Cylindrical Rib-Meat Product via Segmentation and Folding
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Solution Overview
Problem
The meat-producing industry faces increased costs due to heavier carcasses, which result in inefficiencies in processing and manufacturing, as consumers are not interested in larger portion sizes and recognizable meat products, leading to discarded portions and decreased drop credit values.
Innovation Solution
New meat products and processing techniques that involve scoring and folding rib bones to create cylindrically-shaped rib-meat products, allowing for more effective utilization of the carcass, reducing waste, and increasing the value of previously discarded portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional meat processing methods are used for heavier carcasses, then processing costs increase, but consumer interest in larger portion sizes decreases
Solution Approach 1:
The rib slab is divided into multiple rib bones, and the intercostal meat is separated from each rib bone individually. This segmentation allows the meat to be redistributed and reconfigured into new product forms, maximizing utilization of the carcass while maintaining consumer-preferred portion sizes and product recognizability.
Solution Approach 2:
The invention changes the physical form and configuration of the meat product by scoring, loosening, folding, and securing the intercostal meat into a cylindrically-shaped rib-meat product. This parameter change transforms the meat from traditional flat cuts into a three-dimensional rolled structure, enabling new product categories that optimize both carcass utilization and consumer appeal.
2Productivity
If larger carcass sizes are processed, then throughput capacity increases, but manufacturing costs increase
Solution Approach 1:
By segmenting the rib slab into individual rib bones and separating the intercostal meat from each rib, the invention creates modular units that can be efficiently processed and reconfigured. This segmentation enables better control over portion sizes and product formation, reducing waste and optimizing manufacturing efficiency for larger carcasses.
Solution Approach 2:
The invention transitions from two-dimensional flat meat cuts to three-dimensional cylindrically-shaped rolled meat products. This dimensional transformation allows for more efficient use of space during processing and storage, and creates products that maintain consumer appeal while optimizing the utilization of larger carcass portions.
3Adaptability or versatility
If traditional cutting methods are used, then recognizable meat products are maintained, but carcass utilization is reduced
Solution Approach 1:
The rib slab is segmented into individual rib bones with the intercostal meat separated from each one. This segmentation enables the meat to be redistributed across multiple rib bones and reconfigured into new product forms, maximizing carcass utilization while maintaining consumer-preferred portion sizes and product recognizability through the preservation of rib bone structures.
Solution Approach 2:
The invention changes the physical configuration parameter of the meat product by rolling and securing the intercostal meat into cylindrically-shaped structures. This parameter change creates innovative product forms that increase carcass utilization and drop credit values while maintaining the recognizable appearance and appeal of traditional rib products.
Data Source
AI summary
The present disclosure describes new meat products and new processing and cutting techniques that more effectively utilize the animal carcass. A method of forming a rib-meat product and one or more rib-meat products are disclosed. One rib-meat product includes a plurality of rib bones and a substantially cylindrically-shaped meat portion attached to a second end of each of the rib bones in the plurality of rib bones. The substantially cylindrically-shaped meat portion is a continuous piece of meat originally present on the plurality of rib bones. The substantially cylindrically-shaped meat portion includes a flap portion and a stationary portion, and the flap portion has been detached from each of the first ends of the plurality of rib bones and is substantially wrapped around a stationary portion at the second end to form the substantially cylindrically-shaped meat portion.