Popping Candy Manufacturing with Segmented Pressurization
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Solution Overview
Problem
Existing methods for manufacturing popping candy are not continuous, impractical in terms of time and cost, and suffer from significant wastage due to the need to lower gas pressure for instant interference, leading to gas and product loss.
Innovation Solution
A method and apparatus that uses a carbonizator to introduce CO2 into a viscous candy mass, forming bubbles, followed by shaping and molding under controlled pressure in a reactor, minimizing gas loss and allowing for continuous operation with low wastage by recycling excess gas and maintaining pressure for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the whole system is pressurized to prevent gas escape during manufacturing, then the candy production is maintained, but instant interference to the system becomes impossible and gas/product loss occurs when pressure must be lowered
Solution Approach 1:
The system is divided into separate pressurized zones: the carbonizator maintains pressure for continuous production while the molding area can be accessed independently. This segmentation allows the pressurized section to remain operational while enabling interference in non-pressurized sections, resolving the contradiction between system reliability and ease of operation.
Solution Approach 2:
The problematic whole-system pressurization is extracted and replaced with localized pressurization only where needed (in the carbonizator). This allows the rest of the system to remain at atmospheric pressure, enabling instant interference and maintenance without compromising the pressurized zone's functionality.
2Productivity
If the system is pressurized to maintain production, then candy manufacturing continues, but gas and product wastage occur when pressure must be lowered for interference
Solution Approach 1:
By segmenting the pressurized zone to only the carbonizator rather than the entire system, the patent minimizes the volume of pressurized space. This reduces the amount of gas required and the potential loss when pressure adjustments are needed, while maintaining continuous production capability in the pressurized zone.
Solution Approach 2:
The system is designed to recover and recycle gas that would otherwise be lost during pressure adjustments. The localized pressurization design allows for more controlled gas management, enabling recovery mechanisms to capture and reuse excess gas, thereby reducing overall substance loss.
3Device complexity
If conventional molding methods are used without localized pressurization, then the system is simpler, but gas escape occurs from the candy mass
Solution Approach 1:
The pressurization function is extracted from the general molding process and applied specifically to the carbonizator where CO2 introduction occurs. This targeted approach prevents gas escape at the critical point without requiring complex pressurization of the entire molding system, maintaining relative simplicity while preventing substance loss.
Solution Approach 2:
The carbonizator acts as an intermediary pressurized chamber between CO2 supply and the candy mass. This intermediate pressurized zone controls gas introduction efficiently, preventing direct gas escape to the atmosphere while avoiding the need for complex whole-system pressurization.
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 solution enables continuous, efficient production of popping candy with reduced wastage and increased manufacturing capacity by maintaining pressure and recycling gas, thus minimizing time and energy losses during heating and cooling.
Implementation Method 1
introducing CO2 gas into the mass while it is still viscous
Implementation Method 2
maintaining pressure for efficient production
Implementation Method 3
cooling down the reactor (3) to 25° C. and hardening the candy
Data Source
AI summary
A method and apparatus for producing popping candy which is formed in molds. A reactor with one or more trays holds the product and one or more moveable transmission mechanisms and one or more lids provided at each end of the reactor act as inlets and outlets. One or more two way valves regulate and maintain inside pressure of the reactor and cooling and heating mechanisms are provided.