Dual Tumble Dryer Layout for High-Capacity Softgel Drying
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Solution Overview
Problem
Softgel manufacturers face lengthy drying times and low volume capacity in traditional drying systems, which hinder efficient production and packaging of gelatin capsules.
Innovation Solution
A dual tumble dryer unit system with multiple zones and air handler units, featuring dual tumble dryer assemblies with rotating baskets and blowers, allows for simultaneous drying of softgels through defined paths, optimizing air flow and temperature control across zones to reduce drying time and increase capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional drying tunnels are used, then drying is completed, but drying time is excessively long (up to seven days)
Solution Approach 1:
The drying system is divided into multiple zones (first zone, second zone, third zone) with different temperature and humidity conditions. Each zone performs a specific drying function, allowing simultaneous processing of multiple batches and reducing overall drying time from seven days to approximately 13 hours.
Solution Approach 2:
The invention transitions from a single-pass drying tunnel to a multi-zone three-dimensional drying system with vertical and horizontal airflow paths. This dimensional expansion allows for increased processing capacity and reduced drying time by enabling parallel drying operations.
2Productivity
If traditional drying tunnels are used, then drying is completed, but processing volume is limited
Solution Approach 1:
The drying system is divided into multiple independent zones (first zone with first air handler, second zone with second air handler, third zone with third air handler) that can operate semi-independently. This segmentation allows for increased processing volume while maintaining manageable system complexity through modular design.
Solution Approach 2:
Each air handler unit serves multiple functions: heating, humidification, air circulation, and temperature control for its respective zone. This multi-functionality increases processing capacity without proportionally increasing system complexity.
3Productivity
If multiple drying paths are implemented, then capacity increases, but system complexity increases
Solution Approach 1:
The drying system is divided into multiple independent drying paths (first drying path, second drying path) with separate air handling for each path. This segmentation allows simultaneous processing of multiple batches, increasing capacity while keeping each individual path relatively simple and manageable.
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 system significantly reduces drying time to approximately 13 hours, enabling faster production and handling of up to 15,000 softgels, while maintaining desired hardness and quality, and allows for efficient packaging and bottling.
Implementation Method 1
a first blower disposed in the first section and positioned to blow air on the first basket
Implementation Method 2
a first basket positioned to rotate about a first horizontal axis
Data Source
AI summary
A dual tumble dryer unit that includes a housing that defines an interior, a divider that extends between first and second side walls and divides the interior into first and second sections, and first and second dryer assemblies that are positioned in the first and second sections. The first and second dryer assemblies each include a basket positioned to rotate about a horizontal axis, and a blower disposed positioned to blow air on the basket. A first drying path is defined between a first entry opening defined in the first side wall, the first basket and a first exit opening defined in the second side wall, and a second drying path is defined between a second entry opening defined in the first side wall, the second basket and a second exit opening defined in the second side wall.