Continuous Flow Immersion Freezing to Minimize Ice Crystal Damage
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Solution Overview
Problem
Existing freezing methods for consumable products, such as food, result in quality loss due to ice crystal formation, dehydration, and cellular damage, while commercial systems cause sensory deterioration and are inefficient, and domestic systems lack user-adjustable temperature control.
Innovation Solution
An apparatus and method using an inner housing with controlled heat exchange fluid flow and computational fluid dynamics to minimize ice crystal formation and maintain product integrity, employing a heat exchange fluid that does not freeze above −70°C, with a heat transfer coefficient of at least 0.5°C per minute.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If slow freezing processes are used, then energy consumption is reduced, but ice crystal growth is more severe causing cellular damage and drip loss
Solution Approach 1:
The patent applies parameter changes by transitioning from slow freezing to rapid freezing, changing the temperature parameter from gradual reduction to swift drop below freezing point. This rapid temperature change prevents ice crystal growth while maintaining energy efficiency through the continuous flow system that prevents product dehydration and maintains structural integrity.
Solution Approach 2:
The patent implements the skipping principle by rushing through the freezing process using rapid cooling. The continuous flow of freezing medium quickly passes through the critical freezing zone, forming fine ice crystals before they can grow and damage cellular structures. This approach skips the harmful intermediate stage of slow ice crystal formation.
2Speed
If liquid nitrogen immersion systems are used, then freezing speed is increased, but product sensory quality deteriorates and packaging is damaged
Solution Approach 1:
The patent changes the temperature parameter from extreme cryogenic levels (liquid nitrogen at -196°C) to a controlled freezing range. This parameter adjustment maintains rapid freezing speed while preventing the excessive cold that causes packaging brittleness and sensory quality loss. The continuous flow system further modulates the thermal parameter to achieve optimal freezing without over-freezing.
Solution Approach 2:
The patent introduces a continuous flow freezing medium as an intermediary between the product and extreme cold. This mediator transfers heat away rapidly but controllably, preventing direct contact with ultra-low temperatures that would damage packaging and sensory qualities. The flowing medium acts as a buffer that enables fast freezing without the harmful effects of liquid nitrogen immersion.
3Duration of action of stationary object
If conventional freezing systems are used, then product shelf life is extended, but textural and taste quality is lost due to dehydration
Solution Approach 1:
The patent applies continuity of useful action through the continuous flow of freezing medium. The constant movement of the freezing medium ensures continuous heat extraction and prevents dehydration by maintaining uniform temperature distribution. This continuous action preserves product quality while extending shelf life, unlike static freezing systems that allow dehydration to occur.
Solution Approach 2:
The patent changes the thermal parameter from gradual temperature reduction to rapid freezing, which fundamentally alters the freezing mechanism. This parameter change prevents dehydration by quickly forming a protective ice structure that locks in moisture, thereby maintaining textural and taste quality while extending shelf life through the preserved product integrity.
4Ease of operation
If upright display design is used in domestic freezing systems, then consumer access is facilitated, but cooling efficiency is compromised
Solution Approach 1:
The patent applies pneumatic and hydraulic principles by using a continuous flow liquid system for heat extraction. The flowing freezing medium dynamically adapts to the product arrangement, efficiently cooling items regardless of their position. This fluid-based cooling system maintains high cooling efficiency in the upright display configuration by continuously circulating the freezing medium around all products.
Solution Approach 2:
The patent implements dynamics by transitioning from static cooling to dynamic continuous flow cooling. The moving freezing medium actively adapts to the upright display arrangement, maintaining efficient heat transfer despite the vertical orientation. This dynamic system preserves cooling efficiency while enabling easy consumer access through the upright configuration.
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 method preserves the nutritional value and safety of consumable products by minimizing ice crystal formation and drip loss, maintaining product integrity without the use of sugars or synthetic additives, and achieving rapid freezing within a reasonable time frame.
Implementation Method 1
consumable products received in the compartment of the inner housing are immersed in the heat exchange fluid to exchange heat with the heat exchange fluid
Implementation Method 2
a series of apertures to accommodate a continuous heat exchange fluid flow through the apparatus
Implementation Method 3
heat transfer coefficient of at least 0.5°C per minute
Implementation Method 4
Fast freezing can minimise migration of water into extracellular spaces, thereby promoting formation of smaller intracellular ice, producing a more homogeneous structure with less damage to tissue
Implementation Method 5
phase transitions of foods are highly relevant in the quality of preserved foods
Data Source
AI summary
An apparatus for preserving consumable products comprising an inner housing arranged within an outer insulated housing, wherein walls of the inner housing define a compartment for receiving consumable products, said walls comprising an inlet wall for inflow of a heat exchange fluid into the compartment, an opposed outlet wall for outflow of a heat exchange fluid out of the compartment, side walls and a base, the side walls and base adjoining the inlet wall to the outlet wall, wherein the inlet wall and outlet wall each include a series of apertures to accommodate a continuous heat exchange fluid flow through the apparatus such that, in operation, consumable products received in the compartment of the inner housing are immersed in the heat exchange fluid to exchange heat with the heat exchange fluid.