Method and apparatus for producing instant fried noodles
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Solution Overview
Problem
Existing methods for producing instant noodles result in a noodle lump with a poorly coated dense portion due to uneven frying, leading to an unappetizing distribution of ingredients.
Innovation Solution
A method involving a two-stage frying process where the retainer is partially dipped in frying oil at a controlled flow rate and surface level, followed by complete immersion, ensuring uniform coating and reducing the difference in density between the upper and lower portions of the noodle lump.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the whole lidded retainer filled with noodle strings is dipped in frying oil at a time, then the frying process is simple and fast, but the noodle strings float and collect near the lid causing poor oil coating in dense portions
Solution Approach 1:
The frying process is divided into two distinct stages: first frying where only the lower portion of the retainer is dipped in oil, and second frying where the entire retainer is dipped. This segmentation allows different parts of the noodle strings to be fried at different times, preventing them from floating and collecting near the lid while ensuring uniform oil coating in dense portions.
Solution Approach 2:
The first frying stage serves as a preliminary action that fixes the lower portion of the noodle strings to the retainer bottom before the second frying stage. This preliminary fixation prevents the noodle strings from floating during the subsequent deep frying, ensuring proper oil coating distribution.
2Manufacturing precision
If the retainer is partially dipped in frying oil, then the noodle strings adhere to the bottom and swell upward improving oil coating, but the frying process becomes more complex
Solution Approach 1:
The retainer is designed with a movable lid that can be opened or closed based on the frying stage. During first frying, the lid is open to allow partial dipping; during second frying, the lid is closed for complete immersion. This dynamic adjustment simplifies the overall process while achieving uniform oil coating.
3Productivity
If high flow rate frying oil is supplied to the upstream portion, then the frying process is efficient, but the noodle lump shape is impaired by flow resistance
Solution Approach 1:
Different flow rates of frying oil are supplied to different portions of the frying tank. The upstream portion receives oil at a flow rate of 90% or less of the downstream portion's flow rate. This local quality adjustment ensures that the noodle lump shape is not impaired by excessive flow resistance while maintaining overall frying efficiency.
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 method produces a noodle lump with a homogeneous texture and reduced density difference, enhancing the frying efficiency and ensuring that ingredients are evenly distributed, improving the overall quality and appearance of the instant noodles.
Implementation Method 1
the frying oil blows up through evaporation of moisture from the noodle strings dipped in the frying oil
Implementation Method 2
dipping, in frying oil held in a frying oil tank, a retainer holding a group of noodle strings having been gelatinized
Data Source
AI summary
Frying is performed in two stages so as to dip a retainer in frying oil at a prescribed dipping ratio and then to dip the whole of the retainer in the frying oil, and in addition, flow rates of the frying oil supplied from an upstream side and a downstream side of a frying oil tank and a surface level of the frying oil are controlled. Therefore, a noodle lump can be prevented from peeling off and floating from the bottom of the retainer before fixing the shape of the noodle lump due to a pressure applied by the frying oil so as not to impair the shape of the noodle lump, and as a result, frying efficiency or production efficiency can be improved. Besides, a noodle lump that has a very small number of coarse or dense portions in a distribution of noodle strings can be stably produced.