Collagen Casing Extrusion Head with Rotating Sleeves
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cylindrical collagen casings lack sufficient strength and gas permeability, and existing manufacturing methods do not allow for diverse thicknesses or predefined gas permeability values.
Innovation Solution
An extruder apparatus with a specialized extruding head that uses annular gaps with rotating sleeve members to produce collagen casings with helically aligned fibrils in multiple layers, allowing for varied thickness and gas permeability, and featuring sublayers with different fibril orientations to reduce mechanical stress and enhance tear strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional extrusion methods are used to produce collagen casings, then the manufacturing process is simple, but the casings lack sufficient strength and gas permeability control
Solution Approach 1:
The extrusion device segments the collagen material extrusion into multiple annular gaps, each producing distinct layers with specific fibril orientations. The head divides the single extrusion stream into multiple parallel streams that are later combined, allowing each gap to be optimized for specific mechanical properties while maintaining overall device functionality
Solution Approach 2:
The invention introduces rotational motion in the circumferential direction to the extrusion process, creating helically oriented fibrils that wrap around the casing in multiple layers. This adds a rotational dimension to the traditional linear extrusion, producing a three-dimensional fibrous network that significantly enhances tear strength while controlling gas permeability through the helical structure
2Adaptability or versatility
If single-layer collagen casings are produced, then the manufacturing process is simple, but the casings cannot achieve diverse thicknesses or predefined gas permeability values
Solution Approach 1:
The extrusion head is divided into multiple annular gaps arranged concentrically, with each gap producing a separate layer of collagen casing. This segmentation allows independent control of thickness and fibril orientation for each layer, enabling diverse overall thicknesses and customized gas permeability profiles by adjusting which gaps are active and their respective parameters
Solution Approach 2:
The device incorporates rotatable sleeve members that can be independently rotated at different speeds and directions during extrusion. This dynamic capability allows real-time adjustment of helical fibril pitch and orientation in each layer, providing versatile control over gas permeability and mechanical properties while adapting to different product requirements
3Reliability
If helically aligned fibrils are produced through rotating surfaces, then gas permeability and mechanical strength are improved, but the device complexity increases
Solution Approach 1:
The device merges multiple extrusion functions into a single integrated head assembly where multiple annular gaps and rotatable sleeves work simultaneously. The combined output of multiple layers with different helical orientations creates a uniform, multi-layered casing structure with consistent mechanical and gas permeability properties throughout
Solution Approach 2:
The rotating sleeve members are designed to be driven directly by the extrusion process itself, where the pressure differential and material flow automatically induce rotation. This self-service mechanism reduces the need for complex external drive systems while maintaining consistent helical fibril alignment and casing uniformity
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
The solution achieves casings with high mechanical strength, controlled gas permeability, and reduced surface defects, ensuring uniformity and effectiveness in food applications like sausages and fish products.
Implementation Method 1
The die comprises: frame means; inner, middle and outer rotors on said frame means which are concentric and have facing surfaces which define inner and outer annular polymer flow channels; means for providing a flow of polymer to each of said annular channels; and means for rotating the inner and outer rotors in a given direction and rotating the middle rotor in the opposite direction for shearing said polymer flows in said channels
Implementation Method 2
discharging the common stream while the polymers therein remain in molten condition from said die through an exit passage defined by two generally concentric spaced apart cylindrical walls while rotating such walls in generally opposite relative directions whereby the opposite surfaces of the common extruded stream contiguous to such walls are subjected while passing through said exit passage to the smearing action of said rotating walls to thereby peripherally shear out the attenuated polymer dispersion through the thickness of the common stream
Implementation Method 3
subjecting the respective tubular streams during such extrusion to significant attenuation generally in the direction of extrusion flow to attenuate and elongate the dispersed polymer material
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to cylindrical collagen casings for foodstuff, such as sausages or fish products, that are edible so that it is unnecessary to remove the casing before the foodstuff is eaten and at the same time have increased resistance to tearing without the need of using additional nets. In order to improve the strength and gas permeability parameters of the collagen casing (100, 200, 300), a collagen gel mixture is extruded through annular gaps (31, 32, 33), where at least one of these gaps (32) is located between two sleeve members provided with annular projections (28, 29) tapered in an axial direction (L) and extending outside the external side of the housing member (21 ) of a head of an extruder apparatus and the outlets of said annular gaps (32) between each pair of neighbouring sleeve members are located at the ends of corresponding annular projections (28, 29).