Viscous Gelling Solution Co-Extrusion for Thin Casing Control
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Solution Overview
Problem
The co-extrusion process for food products, particularly in sausage production, faces challenges in controlling the economics and quality of the extruded products due to the variability of viscoelasticity in casing materials, leading to excessive use of viscous gelling solutions and inconsistent product specifications.
Innovation Solution
A method that maintains the viscoelasticity of the viscous gelling solution within a specific time window of up to 48 hours, ensuring the grammage of the external layer does not exceed 200 g/m2, by mixing casing material components and controlling the co-extrusion process to achieve a strong yet thin casing with reduced material costs and improved process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the viscous gelling solution is used beyond the specific time window after mixing, then the casing material becomes too weak to provide sufficient strength, but using it within the time window increases material costs due to reduced usability period
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the gelling solution (specific ratios of gelling agents, salts, and pH levels) to extend the time window while maintaining strength. It also changes the physical parameter of viscoelasticity control through additives that slow down the gelling process, allowing the solution to remain usable for extended periods without losing casing-forming capability.
2Strength
If a thicker layer of viscous gelling solution is used to ensure sufficient casing strength, then the product quality improves, but the material costs and grammage increase excessively
Solution Approach 1:
The patent changes the chemical parameters of the gelling solution by incorporating specific salts (calcium chloride, calcium nitrate) and adjusting pH levels (3.5-5.5) to enhance the gelation efficiency. This allows the formation of strong casings with thinner layers, reducing grammage from typical values to below 200 g/m² while maintaining or improving casing strength and product quality.
3Ease of operation
If the viscoelasticity of the viscous gelling solution varies over time, then the co-extrusion process becomes difficult to control, but maintaining constant viscoelasticity requires precise control of the time window
Solution Approach 1:
The patent applies preliminary action by pre-determining and specifying the exact time window (e.g., 2-24 hours) within which the gelling solution must be used after mixing. This preliminary specification of the usable time frame allows operators to control the process simply by timing the application, without requiring complex real-time viscoelasticity monitoring systems.
Solution Approach 2:
The patent implements feedback mechanisms through viscosity measurements and pH monitoring during the gelling process. By measuring these parameters at different time points and adjusting the formulation accordingly, the system provides feedback on the gelling progression, enabling operators to optimize the time window and maintain consistent viscoelasticity for reliable co-extrusion process control.
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 approach enables the production of food products with consistent product specifications, reduced material costs, and enhanced control over the co-extrusion process by maintaining high viscoelasticity, resulting in a strong casing with minimal amounts of viscous gelling solution, thereby improving the overall efficiency and quality of the co-extruded products.
Implementation Method 1
the viscoelasticity of the viscous gelling solution at the moment of the co-extrusion is thus maintained above a set minimum viscoelasticity value
Data Source
AI summary
The invention relates to a method for preparing food products by means of co-extrusion, wherein at least two casing material components are mixed to make a viscous gelling solution. This viscous gelling solution is subsequently co-extruded whereby the gelling solution is forming the external layer of an extruded strand of food dough. The invention also relates to a viscous gelling solution obtainable by such method as well as a system for co-extrusion of food products.