Rocker Chiller Deflector Layout for Uniform Carcass Residence Time
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Solution Overview
Problem
In rocker chillers for poultry processing, the axial movement of carcasses can lead to varying residence times and temperatures due to surges caused by the dasher's motion, resulting in inconsistent chilling outcomes.
Innovation Solution
The implementation of side and central deflectors within the chiller tank constrains axial movement while allowing unrestricted transverse motion, guiding carcasses through serpentine paths to ensure uniform progression and temperature consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the dasher oscillates to agitate and lift the liquid and carcasses, then heat exchange efficiency is improved, but axial displacement of carcasses occurs causing varying residence times
Solution Approach 1:
The chiller is segmented into multiple zones by installing deflectors at intervals along the tank length. These deflectors divide the continuous axial flow path into discrete segments, forcing carcasses to follow a stepped progression pattern rather than continuous axial movement, thereby standardizing residence time while preserving the benefits of dasher agitation.
Solution Approach 2:
The deflectors redirect carcass movement from primarily axial displacement to transverse oscillation patterns. By introducing this dimensional constraint, carcasses are forced to move laterally across the tank width rather than progressing axially, eliminating the harmful axial surges while maintaining the necessary transverse agitation for heat exchange.
2Manufacturing precision
If deflectors are installed to constrain axial movement, then residence time uniformity is improved, but transverse movement of carcasses is restricted
Solution Approach 1:
The deflectors are designed with selective permeability - they are solid barriers to axial movement but include gaps or are positioned to allow transverse passage. This local quality differentiation enables the deflectors to simultaneously constrain axial displacement while permitting the necessary transverse oscillation for heat exchange.
Solution Approach 2:
The deflectors are positioned and shaped to guide carcasses along curved or serpentine paths rather than straight axial lines. This curvature allows carcasses to maintain transverse mobility and oscillation while following a constrained trajectory that ensures uniform axial progression through the chiller.
3Productivity
If the dasher moves carcasses vigorously to maintain turbulence, then heat exchange rate increases, but axial surges cause inconsistent progression rates
Solution Approach 1:
The deflectors serve as intermediary structures between the dasher's vigorous agitation and the carcasses' axial progression. They absorb and redirect the turbulent energy into transverse oscillation patterns, preventing direct axial surges while maintaining the high levels of turbulence necessary for efficient heat exchange.
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 ensures that all carcasses spend a consistent amount of time in the chiller, achieving more uniform temperatures at the exit and enhancing heat exchange efficiency by maintaining carcass turbulence in the liquid.
Implementation Method 1
a dasher that oscillates across the bottom wall to impart turbulence in the heat exchanging liquid and among carcasses so as to increase the rate of temperature change in the carcasses
Implementation Method 2
Warm carcasses are added to the tank at one end and give up heat to the liquid in the tank as they migrate down the length of the tank
Data Source
AI summary
A rocker chiller 10 includes a tank 12 with a dasher assembly 26 that oscillates across the curved bottom wall of the tank. A series of central deflectors 40 are positioned at intervals along the length of the tank and another series of side deflectors 46 are mounted at intervals along the upwardly extending side walls 16 and 18 of the tank. The side deflectors are offset longitudinally with respect to the central deflectors. The offset relationship of the side deflectors and central deflectors creates serpentine paths through the elongated tank on both sides of the tank that require the carcasses to move through more of the heat exchanging liquid and which reduces the tendency of carcasses passing each other.