CONTINUOUS EXTENDED HOLDING TANK WITH VARIABLE RESIDENT TIME AND PROCESS

Abstract: A tank (15) for holding a liquid for a predetermined time in a continous flow process. The tank includes an inner compartment (40) with an inlet (16) and an outer compartment (20) with an outlet (18). The outer compartment encloses the inner compartmemt except its inlet. The liquid enters through the inlet and is forced upwardly in a non-preferential flow. The liquid overflows out of the inner compartment into the outer compartment and exits through the outlet. A pump (90) is connected to the outlet and a variable throttle valve (80) is connected to output of the pump. A level sensor (60-63) for the liquid is connected to a computerized control unit (70) to monitor the liquid level and to activate the throttle valve to either increase or decrease output flow, and thus adjusting the liquid level.

Description: I. TITLE: CONTINUOUS EXTENDED HOLDING TANK WITH VARIABLE RESIDENT TIME AND PROCESS II. TECHNICAL FIELD The present invention relates to a holding tank and process for holding a fluid for a variable resident time, and more particularly, to the type that is used in continuous flow processing of milk. III. BACKGROUND ART The processing of liquids, and in particular milk, requires inter alia exposure to predetermined temperatures over a given time period. For pasteurizing milk in a modern continuos flow process the milk is typically exposed to a relatively high temperature (72^ to 75^ C) for a relatively short time (16 seconds). And this is referred to as the HTST (High Temperature Short Time) method. Another method for pasteurizing milk is known as the LTH (Low Temperature Long Time) method wherein the milk is held for 30 minutes at a relatively lower temperature of 63-65^ C. Both processes have their advantages and disadvantages. The longer holding time of the latter method, however, makes it impractical for use in continuos flow processes since it would require an extraordinarily long conduit. Thus, the desirability of having a device that can provide a variable holding time in a continuous flow environment. Furthermore, it is also desirable that this device be capable of readily changing the holding time as required or desired. The present invention provides the user with this flexibility permitting the immediate adjustment of holding times to achieve the projected output characteristics. The closest reference known to applicant corresponds to German patent No. 343,889 issued in 1921. Basically, the heating unit of the foreign patentee utilizes chambers with smaller diameters (for faster flow) where the milk rises to prevent the heavier solids from separating. The only concern in that patented invention was to mechanically prevent the settlement of the heavier particles. In the present invention there is no preferential flow and the milk follows the first in, first out rule. More important, the foreign patent does not disclose level sensors or any other mechanisms for changing the holding time. IV. SUMMARY OF THE INVENTION It is one of the main objects of the present invention to provide a holding tank that permits holding a liquid for a selectable predetermined time period at a given temperature. It is another object of this invention to provide a holding tank with an inlet and an outlet to be used in a continuous flow process that ensures the non-preferential flow of the milk being held as it progresses up an inner compartment and spilling over a horizontal rim to an outer compartment. It is still another object of the present invention to provide a holding tank with capabilities for readily varying the resident time for the liquid passing through it. It is yet another object of this invention to provide a holding tank that is relatively inexpensive to manufacture and maintain while retaining its effectiveness. It is another object of this invention to provide a process for varying the amounts of holding time in a continuous flow process of milk. It is another object of this invention to provide a process that includes the capability of varying the holding time and maximizing the yield of precipitating whey proteins at higher than conventional pasteurization temperature. It is one of the main objects of the present invention to increase the yield in the production of cheese by enhancing the precipitation of whey proteins and their capture in the resulting curd. It is another object of this invention to provide a process that is compatible with a continuous flow process that ensures the non- preferential flow of the milk. It is still another object of the present invention to provide a process that is economically attractive in the production of cheese to enhance the yield. It is another object of this invention to provide a process that can readily vary the amounts of holding time in a continuous flow process of milk depending on the yield being obtained. It is another object of this invention to provide a process that includes the capability of varying the holding time and maximizing the yield of precipitating whey proteins at higher than conventional pasteurization temperature. Further objects of the invention will be brought out in the following part of the specification, wherein detailed description is for the purpose of fully disclosing the invention without placing limitations thereon. V. BRIEF DESCRIPTION OF THE DRAWINGS With the above and other related objects in view, the invention consists in the details of construction and combination of parts as will be more fully understood from the following description, when read in conjunction with the accompanying drawings in which: Figure 1 represents an elevational front view of the present invention and a partial cross section of the tank compartments. Figure 2 shows a top view of the present invention. VI. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings, where the present invention is generally referred to with numeral 10, it can be observed that it basically includes insulated holding tank assembly 15 with inner compartment 40 inside of outer compartment 20, cover assembly 30 and support assembly 19. Outer compartment 20 is maintained vertically and includes a slightly inclined bottom 21 that facilitates drainage of the liquid contained therein. In one of the contemplated applications of the invention, the liquid is milk. The milk, in one of the applications contemplated by the inventor needs to be kept at a temperature between 80 and 90 degrees centigrade for a period of time that could be between 7 and 35 minutes, in order to provoke the denaturation of the milk serum or whey proteins. It has been found that in making cheese the production yield is increased if the otherwise soluble whey proteins are caused to lose their solubility (denature) and allowed to join to the casein curd. In operation, the liquid enters inner tank 40 through inlet 16 reaching the top horizontal rim of inner compartment 40 under a predetermined relatively low flow rate that avoids turbulence. The liquid travels upwardly, uniformly. When it reaches the top, the liquid overflows by the open end defined by horizontal rim 44 to outer compartment 20. The liquid then starts traveling downwardly in a laminar flow over external lateral surface 43 and is deposited in annular space 25. The liquid is continuously poured over the liquid that had preceded it so that the first liquid through inlet 16 in is the first liquid out through outlet 18, thereby keeping its preferential position and ensuring being held within holding tank 15 a selectable predetermined amount of time. Initially, outlet 18 is kept closed until enough liquid has accumulated to achieve the desired level for the outer compartment. Valve 12 is preceded by pump 11 and both regulate the flow of the milk. Level sensors 60; 61; 62 and 63 are connected to control unit 70. Sensors 60; 61; 62 and 63 provide a signal to control unit 70 depending on whether or not the level of the liquid has reached a predetermined level where the particular sensor is located. Sensors 60; 61; 62 and 63 can be replaced with a level sensor that could be telescopically inserted inside compartment 20, or by any other equivalent means to sense the level of the liquid, such as pressure sensors that determine the level of the liquid by sensing pressure at a given position inside the body of milk. Sensors 60; 61 and 62, in the preferred embodiment, provide an output to control unit 70, which may be implemented into a general purpose micro-processor with memory for storing data and instructions. Control unit 70 is connected to sensors 60; 61 and 62 and controls variable throttle valve 80. Valve 80, in the preferred embodiment, is pneumatically activated but other types of valves, such as electrical ones, can also be used. Valve 80 is preceded by pump 90, which in the preferred embodiment can be implemented with a sanitary centrifugal pump. If a user wants to increase the holding time, control unit 70 can be programmed to close valve 80 more until the level reaches sensor 61, and them adjust to the original flow rate. And vice versa, if the holding time is to be reduced, the level may be brought to that of sensor 63. In this manner, the levels for the liquid inside outer compartment 20 will establish the pre-determined resident time for the liquid. Alarm assembly 75 is disposed for displaying audio, visual, or both, signals to alert a user that a predetermined level has been reached. The temperature inside compartment 20 is preferably kept constant through the use of thermic insulator 100. Cover assembly 30 has, in the preferred embodiment, manhole 32, air inlet 36, tab 34, washing assembly 38 and temperature probe 39. Manhole 32 permits easy access inside compartment 20. Tab 34 includes opening 35 to facilitate the lifting of cover assembly 30. Air inlet and outlet 36 is designed to keep a low pressure on the liquid in order to push it out through outlet 18 without any deformation to the internal surfaces of the both compartments 20 and 40, and to keep a constant pressure during the process. Washing assembly 38 includes nozzle 37 with a plurality of holes to direct water (or the cleaning liquids) in different directions when the tank is being cleaned. Temperature probe assembly 39 extends downwardly a sufficient distance to ensure that it comes in contact with the liquid for all the levels to be used. Holding tank 10 works in the following manner. The liquid, typically milk, to be pasteurized, comes through inlet 16 and dispersed. The liquid is pushed upwardly displacing the liquid that preceded it until it overflows inner compartment 40. The liquid comes down pushing the liquid that had preceded it until it is pushed out through outlet 18. This movement of the liquid is aided by pump 90, and if desired, a slight pressure introduced through air inlet and outlet 36. It is important to note that the liquid, as it travels through holding tank 10, it is forced to reside, and consequently maintain a predetermined temperature, for a predetermined amount of time. This amount of time (as well as the temperature) can be varied by the user. The amount of time the liquid stays or resides inside holding tank 10 will be determined by the level at which the device is chosen to operate. For instance, if the device is programmed to operate so that sensor 63 is to control valve 80, then the resident time of the liquid will be smaller than if sensor 62 is selected. This is so because the liquid has to travel (and push the preceding liquid) over a longer path (determined by the level of the liquid). The miniinuπi resident time will consequently be determined, inter alia, by the height dimensions (assuming a constant liquid flow rate through inlet 16) of inner compartment 40, and it can be adjusted by selecting one of the sensors 60 through 63 located at different levels, or through the use of any other level sensors. In the preferred embodiment, it has been found that a holding tank 16 having inner compartment 40 with a substantially cylindrical shape (76.2 cm. in diameter, 139.1 cm. in height plus a concave bottom with maximum height of 15.2 cm. ) with capacity of 662 liters and outer compartment 20 also having a substantially cylindrical shape (182.9 cm. diameter, 212.1 cm. height with convex bottom surface having 48.74 cm. height) works well at 132.4 liters per second. It has been found that in making cheese the production yield is increased if the otherwise soluble whey proteins are caused to lose their solubility (denature) and allowed to join the casein curd. To accomplish this in a continuos flow milk process, the temperature needs to be maintained within a certain range for a predetermined time periods. In one of the contemplated methods for practicing the invention, the first step is for the milk needs to be kept at a temperature between 75 and 85 degrees centigrade for a period of time that could be between 10 and 30 minutes, in order to provoke the denaturation of the milk serum or whey proteins. The temperature of the milk is raised by passing it through heat exchanges. The milk is brought to a temperature between 75 and 85 degrees centigrade. Then, it is held in a non- preferential flow tank, with first in-first out capabilities, for a period of time that may vary from 10 minutes to 30 minutes. The optimum being 80 degrees centigrade for 12 minutes for fresh curds. The milk temperature is then lowered to between 38 and 48 degrees centigrade (depending on final moisture desired) and it is ripen by adding a starter, such as mesophilic or thermophilic lactic cultures. The amount of starter used is the conventional amount for each type of cheese. A coagulation agent, such as rennet chemosin, is then added to the milk. For chemosin, the proportion that may vary from 50 ml./ 1000 liters to 60 ml./ 1000 liters, obtaining the best results at approximately 54 milliliters per 1000 liters of milk. One of the chemosin products that can be used is Chy-Max, a registered mark of Hansen Laboratories, Inc. Madison, Wisconsin. The chemosin strength is 1:50,000. The typical process uses from 44-46 ml. per/ 1000 liters. Therefore, the present invention contemplates using more coagulation agent, approximately 22% more, to improve coagulation effect on casein protein. The resulting curd is then cut in small pieces of approximately 0.5 cm. in average diameter augment its effective surface area. Before coagulation calcium chloride is then added to the curd mass at this point in the following proportions: 400 to 440 grams per 1000 liters of milk used. The Calcium chloride used is the granulated food grade 94.5% purity type. The best results are obtained at 420 grams per 1000 liters. Typically, only 150-170 grams per 1000 liters is used. Therefore, the present invention uses approximately 150 to 190% more than what is conventionally used. The resulting curds are drained. The use of conventional draining assemblies hereby removing the whey. At this point, if desired, a user undertakes the cheddaring process step as it is conventionally known. The curds are molded in molds maintaining the temperature between 38 and 45 degrees centigrade. Then, depending on the type of cheese, the curd may be turned over to shape it or press it. Since the objective of this process is for the curd to capture whey protein that would otherwise have been wasted in the whey, then this added protein must be taken into consideration to keep the protein/ fat ratio as desired. This ratio is what characterizes the resulting cheese. Therefore, if a user desires to maintain the ratio constant, he or she needs to compensate by increasing proportionally the fat content of the milk being used. In the typical curd producing process, the milk protein includes 80% of casein and 20% of whey protein. Most of the whey protein is dissolved and lost with the whey along with other substances, such as lactose fat and minerals. It has been found that the whey protein amounts to 11% of the whey solids, using conventional methods. On the other hand, using the process subject of the present invention the applicant has obtained only 8.5 to 9.0% of the solid as whey protein. The difference being obviously kept by the curd mass. This is an absorption increase of whey protein of approximately 23%. Therefore, if the protein/fat ratio is to be kept constant, for a given type of cheese characteristics, then the fat content should be proportionately increased. For example, if in a conventional process milk with 3.0% fat is used, we know that the curd will have 80% of the total protein content (most of it casein). The other 20% is wasted. When 23% of this 20% is captured, that means that the total protein captured will be increased by 4.6% ( 23% times 20%). Therefore, 3.0 is to 80% X is to 84.6% X= (84.6/80) 3.0=3.17 then the milk fat needs to be adjusted to 3.17 percent to keep the same protein /fat ratio. VII. INDUSTRIAL APPLICABILITY It is apparent from the previous paragraphs that an improvement of the type for such a holding tank in a continuous flow process and the process for enhancing the incorporation of seric proteins to the curd of cheese is quite desirable to be used for credentials and identification cards. The foregoing description conveys the best understanding of the objectives and advantages of the present invention. Different embodiments may be made of the inventive concept of this invention. It is to be understood that all matter disclosed herein is to be interpreted merely as illustrative, and not in a limiting sense.

Claims: VI. CLAIMS What is claimed is: 1. A tank assembly for holding a liquid for a predetermined time in a continuous flow, comprising: A) first compartment means for holding said liquid housed within said tank assembly and extending vertically therein with an upper end having an opening defining a horizontal rim, and further including a lower end having an inlet for said liquid; B) second compartment means completely housing said first compartment means except for said inlet, and said second compartment means having a bottom with an outlet for discharging said liquid overflowing said rim; and C) means for maintaining a constant flow of said liquid entering said inlet and exiting said outlet. 2. The tank set forth in claim 1 wherein said second compartment means includes a plurality of level sensing means. 3. The tank set forth in claim 2 further including: D) valve means for controlling the flow of said liquid through said outlet. 4. The tank set forth in claim 3 further including: E) programmable means for controlling said valve means and having input means connected to said plurality of sensing means so that the level of said liquid within said second compartment means is adjustable thereby also making the holding time adjustable. 5. The tank set forth in claim 4 wherein said programmable means includes computer means and memory means for storing data and instructions. 6. The tank set forth in claim 5 wherein said first and second compartment means have a substantially cylindrical shape. 7. The tank set forth in claim 6 wherein said bottom has a convex shape, is slightly slanted and said outlet is positioned in the lowermost portion so that drainage is facilitated. 8. The tank set forth in claim 7 further including: F) temperature sensing means for measuring the temperature of said liquid and being connected to said programmed means. 9. The tank set forth in claim 8 further including: G) alarm means for displaying audio, visual, or both, signals to alert a user that a predetermined level has been reached. 10. The tank set forth in claim 9 further including: H) output means for monitoring the level and temperature of said liquid, said output means being connected to said programmable means. 11. A process for making cheese, comprising: A) raising the temperature of the milk to a temperature between 75 degrees centigrade and 85 degrees centigrade for a period of time not less than 10 minutes and not more than 30 minutes; B) lower the temperature of the milk to between 38 degrees centigrade and 48 degrees centigrade; C) coagulating the milk by adding a coagulation agent at rate between 20 and 40 percent above the conventional rate; D) cutting the curd in small pieces so that the effective surface area is increased to maximize the adhesion of whey protein to the curd; E) adding calcium chloride to the milk at the rate between 150 and 190 percent above the conventional rate; F) draining the resulting curd; and G) molding the resulting curd pieces maintaining the temperature between 38 degrees centigrade and 48 degrees centigrade. 12. The process set forth in claim 1 wherein the temperature in step A, above, is raised to approximately 80 degrees centigrade for approximately 12 minutes. 13. The process set forth in class 2 wherein the coagulation agent used in chemosin. 14. The process set forth in claim 3 wherein the chemosin is used at a rate between 50 and 60 milliliters per thousand liters of milk and the strength being 1:50,000. 15. The process set forth in claim 4 wherein the rate of the calcium chloride used is between 400 to 440 grams per thousand liters of milk and the calcium chloride being granulated food grade type at 94.5% purity.

Inventors: SANCHELIMA JUAN ANDRES, SANCHELIMA, JUAN, ANDRES
Applicants: SANCHELIMA JUAN ANDRES, SANCHELIMA, JUAN, ANDRES
Application year: 1998
Main classification: F01M11
IPC codes: A23C19