Viscous Gel Nozzle System for Bubble-Free Meat Analogues
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Solution Overview
Problem
Existing methods for producing animal feed or foodstuffs using meat or fish emulsions and viscous gels introduce gas bubbles, which impair the authenticity of the final product by disturbing the natural texture and appearance, particularly the striped meat pattern.
Innovation Solution
A method involving the preparation of a viscous gel under high pressure without gas bubbles, followed by laminar dispersion and partial incomplete mixing to create droplets of at least 0.3 mm in size, which are then solidified and cut to mimic natural meat or fish texture, using a static mixer and specific nozzle configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a viscous gel is prepared by intimately mixing gel-forming components with water in a cutter, then the gel can be used as a second stream of material, but gas bubbles are introduced into the stream and end product, impairing the authenticity of meat or fish analogues
Solution Approach 1:
The harmful element (gas bubbles) is extracted from the system by changing the mixing approach from a cutter to a high-pressure nozzle system, where liquid is forced through a nozzle into the gel-forming component, eliminating bubble formation while maintaining ease of manufacture
Solution Approach 2:
The mechanical mixing system (cutter) is replaced with a high-pressure fluid injection system (nozzle), substituting mechanical agitation with pressure-driven liquid introduction, thereby preventing gas bubble entrapment while achieving homogeneous gel preparation
2Ease of manufacture
If gas bubbles are present in the viscous gel, then the gel can be easily prepared and applied, but the striped meat pattern (fibres) is disturbed, reducing the authenticity of the meat or fish analogue
Solution Approach 1:
Gas bubbles are eliminated from the gel preparation process by using high-pressure nozzle injection instead of mechanical mixing, ensuring the meat pattern remains undisturbed and authentic while maintaining ease of application
Solution Approach 2:
The preparation method changes from low-pressure mechanical mixing to high-pressure fluid injection, altering the physical parameters of the process to prevent bubble formation while preserving the ability to easily apply the gel
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 method prevents gas bubbles in the final product, preserving the authenticity of meat or fish analogues by maintaining a natural texture and appearance, similar to original pieces, without compromising the viscosity or adding fibers.
Implementation Method 1
the introduction of the liquid into the gel-forming component located in the mixing chamber being performed by means of a first nozzle unit under high pressure
Implementation Method 2
making a laminar dispersion of the second stream of material in the first stream of material in an apparatus for at least partially incompletely mixing the first and second streams of material
Implementation Method 3
withdrawing the first stream of material containing the second stream of material in the form of droplets through a second nozzle unit
Implementation Method 4
solidifying the first stream of material containing the second stream of material in the form of droplets
Data Source
AI summary
The present invention relates to a method of producing an animal animal feed or foodstuff comprising the steps of: (i) providing at least a first stream of material, preferably comprising a meat and/or fish emulsion, (ii) preparing a viscous gel comprising at least one gel-forming component and a liquid, especially water, by introducing the gel-forming component and the liquid into a mixing chamber, the introduction of the liquid into the gel-forming component located in the mixing chamber being performed by means of a first nozzle unit under high pressure, (iii) providing the viscous gel obtained in step (ii) as or in at least one second stream of material, (iv) making a laminar dispersion of the second stream of material in the first stream of material in an apparatus for at least partially incompletely mixing the first and second streams of material, so that the second stream of material is distributed in the first stream of material in the form of droplets with a size of at least 0.3 mm, preferably 0.3 mm to 8 mm, (v) withdrawing the first stream of material containing the second stream of material in the form of droplets through a second nozzle unit, and (vi) solidifying the first stream of material containing the second stream of material in the form of droplets; and an animal feed or foodstuff which can be prepared with said method.