Flowable Mass Refining via Droplet Segmentation
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Solution Overview
Problem
Current methods for refining free-flowing cocoa or chocolate masses are inefficient and costly, as they fail to effectively remove unwanted substances and incorporate desired components in a gentle and cost-effective manner.
Innovation Solution
A method involving a portioning member, such as a nozzle or centrifugal element, is used to portion the mass into individual portions that flow through a gas-containing space, promoting material exchange and mixing by gravitational force, with optional vibration and multi-component nozzles for efficient incorporation of additional substances, and a heat exchanger for temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional roller mills and conches are used for refining cocoa masses, then the refining process can be performed, but the process is costly and inefficient in removing unwanted substances and incorporating desired components
Solution Approach 1:
The continuous mass is segmented into discrete droplets through the nozzle array, creating numerous small portions that increase surface area for material exchange. This segmentation enables more efficient refinement by allowing gas to contact a larger total surface area of the cocoa mass simultaneously, improving both productivity and cost-effectiveness
Solution Approach 2:
The invention uses a gas stream (pneumatic field) to transport the portioned droplets through the refining chamber and facilitate material exchange. The gas flow carries droplets along the curved path, enables evaporation and mixing, and eliminates the need for mechanical contact with expensive refining equipment, thereby reducing costs while maintaining high refining efficiency
2Quantity of substance
If the mass is portioned into individual portions to increase surface-to-volume ratio, then material exchange is promoted, but the device complexity increases
Solution Approach 1:
The nozzle array automatically portions the continuous mass into droplets based on the flow rate and nozzle geometry, without requiring complex external control mechanisms. The system self-regulates the portioning process through fluid dynamics principles, achieving high surface-to-volume ratio while keeping the device relatively simple
Solution Approach 2:
The nozzle array serves multiple functions simultaneously: it portions the mass into droplets, distributes them across the chamber, and controls their flow rate. This multi-functionality reduces the need for separate components, thereby increasing surface-to-volume ratio without proportionally increasing device complexity
3Productivity
If a high-pressure gas environment is used to promote material exchange, then refining efficiency improves, but foreign gases may be sucked in and heavy construction is required
Solution Approach 1:
The system uses an inert or controlled gas atmosphere that prevents foreign gas contamination while promoting material exchange. The gas flow is directed to create a protective environment around the droplets, allowing efficient evaporation and mixing without sucking in unwanted external gases, thus maintaining high refining efficiency without the need for heavy pressure-containing construction
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 refinement process by improving the surface-to-volume ratio for material exchange, allowing for efficient removal of unwanted substances and incorporation of desired components, while maintaining a low-pressure gas environment to prevent foreign gas intake and using lightweight construction, thus reducing costs and improving process efficiency.
Implementation Method 1
The gas preferably has a pressure of 0.1 bar to 5 bar... The gas contained in the spatial area is caused to flow relative to the impact surface
Implementation Method 2
the material exchange between the gas-containing space and the mass portions moved through it is promoted
Implementation Method 3
Allowing the mass moved through the spatial area to strike an impact surface adjoining the spatial area, so that the mass flows along the impact surface under the influence of at least the gravitational force
Implementation Method 4
a nozzle is used as the portioning member, with the mass being portioned by moving the mass through the nozzle
Implementation Method 5
bringing the temperature of the fat mass to 20°C to 300°C before going through steps S1) to S4); and/or keeping the temperature of the fat mass at 20°C to 300°C during steps S1) to S4)
Data Source
Figure 1
AI summary
The invention relates to a device for refining flowable masses, particularly flowable fatty masses comprising cocoa or chocolate, and has a portioning member (2) in a gas-containing space region (4) for portioning a moved flowable mass (M) into individual mass portions and for transferring moved mass portions into the gas-containing space region (4), an impact surface (8) abutting the space region for allowing the mass (M) moved through the space region (4) to impinge, wherein the mass under the action of at least one gravitational force can flow along the impact surface (8), and a collecting member (10) for combining mass (M’) that flowed along the impact surface and was refined at a collection point (12).