Grain Puffing Apparatus Using Weight-Based Feedback to Prevent Burning
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Solution Overview
Problem
Existing methods for puffing grains lack accurate temperature control, leading to rapid burning and undesirable discoloration of puffed grain products due to unreliable temperature sensors and difficulty in maintaining a stable high temperature in small devices.
Innovation Solution
A method and apparatus that preheat the puffing apparatus and control temperature based on the rate of moisture loss from the grain food, using a weight sensor to determine the moisture loss and adjust heating accordingly to achieve a predetermined end moisture content, thereby preventing burning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high temperature is applied for puffing, then grain volume increases and starch gelatinizes, but the grain burns quickly due to moisture loss
Solution Approach 1:
The patent employs a feedback control system where a weight sensor continuously monitors the weight of the grain during puffing, and the control unit adjusts the heating power based on the rate of weight loss (moisture evaporation rate). This closed-loop feedback prevents burning by dynamically adjusting temperature to maintain optimal moisture loss rate.
Solution Approach 2:
The patent changes the control parameter from fixed temperature or time to dynamic weight loss rate monitoring. By controlling the heating process based on real-time weight measurements, the system adapts temperature parameters to prevent burning while achieving complete puffing.
2Measurement precision
If temperature sensors are used for control, then temperature monitoring is possible, but the sensors are not accurate or reliable and temperature fluctuates
Solution Approach 1:
The patent uses weight loss rate as an intermediary parameter to indirectly control and monitor the puffing process. Instead of directly measuring temperature with unreliable sensors, the system measures weight loss (which correlates with moisture evaporation and thus puffing progress) to infer the appropriate heating level.
Solution Approach 2:
The patent replaces the thermal measurement system (temperature sensors) with a mechanical measurement system (weight sensor). This substitution provides more reliable and accurate measurements, as weight can be measured precisely without the instability issues of temperature sensors in high-heat environments.
3Productivity
If heating continues to ensure complete puffing, then grain expansion is maximized, but the grain becomes over-heated and burned
Solution Approach 1:
The feedback control system stops heating when the weight loss rate decreases below a threshold, indicating that puffing is complete and further heating would cause burning. This automatic termination ensures complete puffing without over-heating.
Solution Approach 2:
The grain itself provides the termination signal for the heating process through its weight loss pattern. As the grain puffs and loses moisture, the rate of weight loss naturally decreases, and this self-generated signal triggers the control system to stop heating, eliminating the need for external timing or temperature estimation.
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 approach allows for precise control of the puffing process, ensuring the grains are puffed to a desirable texture and appearance without burning, enabling consistent production of high-quality puffed grain foods like puffed rice in domestic settings.
Implementation Method 1
The popping or puffing process involves superheating the grains to create superheated steam from water present in the grain, to melt or gelatinize the starch granule
Implementation Method 2
superheating the grains to create superheated steam from water present in the grain, to melt or gelatinize the starch granule
Implementation Method 3
The superheated steam also causes a pressure increase in the grain, leading eventually to rupture of the outer layer, followed by an increase in grain volume (puffing)
Implementation Method 4
determining a moisture loss or a rate of moisture loss from the grain food in the puffing apparatus based on a weight loss or a rate of weight loss of the grain food being puffed
Data Source
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AI summary
There is provided an apparatus (100) and method (200) of puffing grain food. The puffing chamber is pre-heated, and the moisture loss from the grain food during the puffing process is determined and the temperature controlled based on the determined moisture loss, until a desired end moisture content of the puffed grain food is obtained.