Tower screen dual surface finish
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Solution Overview
Problem
Current block formers struggle to produce well-formed blocks of cheese with high salt content, low-fat content, or low moisture, as they lack sufficient fuseability, leading to undesirable cracks and premature separation of the curd pillar.
Innovation Solution
A block former with an upright drainage column divided into an upper and lower part, featuring different interior surface finishes: a smooth finish for the upper part and a shot-peened finish for the lower part, which increases friction, allowing the upper portion of the curd pillar to descend faster and fuse more effectively, preventing separation and cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a uniform interior surface finish is used throughout the drainage column, then the curd pillar descends at a consistent rate, but the cheese lacks sufficient fuseability and develops cracks
Solution Approach 1:
The drainage column's interior surface is divided into two zones with different friction characteristics: the upper portion has a smooth finish to allow rapid descent and fusion of the curd pillar top, while the lower portion has a rough finish to provide controlled friction. This local differentiation resolves the contradiction by allowing different regions to serve different functional purposes - the upper region promotes fusion while the lower region maintains structural integrity.
2Productivity
If the curd pillar descends quickly through the drainage column, then production efficiency increases, but the lower portion separates prematurely from the upper portion
Solution Approach 1:
The drainage column applies different surface finishes to different vertical zones: the upper portion has a smooth finish that enables fast descent and fusion, while the lower portion has a rough finish that provides higher friction to prevent premature separation. This spatial differentiation of surface properties allows the system to achieve both rapid processing and structural stability.
Solution Approach 2:
The system dynamically adjusts the interaction between the curd pillar and drainage column surface along the descent path. The friction coefficient varies with position - low in the upper region to accelerate fusion, and high in the lower region to maintain grip and prevent separation. This dynamic variation in friction characteristics resolves the contradiction between speed and stability.
3Stability of the object's composition
If the friction between the drainage column and curd pillar is increased, then the curd pillar maintains stability, but the fusion of the curd becomes insufficient
Solution Approach 1:
The drainage column interior surface is differentiated into two friction zones: the upper portion has a smooth finish with low friction to promote curd fusion, while the lower portion has a rough finish with high friction to maintain pillar stability. This local quality variation allows the system to optimize both fusion and stability in their respective regions.
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 enables the production of uniform blocks with higher salt content, lower fat content, or lower moisture, effectively preventing cracks and premature separation, thus producing well-formed cheese blocks with improved fusion.
Implementation Method 1
the interior surface at the lower part has a second finish that provides higher friction with the pillar of curd relative to the first finish
Implementation Method 2
Curd particles that are in the form of cubes, slices, and flakes, which are conventionally referred to as curd chips, are drawn by a vacuum to a top of the block former tower
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A block former (1) for the production of blocks of cheese (19) includes an upright drainage column (2) having a feed opening (3) for curd particles (4) at an upper end (5) of the drainage column (2). The drainage column (2) includes an inner wall (6) having an interior surface (7) against which a pillar of curd (8) formed of the curd particles (4) slides as the pillar of curd (8) moves downwardly through the drainage column (2). The upright drainage column (2) is divided into an upper part (9) and a lower part (10). The interior surface (7) at the upper part (9) has a first finish and the interior surface (7) at the lower part (10) has a second finish that provides higher friction with the pillar of curd (8) relative to the first finish.