Rack-Aisle Freezing Layout for One-Stage Pallet Cold Storage
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Solution Overview
Problem
Conventional freezer warehouses require multiple stages for freezing and storage, leading to inefficiencies in space usage, increased transportation needs, and less efficient stocking and retrieval systems due to the use of blast freezers and separate storage locations.
Innovation Solution
A one-stage freezing system utilizing a specially configured rack system that allows cold air to flow directly through palletized products in an open warehouse space, eliminating the need for blast freezers and separate storage areas, with chillers positioned remotely to produce and recirculate cold air through spacers and openings in the racking structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional multi-stage freezing systems with blast freezers are used, then product freezing capability is achieved, but warehouse space is wasted and transportation needs increase
Solution Approach 1:
The patent merges the blast freezing function and storage function into a single integrated warehouse space. The rack system allows cold air to flow directly through palletized products in the open warehouse, eliminating the need for separate blast freezers and storage areas. This combining of functions resolves the contradiction by achieving both freezing capability and space efficiency in one system.
Solution Approach 2:
The rack-aisle system serves multiple functions simultaneously: it acts as both a freezing mechanism and a storage structure. The same open warehouse space serves dual purposes as both the freezing chamber and storage area, making the system universal and eliminating the need for separate dedicated spaces for each function.
2Quantity of substance
If separate storage locations are used for frozen products, then product storage is achieved, but stocking and retrieval efficiency decreases
Solution Approach 1:
The patent combines storage and freezing operations into the same location. Products are frozen and stored in the same open warehouse space on the same rack system, eliminating the need to transport products between separate freezing and storage locations. This integration directly improves stocking and retrieval efficiency while maintaining storage capacity.
3Speed
If blast freezers are used for initial freezing, then rapid freezing is achieved, but device complexity and space requirements increase
Solution Approach 1:
The patent extracts the blast freezing function from a separate dedicated device and integrates it into the overall rack-aisle warehouse system. Instead of using standalone blast freezers, the freezing capability is built into the rack system itself through strategic chiller placement and airflow design, reducing device complexity while maintaining freezing speed.
Solution Approach 2:
The rack system becomes multi-functional, serving as both storage racks and the freezing mechanism. The chillers positioned at strategic locations within the rack structure provide rapid freezing capability while the same structure serves as storage, eliminating the need for separate blast freezer equipment and reducing overall system complexity.
4Ease of operation
If chillers are positioned remotely from storage chambers, then space for maneuvering is improved, but airflow efficiency may be affected
Solution Approach 1:
The patent positions chillers in three-dimensional space within the open warehouse environment rather than confining them to specific locations. By utilizing vertical and horizontal positioning options within the rack-aisle structure, the system maintains adequate maneuvering space for forklifts while ensuring chillers are placed at optimal locations for efficient cold air distribution through the products.
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
This configuration increases storage capacity, reduces space requirements, improves storage management, and allows for easier product access and handling by enabling more efficient airflow and reduced transportation needs, while maintaining the frozen state of products.
Implementation Method 1
Cold air produced in warehouse 2 is drawn through spacers 20 (see FIG. 6) separating rows of cases of product on the pallet. This air cools the product down while being drawn into chamber 6
Implementation Method 2
Air handlers, such as fans 12 inside or in air flow communication with chamber 6 assist in drawing the air within warehouse 2 through the palletized and/or through the product cases and into the channel
Implementation Method 3
Because the cold air moves around product prior to entering chamber 6, it provides an efficient means for freezing
Data Source
AI summary
An installation and method for freezing and cold storage of palletized product. A chiller is provided in the interior of a cold storage warehouse space that maintains the temperature of ambient air within the space below freezing. A plurality of racking structures each define an air flow chamber having air intake openings on opposite sides thereof and an air outlet to enable freezing air to be drawn into the chamber through the intake openings and exhausting into the warehouse space. Pallets on pallet guides are pressed against the intake openings such that freezing air is drawn through the palletized product to thereby quickly freeze the product. The pallet structure and air flow chambers are arranged in spaced-apart rows to enable a forklift to pass down the aisles so as to place and remove the palletized product.