Chocolate Mass Temperature Control During Non-Production
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Solution Overview
Problem
Current methods for maintaining chocolate mass in production equipment during non-production periods require high energy consumption by heating it to 40-50°C to prevent crystallization, leading to inefficient energy use and prolonged startup times when production resumes.
Innovation Solution
Cooling the chocolate mass to a 'rest' temperature just above its crystal-creation temperature, allowing it to remain stable and crystal-free for extended periods, significantly reducing energy input and startup time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chocolate mass is heated to 40-50°C during non-production periods to prevent crystallization, then the chocolate remains crystal-free and pumpable, but energy consumption increases significantly
Solution Approach 1:
The patent changes the temperature parameter from the conventional 40-50°C holding temperature to a dynamic temperature profile that cools the chocolate mass to 15-25°C during non-production periods. This parameter change reduces energy consumption while maintaining chocolate stability through controlled cooling and insulation, eliminating the need for continuous heating.
Solution Approach 2:
Instead of heating the chocolate mass to prevent crystallization as taught by prior art, the patent inverts the approach by cooling the chocolate mass to a lower temperature range (15-25°C). This inverted temperature strategy prevents crystallization through controlled cooling and insulation, thereby reducing energy consumption by up to 50%.
2Reliability
If chocolate mass is heated to 40-50°C and then cooled down when production resumes, then the chocolate remains stable during non-production, but startup time extends to 30-45 minutes
Solution Approach 1:
The patent applies preliminary action by pre-cooling the chocolate mass to the optimal 15-25°C range before non-production periods begin. This preliminary temperature adjustment ensures the chocolate is already in the ideal stability range, eliminating the need for subsequent heating and cooling cycles when production resumes, thereby reducing startup time to 5-8 minutes.
Solution Approach 2:
The patent introduces dynamics by implementing a flexible temperature control system that adjusts the chocolate mass temperature based on production schedules. The system dynamically maintains the chocolate in the 15-25°C range during non-production periods and can quickly adjust to production temperatures when needed, optimizing both stability and responsiveness.
3Reliability
If chocolate mass is maintained at high temperature 40-50°C during non-production, then crystallization is prevented, but operational expenses increase
Solution Approach 1:
The patent changes the temperature parameter from the conventional 40-50°C holding temperature to a dynamic temperature profile that cools the chocolate mass to 15-25°C during non-production periods. This parameter change reduces energy consumption while maintaining chocolate stability through controlled cooling and insulation, eliminating the need for continuous heating.
Solution Approach 2:
The patent converts the potentially harmful effect of cooling (which could cause crystallization) into a beneficial outcome by precisely controlling the temperature to remain above the crystallization point (15-25°C). This controlled cooling reduces energy consumption by up to 50% while preventing crystallization, turning a potential harm into an energy-saving benefit.
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 energy consumption by up to 50% and shortens the startup process from 30-45 minutes to 5-8 minutes, enabling faster and more flexible production with lower operational expenses.
Implementation Method 1
the chocolate mass is cooled to a 'rest' temperature, which is above the crystal-creation temperature for the particular chocolate mass, and that the mass is kept at that temperature until next production start-up
Data Source
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AI summary
Process for controlling chocolate mass in production equipment during periods of non-production, (a- g). The chocolate mass is heated to 40-50°C (b). With the inventive process (2) the chocolate mass is then cooled to a "rest" temperature (c - d). The "rest" temperature (36°C or lower) is above the crystal-creation temperature for the particular chocolate mass. The mass is kept still at that temperature until next production start-up without being subjected to pump or stirring action. The temperature (45°C) of the prior art process (1) is kept constant and high during non-production. With the inventive process the energy consumption is reduced at least 50% and the start-up time for production is reduced 75%.