Extrusion Die with Triangular Plane for Meat Analogue Marbling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing meat analogues struggle to achieve precise control over the embedding of fat phases within protein phases, particularly in mimicking the marbled appearance of real meat, and are not feasible for mass production.
Innovation Solution
An extrusion system with a die featuring multiple ports for independent feeding of protein and fat phases, an isosceles triangular extrusion plane with controlled vertex angles, and sequential feeding to actively form marbling patterns, allowing for precise control over the structure and distribution of fat within the protein phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fat is injected into the voids of the fibrous macrostructure, then the fibrous structure can be controlled, but precise marbling cannot be achieved
Solution Approach 1:
The die is segmented into multiple independent channels, each capable of delivering different phases (protein or fat) separately. This segmentation allows precise control over where fat is deposited in the extrudate, enabling marbling patterns rather than just filling voids. Each channel acts as an independent pathway that can be controlled to create specific spatial distributions of fat within the protein matrix.
Solution Approach 2:
The invention transitions from a single-plane extrusion approach to a multi-dimensional feeding system with channels arranged in different spatial orientations (e.g., alternating sides, different depths). This dimensional arrangement allows fat to be deposited in a controlled pattern throughout the volume of the extrudate, creating three-dimensional marbling structures rather than two-dimensional void filling.
2Manufacturing precision
If 3D printing is used to produce marbled beef analogues, then marbling can be achieved, but mass production is not feasible
Solution Approach 1:
The extrusion system operates continuously with multiple channels delivering phases in a continuous stream, rather than the layer-by-layer additive process of 3D printing. The sequential or simultaneous feeding of protein and fat phases through multiple channels maintains continuous production flow, enabling high-volume manufacturing while preserving marbling control. The process eliminates idle time between layers and allows parallel material deposition.
Solution Approach 2:
Multiple feeding channels and phases are merged into a single extrusion process that produces a unified marbled structure. Instead of building the product incrementally as in 3D printing, the system combines protein and fat phases in a continuous co-extrusion process, merging the formation of the fibrous matrix and fat deposition into one simultaneous operation that scales efficiently for mass production.
3Manufacturing precision
If multiple phases are extruded sequentially, then marbling structure is controlled, but process time increases
Solution Approach 1:
The system employs periodic switching between feeding different phases through different channels, creating alternating patterns of protein and fat deposition. This periodic action allows precise control over the spatial distribution and frequency of fat inclusions within the protein matrix. By rhythmically switching channel activation, the system creates consistent marbling patterns without requiring complete sequential processing of all phases, reducing overall cycle time while maintaining distribution control.
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
Enables the creation of meat analogues with controlled marbling, improved structural integrity, and scalability for mass production, while maintaining the appearance and taste of real meat.
Implementation Method 1
a feed channel, wherein the at least two ports lead into the feed channel, wherein the feed channel leads/connected to the extrusion plane such that the protein phase and/or fat phase is conveyed from the feed section to the extrusion plane
Implementation Method 2
the fat phase actively breaks the protein paste and does not 'passively' fill voids as in the patent mentioned above, thereby mimicking the appearance of real meat pieces
Data Source
AI summary
Provided is an extrusion system including an extruder and a die. The die includes a feed section with at least two ports for injecting a protein phase and/or fat phase, a feed channel, an extrusion plane with side walls and a die exit. Each of the ports is connected to an independent channel providing the protein phase and/or fate phase. The at least two ports lead into the feed channel. The feed channel leads to the extrusion plane such that the protein phase and/or fat phase is conveyed from the feed section to the extrusion plane. The extrusion plane has an isosceles triangular shape with the legs of the triangle forming the side walls and the base of the triangle forming the die exit. The feed channel leads into the extrusion plane at the apex of the triangle of the extrusion plane.