Systems and methods for mitigating undesired temperature changes during food processing
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Solution Overview
Problem
Aseptic food processing systems face inefficiencies and product quality issues due to sudden temperature changes during the transition from recirculating water to food products, leading to potential loss of sterility and overheating, which are costly and timely problems.
Innovation Solution
The implementation of a system with a computer-controlled steam valve that adjusts its position based on calculated parameters such as residence time, temperature measurements, and flow rates to maintain optimal heating medium temperatures, minimizing temperature drops and overshoots during the water-to-food product transition in a heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water is recirculated through the system to maintain sterility, then sterility is maintained, but sudden temperature drop occurs during water-to-food product transition
Solution Approach 1:
The control system performs preliminary actions by detecting the water/food product interface position and calculating required steam valve adjustments before the interface reaches the heat exchanger. The system computes the necessary steam addition in advance based on residence time calculations, allowing proactive temperature compensation rather than reactive control.
Solution Approach 2:
The system continuously monitors the position of the water/food product interface and uses this feedback to dynamically adjust steam valve positioning. Temperature sensors provide real-time feedback on heating medium temperature, allowing the control algorithm to compute corrective steam valve movements to maintain temperature within acceptable ranges during the transition.
2Reliability
If steam valve is opened to compensate for temperature drop, then sterility is maintained, but temperature overshoot may occur causing product degradation
Solution Approach 1:
The system dynamically positions the steam valve based on real-time calculations of interface position, residence time, and temperature conditions. Rather than using fixed valve positions, the control algorithm continuously computes optimal valve positioning to provide precisely the amount of steam needed to maintain temperature without causing overshoot that would degrade the food product.
Solution Approach 2:
The control system changes multiple parameters simultaneously including steam valve position, steam flow rate, and timing of steam addition. By dynamically adjusting these parameters based on calculated residence time and interface position, the system maintains temperature within a narrow acceptable range to prevent both sterility loss and product degradation.
3Device complexity
If manual control methods are used, then system complexity is low, but temperature control precision is insufficient
Solution Approach 1:
The system replaces manual mechanical control with an automated control algorithm that uses computer processing to calculate optimal steam valve positioning. The control system substitutes human operator judgment with automated calculations based on residence time, interface position, and temperature feedback, achieving precise temperature control without requiring complex manual coordination.
Solution Approach 2:
The control system serves itself by automatically detecting interface position, calculating required steam adjustments, and positioning the steam valve without external intervention. The algorithm continuously monitors system conditions and self-adjusts steam valve positioning to maintain temperature precision, eliminating the need for manual control while achieving high manufacturing precision.
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 solution effectively mitigates temperature fluctuations, reducing the risk of sterility loss and overheating, thereby improving manufacturing efficiency and product quality by automatically controlling the steam valve to maintain stable temperatures throughout the aseptic processing.
Implementation Method 1
a food product is typically heated by water, which is heated by steam
Implementation Method 2
the steam source provides steam to the heating medium heater to heat the heating medium
Implementation Method 3
at least one heat exchanger comprising a heating medium
Data Source
AI summary
The present disclosure provides systems and methods for manufacturing food products. In a general embodiment, a system for manufacturing a food product is provided and includes at least one heat exchanger, at least one food product tank, at least one steam source having a steam valve, a computer having a computer processor, and a computer-readable medium accessible to the computer and containing a software program therein that is programmed to cause the computer processor to automatically control the steam valve to move from a first position to a second, calculated position to maintain a temperature of a heating medium that is sufficient to maintain sterility of the food product during a recirculating water-to-food product transition in the heat exchanger. Methods for manufacturing food products are also provided.