Aqueous Material Phase-Change Extrusion for Continuous Freezing
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Solution Overview
Problem
Existing batch freezing methods for liquid aqueous materials, such as milk and juice, result in preferential freezing, solute concentration, and mechanical damage, leading to product degradation and increased handling costs, especially in small-scale facilities with infrequent transportation.
Innovation Solution
A continuous process and apparatus that rapidly freezes liquid aqueous materials within a tube under pressure, forming a self-lubricating frozen extrusion with dendritic crystals, allowing for continuous production of discrete frozen units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batch freezing is used to freeze liquid aqueous material, then the material can be stored in frozen form, but the process is slow and causes preferential freezing of pure water, creating reduction in freezing point of remaining aqueous component and concentration of other solutes
Solution Approach 1:
The patent changes the freezing rate parameter from slow (batch) to rapid (continuous), which fundamentally alters the freezing behavior. Rapid freezing prevents preferential freezing of pure water and avoids solute concentration, while maintaining product integrity through controlled phase change dynamics
Solution Approach 2:
The invention implements continuous freezing through a continuous process where liquid aqueous material is continuously fed into a freezing extrusion device and continuously frozen as it passes through the device, eliminating the intermittent nature of batch processing and maintaining consistent product quality
2Reliability
If slow freezing occurs in batch process, then the material can be frozen, but gross segregation of components occurs causing mechanical damage to food components and structures
Solution Approach 1:
By changing the freezing rate from slow to rapid, the patent prevents gross segregation of components. The rapid freezing creates a fine crystal structure that embeds food components within the ice matrix, preventing mechanical damage while maintaining product integrity
Solution Approach 2:
The patent replaces the mechanical mixing and handling operations required in batch processing with a continuous fluid-based freezing process. The continuous feeding and freezing mechanism eliminates the need for extensive product handling, reducing mechanical damage risks
3Reliability
If batch freezing is used, then the material can be frozen, but extensive product handling is required to fill vessels, empty them, and repack frozen products increasing labor and capital costs
Solution Approach 1:
The continuous freezing process eliminates the need for filling, emptying, and repacking operations. Material is continuously fed into the freezing device and continuously produced as frozen extrusion, which can be directly packaged or stored without intermediate handling steps
Solution Approach 2:
The system produces frozen material in a continuous form that is ready for direct use or storage. The continuous extrusion format eliminates the need for complex vessel handling and repacking operations, allowing the system to serve its own storage and packaging needs
4Reliability
If rapid freezing is used to prevent solute concentration and mechanical damage, then product integrity is maintained, but the process requires continuous operation and specialized equipment
Solution Approach 1:
The freezing extrusion device performs multiple functions: it freezes the material, forms the frozen extrusion shape, and enables continuous processing. This multi-functionality reduces the need for separate specialized equipment while maintaining rapid freezing capabilities and product integrity
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
The process maintains product integrity by preventing mechanical damage and solute concentration, reducing handling costs, and enabling efficient storage and transportation of frozen materials in discrete units.
Implementation Method 1
cooling the liquid aqueous material to cause a progressive phase change in which substantially all of the aqueous material changes from liquid form to frozen form within the tube
Implementation Method 2
cooling the liquid aqueous material to cause a progressive phase change in which substantially all of the aqueous material changes from liquid form to frozen form within the tube
Implementation Method 3
continuously pumping aqueous material in liquid form into the tube inlet under pressure
Implementation Method 4
pumping the aqueous material through the tube from the tube inlet to the tube outlet
Data Source
AI summary
The invention relates to a continuous process for freezing a flow of aqueous material in liquid form and moving the aqueous material through at least one tube from an inlet of the tube to an outlet of the tube so as to form a breakable or cuttable frozen extrusion without bursting the tube. The process creates an extruded material that comprises liquid aqueous material entrapped between frozen aqueous material to self-lubricate the extrusion as it moves through the tube. An apparatus for carrying out the process of the invention is also provided.