Electrostatic Powder Coating for Uniform Two-Sided Snack Seasoning
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Solution Overview
Problem
Existing systems for applying seasoning to snack foods, particularly large disc-shaped products like rice cakes and dairy products, result in uneven coating, significant waste, and increased maintenance due to aerosol dispersion, leading to operational inefficiencies and environmental pollution.
Innovation Solution
An apparatus using an electrostatic powder spray system with vertically oriented conveyors and guides ensures uniform coating of both sides of disc-like products in a single pass, minimizing waste and environmental impact by attracting aerosol components to the product rather than the atmosphere.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If gravity feed powder coating is used, then equipment simplicity is maintained, but coating uniformity deteriorates and powder waste increases
Solution Approach 1:
The patent replaces the gravity-based mechanical powder delivery system with an electrostatic field-based delivery system. The electrostatic powder spray unit uses electrostatic forces to precisely control powder distribution, achieving uniform coating while eliminating the wasteful spray pattern inherent in gravity feed systems.
Solution Approach 2:
The patent changes the delivery mechanism from passive gravity flow to active electrostatic field control. By applying electrostatic charge to the powder particles and using an oppositely charged conveyor, the system achieves precise control over powder deposition, improving coating uniformity while reducing waste.
2Manufacturing precision
If drum coating process is used, then coating coverage is improved, but processing time increases and equipment complexity increases
Solution Approach 1:
The patent extracts the coating process from the traditional drum-based sequential system and implements it as a direct electrostatic spray application. This eliminates the need for drum rotation, tumbling, and multiple processing stages, achieving full surface coverage in a single pass while dramatically reducing processing time.
Solution Approach 2:
The patent transitions from a horizontal drum-based coating process to a vertical electrostatic spray system. By orienting the conveyor vertically and using electrostatic field forces, the system achieves three-dimensional coating coverage without the time-consuming drum rotation and tumbling cycles.
3Device complexity
If conventional powder delivery is used, then equipment simplicity is maintained, but aerosol dispersion into atmosphere increases causing pollution and waste
Solution Approach 1:
The patent creates a controlled electrostatic field environment that captures and directs powder particles onto the product surface. The electrostatic attraction between the charged powder and oppositely charged conveyor prevents powder from escaping into the atmosphere, effectively creating a contained coating environment without complex enclosures.
Solution Approach 2:
The patent replaces the uncontrolled mechanical powder delivery system with an electrostatic field-based system that precisely directs powder particles. This substitution eliminates the aerosol dispersion problem by using electrostatic forces to control particle trajectories and prevent atmospheric release.
4Manufacturing precision
If multiple conveyors and flipping stages are used, then complete surface coating is achieved, but equipment complexity and floor space increase
Solution Approach 1:
The patent segments the coating function into electrostatic charge generation and field-based particle direction. By dividing the powder delivery system into charged spray units and charged conveyor sections, the system achieves complete surface coverage without requiring multiple conveyors or mechanical flipping stages.
Solution Approach 2:
The patent transitions from a horizontal multi-conveyor system requiring product flipping to a vertical electrostatic spray system. The vertical orientation combined with electrostatic field forces enables coating of all product surfaces in a single pass, eliminating the need for complex multi-conveyor arrangements and flipping mechanisms.
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
Achieves uniform seasoning application with reduced waste and maintenance costs, improving operational efficiency and worker safety by minimizing aerosol release and simplifying cleaning processes.
Implementation Method 1
an electrostatic powder spray unit and an electrostatic coating discharge unit comprising an electrode and coating dispenser; wherein, in use, the conveyor support surface is arranged to provide a support to an edge surface of the confectionary product
Implementation Method 2
wherein at least one of the conveyor or guides is oppositely charged relative to the electrostatic charge unit; whereby, in use, a single pass of the products though the apparatus is sufficient to enable a substantially uniform application of the electrostatically charged product to the first and second major surfaces
Implementation Method 3
By reason of the electrostatic application of the powder to an oppositely charged (grounded) vertically oriented disc-like product, aerosol components are attracted to the vertically oriented disc-like product rather than remaining in the atmosphere associated with the processing machine
Data Source
Figure 1a~1c
Figure 2~3
Figure 4~4a
AI summary
The present invention relates to an improved apparatus and method for delivering a comestible coating substance and more particularly, though not necessarily, to an improved apparatus for delivering a powder coating to disc-like or disc-shaped or products such as rice cakes, potato crisps/chips, dairy product and crisp/chip-like products in a manufacturing and/or packaging procedure. The present invention seeks to provide an improved system and provides a delivery system that enables first and second major surfaces of the disc-like products to be coated simultaneously.