Process for obtaining a product in the form of gazeified granules, particles or beads, and corresponding installation
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Solution Overview
Problem
Existing processes for producing cryogenic granules or beads are complex, require specific equipment to handle extreme temperature and pressure, and do not preserve the integrity and properties of the starting matrix, particularly for food products, nor do they achieve the desired levels of gas saturation and foam formation.
Innovation Solution
A process that gasifies a liquid, semi-liquid, or pasty matrix by dissolving gas generated from cryogenic fluid evaporation in a high molecular density zone above the matrix drops before immersion in a cryogenic fluid within a closed enclosure, allowing natural convection gas evacuation, achieving supersaturation without increasing internal pressure, and using equipment with a vent to maintain atmospheric pressure or higher.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the matrix is brought into contact with high pressure gas atmosphere to dissolve gas in large quantity, then gas saturation is improved, but equipment complexity and safety requirements increase due to extreme pressure conditions
Solution Approach 1:
The invention changes the pressure parameter from high pressure (2 bars or more) to atmospheric pressure, and instead increases the gas concentration in the atmosphere. This allows achieving high gas saturation without requiring pressure-resistant equipment, thus resolving the contradiction between gas saturation and equipment complexity
Solution Approach 2:
The invention introduces an intermediary medium - a gas-permeable membrane - that allows gas transfer from the atmosphere to the liquid matrix without requiring direct high pressure contact. The membrane enables gas dissolution at atmospheric pressure while maintaining safety and simplicity
2Ease of operation
If the process is conducted in an open system for continuous product recovery, then ease of operation is improved, but gas loss and worker safety risks worsen due to anoxia risk
Solution Approach 1:
The invention uses an inert or controlled gas atmosphere (rich in the desired gas) instead of open air. This creates a safe breathing environment for workers while allowing continuous operation and product recovery, resolving the contradiction between ease of operation and safety risks
Solution Approach 2:
The invention enables continuous operation in a closed but controlled atmosphere where gas is continuously circulated and maintained at safe concentrations. This allows uninterrupted production while maintaining worker safety through proper atmospheric control and monitoring
3Temperature
If conventional cryogenization methods are used, then freezing is achieved, but gas dissolution and foam formation properties worsen due to insufficient gas saturation
Solution Approach 1:
The invention performs gas dissolution in the atmosphere before cryogenization occurs. By pre-saturating the liquid matrix with gas at atmospheric pressure before freezing, the process ensures high gas saturation in the final frozen product, resolving the contradiction between freezing and gas saturation
Solution Approach 2:
The invention maintains continuous gas dissolution throughout the cryogenization process by keeping the matrix in contact with the gas-rich atmosphere during freezing. This continuous exposure ensures maximum gas saturation is achieved and maintained in the frozen product
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 method allows for the production of cryogenic products with high gas saturation in a single step, preserving the matrix's physicochemical and organoleptic properties, and enables continuous or batch collection of supersaturated granules or beads, enhancing storage resistance to oxidation and foam formation upon reheating.
Implementation Method 1
dissolving, in large quantity, the gas generated by the evaporation of the cryogenic fluid in the matrix drops
Implementation Method 2
increasing the number of gas molecules in a zone of high gas density... located above the surface of the cryogenic fluid and on the trajectory of the matrix drops
Implementation Method 3
cryogenizing the matrix drops by immersion in a cryogenic fluid
Implementation Method 4
cryogenizing the matrix drops by immersion in a cryogenic fluid
Implementation Method 5
a vent arranged to allow evacuation of the gas generated by the evaporation of the cryogenic fluid by natural convection
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method and associated equipment for obtaining a product in the form of deep-frozen, dissolved-gas-rich granules, particles or beads from a liquid, semi-liquid or pasty matrix (2), comprising the following steps: gasification of the matrix (2) by incorporating a gas; dispensing the matrix (2) in the form of drops; and cryogenically freezing the matrix drops by immersion in a cryogenic fluid (70), the step of gasification of the matrix (2) involving dissolving a large amount of the gas generated by the evaporation of the cryogenic fluid in the drops by increasing the number of gas molecules in a high gas density zone, called high molecular density zone, located above the surface of the cryogenic fluid and on the path of the matrix drops before they are immersed in the fluid.