Conveyor Freezer Agitation for IQF and Tray Product Switching
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Solution Overview
Problem
Existing freezer technologies are inefficient in processing both individual quick-frozen (IQF) and non-IQF products simultaneously, as they require separate equipment and processes, leading to reduced production capacity and increased labor costs due to the need for manual arrangement of products and potential product damage from standard freezing processes.
Innovation Solution
A freezer apparatus with a conveyor system and agitation assemblies, featuring independently controlled camshafts and motors, allows for flexible operation between IQF and non-IQF modes by adjusting agitation speed and motion to prevent product adhesion and optimize heat transfer, using mobile side guides to maintain product stability during agitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard freezing processes are used, then products can be frozen, but products may stick together and require manual arrangement, increasing labor costs and reducing productivity
Solution Approach 1:
The patent applies vibration to the conveyor belt during the freezing process to prevent products from sticking together. The vibratory motion keeps individual products separated as they freeze, eliminating the need for manual arrangement and maintaining high production capacity while producing IQF (individually quick frozen) products
2Adaptability or versatility
If agitation assemblies are always active, then IQF products can be produced, but tray products may be scattered and displaced from trays
Solution Approach 1:
The patent makes the agitation assembly dynamically controllable, allowing it to be activated or deactivated based on the product type being processed. When tray products are being frozen, the agitation assembly is deactivated to prevent scattering. When loose IQF products are being frozen, the agitation assembly is activated to prevent sticking. This dynamic control enables the same equipment to handle both product types effectively
3Reliability
If separate equipment is used for IQF and non-IQF products, then each product type can be optimized, but production capacity is reduced due to equipment removal and relocation
Solution Approach 1:
The patent designs a universal freezing system that can process both IQF and non-IQF products using the same conveyor and freezing chamber. The key is the controllable agitation assembly that can be adjusted based on product requirements. This multi-functionality eliminates the need to remove or relocate equipment when switching between product types, maintaining full production capacity while ensuring optimal processing for each product type
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 solution enables efficient processing of both IQF and non-IQF products on the same line, reducing labor and increasing production capacity while minimizing product damage and freezing time, with improved heat transfer and product quality.
Implementation Method 1
at least one agitation assembly comprising at least one cam attached to at least one camshaft, said at least one camshaft rotatably mounted below said bottom surface of said conveyor
Implementation Method 2
conveyor for transporting products through a refrigeration medium
Data Source
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AI summary
An apparatus for chilling or freezing products which may be operated in the IQF and non-IQF modes, having conveyor for transporting products through a refrigeration medium, said conveyor having a top surface and a bottom surface, conveyor motor to move said conveyor; at least one agitation assembly comprising at least one cam attached to at least one camshaft, said at least one camshaft rotatably mounted below said bottom surface of said conveyor, such that the cam makes initial contact with the conveyor when its vertical component of velocity is at or near its maximum during each 360° rotation of the camshaft, and an independently controlled agitation motor operatively associated with the at least one agitation assembly to operate the agitation assembly to cause the agitation of the conveyor and the products thereon when said apparatus is operated in the IQF mode. An apparatus for chilling or freezing products comprising a conveyor and at least one mobile side guide contacting the conveyor.