Batter Mixing Load Cells for Consistent Ingredient Ratios

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Solution Overview

Problem

Existing batter mixing systems fail to measure a predetermined ratio of wet and dry ingredients, leading to inconsistent product quality and excess production costs due to varying ingredient ratios and temperature-induced viscosity changes.

Innovation Solution

A batter mixing system that utilizes load cells to measure precise weights of solid and liquid ingredients, eliminating the need for viscosity measurements and recirculation, ensuring a consistent ratio of solids to liquids through a two-tank configuration with a control system for autonomous mixing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If recirculation pumps are used to maintain continuous batter flow, then productivity is improved, but temperature increases due to pump friction causing viscosity changes and ingredient ratio inconsistencies

Engineering Contradiction:

Improvecontinuous batter flowVSAvoidingredient ratio consistency

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent removes the recirculation pump from the system entirely, eliminating the source of friction-generated heat that caused temperature increases and viscosity changes. The system uses a single-pass flow configuration where batter flows through the mixing chamber once and is then applied to food products, avoiding continuous recirculation that created manufacturing precision issues.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system divides the batter handling into distinct functional zones: a mixing chamber where ingredients are combined, a distribution tank that receives the mixed batter, and an application system. This segmentation allows each component to perform its specific function without interfering with the ingredient ratios established in the mixing chamber.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If viscosity monitoring is used to adjust batter consistency, then manufacturing precision is improved, but device complexity increases due to multiple sensors and control mechanisms

Engineering Contradiction:

Improvebatter consistency controlVSAvoidmonitoring system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex electronic viscosity monitoring and control systems with a simpler mechanical approach using load cells to measure ingredient weights. By precisely controlling the weight ratios of ingredients added to the mixing chamber, the system achieves consistent batter viscosity without requiring complex sensors, actuators, or control algorithms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses the natural properties of the ingredients and the mixing process itself to achieve consistent results. The load cell measurements provide direct feedback on ingredient addition, allowing the system to self-regulate ingredient ratios without external monitoring of batter viscosity properties.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If refrigerated jacketed tanks are used to maintain temperature, then manufacturing precision is improved, but device complexity and energy consumption increase

Engineering Contradiction:

Improvetemperature stabilityVSAvoidrefrigeration energy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by stationary object

Solution Approach 1:

The patent removes the refrigerated jacketed tank system from the mixing apparatus, eliminating the need for continuous refrigeration energy input. Instead, the system uses ambient temperature ingredients and relies on the short residence time of batter in the mixing chamber to maintain temperature stability without active cooling.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system prepares ingredients at appropriate temperatures before mixing, ensuring that the batter achieves desired consistency without requiring post-mixing temperature control. This preliminary temperature management eliminates the need for energy-intensive refrigeration systems.

Inventive Principle:

Principle #10Preliminary action

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

The system ensures consistent batter quality by measuring ingredient ratios by weight, eliminating recirculation and temperature-induced viscosity changes, resulting in predictable batch production with reduced costs.

Implementation Method 1

The load cell can function as a level sensor such that level sensors are not required in the mix tank or the distribution tank

Methodology Applied

Scientific EffectLoad cell measurement:

Implementation Method 2

A distribution tank is in communication with the mix tank via a transfer pump

Methodology Applied

Scientific EffectPump: Pump

Data Source

PatentUS20250241318A1System and method for batter mixing and application

Publication Date: 2025.07.31 MATHER PROCESS SOLUTIONS

AI summary

A batter mixing system has a mix tank. The mix tank includes a dry mix feed, a liquid feed, a mixer, and a mix tank load cell. A distribution tank is in communication with the mix tank via a transfer pump. The distribution tank includes a distribution tank load cell. The distribution tank is in further communication with a process line via a feed pump. A control system is in communication with each of the mix tank load cell and the distribution tank load cell. The control system is configured to operate each of the mix tank and the distribution tank.