Planetary Roller Extruder for Confectionery Crystallization
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Solution Overview
Problem
Conventional confectionery production processes are complex, labor-intensive, and result in substantial variation between products due to multiple machinery steps and manual labor, leading to high costs and lengthy product setting times before packaging.
Innovation Solution
A method utilizing a planetary roller extruder to mix and form confectionery compositions, which removes moisture, forms crystals, and controls density through mechanical shear and gas input, allowing for direct output to packaging without additional sizing or treatment, significantly reducing production time and equipment needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple production steps with multiple pieces of machinery are used, then confectionery products can be formed, but device complexity and production time increase
Solution Approach 1:
The patent combines multiple separate production operations (mixing, cooking, cooling, crystallization, and extruding) into a single continuous process within one extruder device. The extruder performs all these functions sequentially as the confectionery composition passes through different zones, eliminating the need for multiple separate machines and reducing device complexity.
Solution Approach 2:
The extruder is designed as a multi-functional device that can perform mixing, heating, cooling, crystallization, and extruding operations within a single machine. This universal device replaces multiple specialized machines, simplifying the overall production system while maintaining all necessary confectionery formation functions.
2Ease of manufacture
If multiple production steps with manual labor are used, then confectionery products can be formed, but labor costs and product variation increase
Solution Approach 1:
The patent implements a continuous production process where the confectionery composition flows continuously through the extruder, undergoing all transformations without interruption. This continuous automated process eliminates manual labor between steps and ensures consistent product quality, as the composition passes through standardized zones for mixing, cooking, cooling, and extruding without human intervention.
3Manufacturing precision
If lengthy cooling and setting periods are allowed, then confectionery products can be properly formed, but productivity decreases
Solution Approach 1:
The patent controls the temperature parameters dynamically throughout the extrusion process. The composition is heated to cooking temperature, then cooled to crystallization temperature, and finally extruded at controlled temperatures. These parameter changes are achieved rapidly through the efficient thermal zones within the extruder, maintaining product quality while minimizing processing time.
Solution Approach 2:
The necessary cooling and crystallization actions are performed preliminarily within the extruder before the composition exits. The composition is pre-cooled to the required temperature and pre-crystallized within the device, eliminating the need for lengthy post-extrusion cooling and setting periods, thus increasing productivity without compromising quality.
4Manufacturing precision
If additional cooling and mixing steps are added, then confectionery composition can be properly formed, but loss of time and productivity decrease
Solution Approach 1:
The patent merges cooling and mixing operations into the same continuous process within the extruder. As the composition moves through the device, it undergoes cooling while simultaneously being mixed by the extrusion action, eliminating the need for separate cooling and mixing steps and reducing total production time.
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 simplifies the production process, reduces labor costs, and achieves consistent product quality by forming confectionery within a single machine, enabling rapid throughput and minimizing equipment footprint while ensuring product readiness for packaging.
Implementation Method 1
Crystals are formed in the confectionery composition while the confectionery composition is being extruded in said planetary roller extruder
Implementation Method 2
Moisture is removed from said confectionary composition in said mixer
Implementation Method 3
The confectionery composition may be aerated within said planetary roller extruder to control a density thereof
Data Source
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AI summary
A method for extruding a confectionery is provided including supplying a plurality of ingredients to a mixer. The ingredients are mixed to form a confectionery composition in said mixer. Crystals are formed in the confectionery composition while the confectionery composition is in said mixer and the confectionery composition is output from said mixer.