Cryogenic Meat Chilling Control via Torque Feedback
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Solution Overview
Problem
Existing methods for determining the amount of cryogenic coolant, such as liquid nitrogen, in meat processing are unreliable due to variations in pressure, temperature, and meat composition, leading to inconsistent texture and increased waste in forming meat products like burger patties.
Innovation Solution
A control system that calculates the precise amount of cryogenic liquid needed based on an algorithm incorporating the mass of food product, ratio of frozen to fresh meat, and correction factors for product size and shape, ensuring consistent chilling and texture for meat products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid nitrogen is added to chill meat products in a blender, then the meat pieces achieve proper adhesion for patty formation, but the processing cost increases due to cryogen consumption
Solution Approach 1:
The system uses a torque sensor to continuously monitor the load on the impellor during the chilling process. This feedback signal is processed by a microprocessor that correlates torque variations with product viscosity and temperature, enabling real-time detection of the optimal chilling point. This feedback mechanism ensures reliable patty formation while precisely controlling liquid nitrogen consumption to minimize costs.
Solution Approach 2:
The invention replaces traditional mechanical monitoring methods (operator judgment based on sound, manual temperature measurement) with an electronic sensing system. The torque sensor and microprocessor system automatically detect chilling completion by measuring rotational resistance, eliminating the need for excessive cryogen use and manual intervention, thus reducing both cost and improving reliability.
2Manufacturing precision
If more liquid nitrogen is added to ensure proper chilling, then product texture and adhesion improve, but waste increases due to excessive cryogen consumption
Solution Approach 1:
The torque sensor provides continuous feedback on the chilling process progress. The microprocessor analyzes torque variations to determine when the meat product reaches the optimal viscosity for patty formation. This feedback control ensures precise texture consistency while preventing excessive liquid nitrogen addition, thereby minimizing cryogen waste.
Solution Approach 2:
The system allows the chilling process to self-regulate based on real-time torque measurements. The microprocessor automatically controls the liquid nitrogen injection timing and quantity based on detected product state, eliminating the need for operator intervention and preventing over-chilling that would lead to cryogen waste.
3Ease of operation
If traditional methods (chill time, operator judgment, temperature measurement) are used to determine cryogen amount, then the process is simple to operate, but measurement precision is insufficient leading to inconsistent results
Solution Approach 1:
The invention replaces simple but imprecise methods (operator judgment, manual temperature measurement) with an electronic torque sensing system. The torque sensor and microprocessor automatically and precisely measure chilling progress based on rotational resistance, providing consistent results while requiring minimal operator intervention, thus maintaining ease of operation while dramatically improving measurement precision.
Solution Approach 2:
The system continuously monitors torque during chilling and provides real-time feedback to the control system. This automated feedback loop eliminates the need for operators to make subjective judgments or take manual temperature readings, ensuring precise and consistent cryogen measurement while keeping the system easy to operate through automatic control.
4Temperature
If liquid nitrogen is sprayed inside the blender to chill meat products, then freezing point is achieved for proper adhesion, but cold spots are created leading to non-uniform chilling
Solution Approach 1:
The system uses torque monitoring to detect the optimal moment to begin liquid nitrogen injection. By initiating chilling at the precise moment when the meat pieces have reached the appropriate state through mechanical tumbling, the system ensures uniform heat distribution and prevents cold spot formation, achieving freezing point uniformly throughout the product.
Solution Approach 2:
The torque sensor provides continuous feedback on the distribution and uniformity of chilling throughout the meat product. The microprocessor uses this information to control liquid nitrogen injection timing and quantity, ensuring uniform temperature distribution and preventing localized cold spots while achieving the required freezing point for proper adhesion.
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 allows for consistent texture and adhesion in meat products, reducing waste and processing costs by delivering cryogenic liquid in staged increments, ensuring uniform chilling and minimizing 'cold spots' in meat batches.
Implementation Method 1
at least a portion is cooled to a preselect temperature below the freezing point of water. The freezing point of the meat pieces in this processing equipment is typically accomplished with cryogens such as liquid nitrogen spray inside of the blender
Implementation Method 2
liquid nitrogen spray inside of the blender
Data Source
AI summary
The present invention generally relates to a process for chilling meat products suited for subsequent shape formation in a tumbler or blender using a cryogenic liquid as a refrigerant. The process is primarily designed for the formation of food products such as a burger patty and comprises the steps: (a) measuring the mass of meat to be chilled in said blender' (b) measuring the mass of frozen meat to be added to said blender; (c) calculating the amount of cryogenic liquid to be added to said blender to chill the mass of meat added to said blender in steps (a) and (b) to a preselected first temperature; (d) increasing the calculated amount of cryogenic liquid to be added to said blender derived in step (c) by a predetermined constant as the size of the burger patty to be chilled decreases from a preselect standard; and, (e) introducing the cryogenic liquid to said blender in staged or cycled increments.