Batch Grain Beverage Mixing with External Homogenization
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Solution Overview
Problem
Conventional production of grain-based beverages from unprocessed grain materials results in significant environmental waste and high production costs due to the need for continuous high-capacity production lines, which are not suitable for small-scale producers.
Innovation Solution
A method and system utilizing a mixing apparatus with a circulation arrangement and an external homogenization device to produce grain-based beverages in batches, reducing particle size without the need for separate filtration, thereby minimizing system complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional continuous production lines are used for high-capacity production, then productivity is improved, but device complexity and investment cost increase significantly
Solution Approach 1:
The patent combines multiple separate production stations (mixing, enzymatic treatment, homogenization, heating, cooling) into a single integrated batch processing system. The mixing vessel serves as the central hub where all operations are performed sequentially, eliminating the need for multiple separate stations and complex transfer mechanisms between them.
Solution Approach 2:
The mixing vessel is designed to perform multiple functions: mixing grain material with water and enzymes, heating the slurry for enzymatic treatment, cooling it down, and facilitating homogenization. This multi-functional approach replaces the need for dedicated equipment for each operation, reducing overall system complexity while maintaining high productivity.
2Manufacturing precision
If fiber separation using conventional decanter is implemented, then particle size is controlled, but significant solid by-product waste is generated
Solution Approach 1:
Instead of discarding the solid residue as waste, the patent homogenizes it back into the liquid fraction through intensive mixing and circulation. This converts the harmful waste product into a beneficial component that can be retained in the final beverage, improving both particle size control and reducing substance loss.
Solution Approach 2:
The patent recovers solid particles that would normally be discarded by the decanter and reintroduces them into the liquid phase through homogenization. This recovery process eliminates waste while maintaining desirable particle size distribution in the final product.
3Manufacturing precision
If multiple separate production stations are used, then manufacturing precision is improved, but ease of operation and flexibility decrease
Solution Approach 1:
While using a single integrated vessel, the patent segments the processing into distinct operational phases (mixing, heating, cooling, homogenization) that can be controlled independently through a programmable controller. This allows precise control of each process step while maintaining operational simplicity through automated sequencing.
Solution Approach 2:
The patent employs dynamic control where the programmable controller automatically adjusts process parameters (temperature, mixing speed, timing) based on the current operational phase. This dynamic adaptation enables precise manufacturing control while simplifying operator intervention to merely initiating and monitoring the automated sequence.
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
Enables flexible, cost-effective batch production of grain-based beverages with reduced waste and increased production yield, retaining nutritional value, and achieving desirable particle sizes for consumer acceptance.
Implementation Method 1
operating, during a second time period after the first time period, a circulation arrangement to transfer the slurry on an external circulation path from the mixing chamber through a homogenization device and back to the mixing chamber, wherein the homogenization device is operated to reduce a particle size of the slurry
Implementation Method 2
operating a mixing device of the mixing apparatus during a first time period to generate a batch of slurry in the mixing chamber
Data Source
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AI summary
A method of manufacturing a grain-based beverage for human consumption enables batch production and may implemented in a system of low complexity. The method comprises introducing water, grain material and one or more enzymes into a mixing chamber (10A) of a mixing apparatus (10); operating a mixing device (12) of the mixing apparatus during a first time period to generate a batch of slurry in the mixing chamber; operating, during a second time period after the first time period, a circulation arrangement (13) to transfer the slurry on an external circulation path from the mixing chamber through a homogenization device (16) and back to the mixing chamber; introducing one or more further ingredients into the mixing chamber of the mixing apparatus; and operating the mixing apparatus and/or the circulation arrangement to produce the grain-based beverage based on the slurry and the one or more further ingredients.