Cheese Forming Device for Direct Sliceable Block Production
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Solution Overview
Problem
Current cheese production methods result in large blocks that require additional processing steps for slicing, leading to increased time and cost, as well as significant waste due to irregular cutting and the contamination of whey streams with inclusions, which can render valuable whey unusable.
Innovation Solution
A device and method for forming sliceable cheese blocks using an extruder-processed cheese system with a pipe adapter, forming chamber, and packaging attachment, allowing for direct formation and packaging of cheese loaves with inclusions, reducing waste and contamination by processing cheese curds under controlled pressure and packaging them in a way that maintains shape and usability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large blocks of cheese are produced in cheese manufacturing plants, then production efficiency is improved, but additional processing steps are required for slicing and waste increases
Solution Approach 1:
The forming device segments the cheese production process by creating individually sized blocks directly in the packaging container, eliminating the need for subsequent cutting operations. Each block is formed to its final size within the container, allowing direct packaging without additional processing steps for slicing or repackaging.
2Productivity
If large blocks of cheese are produced, then production efficiency is improved, but waste due to trim losses increases
Solution Approach 1:
The device performs preliminary action by forming each cheese block to its precise final dimensions before packaging. The forming chamber is configured to match the container dimensions, ensuring that cheese is formed to the exact size needed, thereby eliminating trim losses that would occur with subsequent cutting operations.
3Adaptability or versatility
If inclusions are added to cheese during traditional processing, then product variety is improved, but whey contamination occurs rendering valuable whey unusable
Solution Approach 1:
The device extracts or separates the whey removal step from the inclusion addition step. By forming cheese blocks directly in packaging containers and removing whey before inclusions are added, the system prevents contamination of the whey stream with inclusions, allowing the whey to be recovered and reused while still enabling product variety through inclusion addition.
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 minimizes waste, reduces processing steps, and allows for the recovery of usable whey by forming sliceable cheese blocks directly from extruder-processed cheese, maintaining product integrity and enabling efficient large-scale production of inclusion-based cheeses.
Implementation Method 1
A device and method for forming sliceable cheese blocks using an extruder-processed cheese system
Implementation Method 2
processing cheese curds under controlled pressure
Data Source
AI summary
Disclosed is a device for forming cheese blocks of dimensions that facilitate slicing without first having to larger cut blocks of cheese to appropriate dimensions. The device comprises: (a) a pipe adapter having a proximal end and a distal end; (b) a forming chamber of internal dimensions for forming a sliceable cheese loaf, wherein the forming chamber having a proximal end and a distal end, and wherein the proximal end is fluidly connected to the distal end of the pipe adapter; (c) a portal cover, positioned to open or close a portal located at the distal end of the forming chamber; (d) a packaging attachment adapter located at the distal end of the forming chamber; (e) a packaging support device supporting a package positioned to receive the cheese loaf.