Oral Product Forming Rollers for Uniform Extrudate Cutting
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Solution Overview
Problem
Existing methods for cutting extruded material into oral products, such as chewing gum or lozenges, often result in deformation and uneven surfaces due to varying velocities of the extruded material, leading to undesirable dimensions and textures.
Innovation Solution
A machine with forming rollers and a cutting section that maintains and reshapes the extrudate's cross-sectional shape, using a drive motor and gear train to synchronize roller speeds and a programmable logic controller to ensure uniform cutting, along with a cutting ledger for temperature control and a rotary cutting blade actuated by sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cutting methods are used on extruded material, then the cutting operation can be performed, but the extruded material deforms and produces uneven surfaces due to varying velocities
Solution Approach 1:
The patent applies preliminary action by cooling the extrudate before cutting to reduce its temperature and increase its rigidity. This pre-cooling step prevents deformation during cutting by ensuring the material is sufficiently stiff to maintain its shape when subjected to cutting forces, thereby eliminating the harmful effects of varying velocities and deformation.
Solution Approach 2:
The patent implements beforehand cushioning by providing support to the extrudate during the cutting operation. The cutting surface or anvil provides a supportive base that prevents the extrudate from deforming under the cutting blade, cushioning against the harmful effects of velocity variations and ensuring uniform cut surfaces.
2Ease of manufacture
If the extrudate is cut while soft and warm, then the cutting operation is easier, but the cross-sectional shape becomes deformed and non-uniform
Solution Approach 1:
The patent applies preliminary action by cooling the extrudate before cutting to reduce its temperature and increase its rigidity. This pre-cooling step prevents deformation during cutting by ensuring the material is sufficiently stiff to maintain its shape when subjected to cutting forces, thereby eliminating the harmful effects of varying velocities and deformation.
Solution Approach 2:
The patent changes the temperature parameter of the extrudate from warm to cool before cutting. This parameter change increases the rigidity and dimensional stability of the material, allowing it to maintain its cross-sectional shape during cutting while still being workable, thus resolving the contradiction between ease of manufacture and shape uniformity.
3Manufacturing precision
If forming rollers are used to maintain extrudate shape, then dimensional consistency is improved, but the device complexity increases
Solution Approach 1:
The forming rollers serve multiple functions: they maintain the extrudate's cross-sectional shape, transport the extrudate through the cooling section, and provide support during cutting. This multi-functionality reduces the need for separate components, thereby mitigating the increase in device complexity while achieving dimensional consistency.
Solution Approach 2:
The patent combines the functions of shaping and transporting into a single set of forming rollers. By merging these functions, the device complexity is minimized while still achieving the desired dimensional consistency of the extrudate throughout the processing line.
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 machine produces oral products with consistent dimensions, smooth surfaces, and controlled additive release, preventing deformation and ensuring uniform weights and release properties.
Implementation Method 1
cooling the extrudate in a cooling section after the extrudate passes through a final pair of forming rollers
Implementation Method 2
The drive motor and gear train can maintain a rotation of each forming roller at a speed consistent with the speed of the extrudate as it exits the extrusion die
Implementation Method 3
extruding a mixture of a polymer and one or more flavorants, sweeteners, and/or actives to form an extrudate having a predetermined cross-section
Data Source
AI summary
A method of forming an oral product includes extruding a mixture, conveying the extruded mixture through one or more pairs of forming rollers, and cutting the extruded mixture into one or more oral products. The mixture can include polymer and at least one flavorant, sweetener, active ingredient, or combination thereof. The extruded mixture forms an extrudate having a predetermined cross-sectional shape. The one or more pairs of forming rollers abut to define a passage there between as each forming roller rotates. The passage has a cross-sectional shape corresponding to the predetermined cross-sectional shape. The method can be performed using a machine including an extruder, one or more pairs of forming rollers, and a cutting device.