Liquid Extract Production System with Real-Time Solid Content Control
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Solution Overview
Problem
Conventional methods for producing liquid extract, such as from coffee beans, are inefficient due to inadequate or excessive solid content, affecting flavor and aroma, and result in wasteful water usage and treatment issues.
Innovation Solution
A liquid extract production system comprising a processing liquid tank, extractor, liquid extract tank, flow meters, and density meters to measure and control the flow rate and solid content concentration, allowing for real-time monitoring and adjustment of the extraction process to achieve desired solid content levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the extraction step is restarted when solid content is inadequate, then the solid content can be increased, but production time is wasted and water is wasted
Solution Approach 1:
The system implements real-time feedback control by continuously measuring the solid content of liquid extract during extraction using a density meter and flow meter. The controller receives signals from these meters and automatically adjusts the extraction process, eliminating the need to restart extraction when solid content is inadequate. This real-time monitoring and automatic adjustment ensures precise solid content control while preventing time waste from restarting operations.
Solution Approach 2:
The patent replaces manual measurement and decision-making processes with automated instrumentation. Density meters and flow meters continuously monitor extraction parameters, and a controller automatically manages the extraction process based on real-time data. This substitution of mechanical/manual operations with automated systems enables precise solid content control without the time loss associated with manual checking and restarting.
2Manufacturing precision
If the liquid extract is discarded when solid content is excessive, then the extraction quality can be maintained, but water and production resources are wasted
Solution Approach 1:
The system uses real-time feedback from density meters and flow meters to continuously monitor solid content during extraction. When the solid content approaches the desired range, the controller automatically stops the extraction process, preventing excessive solid content development. This eliminates the need to discard over-extracted liquid extract, thereby conserving water and production resources while maintaining extraction quality.
Solution Approach 2:
The system performs preliminary action by predicting when the liquid extract will reach the desired solid content based on real-time monitoring trends. The controller proactively stops the extraction process before the solid content becomes excessive, preventing the need to discard the liquid extract. This preliminary intervention conserves water and resources while maintaining product quality.
3Productivity
If real-time monitoring and control systems are added to the extraction process, then production efficiency and quality stability are improved, but device complexity increases
Solution Approach 1:
The system employs multi-functional instrumentation where density meters and flow meters serve multiple purposes: they monitor solid content, track extraction progress, and provide data for automatic control decisions. The controller integrates multiple functions including receiving signals from various sensors, processing data, and managing extraction parameters. This multi-functionality reduces the need for separate dedicated components, thereby improving production efficiency while limiting the increase in device complexity.
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 system enables efficient production of liquid extract with stable flavor and aroma by stopping the extraction process when desired solid content is reached, reducing waste and improving production efficiency.
Implementation Method 1
a density meter positioned in the second flow path for measuring the solid content concentration in the liquid extract in the second flow path, wherein the density meter measures the refractive index of the liquid extract and calculates the Brix of the liquid extract based on the measured refractive index
Data Source
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AI summary
ABSTRACT A liquid extract production system capable of efficiently producing a liquid extract. The system comprising an extractor for extracting a liquid extract from extraction raw materials, a liquid extract tank for storing the liquid extract, a flow path of liquid extract that connects the extractor and the liquid extract tank, a flow meter for measuring the flow rate of the liquid extract provided in the flow path, a density meter for measuring the solid content concentration of the liquid extract provided in the flow path, a solid content calculation unit for calculating the solid content included in the liquid extract that flowed through the flow path based on the measured flow rate and solid content concentration, and a liquid transfer controller for controlling the transfer of liquid extract from the extractor to the liquid extract tank based on the calculated solid content.