Jerky Thermal Processing with Superheated Steam Drying
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Solution Overview
Problem
Current jerky manufacturing processes face issues with non-uniform drying, extended processing time, case hardening, and safety concerns due to airflow limitations and condensation in traditional thermal processing ovens, leading to under or over drying, yield issues, and potential food safety hazards.
Innovation Solution
The use of superheated steam to control moisture release from jerky products, ensuring uniform processing, reducing processing time, and enhancing safety by vaporizing moisture while maintaining a controlled environment to achieve the desired water activity and lethality, thereby improving yield, appearance, and shelf life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional convection drying with recirculating fans is used, then the product can be dried, but non-uniform drying occurs leading to under or over drying and yield issues
Solution Approach 1:
The patent changes the fundamental parameter of the drying medium from ambient air to superheated steam. This parameter change enables uniform heat and mass transfer throughout the product, eliminating the non-uniform drying that occurs with traditional convection methods while maintaining efficient moisture removal.
Solution Approach 2:
The patent utilizes the phase transition of water from liquid to vapor within the product during superheated steam treatment. The superheated steam causes internal moisture to vaporize and diffuse outward, creating uniform drying from the inside out rather than from the outside in as occurs with traditional convection.
2Manufacturing precision
If extended processing time is used to achieve uniform drying, then drying uniformity improves, but productivity decreases
Solution Approach 1:
By changing to superheated steam as the processing medium, the patent achieves rapid and uniform moisture vaporization and diffusion throughout the product. This parameter change reduces processing time significantly while maintaining uniform drying, as the superheated steam penetrates the product and causes internal moisture to escape uniformly from all surfaces simultaneously.
3Reliability
If traditional thermal processing with high relative humidity is used, then microbial lethality is achieved, but condensation occurs on product surface creating additional moisture and discoloration
Solution Approach 1:
The patent changes the processing medium from high humidity air to superheated steam, fundamentally altering the thermal and moisture environment. This parameter change eliminates condensation because the superheated steam environment prevents moisture accumulation on surfaces, while still achieving the necessary microbial lethality through controlled temperature and time.
Solution Approach 2:
The superheated steam creates an inert-like environment that prevents oxidation and discoloration while achieving microbial lethality. The steam environment excludes oxygen and other reactive gases, preventing the harmful effects of oxidation on the product surface during the lethality phase.
4Speed
If airflow runs down the sides of the oven and returns upward through the product, then convection is achieved, but case hardening occurs trapping moisture
Solution Approach 1:
The patent uses phase transition of internal moisture to vapor during superheated steam treatment. This causes moisture to be released uniformly from the interior of the product and diffuse outward, preventing case hardening that occurs when external airflow removes surface moisture too rapidly while the interior remains wet.
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 results in a more uniform product with better yield, appearance, and flavor, reduced processing time, lower energy consumption, and improved safety, while maintaining a safer and more efficient manufacturing process.
Implementation Method 1
This invention utilizes the ability of superheated steam to release moisture at a controlled rate out of jerky products. This is done by vaporizing the water content, in effect boiling the moisture
Implementation Method 2
The product, being colder than the airstream, has a lower dew point than the atmosphere and, therefore, condensation occurs on the product's surface
Data Source
AI summary
A thermal process used to modify the moisture content and appearance of food, primarily meat, poultry and fowl, so that the resulting product will meet the USDA label requirement as “Jerky”. The process takes place in one or more enclosed insulated chambers which have temperature and relative humidity controls and reversing horizontal air flow. The process preconditions the product and also controls the application of superheated steam to the product, thereby controlling the reduction of free and bound moisture (water activity) exiting from the product. In addition, enhanced heated vapors can be added to be absorbed into the product's surface pours, thereby changing the appearance and flavor of the product and improving the end products' yields. The completed process also has the advantages of meeting lethality treatment requirements while also reducing the thermal processing time and energy associated with existing Jerky manufacturing methods.