Apparatus, system and method for chilling sauces and liquids
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Solution Overview
Problem
Mechanical chilling systems in the food processing industry are limited by size, efficiency, and maintenance requirements, leading to longer chill times, bacterial growth, and increased operational costs, especially when handling high heat loads or large temperature differences.
Innovation Solution
The use of a cryogenic system with nitrogen or carbon dioxide as a cryogen, injected directly into the liquid through food-grade plastic nozzles, facilitating convective heat transfer and reducing chill time, while avoiding conductive heat transfer issues and maintenance challenges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical chilling systems with coils and refrigerants are used, then the system provides controlled cooling, but the chilling time is prolonged due to limited heat transfer capacity
Solution Approach 1:
The patent replaces the mechanical refrigeration system (compressor, condenser, evaporator, expansion valve) with a cryogenic fluid injection system. Liquid nitrogen or carbon dioxide is injected directly into the product or processing vessel, eliminating the complex mechanical refrigeration cycle and dramatically reducing chilling time from hours to minutes.
Solution Approach 2:
The patent utilizes the phase transition of cryogenic fluids from liquid to gas as they absorb heat from the product. This phase change occurs at extremely low temperatures (nitrogen at -196°C, carbon dioxide at -78°C), providing intense cooling effect and rapid heat transfer that mechanical systems cannot achieve.
2Stress or pressure
If stainless steel nozzles are used for cryogen injection, then conductive heat transfer is improved, but the nozzles become blocked by frozen product buildup
Solution Approach 1:
The patent employs composite material construction for the nozzle system, using materials with lower thermal conductivity than stainless steel. This prevents excessive heat transfer that would cause product freezing and blockage, while still allowing sufficient heat transfer for effective chilling. The composite approach balances thermal performance with operational reliability.
Solution Approach 2:
The patent applies different material properties to different parts of the injection system. The nozzle interior surfaces are designed with specific thermal characteristics that prevent product adhesion, while maintaining effective cryogen flow. This localized material selection solves the blockage problem without compromising overall heat transfer efficiency.
3Productivity
If mechanical chilling systems operate at full capacity, then production output increases, but maintenance requirements and operational costs increase
Solution Approach 1:
The patent eliminates the complex mechanical refrigeration system with moving parts (compressors, condensers, evaporators, expansion valves) and replaces it with a simple cryogenic fluid injection system. This dramatically reduces maintenance requirements while maintaining high production output, as the injection system has no moving parts and requires minimal operational oversight.
4Power
If water-to-sauce heat exchangers are used, then cooling capacity is increased, but the system becomes limited by heat exchanger size and design
Solution Approach 1:
The patent replaces the water-to-sauce heat exchanger system with direct cryogenic fluid injection. This eliminates the intermediate heat exchanger components and their size limitations, providing unlimited cooling capacity that is not constrained by heat transfer surface area or design geometry.
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 significantly reduces chill time, increases production rates, lowers operational costs, and improves product quality by effectively controlling temperature and bacteria growth, with flexible handling of high heat loads and reduced maintenance needs.
Implementation Method 1
injected directly into the liquid through food-grade plastic nozzles, facilitating convective heat transfer
Implementation Method 2
The use of a cryogenic system with nitrogen or carbon dioxide as a cryogen, injected directly into the liquid
Data Source
AI summary
An apparatus for treating a flowable food product includes a container constructed from a first plastic material; an injection chamber arranged within the container, and including an inlet and an outlet in fluid communication with the injection chamber; at least one nozzle constructed from a second plastic material, the at least one nozzle including a first end in fluid communication with a source of cryogen and a second end in fluid communication with the chamber for providing the cryogen to the chamber. A related system and method are also provided.