Irregular Die Extrusion for Random Pet Jerky Shapes
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Solution Overview
Problem
Conventional pet food manufacturing processes fail to cost-effectively produce jerky-style products with variable thickness, texture, and non-uniform shapes and sizes that are semi-moist and shelf-stable for long periods without refrigeration, mimicking the natural appearance and texture of human-grade jerky.
Innovation Solution
A continuous manufacturing process involving grinding proteinaceous material, mixing with preservatives and flavor enhancers, extruding through irregular die openings, and cutting at multiple angles to produce jerky treats with random sizes and shapes, incorporating dual grinding steps and unique cutting operations to achieve varied textures and appearances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional extrusion techniques are used to produce pet food, then production efficiency and cost-effectiveness are improved, but the product appearance becomes uniform and processed-looking, lacking natural texture variation
Solution Approach 1:
The patent applies asymmetry by using irregularly shaped die openings instead of conventional uniform circular or rectangular openings. The die includes openings of varying shapes (e.g., teardrop, triangular, irregular polygons) that produce extrudates with non-uniform cross-sections, creating a more natural, varied appearance while maintaining continuous production efficiency
Solution Approach 2:
The patent implements local quality by varying the geometry of different die openings within the same extrusion plate. Each opening can have different dimensions, shapes, and orientations, allowing each extrude to have unique local characteristics in terms of thickness, surface texture, and cross-sectional shape, while the overall process remains efficient and continuous
2Shape
If human-grade jerky processing is used, then natural texture and appearance are achieved, but production time increases and costs become prohibitive for pet food
Solution Approach 1:
The patent applies parameter changes by modifying the extrusion parameters (pressure, temperature, die geometry) to produce pet food that mimics the appearance of slowly processed human-grade jerky. The irregular die openings and controlled extrusion conditions create wrinkled surfaces and varied thicknesses that resemble natural drying effects, achieving the desired appearance in a faster, more efficient process
Solution Approach 2:
The patent uses copying by replicating the visual and textural characteristics of human-grade jerky through engineered extrusion rather than actual slow drying. The die design and extrusion process copy the appearance features (wrinkles, irregular shapes, varied thickness) of naturally dried meat products without requiring the extended processing time and high ingredient costs of true human-grade jerky production
3Shape
If irregular die openings are used for extrusion, then variable thickness and texture are achieved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the extrusion process into discrete, modular die openings. Each opening is an independent geometric shape that can be designed and manufactured separately, then assembled into the extrusion plate. This modular approach allows for complex overall geometry while keeping individual components relatively simple and manufacturable
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, mimicking the natural, wrinkled texture of human-grade jerky while being cost-effective for high-volume production.
Implementation Method 1
extruding said foodstuff through at least one die opening that is at least partially irregular to form at least one strip of extrudate
Implementation Method 2
extruding said foodstuff through at least one die opening
Data Source
AI summary
Apparatus, systems and methods are disclosed to manufacture a plurality of edible pieces in a continuous process where each piece is generally different in thickness, shape, size and/or texture from another piece, so as to create, in the aggregate product distribution, pieces of randomly varying thickness, size, shape and/or texture. More specifically, the present invention, in its various embodiments, provides a process for manufacturing pet jerky treats comprising: grinding proteinaceous material, mixing said proteinaceous material with preservatives and flavor enhancers to form a blend of foodstuff, extruding said foodstuff through at least one die opening that is at least partially irregular to form at least one strip of extrudate that is at least partly irregular in shape, transporting said strip in a first longitudinal direction to a first cutting operation, cutting said strip at a first cutting angle to form a first set of pieces, transporting said first set of pieces in a second longitudinal direction to a second cutting operation, cutting said first set of pieces in said second cutting operation at a second angle to form a second set of pieces, such that the said second set of pieces cumulatively produced during a process run generally appear to be of random sizes and shapes.