A pet food feed freeze-drying sterilization water recycling integrated automatic process method

Abstract

The application is a kind of pet food feed freeze-drying sterilization water recycling integrated automation process method, which includes the following parts: the in-out material RGV of the freeze-drying material car conveying part, the in-out material flat car, the material car, the low rail in the warehouse; the cold trap box, the switching cover plate, the winding rope motor, the plate type cold trap, the cold trap refrigeration interface, the defrosting water purifier interface of the freeze-drying warehouse lower switching cold trap part; the evacuation and aeration channel, the evacuation and aeration sieve plate, the vacuum unit interface, the negative pressure generator interface, the ozone generator interface and the like of the freeze-drying warehouse evacuation and aeration vacuum sterilization defrosting part; its characteristics are that the RGV low rail material car automatic in-out conveying system, the freeze-drying warehouse lower switching plate type cold trap, the vacuum warehouse negative pressure defrosting low temperature ozone sterilization and the like optimization scheme are adopted, the pet food raw material freeze-drying sterilization water recycling one-time automation process is completed, and the green energy-saving freeze-drying of the pet food, high-protein feed carbon sink industry in the new era becomes a reality.

Description

Technical Field

[0001] This invention pertains to green deep processing automated freeze-drying systems in the pet food and feed industry, and specifically relates to an integrated automated process method for freeze-drying and sterilizing pet food and feed, and water recovery. Background Technology

[0002] With the progress of the times, green development, and consumption upgrades, the food industry is moving towards nutrition, health, and green ecology. This is clearly no exception for the highly competitive pet food and feed industry. In recent years, freeze-drying technology, which offers high shelf life, easy storage and transportation, and extremely high preservation of original ingredients, has gained popularity and attracted widespread attention in the pet food and feed industry. Especially for algae protein feed in aquaculture, traditional drying processes simply cannot meet the quality requirements, making freeze-drying the best alternative. Furthermore, "carbon sink fisheries" have been proven to be a typical negative-carbon green economic model. In today's context of clearly defined "dual carbon" goals, this has brought a golden opportunity to the feed industry, one that no far-sighted company would miss. However, conventional freeze-drying processes are energy-intensive (drying... The high energy consumption, low yield (over 80% moisture loss in raw materials), and lack of environmental friendliness (refrigeration refrigerant CWP > 1000) are problems. In particular, the bacterial flora of pet food raw materials is uncontrolled, and the freeze-drying process itself cannot achieve the high-temperature sterilization of drying processes. Therefore, a sterilization process is usually required after freeze-drying, further increasing production costs. Furthermore, most current freeze dryers use a single-end rail conveyor system, which is time-consuming, labor-intensive, unsafe, does not comply with pet food safety and hygiene standards, and is difficult to automate. These issues are out of step with modern requirements. This invention addresses the practical problems of "additional sterilization, single-end rail conveyor system, non-compliance with standards, and difficulty in automation" in the freeze-drying of pet food raw materials. (The problems of high energy consumption, low yield, and lack of environmental friendliness have been addressed in "A Complete System for Carbon Dioxide Refrigeration Heating and Negative Pressure Defrosting Water Recovery in a Freeze Dryer" ZL). (As addressed in 202222690540.X), a one-time automated freeze-drying process with freeze-drying sterilization water recovery was completed by adopting a bottom-mounted switching plate cold trap in the freeze-drying chamber, low-temperature ozone sterilization in the vacuum chamber, and RGV low-rail material car entering and exiting at both ends, making green and energy-saving freeze-drying of pet food raw materials and high-protein feed a reality.

[0003] Freeze-drying technology for pet food involves rapidly freezing water-containing materials (unsterilized) and then heating them in a vacuum environment, causing the ice crystals in the material to sublimate directly, thus obtaining a dried product. Because the freeze-drying process takes place in a low-temperature, low-oxygen environment, the original structural composition of the freeze-dried product changes very little (including the microbial community), which is a key characteristic of freeze-drying! However, this is a drawback for unsterilized pet food raw materials. Unlike oven drying, it cannot be sterilized at high temperatures simultaneously with drying. Therefore, a sterilization process must be added after freeze-drying to meet pet food safety and hygiene requirements. This additional sterilization process not only increases process costs but also significantly reduces production efficiency, as the temperature and humidity of freshly freeze-dried products are particularly unsuitable for ozone sterilization (other sterilization methods are even more expensive). Furthermore, existing single-entry, one-way freeze dryers, even with ozone introduced into the chamber (requiring a sealed chamber and redesigned vacuum unit), cannot solve the sterilization problem because the overlapping single-entry, one-way flow does not meet pet food safety and hygiene requirements! Therefore, in order to meet the green freeze-drying needs of large-scale modern pet food and feed factories, a complete set of automated freeze-drying machine system with one-time recycling of sterilized water has been specially designed for pet food and feed. While making full use of the limited space of the freeze-drying chamber and the low-temperature vacuum environment, it realizes an integrated automated process of freeze-drying sterilization water recycling that meets pet food safety and hygiene standards and is highly efficient and energy-saving. It is the best alternative for the green development of the pet food and feed industry in the new era. Summary of the Invention

[0004] The purpose of this invention is to solve the practical problems of conventional freeze dryers being unsuitable for pet food raw materials with uncontrolled microbial flora, not being able to simultaneously sterilize during the freeze-drying process, having to enter and exit from only one end of the overhead rail, not meeting pet food safety and hygiene standards, and being difficult to automate. This invention provides an integrated automated process for freeze-drying, sterilizing, and recycling water in pet food feed. It utilizes a set of systems including a bottom-mounted switching plate cold trap negative pressure water recycling system within the freeze-drying chamber, an integrated vacuum sterilization and defrosting system, and an automated transport system with RGV low-rail trolleys entering and exiting from both ends. This achieves an integrated automated, green, and energy-saving freeze-drying process for high-protein pet food feed, sterilizing, and recycling water.

[0005] The technical solution adopted by the present invention to solve the problem is: an integrated automated process method for freeze-drying, sterilizing and recycling water in pet food feed, including a freeze-drying chamber; a feed inlet door and a discharge door; a freeze-drying material transport section A; a freeze-drying chamber lower switching cold trap section B; and a freeze-drying chamber evacuation, gas filling, vacuum sterilization and defrosting section C.

[0006] The freeze-drying material transport section A consists of an infeed RGV, an infeed flatcar, and an electromagnetic stop block for the push chain; a material car, a material car electromagnetic attractor, and an internal low rail; and an outfeed RGV, an outfeed flatcar, and an electromagnetic stop block for the pull chain (see...). Figure 1The feeding RGV, feeding hopper door, and discharging RGV and discharging hopper door are located at both ends of the freeze-drying chamber and move vertically along the axis of the freeze-drying chamber on their respective guide rails. The feeding flatcar and discharging flatcar on the feeding RGV and discharging RGV can move axially along the axis of the freeze-drying chamber on their respective guide rails. The electromagnetic stop block of the push chain and the electromagnetic stop block of the pull chain can drive the flatcar loading car to move axially along the low rail inside the chamber.

[0007] The freeze-drying chamber lower-positioned switching cold trap section B consists of a cold trap housing; a left sealing ring and a right sealing ring; a housing partition; a switching cover; a guide rod; a guide positioner; a rope winding motor; a rope pulley; a traction rope; a left plate-type cold trap and a right plate-type cold trap; a left cold trap liquid supply electric valve and a right cold trap liquid supply electric valve; a left cold trap refrigeration liquid supply interface and a right cold trap refrigeration liquid supply interface; a left cold trap return gas electric valve and a right cold trap return gas electric valve; a left cold trap refrigeration return gas interface and a right cold trap refrigeration return gas interface; a left defrost drain valve and a right defrost drain valve; and a left defrost water purifier interface and a right defrost water purifier interface (see...). Figure 1 , Figure 2 The cold trap chamber is located below the main chamber, divided into two symmetrical chambers by a partition. At least one set of cold trap water inlets is located on the top of the chamber, and it is isolated from the freeze-drying chamber by a switching cover and left and right side sealing rings. The switching cover is connected to the guide rod and guide positioner via bearing seat fixing components. The rope winding motor is connected to both ends of the guide rod via a rope wheel and traction rope. A left-plate cold trap and a right-plate cold trap are installed in the left and right cold trap chambers respectively, with the left and right cold trap liquid supply pipes located below their respective left and right sides. The left and right cold trap liquid supply electric valves, the left and right cold trap refrigeration liquid supply interfaces, and the right cold trap refrigeration liquid supply interfaces are connected to them respectively. The left and right cold trap return gas pipes are located above their respective left and right sides. The left and right cold trap return gas electric valves, the left and right cold trap refrigeration return gas interfaces, and the right cold trap refrigeration return gas interfaces are connected to them respectively. Defrost drain pipes are located at the bottom of the left and right cold trap chambers respectively. The left and right defrost drain electric valves, the left and right defrost drain electric valves, the left and right defrost water purifier interfaces, and the right defrost water purifier interfaces are connected to them respectively.

[0008] The freeze-drying chamber vacuum sterilization and defrosting section C comprises: a left vacuum and inflation channel, a right vacuum and inflation channel; a left vacuum and inflation screen plate, a right vacuum and inflation screen plate; a left vacuum electric valve, a right vacuum electric valve; a left vacuum unit interface, a right vacuum unit interface; a left negative pressure steam electric valve, a right negative pressure steam electric valve; a left negative pressure steam generator interface, a right negative pressure steam generator interface; a left ozone inflation electric valve, a right ozone inflation electric valve; a left ozone generator interface, a right ozone generator interface (see...). Figure 2The left and right evacuation and inflation channels are located on the outside of the left and right cold trap boxes, respectively; the left and right evacuation and inflation screen plates are located on the lower inner side of their respective evacuation and inflation channels; the left and right evacuation electric valves; the left and right vacuum unit interfaces; the left and right negative pressure steam electric valves; the left and right negative pressure steam generator interfaces; the left and right ozone inflation electric valves; and the left and right ozone generator interfaces are connected to their corresponding channels via pipes.

[0009] An integrated automated process for freeze-drying, sterilization, and water recovery of pet food feed comprises the following steps: The automated transport, freeze-drying, sterilization, and water recovery components of this complete system, along with other systems of the freeze dryer, are controlled locally and remotely via a computer or mobile terminal, configuration module, PLC module, and corresponding system control components through 4G or 5G networks. According to the freeze-drying process requirements, the freeze dryer control system initiates the refrigeration, quick-freezing, heat recovery, and energy storage programs according to the program. After the material is quick-frozen, the application sequence of this complete system is: freeze-drying material transport section A → freeze-drying chamber lower switching cold trap section B → freeze-drying chamber evacuation, inflation, vacuum sterilization, and defrosting section C.

[0010] Freeze-drying material transport section A: When the freeze-drying material cart needs to enter the silo, the silo door opens, and the RGV (Receiving Vehicle) loaded with quick-frozen material automatically aligns with the low rail inside the silo. After alignment and stabilization, the feeding flatcar on the RGV extends horizontally and connects with the low rail inside the silo. Simultaneously, the electromagnetic stop of the push chain engages with the electromagnetic attractor of the material cart (both front and rear feeders engage simultaneously). Under the action of the push chain, the material cart is propelled to the designated position inside the silo and stops. The electromagnetic attractor of the material cart unlocks, disengages from the electromagnetic stop of the push chain, the feeding flatcar retracts, and the silo is closed. Close the feed hopper door and start the freeze-drying process. When the freeze-dried material cart needs to exit the hopper, the discharge hopper door opens, and the discharge RGV automatically aligns with the low rail inside the hopper. After alignment and stabilization, the discharge flatcar on the discharge RGV extends and connects with the low rail inside the hopper. At the same time, the pull chain electromagnetic stop engages with the material cart electromagnetic attractor. Under the action of the pull chain, the material cart is pulled to the designated position on the discharge RGV and stabilized. The discharge flatcar is retracted, the discharge hopper door is closed, and the post-exit procedure of the freeze-dried material cart begins. In this way, the entire process of the freeze-dried material cart automatically entering and exiting the freeze-drying hopper is completed.

[0011] Freeze-drying chamber with lower-mounted cold trap switching section B: When the freeze-drying chamber starts the freeze-drying process, the cold trap switching cover on one side of the cold trap chamber opens (e.g., Figure 2On the right side, the liquid supply electric valve and return gas electric valve of the cold trap are opened to cool the cold trap. When the cold trap reaches the set temperature (if operating continuously, the temperature is reached when the switching cover is opened), the evacuation electric valve is opened to evacuate the freeze-drying chamber. When the set vacuum level is reached, the freeze-drying heating program is started to perform freeze-drying operations. After the freeze-drying program has been running for a period of time, the set cold trap switching time is reached, the rope winding motor is turned on, and the rope wheel drives the traction rope to pull the guide rod fixed on the switching cover, so that the switching cover is positioned in the direction of the guide positioner to the designated position of the right cold trap, and the sealing ring is pressed to isolate and seal it, completing the left to right switching of the cold trap chamber cover. At this time, the open left cold trap has reached the freeze-drying working temperature and pressure under the control of the pre-set program, and can directly take over the right cold trap to continue the freeze-drying operation. Since the switching cover has been switched to isolate the right cold trap from the freeze-drying chamber, the liquid supply electric valve, return gas electric valve and evacuation electric valve of the right cold trap can be closed at this time. The process begins with stopping refrigeration and evacuation; opening the negative pressure steam electric valve to defrost the cold trap; once defrosting is complete (reaching the set defrosting time), closing the negative pressure steam electric valve, opening the drain electric valve to complete drainage, and closing the drain electric valve; then opening the liquid supply electric valve and the evacuation electric valve to prepare for the next cold trap switch; repeating this switching process until the final unloading stage. At this point, the freeze-drying chamber has stopped heating, so the open-side cold trap can shut off refrigeration and evacuation, and open the ozone inflation electric valve inside the chamber. Ozone flows through the inflation screen plate and through the cold trap channel to perform low-temperature ozone sterilization on the freeze-dried product. Once the set sterilization time is reached, the ozone inflation electric valve is closed, the discharge chamber door is opened, and the freeze-dried sterilized product is discharged. Simultaneously, the closed-side cold trap continues defrosting, drainage, refrigeration, and evacuation preparation. Once the next batch of material enters the chamber, the freeze-drying operation begins immediately, eliminating the waiting time for cold trap defrosting and the external sterilization process, significantly improving work efficiency and saving costs.

[0012] Section C of the freeze-drying chamber evacuation, inflation, vacuum sterilization, and defrosting: When the cold trap on this side needs to be evacuated, defrosted, and inflated for sterilization, the corresponding electric valve is opened (other valves are closed and interlocked). The airflow passes through the holes of the lower sieve plate and through each channel of the plate-type cold trap to complete the entire process of efficient evacuation, negative pressure defrosting, and ozone low-temperature sterilization of the freeze-drying chamber.

[0013] The beneficial effects of this invention are as follows: This invention addresses the practical problems that conventional freeze dryers cannot complete freeze-drying and sterilization in one go, do not meet pet food safety and hygiene standards, and are difficult to automate. It provides an integrated automated process for freeze-drying and sterilizing pet food and feed, which utilizes a set of a bottom-mounted switching plate cold trap negative pressure defrosting and water recovery system in the freeze-drying chamber, an integrated vacuum sterilization and defrosting system, and an automated conveying system with RGV low-rail material cars entering and exiting at both ends. This achieves an integrated automated, green, and energy-saving freeze-drying process for freeze-drying and sterilizing pet food and feed, which integrates water recovery. Attached Figure Description

[0014] The following is in conjunction with the appendix Figure 1 , Figure 2 The following is a detailed explanation using specific examples: Appendix Figure 1 , Figure 2 This is a schematic diagram of an integrated automated process for freeze-drying, sterilizing, and recycling water in pet food feed.

[0015] Figure 1 In the middle: 0-100 - Feed hopper door; 0-200 - Freeze-drying chamber body; 0-300 - Discharge hopper door; A-Freeze-dried material transport section: 1-100-Feeding RGV; 1-101-Feeding flatcar; 1-102-Electromagnetic stop block of the push chain; 1-200-Material car; 1-201-Material car electromagnetic actuator a; 1-202-Material car electromagnetic actuator b; 1-203-Inner low rail; 1-300-Discharge RGV; 1-301-Discharge flatcar; 1-302-Pull-out chain electromagnetic stop block; B-Freeze-drying chamber with lower-positioned switching cold trap section: 2-100-Cold trap body; 2-101-Left side sealing ring; 2-200-Switching cover plate; 2-201-Guide rod; 2-202-Guide positioner; 2-300-Left plate type cold trap; 2-301-Left cold trap liquid supply electric valve; 2-311-Left cold trap refrigeration liquid supply interface; 2-302-Left cold trap return gas electric valve; 2-312-Left cold trap refrigeration return gas interface; 2-303-Left cold trap defrost drain valve; 2-313-Left cold trap defrost water purifier interface. Figure 2 middle: B-Freeze-drying chamber lower-position switching cold trap section: 2-102-Right side sealing ring; 2-103-Box partition; 2-203-Rope winding motor; 2-205-Rope pulley; 2-206-Traction rope; 2-500-Right plate type cold trap; 2-501-Right cold trap liquid supply electric valve; 2-511-Right cold trap refrigeration liquid supply interface; 2-502-Right cold trap return gas electric valve; 2-512-Right cold trap refrigeration return gas interface; 2-503-Right cold trap defrost drain valve; 2-513-Right cold trap defrost water purifier interface. C-Freeze-drying chamber evacuation, gas filling, vacuum sterilization, and defrosting section: 3-100-Left evacuation and gas filling channel, 3-101-Left evacuation and gas filling screen plate; 3-102-Left evacuation electric valve, 3-112-Left vacuum unit interface; 3-103-Left negative pressure steam electric valve, 3-113-Left negative pressure steam generator interface; 3-105-Left ozone gas filling electric valve, 3-115-Left ozone generator interface; 3-200-Right evacuation and gas filling channel, 3-201-Right evacuation and gas filling screen plate; 3-202-Right evacuation electric valve, 3-212-Right vacuum unit interface; 3-203-Right negative pressure steam electric valve, 3-213-Right negative pressure steam generator interface; 3-205-Right ozone gas filling electric valve, 3-215-Right ozone generator interface. Detailed Implementation

[0016] Example, see attached document Figure 1 , Figure 2 This includes: feed hopper door 0-100; freeze-drying chamber body 0-200; discharge hopper door 0-300; freeze-drying material cart transport section A; freeze-drying chamber lower switching cold trap section B; freeze-drying chamber evacuation, gas filling, vacuum sterilization and defrosting section C.

[0017] The freeze-drying material transport section A consists of an infeed RGV 1-100; an infeed flatcar 1-101; an electromagnetic stop block 1-102 for the push chain; a material cart 1-200; an electromagnetic attractor a 1-201; an electromagnetic attractor b 1-202 for the material cart; an internal low rail 1-203; an outfeed RGV 1-300; an outfeed flatcar 1-301; and an electromagnetic stop block 1-302 for the pull chain. The infeed RGV 1-100, the infeed bin door 0-100, the outfeed bin door 0-300, and the outfeed RGV 1-300 are located at both ends of the freeze-drying bin body 0-200, and move vertically along the axis of the freeze-drying bin on their respective guide rails. The infeed RGV 1-100 and the outfeed RGV 1-200... The feeding flatcar 1-101 and discharging flatcar 1-301 can move horizontally along the axial direction of the freeze-drying chamber on their respective guide rails; the electromagnetic stop block 1-102 of the push chain and the electromagnetic stop block 1-302 of the pull chain can drive the flatcar loading car 1-200 to move horizontally along the axial direction of the freeze-drying chamber on the low rail 1-203 inside the chamber.

[0018] The freeze-drying chamber with lower switching cold trap section B consists of: a cold trap housing 2-100; a left sealing ring 2-101; a right sealing ring 2-102; a housing partition 2-103; a switching cover 2-200; a guide rod 2-201; a guide positioner 2-202; a rope winding motor 2-203; a rope pulley 2-205; a traction rope 2-206; a left plate-type cold trap 2-300; a left cold trap liquid supply electric valve 2-301; a left cold trap refrigeration liquid supply interface 2-311; a left cold trap return gas electric valve 2-302; a left cold trap refrigeration return gas interface 2-312; and a left cold trap defrost drain valve 2-300. Composed of: 303; left cold trap defrost water purifier interface 2-313; right plate cold trap 2-500; right cold trap liquid supply electric valve 2-501; right cold trap refrigeration liquid supply interface 2-511; right cold trap return gas electric valve 2-502; right cold trap refrigeration return gas interface 2-512; right cold trap defrost drain valve 2-503; right cold trap defrost water purifier interface 2-513; the cold trap box 2-100 is located below the freeze-drying chamber 0-200, divided into two symmetrical boxes by a box partition 2-103, and at least one set of cold trap water collection ports is opened on the top of the box, connected by a switching cover 2-2. 00 and the left sealing ring 2-101, right sealing ring 2-102 are switched and isolated from the freeze-drying chamber; the switching cover plate 2-200 is connected to the guide rod 2-201 and the guide positioner 2-202 through the bearing seat fixing component; the rope winding motor 2-203 is connected to both ends of the guide rod 2-201 through the rope wheel 2-205 and the traction rope 2-206; the left and right cold trap boxes are respectively equipped with a left plate type cold trap 2-300 and a right plate type cold trap 2-500; the left and right cold trap liquid supply pipes are respectively placed below their right and left sides; the left cold trap liquid supply electric valve 2-301, the left cold trap refrigeration liquid supply interface 2-311; the right cold trap The liquid supply electric valve 2-501 and the right cold trap refrigeration liquid supply interface 2-511 are respectively connected to it; the left and right cold trap return gas pipes are respectively located on the upper left and right sides; the left cold trap return gas electric valve 2-302 and the left cold trap refrigeration return gas interface 2-312 are respectively connected to it; the bottom of the left and right cold trap boxes are respectively equipped with defrost drain pipes; the left defrost drain electric valve 2-303 and the left defrost water purifier interface 2-313 are respectively connected to it.

[0019] The freeze-drying chamber vacuum sterilization and defrosting section C comprises: a left vacuum filling channel 3-100, a left vacuum filling screen plate 3-101; a left vacuum electric valve 3-102, a left vacuum unit interface 3-112; a left negative pressure steam electric valve 3-103, a left negative pressure steam generator interface 3-113; a left ozone filling electric valve 3-105, a left ozone generator interface 3-115; a right vacuum filling channel 3-200, a right vacuum filling screen plate 3-201; a right vacuum electric valve 3-202, a right vacuum unit interface 3-212; a right negative pressure steam electric valve 3-203, a right negative pressure steam generator interface 3-213; a right ozone filling electric valve 3-205, a right ozone generator interface 3-215; and a left vacuum filling channel. 3-100 and the right evacuation and inflation channel 3-200 are respectively placed outside the left and right cold trap boxes; the left evacuation and inflation screen plate 3-101 and the right evacuation and inflation screen plate 3-201 are placed inside the lower side of their respective evacuation and inflation channels; the left evacuation electric valve 3-102 and the left vacuum unit interface 3-112; the left negative pressure steam electric valve 3-103 and the left negative pressure steam generator interface 3-113; the left ozone inflation electric valve 3-105 and the left ozone generator interface 3-115; the right evacuation electric valve 3-202 and the right vacuum unit interface 3-212; the right negative pressure steam electric valve 3-203 and the right negative pressure steam generator interface 3-213; the right ozone inflation electric valve 3-105 and the right ozone generator interface 3-215 are respectively connected to their corresponding channels through pipes.

[0020] An integrated automated process for freeze-drying, sterilization, and water recovery of pet food feed comprises the following steps: The automated transport, sterilization, and water recovery components of this complete system, along with other systems of the freeze dryer, are controlled locally and remotely via a computer or mobile terminal, configuration module, PLC module, and corresponding system control components through 4G or 5G networks. According to the freeze-drying process requirements, the freeze dryer control system initiates refrigeration, quick-freezing, heat recovery, and energy storage programs according to the program. After the material is quick-frozen, the application sequence of this complete system is: freeze-drying material transport section A → freeze-drying chamber lower switching cold trap section B → freeze-drying chamber evacuation, inflation, vacuum sterilization, and defrosting section C.

[0021] Freeze-drying material transport section A: When the freeze-drying material cart needs to enter the silo, the inlet silo door 0-100 opens, and the inlet RGV 1-100, loaded with quick-frozen material cart 1-200, automatically aligns with the low rail 1-203 inside the silo. After alignment and stabilization, the inlet flatcar 1-101 on the inlet RGV 1-100 extends and laterally connects with the low rail 1-203 inside the silo. Simultaneously, the electromagnetic stop 1-102 of the push chain engages with the electromagnetic attractor a 1-201 of the material cart (the front and rear material carts engage simultaneously). Under the action of the push chain, the material cart 1-200 is driven and pushed to the designated position inside the silo and stabilized. The electromagnetic attractor a 1-201 then engages. 1-201 unlocks, disengages from the electromagnetic stop 1-102 of the propulsion chain, retracts the feeding flatcar 1-101, closes the feeding hopper door 0-100, and begins the freeze-drying process. When the freeze-drying material cart needs to exit the hopper, the discharge hopper door 0-300 opens, and the discharge RGV 1-300 automatically aligns with the inner low rail 1-203. After alignment and stabilization, the discharge flatcar 1-301 on the discharge RGV 1-300 extends and connects with the inner low rail 1-203. Simultaneously, the pull-out chain electromagnetic stop 1-302 engages with the material cart electromagnetic attractor b 1-202, pulling the material cart 1-200 out onto the discharge RGV under the action of the pull-out chain. Once the 1-300 stops at the designated position, the discharge flatcar 1-301 is retracted, the discharge hopper door 0-300 is closed, and the post-discharge procedure for the freeze-dried material cart begins; thus, the entire process of the freeze-dried material cart 1-200 automatically entering and exiting the freeze-drying hopper is completed.

[0022] Freeze-drying chamber lower-mounted cold trap switching section B: When the freeze-drying chamber starts the freeze-drying process, the cold trap switching cover 2-200 on one side of the cold trap chamber 2-100 opens (e.g., Figure 2On the right side, the liquid supply electric valve and return gas electric valve of the cold trap are opened to cool the cold trap. When the cold trap reaches the set temperature (if continuous operation is performed, the temperature is reached when the switching cover is opened), the vacuum electric valve is opened to evacuate the freeze-drying chamber. When the set vacuum level is reached, the freeze-drying heating program is started to perform freeze-drying operations. After the freeze-drying program has been running for a period of time, the set cold trap switching time is reached, the rope winding motor 2-203 is turned on, and the rope wheel 2-205 drives the traction rope 2-206 to pull the guide rod 2-201 fixed on the switching cover 2-200, so that the switching cover 2-200 is positioned in the direction of the guide positioner 2-202 to the designated position of the right cold trap, and the sealing ring is pressed to isolate and seal it, completing the left to right switching of the cold trap box cover. At this time, the open left cold trap has reached the freeze-drying working temperature and pressure under the control of the pre-set program, and can directly take over the right cold trap to continue the freeze-drying operation. Since the switching cover 2-200 has been switched to isolate the right cold trap from the freeze-drying chamber, the right cold trap can be closed at this time. The liquid supply electric valve, return gas electric valve, and evacuation electric valve are activated to stop refrigeration and evacuation. The negative pressure steam electric valve is opened to defrost this cold trap. When defrosting is complete (the set defrosting time has been reached), the negative pressure steam electric valve is closed, the drain electric valve is opened to complete drainage, and the drain electric valve is closed. The liquid supply electric valve and evacuation electric valve are then opened to prepare for the next cold trap switchover. This switching process is repeated until the final unloading stage. At this point, the freeze-drying chamber has stopped its heating process, so the open-side cold trap can be shut down for refrigeration and evacuation, and the chamber can be opened. The internal ozone filling solenoid valve allows ozone to flow through the filling screen plate and into the cold trap channel for low-temperature ozone sterilization of the freeze-dried products. Once the sterilization time is reached, the ozone filling solenoid valve is closed and the discharge hopper door is opened (0-300°), allowing the freeze-dried and sterilized products to exit the hopper. Simultaneously, the closed-side cold trap continues to undergo defrosting, drainage, cooling, and evacuation preparations. Once the next batch of materials enters the hopper, the freeze-drying operation begins immediately, eliminating the need for cold trap defrosting waiting time and external sterilization procedures, significantly improving work efficiency and saving costs.

[0023] Section C of the freeze-drying chamber evacuation, inflation, vacuum sterilization, and defrosting: When the cold trap on this side needs to be evacuated, defrosted, and inflated for sterilization, the corresponding electric valve is opened (other valves are closed and interlocked). The airflow passes through the holes of the lower sieve plate and through each channel of the plate-type cold trap to complete the entire process of efficient evacuation, negative pressure defrosting, and ozone low-temperature sterilization of the freeze-drying chamber.

[0024] The design principle of this invention is based on the principle that freeze-drying pet food feed involves rapidly freezing water-containing materials (unsterilized) and then heating them in a vacuum environment, causing the ice crystals in the material to sublimate directly, thus obtaining a dried product. Because the freeze-drying process takes place in a low-temperature, low-oxygen environment, the original structural components of the freeze-dried product change very little (including bacteria), which is a key characteristic of freeze-drying! However, this is a drawback for unsterilized pet food raw materials. Unlike oven drying, it cannot be sterilized at high temperatures simultaneously with drying. Therefore, a sterilization process must be added after freeze-drying pet food raw materials to meet pet food safety and hygiene requirements. This additional sterilization process not only increases process costs but also significantly reduces production efficiency because the temperature and humidity of freshly freeze-dried products are particularly unsuitable for ozone sterilization (other sterilization methods are even more expensive). Furthermore, existing single-entry, single-exit freeze dryers, even with ozone introduced into the chamber (requiring redesign of chamber sealing, vacuum units, etc.), cannot solve the sterilization problem because the overlapping single-entry, single-exit freeze-drying process does not meet pet food safety and hygiene requirements! To meet the green freeze-drying needs of large-scale modern pet food and feed factories, a complete set of automated freeze-drying machine system integrating freeze-drying sterilization and water recovery has been specially designed for pet food and feed. While making full use of the limited space and low-temperature vacuum environment of the freeze-drying chamber, it adopts a bottom-mounted switching plate cold trap in the freeze-drying chamber, low-temperature ozone sterilization and negative pressure defrosting in the vacuum chamber, and automatic entry and exit at both ends of the RGV low-rail material car. It realizes a one-time automated process of freeze-drying sterilization and water recovery that meets pet food safety and hygiene standards and is highly efficient and energy-saving. It is the best alternative for the green development of the pet food, high-protein feed industry and carbon sequestration industry in the new era.

[0025] This invention addresses the practical problems of ordinary freeze dryers being unsuitable for pet food ingredients, requiring "additional sterilization," and having "one-way entry and exit of the hanging rail, non-standard operation, and difficulty in automation" (the issues of high energy consumption, low output, and environmental unfriendliness have been solved in "A Complete System for Carbon Dioxide Refrigeration, Heating, and Negative Pressure Defrosting and Water Recovery in a Freeze Dryer" ZL202222690540.X). It adopts a process scheme of negative pressure defrosting with a bottom-mounted switching plate cold trap in the freeze-drying chamber, low-temperature ozone sterilization in the vacuum chamber, and automatic entry and exit of the RGV low-rail material car at both ends, forming an integrated automated freeze dryer system for pet food and feed freeze drying, sterilization, and water recovery, making green and energy-saving freeze drying of pet food and high-protein feed a reality.

[0026] The system control of this invention, together with other systems of the freeze dryer, is completed by a computer (mobile terminal) + configuration + PLC module + corresponding system measurement and control components, through 4G and 5G networks, under local and remote automatic programmed control. According to the freeze-drying process requirements, after completing the material quick-freezing process, the freeze dryer control system sequentially executes the operations of the freeze-drying material cart transportation section A → the freeze-drying chamber lower switching cold trap section B → the freeze-drying chamber evacuation, gas filling, vacuum sterilization and defrosting section C according to the control requirements of this complete system; finally, it completes the one-time automated green energy-saving freeze-drying process of pet food and feed freeze-drying sterilization water recovery.

Claims

1. An automated process for integrating freeze-drying sterilization and water recovery in pet food feed, characterized in that... include: Feed hopper door (0-100); freeze-drying chamber body (0-200); Discharge hopper door (0-300); freeze-drying material cart transport section (A); freeze-drying hopper lower switching cold trap section (B); freeze-drying hopper evacuation, inflation, vacuum sterilization, and defrosting section (C); the freeze-drying material cart transport section (A) consists of a feeding RGV (1-100); a feeding flatcar (1-101); a push chain electromagnetic stop (1-102); a material cart (1-200), a material cart electromagnetic attractor a (1-201), a material cart electromagnetic attractor b (1-202), and an internal low rail (1-203); a discharge RGV (1-300), a discharge flatcar (1-301), and a pull-out chain electromagnetic stop (1-302); freeze-drying hopper lower... The switching cold trap section (B) consists of: a cold trap housing (2-100); a left sealing ring (2-101); a right sealing ring (2-102); a housing partition (2-103); a switching cover (2-200); a guide rod (2-201); a guide positioner (2-202); a rope winding motor (2-203); a rope pulley (2-205); a traction rope (2-206); a left plate-type cold trap (2-300); a left cold trap liquid supply electric valve (2-301); a left cold trap cooling liquid supply interface (2-311); a left cold trap return gas electric valve (2-302); a left cold trap cooling return gas interface (2-312); and a left cold trap... The cold trap consists of: a defrost drain valve (2-303); a left cold trap defrost water purifier interface (2-313); a right plate-type cold trap (2-500); a right cold trap liquid supply electric valve (2-501); a right cold trap refrigeration liquid supply interface (2-511); a right cold trap return gas electric valve (2-502); a right cold trap refrigeration return gas interface (2-512); a right cold trap defrost drain valve (2-503); and a right cold trap defrost water purifier interface (2-513). The freeze-drying chamber vacuum sterilization and defrosting section (C) consists of a left vacuum inflation channel (3-100), a left vacuum inflation sieve plate (3-101), and a left vacuum electric valve (3-102). The system consists of: left vacuum unit interface (3-112); left negative pressure steam electric valve (3-103), left negative pressure steam generator interface (3-113); left ozone charging electric valve (3-105), left ozone generator interface (3-115); right evacuation and charging channel (3-200), right evacuation and charging screen plate (3-201); right evacuation electric valve (3-202), right vacuum unit interface (3-212); right negative pressure steam electric valve (3-203), right negative pressure steam generator interface (3-213); right ozone charging electric valve (3-205), right ozone generator interface (3-215).

2. The integrated automated process for freeze-drying and sterilizing pet food feed and water recovery as described in claim 1, characterized in that... The freeze-drying material transport section (A) includes a feeding RGV (1-100), a feeding hopper door (0-100), and a discharging RGV (1-300) and a discharging hopper door (0-300), which are located at both ends of the freeze-drying chamber (0-200) and can move vertically along the axis of the freeze-drying chamber on their respective guide rails. The feeding flatcar (1-101) and discharging flatcar (1-301) on the feeding RGV (1-100) and discharging RGV (1-300) can move axially along the axis of the freeze-drying chamber on their respective guide rails. The electromagnetic stop block (1-102) of the push chain and the electromagnetic stop block (1-302) of the pull chain can drive the flatcar loading car (1-200) to move axially along the low rail (1-203) inside the chamber.

3. The integrated automated process for freeze-drying and sterilizing pet food feed and water recovery as described in claim 1, characterized in that... The lower switching cold trap section (B) of the freeze-drying chamber has a cold trap box (2-100) located at the bottom of the freeze-drying chamber body (0-200). It is divided into two symmetrical boxes by a box partition (2-103), and at least one set of cold trap water inlets is opened on the top of the box. It is isolated from the freeze-drying chamber by a switching cover plate (2-200) and left and right sealing rings (2-101 and 2-102). The switching cover plate (2-200) is connected to the guide rod (2-201) and guide positioner (2-202) via a bearing seat fixing component. The rope winding motor (2-203) is connected to both ends of the guide rod (2-201) via a rope pulley (2-205) and a traction rope (2-206). A left-plate type cold trap (2-300) and a right-plate type cold trap (2-500) are respectively installed in the left and right cold trap boxes. The liquid supply pipes are located on the lower right and left sides respectively; the left cold trap liquid supply electric valve (2-301) and the left cold trap refrigeration liquid supply interface (2-311) are connected to them respectively; the right cold trap liquid supply electric valve (2-501) and the right cold trap refrigeration liquid supply interface (2-511) are connected to them respectively; the left and right cold trap return gas pipes are located on the upper left and right sides respectively; the left cold trap return gas electric valve (2-302) and the left cold trap refrigeration return gas interface (2-312) are connected to them respectively; the bottom of the left and right cold trap boxes are respectively equipped with defrost drain pipes; the left defrost drain electric valve (2-303) and the left defrost water purifier interface (2-313) are connected to them respectively; the right defrost drain electric valve (2-503) and the right defrost water purifier interface (2-513) are connected to them respectively.

4. The integrated automated process for freeze-drying and sterilization of pet food feed and water recovery as described in claim 1, characterized in that... The freeze-drying chamber's evacuation, inflation, vacuum sterilization, and defrosting section (C) includes a left evacuation and inflation channel (3-100) and a right evacuation and inflation channel (3-200) located on the outside of the left and right cold trap boxes, respectively; a left evacuation and inflation screen plate (3-101) and a right evacuation and inflation screen plate (3-201) located on the lower inner side of their respective evacuation and inflation channels; a left evacuation electric valve (3-102) and a left vacuum unit interface (3-112); a left negative pressure steam electric valve (3-103) and a left negative pressure steam... Steam generator interface (3-113); left ozone charging electric valve (3-105), left ozone generator interface (3-115); right vacuum electric valve (3-202), right vacuum unit interface (3-212); right negative pressure steam electric valve (3-203), right negative pressure steam generator interface (3-213); right ozone charging electric valve (3-205), right ozone generator interface (3-215) are connected to their corresponding channels through pipelines.

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