Multi-Layer Extrusion for Nutritional Preservation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for manufacturing pet chews often result in the degradation of nutritional additives like vitamins, minerals, and herbs due to elevated temperatures and shear conditions, leading to reduced nutritional effectiveness in the final product.

Innovation Solution

The use of multiple extruders of different sizes, each operating under specific processing conditions such as varying barrel temperatures, residence times, and shear rates, allows for the differential processing of ingredients, minimizing thermal and shear history, and enabling the formation of multi-layered pet chews with preserved nutritional value.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a single extrusion process is used to manufacture pet chews, then production efficiency is improved, but nutritional additives degrade due to elevated temperatures and shear conditions

Engineering Contradiction:

Improveproduction efficiencyVSAvoidthermal degradation of nutritional additives

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent divides the extrusion process into multiple separate extruders, each handling specific compositions with different thermal and shear sensitivities. This segmentation allows independent optimization of processing parameters for each extruder, preventing degradation of sensitive nutritional additives while maintaining overall production efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different processing conditions (temperature, shear rate, residence time) to different extruders based on the specific requirements of each composition. Extruders processing thermally sensitive materials operate at lower temperatures and shorter residence times, while other extruders can use higher temperatures for efficient processing of less sensitive materials.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If multiple extruders with different processing parameters are used, then nutritional additive integrity is preserved, but device complexity increases

Engineering Contradiction:

Improvethermal degradation of nutritional additivesVSAvoidnumber of extruders and processing parameters

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent combines multiple extruders with differentially controlled processing parameters into a unified extrusion system that produces a multi-layered pet chew. The extruders are merged at the die assembly, where their outputs are combined to form the final product structure, integrating complexity into a coordinated system rather than separate operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent systematically varies key processing parameters (barrel temperature, shear rate, residence time) across different extruders to optimize each composition's processing. This parameter differentiation is controlled through adjustable settings on each extruder, allowing precise management of thermal and mechanical history for each material layer.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If separate extruders process different compositions, then processing conditions can be optimized for each material, but manufacturing complexity increases

Engineering Contradiction:

Improveprocessing condition optimizationVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent employs multiple extruders that can each handle different composition types (thermally sensitive, thermally insensitive, high-fat, low-fat), making the system universally capable of processing various material requirements. Each extruder serves multiple functions by adjusting its parameters to match the specific needs of different compositions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent implements dynamic control of processing parameters on each extruder based on the specific composition being processed. Barrel temperatures, shear rates, and residence times are adjusted in real-time according to material properties, allowing the manufacturing system to adapt to different material requirements while maintaining operational efficiency.

Inventive Principle:

Principle #15Dynamics

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 effectively preserves the nutritional and therapeutic value of additives by processing thermally sensitive materials under optimal conditions, ensuring their efficient delivery and maintaining their integrity in the final pet chew product.

Implementation Method 1

The first extruder is configured to operate at a selected barrel temperature (BT1)

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a selected shear rate (γ1)

Methodology Applied

Scientific EffectShear stress: Shear Stress

Data Source

PatentUS8771775B2Multi layer extrusion

Publication Date: 2014.07.08 TFH PUBLICATIONS INC

AI summary

A pet chew may be manufactured by co-extruding multiple compositions to form a layered construction. Separate extruders may be provided to tailor processing conditions to heat and/or shear sensitive compositions, such as nutritional additives, and the respective extrudates may be combined such that relatively higher levels of nutritional compositions may be provided as an outer layer.