Gambrel Track Sanitizing With Potassium Cleaner Dips
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Solution Overview
Problem
Current cleaning and sanitization systems in meat and food processing plants are inefficient, wasteful, and unsanitary, particularly due to the use of caustic soda baths and oil dips, which lead to water and energy waste, bacterial growth, and unsanitary conditions.
Innovation Solution
A system utilizing a potassium-based cleaner like AquaKlean H4H, combined with agitation methods such as jets, brushes, and ultrasonic emitters, and a spray cleaning method, to clean and sanitize hooks, trollies, and knives, reducing water and energy consumption while maintaining sanitary conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a three-step cleaning process using caustic soda bath, water rinse, and oil dip is used, then cleaning effectiveness is improved, but water consumption increases and energy waste occurs
Solution Approach 1:
The patent extracts and eliminates the oil dip step from the traditional three-step cleaning process, replacing it with a foam application system that applies cleaning foam directly to the equipment surfaces, thereby removing the source of water contamination and bacterial growth while maintaining cleaning effectiveness
Solution Approach 2:
The patent changes the physical state and application method of the cleaning agent from liquid caustic soda requiring immersion and rinsing to foam that can be applied directly and left to dwell, fundamentally altering the cleaning process parameters to reduce water usage and eliminate the need for rinsing
2Reliability
If a three-step cleaning process using caustic soda bath, water rinse, and oil dip is used, then cleaning effectiveness is improved, but energy consumption increases
Solution Approach 1:
The patent removes the oil dip step that requires heating and the hot water rinse step, eliminating the need for continuous heating of large volumes of water and steam generation, thereby significantly reducing energy consumption while maintaining cleaning effectiveness through foam application and air drying
Solution Approach 2:
The patent changes the cleaning process from requiring high temperature hot water immersion and steam to using foam at ambient or lower temperatures that air-dries naturally, fundamentally altering the thermal parameters to reduce energy consumption
3Ease of operation
If an oil dip is used in the final cleaning step, then lubrication is provided, but bacterial growth occurs and sanitation deteriorates
Solution Approach 1:
The patent extracts and eliminates the oil dip step from the cleaning process, removing the medium that supports bacterial growth and hydrogen sulfide generation, while providing lubrication through alternative means such as food-grade lubricants applied separately or through the foam formulation itself
Solution Approach 2:
The patent converts the harmful effect of oil accumulation that promotes bacterial growth into a benefit by using foam that leaves no oily residue, preventing bacterial growth and hydrogen sulfide generation while still providing necessary lubrication through non-organic alternatives
4Reliability
If caustic soda bath is used for cleaning, then cleaning power is improved, but water and energy waste increases
Solution Approach 1:
The patent changes the cleaning agent from liquid caustic soda requiring hot water immersion to foam formulation that can clean effectively at lower temperatures, and changes the application method from immersion to direct foam application, fundamentally altering the thermal and chemical parameters to reduce energy waste
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 cleans and sanitizes metal surfaces with reduced water and energy usage, eliminates bacterial growth, and ensures sanitary conditions by using environmentally friendly cleaners and efficient cleaning methods.
Implementation Method 1
A system utilizing a potassium-based cleaner like AquaKlean H4H, combined with agitation methods such as jets, brushes, and ultrasonic emitters
Implementation Method 2
A system utilizing a potassium-based cleaner like AquaKlean H4H, combined with agitation methods such as jets, brushes, and ultrasonic emitters
Data Source
AI summary
A cleaning system for a meat-packing plant includes a tank with a potassium-based cleaner disposed in the tank. A track has a gambrel disposed on the track. The track includes a dip over the tank to dip the gambrel into the potassium-based cleaner as the gambrel moves along the track. A processed animal carcass is removed from the gambrel prior to the gambrel being dipped into the potassium-based cleaner. A fresh animal carcass is disposed on the gambrel after the gambrel is dipped into the potassium-based cleaner.