Extrusion Device with Cooling Die for Meat Texture
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Solution Overview
Problem
Existing food products that imitate meat and fish textures, nutrition quality, color, and bite face challenges in replicating the sensory properties of real meat, particularly due to issues with texture, tenderness, and juiciness, which are not adequately addressed by current manufacturing methods.
Innovation Solution
A device and method for manufacturing a product that imitates meat and fish properties by combining vegetable proteins with animal cells using an extrusion process. The animal cells are added downstream of the extruder section where high shear rates occur, allowing for the production of a product with improved texture and organoleptic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thermal energy and mechanical energy are increased in the extrusion process, then texturing is improved, but bite and tenderness deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-cooling the extrudate immediately after extrusion using a cooling die before the texturing process. This preliminary cooling prevents excessive texturing and rubber-like character development during subsequent processing, thereby preserving bite and tenderness while still achieving adequate texturing
Solution Approach 2:
The patent employs periodic action through alternating heating and cooling zones in the extrusion process. The process cycles between thermal energy input for texturing and cooling periods to control the degree of texturing, preventing continuous high-energy input that would cause rubber-like characteristics
2Manufacturing precision
If high shear rate is applied in the extruder, then mixing and texturing are improved, but cellular material structure deteriorates
Solution Approach 1:
The patent segments the extrusion process into distinct zones: a high-shear mixing zone for thorough blending, followed by a low-shear texturing zone that minimizes damage to cellular material. This spatial segmentation allows each zone to perform its specific function without compromising the other
Solution Approach 2:
The patent introduces a cooling die as an intermediary component between the high-shear extrusion zone and the final product formation. This cooling die rapidly cools the extrudate, stabilizing the cellular material structure and preventing further shear-induced damage while maintaining achieved texturing
3Productivity
If vegetable proteins are processed using conventional extrusion, then productivity is improved, but organoleptic properties deteriorate
Solution Approach 1:
The patent applies preliminary cooling action immediately after extrusion to vegetable protein materials. This rapid cooling prevents over-texturing and rubber-like character development, preserving desirable organoleptic properties while maintaining the productivity benefits of continuous extrusion processing
Solution Approach 2:
The patent changes the temperature parameter dynamically during the extrusion process by introducing controlled cooling zones. This parameter change optimizes the balance between productivity (requiring high-temperature extrusion) and organoleptic quality (requiring lower temperatures to prevent rubber-like character)
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 method enables the creation of food products that closely mimic the texture and sensory characteristics of real meat and fish, enhancing consumer acceptance by addressing the challenges of texture, nutrition, color, and bite.
Implementation Method 1
thermal energy (heating the extruder housing and cooling water in a cooling die or introduction of steam into the system)
Implementation Method 2
mechanical energy (specific mechanical energy input)
Implementation Method 3
cooling water in a cooling die
Data Source
AI summary
A device for the manufacture of a product that imitates properties of meat and fish and their role in diets. The device comprising an extruder and a cooling die arranged downstream of the exit of the extruder. An inlet port for the insertion of cellular material is provided in a region of the extruder in the vicinity of the extruder outlet to the outlet of the cooling die, preferably between the exit of the extruder and the outlet of the cooling die. Also described is a system comprising the device, and a method for the manufacture of a product that imitates properties of meat and fish and their role in diets with the device or system, and a product that imitates properties of meat and fish and their role in diets.