Continuous Extrusion for Alternative Meat Texture and Flow Control
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Solution Overview
Problem
Current methods for producing cut meat products from plant-based or cultured cells face challenges in industrialization, including the need for multiple pumps and limited production rates due to issues with uniform material flow and texture replication.
Innovation Solution
A continuous extrusion process using a customizable component with independent material displacement mechanisms and 3D-shaped die units, allowing for the simultaneous extrusion of multiple materials at controlled flow rates to mimic the texture and structure of real meat products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate pumps are used to deliver different materials through differently shaped dies, then uniform material flow can be achieved, but the device complexity increases making the approach impractical
Solution Approach 1:
The patent combines multiple material delivery functions into a single pump system. The extrusion device uses one pump to deliver multiple materials through a multi-channel manifold structure, eliminating the need for separate pumps for each material while maintaining uniform flow distribution across all channels.
Solution Approach 2:
The patent segments the flow path into multiple independent channels within a single pump system. The manifold structure divides the incoming material stream into separate pathways that can be independently controlled, allowing uniform flow distribution without requiring multiple pumps.
2Manufacturing precision
If traditional 3D printing methods are used to produce alternative cut meats, then texture can be replicated, but the production rate is too slow to meet industrial standards
Solution Approach 1:
The patent implements a continuous extrusion process where materials are continuously pumped and extruded through the die assembly, eliminating the layer-by-layer deposition inherent in 3D printing. This continuous action maintains texture quality while dramatically increasing production speed to meet industrial standards.
Solution Approach 2:
The patent replaces the mechanical layer-by-layer building mechanism of 3D printers with a continuous extrusion and forming system. The extruded materials are shaped into cut meat products through a forming section rather than being deposited layer by layer, achieving both high speed and texture fidelity.
3Adaptability or versatility
If multiple materials are extruded through differently shaped dies, then diverse product shapes can be produced, but achieving uniform flow rates becomes difficult
Solution Approach 1:
The patent applies local quality control within the manifold structure, where each channel can have different geometric characteristics tailored to its specific material and desired output shape, while the overall system maintains uniform flow distribution through balanced channel design and flow control features.
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
This approach enables high reproducibility and significantly increased production rates, up to 30 Kg/min, while maintaining the texture and visual attributes of real meat cuts, surpassing traditional 3D printing capabilities.
Implementation Method 1
a plurality of pumps configured and operable to dispense a material from one or more of the reservoirs into corresponding feeding tubes
Implementation Method 2
Flow rates of the different component are adjusted and synchronized with a conveyor belt that removes the extruded material
Data Source
AI summary
The technology disclosed herein concerns systems and processes for producing cut meat and cut fish products.