System for ice manufacturing
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Solution Overview
Problem
Current systems for manufacturing clear ice are time-consuming, wasteful, and labor-intensive, with a need for efficient, less labor-intensive, safer, and less wasteful methods.
Innovation Solution
The system employs a freezing module that freezes water into clear ice sheets or slabs using plate freezers and circulation pumps to remove air bubbles, combined with a demolding module and material handling gantry for automated processing and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If slow freezing with constant circulation is used to make clear ice, then air bubbles are removed and clear ice is produced, but the manufacturing time increases to several days
Solution Approach 1:
The freezing process is divided into multiple stages with different circulation patterns. The first stage uses constant circulation to remove air bubbles, while the second stage reduces or stops circulation to complete freezing, thereby reducing total freezing time while maintaining ice clarity.
Solution Approach 2:
The circulation pump operates periodically rather than continuously, with circulation enabled during initial freezing to remove air bubbles and then disabled or reduced for the remainder of the freezing process, achieving clear ice in less time.
2Reliability
If single-use liners are used in freezing chambers, then food safety is ensured and ice removal is facilitated, but the device complexity and waste increase
Solution Approach 1:
Single-use food-safe liners are employed in the freezing chambers to ensure food safety compliance and facilitate easy ice removal. Although these liners increase waste, they eliminate the need for complex cleaning and sanitization systems, thereby reducing overall device complexity.
3Adaptability or versatility
If manual handling and trimming of ice blocks is performed, then flexibility in processing is maintained, but labor intensity and safety risks increase
Solution Approach 1:
The system incorporates automated ice block extraction and trimming mechanisms that perform tasks previously requiring manual labor. The machine automatically removes ice blocks from chambers and trims them to specified dimensions, reducing labor intensity while maintaining processing flexibility through programmable parameters.
Solution Approach 2:
Manual mechanical handling and trimming operations are replaced with automated mechanical systems including robotic arms, automated trimmers, and conveyor systems, thereby reducing labor intensity and safety risks while preserving adaptability through programmable control.
4Strength
If thick ice blocks are frozen to ensure proper anchoring and prevent cracking, then structural integrity is improved, but the freezing time increases due to ice's insulating properties
Solution Approach 1:
The freezing process is segmented into phases: an initial phase with constant circulation to remove air bubbles from the ice structure, followed by a second phase with reduced or no circulation to complete freezing. This segmentation ensures structural integrity while reducing total freezing time by optimizing circulation timing.
Solution Approach 2:
Air bubble removal is performed as a preliminary action during the initial freezing phase before the bulk of the ice forms. By removing air bubbles early when the ice structure is still developing, the system ensures structural integrity without requiring excessive freezing time for thick blocks.
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 enables the rapid and safe production of clear, dense ice with minimal waste and labor, ensuring compliance with food regulations and reducing risks to laborers.
Implementation Method 1
a freezing module 102. The freezing module 102 freezes water into clear sheets or slabs of ice
Implementation Method 2
using plate freezers and circulation pumps to remove air bubbles
Data Source
Figure 1A
Figure 1B~1C
Figure 2
AI summary
A system for manufacturing clear ice products is provided. The system includes a freezing module, a demolding module, and a converting station. The freezing module includes a frame comprising a plurality of levels, a plate freezer provided at each level, and at least one mold provided for placement on each plate freezer and suitable for receiving water. A control frame is provided associated with each plate freezer and is movable from an elevated position to fill position. In the fill position, the control frame is at least partially disposed within the mold. One or more circulation pumps are associated with each control frame for circulating water in the mold to release air bubbles as the water freezes. The demolding module removes the mold from the freezing module and removes formed ice from the mold. The converting station converts the formed ice into a clear ice product.