Adiabatic Extrudate Composition for Energy-Efficient Pasteurization
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Solution Overview
Problem
Existing methods for producing easy-to-swallow dietary supplements are not sustainable or cost-effective, as they require additional energy for heating or cooling to achieve microbial reduction, and often result in food waste due to temperature control difficulties during adiabatic extrusion.
Innovation Solution
The use of a composition comprising at least 10% starch powder and 10% semolina, with a specific weight ratio and viscosity characteristics, extruded under adiabatic conditions to quickly reach and maintain pasteurization temperature without additional energy, ensuring microbial safety and product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the housing of an extruder is heated to reduce microorganisms, then microbial quality is improved, but energy consumption increases
Solution Approach 1:
The extrusion process itself generates the necessary heat through adiabatic compression and friction of the material against the extruder walls and screw. The system uses its own operational energy to achieve pasteurization temperatures without external heating, making the process self-sufficient for microbial reduction
Solution Approach 2:
The invention changes the thermodynamic parameters of the extrusion process by operating under adiabatic conditions (no heat exchange with surroundings). This causes the temperature to rise naturally during extrusion due to compression work, transforming the process from isothermal to adiabatic to achieve pasteurization
2Use of energy by moving object
If adiabatic extrusion is used to avoid energy consumption, then energy efficiency is improved, but temperature control becomes difficult
Solution Approach 1:
The invention implements feedback control by monitoring the temperature during adiabatic extrusion and adjusting operational parameters (screw speed, feed rate, moisture content) to maintain temperature within the pasteurization range. This ensures consistent microbial reduction while avoiding overheating
Solution Approach 2:
The invention performs preliminary conditioning of the material before extrusion by controlling moisture content and pre-mixing ingredients to achieve optimal rheological properties. This preliminary preparation ensures that the material responds predictably to adiabatic heating during extrusion, facilitating temperature control
3Use of energy by moving object
If pasteurization temperature is not reached quickly, then energy is saved, but product quality deteriorates due to microbial contamination
Solution Approach 1:
The invention applies preliminary anti-action by adding antimicrobial agents or selecting ingredients with natural preservative properties before extrusion. This creates a protective effect that works synergistically with the adiabatic heating to ensure microbial safety even if temperature rise is delayed
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 effectively reduces pathogenic microorganisms while maintaining product quality and taste, achieving compliance with microbiological guidelines without additional energy consumption.
Implementation Method 1
viscosity of such composition increases in a controlled manner when adiabatic extrusion is started. An increase in viscosity means more friction/pressure, resulting in a temperature which is high enough for pasteurization.
Implementation Method 2
pasturization can be done within the extruder even if extrusion is done under adiabatic conditions. Adiabatic extrusion means to operate with no input or extraction of heat
Data Source
AI summary
Methods of making extrudates comprising water-soluble vitamins and other micronutrients are provided, whereby the extrudates are obtained by adiabatic extrusion. During extrusion, temperature is controlled by the viscosity of the composition which is being extruded. Pasteurization temperature is reached, i.e., the extrudates that are formed by the methods meet the requirements set out in microbiological guidelines.