Mould Drum Sequential Filling for Uniform Food Product Moulding
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Solution Overview
Problem
High-capacity drum moulding installations for food products, such as meat patties, face issues with non-uniformity in shape and composition due to simultaneous filling of multiple mould cavities, leading to variations in density and taste, which are particularly problematic at high production speeds.
Innovation Solution
The method involves controlling the drum rotation and pump operation to ensure sequential filling of mould cavities, with a pause between each filling event, using a mass feed member with a singular slot mouth and a pump that maintains a target pressure, allowing only one cavity to be filled at a time to achieve uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple mould cavities are filled simultaneously to increase production capacity, then productivity is improved, but manufacturing precision deteriorates due to non-uniformity in shape and composition
Solution Approach 1:
The invention segments the filling process by arranging mould cavities in sequential positions along the drum circumference, so that cavities are filled one after another rather than simultaneously. This segmentation allows each cavity to receive consistent mass pressure and filling conditions, thereby maintaining manufacturing precision while still achieving high productivity through continuous sequential filling.
2Productivity
If pump operates continuously at high pressure to maintain filling speed, then productivity is improved, but manufacturing precision deteriorates due to pressure drops affecting uniformity
Solution Approach 1:
The pump operation is designed with periodic action, where the pump pressure is synchronized with the sequential filling of mould cavities. The pump maintains high pressure during each filling event and allows pressure recovery between filling events. This periodic operation ensures that each cavity receives consistent pressure for uniform filling, while the overall high productivity is maintained through the continuous cyclic nature of the process.
3Productivity
If drum rotation speed is increased to boost production capacity, then productivity is improved, but manufacturing precision deteriorates due to reduced filling time per cavity
Solution Approach 1:
The invention maintains continuity of useful action by ensuring that the sequential filling process operates without interruption. The drum rotates continuously at high speed, and the pump continuously supplies mass to each cavity in sequence. This continuous operation allows the system to achieve high productivity while maintaining manufacturing precision, as each cavity receives complete and consistent filling despite the high rotation speed.
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 enhances the uniformity of food products by ensuring each mould cavity is filled independently, reducing pressure drops and maintaining consistent mass pressure, resulting in more consistent shape, density, and taste across the batch.
Implementation Method 1
operating the pump so as to feed ground meat mass to the mass feed member and establish a ground meat mass pressure in the chamber of said mass feed member
Implementation Method 2
transfer of pressurized ground meat mass via the mouth into each passing mould cavity
Data Source
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AI summary
A method for moulding food products from a pumpable foodstuff mass, wherein use is made of a moulding device with a mould drum (22) provided with mould cavities (25) having a fill opening for the introduction of foodstuff mass. A mass feed member (15) transfers mass into passing mould cavities. A pump (5) is connected to the inlet of the mass feed member. Product removal takes place downstream of the fill position. The operation of the pump and the rotation of the mould drum are controlled in combination with the design of the mould cavities pattern on the drum and of the mouth (18) of the mass feed member such that in the method all mould cavity filling events during a revolution of the mould drum are performed in sequential order.