Vertical plate freezer system
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing plate freezer systems are labor-intensive, pose safety hazards due to heavy frozen blocks, and risk bacterial contamination during manual handling, with inefficient space usage and lengthy unloading times.
Innovation Solution
A plate freezer apparatus featuring a frame with vertically disposed freezing plates and a flooring system that raises frozen material for controlled release via paddle members, allowing blocks to slide off for collection, combined with an automated cleaning system using spray bars and spray balls for efficient cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual handling of frozen blocks is used for removal, then device complexity is reduced, but productivity decreases and safety hazards increase
Solution Approach 1:
The system uses the frozen blocks' own weight and the tilted frame to enable self-unloading. When the frame is tilted, gravity causes the blocks to automatically slide off the plates onto the conveyor without requiring manual handling or complex robotic manipulation, thus maintaining simple device structure while dramatically improving unloading speed
Solution Approach 2:
The frame is designed to be dynamically tiltable between horizontal and inclined positions. This dynamic adjustment allows the system to switch between loading mode (horizontal) and unloading mode (inclined), enabling automated block removal while keeping the overall device structure relatively simple
2Device complexity
If manual handling of frozen blocks is used, then device complexity is reduced, but safety hazards increase due to heavy blocks
Solution Approach 1:
The frozen blocks self-unload through gravity when the frame is tilted, eliminating the need for workers to manually handle 70kg blocks. The system performs the heavy lifting and transfer automatically, removing safety hazards while maintaining simple device architecture
Solution Approach 2:
The tilted frame acts as an intermediary mechanism that transfers the blocks from the plates to the conveyor without human intervention. This intermediate gravitational transfer mechanism eliminates direct contact between workers and heavy blocks, resolving safety issues while keeping the system structurally simple
3Device complexity
If manual handling is used, then device complexity is reduced, but product contamination risk increases
Solution Approach 1:
The automated gravity-based unloading system eliminates human contact with the frozen blocks during removal. By making the system self-serving, it prevents bacterial contamination from manual handling while avoiding complex automated handling mechanisms that would increase device complexity
4Ease of operation
If conveyor extends parallel to plate freezer, then ease of operation is improved, but space efficiency deteriorates
Solution Approach 1:
The conveyor is repositioned from a parallel arrangement (wasting floor space) to a perpendicular arrangement at the distal end of the frame. This dimensional change in conveyor placement reduces the footprint while maintaining operational accessibility, as the conveyor can still receive blocks efficiently from the tilted plates
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
Significantly reduces unloading time, eliminates manual handling risks, and ensures efficient space use, with automated cleaning minimizing downtime and preventing bacterial contamination.
Implementation Method 1
the flooring system is configured to be raised so as to lift any frozen material present in freezing cavities out of the freezing cavities so that the frozen material extends from the freezing cavities to project above an upper edge of the freezing plate members
Implementation Method 2
Refrigerant is delivered to the plates to provide form such that the plates act as evaporators to absorb heat energy from the product thereby rapidly freezing the product
Implementation Method 3
automated cleaning system using spray bars and spray balls for efficient cleaning
Data Source
Figure 1
Figure 2
Figure 3
AI summary
There is disclosed a plate freezer apparatus. The plate freezer apparatus comprises a first frame member configured to support a plurality of vertically disposed freezing plate members arranged to define a freezing cavity therebetween and a flooring system configured to extend below the freezing plate members to form a base for the freezing cavities, wherein the flooring system is configured to be raised so as to lift any frozen material present in freezing cavities out of the freezing cavities so that the frozen material extends from the freezing cavities to project above an upper edge of the freezing plate members. A second frame member is mounted above said first frame member so as to extend substantially a length of the first frame member, the second frame member having a plurality of paddle members mounted therein that are individually actuable to extend between a horizontal axis where the paddle members extend substantially parallel with the second frame member, and a vertical axis where the paddle members extend from the second frame member to be received between the frozen material raised from the freezing cavities. The first frame member further comprises a lifting mechanism adjacent a proximal end thereof, the lifting mechanism being actuable to raise the proximal end of the first frame member so as to tilt the first frame member towards a distal end and wherein the paddle members are actuable to facilitate controlled release of the frozen material such that upon release the frozen material is able to slide along the upper edges of the plates and off the distal end of the first frame member for collection.