Moulding Device with Segmented Cells for Food Products
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing moulding devices for food products often result in non-uniform organoleptic properties and appearance due to variations in dimensions caused by shrinkage during heat application, leading to inconsistent final products, especially in grilled meat products like hamburgers.
Innovation Solution
A moulding device with a mould cavity configured into multiple moulding cells that allow for stepwise dynamic filling, controlling fibre orientation and air inclusion, and featuring flow restricting means like protrusions to reduce appendage formation and enhance uniform shrinkage, resulting in a more consistent product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a mould cavity is filled dynamically during movement, then productivity is improved, but manufacturing precision deteriorates due to non-uniform fibre orientation and air inclusion
Solution Approach 1:
The mould cavity is divided into multiple moulding cells arranged in the movement direction. Each cell acts as an independent filling zone, allowing the mass to be distributed uniformly across multiple compartments during dynamic filling. This segmentation prevents uncontrolled mass flow and air entrapment while maintaining high production efficiency through continuous operation.
Solution Approach 2:
Flow restricting means are introduced at specific locations within the mould cavity to control mass flow characteristics in different zones. The flow restriction is applied locally at the inlet region where mass enters the moulding cells, creating controlled flow conditions that ensure uniform fibre orientation and consistent filling patterns across all cells without compromising overall productivity.
2Productivity
If the mould cavity is filled quickly during movement, then productivity is improved, but manufacturing precision worsens due to air entrapment and non-uniform filling
Solution Approach 1:
Dividing the cavity into multiple moulding cells allows rapid filling to be distributed across several small compartments rather than one large cavity. This enables faster filling speeds while maintaining uniformity, as each small cell can be filled quickly and completely without trapping air that would occur in a single large cavity filled at the same speed.
Solution Approach 2:
Flow restricting means are positioned at the inlet zone to control the rate and pattern of mass entry into the moulding cells. This local flow control ensures that mass is distributed uniformly across all cells during rapid filling, preventing air entrapment and ensuring consistent filling quality throughout the cavity while maintaining high filling speeds.
3Ease of manufacture
If fibre orientation is uncontrolled during filling, then ease of manufacture is improved, but manufacturing precision deteriorates due to non-uniform shrinkage
Solution Approach 1:
Flow restricting means are implemented at the inlet region to control fibre orientation locally as mass enters the moulding cells. This local control mechanism guides fibres to align uniformly in the desired direction during filling, ensuring consistent shrinkage patterns during subsequent cooking without complicating the overall manufacturing process.
Solution Approach 2:
The segmentation into multiple moulding cells creates discrete zones where fibre orientation can be controlled independently. Each cell develops uniform fibre alignment through the flow restriction, and when all cells are combined, the overall product exhibits consistent fibre orientation and uniform shrinkage characteristics.
4Productivity
If appendage formation occurs during filling, then productivity is improved through complete cavity filling, but manufacturing precision worsens due to dimensional inconsistency
Solution Approach 1:
Dividing the cavity into multiple moulding cells prevents appendage formation by providing multiple discharge paths for excess mass at the cavity outlet. During dynamic filling, mass that would otherwise form appendages in a single large cavity is instead distributed evenly across the cell boundaries, ensuring complete cavity utilization without dimensional inconsistencies.
Solution Approach 2:
Flow restricting means are positioned to control mass flow specifically at the inlet zone where appendages typically form. This local flow control prevents excess mass from accumulating and forming appendages while still allowing complete filling of all moulding cells, maintaining both productivity and dimensional consistency.
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 solution achieves uniform organoleptic and appearance characteristics in moulded products, reducing cooking time and retaining moisture, resulting in a tender meat product with excellent bite and consistent browning.
Implementation Method 1
The bottom of the mould cavity of the moulding member is made from a porous material or the moulding element is made of a porous material. A structure having passages that open into the mould cavity, such as said porous structure may assist in de-aeration during filling by allowing air to escape from the mould cavity when it is being filled through the passages (pores) and/or assist in removal of moulded products from a mould cavity at a product release position by blowing air through the passages into the mould cavity.
Data Source
Figure 1
Figure 2a~2d
Figure 3a~3d
AI summary
A moulding device (10) for moulding three dimensional products from a mass of foodstuff starting material suitable for consumption, comprises a moulding member (16) having a moulding surface which is provided with at least one mould cavity which is delimited by a bottom and a peripheral wall defining a cavity opening in the moulding surface. The mould cavity has a cavity height which is defined between the bottom and the cavity opening. The moulding member can be moved along a movement path from a fill position for filling the mass into the mould cavity to a product release position for releasing a moulded product from the mould cavity and from the product release position to the fill position. A mass distribution device (18) is arranged at the fill position along the movement path of the moulding member for filling the mass into the mould cavity. The mass distribution device is configured to contact the moulding member in a sealing manner while the moulding member is moved. The mould cavity is provided with walls which are configured to define a plurality of moulding cells within the mould cavity. At least two of the moulding cells are arranged behind one another in the direction of the movement path of the moulding member. Each wall has a height which is 10-100% of the cavity height of the mould cavity.