Vacuum Particulate Applicator for Uniform Food Coating
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Solution Overview
Problem
Existing methods for applying solid edible particulates to food substrates are inefficient and messy, often resulting in wasted material due to air currents disrupting the application process, leading to uneven coating and increased costs due to overfeeding to compensate for losses.
Innovation Solution
An apparatus using a particulate supply, metered dosing system, vacuum system, and applicator nozzle to deliver solid edible particulates vertically through air currents to the substrate surface, ensuring precise deposition without penetration, allowing for controlled and uniform application in desired patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solid edible particulates are applied by force of gravity, then the application process is simple, but the material is wasted due to air currents disrupting the falling particles
Solution Approach 1:
The patent uses a vacuum system with a venturi vacuum source to create a controlled air current that draws particulates through a conduit and directs them onto the substrate. This pneumatic approach replaces gravity-based application, allowing precise control of particle delivery while minimizing waste through targeted deposition.
Solution Approach 2:
The invention changes the physical parameters of particle delivery by controlling air flow velocity and vacuum pressure. By adjusting these parameters, the system achieves optimal particle deposition efficiency, ensuring particles reach the substrate without being scattered by uncontrolled air currents.
2Quantity of substance
If larger solid particles are used for coating, then the coating coverage is improved, but clogging occurs in the machinery
Solution Approach 1:
The vacuum system with venturi design creates sufficient suction to transport larger particulates through the conduit without requiring mechanical conveyance systems that are prone to clogging. The air flow keeps particles suspended and directed, allowing larger coating particles to be delivered effectively.
Solution Approach 2:
The patent introduces air flow as an intermediary medium to transport particulates from the supply container through the conduit to the substrate. This intermediary approach eliminates direct mechanical contact between large particles and conveyor mechanisms, preventing clogging while maintaining delivery efficiency.
3Manufacturing precision
If more particulate material is fed to compensate for losses, then the minimum coating requirement is met, but the cost increases
Solution Approach 1:
The system provides visual feedback through a transparent or translucent conduit, allowing operators to observe particle flow and deposition in real-time. This enables precise control of material feeding, ensuring only the necessary amount of particulates is used to achieve the desired coating, thereby minimizing waste and cost.
Solution Approach 2:
The patent replaces gravity-based mechanical delivery with a controlled pneumatic system. This substitution allows for more efficient particle transport and deposition, reducing the amount of material needed to achieve adequate coating coverage and lowering overall material costs.
4Quantity of substance
If air currents are used to force excess seasoning upward, then the underside of the substrate is coated, but the process becomes messy and inefficient
Solution Approach 1:
The vacuum system directs air flow through the conduit to carry particulates to the substrate. By controlling the vacuum pressure and air flow direction, the system achieves precise deposition on the substrate surface without creating uncontrolled air currents that would scatter particles and create messiness.
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
Achieves a high percentage of particulate deposition (at least 90%) in desired patterns on the substrate surface, minimizing waste and ensuring cost-effective application of edible toppings, while maintaining a clean and efficient process.
Implementation Method 1
a vacuum system operatively associated with the dosing system and the conduit that supplies a directed stream of air to accelerate the particulates from the dosing system through the conduit and at least substantially vertically through the nozzle
Implementation Method 2
The vacuum system includes a venturi vacuum source
Implementation Method 3
The particulates are applied onto the upper surface of the substrate at a velocity sufficient to eject the particulates from the nozzle so as to cut through air currents between the nozzle and substrate
Implementation Method 4
to deposit and adhere a substantial amount of the particulates in a desired pattern on the substrate
Data Source
AI summary
The invention relates to an apparatus and method for applying solid edible particulates to an exposed upper surface of an edible substrate. The apparatus includes a particulate supply, a metered dosing system, a conduit through which the measured particulates are to the edible substrate, an applicator nozzle to direct the measured particulates from the conduit onto the upper surface of the substrate, and a vacuum system that supplies a directed stream of air to accelerate the particulates from the dosing system through the conduit and at least substantially vertically through the nozzle. The particulates are ejected at a velocity sufficient to cut through air currents between the nozzle and substrate, but insufficient to fully penetrate the upper surface of the substrate, to deposit and adhere a substantial amount of the particulates in a desired pattern onto the upper surface of the substrate.