Co-Extruded Sausage Casing with Segmented Layers

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Solution Overview

Problem

Co-extrusion methods for sausage production limit the freedom of casing composition and structure due to material and processing constraints, restricting the variety and efficiency of sausage products that can be produced.

Innovation Solution

The method involves applying multiple layers of casing mass material, where at least one layer is converted to a solid state, allowing for enhanced functional demands such as strength, shelf life, and texture, and enabling the use of different materials like alginate and collagen in separate layers without mixing, along with the option of using various additives and treatments to optimize properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If co-extrusion method is used for automated sausage production, then productivity is improved, but the freedom of casing composition and structure is limited

Engineering Contradiction:

Improveautomated production efficiencyVSAvoidcasing composition freedom

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The casing is divided into multiple separate layers (inner casing layer and outer casing layer) that are applied sequentially rather than as a single homogeneous layer. This segmentation allows each layer to have different compositions and functions, enabling greater versatility in casing design while maintaining automated production efficiency through a systematic multi-step application process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the casing structure are assigned different qualities and functions. The inner casing layer contacts the food dough and provides primary containment, while the outer casing layer provides structural support and surface characteristics. This local differentiation of properties enables optimized performance for each function while maintaining overall production efficiency.

Inventive Principle:

Principle #3Local quality

2Reliability

If multiple casing materials are used to optimize functional demands, then product characteristics are improved, but device complexity increases

Engineering Contradiction:

Improvecasing functional performanceVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The casing application process is segmented into distinct steps with separate material applications. Each casing material can be optimized for specific functional requirements (e.g., adhesion, strength, texture) without requiring complex mixing or blending processes, thereby maintaining relatively simple production equipment while achieving superior functional performance through material differentiation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first casing layer is applied and partially solidified before applying the second layer. This preliminary action allows each layer to be independently optimized and controlled, simplifying the overall process by avoiding the need for complex simultaneous multi-material extrusion equipment while still achieving the benefits of multiple specialized materials.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If single layer casing is used, then manufacturing simplicity is maintained, but functional optimization is limited

Engineering Contradiction:

Improvecasing application simplicityVSAvoidcasing functionality

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

Rather than using a single complex multi-functional material, the system segments the casing into multiple simpler layers, each optimized for a specific function. This approach maintains manufacturing simplicity by using straightforward sequential application processes while dramatically increasing functional versatility through material differentiation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multi-layer casing structure functions as a composite material system where each layer contributes specific properties. This composite approach enables the combination of multiple functional characteristics (adhesion, strength, texture, permeability) that would be difficult to achieve in a single homogeneous material, while maintaining ease of manufacture through sequential application.

Inventive Principle:

Principle #40Composite materials

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 allows for a wider range of sausage product variations, improved processing efficiency, reduced ingredient costs, and enhanced product characteristics like longer shelf life and better handling, while maintaining the benefits of automated production.

Implementation Method 1

at least one is at least partially converted to a substantial solid state, e.g. under the influence of the pH applied

Methodology Applied

Scientific EffectpH-induced gelation: Gel

Implementation Method 2

producing by means of co-extrusion a sausage strand with the extrusion of a centre of food dough at least partially provided with a layer of the casing mass material

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentUS11224229B2Method for manufacturing sausage products, sausage and sausage production

Publication Date: 2022.01.18 MAREL FURTHER PROCESSING BV

AI summary

The invention relates to a method for manufacturing sausage products by means of co-extrusion, wherein the method comprises the steps of: providing a food dough (6); providing a viscous casing mass material (8); and producing by means of co-extrusion a sausage strand (2) with the extrusion of a centre of food dough at least partially provided by layered casing mass material.