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Solution Overview
Problem
The industrial food processing industry has not successfully mass-produced sunny side up eggs due to the need for delicate cooking and handling, as existing conveyor systems fail to provide the necessary slow and uniform heating required for this food product.
Innovation Solution
A conveyor system with a lower PTFE conveyor belt and an upper conveyor system featuring a frame with moveable molds that form receptacles to contain and shape the food product, utilizing both thermal radiation and conduction heating to cook the eggs uniformly, while the transfer roller aids in removing the cooked eggs from the belt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional conveyor systems are used to cook eggs, then mass production is possible, but the eggs cannot be cooked uniformly and delicately enough to maintain clear egg white and liquid yolk
Solution Approach 1:
The cooking process is segmented into multiple heating zones with different temperature profiles. The conveyor system divides the cooking path into distinct sections, each providing specific thermal conditions necessary for uniform cooking of egg white and yolk, thereby maintaining product quality while enabling mass production.
Solution Approach 2:
The system employs dynamically adjustable heating elements and variable speed conveyor mechanisms that can adapt heating intensity and residence time based on product position and type. This dynamic control allows precise thermal management throughout the cooking process, ensuring uniform cooking results at high production volumes.
2Productivity
If fast cooking is used to increase production speed, then productivity improves, but the egg white becomes opaque and yolk overcooks
Solution Approach 1:
Different regions of the cooking chamber provide different thermal qualities - mild heating zones for egg white coagulation and controlled higher temperature zones for yolk setting. The conveyor system positions eggs to receive appropriate local thermal conditions at appropriate times, preserving egg white clarity and yolk liquid consistency while maintaining efficient throughput.
Solution Approach 2:
The heating process uses periodic thermal cycles with phases of gentle heating, brief high-temperature exposure, and cooling intervals. This periodic action pattern allows the egg components to cook at optimal rates sequentially, achieving clear white and liquid yolk even at high production speeds.
3Temperature
If thermal fluid heating systems are used, then heating capability is provided, but temperature control complexity and system size increase
Solution Approach 1:
The patent extracts the thermal fluid circulation system from the conveyor and replaces it with direct heating elements integrated into the conveyor structure. This eliminates the need for separate heating and pumping systems, reducing overall system complexity while maintaining effective temperature control for egg cooking.
Solution Approach 2:
The heating function is merged directly with the conveyor structure by integrating heating elements into the conveyor belts or support framework. This combination eliminates separate thermal fluid systems and simplifies the overall design while providing precise temperature control throughout the cooking zones.
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 system enables the continuous production of cooked sunny side up eggs with a clear, bright egg white and a liquid yolk, allowing for efficient cooking and packaging, overcoming the challenges of delicate handling and uniform heating.
Implementation Method 1
utilizing both thermal radiation and conduction heating to cook the eggs uniformly
Implementation Method 2
utilizing both thermal radiation and conduction heating to cook the eggs uniformly
Implementation Method 3
two polytetrafluoroethylene (PTFE, e.g. Teflon) conveyor belts, one below the food product, and one above, to pinch the food product while being transferred through the grill. Heating platens are located below the bottom belt and above the top belt to transfer heat through the belts by conduction to the food product.
Data Source
AI summary
A conveyor system includes an upper and lower synchronized conveyors that transfer a food product, such as eggs, through a heating system to cook the food product. The lower conveyor includes a belt and the upper conveyor includes rings that are moveably held within frames. The rings and belt are brought together to define receptacles in which the food product is arranged during cooking. After cooking, the rings are lifted off of the belt, leaving the food product on the belt. A transfer roller transfers the cooked food product from the belt for further processing, such as freezing of the food product.