System and method for producing an extruded protein product
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Solution Overview
Problem
Current extrusion technologies face limitations in producing extruded protein products with oriented fibers at commercially viable rates while maintaining a meat-like texture, as traditional cooling die channels often result in uneven shear and texturization challenges.
Innovation Solution
A system utilizing an elongated die with a continuous loop transverse cross-section and a transition apparatus to distribute and align the protein composition, allowing for the formation of parallel-oriented fibers, which enhances texture and production rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional cooling die channels are used, then the extrusion process can be simplified, but the shear distribution becomes uneven and texturization quality deteriorates
Solution Approach 1:
The die channel is segmented into multiple zones with different functions: a transition zone with gradually varying cross-section for uniform shear distribution, and a texturization zone with specific geometric features for fiber alignment. This segmentation allows each zone to perform its function optimally without compromising the other.
Solution Approach 2:
Different regions of the die channel are given different geometric properties tailored to their specific functions. The transition zone has gradually varying dimensions for uniform shear, while the texturization zone has specific features like ridges or grooves for fiber alignment, creating local quality variations that solve the overall problem.
2Ease of operation
If traditional extrusion methods are used, then the process is simpler to operate, but the production rate is limited and cannot meet commercial demands
Solution Approach 1:
The transition apparatus performs preliminary action by pre-distributing the protein composition uniformly and pre-aligning fibers before the material enters the main extrusion channel. This preliminary preparation enables faster extrusion rates while maintaining quality, as the material is already optimized for high-speed processing.
Solution Approach 2:
The transition apparatus acts as an intermediary between the extruder and the extrusion die, mediating the flow characteristics and preparing the material for high-rate extrusion. This intermediary component enables the system to achieve commercial production rates without sacrificing operational simplicity.
3Productivity
If high production rates are achieved, then commercial viability is improved, but the fiber orientation and texture consistency may deteriorate
Solution Approach 1:
The die channel parameters are specifically designed and optimized to maintain stable fiber orientation at high production rates. The cross-sectional dimensions, length-to-diameter ratio, and surface features are tuned to create flow conditions that promote consistent fiber alignment even under high-speed extrusion conditions.
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 system achieves high-quality extruded protein products with a meat-like structure at increased production rates, up to 400 kg/hr, by providing uniform shear and efficient texturization, overcoming previous limitations in production speed and texture consistency.
Implementation Method 1
the channel has a length and gap thickness configured to form oriented fibers from the protein component
Implementation Method 2
an elongated die having an internal longitudinal channel configured to receive the stream from the extruder, the longitudinal channel having a transverse cross-section that is a continuous loop along at least a portion of the length of the die
Data Source
AI summary
The present disclosure relates to systems and methods for producing an extruded protein product. In particular, a system for making an extruded protein product using a system that includes a die including channel having a transverse cross section that is a continuous loop along at least a portion of the length of the die is disclosed.