Food Mass Conveyor and Mixer Buffer for Continuous Moulding

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Solution Overview

Problem

Existing food product moulding lines are labor-intensive, prone to mistakes, material loss, and inconsistent ice crystallization, with energy inefficiencies due to fluctuating temperatures and compositions.

Innovation Solution

An automated food/feed mass transport line comprising at least one grinder, at least two mixers, and a portioning/moulding apparatus, with conveyors connecting them, where at least one mixer acts as a buffer to maintain consistent ice crystallization and temperature, ensuring continuous operation and efficient energy use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual handling with trolleys is used to transport food mass, then flexibility in operation is maintained, but labor intensity increases and handling errors occur

Engineering Contradiction:

Improvemanual handling flexibilityVSAvoidlabor efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces manual mechanical handling with trolleys with an automated conveyor system. The conveyor automatically transports food mass between the grinder, mixers, and portioning apparatus, eliminating manual labor while maintaining continuous material flow and improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service operation where the conveyor automatically feeds material from the grinder to the mixers and then to the portioning apparatus without requiring manual intervention. The system serves itself by maintaining continuous automated material transport throughout the processing line.

Inventive Principle:

Principle #25Self-service

2Quantity of substance

If multiple trolleys are used for material transport, then material can be staged, but mistakes and material loss increase

Engineering Contradiction:

Improvematerial staging capacityVSAvoidmaterial loss

Core Design Contradiction:

Quantity of substanceVSLoss of substance

Solution Approach 1:

The patent replaces the multi-trolley staging system with a continuous conveyor belt that transports food mass directly from the grinder through the mixers to the portioning apparatus. This eliminates material transfer between multiple containers, preventing spillage and contamination while maintaining adequate material supply through continuous flow.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If single mixer is used, then device complexity is reduced, but continuous operation cannot be maintained

Engineering Contradiction:

Improvenumber of mixersVSAvoidcontinuous operation capability

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent divides the mixing function into multiple separate mixer units arranged in sequence. The first mixer performs initial mixing while the second mixer completes the mixing process and serves as a buffer. This segmentation allows one mixer to be emptied and refilled while the other continues operation, enabling continuous production without stopping the portioning apparatus.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements continuous operation by having multiple mixers work in sequence with overlapping cycles. While one mixer is being emptied and refilled, the other mixer continues to supply mixed food mass to the portioning apparatus. This ensures the useful action of mixing and portioning continues without interruption, maintaining constant productivity.

Inventive Principle:

Principle #20Continuity of useful action

4Use of energy by moving object

If ice crystallization is not controlled, then energy consumption is reduced, but product quality becomes inconsistent

Engineering Contradiction:

Improveenergy consumptionVSAvoidproduct consistency

Core Design Contradiction:

Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The patent incorporates temperature control systems in the mixers that monitor and regulate the temperature of the food mass during mixing. This feedback control maintains consistent temperature conditions that prevent uncontrolled ice crystallization, ensuring uniform product quality while optimizing energy usage by only cooling when necessary to maintain the desired temperature range.

Inventive Principle:

Principle #23Feedback

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 system reduces handling errors, minimizes material loss, improves hygiene, and enhances product consistency and energy efficiency by maintaining controlled ice crystallization and temperature, allowing continuous production.

Implementation Method 1

maintain the level of ice crystallization and be able to control and maintain the temperature of the food mass

Methodology Applied

Scientific EffectIce crystallization: Crystallisation

Implementation Method 2

control and maintain the temperature of the food mass in order to obtain a consistent (weight, temperature, and composition) mixed food mass

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS12575578B2Automated food/feed mass transport system

Publication Date: 2026.03.17 GEA FOOD SOLUTIONS BAKEL BV

AI summary

A food processing line that includes at least one grinder which grinds or pre-grinds food to form a food mass; at least two mixers which mix the ground or pre-ground food mass or at least two mixer-grinders which further mixes and grinds the ground or pre-ground food mass; and at least one portioning/moulding apparatus to portion and/or mould individual food/feed products. The at least one grinder, the at least two mixers, and the at least one portioning/moulding apparatus are connected by conveyors.