Three-Head Brine Injection Plant for Whole Muscle Meat
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Solution Overview
Problem
Current methods for treating whole muscle meat by brine injection and massaging are limited by low brine absorption rates due to the use of two injector heads, inadequate rotary drum size, and low rotation speeds, resulting in suboptimal weight gain and meat quality.
Innovation Solution
A plant with three injector heads and a larger rotary drum with increased rotation speeds, allowing for exponential injection and improved brine absorption, along with a conveyor system for efficient meat handling and independent brine supply for each head, enhances brine penetration and absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two injector heads are used for brine injection, then the injection process is simplified, but brine absorption is limited to 70-105% weight increase
Solution Approach 1:
The injection process is segmented into multiple sequential injections (first, second, and third injections) with specific time intervals between them. This segmentation allows the muscle tissue to absorb brine progressively without displacement, achieving weight increases of 150-250% compared to the 70-105% limitation of two-head systems.
Solution Approach 2:
The system employs periodic injection cycles with controlled time intervals between successive brine injections. The first injection occurs immediately, the second injection occurs after a first time interval (allowing initial absorption), and the third injection occurs after a second time interval (allowing further absorption). This periodic timing optimizes absorption while preventing brine displacement.
2Productivity
If injections are performed too close in time, then processing efficiency is improved, but new brine displaces previously injected brine reducing absorption
Solution Approach 1:
The system implements a periodic injection schedule with three distinct phases: immediate first injection, second injection after a first time interval (e.g., 10-60 seconds), and third injection after a second time interval (e.g., 30-120 seconds). These time intervals are specifically calibrated to allow progressive brine absorption while preventing displacement, optimizing both productivity and absorption.
3Quantity of substance
If injections are performed too far apart in time, then brine absorption is improved, but intermuscular spaces close hindering subsequent infiltration
Solution Approach 1:
The system uses a three-phase periodic injection approach with optimized time intervals. The first injection occurs immediately to open intermuscular spaces, the second injection occurs after a first time interval (maintaining spaces open), and the third injection occurs after a second time interval (still within the absorption window). This timing ensures spaces remain open for efficient infiltration while maximizing absorption.
4Quantity of substance
If rotary drum diameter and rotation speed are increased for intense massaging, then brine absorption is improved, but vibrations and instability increase
Solution Approach 1:
The rotary drum incorporates counterweights or balancing mechanisms to offset the centrifugal forces and vibrations generated at higher rotation speeds. This allows the drum to operate at increased speeds (e.g., 10-20 rpm) with larger diameters (e.g., 1.5-2.0 meters) for intense massaging and improved brine absorption, while maintaining operational stability and preventing excessive vibrations.
5Stability of the object's composition
If low rotation speeds are used in the rotary drum, then stability is maintained, but massaging intensity is insufficient requiring longer times
Solution Approach 1:
By incorporating counterweights or balancing mechanisms in the rotary drum, the system can operate at higher rotation speeds (e.g., 10-20 rpm) without excessive vibrations. This increased speed provides intense massaging action that significantly reduces the required processing time (e.g., from several hours to 30-120 minutes) while maintaining drum stability through the counterbalancing effect.
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 solution achieves a weight increase of over 220% in whole muscle meat, improving meat quality and reducing processing time, while minimizing intermuscular paste formation and increasing yield.
Implementation Method 1
a pressurized brine supply device for injecting the brine into the whole muscle meat
Implementation Method 2
causing said whole muscle meat to absorb part of the injected brine, with the corresponding increase in weight
Implementation Method 3
by means of the rotation of the rotary drum, the whole muscle meat is turned, bringing about the tenderization thereof and additional brine absorption
Implementation Method 4
the whole muscle meat contained in said drum does not fall from a considerable height, and therefore it is not subjected to intense massaging
Data Source
AI summary
The invention relates to a plant and method for the treatment of whole muscle meat, wherein the proposed plant includes a brine injection apparatus (1) with a conveyor device (10); three successive injector heads (20), each provided with a plurality of injector needles (21) connected to pressurized brine supply devices (30); one of said injector heads being connected to a first pressurized brine supply device (31), being independent from the remaining injector heads (20); and said plant also including at least one massage application apparatus (2) including a rotary drum (40) of between 140 cm and 210 cm for loading the whole muscle meat after injection thereof, operated at between 14 and 20 revolutions per minute, obtaining an increase in weight of the whole muscle meat greater than 220%.