Two-Stage Food Cooling Chamber to Prevent Phase Change
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Solution Overview
Problem
Current food processing technologies face challenges in rapidly cooling heated foods without causing a phase change, which compromises nutrient retention and food safety, leading to over-processing or spoilage.
Innovation Solution
A rapid cooling system utilizing a heat exchanger and cooling chamber that introduces two coolants to rapidly cool heated food products from an elevated temperature to a lower temperature without causing a phase change, integrating with existing aseptic systems and using inert gases to displace oxidizing gases and maintain product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermal processing is used to destroy microorganisms, then food safety is improved, but nutrient retention deteriorates due to over-processing
Solution Approach 1:
The cooling process is divided into two distinct stages: first stage uses a first coolant to rapidly reduce temperature from processing temperature to intermediate temperature, second stage uses a second coolant to cool from intermediate temperature to final storage temperature. This segmentation allows optimization of each stage independently, achieving rapid cooling that preserves nutrients while ensuring food safety.
Solution Approach 2:
The system changes cooling parameters by using different coolants with different temperatures for different cooling stages. The first coolant operates at higher temperature for initial rapid cooling, while the second coolant operates at lower temperature for final cooling. This parameter change enables controlled cooling that prevents nutrient degradation while maintaining food safety.
2Loss of substance
If rapid cooling is implemented to preserve nutrients, then nutrient retention is improved, but risk of phase change increases which compromises food safety
Solution Approach 1:
The cooling system dynamically adjusts cooling intensity through two stages with different coolants. The first stage provides intense rapid cooling to preserve nutrients, while the second stage provides gentler cooling to ensure complete temperature reduction without phase change. This dynamic approach balances nutrient preservation with food safety.
Solution Approach 2:
The first coolant acts as an intermediary between the heated food and the second coolant. It performs the initial rapid cooling task, reducing the temperature burden on the second coolant and preventing direct exposure to extreme cold that could cause phase change. This intermediary approach enables safe rapid cooling.
3Reliability
If extended cooling time is used to ensure food safety, then food safety is improved, but productivity deteriorates due to increased processing time
Solution Approach 1:
The two-stage cooling system operates continuously without interruption. The first coolant continuously cools the food to intermediate temperature, then the second coolant continuously completes the cooling to final temperature. This continuous operation reduces total cooling time while ensuring food safety, thereby improving productivity.
Solution Approach 2:
The first cooling stage rapidly skips through the critical temperature range where nutrient degradation occurs, achieving quick temperature reduction. This rushing through of the dangerous temperature zone minimizes exposure time and preserves nutrients while maintaining food safety, improving overall processing efficiency.
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 effectively and rapidly cools heated food products, enhancing nutrient retention and food safety while avoiding phase changes, thus improving the overall quality and sustainability of food processing by reducing energy costs and capital expenditures.
Implementation Method 1
a heat exchanger adapted to receive a first coolant at a first temperature and eject the first coolant at a second temperature
Implementation Method 2
a cooling chamber disposed within the heat exchanger in thermal communication with the heat exchanger
Implementation Method 3
using inert gases to displace oxidizing gases and maintain product quality
Data Source
AI summary
A rapid cooling system for processing food is disclosed which includes a heat exchanger adapted to receive a first coolant (Coolant-I) at a first temperature and eject Coolant-I at a second temperature, a cooling chamber disposed within the heat exchanger in thermal communication with the heat exchanger, the cooling chamber includes a first inlet adapted to receive a product at an elevated temperature (T1), a second inlet adapted to receive a second coolant (Coolant-II) at a low temperature (T2), and an outlet adapted to release a combination of the product and Coolant-II at a low temperature (Tout) and pressure (Pout), wherein cooling of the product from T1 to Tout does not cause a phase change in the product.