Cheese Block Former with Segmented Drainage Column
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Solution Overview
Problem
Current block formers struggle to produce well-formed blocks of cheese with high salt content, low fat content, or low moisture, as they face issues with fuseability, premature separation of curd portions, and crack formation in the cheese blocks.
Innovation Solution
A block former with an upright drainage column divided into upper and lower parts, featuring different interior surface finishes and a relief gap to enhance curd fusion and prevent adhesion, allowing for the production of cheese with higher salt content, lower fat content, or lower moisture levels by controlling the sliding motion and friction of the curd pillar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional block formers are used to produce cheese blocks with high salt content, low fat content, or low moisture, then the cheese blocks may achieve the desired composition, but the curd particles fail to fuse properly causing cracks and premature separation in the blocks
Solution Approach 1:
The drainage column is divided into an upper part with a smaller inner cross-sectional area and a lower part with a larger inner cross-sectional area. This creates different local conditions: the upper part provides confinement and pressure to enhance curd particle fuseability, while the lower part provides space for the fused curd pillar to slide and form uniform blocks without cracking
Solution Approach 2:
The drainage column is segmented into distinct upper and lower parts with different geometries. The upper part focuses on curd fusion through confinement, while the lower part focuses on block formation and sliding. This segmentation allows each section to optimize its specific function, resolving the contradiction between fuseability and block integrity
2Device complexity
If the drainage column has a uniform cross-sectional area, then the structure is simple, but the curd pillar adheres to the wall causing premature separation and reducing block quality
Solution Approach 1:
The drainage column employs asymmetric geometry with the upper part having a smaller inner cross-sectional area than the lower part. This asymmetric design creates optimal conditions for curd fusion in the upper section while preventing adhesion in the lower section, thereby improving block quality without excessive complexity
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 solution enables the production of uniform, crack-free blocks of cheese with improved fuseability, preventing premature separation and ensuring higher salt content, lower fat content, or lower moisture levels, suitable for cheeses like parmesan and reduced fat cheddar.
Implementation Method 1
Curd particles that are in the form of cubes, slices, and flakes, which are conventionally referred to as curd chips, are drawn by a vacuum to a top of the block former tower or column.
Implementation Method 2
A vacuum is applied to the column for removing whey and air from the curd to form the cheese.
Implementation Method 3
A relief gap is formed in the inner wall at a location at which the upper part and the lower part meet, to enable sliding of the pillar of curd against the interior surface of the inner wall.
Data Source
Figure 1~2
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Figure 5~6
AI summary
A block former (1) for the production of blocks of cheese (19) includes an upright drainage column (2) having a feed opening (3) for curd particles (4) at an upper end (5) of the drainage column (2). The drainage column (2) includes an inner wall (6) having an interior surface (7) against which a pillar of curd (8) formed of the curd particles (4) slides as the pillar of curd (8) moves downwardly through the drainage column (2). The upright drainage column (2) is divided into an upper part (9) and a lower part (10). The upper part (9) has an inner cross-sectional area that is less than an inner cross-sectional area of the lower part (10).