Layered Meat Emulsion Gel Composite Texture
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Solution Overview
Problem
Existing processes for manufacturing animal feed or foodstuffs using meat and fish emulsions fail to maintain the natural texture and appearance of the raw materials, particularly during sterilization, resulting in products that lack the fibrous structure and texture of natural meat and fish.
Innovation Solution
A process involving a meat or fish emulsion as the first stream and a gel-forming substance as the second stream, where the second stream is coarsely dispersed into the first as droplets or layers, discharged through a nozzle or screen plate, and then solidified and cut into thin slices to achieve a natural, fibrous texture and varied size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sterilisation is performed on meat or fish emulsions, then hygiene and safety are improved, but the original texture and appearance are completely lost
Solution Approach 1:
The material stream is segmented into multiple alternating layers of meat/fish emulsion and gel-forming substance, allowing differential treatment during sterilization. The gel layers protect the emulsion layers from complete texture loss while still achieving hygienic sterilization of the overall product.
Solution Approach 2:
The invention creates a composite material structure combining meat/fish emulsion with gel-forming substances. This composite structure allows the gel components to maintain structural integrity during sterilization while the emulsion components retain their textural properties, achieving both hygiene and texture preservation.
2Stability of the object's composition
If the second stream of material is completely blended into the first stream, then homogeneity is improved, but the fibrous meat or fish structure is lost
Solution Approach 1:
Instead of complete blending, the invention creates local variations in composition with distinct layers of different materials. Each layer maintains its local characteristics (emulsion or gel), preserving the fibrous structure in emulsion layers while achieving overall compositional stability through the controlled layered architecture.
Solution Approach 2:
The material is segmented into discrete layers rather than being completely mixed. This segmentation preserves the fibrous structure within each emulsion layer while creating a homogeneous multi-layered composite overall, satisfying both requirements through hierarchical organization.
3Shape
If the product is cut into thin slices, then the natural appearance is improved, but complete disintegration occurs
Solution Approach 1:
The alternating gel layers act as structural reinforcement within the composite material. When sliced, these embedded gel layers prevent complete disintegration by serving as internal scaffolding, while still allowing the product to be cut into thin slices for natural appearance and serving.
Solution Approach 2:
The gel-forming substance acts as an intermediary structural element between the emulsion layers. During slicing, this intermediary gel network provides mechanical support that prevents complete disintegration while allowing thin slicing for aesthetic purposes, mediating between the conflicting requirements of appearance and structural integrity.
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 produces animal feed or foodstuffs with a texture and appearance similar to natural meat or fish, satisfying consumer expectations by creating irregularly sized and shaped pieces that closely mimic natural products, while being simple and cost-effective to manufacture.
Implementation Method 1
at least one second stream of material, comprising at least one gel-forming and/or gel-like substance
Implementation Method 2
solidifying at least the first stream of material contained in the combination of materials obtained in step (ii)
Data Source
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AI summary
A process for manufacturing an animal feed in the form of pieces varied in size and irregular in shape is provided. The process comprises creating a solidified combined stream of material comprising stratified layers of first and second streams of material and cutting the solidified combined stream of material to form slices having a thickness of less than 6 mm. The arrangement of the shaped, layered second streams within the solidified combined stream of material and/or the incomplete disintegration of the shaped, layered second streams provide animal feed in the form of pieces varied in size and/or irregular in shape.