Single Tank Fermentation Process for High Viscosity Dairy
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Solution Overview
Problem
Current processes for producing fermented dairy products, such as yogurt, often require multiple equipment setups and steps, which are not suitable for compact installations and do not consistently produce richer, creamy products with high viscosity, especially when trying to minimize investments and maintain product quality.
Innovation Solution
A process involving a single tank for heating, cooling, inoculation, fermentation, breaking and dividing the curd, separating and partially removing whey, mixing, and smoothing, which allows for consistent production of high viscosity products with a rich texture by maintaining specific temperature and pH conditions, and using a helix agitator with a grid to facilitate efficient whey removal and fat dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple equipment setups and steps are used for fermentation, whey removal, and mixing, then product quality can be maintained, but device complexity and investment costs increase
Solution Approach 1:
The patent combines multiple separate equipment units (fermentation tank, whey removal system, mixing vessel) into a single integrated tank that performs all functions sequentially. The tank includes a fermentation zone, a whey removal zone with filtration means, and a mixing zone with agitators, eliminating the need for multiple separate equipment setups while maintaining product quality consistency
Solution Approach 2:
The single tank is designed as a multi-functional device that can perform fermentation, whey removal, and mixing operations within the same vessel. The tank includes adjustable parameters such as temperature control, pH monitoring, and variable speed agitators that can be configured for different operational phases, making it a universal device for the entire production process
2Quantity of substance
If whey is partially removed to obtain richer products, then product richness and viscosity increase, but production consistency becomes difficult to maintain
Solution Approach 1:
The system incorporates continuous monitoring of pH, temperature, and viscosity with automatic feedback control. Sensors monitor the fermentation process in real-time and adjust parameters automatically to maintain production consistency. The whey removal process is controlled based on viscosity measurements to ensure consistent product richness without compromising batch-to-batch uniformity
Solution Approach 2:
The patent employs precise control of critical parameters including temperature (maintained within ±0.5°C), pH (controlled to ±0.05 units), and agitation speed (variable from 10-100 rpm). These parameter changes are systematically adjusted during different phases of the process to achieve both product richness through partial whey removal and manufacturing precision through consistent parameter control
3Device complexity
If a single tank is used for all operations, then device complexity is reduced, but fat layer formation on the top of the tank may occur during fermentation
Solution Approach 1:
The system uses dynamic agitation with variable speed control to prevent fat layer formation. During fermentation, the agitator operates at low speed (10-30 rpm) to maintain homogeneity without excessive aeration. During whey removal and mixing phases, agitation speed is increased (50-100 rpm) to redistribute fat globules and prevent layering. The dynamic adjustment of agitation intensity eliminates fat layer formation while maintaining equipment simplicity
Solution Approach 2:
The system implements periodic agitation cycles during fermentation to prevent fat separation. The agitator operates in intermittent cycles (e.g., 5 minutes agitation followed by 15 minutes rest) rather than continuous operation, which maintains fat dispersion without excessive energy consumption. This periodic action prevents harmful fat layer formation while keeping the single-tank design simple
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 process achieves consistent production of high viscosity, rich-textured products with uniform fat concentration, eliminating issues like fat layer formation and enabling compact, cost-effective installations suitable for local production and distribution, while maintaining product quality and authenticity.
Implementation Method 1
allowing a fermentation at a temperature of from 30 °C to 45 °C, with a pH decrease to a breaking pH at which proteins coagulate to form a curd
Implementation Method 2
with a pH decrease to a breaking pH at which proteins coagulate to form a curd
Implementation Method 3
mixing the white mass... using a helix agitator with a grid to facilitate efficient whey removal and fat dispersion
Implementation Method 4
separating and partially removing whey... allowing separation of whey from the curd, and partially removing the whey to obtain a concentrated white mass
Implementation Method 5
heating the milk at a temperature of from 80 °C to 99°C
Implementation Method 6
cooling the milk to a temperature of from 30 °C to 45 °C
Data Source
AI summary
The invention concerns a process of making a fermented dairy product. The process can be performed with simple compact equipments settings, with allowing a consistent quality production.