Mould Drum Air Ejection Pressure Control for Food Products
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Solution Overview
Problem
Existing food product moulding installations face challenges in efficient operation, particularly in maintaining optimal ejection of moulded products without excessive compressed air usage or product damage, and ensuring uniformity in weight and quality of the moulded products.
Innovation Solution
A moulding installation with a controller that automatically adjusts the ejection air pressure based on input parameters such as fill pressure, volumetric flow rate, and rotational speed, using a pressurized air system with air permeable mould cavities and a computerized controller to optimize ejection conditions for different foodstuff masses and mould drums.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressurized air is used to eject moulded food products from mould cavities, then ejection effectiveness is improved, but compressed air consumption increases and product damage may occur
Solution Approach 1:
The system dynamically adjusts the ejection air pressure parameter based on the specific food product being manufactured. The controller receives product identification and automatically sets optimal ejection pressure parameters, preventing both excessive pressure (which causes product damage) and insufficient pressure (which causes ejection failure). This resolves the contradiction by optimizing the pressure parameter for each product type.
Solution Approach 2:
The system incorporates feedback mechanisms where the controller monitors ejection effectiveness and adjusts air pressure accordingly. By detecting whether products are properly ejected and adjusting the pressurized air delivery in response, the system minimizes compressed air consumption while maintaining reliable ejection, resolving the contradiction between ejection effectiveness and air consumption.
2Productivity
If manual adjustment of ejection air pressure is used, then system complexity is reduced, but operational efficiency decreases and air pressure optimization is difficult
Solution Approach 1:
The system performs self-adjustment of ejection air pressure based on automatic product identification. When a product is placed on the conveyor, the system automatically detects the product type and adjusts the ejection pressure without requiring manual intervention. This self-service capability improves operational efficiency while the automation is integrated into the existing control infrastructure, keeping complexity manageable.
Solution Approach 2:
The control system serves multiple functions: it identifies products, determines optimal parameters, adjusts ejection pressure, and coordinates with the manufacturing process. By consolidating these functions into a single multi-functional controller, the system achieves high operational efficiency without proportionally increasing complexity, as the same control unit handles multiple tasks.
3Reliability
If ejection air pressure is increased to prevent product sticking, then ejection reliability is improved, but product damage increases and air waste occurs
Solution Approach 1:
The system dynamically changes the ejection air pressure parameter based on product characteristics. Different food products have different sticking tendencies and pressure tolerances. The controller automatically selects and applies the appropriate pressure parameter for each product type, ensuring reliable ejection without causing product damage. This resolves the contradiction by optimizing pressure for each specific product rather than using a fixed high pressure for all products.
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
Enhances operational efficiency, reduces compressed air wastage, and ensures consistent product quality by automatically setting ejection air pressure, preventing product sticking and damage, and allowing for seamless transitions between different food products and mould configurations.
Implementation Method 1
a pressurized air source that is operable to feed pressurized air at a controllable ejection air pressure thereof to one or more of the air ducts associated with one or more mould cavities
Implementation Method 2
The air causes a reduction or elimination of stick between the moulded food product and the mould cavity surface and may cause an effective ejection force on the food product
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A moulding installation and method for moulding food products from a pumpable foodstuff mass. A revolving mould drum is provided with multiple mould cavities and a mass feed member is arranged at a fill position to transfer foodstuff mass into passing mould cavities. Said foodstuff mass forms a food product in said mould cavity. A pressurized air food product ejection system comprises air ducts in the mould drum that extend to said cavities and at least a portion of the surface delimiting a mould cavity is air permeable. Said ejection system further comprises a pressurized air source to feed pressurized air at a regulated ejection air pressure thereof to said air ducts. A controller is adapted to input at least one target parameter related to filling of the mould cavities with said foodstuff mass via said mouth of the mass feed member. The controller is adapted to automatically set an ejection air pressure by said pressurized air source on the basis of the inputted target parameter.