Hydrator Vertical Tube Fluid Mixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydration processes for food products, such as dough and batter production, often require mechanical mixing which can lead to inefficient energy use, uneven product distribution, and increased equipment costs, as well as heating issues.
Innovation Solution
A hydrator system that combines wet and dry ingredients without mechanical stirring, using a vertically oriented tube with rotating fan and dry blades to aerate and break down dry ingredients before adding low-pressure liquid through a nozzle, creating a uniform product without mechanical kneading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If mechanical mixing and kneading are used to combine wet and dry ingredients, then the ingredients are thoroughly mixed, but energy consumption increases and heating issues occur
Solution Approach 1:
The patent replaces mechanical mixing and kneading systems with a fluid dynamic system. Liquid is injected at high velocity through nozzles to create intense turbulence and shear forces that mix dry ingredients without mechanical contact. This substitution eliminates the need for motors, shafts, and mixing blades, dramatically reducing energy consumption while achieving uniform dough composition.
Solution Approach 2:
The invention uses hydraulic injection of liquid at controlled pressures (typically 5-50 bar) to achieve mixing. The liquid stream creates a fluidized bed effect and turbulent flow patterns that thoroughly combine ingredients. This hydraulic approach replaces traditional mechanical power transmission systems, reducing both energy consumption and equipment complexity.
2Productivity
If high-pressure liquid spraying is used for hydration, then mixing efficiency improves, but equipment complexity and cost increase
Solution Approach 1:
The mixing chamber is segmented into distinct zones: a fluidization zone where liquid first contacts dry ingredients, a mixing zone where turbulence completes incorporation, and a discharge zone. Multiple nozzles are strategically positioned to create sequential mixing stages. This segmentation allows efficient mixing at moderate pressures while simplifying equipment design compared to single-stage high-pressure systems.
Solution Approach 2:
The system uses dynamic flow patterns created by injected liquid to achieve mixing. The liquid stream velocity, flow rate, and injection angle are optimized to create natural turbulence and eddy currents that enhance mixing efficiency. This dynamic approach replaces static high-pressure mechanisms, reducing equipment complexity while maintaining productivity.
3Stability of the object's composition
If mechanical mixing is used to combine ingredients, then hydration is achieved, but temperature control becomes difficult
Solution Approach 1:
By replacing mechanical mixing with fluid injection, the system eliminates the friction and shear heating inherent in mechanical systems. The liquid stream performs mixing through pressure-driven flow and turbulence rather than mechanical friction, maintaining lower temperatures throughout the process. This substitution directly addresses temperature control while achieving uniform hydration.
4Manufacturing precision
If multiple mixing stages are used to ensure uniform product, then product quality improves, but equipment size and cost increase
Solution Approach 1:
The invention creates multiple mixing stages within a compact vertical chamber by varying nozzle positions, angles, and injection points. The fluid flow transitions through different regimes (jet, turbulence, eddy currents) as it moves vertically through the chamber, providing sequential mixing action without requiring large horizontal space. This vertical dimensionality allows multi-stage mixing in a compact footprint.
Solution Approach 2:
Multiple nozzle assemblies are nested within the mixing chamber, with nozzles positioned at different heights and angles. The liquid flow from upper nozzles interacts with material already disturbed by lower nozzles, creating nested mixing zones. This nesting approach provides multiple mixing stages within a single compact chamber, reducing overall equipment size while maintaining product uniformity.
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 results in a more uniform product with reduced energy consumption, smaller equipment, better temperature control, and lower production costs, while avoiding mechanical mixing and kneading.
Implementation Method 1
The liquid stream creates turbulence and shear forces to mix dry ingredients without mechanical contact
Implementation Method 2
The liquid stream creates turbulence and shear forces to mix dry ingredients without mechanical contact
Data Source
AI summary
A hydrator includes a dry module with a vertically oriented tube having a central axis, an interior, an upper inlet aperture, a lower outlet, and an inlet section including a dry inlet. A mixing segment includes a vertically oriented tube having an interior wall, a mixing-segment inlet at an upper end, and a mixing-segment outlet at a lower end. The mixing segment is vertically aligned with and sealingly connected to the outlet of the dry module. A rotating hydrator shaft has a liquid channel and a longitudinal axis aligned with the central axis of the dry module. Dry blades are disposed on and rotate with the hydrator shaft in the mixing segment. A hydrator nozzle is disposed on and rotates with the hydrator shaft and has a plurality of outlets in fluid communication with the liquid channel and open to the mixing segment for discharging liquid from the liquid channel.