Continuous Starch Paste Production via High-Pressure Jet Mixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of starch paste is technically complex due to lump formation caused by immediate contact between ungelatinized starch and hot water, necessitating a multi-step process that is not suitable for continuous operation.
Innovation Solution
A method involving a mixing chamber where starch or protein powders are fed in powder form and subjected to a high-pressure, heated liquid jet at least 50°C, accelerating against an impact surface to achieve gelatinization or dissolution in a single continuous step, preventing lump formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If starch powder and water are mixed immediately at gelatinization temperature, then gelatinization occurs rapidly, but lump formation occurs preventing further water penetration
Solution Approach 1:
The process is divided into two distinct stages: first, cold mixing of starch powder with water below gelatinization temperature to ensure uniform distribution and prevent lump formation; second, heating the pre-mixed suspension to gelatinization temperature to achieve complete gelatinization. This segmentation resolves the contradiction by separating the wetting function from the gelatinization function.
Solution Approach 2:
The starch powder is pre-mixed with cold water before heating to gelatinization temperature. This preliminary action ensures uniform water distribution throughout the starch particles, preventing lump formation during the subsequent heating process and enabling uniform gelatinization.
2Manufacturing precision
If a two-stage process with cold premixing and heating is used, then lump formation is prevented, but the process becomes technically complex and cannot operate continuously
Solution Approach 1:
The cold mixing stage and heating stage are merged into a single continuous vessel where starch powder is continuously fed and simultaneously mixed with cold water, then heated in sequence without interruption. This combining eliminates the need for separate batch operations while maintaining the precision benefits of the two-stage approach.
Solution Approach 2:
The process operates continuously with starch powder being fed continuously and converted to gelatinized paste without batch interruptions. The useful actions of mixing and heating occur in continuous sequence within the same system, eliminating downtime between batches and simplifying overall process operation.
3Productivity
If hot water is introduced first with intensive stirring, then continuous operation is possible, but lump formation still occurs and the process is not suitable for continuous operation
Solution Approach 1:
Instead of adding hot water to starch powder (which causes immediate lump formation), the process inverts the sequence by first mixing starch powder with cold water to achieve uniform distribution, then heating the mixture. This inversion of the traditional approach prevents lump formation while enabling continuous operation.
4Manufacturing precision
If batch processes are used to prevent lump formation, then uniform starch paste is achieved, but safety risks from scalding and manual intervention increase
Solution Approach 1:
The system performs automatic continuous operation with automated feeding, mixing, and heating functions. The process serves itself without requiring manual intervention at high temperatures, eliminating scalding risks to operators while maintaining uniform paste quality through controlled continuous processing.
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
Enables continuous production of a highly viscous suspension or adhesive paste without lump formation, improving safety and efficiency by eliminating batch processes and scalding risks.
Implementation Method 1
the starting material being subjected to a liquid jet emerging from a nozzle under high pressure during this downward movement... the starting material is immediately converted, in particular gelatinized or dissolved, by the combined interaction of process temperature and mechanical application of force
Implementation Method 2
the liquid, before coming into contact with the starting material, has been heated to a process temperature which leads to the conversion of the starchy or protein-containing starting material into the desired conversion product... the process temperature of the liquid, in particular at the nozzle outlet, is at least 50°C
Implementation Method 3
the starting material is accelerated against an impact surface of the mixing container and the starting material is immediately converted... by the combined interaction of process temperature and mechanical application of force
Implementation Method 4
subjected to a liquid jet emerging from a nozzle under high pressure... with a delivery pressure of min. at least 10 bar through a pressure nozzle
Data Source
Figure 1
AI summary
The invention relates to a process for the continuous production of a conversion product, in particular starch paste, fried starch, dissolved gelatin, or protein gluten, wherein starchy and/or protein-containing, preferably powdered, starting material, in particular flour, starch powder, cereal grains, cereal meal, gelatin powder, or gluten powder, is fed to a mixing chamber (2) and the starting material, preferably powder, which enters the mixing chamber (2), is subjected to a liquid in the form of a pressure jet (7) heated to a process temperature (TU) of at least 50°C for the conversion of the starting material into the conversion product, in particular at least to a gelatinization temperature of the starchy starting material, a protein dissolution and/or denaturation temperature of the protein-containing starting material, or a frying temperature, and thereby against apreferably formed by an inner wall of a mixing chamber or a mixing chamber insert, impact surface (10) is conveyed.