Shear-Free Mixing of Pulp Beverages Using Positive Displacement
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Solution Overview
Problem
Current beverage mixing technologies are inadequate for handling fluids containing pulp and fibers, as they often damage these components due to shearing and require expensive equipment and frequent product changes, leading to inefficiencies and waste.
Innovation Solution
A method utilizing shear-free agitation with positive displacement pumps and a circulating mixing container to gently mix and handle pulp and fiber-containing fluids, eliminating the need for centrifugal pumps and control valves, and allowing for efficient carbonation and complete utilization of syrup content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If centrifugal pumps are used to convey and pressurize the beverage, then the conveying and pressure increase tasks are fulfilled, but the solid components such as pulp and fibers are damaged due to small gap widths and high shear forces
Solution Approach 1:
The harmful centrifugal pump with small gaps and high shear forces is extracted and replaced with a positive displacement pump that has large gaps and low shear forces, thereby removing the source of damage to solid components while maintaining conveying and pressurization functions
Solution Approach 2:
The gap width parameter is changed from small (centrifugal pump) to large (positive displacement pump), and the shear force parameter is changed from high to low, thereby conveying and pressurizing the beverage without damaging pulp and fibers
2Ease of operation
If control valves are used to control the beverage flow, then the flow control task is fulfilled, but the solid components are damaged due to small gap widths in the valves
Solution Approach 1:
Control valves with small gaps are extracted and replaced with a control system based on positive displacement pump displacement control, thereby removing the source of damage to solid components while maintaining flow control capability
Solution Approach 2:
The mechanical control valve system is replaced with a pump displacement control system, thereby controlling beverage flow without using valves that have small gaps and damage solid components
3Temperature
If plate heat exchangers are used for cooling the beverage, then the cooling task is fulfilled, but the solid components are damaged due to small gap widths in the plates
Solution Approach 1:
Plate heat exchangers with small gaps are extracted and replaced with a tubular heat exchanger that has large gaps, thereby removing the source of damage to solid components while maintaining cooling efficiency
Solution Approach 2:
The gap width parameter of the heat exchanger is changed from small (plate type) to large (tubular type), thereby cooling the beverage without damaging pulp and fibers
4Device complexity
If the mixing tank volume is kept small to reduce equipment size, then the equipment complexity is reduced, but the syrup content cannot be fully utilized and frequent product changes are required
Solution Approach 1:
The mixing tank is pre-filled with a large volume of water before syrup addition, thereby creating sufficient mixing zone volume to fully utilize syrup content and avoid frequent product changes without requiring excessively large equipment
Solution Approach 2:
The mixing process transitions from adding syrup to a small tank to adding syrup to a large pre-filled water volume, thereby increasing the effective mixing zone volume and enabling complete syrup utilization
5Stress or pressure
If centrifugal pumps are operated at high speeds to increase pressure for carbonation, then the pressure increase is sufficient, but the pulp and fibers are damaged due to high shear forces
Solution Approach 1:
High-speed centrifugal pumps are extracted and replaced with positive displacement pumps that operate at low speeds, thereby removing the source of damage to solid components while maintaining sufficient pressure increase for carbonation
Solution Approach 2:
The rotational speed parameter is changed from high (centrifugal pump) to low (positive displacement pump), and the pressure increase is achieved through displacement control rather than speed, thereby pressurizing the beverage without damaging pulp and fibers
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 minimizes damage to pulp and fibers, reduces waste and energy consumption, and enables efficient processing and reuse of mixed products, ensuring complete utilization of syrup and reducing downtime and CO2 usage.
Implementation Method 1
The means for moving the fluid without shearing comprises a first displacement pump, in particular a first piston or screw pump
Implementation Method 2
the first or the second positive displacement pump is operated as a thrust pump and the second or the first positive displacement pump is operated as a brake pump, as a result of which the pressure of the fluid between the two positive displacement pumps is increased
Implementation Method 3
Means for introducing a gas into the fluid located between the first and the second displacement pump during operation of the device, in particular means for carbonating the fluid
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The present invention relates to a device for mixing a pulp- and/or fiber-containing fluid, which includes means for shear-free movement of the fluid. The present invention further relates to a corresponding method.