Description:The apparatus of the present invention comprises several key components that work together to provide a seamless and efficient process for producing besan paste. The system is designed with the following principal components:
1. Dual Feeding Mechanism
2. Horizontal Screw Mixing Assembly
3. Paste-Making Worm Assembly
4. Rotary Discharge System
5. Optional Fryer Attachment
1. Dual Feeding Mechanism
The dual feeding mechanism of the present invention is designed to enhance operational flexibility and convenience. It includes:
• Gravity-Fed Hopper System: A traditional feeding mechanism where besan and masala are fed directly into the machine from an overhead hopper. This setup utilizes gravity to facilitate the feeding process. This method is suitable for scenarios where the hopper is mounted above the main apparatus. However, the gravity-fed system requires manual lifting and pouring of raw materials, which can be labor-intensive, especially in large-scale operations.
• Ground-Level Screw Feeding Mechanism: An innovative alternative feeding system where besan and masala can be poured into a hopper located at ground level. This mechanism employs a screw conveyor or auger to lift and transport the ingredients from the ground-level hopper to the main processing unit. This feature significantly improves convenience and productivity by allowing operators to load raw materials without the need for manual lifting to elevated hoppers. The screw conveyor is powered by an electric motor and designed to operate at a controlled speed to ensure consistent feeding of ingredients into the processing unit. This feeding mechanism is particularly beneficial for large-scale production facilities where frequent refilling is required.
2. Horizontal Screw Mixing Assembly
The horizontal screw mixing assembly is a critical component responsible for initially mixing besan and masala before the paste-making process begins. The assembly comprises:
• Mixing Chamber: A cylindrical or semi-cylindrical chamber where the ingredients are introduced for mixing. The chamber is designed to ensure even distribution of the ingredients as they pass through the system.
• Horizontal Mixing Screw: A continuous screw or auger rotates within the mixing chamber to uniformly mix the besan and masala. The screw is powered by a motor and designed to operate at a controlled speed to ensure thorough mixing. The horizontal configuration allows for efficient movement of ingredients from the inlet to the outlet of the mixing chamber.
• Output Port: The mixed ingredients are continuously discharged from the horizontal screw mixing assembly and transferred to the next stage of the apparatus.
3. Paste-Making Worm Assembly
The paste-making worm assembly is designed to convert the dry mixture of besan and masala into a smooth and consistent paste or dough by incorporating controlled amounts of water and oil. The assembly includes:
• Worm Screw: A helical screw located within a cylindrical chamber. The worm screw is driven by a motor, which ensures consistent movement of the mixture through the chamber.
• Water Inlet: A dedicated inlet for the addition of water into the paste-making chamber. The water flow is regulated through a valve or pump to ensure precise and consistent addition of water to the mixture.
• Oil Inlet: A separate inlet for introducing oil into the mixture. The oil flow is similarly regulated to provide the desired consistency and texture of the dough.
• Blending Chamber: The paste-making chamber is designed to facilitate the blending of dry ingredients with water and oil, producing a homogeneous paste. The chamber's internal configuration ensures thorough mixing of all components as the mixture progresses through the worm screw.
• Hydration Process: The continuous addition of water and oil during the movement of the mixture ensures gradual hydration, preventing the formation of lumps and producing a uniform dough with consistent quality.
4. Rotary Discharge System
The rotary discharge system is an essential component designed to enable continuous extrusion of the prepared dough or paste. The system includes:
• Rotary Gearbox: Located at the discharge end of the paste-making worm assembly, the rotary gearbox regulates the extrusion rate by controlling the rotational speed of the worm screw. The gearbox provides precise control over the discharge rate, ensuring consistent and uninterrupted output of the paste.
• Die Attachment: An optional attachment that shapes the extruded paste into desired forms, such as long strands for making Sev or other shapes suitable for various snacks. The die can be interchanged depending on the desired product.
• Continuous Extrusion: The rotary discharge system allows the prepared dough to be extruded continuously without interruptions. The continuous extrusion feature enhances productivity and ensures a uniform output of the final product.
5. Optional Fryer Attachment
The invention further provides the option of connecting the continuous extrusion apparatus to a modular fryer for producing various fried besan-based snacks. The fryer attachment is designed to receive the extruded paste directly from the rotary discharge system, allowing for immediate frying and production of finished products.
The fryer may include features such as:
• Temperature Control System: Ensures the frying process is conducted at the optimal temperature for the specific product being prepared.
• Continuous Frying Belt: Allows for the automatic movement of extruded snacks through the frying chamber, ensuring uniform cooking and high throughput.
This modular fryer attachment enhances the versatility of the apparatus by allowing users to produce fried snacks directly from the continuous extrusion process. , C , Claims: I/We Claims,
1. An Automated Besan Paste Preparation Apparatus with Dual Feeding Mechanism and Continuous Extrusion System comprising:
a. A dual feeding mechanism consisting of a gravity-fed hopper system and an alternative ground-level screw feeding mechanism for consistent supply of raw materials;
b. A horizontal screw mixing assembly configured to uniformly blend besan and masala through continuous rotational motion;
c. A paste-making worm assembly for controlled addition of water and oil to the mixed ingredients, resulting in a consistent and homogeneous paste;
d. A rotary discharge system connected to the paste-making worm assembly, facilitating continuous extrusion of the prepared paste; and
e. An optional modular fryer attachment configured to receive extruded paste for direct frying to produce various besan-based food products,
Characterized by the integration of a dual feeding mechanism including a gravity-fed hopper and a ground-level screw feeding system for enhanced ease of operation, a horizontal screw mixing assembly for thorough mixing, a paste-making worm assembly for controlled addition of water and oil, a rotary discharge system enabling continuous extrusion, and an optional fryer attachment for direct frying of extruded paste.
2. The apparatus as claimed in claim 1, wherein the ground-level screw feeding mechanism comprises a screw conveyor powered by an electric motor to lift besan and masala from ground level to the mixing assembly.
3. The apparatus as claimed in claim 1, wherein the horizontal screw mixing assembly includes a cylindrical chamber housing a rotating screw for thorough mixing of dry ingredients before the paste-making process.
4. The apparatus as claimed in claim 1, wherein the paste-making worm assembly includes a blending chamber equipped with separate inlets for controlled addition of water and oil, producing a smooth and uniform paste.
5. The apparatus as claimed in claim 1, wherein the rotary discharge system comprises a rotary gearbox for regulating the extrusion rate of the prepared paste, providing continuous and consistent output.
6. The apparatus as claimed in claim 1, wherein the modular fryer attachment is configured to receive the extruded paste directly from the rotary discharge system for immediate frying, enhancing the efficiency of the production process.
7. The apparatus as claimed in claim 1, wherein the dual feeding mechanism allows the apparatus to operate with either gravity-fed or ground-level screw feeding, providing flexibility and scalability for various production environments.
8. The apparatus as claimed in claim 1, wherein the apparatus is capable of preparing various dough and paste types beyond besan paste, thereby enhancing its versatility and application range.