Rotating Spray Bar Assembly for Continuous Meat Processing Cleaning
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Solution Overview
Problem
Conventional oscillating spray bar assemblies in meat processing facilities are inefficient, leading to increased water and chemical consumption, as they spray only during the downstroke, resulting in intermittent surface impact and inefficient debris and bacteria removal.
Innovation Solution
A rotating spray bar assembly with a plurality of linear distribution manifolds forming a rotary cage, a distribution valve with a fixed and rotating distribution block, and a motor-driven system to ensure continuous and optimized spray coverage, allowing for increased contact time and reduced fluid usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional oscillating spray bar assemblies spray only during the downstroke, then the spray mechanism is simple, but the spray coverage is intermittent and inefficient
Solution Approach 1:
The spray bar assembly transitions from oscillating motion to continuous rotation, allowing the spray nozzles to continuously contact the carcass surface. The rotational movement is controlled to maintain optimal spray angles while eliminating the intermittent spray pattern caused by oscillation, thereby improving spray coverage efficiency without requiring complex control systems.
Solution Approach 2:
The spray mechanism operates continuously during rotation rather than intermittently during oscillation. The spray nozzles maintain continuous contact with the carcass surface throughout the rotation cycle, ensuring uninterrupted spray coverage and eliminating the idle time present in oscillating systems, thus improving productivity.
2Quantity of substance
If oscillating spray bar assemblies operate with up and down strokes, then the mechanism can cover a wide area, but water and chemical consumption increases
Solution Approach 1:
The rotating spray bar assembly concentrates spray application on the specific areas of the carcass that require treatment, rather than spraying uniformly during both up and down strokes. The rotational motion allows precise positioning of spray nozzles relative to the carcass surface, applying fluid only where needed and reducing overall consumption while maintaining adequate coverage area.
3Productivity
If conventional spray assemblies use intermittent spraying, then the system is simpler to operate, but cleaning efficiency decreases
Solution Approach 1:
The system transitions from oscillating motion requiring bidirectional control to unidirectional rotation, which is mechanically simpler to implement and control. The continuous rotational movement provides consistent spray contact with the carcass surface, improving cleaning efficiency while maintaining operational simplicity through a single-direction motion system.
4Object-generated harmful factors
If oscillating spray bars spray during both up and down strokes, then coverage is more comprehensive, but debris removal effectiveness decreases
Solution Approach 1:
Instead of spraying during both up and down strokes as in conventional oscillating systems, the rotating spray bar assembly sprays in a single continuous direction. This inversion of the spray pattern ensures that debris is consistently pushed downward by the spray force, improving removal effectiveness while maintaining adequate coverage through the rotational motion.
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 rotating spray bar assembly achieves enhanced spray coverage with reduced waste, providing continuous and uninterrupted spraying, resulting in improved cleaning efficiency and reduced fluid consumption, while maintaining a smaller footprint.
Implementation Method 1
A rotating spray bar assembly, and methods of use, which increase contact time and reduce the amount of liquid or gas sprayed.
Data Source
AI summary
Rotating spray systems and related methods for enhancing spray performance can include one of more rotating spray assemblies formed of a plurality of individual, linear distribution manifolds to define a rotary cage. The rotary cage is fluidly coupled to a rotating distribution block on a distribution valve, with each linear distribution manifold being fluidly coupled to one of a plurality of distribution conduits defined in the rotating distribution block. The distribution valve further includes a fixed distribution block having an arcuate aperture defined therein. The rotating distribution block rotates relative to the fixed distribution block to individually and sequentially engage each distribution conduit with the arcuate aperture. When the individual distribution conduits are fluidly engaged with the arcuate aperture, pressurized fluid supplied to the distribution valve is supplied to the corresponding linear distribution manifold for spraying by one or more spray nozzles fluidly connected to each linear distribution manifold.