Poultry Skin Penetration Roller for Breading Adhesion

Solution Overview

Problem

Existing methods for preparing poultry skin for breading, which involve high scalding to remove the cuticle for better adhesion, result in yield reduction and skin discoloration, and are not efficient.

Innovation Solution

A method and apparatus that use a roller assembly with circular blades having radially protruding teeth to penetrate the skin with small holes, improving coating adhesion without scalding, by passing the poultry item between oppositely rotating rollers with inwardly urging blades.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high scalding temperature (≧60° C.) is used to remove the cuticle, then adhesion of coating material is improved, but yield of poultry item is reduced by 4-6% and skin discoloration occurs

Engineering Contradiction:

Improveadhesion of coating materialVSAvoidyield of poultry item

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent extracts only the cuticle layer from the poultry skin through mechanical means (blades with teeth) rather than removing the entire skin through scalding. This selective extraction achieves the adhesion improvement goal while preserving the underlying skin layers, thereby maintaining yield and preventing discoloration.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the thermal/scalding process with a mechanical process. Instead of using high temperature scalding to remove the cuticle, the invention uses blades with teeth that mechanically penetrate and remove only the cuticle layer, thus achieving the same adhesion benefit without the harmful thermal effects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If high scalding temperature (≧60° C.) is used to remove the cuticle, then adhesion of coating material is improved, but skin discoloration occurs during air chilling

Engineering Contradiction:

Improveadhesion of coating materialVSAvoidskin discoloration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts only the cuticle layer from the poultry skin through mechanical means (blades with teeth) rather than removing the entire skin through scalding. This selective extraction achieves the adhesion improvement goal while preserving the underlying skin layers, thereby maintaining yield and preventing discoloration.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the thermal/scalding process with a mechanical process. Instead of using high temperature scalding to remove the cuticle, the invention uses blades with teeth that mechanically penetrate and remove only the cuticle layer, thus achieving the same adhesion benefit without the harmful thermal effects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If traditional scalding method is used to prepare poultry skin, then coating adhesion is improved, but processing efficiency is reduced

Engineering Contradiction:

Improvecoating adhesionVSAvoidprocessing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the thermal/scalding process with a mechanical process. Instead of using high temperature scalding to remove the cuticle, the invention uses blades with teeth that mechanically penetrate and remove only the cuticle layer, thus achieving the same adhesion benefit without the harmful thermal effects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental parameter of the preparation process from thermal (scalding temperature) to mechanical (blade penetration force and tooth configuration). This parameter change enables a more efficient process that achieves the same adhesion improvement without the time-consuming scalding step.

Inventive Principle:

Principle #35Parameter changes

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

Enhances breading adhesion without reducing poultry yield or causing skin discoloration, allowing for better coating adherence without the need for high scalding processes.

Implementation Method 1

a plurality of circular blades laterally spaced apart and substantially parallel and having a plurality teeth radially protruding (extending) from the edge of the blades for forcibly engaging and penetrating the skin of the poultry item

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS8858305B2Method and apparatus for preparing poultry skin

Publication Date: 2014.10.14 TYSON FOODS INC

AI summary

Penetrating the skin of a poultry item with an array of small holes accomplished by using a plurality of circular blades laterally spaced apart and substantially parallel and having a plurality teeth protruding from the edge of the blades and forcibly engaging and penetrating the skin of the poultry item with the plurality of teeth. The plurality of circular blades can have a common axis of rotation and rotating about a shaft extending along the common axis thereby forming a roller of blades.