Stuffing Filler Nozzle With In-Line Hydration to Prevent Sogginess
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Solution Overview
Problem
Conventional methods for filling meat products with stuffing result in soggy textures due to the breakdown of starch molecules in staled breadcrumbs when mixed with liquid, leading to undesirable stuffing characteristics.
Innovation Solution
An apparatus and method that involves a conduit system with a fluid injector and nozzle to introduce fluid into dry food material, increasing its moisture content and maintaining texture, using an axially rotatable screw and back pressure control to ensure thorough mixing and filling without immediate use of pre-mixed stuffing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If dry stuffing is pre-mixed with liquid before filling, then the stuffing achieves proper moisture content for filling, but the starch molecules break down and the breadcrumbs become soggy with undesirable texture
Solution Approach 1:
The filling process is segmented into two distinct stages: (1) filling the cavity with dry stuffing material first, and (2) subsequently injecting liquid into the filled cavity through the conduit system. This segmentation prevents the starch molecules from being exposed to liquid and mechanical stress simultaneously, thereby preventing breakdown and sogginess while still achieving the desired moisture content in the final product
Solution Approach 2:
The dry stuffing is filled into the cavity before the liquid injection step. This preliminary action of filling the cavity with dry material first creates a structure that can then be hydrated in place, avoiding the premature mixing that causes starch breakdown. The liquid is injected after the stuffing is already positioned in the cavity, maintaining texture integrity
2Productivity
If pre-mixed stuffing is stored in a hopper before filling, then the stuffing is ready for immediate use, but the starch molecules continue to break down over time resulting in increased sogginess
Solution Approach 1:
The system segments the stuffing components (dry material and liquid) into separate storage and delivery paths. The dry stuffing is stored and conveyed through the hopper and conduit in a dry state, maintaining stability. The liquid is injected separately at the point of use, eliminating the time-dependent degradation that occurs when pre-mixed stuffing is stored in the hopper
Solution Approach 2:
The conduit system acts as an intermediary that transports dry stuffing material from the hopper to the filling point without introducing liquid. This intermediary mechanism allows the dry stuffing to be prepared and stored separately, then delivered to the cavity where liquid is injected, preventing the time-dependent sogginess that would occur with pre-mixed stored stuffing
3Quantity of substance
If liquid is injected into the conduit to mix with food material, then the food material achieves increased moisture content, but the mixing process may cause starch breakdown
Solution Approach 1:
The conventional approach is inverted: instead of mixing liquid with dry stuffing in the conduit before filling, the system fills the cavity with dry stuffing first, then injects liquid into the already-filled cavity. This inversion eliminates the mechanical mixing action that causes starch breakdown while still achieving the desired moisture content in the final product
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 apparatus effectively maintains the texture of stuffing by increasing moisture content while filling, preventing sogginess and ensuring optimal stuffing characteristics upon use.
Implementation Method 1
a fluid injector fluidly connected to the conduit and to a fluid source, the fluid injector adapted to permit injection of a fluid into the interior passageway of the conduit for mixing with the food material passing therethrough to obtain a food material having a second moisture content greater than the first moisture content
Implementation Method 2
an axially rotatable screw located within the conduit, fluid injector and nozzle for advancing the food material towards and through the nozzle outlet port
Implementation Method 3
the nozzle outlet port is restricted to generate back pressure in the conduit when the food material having the second moisture content passes through the nozzle outlet port
Implementation Method 4
the fluid injector has a valve between the conduit and the fluid source for controlling fluid flow through the injector, the valve being biased to a closed position and adapted to permit fluid flow through the fluid injector when the back pressure generated in the conduit by the food material having the second moisture content passing through the nozzle outlet port exceeds a predetermined value
Data Source
AI summary
The present invention provides for an apparatus for filling a food material into a cavity of an object. The apparatus has a conduit having a conduit inlet port, a conduit outlet port, and an interior passageway extending between the conduit inlet port and the conduit outlet port. The conduit is adapted to permit passage of a dry food material through the interior passageway from the conduit inlet port to the conduit outlet port. The apparatus also has a fluid injector fluidly connected to the conduit and to a fluid source. The fluid injector is adapted to permit injection of a fluid into the interior passageway of the conduit for mixing with the dry food material passing therethrough to obtain a wet food material. The apparatus also has a nozzle having a nozzle inlet port, a nozzle outlet port, and an interior passageway extending between the nozzle inlet port and the nozzle outlet port. The nozzle is fluidly connected to the conduit and the fluid injector. The nozzle outlet port is adapted to fill the wet food material into the cavity of the object. A method for filling the cavity of the object with the food material is also disclosed. An object having a cavity containing a food material when filled by the method in accordance with the present invention is also disclosed.