Multi-Layer Dough Sheet Alignment for Non-Sticking Snack Pellets
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Solution Overview
Problem
Existing manufacturing processes struggle to effectively couple three or more sheets of dough in snack pellets while preventing sticking, leading to inefficiencies and poor product quality.
Innovation Solution
A pasteurizing apparatus and process that includes means for advancing, detecting, re-aligning, and coupling sheets of dough, using longitudinal and transverse cuts to form a quilted mat, and separating it into multi-layered snack pellets, with adjustable roller thrust and drying units to ensure firm edges and non-sticking surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional single-screw extruders are used to manufacture multi-layered snack pellets, then the manufacturing process is simple, but the different layers cannot be extruded at their respective optimal temperatures and pressures
Solution Approach 1:
The patent divides the extrusion system into multiple independent extruders (typically two or three), each responsible for extruding a specific layer of the multi-layered snack pellet. Each extruder can be independently controlled to operate at its own optimal temperature, pressure, and screw speed, allowing different layers (e.g., cereal layer, binding agent layer, coating layer) to be extruded under their respective optimal conditions without interfering with each other.
Solution Approach 2:
The patent combines the outputs of multiple independent extruders into a single product by using a merging mechanism (such as a merger die or combining zone) where the separately extruded layers are brought together and bonded to form the final multi-layered snack pellet. This merging process allows the benefits of independent extrusion control while achieving integrated product formation.
2Manufacturing precision
If a single extruder is used to extrude multiple layers, then the device complexity is low, but the binding agents do not bind properly and the product lacks desired texture and mouthfeel
Solution Approach 1:
The patent separates the extrusion of different layers into distinct extruders, allowing the binding agent layer to be extruded independently under optimized conditions. This independent extrusion ensures that binding agents are properly distributed and applied to the cereal layer without being mixed or contaminated, achieving uniform binding agent distribution and proper binding functionality.
Solution Approach 2:
The patent applies different extrusion parameters (temperature, pressure, screw speed, die geometry) to different extruders based on the specific requirements of each layer being extruded. For example, the binding agent layer may be extruded at lower temperatures to prevent premature melting, while the cereal layer may be extruded at higher temperatures to achieve proper expansion and texture.
3Manufacturing precision
If multiple extruders are used to extrude different layers independently, then each layer can be extruded at optimal conditions, but the synchronization and merging of layers becomes complex
Solution Approach 1:
The patent incorporates feedback control mechanisms that monitor the extrusion parameters (temperature, pressure, flow rate) of each extruder and automatically adjust them to maintain proper synchronization. Sensors detect variations in layer formation and bonding quality, and the control system responds by adjusting screw speeds, heating zones, or pressure settings to ensure consistent layer alignment and bonding.
Solution Approach 2:
The patent employs dynamic adjustment capabilities where extrusion parameters can be changed in real-time based on product requirements and process conditions. The screw speeds, temperatures, and pressures of multiple extruders can be dynamically adjusted during operation to optimize layer synchronization and bonding, allowing the system to adapt to different snack pellet designs and production conditions.
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-quality, continuous production of multi-layered snack pellets with firm edges and non-sticking surfaces, reducing the risk of non-compliant products and allowing for adaptable operation to varying dough conditions.
Implementation Method 1
Each extruder is equipped with heating zones and cooling zones
Implementation Method 2
The extruders heat and compress the ingredients to form distinct layers
Implementation Method 3
The vacuum tumbler performs a vacuum dehydration step
Implementation Method 4
The steam injector introduces steam into the pellets
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Process for manufacturing multi-layered snack pellets, comprising the steps of: - advancing at least three sheets of dough, each sheet of dough having a main development direction; - during the step of advancing, detecting the position of each of the sheets; - in response to detecting a mispositioning of one or more of the sheets with respect to a corresponding ideal conveying direction, re-aligning the one or more sheets to the ideal conveying direction; - performing longitudinal cuts on each sheet in order to obtain a plurality of strips which continue to advance; - coupling together the plurality of strips obtained by the sheets and performing transverse intermittent cuts on them so that a multi-layered mat (110) of quilted dough is formed; - separating the multi-layered mat (110) into multi-layered snack pellets (100).