Chilled Roller Belt Cheese Forming for Uniform Portion Control
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Solution Overview
Problem
Existing methods for applying cheese to pizzas and sandwiches result in inconsistent quantity and distribution, leading to waste and inefficiencies due to clumping, tearing, and additional processing steps, particularly with shredded and sliced cheese.
Innovation Solution
A method and system for forming cheese into uniform shapes using chilled roller belts to create cheese sheets, which are then cooled, docked, and optionally frozen, allowing for precise portion control and elimination of separation membranes, with the ability to apply a liquid coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If shredded cheese is used for pizza, then cheese can be distributed more easily, but inconsistent sizes and clumping lead to uneven distribution and higher cheese usage
Solution Approach 1:
The cheese is divided into individual shreds of consistent size through controlled grating, with each shred being a separate unit that can be uniformly distributed. The patent specifies that shreds should be substantially uniform in size and shape, preventing clumping while maintaining ease of distribution.
Solution Approach 2:
The patent controls the physical parameters of the cheese shreds, specifically the size and shape, by using a grater with uniformly spaced holes. This parameter control ensures consistent shred dimensions that prevent clumping while maintaining ease of handling and distribution.
2Quantity of substance
If measuring cups and sprinkling devices are used to control cheese quantity, then portion control is improved, but the process is time-consuming and leads to dropped and discarded shreds
Solution Approach 1:
The cheese is pre-formed into a specific shape and size (a disc or cake form) before distribution. This preliminary shaping allows the entire portion to be applied at once rather than requiring gradual dispensing, improving both portion control and application speed.
Solution Approach 2:
The patent uses a carrier substrate (such as parchment paper or a edible base) to hold the pre-portioned cheese shreds. This intermediary allows the cheese to be transferred as a single unit to the pizza, eliminating the problems of dropped shreds and manual portioning.
3Loss of substance
If cheese slices are stacked without separation barriers, then waste from discarded barriers is eliminated, but slices stick together and tear when peeled apart
Solution Approach 1:
The patent removes the need for separation barriers by extracting the cause of sticking through proper cheese processing. The cheese is formed into a single integrated piece (disc or cake) that maintains internal cohesion, eliminating the need for external separation elements.
Solution Approach 2:
The cheese product combines multiple cheese components into a unified composite structure with consistent texture and cohesion throughout. This composite formation ensures that the cheese maintains its integrity as a single piece without requiring additional separation materials.
4Stability of the object's composition
If traditional pasta filata cheese methods are used to form square or rectangular blocks, then cheese structure is maintained, but additional cutting and shaping steps add time and cost
Solution Approach 1:
The cheese is formed into the final desired shape (disc or cake) during the primary forming process rather than requiring subsequent cutting and shaping operations. This preliminary formation of the final shape eliminates additional processing steps while maintaining the cheese's structural integrity.
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
Achieves consistent cheese application with minimal waste and reduced preparation time, enabling precise portion control and improved cooking quality through uniform cheese distribution.
Implementation Method 1
cooling the cheese sheet through contact with the first chilled roller belt
Implementation Method 2
supplying a pasta filata cheese mass to an extruder which distributes the pasta filata cheese mass to a gap formed between two chilled roller belts
Data Source
AI summary
Embodiments may include a method of making a cheese shape. The method may include providing a cheese-shaping system. The cheese-shaping system may include at least a first chilled roller belt. The method may also include supplying a cheese mass in molten form to the first chilled roller belt. A cheese sheet may then be formed on the first chilled roller belt. The method may further include cooling the cheese sheet through contact with the first chilled roller belt. In addition, the method may include forming and removing the cheese shape from the cooled cheese sheet. Furthermore, the method may include applying a liquid application to the cheese shape.