Grain Resonance Disintegration for Low Starch Damage Flour
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Solution Overview
Problem
Existing grain processing methods result in high starch damage, uneven particle sizes, and susceptibility to rancidity and infestation, as they rely on impact-based grinding, which is inefficient and produces flours unsuitable for modern baking standards.
Innovation Solution
The use of resonance disintegration processing, which subjects grains to alternating pressures and shock waves in a high-velocity stream, reducing them to consistent particle sizes without mechanical crushing, thereby minimizing starch damage and retaining natural antioxidants, resulting in flours with improved shelf life and baking performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If impact-based grinding is used to process grains, then particle size reduction is achieved, but starch damage increases and particle size uniformity deteriorates
Solution Approach 1:
The patent replaces traditional impact-based mechanical grinding with resonance disintegration technology. The grains are subjected to resonant vibrations that cause internal stresses and cleavage along natural planes, rather than external impact forces. This substitution of the mechanical action mechanism eliminates starch damage while achieving uniform particle sizes through controlled resonant frequencies.
Solution Approach 2:
The invention applies mechanical vibration in the form of resonance disintegration. Grains are exposed to specific resonant frequencies that cause them to vibrate internally, leading to separation along natural cleavage planes. The vibration parameters (frequency, amplitude) are controlled to achieve desired particle sizes without causing starch damage, directly addressing the contradiction between size reduction and starch integrity.
2Manufacturing precision
If whole grains are processed by impact milling, then flour is produced, but the flour contains large bran pieces and has non-uniform appearance
Solution Approach 1:
Resonance disintegration uses controlled mechanical vibrations at specific frequencies to break down whole grains into uniform flour particles. The resonant action causes grains to fragment along natural planes, producing consistent particle sizes and a uniform appearance without the irregular large bran pieces characteristic of impact milling.
3Productivity
If conventional grinding methods are used, then flour is produced quickly, but the flour becomes rancid and susceptible to infestation
Solution Approach 1:
By replacing impact grinding with resonance disintegration, the patent produces flour that maintains better structural integrity and lower moisture content. This substitution preserves natural antioxidants and creates a more stable product that resists rancidity and infestation, thereby improving shelf life without sacrificing processing efficiency.
4Manufacturing precision
If impact processing is used to reduce grain particle size, then flour is produced, but energy expenditure increases
Solution Approach 1:
Resonance disintegration exploits the natural resonant frequencies of grains to achieve particle size reduction. By tuning the vibration frequency to match the grain's natural resonance, the system achieves efficient energy transfer and fragmentation with minimal energy input, compared to the continuous high-energy impact forces required by conventional grinding.
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 produces high-quality, uniformly sized flours resistant to rancidity and spoilage, with reduced energy expenditure, maintaining nutritional value and baking performance, and allowing for effective separation of bran, germ, and endosperm.
Implementation Method 1
processing of grains and the like to produce comminuted grain products such as flours and particularly relates to non-impact processing of grains such as by subjection thereof to resonance disintegration
Implementation Method 2
The use of resonance disintegration processing, which subjects grains to alternating pressures and shock waves in a high-velocity stream
Data Source
AI summary
Methods for processing of grains and the like and products produced by such processing, the invention in preferred embodiments subjects whole grains or portions of grains to rapid pressure and directional changes in a high velocity fluid stream to instantaneously vary forces acting thereon. Flours of reduced particle sizes having low starch value damage result, the present processing also permitting uniform blending of additives such as during comminution of the grains. Processed grains according to the invention are resistant to spoilage and clumping. Whole grain flours and white flours can be produced according to the invention. Bran, germ and endosperm of grains can also be separated.