Edible Strip Forming Roller System for Consistent Application
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Solution Overview
Problem
Current systems for making strips of edible material are prone to issues like skipping, overuse, labor intensity, blockages, and being recipe and line rate dependent, particularly when dealing with flowable edible materials like confectionary solutions, which can lead to waste and uneven application on bases such as cookies or wafers.
Innovation Solution
A system involving a hopper with a discharge shaping roller and a cooling roller, where the flowable edible material is formed into strips between these rollers, cooled, and then separated by a blade for precise application on a base material, minimizing waste and ensuring consistent coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple open hopper with slotted gate is used, then the device complexity is reduced, but manufacturing precision and control over strip formation deteriorate
Solution Approach 1:
The patent introduces a discharge shaping roller as an intermediary component between the hopper and the edible material discharge point. This roller with its specific surface geometry mediates the flow of edible material, transforming it into a controlled strip shape. The shaping roller acts as a mediator that converts the uncontrolled flow from the hopper into precisely formed strips, resolving the contradiction between simple device structure and precise strip formation.
Solution Approach 2:
The patent changes the physical parameters of the discharge opening by introducing a shaping roller with specific surface characteristics. The roller's surface geometry, material properties, and rotational parameters are optimized to control the flow of edible material. By adjusting these parameters, the system achieves precise strip formation while maintaining relatively simple device architecture.
2Ease of operation
If flowable edible material is used, then ease of application is improved, but reliability deteriorates due to blockages and solids falling out
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of the edible material and the shaping roller. By maintaining the edible material within a specific temperature range and adjusting the roller temperature, the system keeps the material in an optimal flowable state that prevents solids from separating and falling out, while also preventing blockages. This temperature parameter control resolves the reliability issue while preserving ease of application.
Solution Approach 2:
The patent ensures continuous formation and application of edible strips without interruption. The shaping roller continuously shapes the flowable material as it discharges, and the system maintains steady-state operation to prevent variations in material flow that could cause blockages or solids separation. This continuous action improves reliability while maintaining ease of application.
3Manufacturing precision
If recipe and line rate dependent operation is used, then manufacturing precision for specific recipes is improved, but adaptability deteriorates
Solution Approach 1:
The patent introduces dynamic adjustability to the system through the shaping roller mechanism. The roller's parameters such as surface geometry, rotational speed, and position can be dynamically adjusted to accommodate different recipes and production line rates. This dynamic capability allows the same basic device to achieve precise results for various recipes without requiring recipe-specific equipment, thereby improving adaptability while maintaining manufacturing precision.
Solution Approach 2:
The patent designs the discharge shaping roller and associated mechanism to serve multiple functions across different applications. The universal design allows the same basic system to handle various edible materials and recipe requirements by adjusting parameters rather than requiring separate specialized equipment for each recipe type, thus achieving both precision and adaptability.
4Productivity
If too much edible material is supplied in the strip, then productivity is improved, but loss of substance increases due to waste and overuse
Solution Approach 1:
The patent uses parameter changes in the shaping roller design and operation to precisely control the amount of edible material that forms each strip. By adjusting the roller's surface geometry, rotational speed, and position relative to the discharge opening, the system achieves the optimal strip thickness and quantity. This precise parameter control ensures maximum material utilization without waste, while maintaining high productivity through efficient strip formation.
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 reduces waste, minimizes labor, prevents blockages, and allows for consistent and efficient application of edible strips on bases like cookies or wafers, independent of recipe and line rate, resulting in improved production efficiency and reduced skipping or blank spots.
Implementation Method 1
The strip of edible material is deposited on the surface of the cooling roller where is it cooled
Data Source
AI summary
A system and method are provided for making strips of edible material. Edible material is contained in a hopper having a discharge opening including a first side and a second side. A discharge shaping roller is positioned so that its surface is adjacent to the first side and said second side. Similarly, a cooling roller is also positioned so that its surface is adjacent to the first side and the second side. Edible material passes between the first side, the second side, the cooling roller, and the discharge roller to from a strip of edible material that is deposited on the cooling roller. The cooling roller then cools the strip of edible material and it is separated from the cooling roller by a blade. Once the strip is separated from the cooling roller it is deposited on a base of edible material such as a cookie or wafer.