Conching Tool Gap Design for Energy-Efficient Chocolate Processing
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Solution Overview
Problem
Existing conching devices and methods fail to achieve high product quality efficiently and in an energy-saving manner, particularly in chocolate production.
Innovation Solution
A conching device with a container and a rotating shaft equipped with conching tools that exert compression and shear forces, featuring a design that narrows the gap between the tool and the container wall to enhance mixing, along with air and additive introduction below the product level for improved blending and moisture removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional conching devices are used, then basic mixing is achieved, but product quality and energy efficiency are insufficient
Solution Approach 1:
The patent changes the geometric parameters of the conching tool, specifically creating a variable gap between the tool and container wall that transitions from narrow to wide in the rotational direction. This parameter change optimizes the balance between mixing intensity and energy consumption, allowing efficient conching with reduced energy loss.
Solution Approach 2:
The patent introduces dynamic elements by allowing the conching tool to rotate about its longitudinal axis while simultaneously revolving in an orbit around the container. This dynamic motion pattern creates varying shear forces and improves mixing efficiency compared to static or simple rotational configurations.
2Manufacturing precision
If conventional mixing methods are used, then basic blending is achieved, but high product quality cannot be ensured
Solution Approach 1:
The patent applies local quality by creating zones of different gap widths along the conching tool perimeter. The narrow gap region provides intense mixing and shear forces for high-quality blending, while the wide gap region reduces overall energy consumption and allows faster processing, achieving both quality and efficiency goals.
Solution Approach 2:
The patent introduces air and additives below the product level before main mixing occurs. This preliminary action ensures proper distribution and incorporation from the start, reducing total conching time while maintaining high product quality through thorough initial blending.
3Force
If the gap between conching tool and container wall is large, then energy consumption is reduced, but mixing intensity is insufficient
Solution Approach 1:
The patent optimizes the gap parameter by making it variable rather than uniform. The narrow gap sections generate high shear forces for intense mixing where needed, while the wide gap sections reduce overall energy consumption. This parameter optimization resolves the contradiction between force generation and energy efficiency.
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 device achieves high-quality chocolate production with enhanced efficiency and reduced energy consumption by intensifying mixing and moisture removal processes.
Implementation Method 1
exerting compression and/or shear forces
Implementation Method 2
exerting compression and/or shear forces
Implementation Method 3
The inner container wall and thus the receiving space can also be heated or cooled, for example via channels and/or pipes arranged in the container wall through which a heated fluid is conducted
Implementation Method 4
exerting compression and/or shear forces
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a conching device (10) comprising: - a container (22) forming a receiving chamber (24) for a product mass, - a shaft (16) received at least partially in the container (22) and configured to rotate about its longitudinal axis (L), and - at least one conching tool (38) coupled to the shaft (16) for common rotation, such that the conching tool (38) moves along a path (58) in a first direction of rotation (U1) during conching operation of the conching device (10). The conching tool (38) includes an effective surface (52) facing the inner wall of the container (22), configured such that a radial gap (S) between the inner wall of the container and the effective surface (52) decreases at least partially when viewed against the first direction of rotation (U1). The invention further relates to a method for conching a product mass.