Ultrasonic Extrusion Horn for Shape-Retaining Food Products
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Solution Overview
Problem
Conventional extrusion devices for edible products have limitations such as slower line speeds, increased capital expenditures, and difficulties in maintaining product shape and uniformity, especially during subsequent processing steps like slicing and baking.
Innovation Solution
An ultrasonic extrusion apparatus that includes an infeed, a chamber with an ultrasonic horn, and a booster system to apply ultrasonic energy to the flowable substrate, allowing for increased throughput and shape retention of the extruded product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional extrusion devices are used, then capital expenditures and factory floor space are reduced, but line speed and throughput are slower than desired
Solution Approach 1:
The patent applies ultrasonic vibration (mechanical vibration) to the extrusion process by positioning an ultrasonic horn in communication with the extrusion die. The ultrasonic vibrations enhance material flow through the die, increase line speed, and improve product density without requiring additional extrusion units, thereby resolving the contradiction between productivity and device complexity
Solution Approach 2:
The patent changes the physical parameters of the extrusion process by introducing ultrasonic energy at the die level. This parameter change (adding vibrational energy) fundamentally alters material flow characteristics, enabling higher throughput from existing equipment and reducing the need for multiple extrusion units
2Shape
If conventional extrusion devices are used, then equipment simplicity is maintained, but product shape retention during subsequent processing is poor
Solution Approach 1:
Ultrasonic vibrations applied at the extrusion die enhance the density and structural integrity of the product as it exits the die. This mechanical vibration helps the product maintain its shape better during subsequent processing operations like slicing and baking, while the added complexity is minimal (only the ultrasonic horn and control system)
Solution Approach 2:
The ultrasonic energy is applied preliminarily at the moment of extrusion, before subsequent processing steps occur. This preliminary action of vibrating the material as it exits the die establishes better shape retention characteristics that carry through to later processing, avoiding the need for additional shape-correcting equipment
3Manufacturing precision
If conventional extrusion devices are used, then equipment simplicity is maintained, but product density and uniformity are insufficient
Solution Approach 1:
The ultrasonic vibrations create more uniform material flow through the extrusion die by preventing material stagnation and promoting consistent densification. This results in higher product density and uniformity, while the device complexity increase is limited to the ultrasonic generation system rather than requiring multiple extruders or complex processing lines
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 ultrasonic extrusion process enhances product density, uniformity, and shape retention, achieving throughput increases of up to 10 times compared to non-ultrasonically energized extruders while minimizing friction and back pressure, allowing for efficient production of shape-retaining products.
Implementation Method 1
An ultrasonic horn may extend into the chamber and across the extrusion orifice so that an extrusion path of the flowable substrate extends across the ultrasonic horn
Implementation Method 2
transferring energy from the ultrasonic horn to the flowable substrate and extruding the flowable substrate through an extrusion orifice to form a product
Data Source
AI summary
This invention relates generally to ultrasonic extrusion apparatus, methods and products. A flowable substrate may be supplied by an infeed to an extrusion chamber having an ultrasonic horn. The flowable substrate contacts the ultrasonic resonant horn and receives ultrasonic energy before and/or as passing through an extrusion orifice. Suitable flowable substrates may include meat emulsions, pomace solutions, and dough. The extruded product may have virtually any solid or hollow shape. The flowable substrate may form a shape-retaining product that may be cut without significantly deforming.