Oscillating Conveyor Meatball Shaping for Shelf-Stable Pet Food
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Solution Overview
Problem
Current pet food manufacturing processes fail to cost-effectively produce semi-moist meatballs that are shelf-stable for long periods without refrigeration, as existing methods are not suitable for high-volume continuous processing and result in products that are either too dry or prone to spoilage.
Innovation Solution
A method involving a ground mix of proteinaceous material, flavor enhancers, and preservatives is processed through a grinder and mixer, then portioned and rolled using a dual conveyor system with an oscillating overhead conveyor to form spherical meatballs, achieving the desired texture and moisture content, which are then dried to achieve shelf stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional batch mixing and iris valve portioning methods are used, then manufacturing precision and product quality are maintained, but productivity is insufficient for high-volume continuous processing
Solution Approach 1:
The patent implements continuous processing by replacing batch mixing with continuous mixing equipment and batch portioning with continuous extrusion through a die head, enabling uninterrupted production flow suitable for high-volume manufacturing
Solution Approach 2:
The oscillating iris valve mechanical system is replaced with a continuous extrusion die head mechanism that forms meatballs continuously without requiring oscillating motion or batch cycles, simplifying the mechanical system while increasing productivity
2Reliability
If high moisture content is used to improve palatability and texture, then product quality improves, but shelf life decreases due to increased spoilage risk
Solution Approach 1:
The patent modifies the moisture content parameter to an intermediate level (15-30%) that balances palatability with shelf stability, and introduces antioxidants as a new parameter to prevent oxidation and rancidity, thereby extending shelf life while maintaining product quality
Solution Approach 2:
The patent creates a composite formulation combining proteinaceous material, carbohydrates, fats, and antioxidants, where the antioxidants work synergistically with the moisture content control to prevent spoilage and extend shelf life while maintaining palatability
3Duration of action of stationary object
If freeze-drying is used to extend shelf life, then storage stability improves, but product quality deteriorates due to brittleness and crumbly texture
Solution Approach 1:
The patent changes the moisture content parameter to an intermediate level (15-30%) rather than removing moisture through freeze-drying, which preserves the product's natural texture and prevents brittleness while still achieving sufficient shelf stability through controlled drying and antioxidant addition
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 process results in semi-moist meatballs with a texture and appearance similar to human-grade meatballs, maintaining stability and freshness for at least 18 months without refrigeration, addressing the challenge of producing palatable and long-lasting pet food products.
Implementation Method 1
periodically pressing said portions with a second belt of a second conveyor, where said second belt operates in a plane at a height above, and substantially parallel to, said first belt, said second belt moving at a second speed in substantially the same longitudinal direction as said first belt, while also oscillating back and forth in a lateral direction
Implementation Method 2
placing said portions on a first belt of a first conveyor moving at a first speed in a longitudinal direction
Data Source
AI summary
Apparatus, systems and methods are disclosed for manufacturing semi-moist meatballs. An illustrative embodiment provides a method of manufacturing generally spherical pet treats comprising: (a) providing a ground mix of proteinaceous material, flavor enhancers and preservatives to a portioning device that divides said mix into smaller portions of roughly uniform volume, (b) placing said portions on a first belt of a first conveyor moving at a first speed in a longitudinal direction, (c) periodically pressing said portions with a second belt of a second conveyor, where said second belt operates in a plane at a height above, and substantially parallel to, said first belt, said second belt moving at a second speed in substantially the same longitudinal direction as said first belt, while also oscillating back and forth in a lateral direction that is at an angle to said longitudinal direction, such that said portions are transformed into generally spherical shapes.