Dual Waterfall Cabinet for Interior Cavity Antimicrobial Coverage

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Solution Overview

Problem

Existing food processing systems, such as spray bars and dip tanks, face challenges in providing adequate antimicrobial coverage and sanitation while occupying valuable space and resources, with spray bars lacking coverage and dip tanks being inefficient and resource-intensive.

Innovation Solution

A dual waterfall cabinet design that applies antimicrobial solution through two waterfalls aligned with workpieces, allowing for increased coverage of both exterior and interior surfaces, with adjustable features for varying workpiece sizes and a compact, space-saving design that recycles antimicrobial solution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If dip tanks are used to provide adequate antimicrobial coverage, then coverage volume is improved, but facility space occupation and water consumption increase

Engineering Contradiction:

Improveantimicrobial solution coverage volumeVSAvoidfacility space occupation

Core Design Contradiction:

Quantity of substanceVSArea of stationary object

Solution Approach 1:

The cabinet is divided into multiple spray zones (front, rear, and side spray bars) that segment the antimicrobial application process. This segmentation allows comprehensive coverage of poultry carcasses from multiple angles simultaneously, achieving dip-tank-level coverage without requiring a large single-volume tank structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from a two-dimensional surface spray to a three-dimensional enveloping spray system. Multiple spray bars positioned at different locations (front, rear, sides) create a volumetric spray field that surrounds the workpiece, achieving thorough coverage without the space requirements of a dip tank.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Area of stationary object

If spray bars are used to reduce facility space, then space occupation is reduced, but antimicrobial coverage is insufficient

Engineering Contradiction:

Improvefacility space occupationVSAvoidantimicrobial solution coverage volume

Core Design Contradiction:

Area of stationary objectVSQuantity of substance

Solution Approach 1:

The invention merges multiple spray bar systems into a unified cabinet structure with front spray bars, rear spray bars, and side spray bars. This combination creates a coordinated multi-directional spray system that delivers comprehensive coverage equivalent to or exceeding dip tanks, while maintaining a compact footprint.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cabinet serves multiple functions simultaneously: it provides antimicrobial treatment, enables sanitation operations, and accommodates various poultry products. The multi-functional spray system addresses both coverage requirements and space constraints through integrated front, rear, and side spraying capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Area of stationary object

If conventional spray systems are used for sanitation, then facility space is reduced, but cleaning effectiveness and nozzle reliability deteriorate

Engineering Contradiction:

Improvefacility space occupationVSAvoidnozzle performance and sanitation effectiveness

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The invention extracts and eliminates the vulnerability of individual nozzles by replacing them with waterfall spray bars that deliver antimicrobial solution through a continuous flowing surface. This extraction of the nozzle component removes the clogging and misalignment problems inherent in traditional nozzle systems while maintaining compact cabinet dimensions.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The waterfall spray bars act as an intermediary between the antimicrobial solution supply and the poultry carcasses. Instead of relying on small nozzles that are prone to failure, the system uses a continuous water curtain that reliably delivers solution, improving both sanitation effectiveness and system reliability within the same space footprint.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 dual waterfall cabinet enhances antimicrobial coverage by applying 2 to 4 gallons per workpiece, optimizing internal cavity filling, and reduces resource consumption by recycling antimicrobial solution, while maintaining a small facility footprint.

Implementation Method 1

two waterfalls (106, 108) that apply the antimicrobial solution to the workpieces

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 2

recycles antimicrobial solution

Methodology Applied

Scientific EffectFluid recycling:

Data Source

PatentUS12490751B2Dual waterfall cabinet for food processing applications

Publication Date: 2025.12.09 SAFE FOODS CORP

AI summary

A dual waterfall cabinet includes a hollow basin having front and rear openings to allow workpieces to move therethrough. The cabinet also includes waterfall assemblies on either side of the hollow basin that form waterfalls of solution to be applied to the workpieces. To provide thorough interior and exterior coverage, the distance between the waterfalls can vary along a length of the cabinet.