Double Nozzle Extruder for Encrusting Feed Layers
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Solution Overview
Problem
Conventional methods for producing two-layered fish feed are inefficient for mass production due to the need for separate shaping and heating processes, which are labor-intensive and prone to product damage during transportation.
Innovation Solution
A method using an extruder with a double nozzle to simultaneously shape and heat the outer layer while encrusting the inner layer, followed by cutting with a high-speed shutter mechanism to create a continuously extruded, cylindrically shaped product with a fixed length, eliminating the need for a separate heating step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional encrusting machines are used to shape outer and inner layers separately followed by heating, then the product structure can be formed, but the production process becomes multi-step and labor-intensive
Solution Approach 1:
The patent combines the shaping and heating processes into a single integrated extrusion step. The extruder simultaneously forms the outer layer, inner layer, and heats the product through the extrusion process itself, eliminating the need for separate shaping and heating operations that characterize conventional encrusting machine methods.
Solution Approach 2:
The extruder is designed to perform multiple functions: it shapes the outer layer composition, forms the inner layer composition, and heats the product all in one operation. This multi-functional approach replaces the specialized encrusting machine that can only shape, requiring a separate heating step.
2Ease of manufacture
If separate shaping and heating processes are used, then product structure can be formed, but transportation of unheated shaped product becomes laborious and prone to damage
Solution Approach 1:
By merging shaping and heating into one continuous extrusion process, the product is heated immediately upon formation. This eliminates the intermediate stage where shaped but unheated products must be transported, stored, and handled, thereby preventing damage that occurs during such transportation.
3Ease of manufacture
If conventional two-step process is used, then product can be formed, but transportation and storage of shaped product requires special care to maintain shape
Solution Approach 1:
The integration of shaping and heating operations means the product exits the extruder already heated and structurally stable. This eliminates the need for careful handling and special storage conditions that would be required for unheated shaped products, simplifying subsequent operations.
4Ease of manufacture
If encrusting machine is used for shaping, then outer layer can be formed, but separate heating step is required which reduces efficiency
Solution Approach 1:
The extruder is designed as a multi-functional device that can form the outer layer composition, form the inner layer composition, and heat the product all in one operation. This replaces the encrusting machine that can only perform shaping, requiring a separate heating step that reduces productivity.
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
Enables high-speed, efficient mass production of a double-layered feed or food product where the inner layer is completely encrusted with a gelled outer layer, improving production efficiency and reducing labor costs.
Implementation Method 1
preparing an outer layer composition feedstock by adding a secondary feedstock to a protein feedstock and/or a starch feedstock that forms a gel upon heating
Implementation Method 2
simultaneously gelling the outer layer composition feedstock by heat treatment
Data Source
AI summary
Provided is a method of producing a feed or food product in which an inner layer is encrusted with a gelled outer layer composition, the method including the steps of: preparing an outer layer composition feedstock by adding a secondary feedstock to a protein feedstock and/or a starch feedstock that forms a gel upon heating and then mixing by stirring, and preparing an inner layer composition that is encrusted with the outer layer composition; extrusion molding with an extruder provided with a double nozzle so as to cover a surface of the inner layer composition while simultaneously gelling the outer layer composition feedstock by heat treatment; and cutting a continuously extruded cylindrically shaped product to a fixed length with a shutter mechanism while simultaneously encrusting a cut surface with the gelled outer layer composition.