High Velocity Air Drying for Coextruded Sausage Processing
Solution Overview
Problem
Conventional methods for conditioning and cooking coextruded sausages are energy inefficient and time-consuming, requiring large ovens and involving continuous drying air replacement, which affects the quality and efficiency of the process.
Innovation Solution
The use of high-velocity, precisely-directed heated air streams to dry and cook coextruded sausages, combined with a system that includes thermal wheels and ink jet technology for applying liquid coatings, allowing for faster and more energy-efficient processing, precise moisture removal, and improved flavor and color development.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional low air speed heating is used for conditioning and cooking sausages, then the sausages can be cooked evenly, but the process takes a very long time and requires large ovens
Solution Approach 1:
The patent changes the air speed parameter from conventional low speed to high velocity (specifically 5-50 meters per second), which fundamentally alters the heat and mass transfer mechanisms. This parameter change enables rapid moisture removal and cooking in significantly reduced time while maintaining product quality through controlled exposure duration
2Reliability
If conventional ovens are used for drying sausages, then the sausages can be conditioned properly, but the ovens must be very large to accommodate the slow drying process
Solution Approach 1:
The patent employs high velocity air streams (pneumatic system) to achieve rapid conditioning and cooking. The controlled air flow at velocities of 5-50 meters per second provides intense heat and mass transfer that accomplishes in minutes what conventional ovens require hours, dramatically reducing the required oven volume while ensuring reliable product quality
3Loss of substance
If dried intake air is continuously brought into the oven to dry sausages, then the sausages can be sufficiently dried, but the system becomes very energy inefficient due to constant air replacement
Solution Approach 1:
The patent implements continuous high velocity air flow that maintains constant moisture removal without the need for intermittent heating cycles or air replacement. The continuous pneumatic action keeps the sausage surface dry and allows sustained cooking at elevated temperatures, eliminating the energy waste associated with reheating replaced air while maintaining efficient moisture removal
4Manufacturing precision
If liquid smoke is applied to sausages before cooking, then flavor and color can be developed, but the application is imprecise and results in excessive liquid smoke usage
Solution Approach 1:
The patent applies liquid smoke coating to the sausage surface before the high velocity air treatment. The preliminary coating allows the liquid smoke to penetrate and bind to the surface, and the subsequent high velocity air flow distributes and fixes the coating uniformly. This sequence achieves precise application with minimal liquid smoke usage while maximizing flavor and color development
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 significantly reduces processing time, enhances energy efficiency, and enables precise application of liquid coatings, resulting in better quality sausages with reduced waste and energy consumption.
Implementation Method 1
applying a heated, high velocity air stream to the coextruded meat product, thereby mechanically removing moisture from a surface of the casing
Implementation Method 2
applying a heated, high velocity air stream to the coextruded meat product
Implementation Method 3
cooking the coextruded meat product
Data Source
AI summary
A system and method for processing a coextruded meat product including a casing enclosing a meat batter after brining in which a heated, high velocity air stream is applied to the coextruded meat product thereby mechanically removing moisture from a surface of the casing and cooking the coextruded meat product. This system and method can further improve the ability for a liquid coating to be added to the coextruded meat product in a non-drenching manner because of the superior surface preparation of the casing by the jets.