Continuous Ferment Inoculation via Microwave Thawing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for inoculating frozen concentrated ferments in the food and dairy industries require batch processing, intermediate thawing, and handling, which increases the risk of contamination and limits production efficiency.
Innovation Solution
A process and equipment for continuous inoculation of frozen concentrated ferments into a liquid using a microwave or water bath thawing device, allowing direct injection into a flow of liquid without interruption, with features like pressurized inoculation chambers, disposable connections, and flow rate regulation to ensure sterility and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If frozen concentrated ferments are thawed and handled in batch mode using traditional methods, then the ferments can be inoculated into the liquid, but the production process must be interrupted and contamination risk increases
Solution Approach 1:
The patent implements continuous inoculation by connecting the thawing device directly to the fermentation tank via piping, allowing ferments to be continuously transferred and inoculated without batch interruptions. The system maintains continuous flow from thawing through inoculation, eliminating the stop-start nature of traditional batch processing and thereby increasing productivity while maintaining reliability through reduced handling steps.
Solution Approach 2:
The patent merges the thawing device and inoculation system into a single integrated unit where thawed ferments are directly inoculated into the fermentation tank through connected piping. This consolidation eliminates intermediate transfer steps and handling operations, reducing contamination risk while maintaining continuous operation for increased production efficiency.
2Ease of operation
If intermediate thawing containers are used for frozen concentrated ferments, then the ferments can be thawed, but contamination risk increases due to additional handling
Solution Approach 1:
The patent extracts the thawing function and integrates it directly into the inoculation system through piping connections. Instead of using separate intermediate containers for thawing, the system thaws ferments in-place within the closed piping network and directly inoculates them into the fermentation tank, eliminating the need for intermediate handling and reducing contamination risk while maintaining operational ease.
Solution Approach 2:
The patent uses piping as an intermediary medium to transfer thawed ferments directly from the thawing device to the fermentation tank without requiring intermediate containers. This closed-system intermediary eliminates exposure to the environment during transfer, reducing contamination risk while maintaining the ability to easily thaw and inoculate ferments.
3Productivity
If frozen concentrated ferments are added directly to the fermentation tank, then continuous inoculation is achieved, but the ferments must be in liquid form requiring prior thawing
Solution Approach 1:
The patent employs a multi-functional integrated device that combines thawing, holding, and inoculation functions in a single system. The device can thaw frozen ferments, maintain them in a held state, and directly inoculate them into the fermentation tank through integrated piping, eliminating the need for separate equipment for each function and reducing overall system complexity while enabling continuous production.
Solution Approach 2:
The patent performs preliminary thawing of frozen ferments within the integrated device before inoculation. The thawing function is built into the system and activates ferments in advance of their use in the fermentation tank, ensuring they are in liquid form ready for continuous inoculation without requiring separate pre-processing equipment.
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 enhances the regularity and quality of final products by eliminating intermediate handling risks, reducing contamination, and allowing continuous production of fermented products without interrupting the process.
Implementation Method 1
frozen concentrated ferments are thawed by means of a microwave device or a water bath thawing device
Implementation Method 2
frozen concentrated ferments are thawed by means of a microwave device or a water bath thawing device
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Process for continuous inoculation of a food product, in particular a dairy product, with ferments, wherein: frozen concentrated ferments are thawed by means of a microwave device or a water bath thawing device acting on a container containing frozen concentrated ferments, the thawed concentrated ferments are continuously injected, from the container, into a flow of liquid to be inoculated.