Wash Tank Spray Control for Water Recycling in Food Processing
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Solution Overview
Problem
Existing food processing systems face challenges in optimizing water usage, leading to increased costs and inefficiencies due to the dynamic nature of wash systems requiring manual adjustments, which often result in excess water consumption.
Innovation Solution
Implementing a control system with sensors and controllers to manage wash water flow rates based on usable quantity and quality, ensuring efficient water recycling and reduction of chemical additives by dynamically adjusting water sprayer flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustments are used to manage wash water flow rates, then ease of operation is maintained, but water usage efficiency deteriorates due to excess consumption
Solution Approach 1:
The system enables wash water to serve itself by automatically monitoring its own quantity and quality parameters, and self-adjusting flow rates without manual intervention. Sensors detect water level and quality in real-time, triggering automated responses that optimize water usage while maintaining cleaning effectiveness.
Solution Approach 2:
The system implements continuous feedback loops where sensors monitor wash water quantity and quality, feed this information to controllers, which then adjust sprayer flow rates accordingly. This closed-loop control ensures water is used efficiently while maintaining effective cleaning, resolving the contradiction between automated efficiency and operational simplicity.
2Loss of substance
If automated control systems are implemented to optimize water flow rates, then water usage efficiency is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical adjustment systems with electronic sensing and control mechanisms. Instead of manual mechanical valves and flow controls, the system uses electronic sensors to detect water parameters and electronic controllers to modulate flow rates, simplifying the overall system architecture while improving efficiency.
Solution Approach 2:
The system introduces intermediate sensing and control components that act as mediators between the wash water and the sprayer system. These intermediaries (sensors and controllers) translate physical water parameters into automated flow rate adjustments, managing complexity through modular functional blocks rather than monolithic complex mechanisms.
3Reliability
If more water is used to maintain cleaning effectiveness, then cleaning quality is improved, but operational expenses increase
Solution Approach 1:
The system dynamically adjusts water flow rates based on real-time conditions rather than using static fixed rates. Flow rates are continuously optimized to match actual cleaning needs, using more water only when necessary for effective cleaning and less water when conditions permit, thereby maintaining cleaning reliability while reducing overall water consumption and operational expenses.
Solution Approach 2:
The system monitors and responds to changes in water parameters (quantity, quality, flow rate) to optimize cleaning effectiveness. By dynamically changing these parameters based on sensor feedback, the system ensures cleaning quality is maintained while avoiding excessive water usage, thus reducing operational expenses associated with water consumption and disposal.
Data Source
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AI summary
Apparatus for improving water usage in food processing are provided. One example food processing system (300) generally includes a wash tank (110) for containing at least a portion of first wash water and a water sprayer (150) configured to spray a quantity of second wash water on a food product being removed from the wash tank, wherein at least a portion of the quantity of the second wash water sprayed by the water sprayer enters the wash tank and becomes the first wash water. Such a food processing system generally includes a controller (370) configured to determine a usable quantity (and/or quality) of the first wash water in the wash tank and automatically controlling a flow rate of the second wash water for supplying to the water sprayer based on the determined usable quantity (and/or quality) of the first wash water.