Dosing and Mixing Interim Plate for Meat-Analogue Texture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current High Moisture Extrusion (HME) processes for producing meat-like proteins face challenges in replicating the texture, taste, and physical characteristics of natural meats, as they often result in a firm and compact product due to high temperatures and thorough mixing in the extruder, which can destroy ingredients and alter their texture, flavor, and nutritional content.
Innovation Solution
The introduction of a mixing and dosing interim plate (MD interim plate) that allows for the addition of ingredients under cooler conditions, enabling controlled mixing and fiber formation before the extrudate enters the cooling die, allowing for a more natural texture and structure through the use of additives like salts, gases, and liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperature and thorough mixing are used in the extruder, then the extrusion process can be completed efficiently, but the texture, flavor, and nutritional content of ingredients are destroyed and the product becomes overly firm and compact
Solution Approach 1:
The patent divides the mixing process into two distinct stages: (1) initial mixing in the extruder at high temperature for efficiency, and (2) secondary mixing in the interim plate at lower temperature for ingredient preservation. This segmentation allows each stage to optimize for its specific function without compromising the other.
Solution Approach 2:
The interim plate acts as an intermediary device between the extruder and cooling die. It provides a transition zone where additional ingredients can be added and gently mixed without exposing them to the high temperatures of the extruder, thereby protecting sensitive ingredients while maintaining process continuity.
2Productivity
If high temperature mixing is used in the extruder, then the extrusion process proceeds smoothly, but the product texture becomes overly firm and compact rather than natural
Solution Approach 1:
The patent segments the texturization process into two phases: (1) structural formation in the extruder under high temperature and pressure, and (2) texture refinement in the interim plate at lower temperature. This allows the product to first achieve basic structure efficiently, then develop natural texture characteristics without excessive firmness.
Solution Approach 2:
The interim plate enables parameter changes by reducing the temperature at which mixing occurs. This temperature reduction allows ingredients to be incorporated without excessive heat exposure, preserving their natural texture properties and preventing the product from becoming overly compact while maintaining process continuity.
3Device complexity
If ingredients are added in the extruder, then all mixing occurs in one stage, but the added ingredients are exposed to high temperature and lose their texture, flavor, and nutritional content
Solution Approach 1:
The patent segments the ingredient addition and mixing process into two distinct locations: (1) initial ingredients added in the extruder for base mixture formation, and (2) additional ingredients added in the interim plate for gentle incorporation. This segmentation protects temperature-sensitive ingredients from thermal degradation while adding only one device to the system.
Solution Approach 2:
The interim plate serves as an intermediary mixing zone that shields subsequently added ingredients from the high-temperature environment of the extruder. It provides a protected environment where ingredients can be incorporated without direct thermal exposure, preserving their quality attributes.
4Stability of the object's composition
If thorough mixing is performed in the extruder, then homogeneous mixture is achieved, but the natural heterogenous texturization of meat analogues is lost
Solution Approach 1:
The patent segments the mixing intensity across two stages: (1) thorough mixing in the extruder to achieve homogeneous base mixture and ingredient distribution, and (2) gentle, low-degree mixing in the interim plate to preserve heterogenous texturization. This segmented approach allows both homogeneity and natural texture to coexist.
Solution Approach 2:
The patent applies partial mixing action in the interim plate - specifically, a low degree of mixing that is intentionally insufficient to create complete homogeneity. This partial action preserves the heterogenous texturization characteristics needed for natural meat-like appearance while the initial thorough mixing ensures proper ingredient distribution.
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 results in a more natural, heterogenous texturization with enhanced fiber structure and flavor, improving the sensory experience of meat analogues while maintaining ingredient integrity and nutritional value.
Implementation Method 1
an at least one static mixer, which mixes the new ingredients with the protein extrudate to form the enhanced extrudate
Implementation Method 2
a cooling die to cool the protein extrudate and to cool an enhanced extrudate with ingredients added after the extruder
Data Source
AI summary
Embodiments include a system for dosing and mixing ingredients in a High Moisture Extrusion process, the system comprising: an extruder to mix ingredients to turn them into a protein extrudate, a cooling die to cool the protein extrudate and to cool an enhanced extrudate with ingredients added after the extruder, an interim plate connecting the extruder and the cooling die, to add and mix further ingredients, and facilitate movement of the protein extrudate and the enhanced extrudate into the cooling die, the interim plate further comprising one or more interim plate inlets to allow the entry of the protein extrudate from the extruder into the interim plate, and one or more dosing inlets for adding new ingredients to the protein extrudate that exits the extruder and enters the interim plate.