Rotating Roller Coating System for Produce Preservation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Agricultural products are prone to degradation and spoilage due to environmental factors and biotic stressors, and existing methods for preserving them are often inefficient and labor-intensive.
Innovation Solution
An industrial application system that includes a bed with rotating rollers, sprayers, and blowers to apply and dry a protective coating mixture, ensuring complete surface coverage and rapid solvent evaporation, thereby forming a protective coating on perishable items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual treatment methods are used for applying coatings and sanitizing agents, then labor flexibility is maintained, but productivity and treatment efficiency are reduced
Solution Approach 1:
The treatment system is divided into multiple independent rollers (first roller, second roller, third roller) positioned at different locations along the conveyor bed. Each roller can be independently controlled and positioned to perform specific treatment functions at different stages of the process, enabling automated high-speed treatment while maintaining system modularity and manageability
Solution Approach 2:
The patent replaces manual mechanical application methods with an automated conveyor-based system that uses controlled mechanical rollers to apply coatings and sanitizing agents. The system uses a mix tank with agitation to automatically prepare solutions, which are then applied through the roller mechanism, eliminating manual labor while maintaining treatment effectiveness
2Manufacturing precision
If traditional coating application methods are used, then equipment simplicity is maintained, but coating uniformity and surface coverage are insufficient
Solution Approach 1:
The application system uses multiple segmented rollers (first roller for initial coating, second roller for additional coverage, third roller for final treatment) positioned at different locations. This segmentation allows each roller to contribute to different aspects of coating uniformity, ensuring complete surface coverage while keeping each individual roller component simple and manageable
Solution Approach 2:
The mix tank with agitation mechanism prepares the coating solution and sanitizing agent mixture in advance before application. The agitation system pre-mixes the components to ensure uniform concentration and consistency, which then translates to uniform coating application when the solution is applied through the rollers, improving manufacturing precision without requiring complex application mechanisms
3Productivity
If rapid drying is implemented to increase throughput, then productivity is improved, but energy consumption and system complexity increase
Solution Approach 1:
The drying function is merged with the existing conveyor and roller system. The rollers that apply the coating also facilitate drying by rotating to distribute and spread the solution uniformly, and the conveyor movement itself provides airflow and exposure that aids evaporation. This integration achieves rapid drying without requiring separate high-energy drying equipment
Solution Approach 2:
The system uses the motion of the conveyor and rollers themselves to facilitate drying. The continuous movement of produce through the system, combined with the rotation of rollers, creates natural airflow and exposure that promotes solvent evaporation. The system essentially dries the produce through its own operational movements rather than requiring additional energy-intensive drying mechanisms
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 system effectively prevents spoilage by forming a protective coating that reduces moisture loss, oxidation, and infection, with a high efficiency in coating and drying processes, achieving significant improvements in food preservation.
Implementation Method 1
a bed comprising a plurality of rollers, wherein each of the rollers is configured to rotate at a predetermined rotational rate, thereby causing the perishable items on the bed to rotate
Implementation Method 2
one or more sprayers over a first portion of the bed... causing the mixture to be applied to the perishable items via the one or more sprayers
Implementation Method 3
the one or more blowers at least partially remove the solvent from the surfaces of the perishable items, thereby causing the protective coatings to be formed over the perishable items
Data Source
AI summary
An application system for forming protective coatings over perishable items, including: a bed including a plurality of rollers, wherein each of the rollers is configured to rotate at a predetermined rotational rate, thereby causing the perishable items on the bed to rotate; one or more sprayers over a first portion of the bed; one or more blowers over a second portion of the bed; a mixing system configured to prepare a mixture including a coating agent in a solvent; and a liquid delivery system connected inline between the mixing system and the one or more sprayers.