Breadcrumb Manufacturing System with Multi-Stage Drying
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Solution Overview
Problem
Traditional methods for manufacturing Japanese-style breadcrumbs are time-consuming, requiring an extended drying period and the need for cooked dough to go stale, which hinders efficient production.
Innovation Solution
A system and method involving extrusion to form loaves, followed by surface drying, comminution to reduce size, and further drying in a fluid bed dryer, with optional tempering and sizing steps, to produce breadcrumbs quickly and efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional baking and drying methods are used to manufacture Japanese-style breadcrumbs, then the desired texture and crispiness are achieved, but the production time is excessively long
Solution Approach 1:
The patent applies parameter changes by modifying the drying process parameters - using high-temperature rapid drying (200-400°C) instead of traditional low-temperature prolonged drying, and controlling moisture content at each stage (30-50% after extrusion, 10-20% after first drying, 5-15% after second drying) to achieve the desired texture in reduced time
Solution Approach 2:
The drying process is segmented into multiple stages: initial high-temperature rapid drying to remove surface moisture, followed by tempering, then second high-temperature drying to achieve final moisture content. This segmented approach maintains texture quality while reducing total processing time
2Manufacturing precision
If the cooked dough is allowed to go stale before processing, then the breadcrumb texture is improved, but the manufacturing efficiency decreases
Solution Approach 1:
The patent applies preliminary action by performing high-temperature drying immediately after extrusion to achieve the desired texture without requiring the dough to go stale. The controlled moisture removal during the drying stages creates the necessary texture characteristics in advance, eliminating the waiting period
Solution Approach 2:
The natural staling process (biological/chemical aging) is replaced by mechanical-thermal processing (high-temperature drying and tempering). The controlled thermal treatment achieves the same textural effect that would otherwise require time-dependent staling, thereby improving manufacturing efficiency
3Reliability
If extended drying periods are used to produce acceptable breadcrumbs, then the product quality is maintained, but the production speed is reduced
Solution Approach 1:
The patent changes the drying parameters from traditional low-temperature/long-duration to high-temperature/short-duration processing. By controlling temperature (200-400°C), humidity, and duration at each drying stage, the patent maintains product quality while significantly increasing production speed
Solution Approach 2:
The drying process is made continuous through the multi-stage approach with minimal interruptions. The extrusion, drying, tempering, and second drying stages are sequentially connected, maintaining continuous material flow and maximizing production speed while ensuring quality through controlled parameters at each stage
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 significantly reduces production time, allowing for the rapid manufacture of Japanese-style breadcrumbs with desired texture and crispiness without the need for extended drying or staleness of the dough.
Implementation Method 1
The extruder may be heated
Implementation Method 2
The mixture may be cooked during the extrusion step
Implementation Method 3
surface drying the loaves in a first drying step
Implementation Method 4
The first drying step and/or the further drying step may include a fluid bed dryer
Implementation Method 5
The comminuting step may include a first cutting step for coarse cutting followed by a second cutting step for fine cutting
Implementation Method 6
further drying the particles in a second drying step to obtain the breadcrumbs
Implementation Method 7
The first drying step and/or the further drying step may include a fluid bed dryer
Implementation Method 8
The surface drying step may be followed by a tempering step to expose the loaves to ambient air
Data Source
AI summary
A method of manufacturing breadcrumbs, including the steps of forming a mixture, extruding the mixture to form loaves, surface drying the loaves in a first drying step, comminuting the loaves to form particles having a smaller size than the loaves, and further drying the particles in a second drying step to obtain the breadcrumbs.