Food Processing System Water Recycling Method
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Solution Overview
Problem
Food processing systems face significant water consumption during cleaning and product changes, leading to waste and increased sewage volume, as they require multiple water flushes to maintain hygiene and prevent product mixing, especially in regions with scarce fresh water resources.
Innovation Solution
A method that involves pushing a low-concentration and high-concentration sub-composition of food products out of the system using water, sterilizing the system by heating the water, and reusing the sterile water as the first sub-composition for the next product, thereby reducing water usage and enhancing cleaning efficiency by recycling clean water.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the system is flushed multiple times with water to clean and sterilize, then hygiene and product safety are improved, but water consumption increases significantly
Solution Approach 1:
The patent recovers and reuses the flushing water after it has performed its cleaning function. Instead of discarding the water that has been used to flush the system, it is retained and reused for subsequent flushing operations or for preparing the next food product, thereby reducing overall water consumption while maintaining hygiene standards
Solution Approach 2:
The patent changes the concentration parameter of the food product in the flushing water. By allowing the flushing water to contain increasing concentrations of food product (first sub-composition with low concentration, second sub-composition with high concentration), the system reduces the need for multiple complete flushes with fresh water, as the concentrated product itself helps displace residual water
2Reliability
If the system is sterilized by heating water to above 100°C, then microbial safety is improved, but energy consumption increases
Solution Approach 1:
The patent maintains continuous circulation of water through the system during sterilization, ensuring that the heating action is applied efficiently and continuously to all parts of the system. This continuous circulation prevents hot spots and ensures uniform sterilization, reducing the total energy required compared to intermittent or static heating methods
Solution Approach 2:
The system uses its own circulating water to transfer heat throughout the system during sterilization. The water that is being sterilized also serves as the heat transfer medium, eliminating the need for separate heating circuits or additional thermal carriers, thereby reducing energy consumption
3Ease of manufacture
If cleaning chemicals are circulated in the system to enhance cleaning, then cleaning efficiency is improved, but chemical usage and sewage volume increase
Solution Approach 1:
The patent recovers and reuses the cleaning chemicals after they have performed their cleaning function. Instead of draining the chemicals to sewage, they are retained in the system and reused for subsequent cleaning operations or for preparing food products, thereby reducing chemical consumption and minimizing sewage volume while maintaining cleaning efficiency
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 method significantly reduces water consumption by reusing clean water for subsequent food processing, making the cleaning and sterilization process more efficient and cost-effective while minimizing water waste and sewage volume.
Implementation Method 1
The step of sterilizing the system may comprise heating the water present in the system to above 100 °C and circulating the water in the system
Data Source
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AI summary
The invention relates to a method for reducing water consumption of a system (1) for processing a liquid or semi-liquid food product, after an interruption of said processing. The food product is a composition of a first sub-composition having a low concentration and a second sub-composition having a high concentration, wherein said high concentration is greater than said low concentration. The method comprising the steps of pushing said first sub-composition, said second sub-composition and said food product out of the system (1) using water until the system (1) substantially contains only water, sterilizing the system (1) by heating the water present in the system (1), and forming a new food product by adding a new second sub-composition to the sterile water, thereby using said sterile water as said first sub-composition.