Breathable Casing and Truncated Cone Basket for Döner Shaping
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Solution Overview
Problem
The existing methods for producing and conditioning kebabs are labor-intensive, require significant manual effort, and involve lengthy deep-freezing processes due to the thick foil packaging, leading to inefficiencies in shaping, wrapping, and energy consumption.
Innovation Solution
The use of tailored, prefabricated casings that act as molds for shaping the food and can be easily filled and closed, with a breathable fabric and a truncated cone-shaped basket for support, allowing for efficient air escape and faster freezing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick foil packaging is used to wrap the kebab, then food hygiene and protection are improved, but freezing time increases significantly and energy consumption rises
Solution Approach 1:
The packaging is segmented into two distinct parts: a breathable fabric bag for shaping and initial protection, and a thin foil wrap applied only at the end for hygienic protection during storage and transport. This segmentation allows the kebab to be shaped properly while enabling rapid freezing through the breathable fabric, then provides hygiene protection with the thin foil without significantly extending freezing time.
Solution Approach 2:
The fabric bag is prepared in advance with the kebab shaped inside it before freezing begins. This preliminary shaping action eliminates the need for post-freezing trimming and allows the freezing process to focus solely on temperature reduction rather than also forming the shape, thereby reducing total processing time while maintaining hygiene through the subsequent thin foil wrap.
2Shape
If manual trimming and wrapping methods are used, then kebab shape can be adjusted, but labor intensity and production time increase significantly
Solution Approach 1:
The fabric bag itself performs the shaping function through its tapered conical geometry. When the minced meat filling is placed inside and the bag is tied off, the kebab automatically assumes the desired conical shape without requiring manual trimming or shaping operations. This self-service approach eliminates labor-intensive trimming steps while maintaining consistent shape quality across all products.
Solution Approach 2:
The flexible fabric bag conforms to the filling material and provides shaping through its geometric form rather than rigid constraints. The bag's flexibility allows it to adapt to the volume of filling while its tapered shape guides the formation of the characteristic kebab form, eliminating the need for manual shaping operations and significantly improving production efficiency.
3Manufacturing precision
If uniform kebab pieces are produced through manual methods, then shape consistency is achieved, but significant manual skill and time are required
Solution Approach 1:
The fabric bags are manufactured with standardized dimensions, taper angles, and wall thicknesses to ensure uniform shaping characteristics. This homogeneity in the tooling (fabric bags) translates directly to homogeneous kebab products with consistent shape, size, and weight distribution, eliminating the need for skilled manual adjustment while maintaining high manufacturing precision.
Solution Approach 2:
The standardized fabric bags serve multiple functions simultaneously: they contain the filling material, provide the shaping geometry, enable easy handling and transport, and facilitate uniform freezing. This multi-functionality of a single standardized component achieves manufacturing precision without requiring complex manual operations or high skill levels.
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 reduces manual labor, standardizes kebab size and shape, and significantly shortens the freezing time by up to a third, while maintaining food quality and hygiene.
Implementation Method 1
The fabric for the casing (1) according to the invention is relatively heavy - given the large mass of the kebab. It is optionally coated - in particular breathable
Implementation Method 2
In order for the kebab to obtain or maintain the desired shape, a truncated cone-shaped basket, e.g. made of a sieve or perforated sheet material, made of plastic or metal, is proposed within the meaning of claim 4, which serves as a support for the casing according to the invention when filling
Implementation Method 3
This is followed by intensive deep-freezing right down to the core, especially to minus 18-24 degrees C
Data Source
Figure 1a
Figure 1b~2
Figure 3a~3c
AI summary
The invention relates to a casing (1) for producing and conditioning döner, comprising a sack- or bag-shaped part that is conically tapered toward the bottom and that is closed at the bottom end (E) thereof and open at the top end (O) for filling purposes. The casing (1) is preferably composed of textile material and at the open end (O) includes tabs (5) which can be folded around the end (R) of the casing (1) bounding the end (O). A rack (6) for receiving the casing (1) has a stand (17), at the center of which a spit (15) is provided for guiding through the drive pipe (14). A truncated cone-shaped basket (19), which substantially corresponds to the desired döner shape, is fastened to the stand (17). In order to facilitate the removal of the meat from the basket (19), said basket on each of the two mutually opposing sides comprises a spindle (29), wherein each of said spindles (29) can be inserted into a bearing (28; 28') on mutually opposing sides of the rack (6). As a result, the basket (19) can be tilted for removing the filled casing (1).