Moisture and Texture Control in Tortilla Chip Production
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Solution Overview
Problem
Current tortilla and tortilla chip production lines lack effective methods for controlling moisture and texture after baking and frying, relying on pre-baking moisture analysis and lacking surface texture measurement capabilities.
Innovation Solution
A production system incorporating a production line with an oven, fryer, and a production control unit equipped with moisture sensors, laser sensors, and a processor to measure and control moisture and texture, including a masa moisture sensor, chip moisture sensor, laser sensor, and texture classifier, which adjusts oven temperature, belt speed, and fryer settings to achieve desired moisture and texture profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional production lines are used without advanced sensors, then device complexity is reduced, but manufacturing precision of moisture and texture control deteriorates
Solution Approach 1:
The patent replaces mechanical moisture measurement methods with optical and electromagnetic sensing systems. Specifically, it employs optical sensors for surface texture detection and electromagnetic sensors for moisture content measurement, eliminating the need for complex mechanical sampling and laboratory analysis systems while achieving continuous real-time monitoring throughout the production process.
Solution Approach 2:
The production control unit continuously receives feedback from multiple sensors (optical sensors for texture, electromagnetic sensors for moisture) and automatically adjusts production parameters such as cooking time, temperature, and frying conditions. This closed-loop feedback system enables precise real-time control of moisture and texture without requiring complex manual intervention systems.
2Reliability
If moisture measurement is performed only at pre-baking stage, then measurement cost is reduced, but control capability throughout production process deteriorates
Solution Approach 1:
The patent implements continuous moisture measurement throughout the entire production process using electromagnetic sensors positioned at multiple stages (pre-baking, during baking, post-baking, and after frying). This continuous monitoring action ensures reliable moisture control at every critical point, enabling real-time detection and adjustment to maintain consistent product quality from raw material through final processing.
Solution Approach 2:
The electromagnetic moisture sensors serve multiple functions: they measure moisture content at different production stages, detect texture changes, and provide feedback for process control. This multi-functional sensing system eliminates the need for separate specialized measurement devices at each stage, achieving comprehensive control while reducing overall system complexity.
3Manufacturing precision
If surface texture measurement is not implemented, then device complexity is reduced, but product quality consistency deteriorates
Solution Approach 1:
The patent replaces mechanical surface profiling systems with optical sensors that use light reflection and interference patterns to measure surface texture. This optical measurement method provides high-resolution texture data without physical contact, eliminating the need for complex mechanical scanning devices while achieving precise and consistent surface quality control throughout the frying and cooling processes.
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
Enables precise control of moisture and texture throughout the production process, ensuring consistent product quality and compliance with specifications by continuously measuring and adjusting parameters in real-time.
Implementation Method 1
The chip moisture sensor can be a time-domain reflectometry moisture sensor, which is configured to analyze propagation of electromagnetic radiation to determine relative permittivity
Implementation Method 2
a laser sensor, which is configured to measure a surface height of the fried pieces that are emitted from the fryer, such that the laser sensor obtains a continuous sequence of height measurements
Implementation Method 3
the masa moisture sensor is a reflection absorption moisture sensor
Data Source
AI summary
A production system for moisture and texture detection and control in tortilla and tortilla chip production includes a production line, including a cooker/grinder, a sheeter/cutter, an oven, an equalizer, a fryer, and a cooler/packaging machine; and a production control unit, including a processor, non-transitory memory, an input/output component, a moisture controller, a temperature controller, a belt speed controller, a masa moisture sensor, a chip moisture sensor, laser sensors for measuring surface texture of baked and fried chips, a laser controller, a texture classifier, a feedback controller. Also disclosed is a method for production control, including controlling moisture content, measuring masa moisture, controlling oven, measuring baked surfaces, measuring fried surfaces, classifying baked surfaces, classifying fried surfaces, optimizing oven temperature, optimizing oven belt speed, storing and characterizing historical records.