Continuous Malting Device with Gravity-Assisted Discharge Screw
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Solution Overview
Problem
Existing malting devices require high energy and maintenance due to batch processing, leading to downtime, uneven drying, and potential mold growth or over-roasting, with insufficient mixing and heat loss.
Innovation Solution
A continuous malting device with a discharge screw and gravity-assisted movement of kiln-dried material, combined with a heat recovery system and adjustable air flow, ensures even drying and reduced energy consumption by continuously discharging the bottom layer and recycling heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If batch processing is used in the kiln drying unit, then the construction is simple, but downtime occurs due to emptying and filling operations and energy efficiency deteriorates due to heat losses from housing interior cooling
Solution Approach 1:
The patent implements continuous malting operation where green malt is continuously fed into the kiln drying unit and kiln-dried malt is continuously discharged. The feeding device at the housing cover enables continuous input, while the discharge screw at the transition area enables continuous discharge of the bottommost layer. This eliminates batch processing downtime and maintains continuous useful action throughout the drying process.
2Productivity
If batch processing with complete discharge is used, then the discharge is thorough, but heat losses occur due to housing interior cooling during emptying and filling
Solution Approach 1:
The continuous operation mode eliminates the periodic emptying and filling cycles that cause heat losses. The housing interior maintains its temperature continuously as malt is constantly present in the drying chamber, and the discharge screw removes dried malt layer by layer without requiring complete discharge and refilling operations.
Solution Approach 2:
The patent recovers heat from the exhaust air through a heat recovery device with cross heat exchanger. The exhaust air containing thermal energy is routed into the heat recovery device, which preheats the process air before it is fed back to the drying unit, thereby recovering and reusing the thermal energy that would otherwise be lost.
3Device complexity
If stationary kiln drying is used, then the structure is simple, but mixing is insufficient leading to uneven drying quality deteriorates
Solution Approach 1:
The patent introduces dynamic elements into the otherwise stationary kiln structure. The discharge screw rotates to discharge the bottommost layer of kiln-dried material, creating mechanical movement and mixing action. Additionally, the housing shell can rotate about its longitudinal axis, and the rotary floor rotates, all of which provide continuous mixing and repositioning of the malt layers during the drying process, ensuring uniform drying quality.
4Manufacturing precision
If continuous discharge of bottom layer is implemented, then over-roasting and sticking are avoided, but additional components like discharge screw and cover plate are required
Solution Approach 1:
The discharge screw continuously removes the bottommost layer of kiln-dried material throughout the drying process, preventing it from remaining in the hottest zone too long. This continuous action avoids over-roasting and sticking without requiring complex additional mechanisms beyond the screw conveyor itself.
Solution Approach 2:
The cover plate positioned above the discharge screw in the transition area serves as a protective intermediary element. It shields the discharge screw and the underlying rotary floor slots from direct exposure to high temperatures and falling malt, preventing clogging and facilitating problem-free discharge while adding minimal structural complexity.
5Loss of energy
If gravity-assisted movement towards rotary floor is used, then energy efficiency improves, but the housing structure must accommodate rotation
Solution Approach 1:
The patent utilizes gravity as the driving force for moving the kiln-dried material heap in the direction of the rotary floor. By positioning the discharge screw at the transition area between the housing jacket and rotary floor, the system allows the material to move downward under gravity assistance, converting gravitational potential energy into kinetic energy for material transport without requiring additional energy input.
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 enables low-maintenance, energy-efficient operation with uniform malt drying, preventing mold growth and over-roasting, while maintaining a homogeneous malt color and reducing the formation of unwanted compounds.
Implementation Method 1
a discharge screw (13) for the continuous discharge of kilns (3) arranged in the transition area (12) between the housing jacket (9) and the rotating floor (8)
Implementation Method 2
with the remaining kiln dried heap being moved in the direction of the rotary floor by gravity
Implementation Method 3
the exhaust air can be routed into a heat recovery device which, for example, comprises a cross heat exchanger or the like and/or is connected to a malt cooling cascade downstream of the drying unit
Implementation Method 4
a rotary tray (8) which can be rotated about a longitudinal axis (6)
Implementation Method 5
the housing jacket is connected to a rotary drive and is supported by a bearing ring arranged in the area of the rotary floor
Data Source
Figure 1
AI summary
A device for the continuous malting of grain kernels is described, comprising a drying unit (1) with a discharge screw (13) and a housing shell (9), to which a housing cover (10) extends upwards in a longitudinal direction and an air inlet channel (7) connected via a rotating tray (8) extends downwards. To provide a device of the type described above, which, despite simple design conditions, allows for low-maintenance and energy-efficient operation while avoiding downtime and enabling uniform drying of the malt, it is proposed that a feeding device (4) for continuous feeding be arranged in the area of the housing cover (10) and the discharge screw (13) for continuous discharge of the dried material be arranged in the transition area (12) between the housing shell (9) and the rotating tray (8).