Sausage Log Drying Using Microwave and Conditioned Air
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Solution Overview
Problem
Current dry sausage manufacturing processes are time-consuming, capital-intensive, and require significant space due to the lengthy drying and curing periods, which limits production capacity and increases costs, and the existing methods do not efficiently remove moisture from sausage products without affecting their quality.
Innovation Solution
A method involving the use of microwave energy in combination with conditioned air to partially dry sausage logs, followed by further drying in a controlled chamber, which reduces the moisture content to a predetermined moisture-to-protein ratio, thereby shortening the overall processing time and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional drying and curing processes are used for dry sausage production, then product quality is maintained, but processing time is excessively long (days to weeks) and production capacity is limited
Solution Approach 1:
The patent applies parameter changes by modifying the physical state and properties of air during the drying process. Specifically, the air parameters (temperature, humidity, flow velocity) are dynamically adjusted throughout the drying stages. The process uses cold air (0-30°C) with controlled humidity levels and high velocity (0.30-5.49 m/second) to achieve rapid moisture removal without compromising product quality, reducing processing time from weeks to hours
Solution Approach 2:
The patent implements periodic action through multi-stage drying processes with alternating conditions. The drying occurs in distinct stages with different air temperatures, humidity levels, and flow rates. For example, initial high-velocity cold air drying is followed by periods of adjusted humidity control, creating a periodic cycle that efficiently removes moisture while maintaining product integrity
2Quantity of substance
If extended drying and curing periods are used, then moisture content is adequately reduced, but manufacturing space requirements and capital investment increase significantly
Solution Approach 1:
The patent replaces the traditional passive mechanical drying system (relying on natural air circulation and long exposure time) with an active forced convection system. High-velocity air flow (0.30-5.49 m/second) is mechanically induced through fans or blowers to rapidly strip moisture from the sausage surface, substituting the need for large drying rooms and extended time periods with a controlled mechanical air movement system
3Productivity
If high velocity air flow is used for drying, then moisture removal rate increases, but product quality may be compromised due to excessive drying speed
Solution Approach 1:
The patent applies local quality by directing high-velocity air flow specifically at the surface of the sausage product where moisture needs to be removed, while maintaining controlled internal conditions. The air flow parameters are optimized to affect primarily the external moisture layer without causing excessive drying or quality degradation in the product interior, achieving selective moisture removal at different rates
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 significantly reduces the processing time for dry sausage production, achieving the desired moisture-to-protein ratio in a fraction of the time of traditional methods while maintaining product quality and reducing production costs.
Implementation Method 1
introducing a supply of microwaves into the chamber
Implementation Method 2
introducing into the chamber a supply of conditioned air having a relative humidity below 60% and a temperature in the range of 4.44°C to 54.44°C
Data Source
Figure 1A
Figure 1C
Figure 1B
AI summary
A process for manufacturing dry sausage comprising rapid partial drying of sausage logs. The process includes preparing a meat mixture, stuffing the meat mixture into a casing or mould, or extruding into moulds, to form sausage logs, fermenting the sausage logs, heat treating the sausage logs, placing the sausage onto a conveyor, passing the conveyor and sausage log through a chamber, and drying the partially-dried sausage logs. The process also includes introducing a supply of conditioned air into the chamber, the air having a relative humidity below about 60% and a temperature in the range of at least about 40°F to 130°F, and introducing a supply of microwaves into the chamber. The air supply and microwaves, as well as The drying conditions, are selected to reduce the moisture content of the meat to a predetermined moisture to protein ratio.