Egg Treatment Line Using UV Shelling and RF Pasteurization
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Solution Overview
Problem
Existing egg treatment processes struggle to achieve a long shelf life while maintaining high organoleptic qualities similar to fresh products, and they often require lengthy production times and frequent cleaning stops.
Innovation Solution
A process and plant using ultraviolet radiation, radiofrequency electromagnetic radiation, and controlled pasteurization with specific temperature and time parameters, combined with sanitization methods, to reduce bacterial load and ensure high-quality egg products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pasteurization processes are used to achieve long shelf life, then bacterial load is reduced, but organoleptic qualities deteriorate due to high temperatures and extended processing times
Solution Approach 1:
The patent replaces traditional thermal pasteurization with a non-thermal pasteurization system that uses pulsed electric fields (PEF) and ultraviolet (UV) radiation. This substitution eliminates the need for high-temperature heating while achieving effective bacterial reduction, thereby preserving the organoleptic qualities of the egg product. The PEF system applies high-voltage pulses to create electropores in bacterial cell membranes, and UV radiation provides additional sanitization, both without the thermal damage associated with conventional pasteurization.
2Ease of manufacture
If low pasteurization temperatures are used to maintain organoleptic qualities, then product quality is preserved, but production time increases due to prolonged thermal rest times
Solution Approach 1:
The patent replaces thermal pasteurization with non-thermal methods (PEF and UV), eliminating the need for prolonged thermal rest times. The PEF system achieves rapid bacterial inactivation through high-voltage pulse application, and UV radiation provides immediate surface sanitization. This non-thermal approach dramatically reduces processing time while maintaining product quality, as no extended heating periods are required to achieve the same level of pasteurization.
Solution Approach 2:
The patent employs periodic pulsed electric fields rather than continuous heating. The PEF system applies short-duration high-voltage pulses at specific frequencies, creating periodic action that effectively kills bacteria through electroporation. This periodic application of energy achieves pasteurization much faster than continuous thermal exposure, reducing production time while preserving organoleptic qualities.
3Device complexity
If conventional plate heat exchangers are used for pasteurization, then equipment simplicity is maintained, but cleaning frequency and complexity increase
Solution Approach 1:
The patent replaces conventional plate heat exchangers with a non-thermal pasteurization system using PEF and UV technology. This substitution eliminates the complex thermal exchange surfaces that require frequent cleaning and sanitation. The PEF system uses electrical fields that can be easily deactivated and cleaned, while UV radiation provides contactless sanitization. This reduces both the complexity of cleaning procedures and the frequency of maintenance interruptions.
Solution Approach 2:
The patent incorporates self-sanitizing capabilities through the design of the non-thermal pasteurization system. The PEF and UV system can be deactivated and cleaned in place without requiring disassembly or complex procedures. The smooth surfaces and lack of thermal exchange plates allow for rapid cleaning and sanitization, enabling the system to serve itself with minimal maintenance intervention and reduced downtime.
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 process achieves a significantly lower bacterial load in the final product, extending shelf life and maintaining organoleptic qualities comparable to fresh eggs, while reducing production time and minimizing cleaning requirements.
Implementation Method 1
a shelling station (14) in which each egg is shelled by a shelling device (141) housed in a shelling chamber (142) sanitized by irradiation with ultraviolet radiation
Implementation Method 2
the shelling product is irradiated by a radiofrequency electromagnetic emission which can have a frequency between 27.00 MHz and 27.50 MHz and preferably equal to 27.12 MHz
Implementation Method 3
the pasteurization takes place through the use of particular plate heat exchangers that exchange heat with the liquid product to be pasteurized by convection
Data Source
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AI summary
The present invention relates to an apparatus and a process for treating eggs wherein the process comprises: - a phase A of loading eggs from a warehouse (11 ) to a transfer unit(12) by means of a suction cup manipulator (13); - a phase B for feeding the eggs to a shelling station (14) where the eggs are sanitized; - a shelling phase C which involves irradiating the inside of the shelling chamber (142) with ultraviolet radiation, keeping the shelling chamber (142) under over-pressure by means of a filtered air flow and sanitizing each shelling device (141 ) following each shelling; where the shelling product is collected in a refrigerated tank (143); - a step D of filtering the shelling product by means of a chilled piston filter (151 ) and with a sanitized stem (153); - a phase E of pasteurization with a radiofrequency electromagnetic emission; - a transfer phase F by means of at least one flushed pump (17). Following each phase A the suction cups (131 ) are sanitized.