 1, characterized in that, The online detection unit (5) includes an online near-infrared spectrometer (501). The detection probe of the online near-infrared spectrometer (501) extends into the pipeline to detect the characteristic absorption spectrum of the target component in the material in real time, and uses the absorbance deviation or the relative standard deviation of the component content as the uniformity index; the preset threshold is that the absorbance deviation does not exceed five percent, or the relative standard deviation of the component content does not exceed five percent. It also includes a homogeneous stabilization pipe section (502) located upstream of the online near-infrared spectrometer (501), the length of which is five to ten times the outlet diameter of the third mixing unit (3), for ensuring that the mixture reaches a stable flow state before entering the detection area.

4. The static mixing and homogenizing equipment for processing light cream according to claim 1, characterized in that, The reflux pipeline (4) is equipped with a reflux regulating valve (402) and a reflux pump (403). The reflux regulating valve (402) is used to control the reflux ratio, and the reflux pump (403) is used to pump the material from the outlet of the third mixing unit (3) back to the inlet of the first mixing unit (1). The control system (6) is also connected to the reflux regulating valve (402) for dynamically adjusting the reflux ratio according to the detection signal of the online detection unit (5). The reflux ratio can be adjusted from 30% to 50%. When the online detection unit (5) detects that the uniformity index deviates from the preset threshold, the control system (6) increases the reflux ratio; when the uniformity index is better than the preset threshold, the control system (6) decreases or shuts down the reflux ratio.

5. The static mixing and homogenizing equipment for processing light cream according to claim 1, characterized in that, The three-way valve (401) is an electric three-way valve, with its first outlet connected to the return pipeline (4) and its second outlet connected to the downstream filling process pipeline.

6. The static mixing and homogenizing equipment for processing light cream according to claim 1, characterized in that, The pipe diameters of the first mixing unit (1), the second mixing unit (2), and the third mixing unit (3) are DN25 to DN80, and the length of each mixing unit is ten to twenty times the pipe diameter; The first mixing unit (1) is provided with a first in-situ cleaning interface (104), the second mixing unit (2) is provided with a second in-situ cleaning interface (203), and the third mixing unit (3) is provided with a third in-situ cleaning interface (303).

7. A method of using the static mixing and homogenizing equipment for processing light cream as described in any one of claims 1 to 6, characterized in that, Includes the following steps: Step 1: Pump the preheated cream base to 60 to 70 degrees Celsius into the first mixing unit (1) at a set flow rate. The fat content of the cream base is 35 to 40 percent. Step 2: Inject the first batch of additives into the first additive injection port (102). The first batch of additives is initially mixed with the cream base in the first mixing unit (1). The first batch of additives is flavor syrup, and its injection amount is 15% to 30% of the mass of the cream base. Step 3: The pre-mixed material enters the second mixing unit (2), and the second batch of additives is injected at the second additive injection port (201). The second batch of additives is mixed in the second mixing unit (2). The second batch of additives is a mixture of pigments and fragrances. Step 4: The material after secondary mixing enters the third mixing unit (3), and the third batch of additives is injected at the third additive injection port (301). The final mixing and homogenization are carried out in the third mixing unit (3); the third batch of additives is an emulsifier. Step 5: The online detection unit (5) detects the uniformity index of the material exiting the third mixing unit (3) in real time and sends the detection signal to the control system (6). The control system (6) compares the detection signal with a preset threshold. If the uniformity index is better than or equal to the preset threshold, the control system (6) controls the three-way valve (401) to transport the material to the downstream process; If the uniformity index is worse than the preset threshold, the control system (6) controls the three-way valve (401) to introduce the material into the return pipeline (4) and return it to the inlet of the first mixing unit (1) for recirculation and mixing. At the same time, the control system (6) dynamically adjusts the return ratio according to the degree of deviation until the uniformity index meets the standard and then switches to the downstream process.

8. The method of use according to claim 7, characterized in that, In step two, the amount of the first batch of additives injected is 20% to 25% of the mass of the cream base; the reflux ratio of the reflux pipeline (4) is initially set to 0% to 20%. When the uniformity index is worse than the preset threshold, the control system (6) increases the reflux ratio to 30% to 50%.

9. The method of use according to claim 7, characterized in that, The online detection unit (5) uses absorbance deviation as a uniformity index, and the preset threshold is that the absorbance deviation does not exceed 5%. The control system (6) adjusts the reflux ratio in the following manner: when the absorbance deviation does not exceed 3%, the reflux ratio is set to 0%. When the absorbance deviation is greater than 3% but not more than 5%, the reflux ratio is maintained at the initially set 0% to 20%. When the absorbance deviation is greater than 5% but not more than 8%, the reflux ratio is set to 30% to 40%. When the absorbance deviation is greater than 8%, the reflux ratio is set to 50%.

10. The method of use according to claim 7, characterized in that, The emulsifier is a mono- or diglyceride fatty acid ester or lecithin. The emulsifier is added at the end of the third mixing unit (3) and then mixed by the third static mixing element (302) before entering the downstream process.

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