Induction Heated Extrusion Horn for Uniform Meat Processing
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Solution Overview
Problem
Existing food processing systems for meat products face challenges with non-uniform extrusion and cooking due to complex horn designs that do not allow for consistent flow and size throughout the cooking process, leading to inefficiencies and increased dicing/slicing losses.
Innovation Solution
An extrusion horn with an inner compression chamber featuring a tapered interior channel and a combination with a pre-compression nozzle, providing back pressure and uniform flow, along with a cooking plate assembly that maintains separation of extruded pieces using induction heating and non-stick surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a complex horn design is used for extrusion, then the extrusion capability is improved, but the uniformity of flow and size throughout the cooking process deteriorates
Solution Approach 1:
The horn is divided into multiple sections with progressively changing diameters, creating distinct zones for different functions: initial extrusion, cooking, and finishing. This segmentation allows each section to optimize for its specific purpose while maintaining overall uniformity of the extruded product throughout the cooking process.
Solution Approach 2:
The horn design incorporates dynamic adjustments through variable wall thickness and adjustable cooking surfaces that can be modified during operation. This allows the system to adapt to different product requirements and maintain uniform extrusion characteristics throughout the cooking process.
2Device complexity
If the horn design does not allow uniform flow, then extrusion complexity is reduced, but dicing/slicing losses increase
Solution Approach 1:
The horn design utilizes controlled changes in geometric parameters along its length, including diameter, wall thickness, and surface texture. These parameter changes are carefully designed to maintain uniform flow of the extruded product, reducing variability that would otherwise require excessive trimming and increasing dicing/slicing losses.
3Device complexity
If conventional heating methods are used, then equipment complexity is reduced, but cooking uniformity and efficiency deteriorate
Solution Approach 1:
The patent replaces conventional mechanical or thermal conduction heating systems with induction heating technology. This substitution uses electromagnetic fields to directly heat the metal horn and cooking surfaces, providing superior temperature control and uniformity without requiring complex external heating mechanisms.
Solution Approach 2:
The induction heating system utilizes electromagnetic field phase transitions and energy conversion to efficiently transfer energy to the horn and product. This allows for precise control of the cooking process and maintains uniform temperatures throughout the extrusion and cooking operation.
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
The solution ensures uniform product thickness and increased throughput, reducing dicing losses and achieving higher cook yields by maintaining the separation of extruded pieces and applying consistent heat for efficient cooking.
Implementation Method 1
an induction heating element positioned proximate the cooking plate and operable for heating the cooking plate
Implementation Method 2
an induction heating element positioned proximate the cooking plate and operable for heating the cooking plate
Data Source
AI summary
A method and apparatus for an extrusion horn including an inner compression chamber having an interior channel extending from an open infeed port to an open exit port, where a top inner surface of the interior channel progressively tapers down with an initial slope having an initial downward taper to a target thickness, then top inner surface abruptly steps to an increased thickness of the channel, and then progressively tapers down with a secondary slope where the secondary slope has a steeper downward taper than the slope of the initial downward taper. An apparatus and method for extruding extrudate through an extruding horn conducive for producing bacon bits and jerky.