System and method for ice manufacturing
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Solution Overview
Problem
Current systems for manufacturing clear ice are time-consuming, wasteful, and labor-intensive, requiring slow freezing with constant water circulation to remove air bubbles, which can result in opaque ice and pose safety risks during extraction and handling.
Innovation Solution
A system comprising a freezing module with plate freezers, circulation pumps, and a demolding module that automates the process of forming clear ice sheets, allowing for rapid freezing and safe removal, and a converting station for shaping and packaging, reducing manual labor and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If slow freezing with constant water circulation is used to remove air bubbles, then clear ice is produced, but the manufacturing time increases significantly (taking several days)
Solution Approach 1:
The freezing process is divided into multiple stages: initial rapid freezing to form ice, followed by controlled thawing and refreezing cycles. This segmentation allows air bubbles to be expelled during phase transitions while maintaining overall clarity, significantly reducing total processing time compared to continuous slow freezing.
Solution Approach 2:
The system employs periodic circulation of water and repeated freeze-thaw-refreeze cycles. During each cycle, water is circulated to release trapped air bubbles, then frozen again. This periodic action achieves clarity without requiring several days of continuous slow freezing, thereby reducing manufacturing time while maintaining ice quality.
2Ease of operation
If manual extraction and handling of ice blocks is performed, then ice can be removed from chambers, but safety risks and labor intensity increase
Solution Approach 1:
The ice blocks are designed with built-in handles or grip features that enable automatic or semi-automatic extraction mechanisms to remove them safely. This self-service design allows the ice itself to facilitate its own removal, reducing the need for manual handling and associated safety risks while improving operational ease.
Solution Approach 2:
Mechanical extraction devices with specialized grippers or clamps serve as intermediaries between the ice blocks and operators. These intermediaries perform the dangerous extraction task, eliminating direct human contact with heavy, sharp ice edges while maintaining control and safety during the removal process.
3Reliability
If single-use liners are used in chambers, then ice can be formed and removed safely, but material waste increases
Solution Approach 1:
The system implements a recovery process where used liners are collected, cleaned, and reused in subsequent ice formation cycles. This reduces material waste while maintaining the reliability benefits of liner usage, such as preventing ice adhesion to chambers and ensuring proper ice shape formation.
Solution Approach 2:
The liners are designed to be inexpensive and easily replaceable, allowing for frequent replacement without significant cost or waste concerns. This approach maintains the reliability advantages of disposable liners (such as preventing contamination and ensuring consistent ice quality) while minimizing the environmental impact through careful disposal and potential recycling programs.
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 enables efficient, rapid, and safe production of clear ice with minimal waste, eliminating the need for specialized expertise and reducing the risk of injury during ice handling and processing.
Implementation Method 1
One or more circulation pumps are associated with each control frame, wherein the circulation pumps circulate water in the mold to release air bubbles as the water freezes
Implementation Method 2
a freezing module for creating clear ice sheets. The freezing module includes a frame comprising a plurality of levels, a plate freezer provided at each level
Data Source
AI summary
A system for manufacturing clear ice products is provided. The system includes a freezing module, a demolding module, and a converting station. The freezing module includes a frame comprising a plurality of levels, a plate freezer provided at each level, and at least one mold provided for placement on each plate freezer and suitable for receiving water. A control frame is provided associated with each plate freezer and is movable from an elevated position to fill position. In the fill position, the control frame is at least partially disposed within the mold. One or more circulation pumps are associated with each control frame for circulating water in the mold to release air bubbles as the water freezes. The demolding module removes the mold from the freezing module and removes formed ice from the mold. The converting station converts the formed ice into a clear ice product.