Two-Stage Frying Process for Uniform Density in Instant Fried Noodles
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Solution Overview
Problem
Existing methods for producing instant noodles result in a dense upper portion and coarse lower portion due to inadequate oil coating when noodle strings float and come into contact with the lid during frying, leading to poor distribution and increased resistance from frying oil flow.
Innovation Solution
Implementing a two-stage frying process where the retainer is partially dipped in frying oil at a controlled ratio (half frying) followed by complete immersion (deep frying), with a flow rate control mechanism to prevent shape impairment, ensuring uniform coating and distribution of frying oil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the whole lidded retainer filled with noodle strings is dipped in frying oil at a time, then the frying process is simple and fast, but the noodle strings float and collect near the lid, causing poor oil coating and non-uniform density distribution
Solution Approach 1:
The frying process is divided into three distinct stages: (1) initial dipping where only part of the retainer is submerged, (2) floating stage where noodle strings naturally rise and expand, and (3) final dipping where the entire retainer is submerged. This segmentation allows each stage to serve its specific function - initial coating, expansion space, and final uniform coating - resolving the contradiction between speed and uniformity.
Solution Approach 2:
The first dipping action is performed as a preliminary step before the noodle strings have a chance to float. This initial coating establishes a base layer of oil on the noodle strings, and subsequent steps build upon this foundation. The preliminary action ensures that even when strings float, they already have oil coating, preventing poor coverage.
2Manufacturing precision
If the retainer is completely dipped in frying oil, then oil coating is thorough, but the flowing oil creates resistance that impairs the shape of the noodle lump
Solution Approach 1:
The complete dipping process is segmented into two separate actions: an initial partial dip that establishes coating without full submersion, and a final complete dip that occurs after the noodle lump has stabilized in shape. This timing segmentation allows the lump to maintain its formed shape during the second dipping, preventing flow-induced deformation while achieving thorough coating.
Solution Approach 2:
The noodle lump shape is preliminarily formed during the first dipping and floating stage, creating a stable structure. Only after this shape is established does the complete second dipping occur, ensuring that the oil flow does not disrupt shape formation while still achieving uniform coating.
3Use of energy by moving object
If noodle strings are allowed to float freely during frying, then moisture evaporation is efficient, but the strings collect near the lid creating a dense upper portion and coarse lower portion
Solution Approach 1:
The floating and evaporation process is segmented as a distinct stage between two dipping actions. The first dip provides initial coating, then floating allows evaporation and expansion, and the second dip provides final coating. This segmentation ensures evaporation efficiency is maximized during the floating stage while the second dip corrects any density non-uniformities that develop.
Solution Approach 2:
The floating stage allows the noodle strings to naturally rise and expand, creating the desired porous structure and volume. The 'disorderly' floating behavior is actually utilized to achieve expansion, and then the second dipping recovers and stabilizes the structure, converting the floating-induced non-uniformity into a desirable expanded form with uniform final coating.
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 method produces instant noodles with a homogeneous distribution of noodle strings, reducing the difference in density between upper and lower portions, and enhancing frying efficiency by preventing shape distortion and ensuring consistent coating.
Implementation Method 1
the frying oil blows up through evaporation of moisture from the noodle strings dipped in the frying oil
Implementation Method 2
dipping, in frying oil held in a frying oil tank, a retainer holding a group of noodle strings having been gelatinized
Data Source
Figure 1~2
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AI summary
[Problem to be Solved] The present invention relates to instant fried noodles having a small number of coarse or dense portions and homogeneously fried. [Solution] In the present invention, frying is performed in two stages so as to dip a retainer in frying oil at a prescribed dipping ratio and then to dip the whole of the retainer in the frying oil, and in addition, flow rates of the frying oil supplied from an upstream side and a downstream side of a frying oil tank and a surface level of the frying oil are controlled. Therefore, a noodle lump can be prevented from peeling off and floating from the bottom of the retainer before fixing the shape of the noodle lump due to a pressure applied by the frying oil so as not to impair the shape of the noodle lump, and as a result, frying efficiency or production efficiency can be improved. Besides, a noodle lump that has a very small number of coarse or dense portions in a distribution of noodle strings can be stably produced. A difference in density of noodle strings between an upper half portion and a lower half portion of a dried noodle lump is preferably at least 13% or less.