Roller Gum Sheet Forming for Uniform Thickness and Low Energy
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Solution Overview
Problem
Traditional gum manufacturing processes are time-consuming and energy-intensive, requiring significant machinery and resulting in non-uniform outputs, with challenges in reducing gum thickness and preventing sticking to rollers, while also affecting the preservation of shear and temperature-sensitive ingredients.
Innovation Solution
A method using a pair of rollers to form a substantially continuous and flat gum sheet with a uniform thickness between 0.3 mm to 10 mm, eliminating the need for sizing extruders and rollers, and preventing adhesion without dusting agents, while consuming less energy and maintaining ingredient integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a sizing extruder with a small rectangular orifice is used to reduce gum thickness, then the gum thickness is reduced, but a relatively sizeable amount of force (30 HP drive) is required and the product remains too thick
Solution Approach 1:
The patent removes the sizing extruder from the traditional gum manufacturing process entirely. Instead of forcing gum through a small orifice requiring 30 HP, the invention uses a pair of rollers that simply pass over the gum mass, extracting the thickness reduction function from the extruder and achieving the same result with minimal power consumption.
Solution Approach 2:
The patent replaces the high-power extrusion mechanism with a low-power rolling mechanism. The rollers apply gentle pressure to pass the gum mass through, substituting the intense mechanical forcing of the extruder with a simpler rolling action that achieves thickness reduction without requiring 30 HP drive power.
2Volume of moving object
If a series of sizing rollers are employed to progressively reduce gum thickness from 25 mm to 2-6 mm, then the gum thickness is reduced, but dusting with particulate material is required to prevent sticking
Solution Approach 1:
The patent eliminates the need for dusting agents by removing the sticking problem at its source. The invention uses a pair of rollers with a specific configuration that prevents gum adhesion without requiring particulate materials, extracting the anti-sticking function from the dusting process.
Solution Approach 2:
The patent introduces a liquid release agent as an intermediary between the gum mass and the rollers. This liquid mediator prevents direct adhesion between the gum and roller surfaces, allowing smooth passage without sticking while eliminating the need for solid dusting agents.
3Volume of moving object
If traditional sizing machinery with multiple rollers and extruders is used, then gum thickness is reduced, but the process is time-consuming and energy-intensive
Solution Approach 1:
The patent combines multiple separate operations (extrusion, rolling, thickness reduction) into a single integrated rolling step. The pair of rollers performs all thickness reduction functions that traditionally required a sequence of extruders and multiple roller passes, merging the process steps and eliminating production time delays.
Solution Approach 2:
The patent enables continuous processing by eliminating the sequential steps and intermediate handling required in traditional machinery. The gum mass passes continuously through the roller pair without interruption for repositioning or adjustment, maintaining continuous useful action throughout the thickness reduction process.
4Ease of operation
If warm pliable gum product is produced, then the gum is easy to process, but it does not package well and requires subsequent cooling and conditioning
Solution Approach 1:
The patent changes the temperature parameter of the gum product during processing. The roller system incorporates cooling to reduce the gum temperature and increase its stiffness, transforming the product from warm and pliable to cooler and more rigid, thereby achieving both ease of processing and packaging readiness in a single step.
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 reduces energy consumption, preserves sensitive ingredients, and produces a more uniform and aesthetically pleasing gum product with reduced production downtime and costs, and allows for wider sheet production with minimal thickness variance.
Implementation Method 1
surface areas of the gum mass in proximity to the pair of rollers being pulled by the pair of rollers at a greater velocity than more internal areas of the gum mass disposed distal to the pair of rollers
Implementation Method 2
sizing the gum mass into a substantially continuous and flat gum sheet having a substantially uniform thickness
Data Source
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AI summary
Disclosed is a method for forming gum, the method including providing a pair of rollers including a first roller and a second roller, and sizing a gum mass into a substantially continuous and flat gum sheet having a substantially uniform thickness between about 0.3 mm to 10 mm via a moving of the gum mass through a gap between the pair of rollers.