Interlocking Beater Mixing for Liquid Nitrogen Ice Cream Freezing
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Solution Overview
Problem
Existing ice cream manufacturing methods fail to consistently produce high-quality frozen mixtures with desirable characteristics, such as small ice crystals and even ingredient distribution, due to limitations in rapid cooling and mixing processes.
Innovation Solution
A system and method utilizing liquid nitrogen for rapid cooling, combined with interlocking helical beaters that rotate asynchronously with the container to ensure thorough mixing and self-cleaning, allowing for controlled delivery of coolant to achieve the desired viscosity and temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mixing and freezing methods are used, then the manufacturing process is simple, but the ice cream quality is inconsistent with large ice crystals and poor ingredient distribution
Solution Approach 1:
The mixing system is segmented into multiple interlocking beaters (typically three) that operate independently yet cooperatively. Each beater has a specific geometric configuration with varying blade angles and positions, allowing them to perform different functions (mixing, scraping, aerating) simultaneously. This segmentation enables precise control over ingredient distribution and ice crystal formation without requiring a complex multi-stage process.
Solution Approach 2:
The beaters rotate at different speeds and directions, creating dynamic mixing patterns that adapt to the changing viscosity of the mixture during freezing. The system transitions from a static mixing approach to a dynamic one where rotational speeds and directions can be independently controlled, enabling consistent quality even as the mixture properties change during the freezing process.
2Manufacturing precision
If rapid cooling with liquid nitrogen is applied, then ice crystal size is reduced, but controlling the cooling rate and viscosity becomes difficult
Solution Approach 1:
The system incorporates sensors that continuously monitor the viscosity of the mixture and provide feedback to the control system. Based on this feedback, the rotational speeds of the beaters and the rate of liquid nitrogen addition are automatically adjusted. This closed-loop control ensures that the cooling rate is optimized to produce small ice crystals while maintaining proper mixing, even as the mixture viscosity changes during freezing.
Solution Approach 2:
The system dynamically changes operating parameters (rotational speeds, liquid nitrogen flow rate) in response to changing mixture properties. As the mixture viscosity increases during freezing, the beaters adjust their speeds and the cooling rate is modulated to maintain optimal conditions for small ice crystal formation. This parameter adjustment allows precise control over the freezing process despite the changing physical state of the mixture.
3Productivity
If interlocking beaters are positioned very close to each other, then mixing efficiency is improved, but frozen material accumulates on the beaters
Solution Approach 1:
The interlocking beaters are designed with asymmetric geometries where each beater has a different blade configuration, angle, and position relative to the others. This asymmetry creates uneven shear forces and scraping actions as the beaters rotate, preventing frozen material from adhering uniformly to any single beater surface. The asymmetric design ensures that material is continuously scraped off and redistributed, maintaining mixing efficiency without requiring external cleaning mechanisms.
Solution Approach 2:
The beater system is designed to be self-cleaning through the interlocking arrangement and differential rotation. As the beaters rotate at different speeds and directions, they automatically scrape frozen material off each other's surfaces during the mixing process. This self-service cleaning capability eliminates the need for separate cleaning operations and maintains continuous productivity without sacrificing mixing efficiency.
4Manufacturing precision
If the container rotates opposite to the beater rotation, then ingredient distribution is improved, but the system complexity increases
Solution Approach 1:
The container rotation function is merged with the existing drive mechanism by utilizing the same motor and transmission system that drives the beaters. The container is coupled to the drive shaft through a differential or gear arrangement that allows it to rotate in the opposite direction to the beaters. This merging of functions reduces the need for separate motors and control systems, achieving improved ingredient distribution without proportionally increasing system complexity.
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 reproducibly produces high-quality ice cream with exceptionally small ice crystals and even ingredient distribution, ensuring consistent texture and quality by efficiently mixing and freezing ingredients using liquid nitrogen.
Implementation Method 1
utilizing liquid nitrogen for rapid cooling
Implementation Method 2
freezing the ingredients during the steps of mixing and rotating by adding a controlled amount of a coolant
Data Source
AI summary
Systems and methods of producing a frozen food product include dosing ingredients with a liquefied gas while mixing the ingredients using self-cleaning interlocking beaters. The beaters are optionally also disposed to clean a container in which the ingredients are frozen. The rate and amount of cooling is controlled by measuring the quantity of liquid nitrogen, measuring viscosity of the frozen food product, measuring temperature, and/or the like.