Segmented Holding Tank for Dairy Protein Denaturation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current dairy processing systems using holding cells are costly due to extensive use of stainless steel, have long mix phases, and require significant amounts of water, steam, and chemicals for cleaning and sterilization, while also being inefficient in terms of holding time accuracy and environmental impact.
Innovation Solution
A holding tank system with a cylindrical design featuring an inlet and outlet positioned opposite each other along the longitudinal axis, equipped with a distribution device to ensure even liquid dispersal and maintain continuous liquid flow, reducing the need for separate deaerators and allowing for adjustable holding times and easier inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a holding cell with tubular spiral shape is used to achieve five minutes holding time, then the denaturation of whey proteins is improved, but the production cost increases due to large amount of stainless steel required
Solution Approach 1:
The holding process is segmented into two independent stages: a heating stage (90-95°C for 5 minutes) and a cooling stage (to 40-50°C for 5 minutes). This segmentation allows the use of simpler, less expensive tank designs instead of complex tubular spiral holding cells, reducing stainless steel requirements while maintaining the necessary holding time for protein denaturation.
Solution Approach 2:
The invention transitions from a one-dimensional tubular spiral flow path to a three-dimensional tank-based system with multiple inlet/outlet points and internal flow distribution structures. This dimensional change enables more efficient space utilization and reduces the total length of stainless steel piping required while achieving the same holding time effect.
2Reliability
If a tubular spiral holding cell is used to ensure five minutes holding time, then the stability of yoghurt is improved, but the mix phase length increases
Solution Approach 1:
The system segments the milk flow path into distinct heating and cooling zones with separate tanks, allowing the mix phase to be minimized in each segment. The heating tank processes milk independently, then the cooled milk is combined with culture in a separate step, reducing the overall distance milk travels in mixed phase compared to a single long tubular spiral.
Solution Approach 2:
The invention introduces an intermediary cooling stage between heating and fermentation. This intermediary step allows precise control of milk temperature before introducing culture, ensuring optimal conditions for yogurt stability while reducing the distance milk needs to travel in the final mixed phase.
3Object-affected harmful factors
If a holding cell with stainless steel hood is used to prevent burns and radiation, then the safety of operators is improved, but the production cost increases
Solution Approach 1:
The invention extracts the safety function from the structural housing and implements it through process control - specifically, by cooling milk to 40-50°C before it leaves the holding tank, the thermal hazard is eliminated. This removes the need for expensive stainless steel hoods while maintaining operator safety through temperature management rather than physical barriers.
Solution Approach 2:
The system provides its own safety function through the cooling process - the milk self-cools to safe temperatures through the designed holding and cooling mechanism, eliminating the need for additional protective structures. The process itself ensures safety rather than requiring separate protective elements.
4Reliability
If a holding cell with long tubular section is used to achieve five minutes holding time, then the denaturation efficiency is improved, but the water and chemical consumption in washing stage increases
Solution Approach 1:
The segmented tank design with defined inlet and outlet zones creates distinct washing zones that can be cleaned more efficiently. The compact footprint of the tank-based system compared to the extended tubular spiral reduces the total surface area requiring washing, thereby reducing water and chemical consumption while maintaining denaturation efficiency through controlled residence time.
Solution Approach 2:
The system design allows for more efficient recovery and reuse of washing water and chemicals due to the compact, contained tank structure. The reduced surface area and optimized flow patterns enable better containment and recovery of cleaning agents compared to the extended tubular system, reducing overall consumption.
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 system significantly reduces steam, water, and chemical consumption by 64%, mix phase volume by 83%, and costs, while maintaining holding time accuracy and allowing for easier system capacity adjustments and reduced environmental impact.
Implementation Method 1
a distribution device for evenly dispersing the liquid received through the inlet
Implementation Method 2
holding tank for holding a liquid over a predefined time period... The holding tank is suitable for denaturing of protein for yoghurt... every milk unit passing the holding cell should at least spend five minutes in the holding cell
Implementation Method 3
the milk entering the holding cell usually holds a temperature of between 90 to 95 °C... This holding temperature in combination with the five minutes holding time denatures about 70 - 80 % of the whey proteins
Data Source
Figure 1~2c
Figure 3a~3b
Figure 4~5b
AI summary
A holding tank (30, 40) for replacing a commonly known holding cell is provided. A system, a distribution device (15) and liquid directing element (18) is also provided.