Pig Scalding Pool Segmentation and Sensor Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current pig scalding systems in slaughterhouses face issues with inconsistent scalding temperatures, inadequate size and weight adaptation for pigs, operator-dependent scalding conditions, unstable scalding effects, and high labor and production costs due to inefficient mechanical wobbling scalding and costly tunnel scalding methods.
Innovation Solution
A novel pig body scalding system with a separating fence dividing the scalding pool into high-speed and constant-speed regions, equipped with infrared thermometers, pressure sensors, and a control system to adjust steam heating pipes and tracks based on real-time pig body temperature and mass, ensuring targeted scalding and reducing heat loss through heat insulation materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If canal scalding is used to reduce equipment costs, then production costs are reduced, but scalding temperature consistency deteriorates
Solution Approach 1:
The scalding pool is divided into multiple independent scalding areas (first scalding area, second scalding area, third scalding area) with separate steam heating pipes and temperature control systems. Each area can independently control its water temperature, ensuring consistent scalding temperature across different regions while using the cost-effective canal scalding structure.
Solution Approach 2:
Different scalding areas are equipped with independent temperature control systems and steam heating pipes. The control system adjusts steam valve openings based on real-time temperature feedback from each specific area, allowing localized temperature optimization and consistency without requiring expensive tunnel scalding equipment.
2Ease of manufacture
If traditional canal scalding is used, then equipment cost is reduced, but scalding effect stability deteriorates
Solution Approach 1:
Temperature sensors are installed in each scalding area to detect water temperature in real-time. The detected temperature signals are transmitted to the control system, which automatically adjusts the steam valve openings to maintain stable scalding temperatures. This closed-loop feedback control ensures consistent scalding effects without requiring expensive automated tunnel scalding equipment.
Solution Approach 2:
The control system automatically regulates steam valve openings based on real-time temperature detection from each scalding area, enabling the system to self-adjust and maintain stable scalding conditions without manual intervention, thereby improving scalding effect stability while using cost-effective canal scalding infrastructure.
3Ease of manufacture
If mechanical wobbling scalding is used to simplify equipment, then equipment cost is reduced, but scalding efficiency deteriorates
Solution Approach 1:
The system introduces a wobbling track that enables dynamic wobbling movement of pig carcasses during scalding. This dynamic motion enhances the scalding effect and hair removal efficiency without requiring complex mechanical wobbling scalding equipment. The wobbling track can be integrated into the existing canal scalding system, maintaining equipment simplicity while improving productivity.
4Ease of operation
If uniform scalding conditions are applied to all pigs, then operation simplicity is maintained, but scalding suitability for different sizes deteriorates
Solution Approach 1:
The system divides the scalding pool into multiple scalding areas with independent temperature control. Different pig sizes can be directed to different scalding areas with optimized temperature conditions. For example, smaller pigs can be scalded in areas with lower temperatures while larger pigs receive higher temperature treatment, ensuring optimal scalding effects for each size category while maintaining relatively simple operation through automated control.
Solution Approach 2:
By segmenting the scalding pool into multiple independently controlled areas, the system can provide customized scalding conditions for different pig sizes. Each scalding area can be optimized for specific pig size ranges, improving adaptability while the automated control system keeps operational complexity manageable.
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 stable water temperatures, efficient hair removal, reduced energy consumption, lower labor and production costs, and improved meat quality by optimizing scalding conditions for each pig, with heat loss reduced by approximately 80% compared to traditional methods.
Implementation Method 1
An infrared thermometer and pressure sensor connected with a control system is provided below the pig body hanging track. The infrared thermometer and pressure sensor measures a body temperature and a mass of a pig body hung on the track in real time
Implementation Method 2
At least three steam heating pipes provided with steam valves are distributed in the scalding region in the scalding pool body
Implementation Method 3
At least three steam heating pipes provided with steam valves are distributed in the scalding region in the scalding pool body. A bottom of each of the steam heating pipes is provided with an immersed steam sprayer
Implementation Method 4
achieving a more efficient and effective hair-removing, greatly reducing heat loss of the scalding pool, improving the energy utilization rate
Data Source
AI summary
A novel pig body scalding system, includes a scalding pool body. A separating fence in the middle of a scalding region in the scalding pool body divides the scalding region into a high-speed scalding and constant-speed scalding region; moreover, the two sides of the separating fence has a high-speed and a constant-speed scalding track corresponding to the to the high-speed and constant-speed scalding region respectively. The starting end of the high-speed scalding and that of the constant-speed scalding track can be connected with the same wobbling track, and wobbling track is located at the tail end of a pig body hanging track; an infrared thermometer and pressure sensor connected with a control system is provided below the pig body hanging track. The scalding system can perform targeted scalding on each pig body according to the condition of each pig body, thereby greatly reducing the influence of scalding on pork quality.