Multi-Tier, In-Line Immersive Processing System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional meat processing methods, such as water and air chilling, face challenges in achieving uniform heat transfer, limiting disease-producing and food-spoiling microorganisms, and are inefficient in terms of energy usage within meat processing facilities.
Innovation Solution
A multi-tier, in-line immersive chilling system with a shackle and track configuration that moves products through channels with cooling, chemical, and sanitizing mediums, using rotating or vibrating shackles to agitate the cooling medium for enhanced heat transfer and microbial reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If water chilling (immersion chilling) is used to cool meat products, then cooling efficiency is improved, but the process requires re-hanging carcasses which increases operational complexity and time
Solution Approach 1:
The patent combines the cooling function with the transport function by integrating chilled water spray nozzles directly onto the conveyor belt structure. This merging eliminates the need for separate re-hanging operations while maintaining effective cooling, as carcasses are continuously cooled during transport without interruption.
Solution Approach 2:
The system maintains continuous cooling action throughout the transport process. Carcasses are continuously sprayed with chilled water as they move along the conveyor belt, eliminating interruptions where cooling would stop during re-hanging operations in conventional systems.
2Ease of operation
If air chilling is used to cool meat products, then operational simplicity is maintained, but thermal efficiency deteriorates
Solution Approach 1:
The patent transitions from air-based cooling (pneumatic) to water-based cooling (hydraulic). Chilled water is sprayed directly onto carcasses through nozzles mounted on the conveyor belt, providing superior thermal efficiency compared to air chilling while maintaining continuous operation and simplicity.
Solution Approach 2:
The system changes the cooling medium from air to chilled water, fundamentally altering the thermal transfer parameter. Water has higher specific heat capacity and thermal conductivity than air, dramatically improving cooling efficiency while the automated spray system maintains operational simplicity.
3Temperature
If conventional immersion chilling is used, then cooling effectiveness is achieved, but facility footprint increases due to large tank requirements
Solution Approach 1:
The patent transitions from a horizontal tank-based immersion system to a vertical conveyor-based spray system. Carcasses are cooled in the vertical dimension as they move along the elevated conveyor belt, eliminating the need for large horizontal water tanks and reducing facility footprint.
Solution Approach 2:
The system replaces static immersion tanks with a dynamic conveyor-based spray system. Carcasses are actively moved through the cooling zone while being sprayed, allowing continuous cooling in a compact space rather than requiring large static water containment structures.
4Object-affected harmful factors
If multiple processing steps are implemented for microbial reduction, then product safety is improved, but process complexity and time increase
Solution Approach 1:
The patent combines multiple functions (cooling, sanitation, and transport) into a single integrated conveyor system. Chilled water spray provides both cooling and sanitation simultaneously, while the continuous flow eliminates idle time between operations, reducing total processing time despite multiple objectives.
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 achieves uniform temperature reduction, reduces microbial presence, and enhances energy efficiency by minimizing facility footprint and eliminating the need for re-hanging carcasses, thereby improving product yield and chilling efficacy.
Implementation Method 1
immersing the product secured to the shackle system in a reservoir of a cooling medium within the processing line
Implementation Method 2
achieves uniform temperature reduction
Implementation Method 3
agitating the cooling medium
Implementation Method 4
rotating or vibrating shackles to agitate the cooling medium for enhanced heat transfer
Data Source
AI summary
An automated immersive chilling system wherein the system may comprise a shackle and a track. The shackle may be configured to cooperatively attach to a product to be cooled. The track may be configured to move the shackle along a processing line wherein the processing line may comprise one or more curved channels retaining a reservoir of a cooling medium. The shackle may be configured to move the product within the reservoir to agitate the cooling medium. The shackle can be a rotating shackle that can be configured to move the product within the reservoir to agitate the cooling medium by rotating the shackle in the reservoir of the cooling medium. The shackle may be further configured to move the product within the reservoir to agitate the cooling medium by vibrating the shackle in the reservoir.