Closed Fermentation Tank Jet Head for Kombucha Biofilm Prevention
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Solution Overview
Problem
The industrial production of fermented beverages like kombucha is hindered by the formation of a cellulose-based biofilm (SCOBY) during fermentation, which is difficult to remove and leads to contamination, reduced tank efficiency, and limited production capacity due to manual removal and clogging issues.
Innovation Solution
A method involving a closed fermentation tank with circulation and aeration of the fermenting liquid using a jet head, preventing biofilm formation and allowing for efficient cleaning and aseptic production, combined with centrifugation and filtration for particle and microorganism removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a closed fermentation tank with circulation and aeration is used, then biofilm formation is prevented and production efficiency is enhanced, but device complexity increases due to additional circulation and aeration systems
Solution Approach 1:
The patent combines the circulation system and aeration system into a single integrated setup within the closed fermentation tank. The circulation pumps and aeration devices work together to achieve both liquid movement and oxygen supply, reducing the need for separate systems and minimizing overall device complexity while maintaining high productivity.
Solution Approach 2:
The circulation system serves multiple functions: it prevents biofilm formation by continuous liquid movement, enables efficient oxygen distribution throughout the fermentation medium, and facilitates heat transfer. This multi-functionality allows a single system to address multiple process requirements, improving productivity without proportionally increasing device complexity.
2Reliability
If manual removal of biofilm is performed, then contamination is reduced, but loss of time and productivity decrease due to intensive manual labor
Solution Approach 1:
The closed fermentation tank with circulation and aeration prevents biofilm formation in the first place by maintaining continuous liquid movement and adequate oxygen supply. This preliminary anti-action eliminates the need for subsequent biofilm removal operations, saving time and maintaining contamination control without requiring manual intervention.
Solution Approach 2:
The system uses its own circulation and aeration mechanisms to prevent biofilm accumulation, making the process self-maintaining. The continuous liquid flow and oxygen supply create conditions that naturally inhibit biofilm formation, eliminating the need for external manual removal operations and associated time losses.
3Device complexity
If standard open container fermentation is used, then device complexity is reduced, but contamination risk increases and production capacity is limited
Solution Approach 1:
The patent integrates multiple functions (fermentation, circulation, aeration, and contamination prevention) into a single closed tank system. This merging allows the system to maintain simplicity while achieving high reliability, as the closed design inherently prevents contamination while the integrated circulation and aeration systems manage the fermentation process efficiently.
4Manufacturing precision
If centrifugation and filtration are applied, then liquid clarification is improved and shelf life is extended, but device complexity and processing time increase
Solution Approach 1:
The circulation system in the closed fermentation tank performs preliminary clarification by continuously moving the liquid and preventing particle settlement during fermentation. This preliminary action reduces the burden on subsequent centrifugation and filtration steps, achieving high liquid clarification without requiring overly complex processing systems.
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 eliminates biofilm formation, enhances production efficiency, reduces contamination, and improves the quality and shelf life of the fermented beverage by ensuring thorough cleaning and sterilization.
Implementation Method 1
the fermenting liquid is circulated in the fermentation tank
Implementation Method 2
at least a portion of the fermenting liquid is mixed with oxygenated air outside the fermentation tank
Implementation Method 3
fermenting liquid in a closed fermentation tank, by means of microorganisms
Implementation Method 4
centrifugation and filtration for particle and microorganism removal
Implementation Method 5
centrifugation and filtration for particle and microorganism removal
Data Source
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AI summary
The present invention relates to a method for the industrial production of a beverage based on a fermented liquid, wherein the liquid is fermented by means of microorganisms in a closed fermentation tank, wherein the fermenting liquid is circulated in the fermentation tank and wherein at least a portion of the fermenting liquid is mixed with air outside the fermentation tank, and then reintroduced into the fermentation tank. The invention also relates to a device for the industrial production of a fermented drink, the device comprising a closed fermentation tank provided internally with a jet head the fermentation tank being provided with a first conduit suitable for transporting a portion of the fermenting drink from the fermentation tank to an oxygenator, wherein the first conduit opens into the oxygenator and a second conduit exits from the oxygenator and opens into an inlet of the jet head into the fermentation tank.