Multi-Stage Puree Extraction for High Viscosity Without Overheating
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Solution Overview
Problem
Existing methods for producing high-viscosity puree and juice from vegetable products face challenges in achieving sufficient viscosity and efficiency due to high energy consumption and product overheating, particularly when using high rotation speeds.
Innovation Solution
A plant design with multiple extraction sections and a treatment section, utilizing rotors with varying angular velocities and sieves of different hole sizes, along with a treatment section that allows for extended residence time and controlled angular velocity to enhance viscosity without overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high rotation speed is used to increase viscosity, then the turbulence increases and waste product reduces size, but energy consumption increases significantly
Solution Approach 1:
The extraction process is divided into multiple sections with different rotor speeds. The first extraction section operates at a first rotation speed, the second at a higher second rotation speed, and the treatment section at a third rotation speed. This segmentation allows each section to perform its specific function optimally without requiring all sections to operate at maximum speed, thereby reducing overall energy consumption while achieving the desired viscosity.
Solution Approach 2:
The system dynamically adjusts rotation speeds across different sections rather than operating at a single fixed speed. The rotors are configured to rotate at different angular velocities tailored to each section's specific requirements, enabling optimal performance for extraction, treatment, and viscosity enhancement without excessive energy expenditure.
2Stability of the object's composition
If very high rotation speed is used to reduce solid parts size, then viscosity increases, but the product is overheated compromising organoleptic properties
Solution Approach 1:
The treatment section is separated from the extraction sections, allowing independent control of rotation speed and residence time. This segmentation enables the treatment of the extracted product to achieve desired viscosity through controlled mechanical action without the excessive heating that occurs in single-high-speed extraction systems.
Solution Approach 2:
The system maintains continuous processing through multiple sections with controlled residence times. The product flows continuously from the first extraction section to the treatment section and then to the second extraction section, allowing gradual viscosity enhancement without sudden overheating that would occur in single-stage high-speed processing.
3Stability of the object's composition
If high rotation speed is used to homogenize product, then viscosity increases, but resident time in extraction section is insufficient
Solution Approach 1:
The processing system is segmented into multiple sections where the treatment section specifically addresses viscosity enhancement. This segmentation allows the product to spend adequate residence time in the treatment section at controlled rotation speeds, ensuring sufficient interaction time for viscosity development without rushing the process.
Solution Approach 2:
The system adds a temporal dimension to the processing by extending the residence time in the treatment section. Instead of attempting to achieve viscosity quickly in the extraction section, the design creates an additional processing dimension where the extracted product undergoes treatment at controlled speeds for sufficient duration to achieve desired viscosity.
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 effectively produces a creamy, high-viscosity product while reducing energy consumption and maintaining organoleptic properties, overcoming the limitations of prior art by ensuring adequate residence time and controlled treatment.
Implementation Method 1
The centrifugal force thus generated by the blades of the rotor on the treated product forces the same against the sieve causing the same to be separated into the extracted food product
Implementation Method 2
the turbulence produced by the rotor within the machine during rotation is increased and, therefore, the processed product is homogenized
Data Source
AI summary
A plant for producing juice and/or puree from a food product includes a first extraction section per subject the food product to a first extraction that produces a first extracted food product including puree, or juice, and a first waste product. The plant has a second extraction section that is positioned downstream of the first extraction section and configured to subject an entering product to a second extraction operation to produce a second extracted food product including the puree, or juice, and a second waste product. The first extraction section, the second extraction section and the treatment section thereinbetween have respective rotors configured to rotate about a respective axis, respectively at a first, a second and a third angular velocity. The third angular velocity is greater than both the first and the second angular velocity, but less than 8000 rpm.