Alkali Metal Salt Emulsifying Agent Preparation System
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Solution Overview
Problem
Current methods for preparing process cheese using sodium phosphates as emulsifying agents face issues such as phosphate buildup in cheese cookers, lumpy consistency, high manufacturing costs due to elevated temperature storage, and human error in measuring dry solids or concentrated solutions, leading to inefficiencies and increased costs.
Innovation Solution
A system that combines an aqueous solution of monosodium phosphate with sodium hydroxide in a reaction vessel, generating an exothermic reaction to produce a liquid mixture of disodium phosphate and trisodium phosphate, which is then dispensed using steam pressure, allowing for precise control and efficient transfer to a cheese cooker while minimizing equipment costs and reducing the risk of crystallization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If concentrated liquid sources of disodium phosphate and trisodium phosphate are stored at elevated temperatures to prevent crystallization, then crystallization is prevented, but expensive heating equipment is required which increases manufacturing costs significantly
Solution Approach 1:
The patent changes the concentration parameter of the phosphate solution from concentrated to diluted form. This parameter change allows the solution to be stored at ambient temperatures without crystallization, eliminating the need for expensive heating equipment while maintaining reliability of the emulsifying agent supply
Solution Approach 2:
The patent employs disposable or easily replaceable dilute phosphate solutions that can be stored at low cost without special temperature control. Rather than investing in expensive permanent heating infrastructure, the system uses economical short-term storage solutions that can be replenished as needed
2Ease of manufacture
If dry solids of sodium phosphates are added to the cheese cooker, then no heating equipment is needed, but phosphate build up occurs within the cooker and the cheese develops a lumpy consistency
Solution Approach 1:
The patent changes the physical state parameter of the phosphate from dry solid to dilute liquid solution. This parameter change enables complete dissolution in the cheese cooker, eliminating lumpy consistency while avoiding phosphate build-up on cooker surfaces, thus improving product consistency without requiring expensive heated storage equipment
3Manufacturing precision
If concentrated liquid sources of disodium phosphate and trisodium phosphate are used, then dissolution is complete, but the solutions must be stored at elevated temperatures to prevent crystallization
Solution Approach 1:
The patent changes the concentration parameter from concentrated to dilute. This parameter change fundamentally alters the crystallization behavior of the phosphate solution, allowing it to remain stable at ambient temperatures while still providing complete dissolution when added to the cheese cooker, thus eliminating the need for elevated temperature storage
4Ease of manufacture
If dry solid sources of disodium phosphate and trisodium phosphate are used, then storage is simple, but human labor is required to physically add and measure the phosphates, resulting in substantial bag disposal cost and human error
Solution Approach 1:
The patent replaces manual mechanical operations (lifting bags, measuring solids) with automated liquid handling systems. Dilute phosphate solutions can be pumped and dispensed automatically with precise control, eliminating human labor for addition and measurement while maintaining simple storage conditions
Solution Approach 2:
The patent introduces a dilute solution as an intermediary form between the stored phosphate and the final application. This intermediary form enables automated delivery systems to handle the phosphate easily through pumping and metering, replacing manual solid handling while maintaining storage simplicity
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 enables precise and reproducible preparation of disodium phosphate and trisodium phosphate emulsifying agents on demand, reducing phosphate buildup, improving product consistency, and lowering manufacturing costs by eliminating the need for expensive heating equipment and minimizing human error.
Implementation Method 1
combining an aqueous solution of monosodium phosphate with sodium hydroxide in a reaction vessel, generating an exothermic reaction to produce a liquid mixture of disodium phosphate and trisodium phosphate
Implementation Method 2
dispensed using steam pressure, allowing for precise control and efficient transfer to a cheese cooker
Data Source
AI summary
A system and method combine a first reactant with a second reactant to create a reaction product. A first pump is in fluid communication with a reaction vessel and a source of the first reactant. A second pump is in fluid communication with the reaction vessel and a source of the second reactant. A gas sparger is located in the reaction vessel, and the gas sparger is in fluid communication with a gas source for providing gas to the reaction vessel. A controller is configured to execute a program stored in the controller to: (i) receive a sensor signal based on a force exerted by the reaction vessel in a direction toward the sensor, and (ii) operate the first pump and the second pump to deliver to the reaction vessel the first reactant and the second reactant thereby causing a reaction that creates the reaction product.