Multi-Layer Pet Treat Injection Molding Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing pet treats or chews lack efficiency in manufacturing multi-component products with varied physical, nutritional, and sensory properties, limiting production capacity and diversity in pet chew options.
Innovation Solution
A method involving injection molding and rotary platen technology to form multi-component pet treats by layering edible compositions with different properties, such as texture, flavor, and nutritional content, allowing for the creation of diverse and attractive treats through the use of edible components like starch, protein, and synthetic polymers, while maintaining nutritional value and preventing degradation during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional single-component molding methods are used, then the manufacturing process is simple, but the product diversity and nutritional variety are limited
Solution Approach 1:
The patent divides the treat into multiple distinct layers, each with different compositions (e.g., starch-based layer, protein-based layer, vegetable matter layer). This segmentation allows each layer to provide different nutritional and textural properties, thereby increasing product diversity without requiring a completely new molding system.
Solution Approach 2:
The patent uses composite materials by combining different edible compositions (starch, protein, vegetable matter) into a single multi-layered product. Each layer maintains its unique properties while being integrated into one treat, achieving versatility through material composition rather than process complexity.
2Adaptability or versatility
If multi-component layering is implemented, then nutritional variety and appeal are enhanced, but production efficiency and output volume decrease
Solution Approach 1:
The patent employs a continuous molding process where multiple layers are formed sequentially in an uninterrupted operation. The molding machine deposits each layer continuously as it moves along the production line, eliminating stopping and starting between layers, thus maintaining high production output while achieving nutritional variety.
Solution Approach 2:
The patent prepares different edible compositions in advance and positions them in ready-to-use forms (e.g., prepared starch mixture, prepared protein mixture, prepared vegetable matter) before the molding process begins. This preliminary preparation allows the multi-layered treat to be assembled quickly during production, maintaining high productivity.
3Ease of operation
If heat treatment is applied to adjust texture, then chewability is improved for different age groups, but degradation of heat-sensitive nutrients occurs
Solution Approach 1:
The patent applies different heat treatments to different layers based on their specific requirements. For example, the starch-based layer may undergo gelatinization at higher temperatures to achieve desired chewability, while heat-sensitive layers (containing vitamins or fresh vegetable matter) are either placed in the mold after cooling or subjected to minimal heat treatment, preserving their nutritional integrity.
Solution Approach 2:
The patent controls temperature parameters during molding and post-processing to achieve appropriate texture without degrading nutrients. By carefully adjusting molding temperature, cooling rate, and any subsequent heat treatment parameters, the treat achieves desired chewability for different age groups while maintaining nutritional content.
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
Enables high-volume production of multi-component pet treats with varied properties, enhancing appeal and nutritional benefits, and extending the life of the treats by allowing pets to choose between different layers, thus addressing the need for more efficient and diverse manufacturing techniques.
Implementation Method 1
forming a first shape from a first material in a first mold cavity, followed by moving the first molded shape to a second mold cavity to form a second material adjacent and in contact with at least a portion of the first material
Implementation Method 2
A first mold cavity and second mold cavity may be provided on a rotary platen or turntable capable of indexing the mold cavities into position to receive the injection nozzles of one or more injection molding machines
Implementation Method 3
The two or more materials may be formed to lie adjacent one another in layered, surrounding, partially surrounding, abutting or interlocked fashion
Data Source
AI summary
A process for manufacturing a multi-layer pet treat or animal chew comprising the indexing of a moveable mold portion into alignment with the first of a plurality of stationary mold portions fed a first composition by a first injection molding unit to form a first layer in a cavity space formed by the aligned mold portions. The moveable mold portion and the first layer may be indexed to align with a second of a plurality of stationary mold portions fed a second composition by a second injection molding unit to form a second layer over said first in the cavity space formed by the aligned mold portion. The compositions fed by the first and second injection molding units may both be edible. In a further aspect, multi-component pet treats may be provided formed from two materials which may be different in physical, optical, sensual, nutritional or compositional properties. One of the materials may specifically include textured vegetable protein.