Cryogen Injection Chamber for Fast Cooling of Flowable Foods
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Solution Overview
Problem
Existing mechanical chilling systems for liquid food products are limited by size, efficiency, and maintenance needs, leading to longer chill times, increased bacteria growth, and operational inefficiencies, particularly when handling high heat loads or large volumes.
Innovation Solution
A cryogenic chilling system using a container and nozzles made of PTFE or plastic, with a cryogen injection chamber and mixer for turbulence, and a degassing separator to manage vaporization, allowing direct convective heat transfer and reducing conductive heat transfer issues, enabling faster and more efficient cooling.
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 chill time is long and the system becomes blocked by frozen product buildup on the coils
Solution Approach 1:
The patent extracts the harmful conductive heat transfer mechanism and replaces it with direct convective heat transfer by injecting cryogen droplets directly into the liquid product. This removes the intermediate coil structure that causes product buildup and blockage, enabling rapid chilling without the time loss and reliability issues of mechanical systems
Solution Approach 2:
The patent replaces the mechanical refrigeration system (compressor, condenser, expansion valve, coils) with a simpler cryogen injection system. The mechanical complexity is substituted by direct injection of liquid nitrogen or carbon dioxide, which provides rapid heat transfer through condensation and evaporation without mechanical moving parts, thereby reducing chill time and eliminating blockage problems
2Strength
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 changes the material parameter of the nozzle from conductive stainless steel to insulating plastic or PTFE. This parameter change prevents conductive heat transfer that would freeze product on the nozzle surface, eliminating blockages while maintaining operational ease. The insulating material allows the nozzle to operate without product buildup despite lower thermal conductivity
3Productivity
If mechanical chilling systems are sized for high heat loads, then the system can handle larger volumes, but the initial system size and cost increase
Solution Approach 1:
The patent introduces dynamic scalability to the system by using adjustable cryogen flow rates and multiple injection points. Rather than requiring a massively oversized mechanical system for peak loads, the cryogen injection system can dynamically increase cooling capacity by simply increasing the flow rate of cryogen, allowing the same compact apparatus to handle varying volumes from small to large loads efficiently
4Reliability
If conventional mechanical systems are used, then the cooling process is controlled, but maintenance and cleaning requirements increase due to condensation and frost buildup
Solution Approach 1:
The patent implements a self-cleaning mechanism where the cryogen injection process naturally prevents frost and condensation buildup on internal surfaces. The direct injection method and insulating materials ensure that no surfaces become cold enough to accumulate moisture, eliminating the need for hot defrost cycles and reducing maintenance to minimal cleaning of the injection chamber, thereby greatly easing repair and maintenance requirements
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 system achieves faster chill times, reduced maintenance, lower operational costs, improved product quality, and increased production rates with better flexibility to handle larger or hotter loads, while minimizing bacterial growth and energy consumption.
Implementation Method 1
providing, in particular injecting, a cryogen through the at least one nozzle into the liquid food product for mixing therewith in the chamber
Implementation Method 2
allowing direct convective heat transfer and reducing conductive heat transfer issues
Implementation Method 3
A cryogenic chilling system using a container and nozzles made of PTFE or plastic, with a cryogen injection chamber and mixer for turbulence
Data Source
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AI summary
In order to overcome problems that earlier apparatus, systems and methods have experienced, an apparatus (10, 100) for treating a flowable food product (26; 85), in particular being a substance selected from liquid comestibles, sauces, and liquid marinates, is proposed, said apparatus (10, 100) comprising: - a container (14, 114) constructed from a first material selected from the group consisting of polytetrafluoroethylene (PTFE), plastic, and PTFE and plastic, in particular further comprising stainless steel; - an injection chamber (18, 118) arranged within the container (14, 114), and including an inlet (20, 220) and an outlet (22, 222) in fluid communication with the injection chamber (18, 118); and - at least one nozzle (42, 142) constructed from a second material selected from the group consisting of PTFE, plastic, and PTFE and plastic, the at least one nozzle (42, 142) including -- a first end in fluid communication with a source of cryogen (28), in particular being a substance selected from the group consisting of liquid nitrogen (LIN), gaseous nitrogen (N2), liquid carbon dioxide (CO2), and gaseous carbon dioxide (CO2), and -- a second end in fluid communication with the injection chamber (18, 118) for providing the cryogen (28) to the injection chamber (18, 118). A related system (12; 71) and a related method for treating a flowable food product (26; 85) are also proposed.