Freeze Tunnel Airflow Layout for Uniform Food Freezing
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Solution Overview
Problem
Conventional freeze tunnels suffer from inefficiencies due to non-uniform air flow and contamination issues, leading to inconsistent freezing of food products and increased operational costs.
Innovation Solution
A novel freeze tunnel design featuring cooling units positioned on opposing sides of the conveyor belt, with fans creating rotationally opposite air flow patterns to ensure uniform cooling, and a multi-stage cooling system with adjustable temperature sections to prevent clumping of food products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If cooling units are positioned vertically aligned with the conveyor, then the structure is simpler, but air flow uniformity and cooling efficiency deteriorate
Solution Approach 1:
The cooling units are positioned asymmetrically relative to the conveyor belt, specifically offset from vertical alignment to create a horizontal distance. This asymmetric positioning allows air to be drawn from above the conveyor and directed through the cooling units, creating more uniform air flow distribution across the conveyor surface while maintaining structural simplicity.
2Device complexity
If single-direction air flow is used, then the system is simpler, but freezing uniformity and productivity deteriorate
Solution Approach 1:
The air flow system is segmented into multiple independent flow paths with fans positioned on opposite sides of the conveyor. Each fan creates its own air circulation pattern, allowing simultaneous multi-directional air flow that enhances freezing uniformity across different zones of the conveyor without requiring a completely complex integrated system.
Solution Approach 2:
The opposing fans create periodic air flow patterns that circulate air in alternating directions across the conveyor. This periodic action ensures continuous refreshment of cold air supply to different areas of the food product, improving overall freezing efficiency and uniformity.
3Temperature
If cooling units are positioned closer to the conveyor, then cooling intensity increases, but contamination risk increases
Solution Approach 1:
The air flow system acts as an intermediary between the cooling units and the food product on the conveyor. Air is drawn from above the conveyor, passes through the cooling units positioned at a safe horizontal distance, and then redistributed across the product. This intermediary air flow mechanism maintains effective cooling intensity while preventing direct contact between cooling unit components and the food product, thereby reducing contamination risk.
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 design achieves uniform air flow and temperature distribution across the conveyor, reducing contamination, improving freezing efficiency, and minimizing product clumping, thereby enhancing the overall performance and efficiency of the freeze tunnel system.
Implementation Method 1
The first and second fans cooperate to circulate air inside the freeze tunnel in two opposite rotational directions
Implementation Method 2
The first fan can be configured to pull air from an area above the conveyor and blow air downward towards the first cooling unit, while the second fan can be configured pull air from an area above the conveyor and blow air downward towards the second cooling unit
Implementation Method 3
The first and second cooling units are not vertically aligned with the conveyor... positioned on the first side of the conveyor, and at least one second cooling unit and at least one second fan are positioned on the second side of the conveyor
Implementation Method 4
Conventional freeze tunnels include a conveyor belt that transports materials through an enclosure that is maintained at a temperature sufficient to freeze the transported materials
Data Source
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AI summary
A freeze tunnel can have a conveyor configured to move food product from a first end to a second end. At least one first cooling unit and at least one first fan can be positioned on the first side of the conveyor, and at least one second cooling unit and at least one second fan can be positioned on the second side of the conveyor. The fans can cooperate to circulate air inside the freeze tunnel in two opposite rotational directions.