Microwave Drying System for Dry Sausage Moisture Control
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Solution Overview
Problem
Current dry sausage manufacturing processes are capital intensive, require extensive time, and limit production capacity due to the need for large drying spaces and the inefficiency of traditional drying methods, which also result in inconsistent product quality and the inability to slice the sausage before drying.
Innovation Solution
A process utilizing a microwave drying system combined with controlled conditioned air flow to reduce moisture content in dry sausage, allowing for slicing before drying and achieving a desirable moisture-to-protein ratio, thereby reducing processing time and increasing product flowability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional air drying methods are used, then the sausage can be dried to desired moisture content, but the processing time extends to days or weeks and requires large drying spaces
Solution Approach 1:
The patent changes the drying parameters by introducing microwave radiation alongside conventional air drying. The microwave component significantly increases the drying rate by directly heating and evaporating moisture within the sausage matrix, reducing the process from days/weeks to minutes while maintaining precise moisture content control through monitored drying cycles.
Solution Approach 2:
The patent merges two drying methods: conventional air drying and microwave drying. The air flow provides gentle drying and moisture removal, while the microwave component accelerates the process by generating internal heat. This combination achieves both the desired moisture content reduction and dramatically shortened processing time.
2Manufacturing precision
If traditional air drying methods are used, then the sausage can be dried to desired moisture content, but the production capacity is limited by the amount of space allocated to drying
Solution Approach 1:
The patent changes the drying parameters by introducing microwave radiation alongside conventional air drying. The microwave component significantly increases the drying rate by directly heating and evaporating moisture within the sausage matrix, reducing the process from days/weeks to minutes while maintaining precise moisture content control through monitored drying cycles.
Solution Approach 2:
The patent replaces the purely mechanical/physical air drying system with a combination that includes microwave energy. This substitution of the drying mechanism from passive air circulation to active microwave heating dramatically increases the drying rate and allows for higher production capacity in the same space.
3Ease of manufacture
If the sausage is sliced after drying, then the casing can be removed after heat treating, but the production process cannot optimize for sliced product preparation
Solution Approach 1:
The patent applies preliminary action by slicing the sausage before the drying process begins. This allows the sausage to be prepared in its final sliced form for immediate use or packaging, and the drying can then be optimized for sliced products with greater surface area exposure, improving both manufacturing efficiency and product readiness.
4Manufacturing precision
If conventional drying processes are used, then the sausage can be cured and dried, but the process is capital intensive and requires tremendous product to be held in process
Solution Approach 1:
The patent changes the drying parameters by introducing microwave radiation alongside conventional air drying. The microwave component significantly increases the drying rate by directly heating and evaporating moisture within the sausage matrix, reducing the process from days/weeks to minutes while maintaining precise moisture content control through monitored drying cycles.
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 significantly reduces processing time and costs while maintaining product quality, enabling the production of a more flowable and consistent dry sausage product that can be efficiently packaged and used in various food applications.
Implementation Method 1
a process utilizing a microwave drying system combined with controlled conditioned air flow to reduce moisture content in dry sausage
Implementation Method 2
controlled conditioned air flow to reduce moisture content in dry sausage
Implementation Method 3
controlled conditioned air flow
Data Source
AI summary
A process for manufacturing dry sausage. The process includes preparing a dry sausage meat mixture, stuffing the mixture into a casing or mold, fermenting the mixture, heat treating the mixture, cooling the mixture to a temperature sufficiently low to permit slicing, slicing the sausage, placing the sausage onto a conveyor, and passing the conveyor and sausage through a chamber. The process also includes introducing a supply of conditioned air into the chamber, the air having a relative humidity below about 60% and a temperature in the range of at least about 40° F. to 130° F., and introducing a supply of microwaves into the chamber. The air supply and microwaves are selected to reduce the moisture content of the meat to a predetermined moisture to protein ratio.