Automated Winding System for Stuffed Food Manufacturing

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Solution Overview

Problem

Existing methods for manufacturing stuffed foods are not easily industrializable and cannot produce them on a large scale with a high production rate, especially when using soft and/or sticky food products.

Innovation Solution

A method involving an additional cutting step using a water jet and drive belts to process the food products, along with a specific installation that includes a winding station, cutting station, and packaging system, allowing for efficient production of cylindrical stuffed foods with a tubular outer casing and a solid inner filling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional manual rolling methods are used to manufacture stuffed foods, then the appearance quality can be maintained, but the production rate is low and industrialization is difficult

Engineering Contradiction:

Improveproduction rateVSAvoidindustrialization difficulty

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent replaces manual mechanical rolling operations with an automated winding mechanism. A continuous sheet of outer food product is fed through a winding station where it is automatically wrapped around a rod to form a tubular casing, then filled with inner food product and sealed. This automated winding and sealing system eliminates the need for manual rolling while maintaining product quality and enabling high-volume production.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The manufacturing process is divided into distinct operational stations: a winding station for forming the tubular outer casing, a filling station for inserting the inner food product, and a sealing station for completing the stuffed food. This segmentation allows each station to be optimized independently and enables continuous high-speed production through coordinated operation of multiple stations.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If soft and/or sticky food products are used for stuffing, then product variety and consumer appeal increase, but handling and processing become difficult

Engineering Contradiction:

Improveingredient flexibilityVSAvoidhandling difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent introduces an intermediary rod or mandrel around which the outer food product sheet is wound to form the tubular casing. This rod serves as a temporary support structure that maintains the shape and structural integrity of the soft outer material during the filling process. The inner food product is inserted around this rod, and after sealing, the rod is removed. This intermediary structure enables precise handling of soft and sticky materials without direct manipulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The outer food product is processed as a continuous flexible sheet that is wound around the rod to form a tubular casing. This thin-film approach allows the soft material to be manipulated as a continuous membrane rather than as rigid pieces, enabling automated handling while maintaining the soft texture and adaptability of the ingredient. The flexible sheet can be precisely controlled during winding and sealing operations.

Inventive Principle:

Principle #30Flexible shells and thin films

3Productivity

If automated winding and sealing systems are implemented, then production efficiency increases, but device complexity increases

Engineering Contradiction:

Improveproduction rateVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The winding station is designed as a multi-functional unit that performs multiple operations: it winds the outer food product sheet around the rod to form the tubular casing, positions the casing for filling, and coordinates with the filling and sealing stations. This universal winding mechanism handles different sizes and types of stuffed foods through adjustable parameters rather than requiring separate dedicated equipment for each product variant, thereby reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 high-rate production of stuffed foods with a satisfactory appearance, even with soft and/or sticky ingredients, while maintaining excellent hygiene standards and facilitating easy cleaning and handling, suitable for industrial use.

Implementation Method 1

The cutting step is carried out by a water jet

Methodology Applied

Scientific EffectWater jet cutting: Jet

Data Source

PatentEP3037006B1Method for manufacturing stuffed food(s), and corresponding facility

Publication Date: 2020.03.25 BEL

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AI summary

This process for manufacturing filled feed(s) (10), each filled feed (10) comprising an outer casing of a first food product, and an inner filling of a second food product, comprises the following steps: - supplying a sheet (24) of the first food product, and a roll (28) of the second food product, and - winding the sheet (24) around the roll (28).