Irregular Die Extrusion for Natural Pet Jerky Appearance
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Solution Overview
Problem
Conventional pet food manufacturing processes fail to cost-effectively produce jerky-style pet food with variable thickness, texture, and non-uniform shapes and sizes that remain semi-moist and shelf-stable for long periods without refrigeration, while also mimicking the natural appearance and aroma of human-grade grilled meat.
Innovation Solution
A continuous manufacturing process involving grinding, mixing, extrusion through irregular die openings, cutting at varying angles, and dehydration to create pet jerky treats that resemble grilled meat, using proteinaceous materials like chicken breast or ground premium chicken meat, with the addition of preservatives and flavor enhancers, and a basting solution with smoke essence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional extrusion techniques with uniform die openings are used, then processing efficiency and productivity are improved, but the product appearance becomes uniform and processed-looking rather than natural and irregular
Solution Approach 1:
The patent applies asymmetry by using irregular die openings instead of uniform circular openings. The die openings have varying shapes, sizes, and orientations that produce extrudates with natural-looking irregularities. This resolves the contradiction by maintaining high productivity through continuous extrusion while achieving non-uniform, natural appearances that conventional uniform dies cannot produce.
Solution Approach 2:
The patent applies local quality by varying the properties of different parts of the die opening. Each die opening can have different dimensions, shapes, and orientations, creating local variations in the extruded product. This allows the overall product to have a natural, irregular appearance while maintaining consistent production efficiency through a single-pass extrusion process.
2Shape
If high concentration of muscle meat and fat is used to create natural jerky appearance, then product quality and aesthetic appeal are improved, but processing time increases and cost becomes prohibitive
Solution Approach 1:
The patent applies parameter changes by modifying the extrusion parameters (pressure, temperature, die geometry) and subsequent processing parameters (drying conditions, cutting angles) to achieve natural jerky appearance without requiring high meat concentrations. The irregular die openings and varied cutting angles create the desired wrinkled, non-uniform appearance through process parameters rather than ingredient composition, reducing both time and cost.
Solution Approach 2:
The patent replaces the traditional mechanical approach of slow drying and natural formation with an engineered extrusion and drying system. By controlling the extrusion process through irregular dies and using optimized drying parameters, the system rapidly produces the natural jerky appearance that would otherwise require extended processing times with high meat concentrations.
3Manufacturing precision
If uniform cutting is used to maintain consistency, then manufacturing precision is improved, but the product lacks randomization and natural appearance
Solution Approach 1:
The patent applies dynamics by introducing variability into the cutting process. Instead of fixed uniform cuts, the system uses varying cutting angles, multiple cutting passes, and potentially random or semi-random cutting patterns. This dynamic approach maintains manufacturing precision through controlled variation, producing natural-looking irregular shapes while ensuring consistent quality through engineered randomness.
Solution Approach 2:
The patent applies segmentation by dividing the extruded product into multiple pieces through sequential cutting operations. Each cut can be at a different angle and position, creating randomly shaped pieces from the continuous extrude. This segmentation process maintains precision through controlled cutting while achieving the desired shape randomization and natural appearance.
4Duration of action of stationary object
If pet food is engineered for long shelf life with high carbohydrate content, then storage stability is improved, but the product lacks the semi-moist texture and appearance of natural jerky
Solution Approach 1:
The patent applies parameter changes by optimizing the moisture content, water activity, and ingredient composition parameters to achieve both long shelf life and semi-moist texture. By carefully controlling these parameters during extrusion and drying, the system produces products that maintain natural jerky appearance and texture while achieving extended shelf stability without requiring high carbohydrate concentrations.
Solution Approach 2:
The patent applies composite materials by combining proteinaceous materials with carefully selected additives and preservatives in specific ratios. This composite formulation achieves the dual goal of long shelf life and natural semi-moist texture by balancing moisture-retaining ingredients with preservation components, creating a product that resembles natural jerky while maintaining stability for extended storage.
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 process results in pet jerky treats that are nutritionally rich, visually appealing, and shelf-stable for 18 months, maintaining a stable moisture content and water activity, while mimicking the natural, wrinkled texture and grilled aroma of human-grade jerky.
Implementation Method 1
dehydration to create pet jerky treats that resemble grilled meat
Implementation Method 2
extrusion through at least one die opening that is at least partially irregular to form at least one strip of extrudate
Data Source
AI summary
Processes, systems, and articles of manufacture are disclosed relating to edible meat pieces obtained from a continuous process where each piece generally appears to be home cooked on a grill or cooked in a smoke house with randomized sear and grill marks and smoke aroma. The invention, in its various embodiments, provides processes for manufacturing shelf-stable food treats comprising: starting with proteinaceous material (ground or whole), mixing the proteinaceous material with preservatives and flavor enhancers to form a foodstuff, extruding proteinaceous material (if ground) through at least one die opening that is at least partially irregular to form at least one strip of extrudate, cooking the extrudate or whole proteinaceous material to form a cooked product, coating the cooked product with a basting solution, grilling the basted products to obtain grilled products with searing, grill marks, and smoke aroma; and cutting the grilled product at a cutting angle into pieces.