Aerated Food Processing with Split Mixing to Cut Viscosity Load
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Solution Overview
Problem
Conventional methods for producing aerated food products require high electrical and thermal loads due to the viscosity of the combined ingredients, which can be unsustainable for some manufacturers and costly in terms of energy expenditure.
Innovation Solution
The method involves separating the Mousse base ingredients and gelatin solution into less viscous counterparts at cooler temperatures, processing them separately in aseptic surge tanks, and then combining and aerating them, reducing the overall electrical and thermal load required for production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If all ingredients are combined and processed together using conventional methods, then the aerated food product can be created, but the electrical and thermal load increases due to high viscosity requiring more energy for pumping and processing
Solution Approach 1:
The food product is divided into multiple separate portions that are processed independently through different pathways before being recombined. This segmentation allows each portion to be processed at optimal conditions with lower viscosity, reducing the electrical and thermal load on pumping and heating systems while maintaining manufacturing capability.
Solution Approach 2:
The ingredients undergo preliminary processing steps separately before combination, including pre-heating, pre-mixing, and pre-aeration at different stages. This preliminary action reduces the viscosity of individual portions before they are combined, thereby decreasing the energy required for subsequent processing steps.
2Strength
If ingredients are combined early in the process, then the final product structure is achieved, but the viscosity increases requiring greater pump energy and motor loads
Solution Approach 1:
The processing sequence is segmented into distinct stages where ingredients are combined progressively rather than all at once. Each segmentation stage allows the mixture to maintain lower viscosity, reducing the power requirements for pumping and mixing equipment while still achieving the final product structure through controlled recombination.
Solution Approach 2:
The system dynamically adjusts the combination and processing of ingredient portions based on viscosity requirements at different stages. By controlling when and how portions are combined, the system maintains optimal viscosity levels throughout processing, thereby reducing motor loads and pump energy consumption while preserving product structure.
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 decreases the energy needed for processing by maintaining lower viscosity of the ingredients until blending, thereby reducing pump energy and motor loads, making the process more energy-efficient and cost-effective.
Implementation Method 1
an aerator connected to the mixer, the aerator configured to aerate the mixed food product to create the aerated food product
Implementation Method 2
a mixer connected to the first aseptic surge tank and the second aseptic surge tank, the mixer configured to mix the first food product portion and the second food product portion to create a mixed food product
Data Source
AI summary
A system for creating an aerated food product, whereby a decreased electrical and thermal load may be obtained is disclosed. Furthermore, a method of producing an aerated food product comprising the steps of separately preparing a first food product portion and a second food product portion, transferring the first food product portion to a first aseptic surge tank, transferring the second food product portion to a second aseptic surge tank, mixing a combination of the first food product portion and the second food product portion to create a mixed food product, aerating the mixed food product to create the aerated food product, and dispensing the aerated food product from a filling apparatus into a container is also disclosed. An aerated food product is also disclosed.