Dual Waterfall Cabinet for Compact Antimicrobial Coverage
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Solution Overview
Problem
Existing food processing systems, such as spray bars and dip tanks, face challenges in providing adequate antimicrobial coverage and efficient sanitation while occupying valuable space and resources, with spray bars having inadequate coverage and clogging issues, and dip tanks requiring significant resources and space.
Innovation Solution
A dual waterfall cabinet design that applies antimicrobial solution through two waterfalls aligned with workpieces, allowing for adjustable positioning and recycling of the solution, increasing coverage to both exterior and interior surfaces, and reducing the system's footprint by suspending it from a shackle line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If spray bars are used for antimicrobial application, then the system occupies less space compared to dip tanks, but the coverage and volume of antimicrobial solution application is inadequate
Solution Approach 1:
The cabinet is divided into multiple spray zones with separate nozzle assemblies positioned at different locations (front, rear, top, bottom) to provide comprehensive coverage. Each zone independently applies antimicrobial solution to specific areas, ensuring complete coverage without requiring a large dip tank footprint.
Solution Approach 2:
The spray bars and nozzles are positioned in three-dimensional space around the poultry product (front, rear, top, bottom surfaces) to provide omnidirectional coverage. This spatial arrangement maximizes antimicrobial application coverage within a compact cabinet footprint.
2Quantity of substance
If dip tanks are used for antimicrobial application, then adequate coverage and volume are achieved, but valuable facility space is occupied and significant water and antimicrobial resources are required
Solution Approach 1:
A hydraulic spray system delivers antimicrobial solution under pressure through multiple spray bars and nozzles, achieving thorough coverage comparable to dip tanks. The pressurized spray application ensures adequate penetration and distribution of antimicrobial solution without requiring large volumes or extensive facility space.
Solution Approach 2:
The cabinet includes a recovery system that collects and recycles antimicrobial solution and water from the processing chamber. This recycling mechanism reduces overall consumption of water and antimicrobial resources while maintaining adequate coverage, eliminating the need for large resource-intensive dip tanks.
3Device complexity
If spray bars are used, then the system is compact, but nozzles are frequently clogged or improperly aligned
Solution Approach 1:
The nozzle assemblies are designed with adjustable and repositionable features, allowing operators to optimize nozzle alignment and positioning. This dynamic adjustment capability ensures proper spray patterns and prevents clogging by maintaining optimal fluid flow dynamics, improving reliability without increasing overall system complexity.
Solution Approach 2:
The spray system includes self-cleaning features and designs that minimize clogging through proper fluid dynamics and ease of maintenance. The system is configured to allow easy access for cleaning and maintenance of nozzles, enabling operators to quickly restore proper function without complex repair procedures.
4Reliability
If traditional cabinets are used, then sanitation processes are required, but the sanitation burden is significant
Solution Approach 1:
The cabinet incorporates a solution recovery and recycling system that collects antimicrobial solution and water from the processing chamber. This recovered solution is filtered and reused, reducing the frequency and burden of complete sanitation cycles while maintaining effective sanitation levels throughout operation.
Solution Approach 2:
The system maintains continuous antimicrobial application and solution circulation during operation, preventing contamination buildup and reducing the need for extensive periodic sanitation. The continuous flow and recirculation keep surfaces consistently treated, minimizing sanitation burden while maintaining reliability.
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 dual waterfall cabinet enhances antimicrobial coverage by applying 2 to 4 gallons per workpiece, optimizing for various sizes, and reduces space and resource consumption through adjustable design and recycling, improving sanitation efficiency.
Implementation Method 1
The waterfalls 106, 108 are troughs having a straight edge positioned toward an interior of the cabinet 100 such that, as antimicrobial solution is supplied to the waterfalls 106, 108, the solution spills over the straight edges in a waterfall into the interior of the cabinet 100
Data Source
AI summary
A dual waterfall cabinet includes a hollow basin having front and rear openings to allow workpieces to move therethrough. The cabinet also includes waterfall assemblies on either side of the hollow basin that form waterfalls of solution to be applied to the workpieces. To provide thorough interior and exterior coverage, the distance between the waterfalls can vary along a length of the cabinet.