System and method for producing an extruded protein product
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Solution Overview
Problem
Current extrusion technologies face limitations in producing extruded protein products with oriented fibers at commercially viable rates, as traditional cooling die channels often result in uneven shear and texturization challenges, particularly at higher production speeds.
Innovation Solution
A system utilizing an elongated die with a continuous loop transverse cross-section and adjustable gap thickness and length to provide uniform shear, combined with a transition apparatus for even distribution and potential additive mixing, enables the production of high-quality extruded protein products with oriented fibers at increased rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional cooling die channels are used, then production rates can be increased, but uniform shear and texturization quality deteriorate
Solution Approach 1:
The die channel is segmented into multiple sections with different gap thicknesses along its length. This segmentation allows different sections to provide different shear conditions, enabling uniform texturization throughout the product while maintaining high production rates. The channel is divided into a first section with a first gap thickness and a second section with a second gap thickness, creating zones of varying shear stress.
Solution Approach 2:
Different sections of the die channel are assigned different local properties (gap thicknesses) to optimize texturization at various stages of the extrusion process. The first section has a larger gap for initial shaping, while the second section has a smaller gap for refined fiber orientation, ensuring uniform quality throughout the product.
2Productivity
If extrusion speed is increased to improve productivity, then production rate improves, but fiber orientation uniformity deteriorates
Solution Approach 1:
The die channel is designed to perform preliminary actions on the protein mixture at different stages. The first section with larger gap thickness performs preliminary shaping and coarse fiber alignment, while the second section with smaller gap thickness performs refined fiber orientation. This preliminary action sequence ensures uniform fiber orientation even at high extrusion speeds.
Solution Approach 2:
The die channel geometry is made dynamic through varying gap thickness along its length, creating a gradient of shear conditions that adapts to the extrusion process stages. This dynamic design allows the system to maintain fiber orientation uniformity across a range of extrusion speeds by providing appropriate shear conditions at each position.
3Device complexity
If a simple die channel design is used, then device complexity is reduced, but shear uniformity and texturization capability deteriorate
Solution Approach 1:
The die channel is segmented into multiple sections with different gap thicknesses, transforming a simple uniform-channel design into a multi-section structure. This segmentation, while increasing complexity, enables uniform shear distribution and improved texturization capability by creating zones of different shear intensity.
Solution Approach 2:
The gap thickness parameter is changed along the length of the die channel, creating a gradient structure. This parameter change from constant to variable gap thickness enables uniform shear distribution and improved texturization, justifying the increased structural complexity.
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 allows for the production of extruded protein products with a meat-like texture at rates of up to 400 kg/hr or more, maintaining quality while overcoming traditional die channel limitations in shear and texturization.
Implementation Method 1
the longitudinal channel having a transverse cross-section that is a continuous loop along at least a portion of the length of the die, where the channel has a length and gap thickness configured to form oriented fibers from the protein component in a generally parallel orientation
Data Source
AI summary
The present disclosure relates to systems and methods for producing an extruded protein product. In particular, a system for making an extruded protein product using a system that includes a die including channel having a transverse cross section that is a continuous loop along at least a portion of the length of the die is disclosed.