Softgel Drying Machine with Recirculating Air System
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Solution Overview
Problem
Current softgel drying methods, such as tray drying and continuous drying, are costly and inefficient due to high energy consumption, lengthy processing times, and difficulty in maintaining consistent temperature and humidity conditions, leading to poor drying efficiency and aesthetic issues.
Innovation Solution
A softgel drying machine with a casing, air channel, drying chamber, air return channel, tumbler, and air-drying system that includes a chiller, dehumidification module, and air return cooling module, allowing for controlled temperature and humidity management within a recirculating air environment, reducing energy consumption and maintaining consistent conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tray drying is used, then softgels can be dried in a controlled environment, but the processing time becomes very long (days) and the cost is very high
Solution Approach 1:
The patent implements continuous drying where softgels remain in the tumbling container throughout the entire drying process without removal. The air circulation system continuously recirculates air through the drying chamber, maintaining constant temperature and humidity conditions throughout the drying cycle, eliminating the need for manual intervention and extending the controlled environment beyond just the drying phase
Solution Approach 2:
The patent replaces manual mechanical operations (staff entering rooms to attend softgels, manual tumbling) with an automated air circulation system that includes fans, heaters, and humidity control mechanisms. The system automatically maintains optimal drying conditions without human intervention, reducing both time and cost while maintaining reliability
2Loss of time
If continuous drying is used, then processing time is reduced, but the cost remains very high due to requirement of humidifier system
Solution Approach 1:
The air circulation system serves multiple functions simultaneously: it provides forced air circulation for heat transfer, acts as a humidity control system through recirculation, and functions as a tumbling mechanism. By integrating these functions into a single system rather than requiring separate humidifier and circulation systems, the patent reduces overall cost while maintaining continuous drying capabilities
Solution Approach 2:
The patent recovers and recirculates air that would otherwise be discarded. The air circulation system continuously draws air from the drying chamber, passes it through heating and humidity control elements, and returns it to the chamber. This closed-loop system recovers the thermal energy and moisture content of the air, reducing the energy required for heating and humidification compared to continuous fresh air supply systems
3Measurement precision
If staff frequently access the condition room to attend softgels, then softgel conditions can be monitored, but draft wind enters the room causing condition fluctuations and poor drying efficiency
Solution Approach 1:
The patent replaces manual monitoring by staff with automated sensors and control systems that continuously monitor temperature, humidity, and other drying parameters. The air circulation system automatically adjusts conditions based on sensor feedback, eliminating the need for staff to physically enter the drying chamber and introducing draft winds that would compromise condition stability
Solution Approach 2:
The patent implements a feedback control system where sensors continuously measure drying chamber conditions and feed this information to the control system. The air circulation system then automatically adjusts heating, humidification, and air flow rates to maintain optimal conditions, ensuring stability without requiring manual intervention that would disrupt the environment
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 machine achieves efficient drying with controlled temperature and humidity, reducing processing time and energy costs while maintaining the desired aesthetic shape of softgels by recirculating high-velocity air and utilizing regenerative air systems.
Implementation Method 1
The air blower fan comprises an air blower inlet port, an air blower outlet port, a chiller and an air supply duct
Implementation Method 2
The air-drying system is located at the air generation chamber and comprises at least one air blower fan, a dehumidification module and an air return cooling module
Implementation Method 3
The air return cooling module comprises an air return duct, an air return inlet port and an air return outlet port
Implementation Method 4
the softgel drying machine comprises a casing, an air channel, at least one drying chamber, an air return channel, at least one tumbler and an air-drying system
Data Source
AI summary
The softgel drying machine comprises a casing, an air channel, a drying chamber, an air return channel, a tumbler and an air-drying system. The casing comprises an air circulation chamber and an air generation chamber. The drying chamber comprises at least one air supply opening and at least one air returning plate. The air-drying system comprises at least one air blower fan, a dehumidification module and an air return cooling module. The air blower fan comprises an air blower inlet port, an air blower outlet port, a chiller and an air supply duct. The chiller is coupled to the air blower outlet port. The air return cooling module comprises an air return duct, an air return inlet port and an air return outlet port. The air return inlet port is airtightly coupled to the air return channel through the air return duct.