Modular Rotor-Stator Aeration Apparatus for Food Products
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Solution Overview
Problem
Existing aeration systems for food products are limited in modularity, homogeneous mixing, and bubble size control, leading to inefficiencies and instability in aerated products, particularly when incorporating edible grains or particles.
Innovation Solution
A modular apparatus with multiple pairs of rotor-stator combinations and a gas injector system that allows for flexible adjustment of bubble size and the incorporation of additional compositions, ensuring homogeneous aeration and stable product distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single rotor-stator mixing apparatus is used, then the structure is simple, but the modularity and flexibility are limited
Solution Approach 1:
The mixing apparatus is divided into multiple independent rotor-stator assemblies that can be arranged in series within a common housing. Each rotor-stator assembly functions as a modular unit with its own rotor and stator components, allowing flexible configuration for different mixing and aeration requirements while maintaining overall system coherence.
2Manufacturing precision
If mechanical aeration with rotor-stator is used, then bubble size can be controlled, but homogeneous mixing is insufficient
Solution Approach 1:
The mixing process is divided into multiple stages with separate rotor-stator assemblies, each contributing to progressive mixing and aeration. This segmented approach ensures thorough homogeneous mixing while controlling bubble size at each stage through adjustable rotor-stator clearances and speeds.
Solution Approach 2:
The apparatus allows independent adjustment of operational parameters (rotor speed, stator clearance, gas flow rate) for each rotor-stator assembly to optimize both mixing homogeneity and bubble size distribution. By varying these parameters across different stages, the system achieves both thorough mixing and precise bubble control.
3Adaptability or versatility
If multiple compositions are mixed in a single apparatus, then versatility is improved, but mixing homogeneity deteriorates
Solution Approach 1:
Multiple compositions can be introduced at different stages through separate inlets positioned between rotor-stator assemblies. Each composition is mixed homogeneously in its designated stage before proceeding to the next stage, ensuring that all compositions are thoroughly integrated while maintaining overall mixing homogeneity through the modular architecture.
4Productivity
If conventional aeration systems are used, then the apparatus is compact, but productivity and shelf-life are reduced
Solution Approach 1:
The multi-stage rotor-stator configuration provides progressive aeration and mixing throughout the product flow path, achieving superior aeration efficiency and product stability. The segmented approach allows each stage to contribute to both productivity and shelf-life through controlled shear forces and gas incorporation.
Solution Approach 2:
By optimizing operational parameters across multiple stages (rotor speeds, clearances, gas flow rates), the system achieves enhanced aeration efficiency that directly improves productivity while creating a more stable product structure that extends shelf-life through better bubble distribution and matrix integration.
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 apparatus achieves stable, homogeneous aeration with adjustable bubble sizes, extending shelf-life and reducing stabilizer usage, while being cost-effective and suitable for industrial-scale applications.
Implementation Method 1
a gas injector for injecting, at an upstream position relative to the first pair of a rotor and a stator, a gas in the food product to be aerated
Implementation Method 2
The mixing apparatus mechanically disintegrates large gas bubbles into very small bubbles that are trapped within the food matrix
Implementation Method 3
The mixing apparatus mechanically disintegrates large gas bubbles into very small bubbles that are trapped within the food matrix
Data Source
AI summary
An apparatus (300) for aerating a food product, (200, 300) comprising a housing (10) with an inlet (100) for the food product and an outlet for the aerated food product, and, within the housing (10), first and second pairs (210, 220, 240) of a rotor and a stator each having complementary toothed rims orientated in opposition in the axial direction, and a gas injector (1) for injecting, at an upstream position relative to the first pair (210, 220) of a rotor and a stator, a gas in the food product to be aerated, wherein a further inlet (310) is provided for injecting, at a position between a pair (210, 220) and an adjacent pair (240) of a rotor and a stator, an additional composition to be mixed with the food product.