Frozen Noodle Manufacturing via Ice Lump Cooling

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Solution Overview

Problem

The existing methods for manufacturing frozen noodles quickly after boiling impose a high load on freezers, leading to deterioration in flavor and texture due to evaporation and loss of surface components, and result in reduced production speed or intermittent operation to manage frost.

Innovation Solution

A method involving boiling noodles to a reduced moisture content, applying water to their surfaces, and using an ice lump in the freezing container to lower the noodles' temperature before rapid freezing within 120 seconds, optimizing the weight and moisture content of the ice lump to maintain flavor and texture while reducing freezer burden.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If freshly boiled noodles are frozen immediately to maintain flavor and texture, then the quality of noodles is improved, but the burden on the freezer increases significantly

Engineering Contradiction:

Improvequality of noodlesVSAvoidfreezer burden

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention applies preliminary cooling action by spraying cold water on noodles immediately after boiling, before they enter the freezer. This preliminary action reduces the temperature and thermal load of the noodles, thereby maintaining quality while reducing the burden on the freezer during the actual freezing process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention introduces cold water as an intermediary substance between the hot noodles and the freezer. The cold water acts as a heat transfer medium that rapidly cools the noodle surface, reducing the thermal load that would otherwise be directly imposed on the freezer, thus resolving the contradiction between maintaining quality and reducing freezer burden.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If cold air cooling or water wash cooling is used to lower noodle temperature before freezing, then the freezer burden is reduced, but the flavor and texture of noodles deteriorate

Engineering Contradiction:

Improvefreezer burdenVSAvoidflavor and texture

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention changes the parameter of water temperature used for cooling - specifically using cold water at a controlled temperature rather than ice water or prolonged cold air cooling. This parameter change allows sufficient cooling to reduce freezer burden while avoiding the excessive cooling that would deteriorate flavor and texture.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If boiled noodles are kept at high temperature before freezing to maintain quality, then flavor and texture are preserved, but production speed must be reduced or production stopped for frost removal

Engineering Contradiction:

Improveflavor and textureVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSSpeed

Solution Approach 1:

The invention performs preliminary cooling with cold water spray before freezing, which allows the noodles to be processed and frozen continuously without interruption. This preliminary action eliminates the need to stop production for frost removal, thereby maintaining both quality and production speed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention enables continuous operation of the freezing process by using cold water spray to prevent excessive frost accumulation. This maintains the continuity of useful action in production, allowing noodles to be frozen continuously without stopping for frost removal, thus preserving both quality and production speed.

Inventive Principle:

Principle #20Continuity of useful action

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 enhances freezer productivity while preserving the flavor and texture of noodles, reducing the load on freezers and allowing for continuous production without compromising the quality of frozen noodles.

Implementation Method 1

a step of filling a freezing container with the boiled noodles wherein the water is applied to the surfaces of the noodles and an ice lump containing frozen water

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

an ice lump containing frozen water

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 3

a step of subjecting the boiled noodles to freezing treatment

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

subjecting the boiled noodles to freezing treatment, wherein the freezing treatment is started within 120 seconds from the end of the boiling treatment

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20240156135A1Method for manufacturing frozen noodles

Publication Date: 2024.05.16 NISSIN FOODS HOLDINGS CO LTD

AI summary

A method for manufacturing frozen noodles including a step of subjecting raw noodles or dried noodles manufactured by an ordinary method to boiling treatment to produce boiled noodles containing moisture less than moisture of the noodles after cooking, a step of applying water to surfaces of the boiled noodles by sprinkling or dipping, a step of filling a freezing container with the boiled noodles having water applied to the surfaces and an ice lump containing frozen water, and a step of subjecting the boiled noodles to freezing treatment, in which the freezing treatment is started within 120 seconds from an end of the boiling treatment.