Modular Chiller Rack Retrofit for Rapid Food Cooling
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Solution Overview
Problem
Existing walk-in cooler systems are inadequate for rapid chilling of food products, as they cannot lower temperatures quickly enough to prevent bacterial growth and chemical reactions, and standalone rapid chiller systems are often too large for limited spaces, necessitating a modular and portable solution for seamless integration.
Innovation Solution
A Modular Chiller System that can be retrofitted into existing walk-in coolers, comprising a frame assembly with refrigeration and electrical components, a controller unit, and a remote condenser unit, allowing for rapid temperature reduction and independent operation, with adjustable components for various space configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a standard refrigerated room or storage refrigerator/freezer is used for cooling food, then the system is simple and space-efficient, but it cannot lower the food temperature rapidly enough to prevent bacterial growth and chemical reactions
Solution Approach 1:
The refrigeration system is divided into separate modular components: a remote condenser unit, a frame assembly with evaporator, and a controller unit. This segmentation allows the rapid chilling function to be added to existing walk-in coolers without replacing the entire system, achieving rapid cooling capability while maintaining system simplicity through modular integration.
2Speed
If a standalone rapid chiller system is installed to achieve rapid cooling, then the cooling speed is sufficient, but the system becomes too large for limited kitchen spaces
Solution Approach 1:
The modular chiller system merges with the existing walk-in cooler structure by integrating components into the available space. The remote condenser unit can be positioned outside the chilling chamber, and the frame assembly with evaporator utilizes the existing cooler's interior space, thereby achieving rapid cooling functionality without significantly increasing the overall system volume.
Solution Approach 2:
The system utilizes vertical space and three-dimensional arrangement of components within the walk-in cooler. The frame assembly with evaporator is positioned to maximize air circulation around food products, while the remote condenser unit is placed in an external or unused space, effectively using spatial dimensions to accommodate rapid cooling equipment in limited areas.
3Adaptability or versatility
If existing walk-in cooler systems are used, then the system fits the available space, but it lacks the capability for rapid temperature reduction required by food safety guidelines
Solution Approach 1:
The modular chiller system is designed with universal components that can be integrated into various existing walk-in cooler configurations. The frame assembly with evaporator, remote condenser unit, and controller can be adapted to different cooler sizes and layouts, providing rapid chilling capability across multiple applications without requiring custom-designed systems for each installation.
Solution Approach 2:
The controller unit serves as an intermediary that coordinates between the existing walk-in cooler's refrigeration system and the new rapid chilling components. It manages the operation of the evaporator and condenser units, enabling seamless integration and operation of the modular system within the existing cooler infrastructure.
4Productivity
If the modular chiller system is configured for maximum cooling capacity, then rapid chilling performance is optimized, but the system requires more installation space and resources
Solution Approach 1:
The modular chiller system features adjustable and configurable components that can be dynamically adapted to match the specific requirements of different installations. The frame assembly, evaporator configuration, and condenser unit placement can be modified based on available space and cooling capacity needs, allowing the system to be optimized for productivity while maintaining ease of installation through standardized modular components.
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
Enables rapid and efficient chilling of food products, extending shelf life while maintaining quality, and providing a portable, independent chilling solution that meets food safety guidelines without sacrificing space or requiring extensive installation.
Implementation Method 1
positioning a frame assembly of refrigeration and electrical components on one of the interior walls
Implementation Method 2
positioning a remote condenser unit and interfacing the condenser unit to the frame assembly
Data Source
AI summary
A Modular Chiller System integrated into a single Standalone Rack Assembly having vertically positioned air intakes, heat exchanger, and an air deflector is disclosed. The orientation of the components in the Standalone Rack Assembly allows for maximum heat exchange from a rack of hot food items positioned coextensively to the Chiller System. Hot air from the food rack is received through the air intakes into the heat exchanger where chilled air is recirculated outward through said frame assembly. The Chiller System is portable and can be retrofitted to existing walk-in cooler configurations, or be embodied in standalone and portable refrigeration enclosures.