Dried Rennet Production via Controlled Static Drying
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Solution Overview
Problem
The existing methods for producing dried rennet result in high raw material waste, labor-intensive processes, energy-intensive drying, high bacterial loads, and qualitative variability, leading to inefficient cheese production and increased costs.
Innovation Solution
A method involving grinding bovine abomasa, adding salt to control bacterial proliferation, and drying in a static dryer at controlled temperatures and humidity to minimize waste and bacterial growth, followed by fine grinding to produce a homogeneous dried rennet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If abomasa are inflated with air and dried in ventilated rooms, then drying can be performed, but the process becomes energy-intensive and requires large drying rooms
Solution Approach 1:
The invention changes the physical state of abomasa from inflated (aerated) to deflated state before drying, fundamentally altering the drying parameters required. By removing air from the abomasa, the volume is reduced and moisture content is concentrated, allowing drying to proceed at lower temperatures and in smaller spaces, thus reducing energy consumption while maintaining drying effectiveness
Solution Approach 2:
The invention segments the drying process into distinct stages: first deflating and concentrating the abomasa, then drying in controlled batches. This segmentation allows for more efficient heat transfer and moisture removal compared to drying large inflated abomasa in ventilated rooms, reducing overall energy requirements
2Loss of substance
If abomasa are inflated with air, then they can be dried, but the drying causes accumulation of moist fraction in lower region that must be discarded
Solution Approach 1:
Instead of inflating abomasa with air as in conventional methods, the invention inverts the approach by deflating and concentrating the abomasa before drying. This reversal prevents the formation of moist fractions that would otherwise accumulate and require discarding, allowing the entire abomasum to be utilized effectively
Solution Approach 2:
By changing the physical state from inflated to deflated/concentrated, the invention alters moisture distribution patterns during drying. This parameter change ensures uniform moisture removal throughout the abomasum, preventing localized accumulation of moist fractions and enabling complete utilization of the raw material
3Object-affected harmful factors
If abomasa are dried in ventilated rooms, then drying occurs, but bacterial flora grows excessively leading to putrefactive phenomena
Solution Approach 1:
The invention changes drying parameters by conducting the process in a controlled environment with regulated temperature and humidity rather than in ventilated rooms. By maintaining lower temperatures (15-35°C) and controlling humidity levels, the invention suppresses bacterial growth while still achieving effective moisture removal, thus reducing bacterial load without requiring excessive energy input
4Manufacturing precision
If manual selection and elimination of parts to be discarded is performed, then quality control occurs, but labor costs increase and subjectivity affects consistency
Solution Approach 1:
The invention makes the abomasa self-sufficient by processing them in a concentrated state that eliminates the need for manual selection and elimination of defective parts. The concentration and drying process itself ensures uniform quality across all abomasa, making the system self-regulating and eliminating dependence on manual labor for quality control
Solution Approach 2:
By changing the physical state to concentrated form before drying, the invention creates uniform drying conditions that produce consistent results across all batches. This parameter change eliminates the variability introduced by manual selection processes, achieving manufacturing precision through controlled physical transformation rather than human judgment
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 method significantly reduces raw material waste, energy consumption, and bacterial loads, resulting in a more efficient, cost-effective, and standardized dried rennet with improved cheese production yields and reduced defects.
Implementation Method 1
Adding a salt to the ground mass of abomasa in order to limit bacterial proliferation
Implementation Method 2
Drying the ground mass with added salt in a static dryer at a temperature comprised between 15 °C and 50 °C, preferably between 20 °C and 35 °C, performing a closed cycle of air at controlled temperature and humidity in order to extract moisture from the ground mass
Data Source
Figure 1
AI summary
A method (1) for producing dried rennet (2) using bovine abomasa (3), which comprises the steps of: (I) grinding the abomasa (3); (II) adding a salt to the ground mass (4) of abomasa (3) in order to limit bacterial proliferation; (III) drying the ground mass (5) with added salt in a static dryer (6) at a temperature comprised between 15 °C and 50 °C in order to extract moisture from the mass (5), which has initially a water content comprised between 50% and 90%, until a dried ground mass (7) having a water content comprised between 1% and 10%, preferably between 3% and 7%, is obtained; (IV) finely grinding the ground and dried mass (7), obtaining a dried rennet (2) that is directly usable in the dairy industry.