Round Shaped Collagen Casing via Controlled Heat Shrinking
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Solution Overview
Problem
The existing methods for producing round-shaped collagen casings are energy-intensive, require significant manpower, and result in weakened casings due to collagen loss and inferior sensory properties compared to natural alternatives.
Innovation Solution
A process involving controlled heat shrinking and humidity management of straight collagen casings, with specific humidity and plasticizer levels, to achieve a round shape without structural damage, using a heat transfer unit and supporting elements to ensure even shrinkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional extrusion and rotating segment transformation is used to produce round shaped collagen casing, then the casing can be transformed into a rounded shape, but the process consumes a lot of energy and requires significant manpower for running and maintaining the complex production line
Solution Approach 1:
The patent replaces the complex mechanical rotating segment transformation system with a thermal field-based approach. Instead of using mechanical segments to physically transform the straight casing into a rounded shape, the invention uses controlled heating to induce thermal expansion and shape transformation, thereby reducing mechanical complexity and energy consumption while achieving the desired round shape
Solution Approach 2:
The patent applies controlled changes in temperature parameters to transform the straight collagen casing into a round shape. By adjusting temperature profiles and heating rates, the process achieves shape transformation without requiring complex mechanical systems, thus reducing energy consumption and operational complexity
2Shape
If conventional extrusion and rotating segment transformation is used to produce round shaped collagen casing, then the casing can be transformed into a rounded shape, but the process requires a lot of manpower for running and maintaining the complex production line
Solution Approach 1:
The patent replaces the complex mechanical rotating segment system with a thermal processing system that requires minimal manual intervention. The automated temperature control and thermal transformation process eliminates the need for extensive manpower to operate and maintain complex mechanical segments, thereby improving ease of operation
Solution Approach 2:
The thermal transformation process is self-regulating through controlled heating, where the collagen casing automatically transforms from straight to round shape through thermal expansion. This self-service mechanism eliminates the need for complex mechanical adjustment systems and reduces manpower requirements for operation and maintenance
3Shape
If conventional extrusion method is used to produce round shaped collagen casing, then the casing can be formed, but due to technically unavoidable friction some collagen is rubbed off and collected on the rotating transport rollers, which weakens the resulting round shaped casing due to scuff and causes periodic production interruptions for cleaning
Solution Approach 1:
The patent eliminates the mechanical friction problem by replacing the rotating segment transformation system with a thermal field-based approach. Since the transformation is achieved through controlled heating rather than mechanical contact, there is no friction between the casing and transport surfaces, thereby preventing collagen loss and eliminating the need for periodic cleaning interruptions
Solution Approach 2:
The patent converts the potential harm of friction-induced collagen loss into a benefit by using thermal expansion as the transformation mechanism. The heat-induced expansion naturally transforms the straight casing into a round shape without mechanical contact, thereby eliminating the harmful friction effect while achieving the desired shape transformation
4Ease of manufacture
If conventional production technology is used to produce round shaped collagen casing, then the casing can be manufactured, but the sensorial properties of round shaped artificial edibles are generally markedly worse than their natural alternatives
Solution Approach 1:
The patent applies controlled parameter changes in temperature, humidity, and processing speed to preserve the natural sensorial properties of the collagen casing. By optimizing these parameters during the transformation process, the invention maintains the casing's natural texture and mouthfeel, thereby improving sensorial properties while retaining ease of manufacture
Solution Approach 2:
The patent applies preliminary treatments such as controlled humidification and temperature conditioning before the shape transformation to prepare the collagen casing in a way that preserves its natural properties. These preliminary actions ensure that the subsequent thermal transformation does not compromise sensorial characteristics, thereby maintaining high quality while ensuring manufacturability
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 process minimizes energy consumption, reduces manpower needs, prevents collagen loss, and enhances the quality and performance of the casings by maintaining better structural integrity and sensory properties.
Implementation Method 1
transferring heat energy to the casing by a heat transfer unit to obtain a round shaped collagen casing
Implementation Method 2
the temperature achieved in the innermost ring of the casing is higher than the shrinkage temperature of collagen casing
Data Source
AI summary
The present invention relates to a process to obtain a round shaped collagen casing and to the casing obtained by the process, which is based on a post rounding of a straight collagen casing by controlled heat shrinking.