Dry Cooker Temperature Control for Pasta-Filata Cheese
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Solution Overview
Problem
Conventional dry cookers lack the ability to measure and control the temperature of the curd throughout the cooking and stretching process of pasta-filata cheese, leading to issues with food safety, product quality, flavor development, nutrient retention, and energy efficiency.
Innovation Solution
A dry cooker equipped with multiple heating units, including a flighted auger, heating jacket, and steam injector, along with temperature and pH sensors, allows for continuous temperature and pH monitoring and control of the pasta-filata cheese, using a control unit to adjust heat loads based on real-time data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If temperature measurement is only performed at the output of the dry cooker, then the device complexity is reduced, but the manufacturing precision and quality control are worsened
Solution Approach 1:
The temperature measurement system is segmented into multiple independent measurement points: a first temperature sensor at the inlet of the chamber and a second temperature sensor at the outlet. This segmentation allows independent monitoring of temperature at different stages of the cooking process, enabling precise control without requiring a monolithic complex system.
Solution Approach 2:
The control unit receives temperature data from both the first and second temperature sensors and uses this feedback to dynamically adjust the heat load of the heating media. This closed-loop feedback mechanism enables precise temperature control throughout the cooking process, ensuring manufacturing precision while maintaining reasonable device complexity.
2Manufacturing precision
If multiple heating units with control systems are added, then the temperature control precision is improved, but the device complexity increases
Solution Approach 1:
Different heating units are assigned different local functions: the first heating unit is configured for primarily heating the pasta-filata cheese, while the second heating unit is configured for primarily stretching the cheese to align fibers. Each heating unit has its own temperature sensor and control, allowing localized optimization of temperature control precision for each specific process stage.
Solution Approach 2:
The heating media system serves multiple functions simultaneously: it provides thermal energy for heating, enables stretching through controlled heat distribution, and allows for ingredient addition (such as salt) in between heating units. This multi-functionality reduces the need for separate dedicated systems for each function, thereby limiting the increase in device complexity.
3Reliability
If real-time temperature monitoring is implemented throughout the cooking process, then the food safety is improved, but the energy consumption increases
Solution Approach 1:
The control unit continuously receives real-time temperature data from the first and second temperature sensors and dynamically adjusts the heat load of the heating media accordingly. This feedback control ensures that energy is applied only when and where needed to maintain safe temperatures, preventing unnecessary energy consumption while ensuring food safety throughout the cooking process.
Solution Approach 2:
The heat load of the heating media is dynamically adjusted based on real-time temperature conditions rather than operating at constant maximum capacity. This dynamic adjustment allows the system to maintain food safety requirements while minimizing energy consumption by applying heat only to the extent necessary for safe and quality cooking.
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
The solution enables precise temperature and pH control, ensuring consistent product quality, improved food safety, enhanced flavor development, and increased energy efficiency in the production of pasta-filata cheese.
Implementation Method 1
a flighted auger arranged in the chamber and configured to rotationally heat the pasta-filata cheese
Implementation Method 2
a heating jacket surrounding the chamber and configured to be in fluid connection with the heating media
Implementation Method 3
a heating jacket surrounding the chamber and configured to be in fluid connection with the heating media
Implementation Method 4
a steam injector arranged in connection with the chamber, configured to be in fluid connection with the heating media and configured to inject steam into the chamber
Implementation Method 5
a steam injector arranged in connection with the chamber, configured to be in fluid connection with the heating media and configured to inject steam into the chamber
Data Source
Figure 1
Figure 2a~2b
Figure 3~4
AI summary
A dry cooker 100 for producing pasta-filata cheese is provided. The dry cooker 100 comprises at least two heating units 110, 120, 130. The heating unit 110, 120, 130 comprises a chamber 112, 122, 132 for conveying the pasta-filata cheese from an inlet 111, 121, 131 to an outlet 113, 123, 133, a flighted auger 116, 126, 136, a heating jacket 114, 124, 134 a steam injector 117, 127, 137 a first temperature sensor 115-1, 125-1, 135-1 arranged at the inlet 111, 121, 131 of the chamber 112, 122, 132 and configured to determine 230, 240, 250 a temperature T11, T21, T31 of the pasta-filata cheese, and a control unit 140 configured to control 260 a first heat load S11, S21, S31, HL of the heating media W1, W2, W3, S based on the determined temperature T11, T21, T31 of the pasta-filata cheese at the inlet 111, 121, 131.