Single-Vessel Malted Beverage Drying Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing processes for manufacturing malted beverages are costly and time-consuming due to the use of multiple vessels for mixing, drying, and granulation, which increases apparatus costs, servicing time, and cleaning requirements.
Innovation Solution
A process that combines mixing, drying, and granulation in a single vessel at reduced pressure, using a sugar solution to facilitate optimal flavor and color development, with heating and pressure conditions that accelerate drying and granulation, allowing for the production of a dried malted beverage product with minimal moisture content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple vessels are used for mixing, drying, and granulation, then the quality of the malted beverage product is maintained, but the apparatus cost, running cost, and servicing time increase
Solution Approach 1:
The patent combines mixing, drying, and granulation operations into a single vessel system. The mixer-vessel serves multiple functions: it mixes ingredients initially, then dries the mixture under reduced pressure, and finally granulates the dried product through agitation. This consolidation eliminates the need for separate vessels for each operation, reducing apparatus complexity and cost while maintaining product quality through controlled processing conditions.
Solution Approach 2:
The single mixer-vessel is designed to perform multiple functions sequentially: mixing of ingredients, drying under reduced pressure, and granulation of the dried product. The vessel's design accommodates different operational modes (mixing, drying, granulation) through appropriate agitation and pressure control, making it a universal processing unit that replaces multiple specialized vessels.
2Reliability
If multiple vessels are used for mixing, drying, and granulation, then the processing functions are separated, but the cleaning time and servicing requirements increase
Solution Approach 1:
By combining mixing, drying, and granulation in one vessel, the patent reduces the total number of vessels that require cleaning and servicing. The single-vessel design means fewer seals, connections, and transfer points to maintain, thereby reducing cleaning time and servicing requirements despite performing multiple functions.
3Device complexity
If a single vessel is used for mixing, drying, and granulation, then the apparatus cost and servicing time are reduced, but the process requires integration of multiple functions in one device
Solution Approach 1:
The mixer-vessel is designed with universal capabilities to perform mixing, drying under reduced pressure, and granulation. The system achieves adaptability through controlled agitation speeds and reduced pressure conditions that enable different operational modes within the same vessel, demonstrating that simplified apparatus can still provide versatile functionality.
4Manufacturing precision
If traditional drying methods are used, then the drying function is achieved, but the process time and energy consumption increase
Solution Approach 1:
The patent utilizes phase transition of water from liquid to vapor under reduced pressure conditions. By operating the drying process under reduced pressure, water evaporates at lower temperatures and faster rates, significantly reducing drying time and energy consumption compared to conventional atmospheric drying methods.
Solution Approach 2:
The patent replaces conventional mechanical drying systems with a vacuum-based drying approach. By using reduced pressure to facilitate evaporation rather than relying solely on mechanical heating and air circulation, the system achieves faster drying with lower energy input.
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 reduces production costs, increases throughput, and shortens servicing time, while maintaining the taste and texture profiles of traditional malted beverages, with the ability to produce a high-quality dried product efficiently in a single vessel.
Implementation Method 1
subjecting the mixture in the vessel to heat at a lowered pressure so as to effect drying and granulation of the mixture
Implementation Method 2
subjecting the mixture in the vessel to heat at a lowered pressure so as to effect drying
Data Source
Figure 1
Figure 2~3
AI summary
A process for preparing a dried malted beverage product. The process comprises: a) mixing together solid and liquid constituents of the beverage product in a single vessel so as to form a mixture; b) subjecting the mixture in the vessel to heat at a lowered pressure so as to effect drying and granulation of the mixture and form the dried malted beverage product; and c) discharging the dried malted beverage product from the vessel. The process is carried out in a single vessel for mixing, drying and granulation. Suitable solid constituents include one or more selected from malt extract powder, maltodextrin, cocoa powder, milk powder /dairy creams, whey powder, salt, flavours, natural colours and mixtures thereof. Suitable liquid constituents include one or more selected from water, malt extract, caramelised sugar syrup, natural colours, flavours, soya lecithin, maltodextrin, and mixtures thereof.