Curd Kneading Apparatus Using Steam Injection
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Solution Overview
Problem
Current curd kneading processes for pasta-filata cheese production result in the loss of water-soluble nutrients due to hot water usage, leading to reduced production yield and environmental pollution, and require high energy consumption for heating large amounts of water.
Innovation Solution
A curd-kneading apparatus featuring parallel augers with opposite screw profiles and steam injection, which heats the curd using steam instead of hot water, allowing for continuous operation and retention of nutrients within the paste, reducing water loss and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If hot water is used to heat and knead the curd, then the curd becomes plastic and stringy, but water-soluble nutrients dissolve in the water and are lost, reducing production yield
Solution Approach 1:
A plasticizing agent (chemical substance) is introduced as an intermediary to achieve the plasticization of curd without using hot water. The plasticizing agent mixes with the curd to make it plastic and stringy, eliminating the need for water that would otherwise dissolve and carry away nutrients.
Solution Approach 2:
The thermal process (heating with hot water) is replaced by a chemical process (adding plasticizing agent). Instead of using heat to plasticize the curd, a chemical substance is used to directly alter the curd's physical properties, thereby avoiding nutrient loss through water dissolution.
2Temperature
If hot water is used for kneading the curd, then the curd achieves desired plasticity, but considerable power is required to heat the water, increasing production costs
Solution Approach 1:
The thermal process (heating water to high temperature) is replaced by a chemical process (adding plasticizing agent at ambient or lower temperatures). This substitution eliminates the need for substantial energy input required to heat large quantities of water, thereby reducing production costs.
Solution Approach 2:
The process parameters are changed from high-temperature thermal processing to chemical processing at lower temperatures. By altering the fundamental parameter of temperature and introducing a chemical agent, the energy requirements are dramatically reduced while achieving the same plasticization effect.
3Quantity of substance
If water is used in high percentages during kneading, then the curd achieves desired consistency, but the water must be skimmed and purified before discharge, introducing process complications
Solution Approach 1:
The plasticizing agent serves as an intermediary substance that replaces water in the kneading process. Since the plasticizing agent does not require the same level of treatment as water, the complex skimming and purification processes are eliminated or significantly simplified.
Solution Approach 2:
Water is extracted or removed from the kneading process and replaced by the plasticizing agent. This extraction of water eliminates the need for water treatment infrastructure and processes, thereby reducing device and process complexity.
4Productivity
If traditional plunging arm machines are used for kneading, then the curd can be processed, but the operation is discontinuous, resulting in low production yield
Solution Approach 1:
The kneading process is designed to operate continuously rather than in discontinuous batches. The apparatus maintains continuous motion and processing of curd through the kneading chamber, ensuring uninterrupted operation that maximizes production yield and 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 apparatus achieves a higher production yield by retaining all kneading water and nutrients, with reduced energy consumption and no need for water drainage, producing pasta-filata with a desired moisture level of 45-65% while minimizing environmental impact.
Implementation Method 1
heating the curd using steam instead of hot water
Implementation Method 2
A pair of parallel augers 14, 16 are arranged side-by-side in the channel and have their screw profiles wound in opposite directions
Data Source
Figure 1
Figure 2~3
AI summary
The apparatus comprises a kneading channel (12) slanting downwards from an upstream inlet end (23), which is open to receive curd to be kneaded, to a downstream outlet end (24), which is open to unload the curd. A pair of opposed augers (14, 16) are pivotally supported side-by-side in the kneading channel (12) and are operatively connected to motor means (18) for rotating in opposite directions and moving the curd to the downstream end (24). First stem blowing means (25) are open to the kneading channel (12). A kneading chamber (27) with plunger arms is arranged at the outlet end of the kneading channel (12) for receiving the curd unloaded from the channel.