Jet Stream Comminution for Food Processing
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Solution Overview
Problem
Conventional methods for producing pureed, cooked food from chunky raw materials result in quality loss due to cell damage and separation of solid and liquid phases, leading to uneven cooking and oxidation, along with inefficiencies in energy use and space requirements.
Innovation Solution
A method utilizing a rotating knife system for pre-crushing the raw material to prevent cell damage, followed by a closed cooking system with direct steam heating and controlled chopping to maintain product quality and efficiency, and a pressure sensor for optimizing feed rate to prevent clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a meat grinder with perforated discs is used for comminution, then the raw material is shredded, but the product is crushed and cells are damaged causing juicing and separation of liquid and solid components
Solution Approach 1:
The patent replaces the traditional mechanical meat grinder system with a high-speed jet stream system. The jet stream (supercritical fluid) comminutes the raw material through fluid dynamic forces rather than mechanical contact, eliminating cell damage and juicing while achieving fine comminution. This substitution of mechanical action with fluid dynamic action resolves the contradiction between comminution efficiency and product quality.
2Ease of operation
If a rotary piston pump is used to convey the comminuted product, then the product is transported, but the separation of solid and liquid components causes difficult continuous flow and clogging
Solution Approach 1:
The patent changes the physical state parameters of the comminuted product by treating it with a jet stream, which transforms the material into a homogeneous slurry with controlled viscosity and flow properties. This parameter change eliminates the separation of solid and liquid phases, allowing smooth continuous flow through the pump without clogging, thereby improving both ease of operation and reliability.
3Temperature
If an open belt cooking system is used, then the product is cooked, but the product contacts ambient air causing oxidation and affecting color and flavor
Solution Approach 1:
The patent replaces the open cooking system with a closed cooking system that maintains an inert atmosphere (nitrogen or carbon dioxide environment). This inert environment prevents oxidation of the product during cooking, preserving color and flavor while still achieving the required cooking temperature. The harmful factor of oxidation is eliminated by substituting the reactive ambient air with an inert gas atmosphere.
4Temperature
If an open belt cooking system is used, then the product is cooked, but heat and moisture escape uncontrollably resulting in poor energy efficiency
Solution Approach 1:
The patent employs a closed cooking system with controlled atmosphere containment, effectively using the cooking chamber as a sealed environment. This containment prevents uncontrolled escape of heat and moisture, allowing for better thermal efficiency and energy conservation while maintaining the required cooking temperature. The loss of energy is minimized by the sealed design that retains heat and moisture within the cooking zone.
5Manufacturing precision
If a fine comminutor with open funnel is used for finishing, then the product is further processed, but the product contacts ambient air and oxidizes further
Solution Approach 1:
The patent extends the inert atmosphere protection to the finishing comminution stage. The fine comminutor operates within the closed system maintaining nitrogen or carbon dioxide atmosphere, allowing the product to be further processed to desired fineness without exposure to ambient air. This prevents additional oxidation during the finishing stage while achieving the required product precision.
6Temperature
If conventional cooking installations are used, then the product is cooked, but the space requirement is approx. 3 m by 10 m so a more compact installation is desirable
Solution Approach 1:
The patent combines multiple process functions (comminution, cooking, and finishing) into an integrated continuous processing system. The jet stream comminution and cooking operations are merged in a unified apparatus, eliminating the need for separate large-scale equipment. This consolidation achieves the required cooking temperature while significantly reducing the installation footprint from 3m x 10m to a much more compact configuration.
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 enhances product quality by minimizing oxidation and energy loss, ensuring consistent flow and cooking, and reducing space requirements while maintaining high throughput and product gentleness.
Implementation Method 1
The raw material is comminuted by means of a jet stream in a known manner
Implementation Method 2
The comminuted product is then conveyed to a belt cooking system by means of a rotary piston pump
Implementation Method 3
conveyed to a belt cooking system by means of a rotary piston pump
Data Source
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AI summary
A process for producing pureed, cooked food products from lumpy raw materials, comprising the steps of: - pre-shredding the lumpy raw materials in a pre-shredding unit, - cooking the pre-shredding raw materials in a cooking unit, - finishing the cooked product in a finishing unit, is characterized by the fact that the lumpy raw materials are cut into small pieces by the pre-shredding unit before cooking, resulting in a pumpable mass.