Superheated Steam Drying Method for Sterile Material Processing
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Solution Overview
Problem
Conventional drying methods face challenges in achieving sterility and minimizing the loss of volatile components during the drying process, especially for food products, as they often involve contact with germs and result in excessive loss of volatile components due to elevated temperatures.
Innovation Solution
A method and apparatus utilizing a gaseous atmosphere with superheated steam to dry extruded materials, where the atmosphere is predominantly composed of steam, with temperatures above 100°C, and an extraction unit recovers volatile substances, allowing for efficient drying to specific water content levels while minimizing contamination and component loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional drying methods with contact between material and dry air are used, then drying efficiency is achieved, but sterility cannot be ensured and contamination with germs occurs
Solution Approach 1:
The patent applies this principle by creating a gaseous atmosphere composed predominantly of steam (at least 50% by weight, preferably at least 90% by weight) that is free from germs and micro-organisms. This inert steam environment replaces conventional dry air, allowing efficient drying while preventing contamination, as the steam atmosphere acts as a sterile barrier that eliminates harmful biological factors during the drying process
Solution Approach 2:
The patent applies this principle by changing the physical parameters of the drying atmosphere from conventional dry air to superheated steam with specific temperature (at least 100°C, preferably at least 120°C) and composition parameters (at least 50% by weight steam). These parameter changes enable the atmosphere to serve dual functions: maintaining drying efficiency through controlled temperature and humidity while simultaneously ensuring sterility through the chemical and physical properties of steam
2Productivity
If elevated drying temperature is used to improve drying efficiency, then water removal is enhanced, but volatile components escape and are lost
Solution Approach 1:
The patent applies this principle by utilizing the phase transition of water from liquid to vapor through superheated steam. The steam atmosphere at controlled temperatures (at least 100°C, preferably at least 120°C) provides gentle heat transfer that facilitates water removal from the material through phase change, while the steam environment itself prevents excessive evaporation of volatile components by maintaining a humid equilibrium that selectively removes water rather than other volatile substances
Solution Approach 2:
The patent applies this principle by precisely controlling the temperature parameter (at least 100°C, preferably at least 120°C, but controlled to avoid excessive volatility) and steam concentration parameter (at least 50% by weight, preferably at least 90% by weight) of the drying atmosphere. These controlled parameter changes enable efficient water removal while minimizing the loss of volatile components, as the specific steam composition and temperature range create conditions favorable for water evaporation while suppressing the escape of other volatile substances
3Object-affected harmful factors
If steam content in gaseous atmosphere is increased to improve sterility, then contamination is reduced, but energy consumption increases
Solution Approach 1:
The patent applies this principle by optimizing the steam content parameter within a specific range (at least 50% by weight, preferably at least 90% by weight) and temperature parameter (at least 100°C, preferably at least 120°C). This optimized parameter combination achieves the dual benefit of ensuring sterility through high steam content while managing energy consumption efficiently, as the controlled steam concentration and temperature provide effective contamination prevention without requiring excessive energy input that would be needed for complete steam saturation at higher temperatures
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 approach effectively dries materials to desired moisture levels without contamination and excessive volatile component loss, maintaining product quality by reintroducing extracted substances, thus addressing the limitations of conventional drying methods.
Implementation Method 1
drying the material in the gaseous atmosphere
Implementation Method 2
The gaseous atmosphere, at least in a horizontal partial layer, to be at a temperature of more than 100° C., 120° C., 140° C., 160° C. or 180° C.
Implementation Method 3
extracting from the gaseous atmosphere volatile substances which escape from the material into the gaseous atmosphere
Implementation Method 4
an extraction unit for extracting volatile substances from the gaseous atmosphere
Data Source
AI summary
The invention relates to a method of drying a material, that includes the steps of: providing a gaseous atmosphere with superheated steam in a housing, transporting a material into the housing, and drying the material in the gaseous atmosphere. Thereafter, transporting the dried material out of the housing and extracting from the gaseous atmosphere volatile substances which escape from the material into the gaseous atmosphere, especially flavors. The invention is also direct to an apparatus for drying the extruded material.