Offset Roller Pair for Uniform Chewing Gum Sizing
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Solution Overview
Problem
Traditional gum processing methods are time-consuming and require significant machinery, often resulting in non-uniform outputs and high energy consumption, particularly due to the need for multiple size reduction rollers and high shear extruders which can damage shear-sensitive ingredients.
Innovation Solution
A method using a pair of rollers with a horizontally and vertically offset arrangement to size gum into a uniform sheet, eliminating the need for multiple rollers and high shear extruders, allowing for wider gum production with reduced energy consumption and preserving sensitive ingredients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multiple size reduction rollers are used to reduce gum thickness, then the gum can be reduced to desired thickness, but the process becomes time-consuming and energy-intensive
Solution Approach 1:
The patent combines multiple size reduction rollers into a single pair of rollers that perform the entire thickness reduction process in one operation. The first and second rollers are positioned to receive gum material and reduce its thickness simultaneously, eliminating the need for sequential rolling operations through multiple rollers, thereby reducing processing time while maintaining thickness uniformity.
Solution Approach 2:
The patent divides the gum processing into distinct functional zones: a first region where gum material is received and a second region where thickness reduction occurs. This spatial segmentation allows the single pair of rollers to perform multiple functions (receiving, reducing, and uniformizing thickness) that traditionally required multiple sequential operations, reducing overall processing time.
2Manufacturing precision
If high shear extruders are used to force gum through small orifices, then the gum can be formed into desired shapes, but shear-sensitive ingredients are damaged
Solution Approach 1:
The patent replaces the high-shear mechanical action of traditional extruders with a gentle rolling mechanism. Instead of forcing gum through small orifices using high shear forces, the gum material is passed between the first and second rollers which gradually reduce thickness through contact pressure, preserving shear-sensitive ingredients while achieving the desired shape and size control.
Solution Approach 2:
The patent changes the mechanical parameters from high shear force to low shear contact pressure. The rollers are designed to apply gradual, distributed pressure across the gum material surface, reducing thickness through compression rather than shear, thereby protecting shear-sensitive ingredients while maintaining precise control over final gum dimensions.
3Manufacturing precision
If a series of sizing rollers are used to progressively reduce gum thickness, then the gum can be reduced from thick to thin, but the equipment complexity increases
Solution Approach 1:
The patent merges the functions of multiple sizing rollers into a single pair of rollers. The first and second rollers are positioned and configured to perform the entire thickness reduction sequence that would traditionally require multiple rollers, simplifying the equipment while maintaining precise thickness control through their specific geometric arrangement and gap settings.
Solution Approach 2:
The single pair of rollers is designed to perform multiple functions simultaneously: receiving thick gum material, progressively reducing thickness, and producing uniformly thin gum sheets. This multi-functionality eliminates the need for separate receiving rollers, intermediate sizing rollers, and finishing rollers, thereby reducing device complexity while maintaining manufacturing precision.
4Productivity
If traditional rolling and scoring lines with multiple rollers are used, then gum can be processed into final product, but energy consumption is high
Solution Approach 1:
The patent combines multiple energy-intensive rolling operations into a single pair of rollers that complete the entire thickness reduction process in one pass. By eliminating the need for multiple sequential rolling operations through additional rollers, the system maintains high productivity while significantly reducing total energy consumption associated with driving multiple motorized rolling components.
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 reduces energy consumption by up to 1/30, preserves shear-sensitive ingredients, and enables the production of wider gum sheets with minimal thickness variance, simplifying the processing and packaging of gum products.
Implementation Method 1
compressing the non-uniform mass to form the sheet of gum structure
Implementation Method 2
driving the pair of rollers in opposite directions to pull the non-uniform gum mass through a gap between the pair of rollers
Data Source
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AI summary
Gum manufacturing methods and systems are provided including a set of rollers for compressive forming and sizing of a chewing gum in a single step. Heat transfer systems and methods for altering a temperature of chewing gum are also provided.