Ozonated Water Conveyor Cleaning System for Meat Processing
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Solution Overview
Problem
Meat processing facilities face challenges in maintaining cleanliness and aesthetics between cleanings, as grease and soil collect in recesses of conveyor belts, requiring shutdowns and hazardous chemical use, which can lead to reprimands and increased sanitation efforts.
Innovation Solution
A conveyor cleaning system using ozonated water to break down grease and soil without solvents, allowing continuous operation, featuring a distributor that applies a film of ozonated water to conveyor belts, followed by a high-pressure rinser to remove contaminants, and an ozone generation system to produce safe ozonated water.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conveyor belts are cleaned periodically by shutting down the plant, then microbial counts and aesthetic appearance are improved, but productivity is reduced due to shutdowns and loss of time occurs
Solution Approach 1:
The system applies ozonated water to the conveyor belt before grease and soil have time to compact deeply into recesses. The ozone penetrates and begins breaking down contaminants preemptively, so that when cleaning occurs, the contaminants are already softened and easier to remove, enabling faster cleaning cycles and reduced shutdown time
Solution Approach 2:
The invention enables continuous cleaning action through the use of ozonated water that can be applied during operation. The ozone continuously acts on contaminants as they accumulate, maintaining a cleaner surface throughout operation rather than allowing heavy buildup, thus reducing the frequency and duration of shutdown cleanings
2Reliability
If chemical solvents and hot water are used to remove compacted grease and soil, then cleanliness is improved, but harmful factors are introduced through hazardous chemicals requiring thorough rinsing
Solution Approach 1:
The system uses ozone, a strong oxidant, to chemically break down grease and organic contaminants. The ozone reacts with and oxidizes the contaminants, converting them into simpler, less harmful substances that are easier to remove and do not require hazardous chemical solvents for breakdown
Solution Approach 2:
The invention uses water as the primary cleaning medium, which is safe, inexpensive, and requires no rinsing. The ozonated water performs the cleaning function and then evaporates or is discarded, eliminating the need for secondary rinsing operations required when using chemical solvents
3Reliability
If the plant is shut down for thorough cleaning, then microbial counts are reduced, but loss of time occurs and productivity decreases
Solution Approach 1:
Ozonated water is applied continuously or at frequent intervals to prevent microbial proliferation by maintaining lower microbial loads on surfaces. The ozone's antimicrobial properties act preemptively to control microbial growth before it becomes a serious contamination issue, reducing the need for extended shutdown cleanings
Solution Approach 2:
The system changes the chemical parameter of the cleaning medium by using ozonated water with specific ozone concentrations. This parameter change enables effective microbial control and grease breakdown at lower temperatures and with shorter contact times compared to traditional hot water and chemical systems
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 continuous plant operation with reduced microbial counts and aesthetic degradation, minimizing the use of hazardous chemicals, labor, and water, while ensuring safety and compliance with USDA standards.
Implementation Method 1
The first tank is filled with ozone gas and water. After a predetermined time, such as one minute, undissolved ozone gas is released.
Implementation Method 2
A conveyor system has a treating region and a processing region. A distributor positioned across the treating region deposits a film of ozonated water on the conveyor belt. In the processing region, the conveyor belt is exposed to soiling agents such as grease and other animal matter.
Data Source
AI summary
A conveyor cleaning system includes a treating region, a processing region, and a conveyor belt traveling from the treating region to the processing region. A distributor positioned across the treating region deposits a film of ozonated water on the conveyor belt. In the processing region, the conveyor belt is exposed to soiling agents such as grease and other animal matter. A high-pressure rinser may be positioned over the treating section such that the distributor is positioned between the high-pressure rinser and the processing region. Ozonated water may be generated by a system including first and second tanks. The first tank is filled with ozone gas and water. After a predetermined time, undissolved ozone gas is released. The contents of the first tank are then transferred to a second tank along with more ozone gas. After waiting a predetermined time period, undissolved ozone gas is released from the second tank.