Continuous Beverage Blending System with Automated Flow Control
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Solution Overview
Problem
Current high-speed blending and filling systems for beverages, especially alcoholic blended beverages, are inefficient and cumbersome, requiring large batching tanks and manual adjustments for each recipe, leading to inefficiencies and imprecise control of ingredient ratios.
Innovation Solution
A computer-implemented method and system for determining the required volumetric mass flow of ingredients for a continuous blend system, which calculates and controls the flow of alcohol, syrup, and water based on target ABV, syrup/water ratio, and container filling rate, using a mass flow based multi-stream blending assembly and a computing system to precisely adjust valve actuators for accurate blending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If batch mixing is used with large tanks for alcoholic beverage production, then flexibility in recipe changes is improved, but equipment complexity and production time increase
Solution Approach 1:
The batch mixing process is segmented into continuous streaming components where alcohol, syrup, and water flow separately through controlled valves and mix in a blending section, eliminating the need for large batch tanks while maintaining recipe flexibility
Solution Approach 2:
The system transitions from discontinuous batch mixing to continuous streaming mixing where ingredients flow continuously through the system, enabling uninterrupted production while simplifying equipment by eliminating large storage and mixing tanks
2Adaptability or versatility
If manual adjustments are made for each recipe in batch systems, then adaptability to different recipes is improved, but production time and labor requirements increase
Solution Approach 1:
Flow meters continuously monitor the volumetric flow rates of alcohol, syrup, and water streams, providing feedback to the control system which automatically adjusts valve positions to maintain precise ingredient ratios for any recipe without manual intervention
Solution Approach 2:
The system performs automatic self-adjustment of ingredient flows based on pre-programmed recipe parameters, eliminating the need for manual adjustments and reducing production time while maintaining full recipe adaptability
3Productivity
If high-speed filling is implemented, then productivity increases, but precision control of ingredient ratios becomes more difficult
Solution Approach 1:
Manual or mechanical flow control methods are replaced with electronic control systems that use flow meter feedback and automated valve adjustment to maintain precise ingredient ratios even at high filling speeds
Solution Approach 2:
The system dynamically adjusts flow rate parameters of individual ingredients based on real-time measurements and recipe requirements, enabling precise ratio control that adapts to varying production speeds without compromising accuracy
Data Source
AI summary
A method for determining required volumetric mass flow of alcoholic blended beverage ingredients for a continuous blend system using a computing device includes receiving a required syrup/water ratio, a selected target alcohol strength, an alcohol strength of an alcohol supply, a type of container, and a selected container filling rate; calculating a required volumetric mass flow of ingredients, a required alcohol volumetric mass flow of the alcohol supply, a required blended syrup and water volumetric mass flow of a proportioner, and a required syrup volumetric mass flow of a syrup supply to the proportioner for the production fill; calculating a volumetric mass flow of water in the required alcohol volumetric mass flow of the alcohol supply and a required water volumetric mass flow of a water supply to the proportioner for the production fill accounting for the calculated volumetric mass flow of; and, outputting instructions to the continuous blend system.