Apple Sauce Production Using Two-Stage Refining to Minimize Pulp Loss
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Solution Overview
Problem
Existing apple sauce production methods result in low throughput and high waste due to mechanical peeling that removes pulp and fails to produce chunky apple sauce with crispy chunks, while also requiring excessive use of artificial antioxidants.
Innovation Solution
A method involving slicing apples, pulping them using a rotary slicer with a first sieve to separate chunky pulp from waste, and further refining the waste using a second sieve to minimize waste and achieve crispy apple chunks, followed by heating to deactivate enzymes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical peeling is used to remove peels and cores, then peeling efficiency is improved, but pulp loss increases and throughput decreases
Solution Approach 1:
The invention extracts and removes only the specific unwanted parts (peels, cores, seeds) from the apple using a refiner with precisely sized screens, while preserving the bulk of the pulp. This selective extraction approach maintains high throughput by processing more apple mass per unit time compared to mechanical peeling that removes excessive pulp.
2Ease of manufacture
If mechanical peeling is used to remove peels and cores, then peeling efficiency is improved, but pulp loss increases
Solution Approach 1:
The refiner selectively extracts only peels, cores, and seeds through screens with specific aperture sizes, allowing the pulp to pass through while retaining unwanted elements. This minimizes pulp loss compared to mechanical peeling that removes portions of the pulp along with the peel.
Solution Approach 2:
The invention changes the parameter of screen aperture size in the refiner to optimize the separation between pulp and waste products. By adjusting the screen size, the system achieves effective peeling and coring while maximizing pulp retention.
3Loss of substance
If traditional refining with small sieve holes is used, then waste removal is improved, but chunky apple chunks are lost
Solution Approach 1:
The invention optimizes the screen aperture size parameter in the refiner to a specific range that allows effective waste removal while retaining desirable apple chunks. This parameter optimization resolves the contradiction between waste removal efficiency and chunk retention.
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 optimizes pulp usage, minimizes waste, and generates a chunky apple sauce with crispy chunks while reducing the need for artificial antioxidants, improving throughput and product quality.
Implementation Method 1
The step of forcing the slices comprises the step of rotating a first rotor (33) having a plurality of blades (36); the first rotor (33) forces the slices against the first sieve (34) by means of centrifugal force
Implementation Method 2
heating the purée in order to deactivate enzymes contained therein and to prevent deterioration of the purée
Data Source
AI summary
Method for the production of apple sauce including the following steps:slicing apples generating a plurality of slices having two opposite faces and a peel which develops continuously between the two opposite faces;pulping the slices obtaining a first product and a first waste;refining the first waste generating a second product and a second waste;mixing the first product and the second product;heating the combination of the first product and the second product in order to deactivate enzymes contained therein.