APPARATUS AND METHOD FOR COOLING TEMPERATURE SENSITIVE PRODUCTS

Abstract

An apparatus for cooling temperature sensitive products comprises an ice-making machine comprising at least one nozzle for discharging ice-slurry from the ice-making machine, and at least one conveyor configured to convey at least one temperature sensitive product to a location to receive ice-slurry discharged through the at least one nozzle such that the at least one temperature sensitive product is exposed to ice-slurry

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/661,927 filed on Apr. 24, 2018, U.S. Provisional Patent Application No. 62/727,205 filed on Sep. 5, 2018, and U.S. Provisional Patent Application No. 62/732,729 filed on Sep. 18, 2018 the entireties of which are incorporated herein by reference.

FIELD

This application relates to an apparatus and method for cooling temperature sensitive products.

BACKGROUND

To preserve freshness and inhibit spoiling, foodstuff and other types of temperature sensitive products are often cooled or chilled prior to serving and/or shipping. For example, fishing vessels typically carry refrigeration equipment to allow fish to be chilled as the fish are caught. In this manner, the fish does not spoil and remains edible even over lengthy voyages. Vegetables that are transported by truck or rail are also typically refrigerated during transit to prevent spoiling. Many refrigeration techniques have been employed and include for example, air conditioning units and ice-making machines that produce ice. In the latter case, ice-making machines that produce a slurry of fine ice crystals in a solution have been used to chill food product such as fish and vegetables.

U.S. Pat. No. 9,016,081 to Goldstein discloses a method and apparatus for cooling foodstuff that comprises immersing at least one perforated container containing foodstuff into an ice slurry bath for a period of time sufficient to allow ice slurry to enter the at least one perforated container and then subsequently removing the at least one perforated container from the ice slurry bath.

U.S. Patent Application Publication No. 2012/0042789 to Hognason et al. discloses an apparatus for thawing or cooling food products that includes a tank adapted to be at least partly filled with a liquid. A spiral shaped blade extends between a first end and a second end of the tank, where the spiral shaped blade is mounted to a rotation axis which operates rotational movement of the spiral shaped bladed and thus the conveying of the food products from the first end towards the second end. A temperature controlling system is provided and adapted to control the temperature of the liquid by arranging multiple heat supplying units along the tank for injecting heating or cooling agents into the liquid so as to provide a substantial temperature distribution into the thawing liquid during the thawing or cooling of the food products.

Although techniques have been considered, improvements are desired. It is therefore an object at least to provide a novel apparatus and method for cooling temperature sensitive products.

SUMMARY

It should be appreciated that this Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to be used to limit the scope of the claimed subject matter.

Accordingly, in one aspect there is provided an apparatus for cooling temperature sensitive products comprising an ice-making machine comprising at least one nozzle for discharging ice-slurry from the ice-making machine; and at least one conveyor configured to convey at least one temperature sensitive product to a location to receive ice-slurry discharged through the at least one nozzle such that the at least one temperature sensitive product is exposed to ice-slurry.

In one or more embodiments, the apparatus comprises at least one container dimensioned to receive a predefined number of temperature sensitive products and ice-slurry.

In one or more embodiments, the predefined number of temperature sensitive products is between sixty and eighty.

In one or more embodiments, the at least one conveyor is configured to convey the at least one container to another location to receive the predefined number of temperature sensitive products, wherein the location to receive ice-slurry is downstream of the location to receive the predefined number of temperature sensitive products.

In one or more embodiments, the apparatus comprises a conveyor conveying the predefined number of temperature sensitive products to the at least one container.

In one or more embodiment, the apparatus comprises at least one funnel positioned below a portion of the conveyor and above the at least one container, the at least one funnel directing the predefined number of temperature sensitive products released from the conveyor into the at least one container.

In one or more embodiments, the apparatus comprises a vibration mechanism configured to cause the conveyor to vibrate.

In one or more embodiment, the apparatus comprises at least one funnel positioned below the at least one nozzle, the at least one funnel directing ice-slurry discharged through the at least one nozzle towards the at least one temperature sensitive product.

In one or more embodiment, the at least one temperature sensitive product is bird comprising an open cavity.

In one or more embodiments, the apparatus further comprises a line conveyor conveying the at least one temperature sensitive product to a location adjacent to the at least one nozzle.

In one or more embodiment, the at least one nozzle discharges ice-slurry into the open cavity of the bird.

In one or more embodiment, the apparatus is located in a refrigerated environment.

According to another aspect there is provided a method for cooling temperature sensitive products comprising conveying at least one temperature sensitive product to a location to receive ice-slurry, and discharging ice-slurry from at least one discharge nozzle thereby exposing the at least one temperature sensitive product to ice-slurry.

In one or more embodiments, the method comprises prior to discharging ice-slurry, locating the at least one temperature sensitive product in a container.

In one or more embodiments, the locating comprises releasing the temperature sensitive product from another conveyor into the container.

In one or more embodiments, the method comprises vibrating the conveyor using a vibration mechanism.

In one or more embodiments, the method comprises monitoring a temperature of the at least one temperature sensitive product; and discharging ice-slurry from at least a second discharge nozzle downstream of the at least one discharge nozzle if the temperature is above a threshold temperature.

In one or more embodiment, the method comprises removing the at least one temperature sensitive product from the conveyor if the temperature is below or equal to the threshold temperature.

In one or more embodiments, the ice-slurry is discharged into a cavity of the at least one temperature sensitive product.

According to another aspect there is provided a method for cooling temperature sensitive products comprising communicating a signal to operate a conveyor to convey at least one temperature sensitive product to a location to receive ice-slurry; and communicating a signal to discharge ice-slurry from at least one discharge nozzle such that the at least one temperature sensitive product is exposed to ice-slurry.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described more fully with reference to the accompanying drawings in which:

FIG. 1 is a schematic view of an apparatus for cooling temperature sensitive products;

FIG. 2 is a schematic view of another embodiment of an apparatus for cooling temperature sensitive products;

FIG. 3 is a schematic view of another embodiment of an apparatus for cooling temperature sensitive products;

FIG. 4 is a schematic view of another embodiment of an apparatus for cooling temperature sensitive products;

FIG. 5 is a schematic view of another embodiment of an apparatus for cooling temperature sensitive products;

FIG. 6 is a schematic view of another embodiment of an apparatus for cooling temperature sensitive products;

FIG. 7 is a schematic view of another embodiment of an apparatus for cooling temperature sensitive products;

FIG. 8 is a schematic view of another embodiment of an apparatus for cooling temperature sensitive products;

FIG. 9 is a schematic view of another embodiment of an apparatus for cooling temperature sensitive products;

FIG. 10 is a side view of a container;

FIG. 11 is an isometric view of another container; and

FIG. 12 is a schematic view of another embodiment of an apparatus for cooling temperature sensitive products.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The foregoing summary, as well as the following detailed description of certain examples will be better understood when read in conjunction with the appended drawings. As used herein, an element or feature introduced in the singular and preceded by the word “a” or “an” should be understood as not necessarily excluding the plural of the elements or features. Further, references to “one example” or “one embodiment” are not intended to be interpreted as excluding the existence of additional examples or embodiments that also incorporate the described elements or features. Moreover, unless explicitly stated to the contrary, examples or embodiments “comprising” or “having” or “including” an element or feature or a plurality of elements or features having a particular property may include additional elements or features not having that property. Also, it will be appreciated that the terms “comprises”, “has”, “includes” means “including by not limited to” and the terms “comprising”, “having” and “including” have equivalent meanings.

As used herein, the term “and/or” can include any and all combinations of one or more of the associated listed elements or features.

It will be understood that when an element or feature is referred to as being “on”, “attached” to, “connected” to, “coupled” with, “contacting”, etc. another element or feature, that element or feature can be directly on, attached to, connected to, coupled with or contacting the other element or feature or intervening elements may also be present. In contrast, when an element or feature is referred to as being, for example, “directly on”, “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element of feature, there are no intervening elements or features present.

It will be understood that spatially relative terms, such as “under”, “below”, “lower”, “over”, “above”, “upper”, “front”, “back” and the like, may be used herein for ease of description to describe the relationship of an element or feature to another element or feature as illustrated in the figures. The spatially relative terms can however, encompass different orientations in use or operation in addition to the orientation depicted in the figures.

In the following, an apparatus for cooling temperature sensitive products is described and comprises a tank containing ice-slurry, at least one sensor configured to measure an ice fraction of the ice-slurry in the tank, at least one conveyor configured to convey one or more temperature sensitive products from a first end to a second end, wherein the one or more temperature sensitive products are exposed to ice-slurry when conveyed from the first end to a second end.

Turning to FIG. 1, an apparatus for cooling temperature sensitive products is shown and is generally identified by reference numeral 100. The apparatus 100 comprises a tank 110 containing an ice-slurry bath 120, a sensor 130, a conveyor 140, discharge nozzles 150, an ice-making machine 160, and a circulation loop 170. A master controller (not shown) in this embodiment is communicatively coupled to the sensor 130, the conveyor 140, the discharge nozzles 150 and the ice-making machine 160. The apparatus is used to cool temperature sensitive products P such as for example foodstuff (i.e. fish, broccoli, asparagus etc.), as will be described in more detail below.

The tank 110 comprises openings 112 and 114 located on opposing ends thereof. The tank 110 is made of a rigid material such as for example stainless steel.

The ice-slurry bath 120 is a mixture of brine and phase-changing material. In this embodiment, the brine is sea water and the phase-changing material is ice crystals. As will be described, the amount of ice-crystals in the ice-slurry bath 120 is monitored as an ice-fraction by the sensor 130.

The sensor 130 is positioned within the tank 110 adjacent a bottom surface thereof such that the sensor 130 is submerged in an ice-slurry bath 120. The sensor 120 generates and communicates sensor data to the master controller (not shown). The master controller is programmed to process the sensor data to calculate an ice-fraction of the ice-slurry bath 120.

In this embodiment, the conveyor 140 is a belt conveyor having a length greater than a length of the tank 110. The conveyor 140 has a first end 142 and a second end 144. The first end 142 is adjacent to the opening 112 of the tank 110 and the second end 144 is adjacent to the opening 114 of the tank 110. One or more drain openings (not shown) are provided on the conveyor 140 to drain excess ice-slurry into the ice-slurry bath 120. As will be described in more detail below, the conveyor 140 is used to convey temperature sensitive products P in a direction indicated by arrow A from the first end 142 to the second end 144. Put another way, the conveyor 140 is used to convey temperature sensitive products P through the tank 110. The conveyor 140 operates at a constant speed to ensure each temperature sensitive product P is exposed to ice-slurry for a same amount of time, as will be described. In this embodiment, the master controller is programmed to operate the conveyor. Further, the master controller is programmed to adjust the speed of the conveyor as desired.

The discharge nozzles 150 are positioned within the tank 110 at a position above the conveyor 140. In this embodiment, the discharge nozzles 150 are stationary within the tank 110 and are equally-spaced. The discharge nozzles 150 are in fluid communication with the tank 110 and the ice-making machine 160. The discharge nozzles 150 are configured to discharge ice-slurry received from the tank 110 and/or the ice-making machine 160 onto the temperature sensitive products P as they travel through the tank 110. Each discharge nozzle 150 comprises an adjustable valve (not shown) used to adjust an amount of ice-slurry it receives. In this embodiment, the discharge nozzles 150 are calibrated such that each discharge nozzle 150 receives a same amount of ice-slurry and is configured to discharge at a same rate as the other nozzles 150. In this embodiment, the master controller is programmed to operate the discharge nozzles and to adjust each valve to control an amount of ice-slurry being received by each discharge nozzle.

In this embodiment, the ice-making machine 160 is of the type described in U.S. Pat. Nos. 5,884,501 and 6,056,046, the contents of which are incorporated herein by reference. Generally, the ice-making machine 160 comprises an inlet 162 and an outlet 164. The ice-making machine 160 comprises an ice generator tube having a cylindrical internal heat exchange surface. A blade assembly is disposed within the tube and includes a plurality of blades in contact with the heat exchange surface. The blade assembly is mounted on a shaft driven by a motor via a transmission. Refrigerant circulates through refrigerant circuits in proximity to the heat exchange surface. Brine solution, which in this embodiment is sea-water, is pumped into the ice-making machine 160 via the inlet 162 and is directed towards the heat exchange surface therein. While this is occurring, refrigerant circulates through the refrigerant circuits to cool the heat exchange surface. As the refrigerant flows through the refrigerant circuits, the refrigerant absorbs heat through the heat exchange surface and boils. The brine solution in contact with the heat exchange surface is thus supercooled.

To avoid deposition of ice on the heat exchange surface, which would inhibit heat transfer to the refrigerant and thereby reduce the efficiency of the ice-making machine 160, the blade assembly is rotated by the motor at a rate that is fast enough to allow the blades to remove the supercooled brine solution from the heat exchange surface prior to crystallization of ice crystals on the heat exchange surface. The supercooled brine solution therefore crystallizes in the body of brine solution within the tube allowing the brine solution to act as a secondary refrigerant in the formation of fine ice crystals throughout the brine solution. The supercooled brine solution including the ice crystals exits the ice-making machine 160 via the outlet 164 as ice-slurry.

The circulation loop 170 comprises an ice-slurry line 172, a drain line 174, a delivery line 176 and a pump 178. The ice-slurry line 172 is fluidly connected to the outlet 164 of the ice-making machine 160 and is used to selectively introduce ice-slurry from the ice-making machine 160 into the circulation loop 170. The drain line 174 is fluidly connected to a bottom portion of the tank 110 and is used to selectively drain ice-slurry bath therefrom. The delivery line 176 is fluidly connected at a first end to the ice-slurry line 172 and drain line 174 and at a second end to the discharge nozzles 150. The pump 178 is used to pump ice-slurry received from the drain line 174 and/or ice-slurry line 172 through the delivery line 176 to the discharge nozzles 150.

The master controller in this embodiment is a programmed computing device such as for example a personal computer or other suitable processing device and comprises, for example, a processing unit comprising one or more processors, system memory (volatile and/or non-volatile memory), other non-removable or removable memory (e.g., a hard disk drive, RAM, ROM, EEPROM, CD-ROM, DVD, flash memory, etc.) and a system bus coupling the various computer components to the processing unit. The master controller may also comprise networking capabilities using Ethernet, Wi-Fi, and/or other suitable network format, to enable connection to shared or remote drives, one or more networked computers, or other networked devices.

During operation, ice-slurry received from the bottom of the tank 110 via the drain line 174 and/or from the ice-making machine 160 via the ice-slurry line 172 is pumped to the discharge nozzles 150 via the pump 178. One or more temperature sensitive products P are placed on the conveyor 140 at the first end 142 thereof. As the conveyor 140 conveys each temperature sensitive product P from the first end 142 to the second end 144 in the direction indicated by arrow A, ice-slurry is discharged through the discharge nozzles 150 onto the temperature sensitive product P. As mentioned, the conveyor 140 operates at a constant speed to ensure each temperature sensitive product P is exposed to ice-slurry for a same amount of time. The ice-slurry discharged through the discharge nozzles 150 contacts the temperature sensitive product P and cools it to a desired temperature for shipping or storage. Excess ice-slurry discharged by the nozzles 150 is collected into the ice-slurry bath 120 at the bottom of the tank 110. This ice-slurry is drained through the drain line 174 where it is circulated/pumped back through the delivery line 176 to the nozzles 150. Once a temperature sensitive product P reaches the second end 144, it is removed from the conveyor 140.

While this is happening, the sensor 130 continuously communicates sensor data to the master controller which in turn monitors the ice-fraction of the ice-slurry bath 120 in the bottom of tank 110. Once the master controller detects that the ice fraction of the ice-slurry bath 120 in the tank 110 has dropped below a threshold level, the master controller provides an output signal which is used to control operation of the ice-making machine 160 so that ice-slurry is added to the circulation loop 170 thereby to increase the ice fraction of the ice-slurry bath 120 until it reaches the desired level. By controlling the ice fraction of the ice-slurry bath, the temperature of the ice-slurry bath is maintained and consequently the desired temperature of the temperature sensitive products P is achieved.

In comparison to fluid, the use of ice-slurry, which contains a phase-changing material such as ice crystals, provides a high rate of heat transfer to the temperature sensitive products as the ice-crystals convert from solid to liquid. Further, as ice-slurry maintains a generally constant temperature, the amount of sensors and control that is required to operate apparatus 100 is significantly reduced compared to prior art systems that use a heating or cooling liquid.

Turning now to FIG. 2, another embodiment of an apparatus is shown and is generally identified by reference numeral 200. Apparatus 200 is generally similar to that of apparatus 100 with following exceptions. In this embodiment, apparatus 200 comprises a tank 210 positioned below the conveyor 140. Specifically, the tank 210 is positioned below and between the first end 142 and second end 144 of the conveyor 140. A first portion 212 of a bottom surface 214 of the tank 210 slopes downward towards a second portion 216 of the bottom surface 214 the tank. The second portion 216 forms a basin 218 that is used to collect ice-slurry as an ice-slurry bath 220. An agitator 219 is positioned in the basin 218 and is used to agitate the ice-slurry bath 220.

Similar to apparatus 100, apparatus 200 comprises a circulation loop 270. In this embodiment, the circulation loop 270 comprises an ice-slurry lines 272a and 272b, a drain line 274, a delivery line 276 and a pump 278. The ice-slurry line 272a is fluidly connected to the outlet 164 of the ice-making machine 160 and is used to selectively introduce ice-slurry from the ice-making machine 160 into the circulation loop 270. The ice-slurry line 272b extends from the ice-slurry line 272a and is fluidly connected thereto. The ice-slurry line 272b is used to selectively introduce ice-slurry from the ice-making machine 160 to the ice-slurry bath 220 in the basin 218 of the tank 210. The drain line 274 is fluidly connected to a bottom portion of the basin 218 of the tank 210 and is used to selectively drain ice-slurry therefrom. The delivery line 276 is fluidly connected at a first end to the ice-slurry line 272a and drain line 274 and at a second end to the discharge nozzles 150. The pump 278 is used to pump ice-slurry received from the drain line 274 and/or ice-slurry line 272a through the delivery line 276 to the discharge nozzles 150.

The operation of apparatus 200 is generally similar to that of apparatus 100 with the following exceptions. As ice-slurry is discharged through the discharge nozzles 150 onto the temperature sensitive products P, excess ice-slurry is collected by the bottom surface 214 of the tank 210. Excess ice-slurry that is collected by the first portion 212 of the bottom surface 214 slides along the bottom surface 214 and into the ice-slurry bath 220 in the basin 218. The ice-slurry bath 220 collected in the basin is selectively agitated by the agitator 219 which in this embodiment is controlled by the master controller. As will be appreciated, agitation of the ice-slurry bath 220 ensures homogenous mixing of ice-crystals and liquid.

Turning now to FIG. 3, another embodiment of an apparatus is shown and is generally identified by reference numeral 300. Apparatus 300 is generally identical to apparatus 200, with the following exceptions.

In this embodiment, the conveyor 340 is in the form of a gravity conveyor. Specifically, the conveyor 340 comprises a support 341 made of a low-friction material such as for example Teflon. The support 341 slopes downward from a first end 342 to a second end 344. Drain openings (not shown) are provided on the conveyor 340 to drain excess ice-slurry.

The operation of apparatus 300 is generally similar to that of apparatus 200 with the following exceptions. During operation, a temperature sensitive product P is placed on the conveyor 340 at the first end 342. The temperature sensitive product P travels from the first end 342 to the second end 344 due to the force of gravity. As the gravity conveyor conveys each temperature sensitive product P from the first end 342 to the second end 344, ice-slurry is discharged through the discharge nozzles 150 onto the temperature sensitive product P. Excess ice-slurry discharged by the nozzles 150 is collected into the ice-slurry bath 220 in the tank 210.

Turning now to FIG. 4, another embodiment of an apparatus is shown and is generally identified by reference numeral 400. Apparatus 400 is generally similar to that of apparatus 100 with the following exceptions.

In this embodiment, the conveyor 440 is in the form of a belt conveyor and comprises a number of partitions 441 extending therefrom. The partitions 441 define compartments 443 to separate each temperature sensitive product P when it is travelling from the first end 442 to the second end 444. In this embodiment, a first lifting mechanism 480 is used to place the temperature sensitive product P in one of the compartments 443 adjacent the first end 442 of the conveyor 440. A second lifting mechanism 482 is used to remove the temperature sensitive product P from one of the compartments 443 adjacent the second end 444 of the conveyor 440. In this embodiment, the master controller is programmed to control the first and second lifting mechanisms 480, 482.

Rather than having discharge nozzles positioned above the conveyor 440, apparatus 400 comprises discharge nozzles 450 located at a bottom portion of the tank 110. The discharge nozzles 450 are configured to selectively discharge ice-slurry into the tank 110.

In this embodiment, the volume of ice-slurry bath 120 in the tank 110 is such that the one or more temperature sensitive products P are fully immersed in the ice-slurry bath 120 when placed on the conveyor 440.

Similar to apparatus 100, apparatus 400 comprises a circulation loop 470. In this embodiment, the circulation loop 470 comprises an ice-slurry line 472, drain lines 474a and 474b, a delivery line 476 and a pump 478. The ice-slurry line 472 is fluidly connected to the outlet 164 of the ice-making machine 160 and is used to selectively introduce ice-slurry from the ice-making machine 160 into the circulation loop 470. Drain lines 474a, 474b are fluidly connected to a bottom portion the tank 110 and are used to selectively drain ice-slurry therefrom. The delivery line 476 is fluidly connected at a first end to the ice-slurry line 472 and at a second end to the discharge nozzles 450. The pump 478 is used to pump ice-slurry received from the drain lines 474a, 474b and/or ice-slurry line 472 through the delivery line 476 to the discharge nozzles 450.

The operation of apparatus 400 is generally similar to that of apparatus 100 with the following exceptions. During operation, the first lifting mechanism 480 places a temperature sensitive product P into one of the compartments 443 adjacent the first end 442 of the conveyor 440. As such, the temperature sensitive product P is fully immersed in the ice-slurry bath 120. As the conveyor 440 conveys each temperature sensitive product P from the first end 442 to the second end 444 in the direction indicated by arrow A, the ice-slurry bath 120 cools the temperature sensitive product P to a desired temperature. Ice-slurry is selectively drained out of the tank 110 via the drain lines 474a, 474b where it is circulated/pumped back through the delivery line 476 to the nozzles 450.

While this is happening, the sensor 130 continuously communicates sensor data to the master controller which in turn monitors the ice-fraction of the ice-slurry bath 120. Once the master controller detects that the ice fraction of the ice-slurry bath 120 has dropped below a threshold level, the master controller provides an output signal which is used to control operation of the ice-making machine 160 so that ice-slurry is added to the circulation loop 470 thereby to increase the ice fraction of the ice-slurry bath 120 until it reaches the desired level.

Turning now to FIG. 5, another embodiment of an apparatus is shown and is generally identified by reference numeral 500. Apparatus 500 is generally similar to apparatus 400 with the following exceptions. In this embodiment, apparatus 500 comprises a conveyor 540 in the form of a screw conveyor. Specifically, the conveyor 540 comprises a shaft 541 mounted to a motor (now shown) and a spiral blade 543 coiled around the shaft 541. The master controller is programmed to operate the motor to rotate the shaft 541. As the shaft 541 rotates, the spiral blade 543 conveys the one or more temperature sensitive products P from the first end 542 to the second end 544 in the direction indicated by arrow A. The spiral blade 543 further agitates the ice-slurry bath 120 within the tank 110. An agitator 580 is positioned within the tank 110 and is used to further agitate the ice-slurry bath 120 within the tank 110.

Similar to apparatus 400, apparatus 500 comprises a circulation loop 570. In this embodiment, the circulation loop 570 comprises an ice-slurry line 572, a drain line 574, a delivery line 576 and a pump 578. The ice-slurry line 572 is fluidly connected to the outlet 164 of the ice-making machine 160 and is used to selectively introduce ice-slurry from the ice-making machine 160 into the circulation loop 570. Drain line 574 is fluidly connected to a bottom portion the tank 110 and is used to selectively drain ice-slurry therefrom. The delivery line 576 is fluidly connected at a first end to the ice-slurry line 572 and at a second end to a discharge nozzle 550. The pump 578 is used to pump ice-slurry received from the drain line 574 and/or ice-slurry line 572 through the delivery line 576 to the discharge nozzle 550.

The operation of apparatus 500 is generally similar to that of apparatus 400 with the following exceptions. In this embodiment, as the screw conveyor 540 rotates, the ice-slurry bath 120 is agitated. To ensure ice crystals within the ice-slurry bath 120 do not collect at a particular location due to the rotation of the screw conveyor 540, the agitator 580 further agitates the ice-slurry bath 120.

Turning now to FIG. 6, another embodiment of an apparatus is shown and is generally identified by reference numeral 600. Apparatus 600 is generally similar to that of apparatus 100, with the following exceptions.

In this embodiment, apparatus 600 comprises a temperature sensor 605 positioned outside of the tank 110, adjacent the opening 114 thereof. The temperature sensor 605 generates and communicates sensor data to the master controller (not shown). The master controller is programmed to process the sensor data to calculate the temperature of a temperature sensitive product P exiting the apparatus 600. If the temperature of the temperature sensitive product P is above or below a threshold, the master controller is programmed to adjust the speed of the conveyor 140. For example, if the temperature of the temperature sensitive product P is above a threshold, the master controller is programmed to reduce the speed of the conveyor 140. As a result, it will take longer for the temperature sensitive products to travel from the first end 142 to the second end 144, and thus each temperature sensitive product will receive more ice-slurry from the discharge nozzles 150 thereby reducing the temperature of each temperature sensitive product when it exits the apparatus 600. In another embodiment, rather than adjusting the speed of the conveyor, the master controller may additionally or alternatively be programmed to adjust an amount of ice-slurry being discharged by each discharge nozzle.

In another embodiment, a temperature sensor may be used to determine the temperature of a temperature sensitive product entering the apparatus 600. In this embodiment, the master controller is programmed to adjust the speed of the conveyor and/or the amount of ice-slurry being discharged by each discharge nozzle based on the temperature of the temperature sensitive product entering the apparatus 600.

In another embodiment, a first temperature sensor may be used to determine the temperature of a temperature sensitive product entering the apparatus 600 and a second temperature sensor may be used to determine the temperature of a temperature sensitive product exiting the apparatus 600. In this embodiment, the master controller is programmed to adjust the speed of the conveyor and/or the amount of ice-slurry being discharged by each discharge nozzle based on the temperature of the temperature sensitive product entering the apparatus 600 and/or the temperature of the temperature sensitive product exiting the apparatus 600.

Turning now to FIG. 7, another embodiment of an apparatus is shown and is generally identified by reference numeral 700. Similar to apparatus 100, apparatus 700 comprises a conveyor 140, an ice-making machine 160, and a master controller (not shown). The conveyor 140, ice-making machine 160 and master controller are similar to those described above with reference to FIG. 1 and as such the specifics will not be described further. The apparatus 700 is used to cool temperature sensitive products such as for example raw chickens, as will be described in more detail below. As will be described, the apparatus 700 eliminates the risk of cross-contamination between temperature sensitive products.

The apparatus 700 comprises a line conveyor 710 that has hooks for hanging temperature sensitive products, which in this embodiment is raw chickens C, therefrom. Although not shown, the line conveyor 710 comprises a motor configured to move the conveyor 710 in a direction indicated by arrow A to transport one or more raw chickens C to a position above the conveyor 140. The motor communicates and receives control signals from the master controller.

In this embodiment, the apparatus 700 comprises a plurality of containers 720. Each container 720 is made of a rigid material such as for example stainless steel and comprises an open end 722. A screen 725 is located within the container 720 and is spaced above a bottom thereof. The screen 725 is used to drain water from the ice-slurry as it melts within the container 720. The excess water may be filtered and recycled for use with the ice-making machine 160 or it may simply be discarded. Each container 720 is dimensioned to hold a single temperature sensitive product, which in this embodiment is a raw chicken.

In this embodiment, the apparatus 700 comprises two (2) funnels 730a, 730b. Although not show, each funnel 730a, 730b is held in a fixed position above the conveyor 140 by a support such as for example a guide wire.

In this embodiment, rather than having discharge nozzles 150 like apparatus 100, apparatus 700 comprises a single discharge nozzle 750. The single discharge nozzle 750 is in fluid communication with the ice-making machine 160 and is configured to discharge ice-slurry received from the ice-making machine 160 into the funnel 730b. In this embodiment, the master controller is programmed to operate the discharge nozzle 750 and to control an amount of ice-slurry being delivered thereto.

During operation, a container 720 is placed on the conveyor 140 and is conveyed to a position below the funnel 730a, adjacent the first end 142 of the conveyor 140. At the same time, a raw chicken C is conveyed by the line conveyor 710 to a position above the funnel 730a. The raw chicken C is released from the line conveyor 710, where it is caught by the funnel 730a. The raw chicken C travels through the funnel 730a and into the container 720. Once the raw chicken C is in the container 720 it is conveyed by the conveyor 140 to a position below the funnel 730b. Once the container 720 is below the funnel 730b, the master controller communicates a signal to discharge ice-slurry through the nozzle 750. The ice-slurry discharged through the discharge nozzle 750 travels through the funnel 730b and into the container 720. The ice-slurry surrounds the raw chicken C and beings to cool the raw chicken C. The container 720 travels along the conveyor 140 until it reaches the second end 144, where it is then removed from the conveyor 140. Once the container has been removed, the container together with the ice-slurry and the raw chicken C may be stored or placed on a skid. The raw chicken C may be removed from the container and placed on a metal grating or lattice to allow water to drain through while the raw chicken C is moved to the next stage of the process (e.g. packaging). The apparatus 700 eliminates the risk of cross-contamination between temperature sensitive products as each product is stored and cooled in a separate container.

Turning now to FIG. 8, another embodiment of an apparatus is shown and is generally identified by reference numeral 800. Apparatus 800 is generally similar to that of apparatus 700 with the following exception. In this embodiment, the apparatus 800 comprises a vibration mechanism 810 configured to vibrate the conveyor 140. As each container 720 travels along the conveyor 140, it vibrates to ensure the ice-slurry container therein does not settle.

Turning now to FIG. 9, another embodiment of an apparatus is shown and is generally identified by reference numeral 900. Apparatus 900 is generally similar to that of apparatus 700 with the following exceptions.

In this embodiment, rather than each container being dimensioned to hold a single temperature sensitive product, the apparatus 900 comprises containers 920 dimensioned to hold a predetermined number of temperature sensitive products. In this embodiment, the temperature sensitive products are raw chickens and the predetermined number of raw chickens held by each container 920 is between 60 and 80 raw chickens.

During operation, a container 920 is placed on the conveyor 140 and is conveyed to a position below the funnel 730a, adjacent the first end 142 of the conveyor 140. At the same time, a raw chicken C is conveyed by the line conveyor 710 to a position above the funnel 730a. The raw chicken C is released from the line conveyor 710, where it is caught by the funnel 730a. The raw chicken C travels through the funnel 730a and into the container 920. This process is repeated until the predetermined number of raw chickens C has been reached. As will be appreciated, the number of raw chickens C held by the container 920 may be determined using an electronic counter. Alternatively or additionally, the predetermined number of raw chickens C held by the container 720 may be determined by weighing the container 720.

Once the predetermined number of raw chickens C are in the container 920, the container 920 is conveyed by the conveyor 140 to a position below the funnel 730b. Once the container 920 is below the funnel 730b, the master controller communicates a signal to discharge ice-slurry through the nozzle 750. The ice-slurry discharged through the discharge nozzle 750 travels through the funnel 730b and into the container 720. The ice-slurry surrounds the raw chickens C and begins to cool each raw chicken C. The container 920 travels along the conveyor 140 until it reaches the second end 144, where it is then removed from the conveyor 140. Once the container has been removed, the container together with the ice-slurry and the raw chickens C may be stored or placed on a skid. The raw chickens C may be removed from the container and placed on a metal grating or lattice to allow water to drain through while the raw chickens C are moved to the next stage of the process (e.g. packaging). The apparatus 900 minimizes the risk of cross-contamination between temperature sensitive products as only a small number of temperature sensitive products are stored and cooled in each container 920.

Although each container is described as having an open end and a screen, those skilled in the art will appreciate that alternatives are available. For example, in another embodiment, such as that shown in FIG. 10, each container 850 may additionally or alternatively comprise one or more projections 855 extending from an inner side wall thereof. The projections 855 may be, for example, U-shaped. Each projection 855 may be used to trap ice-slurry contained within the container to help increase the cooling effect of the ice-slurry. Each container may additionally or alternatively comprise ridges extending from an interior surface thereof to maintain the raw chicken C in the middle of the container.

In another embodiment, rather than each container having a separate structure, the containers may all be part of the same structure. An example is shown in FIG. 11. As can be seen, a structure 960 such as for example a trough is used. The structure 960 comprises dividers 965 defining each container 970.

In another embodiment, each container may comprise a lid. In this embodiment, when the container is removed from the conveyor, the lid may be placed on the container to increase the cooling effect.

In another embodiment, each container may comprise one or more inlets and outlets configured to selectively receive or expel ice-slurry therefrom. As an example, once the container has been removed from the conveyor, it may receive a final charge of ice-slurry through the inlet. Excess water may be selectively drained out of the outlet. Further, additives may be added through the inlet such as for example salt.

Those skilled in the art will appreciate that the containers may be stackable on top of one another for ease of storing and transport. It will be appreciated that the containers may be placed in a refrigerated room or storage facility. In another embodiment, each container may be hexagonal shaped such that the containers may be stored in a honey-comb like shape.

Although each container is described as being made of stainless steel, those skilled in the art will appreciate that alternatives are available. For example, each container may be made of aluminum, plastic etc. In another embodiment, each container may be made of plastic and may have an inner surface made of stainless steel.

Those skilled in the art will appreciate that the containers may be manually or automatically placed on the conveyor. In one embodiment where the containers are automatically placed on the conveyor, the master controller may communicate instructions to a lifting mechanism to lift an empty container and place it on the conveyor. Similarly, the containers may be manually or automatically removed from the conveyor. In one embodiment where the containers are automatically removed from the conveyor, the master controller may communicate instructions to a lifting mechanism to remove a filled container from the conveyor and place it for storage.

In another embodiment, the raw chicken C may be removed from the container before or immediately after the container is removed from the conveyor. In this embodiment, once the raw chicken C has been removed, the container may be emptied by dumping the remaining ice-slurry down a drain. Alternatively, the drained ice-slurry may be filtered and cleaned and re-introduced into the ice-making machine.

In another embodiment, each container may comprise an agitating mechanism such as for example a rotatable blade. In this embodiment, the blade may be connected to the master controller and may be actuated to rotate within the container to ensure the ice-slurry does not settle.

In another embodiment, to agitate the ice-slurry in each container, the master controller may communicate a signal to suddenly start and stop movement of the conveyor. Further, an ultrasonic wave may be used to agitate the ice-slurry.

In another embodiment, additives may be added to the ice-slurry before it is discharged from the nozzle. For example, in one embodiment salt may be added to the ice-slurry to reduce the temperature thereof. As such, the cooling rate of the ice-slurry is increased.

In another embodiment, each container may be only partially filled such that only the exterior surface of the raw chicken C is exposed to ice-slurry.

Although in embodiments ice-slurry is only described as being removed from the container after the container has been taken off the conveyor, those skilled in the art will appreciate that alternatives are available. For example, in another embodiment, ice-slurry may be removed from the container at a mid-point. This will allow an exterior surface of the raw chicken C to dry while ice-crystals in contact with the exterior surface of the raw chicken C will continue to provide cooling.

Although in embodiments the containers are described as being placed on and removed from the conveyor, those skilled in the art will appreciate that in another embodiment the containers may be part of or connected to the conveyor.

Although in embodiments the containers are described as being made of a rigid material, those skilled in the art will appreciate that alternatives are available. For example, in another embodiment, the raw chickens C may be placed in a plastic bag. In this embodiment, the plastic bag will be filled with ice-slurry.

Although in embodiments the apparatus is described as comprising two funnels, those skilled in the art will appreciate that any number of funnels may be used.

Those skilled in the art will appreciate that each container may comprise a thermometer in communication with the master controller to indicate a temperature within the container.

Although the conveyor may be any length or width, in embodiments the conveyor has a length between 10 meters to 15 meters and has a width between 1 meter and 3 meters.

In other embodiment, the conveyor may be multi-layered.

Those skilled in the art will appreciate that each raw chicken C may go through the cooling process any number of times, as desired.

Those skilled in the art will appreciate that in another embodiment the container may be placed on the conveyor with the raw chicken C already placed inside of it.

Those skilled in the art will appreciate that in another embodiment the container may be filled with ice-slurry before receiving the raw chicken C.

Although in embodiments the apparatus is described as comprising a single discharge nozzle, those skilled in the art will appreciate that additional discharge nozzles may be placed downstream of the direction of travel of the conveyor. In this embodiment, ice-slurry may be added as desired as the container travels along the conveyor.

Although in embodiments the apparatus is described as immersing one or more temperature sensitive products in ice-slurry, those skill in the art will appreciate that the ice-slurry may be applied inside a temperature sensitive product. An exemplary apparatus 900 is shown in FIG. 12. As can be seen, the apparatus 1000 is similar to apparatus 100 in that it comprises an ice-making machine 160. Since the ice-making machine 160 is identical to that of apparatus 100, the specifics will not be described.

In this embodiment, the apparatus 1000 comprises a line conveyor 1010. Although not shown, the line conveyor 1010 comprises a motor configured to move the conveyor 1010 in a direction indicated by arrow A to transport one or more raw chickens C from a first position to a second position. In this embodiment, the conveyor 1010 is positioned in a low temperature room and as such the raw chickens C are cooled in part by dry freezing.

In this embodiment, rather than having discharge nozzles 150, apparatus 1000 comprises a single discharge nozzle 1050. The single discharge nozzle 1050 is in fluid communication with the ice-making machine 160 and is configured to discharge ice-slurry received from the ice-making machine 160 into an inner cavity of the chicken C. In this embodiment, the master controller is programmed to operate the discharge nozzle 1050 and to control an amount of ice-slurry being delivered thereto.

During operation, a raw chicken C is conveyed by the line conveyor 1010 to a position below the discharge nozzle 1050. As the raw chicken C is conveyed by the line conveyor 1010, it is at least partially cooled as a result of being in a low temperature room. Once the raw chicken C is below the discharge nozzle 1050, the master controller communicates a signal to discharge ice-slurry through the nozzle 1050. The ice-slurry discharged through the discharge nozzle 1050 fills the inner cavity of the chicken C. Once the ice-slurry is inside of the raw chicken C, the ice-slurry beings to cool the raw chicken C from the inside. The raw chicken C continues travel via the line conveyor 1010 to an end point, where it is then removed and stored. The apparatus 1000 eliminates the risk of cross-contamination between temperature sensitive products as each product is cooled separately. Put another way, the ice-slurry used to cool one of the raw chickens C is not used to cool another raw chicken C, unless it is filtered and recycled for further use with the ice-making machine 160.

Although examples are provided using raw chickens, those skilled in the art that other temperature sensitive products may be chilled with the above-described apparatus. Further, other poultry products such as for example ducks or turkeys may be chilled using the above-described apparatus.

Although in embodiments the discharge nozzles are described as all discharging ice-slurry onto the one or more temperature sensitive products, those skilled in the art will appreciate that in another embodiment one or more discharge nozzles may spray a different liquid. For example, in one embodiment all but one of the discharge nozzles may spray ice-slurry. The one discharge nozzle that does not spray ice-slurry may be the discharge nozzle adjacent the second end of the conveyor and may spray a liquid such as for example chilled water. The one or more temperature sensitive products will be covered in ice-crystals when they are positioned below the one discharge nozzle and as such the chilled water may further enhance the cooling effect. In another embodiment, the discharge nozzles may discharge ice-slurry and chilled water simultaneously. In another embodiment, the discharge nozzles may discharge ice-slurry and then may discharge chilled water. In another embodiment, each discharge nozzle may be controlled independently to ensure a uniform temperature is maintained in the ice-slurry bath. In another embodiment, each discharge nozzle may be controlled independently to ensure different parts of the ice-slurry bath have different temperatures.

In another embodiment, ice-slurry from the tank may be drained therefrom and may be fed into the ice-making machine as input. In another embodiment, a liquid portion of the ice-slurry may be drained from the tank and may be fed into the ice-making machine as input. In this embodiment, a filter or screen may be used. In another embodiment, debris or other impurities may be removed from the ice-slurry drained from the tank before being fed into the ice-making machine as input.

Although in embodiments the circulation loop is described as comprising a drain line fluidly connected to a bottom portion of tank, those skilled in the art will appreciate that alternatives are available. For example, in another embodiment the drain line may be connected to a side or a top portion of the tank. In another embodiment, the drain line may selectively drain only a liquid portion of the ice-slurry bath. In another embodiment, the drain line may selectively drain only a solid portion of the ice-slurry bath. In another embodiment, the drain line may selectively drain ice-crystals from the ice-slurry bath.

Although in embodiments, the liquid portion of the ice-slurry bath is described as being sea water, those skilled in the art will appreciate that alternatives are available. For example, the liquid portion may be fresh water and may include temperature depressants, antibacterial agents, etc. Further, ozone or other additives may be added to reduce bacterial growth.

Although in embodiments, agitators are described as being used to ensure a homogenous mixture of ice-crystals and liquid, in another embodiment the ice-crystals collected at a particular location in the tank may be removed from the ice-slurry bath and mixed with a liquid external from the tank. The new mixture of ice-slurry and liquid may then be introduced into the tank.

Although in embodiments, the discharge nozzles are described as being stationary, in another embodiment the discharge nozzle may be moveable in a particular direction such that they follow a particular temperature sensitive product as it travels from the first end to the second end of the conveyor.

Although in some embodiments, the conveyor is described as being a gravity conveyor, those skilled in the art will appreciate that in another embodiment the gravity conveyor may be connected to a vibration unit configured to shake the conveyor to further ensure the temperature sensitive products slide from the first end to the second end.

Those skilled in the art will appreciate that in some embodiments the circulation loops described above may further comprise valves configured to selectively permit ice-slurry to flow therethrough.

Although in embodiments the circulation loop is described as comprising a drain line fluidly connected with the tank and configured to drain ice-slurry therefrom, in another embodiment a screen may be used inside the tank to permit a liquid portion of the ice-slurry to drain out of the drain line while preventing a solid portion of the ice-slurry drain from draining out of the drain line, thereby increasing the ice-fraction of the ice-slurry bath.

Those skilled in the art will appreciate that the tank may comprise one or more insulating layers to reduce heat losses.

Although in embodiments the master controller is described as being programmed to receive and process sensor data, control the conveyor, discharge nozzles, ice making machine, those skilled in the art will appreciate that additional controllers may be used. For example, in another embodiment the conveyor may have its own control system. In another embodiment, each component of the apparatus may have its own local control system, which is connected to and receives command signals from the master controller.

Although only some embodiments are described as using agitators, those skilled in the art that any of the above-described embodiments may utilize agitators.

Although in embodiments agitators are used to agitate the ice-slurry bath, those skilled in the art will appreciate that alternatives are available. For example, water jets, air jets or mechanical means may be used.

Although embodiments have been described above with reference to the accompanying drawings, those of skill in the art will appreciate that variations and modifications may be made without departing from the scope thereof as defined by the appended claims.

Claims

1. An apparatus for cooling temperature sensitive products comprising:

an ice-making machine comprising at least one nozzle for discharging ice-slurry from the ice-making machine; and

at least one conveyor configured to convey at least one temperature sensitive product to a location to receive ice-slurry discharged through the at least one nozzle such that the at least one temperature sensitive product is exposed to ice-slurry.

2. The apparatus of claim 1 further comprising:

at least one container dimensioned to receive a predefined number of temperature sensitive products and ice-slurry.

3. The apparatus of claim 1, wherein the predefined number of temperature sensitive products is between sixty and eighty.

4. The apparatus of claim 2, wherein the at least one conveyor is configured to convey the at least one container to another location to receive the predefined number of temperature sensitive products, wherein the location to receive ice-slurry is downstream of the location to receive the predefined number of temperature sensitive products.

5. The apparatus of claim 2, further comprising:

a conveyor conveying the predefined number of temperature sensitive products to the at least one container.

6. The apparatus of claim 5, further comprising:

at least one funnel positioned below a portion of the conveyor and above the at least one container, the at least one funnel directing the predefined number of temperature sensitive products released from the conveyor into the at least one container.

7. The apparatus of claim 1 further comprising:

a vibration mechanism configured to cause the conveyor to vibrate.

8. The apparatus of claim 1, further comprising:

at least one funnel positioned below the at least one nozzle, the at least one funnel directing ice-slurry discharged through the at least one nozzle towards the at least one temperature sensitive product.

9. The apparatus of claim 1, wherein the at least one temperature sensitive product is bird comprising an open cavity.

10. The apparatus of claim 9, further comprising a line conveyor conveying the at least one temperature sensitive product to a location adjacent to the at least one nozzle.

11. The apparatus of claim 10 wherein the at least one nozzle discharges ice-slurry into the open cavity of the bird.

12. The apparatus of claim 9 wherein the apparatus is located in a refrigerated environment.

13. A method for cooling temperature sensitive products comprising:

conveying at least one temperature sensitive product to a location to receive ice-slurry; and

discharging ice-slurry from at least one discharge nozzle thereby exposing the at least one temperature sensitive product to ice-slurry.

14. The method of claim 13, further comprising:

prior to discharging ice-slurry, locating the at least one temperature sensitive product in a container.

15. The method of claim 14, wherein the locating comprises:

releasing the temperature sensitive product from another conveyor into the container.

16. The method of claim 13, further comprising:

vibrating the conveyor using a vibration mechanism.

17. The method of claim 13, further comprising:

monitoring a temperature of the at least one temperature sensitive product; and

discharging ice-slurry from at least a second discharge nozzle downstream of the at least one discharge nozzle if the temperature is above a threshold temperature.

18. The method of claim 17, further comprising:

removing the at least one temperature sensitive product from the conveyor if the temperature is below or equal to the threshold temperature.

19. The method of claim 13 wherein the ice-slurry is discharged into a cavity of the at least one temperature sensitive product.

20. A method for cooling temperature sensitive products comprising:

communicating a signal to operate a conveyor to convey at least one temperature sensitive product to a location to receive ice-slurry; and

communicating a signal to discharge ice-slurry from at least one discharge nozzle such that the at least one temperature sensitive product is exposed to ice-slurry.