Segmented Cooling Tool for Extruder Uniform Heat Transfer
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Solution Overview
Problem
Existing cooling tools for extruders in the food and animal feed industry face issues with non-uniform cooling, complex structures, and poor cleanability, which affect the texture and appearance of the extrudate, and require robust designs that hinder efficient operation and maintenance.
Innovation Solution
A cooling tool with a ring-section extrudate flow channel, segmented external walls for easy disassembly and cleaning, and a distributor with a constant cross-sectional area to ensure uniform flow velocity, along with apertures that influence product texture by introducing internal shear, allowing for adjustable back pressure and fiber orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cooling dies are used to suppress expansion of extrudate, then product structure is improved, but cooling uniformity is insufficient
Solution Approach 1:
The cooling die is divided into multiple independent cooling zones with separate coolant channels. Each zone can be independently controlled to optimize cooling uniformity across different sections of the annular extrudate flow channel, directly addressing the insufficient cooling uniformity problem while maintaining the dense fibrous product structure.
Solution Approach 2:
Different sections of the cooling die are designed with varying cooling intensities and channel configurations tailored to local thermal conditions. The internal jacket structure incorporates localized cooling zones that adapt to the thermal profile of the extrudate at different positions, ensuring uniform cooling throughout the product while preserving the desired fibrous texture.
2Strength
If bars are used to secure internal jacket, then structural strength is improved, but product flow is disrupted
Solution Approach 1:
The bars that disrupt product flow are completely removed from the annular extrudate flow channel. Instead, the internal jacket is secured using alternative methods such as friction fits, radial clamps positioned outside the flow path, or integrated support structures that do not protrude into the channel, thereby eliminating flow disruption while maintaining structural integrity.
Solution Approach 2:
The support structure for the internal jacket is moved from a radial configuration (bars extending into the channel) to an axial or circumferential configuration. Support elements are positioned in the axial direction or along the circumferential perimeter, providing necessary structural strength without occupying space in the radial flow path of the extrudate.
3Productivity
If cooling tool is made wider for high throughput, then productivity is improved, but flow velocity homogeneity deteriorates
Solution Approach 1:
The cooling die incorporates adjustable width configurations or variable cross-sectional areas along its length. For high throughput operations, the die can be extended or reconfigured to maintain optimal flow velocity distribution, while cooling channel geometry is dynamically adjusted to compensate for increased width, preserving flow homogeneity across the expanded cross-section.
Solution Approach 2:
The cooling channel dimensions, spacing, and coolant flow rates are varied as parameters to compensate for increases in die width. By adjusting these parameters, the cooling system maintains uniform heat extraction across the wider cross-section, ensuring homogeneous flow velocity and consistent product quality even at high throughput capacities.
4Strength
If robust wall structure is used to resist product pressure, then structural strength is improved, but cleanability deteriorates
Solution Approach 1:
The cooling die wall is segmented into removable sections or panels that can be detached for cleaning. The robust structural strength is maintained through the overall framework and support structures, while the segments in contact with the extrudate are designed for easy removal and cleaning, eliminating the trade-off between strength and cleanability.
Solution Approach 2:
The critical load-bearing function of the robust wall structure is copied or transferred to an external framework or support system, allowing the inner cleaning surfaces to be simplified. The structural strength requirement is met by a separate robust framework, while the inner walls are designed with smooth, easily cleanable surfaces that do not require thick or complex structures.
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 cooling tool provides uniform cooling and product distribution, enabling the production of various textures such as chicken-breast, beef, and fish-like structures with improved cleanability and operational efficiency, while maintaining a compact size and high food compatibility.
Implementation Method 1
The cooling tool moreover has at least one coolant flow channel, to which the extrudate flow channel (6) has heat-transfer connection
Data Source
AI summary
A cooling tool (1) for a food or an animal feed extruder (E), the cooling tool has: an inlet end (3) at which extrudate (4) can be led into the cooling tool (1); an outlet end (5) where the cooled extrudate can be discharged; an extrudate flow channel (6) extending from the inlet end to the outlet end; and at least one coolant flow channel (7a, 7b, 7b′) connected to the extrudate flow channel in a heat-transmitting manner. In a cross section (X-X) along the primary flow direction (8), the extrudate flow channel is substantially formed as a ring section; and the outer wall (9) of the extrudate flow channel (6) is formed at least from first and second segments (10, 11). The first and second segments are connected to each other by mechanical connection elements (12). The cooling tool is suitable for wet texturing of food and animal feed.