Agitation Device for Pepper Mash Fermentation
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Solution Overview
Problem
The pepper mash fermentation process is lengthy, typically requiring 90-180 days, which necessitates large infrastructure investments and results in inconsistent product quality due to difficulties in achieving homogenous mixing.
Innovation Solution
Agitating the pepper mash during fermentation maintains a homogeneous state, reduces fermentation time, and improves product consistency by evenly distributing microbiological activity and increasing surface area for sugar conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If static fermentation process is used, then fermentation can be completed, but fermentation time is excessively long (90-180 days)
Solution Approach 1:
The patent applies periodic agitation to the pepper mash during fermentation, alternating between agitation periods and rest periods. This periodic mechanical stimulation accelerates the fermentation process by periodically redistributing microorganisms and substrates, reducing fermentation time from 90-180 days to a significantly shorter duration while maintaining product quality
Solution Approach 2:
The patent implements continuous or near-continuous agitation during the fermentation process, ensuring that microorganisms remain in constant contact with sugar substrates throughout the mash. This continuous mechanical action eliminates idle periods and maintains optimal fermentation conditions throughout the entire process, dramatically increasing productivity
2Manufacturing precision
If recirculation process using pumps is used to mix pepper mash, then mixing can be achieved, but mixing is very difficult and time-intensive with poor homogeneity
Solution Approach 1:
The patent employs mechanical agitation devices that create vigorous mixing action within the fermentation tank, using rotational impellers or similar mechanisms to physically redistribute pepper solids, liquids, and microorganisms throughout the mash. This mechanical vibration and movement achieves complete homogeneity much faster than pump recirculation, eliminating the industry-wide mixing problem
Solution Approach 2:
The patent replaces the inadequate pump recirculation system with a direct in-tank agitation mechanism. Instead of pumping mash out and back through external piping, the agitation device works directly within the fermentation tank, creating efficient mixing action that overcomes the non-Newtonian properties of high-solids pepper mash
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
Agitation significantly reduces fermentation time from 180 days to 40 days, allows for increased tank capacity by 20%, and ensures consistent product quality, thereby enhancing industry efficiency and throughput.
Implementation Method 1
Agitating the pepper mash during fermentation maintains a homogeneous state, reduces fermentation time, and improves product consistency by evenly distributing microbiological activity and increasing surface area for sugar conversion
Implementation Method 2
naturally occurring Lactic Acid Bacteria (LAB) and yeast convert the pepper sugar into lactic acid, lowering the pH to make the pepper mash shelf stable and food safe
Implementation Method 3
During fermentation, the solids in the mash become buoyant due to entrained CO2 and rise to fill the headspace
Data Source
AI summary
The invention includes a method of fermenting pepper mash, where the method includes agitating the mash in a fermentation tank at times. The agitation can be continuous, on a schedule, or intermittently. The method also includes the step of pumping the pepper mash into the tank leaving a headspace of inches. The invention also includes an apparatus of agitating the pepper mash in a fermentation tank, where the apparatus includes an agitator located in the interior of the tank, where the agitator is coupled to a power source for operating the agitator.