Production line and method for in-line processing of food products
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Solution Overview
Problem
Existing in-line processing technologies for food products, such as sausages, face challenges in controlling the quality due to variations in external conditions and require pre-drying before smoking, which can destabilize liquid smoke and increase processing time.
Innovation Solution
A production line and method where liquid smoke is applied before the transit oven, eliminating the need for pre-drying, allowing for stable liquid smoke application at lower temperatures, reducing evaporation, and enabling more controlled processing with separate conveyors and flexible oven conditions, including higher temperatures and humidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid smoke is applied after pre-drying in the oven, then the food products are ready for smoking, but the liquid smoke temperature becomes unstable and evaporation increases
Solution Approach 1:
The patent inverts the conventional process sequence by applying liquid smoke before the oven heating step rather than after. This reversal allows the liquid smoke to be applied at lower temperatures (below 40°C) where it remains stable, preventing thermal degradation and excessive evaporation that would occur if applied after pre-drying.
Solution Approach 2:
The patent performs the liquid smoke application as a preliminary step before the oven heating phase. By applying the liquid smoke to the brined food products while they are still at lower temperatures, the process prevents temperature-induced instability and evaporation losses, while the subsequent oven step completes the drying and cooking process.
2Manufacturing precision
If pre-drying is performed before liquid smoke application, then the food product surface is prepared, but the liquid smoke application becomes less effective due to temperature sensitivity
Solution Approach 1:
The patent reverses the conventional sequence by applying liquid smoke before pre-drying. This allows the liquid smoke to penetrate the food product surface effectively at lower temperatures, where the diffusion process is more controlled and effective, rather than attempting to apply it to a pre-heated surface where temperature sensitivity reduces effectiveness.
Solution Approach 2:
The patent changes the temperature parameter during liquid smoke application by performing it before the oven heating step. This parameter change (lower temperature during application) optimizes the diffusion and penetration of liquid smoke into the food product, while the subsequent heating step completes the processing without compromising the smoke application effectiveness.
3Productivity
If traditional processing sequence is used (pre-drying then smoking), then the process is established, but the total processing time increases
Solution Approach 1:
The patent simplifies the processing sequence by inverting the conventional order to apply liquid smoke before pre-drying. This reversal eliminates the need for separate pre-drying step before smoking, reducing the total number of process steps and overall processing time while maintaining product quality through the optimized sequence of brining, smoking, and then heating.
4Speed
If liquid smoke is applied at higher temperatures, then the processing speed increases, but the liquid smoke becomes unstable and stains the food product
Solution Approach 1:
The patent applies liquid smoke at lower temperatures (below 40°C) before the heating step, which prevents thermal instability and staining of the food product. The smoking action is performed while the food is still cool, and the subsequent oven heating completes the process without causing smoke degradation or unwanted staining that would occur if applied at higher temperatures.
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 enhances quality control, reduces processing time, increases production yields, and allows for more flexible processing conditions, including higher oven temperatures, resulting in better skin characteristics and color formation of the food products.
Implementation Method 1
penetration of liquid smoke in the skin (casing) of the food products is a diffusion reaction that is typically governed by the concentration of the liquid smoke in a liquid smoke solution
Implementation Method 2
a transit oven for drying and heating the brined and smoke treated food products
Implementation Method 3
less evaporation of liquid smoke occurs and also the rate of smoke evaporation is more controlled
Implementation Method 4
incorporating a UV source for additional cross-linking
Data Source
AI summary
The invention relates to a production line for in-line processing of food products, comprising a food transport path that successively leads through: a brine unit; a liquid smoke unit; and a transit oven. The invention also relates to a method for in-line processing of food products, comprising the successive process step: moisturising the food products with a brine; moisturising the food products with a liquid smoke; and heating the food products.