Continuous throughput blast freezer

• US 6,796,142 B2
• Filed: 08/27/2002
• Issued: 09/28/2004
• Est. Priority Date: 08/30/2001
• Status: Expired due to Fees

• Current Assignee: Integrated Marine Systems, Inc.
• Original Assignee: Integrated Marine Systems, Inc.
• Inventors: Burn, Mark
• Primary Examiner(s): Esquivel, Denise L.
• Assistant Examiner(s): Drake, Malik N.
• Application Number:
  US10/229,776
• Publication Number:
  US 20030041614A1
• Time in Patent Office: 763 Days
• Field of Search: 62/60, 62/62, 62/63, 62/65, 623/71, 623/74, 623/78, 623/80, 624/19, 624/40, 624/41, 624/51, 625/15
• US Class Current: 62/380
• CPC Class Codes: F25B 2400/075 with parallel compressors
• CPC Class Codes: F25B 5/02 arranged in parallel
• CPC Class Codes: F25D 13/067 with circulation of gaseous cooling fluid
• CPC Class Codes: F25D 2400/30 Quick freezing
• CPC Class Codes: F25D 25/04 by conveyors in general B65G

Abstract

A high capacity, continuous production blast freezer includes an insulated enclosure and a plurality of adjustable product-carrying trolleys, individually moveable with the enclosure from an entrance location to an exit location. A heat exchanger in the form of an evaporator is provided in the enclosure. The mechanical equipment for the refrigeration system can be placed within the enclosure and separated from the freezing cell by a bulkhead. In one embodiment the enclosure is in the form of a container adapted to be transportable by ship, rail or truck. The arrangement of the heat exchanger or evaporator relative to the product carrying devices and the enclosure is designed to maximize the capacity of the heat exchanger and minimize frost formation, while providing for a maximum amount of product space within the enclosure to maximize throughput of the system.

Claims

1. A freezing system for continuous production of frozen comestibles, comprising:

an insulated enclosure having an entrance for receiving comestibles to be frozen and an exit for delivering frozen comestibles;

a refrigeration system cooling said enclosure to thereby freeze said comestibles; and

a plurality of trolleys moveable within said enclosure between said entrance and said exit, said trolleys for holding comestibles to be frozen;

said trolleys containing adjustment features enabling the placement of said comestibles in said trolleys to be changed depending on the size of said comestibles and a substantially solid panel on at least one side of said trolley extending transverse to the direction of movement of said trolleys through said enclosure substantially blocking the flow of air in the direction of travel of said trolleys through said enclosure;

wherein a continual introduction of said trolleys into said entrance with comestibles to be frozen, the movement of said trolleys within said enclosure between said entrance and said exit, and a continual removal of said trolleys from said enclosure at said exit, provide a continual production of frozen comestibles by said freezing system.

2. The system of claim 1, wherein said insulated enclosure comprises a container sized and adapted to be transported from one place to another.

3. The system of claim 2, wherein said refrigeration system includes a condenser and a compressor and wherein said condenser and compressor are housed within said container.

4. The system of claim 1, wherein said enclosure comprises a plurality of rollers extending from said exit to said entrance and providing an apron for sliding said trolleys from said exit to said entrance.

5. The system of claim 1, wherein said trolleys are adapted to receive a plurality of product trays and wherein said trolleys further comprises an plurality of vertically disposed adjustment features allowing said product trays to be placed within said trolleys at a variety of different heights.

6. The system of claim 5, wherein said tray further comprises heat dissipation fins or other suitable features designed to conduct heat from said tray into air surrounding said tray.

7. The system of claim 1, wherein said trolleys comprise one or more features are adapted to hang comestibles within said trolleys.

8. The system of claim 1, further comprising an entrance vestibule exterior of said container, said entrance vestibule comprising an enclosure for receiving a least one of said trolleys and at least one evaporator, said entrance vestibule chilling said trolley and comestibles loaded thereon and removing moisture from air surrounding said comestibles and moisture from said comestibles prior to movement of said trolley into said insulated enclosure thereby reducing the formation of frost in said insulated enclosure.

9. The system of claim 8, wherein said at least one evaporator comprises a pair of evaporators separately subject to defrost cycles such that when one of said evaporates is subject to a defrost cycle the remaining evaporator is functional.

10. The system of claim 9, wherein said pair of evaporators are separated by a insulation barrier.

11. The system of claim 1, wherein said refrigeration system comprises an evaporator arranged in the interior of said enclosure having a high surface area to depth ratio in which said evaporator has a width and a length to define a face area of said evaporator and a depth, and wherein said width and length are substantially greater than the depth of said evaporator.

12. The system of claim 11, wherein said enclosure comprises a modified shipping container.

25. The system of claim 1 or claim 18, wherein said insulated enclosure further comprises at least one freeze zone separation baffle extending widthwise within said enclosure from the walls of said enclosure to the sides of said trolleys to thereby help reduce longitudinal flow of air within said enclosure.

26. The system of claim 1 or claim 18, wherein said trolleys carry a plurality of horizontally disposed trays supporting said comestibles, and wherein trolleys comprise a plurality of vertical adjustment positions for said trays such that said trays may be spaced relative to each other so as to equalize the flow of horizontally air across said trays as said trolleys are moved through said insulated enclosure.

13. A freezing system for continuous production of frozen comestibles, comprising:

an insulated enclosure having an entrance for receiving comestibles to be frozen and an exit for delivering frozen comestibles;

a refrigeration system cooling said enclosure to thereby freeze said comestibles; and

a plurality of trolleys moveable within said enclosure between said entrance and said exit, said trolleys for holding comestibles to be frozen;

said trolleys containing adjustment features enabling the placement of said comestibles in said trolleys to be changed depending on the size of said comestibles

wherein said insulated enclosure comprises a container sized and adapted to be transported from one place to another; and

wherein said refrigeration system comprises an evaporator placed within said container and a plurality of fans arranged to blow air over said evaporator and through said trolleys in a direction substantially orthogonal to the direction of movement of said trolleys through said container.

14. The system of claim 13, wherein said evaporator is placed above said trolleys within said container.

15. The system of claim 13, wherein each of said trolleys comprises a front side and an opposite rear side, said front and rear sides sized so as to extend width-wise across the interior of said container perpendicular to the direction of travel of said trolley within said container, and wherein at least one of said front side and said rear side comprises a substantially solid panel substantially blocking the flow of air in the direction of travel of said trolley within said container.

16. A freezing system for continuous production of frozen comestibles, comprising:

an insulated enclosure having an entrance for receiving comestibles to be frozen and an exit for delivering frozen comestibles;

a refrigeration system cooling said enclosure to thereby freeze said comestibles; and

a plurality of trolleys moveable within said enclosure between said entrance and said exit, said trolleys for holding comestibles to be frozen;

said trolleys containing adjustment features enabling the placement of said comestibles in said trolleys to be changed depending on the size of said comestibles;

wherein said refrigeration system includes a condenser and a compressor and wherein said condenser and compressor are housed within a second enclosure, and wherein said second enclosure and said insulated enclosure comprise containers adapted to be transported by ship, rail and/or truck.

17. A freezing system for continuous production of frozen comestibles, comprising:

an insulated enclosure having an entrance for receiving comestibles to be frozen and an exit for delivering frozen comestibles;

a refrigeration system cooling said enclosure to thereby freeze said comestibles; and

a plurality of trolleys moveable within said enclosure between said entrance and said exit, said trolleys for holding comestibles to be frozen;

said trolleys containing adjustment features enabling the placement of said comestibles in said trolleys to be changed depending on the size of said comestibles, said trolleys having a substantially solid panel on at least one side of said trolley extending transverse to the direction of movement of said trolleys through said enclosure substantially blocking the flow of air in the direction of travel of said trolleys through said enclosure;

wherein said enclosure comprises a drive mechanism for transporting said trolleys from one place to another within said insulated enclosure, wherein the drive mechanism is adjustable to vary the rate of transport of said trolleys.

18. A mobile, self-contained freezing system for continuous production of frozen comestibles, comprising:

an insulated enclosure having an entrance for receiving comestibles to be frozen and an exit for delivering frozen comestibles;

said insulated enclosure sized and adapted to be transported from one place to another and defining a longitudinal axis;

a heat exchanger in said enclosure;

a plurality of fans arranged to blow air through said heat exchanger in an manner transverse or oblique to the longitudinal axis of said enclosure; and

a plurality of trolleys moveable within said enclosure between said entrance and said exit, said trolleys comprising features for holding comestibles to be frozen;

said trolleys containing adjustment features enabling the placement of said comestibles in said trolleys to be changed depending on the size of said comestibles;

wherein a continual introduction of said trolleys into said entrance with comestibles to be frozen, the movement of said trolleys within said enclosure between said entrance and said exit, and a continual removal of trolleys from said enclosure at said exit, provide a continual production of frozen comestibles by said freezing system.

19. The system of claim 18, wherein said trolleys comprise a substantially solid panel on one side thereof such that when said trolleys are moved within said container said panel is oriented width-wise within said enclosure such that the longitudinal flow of air through said enclosure is substantially reduced.

20. The system of claim 19, wherein said refrigeration system comprises an evaporator placed within said container and a plurality of fans arranged to blow air over said evaporator and through said racks in a direction substantially orthogonal to the direction of movement of said trolleys through said container.

21. The system of claim 18, wherein said evaporator is placed above said trolleys.

22. The system of claim 18, wherein said evaporator is placed below said trolleys.

23. The system of claim 18, further comprising an entrance vestibule comprising a substantially air-tight, insulated enclosure having a source of cold air to thereby pre-chill a trolley loaded with comestibles prior to movement of said trolley into said insulated enclosure and reduce the formation of frost within said enclosure.

24. The system of claim 18, wherein said refrigeration system comprises an evaporator arranged diagonally above said trolleys within said enclosure.

27. A freezing system for continuous production of frozen comestibles, comprising:

an insulated enclosure having an entrance for receiving comestibles to be frozen and an exit for delivering frozen comestibles, said insulated enclosure defining a longitudinal axis;

a heat exchanger placed in and extending in a longitudinal direction in said insulated enclosure so as to form a freezing cell having two compartments for moving comestibles through said enclosure, one compartment on each side of said heat exchanger, said compartments extending along the longitudinal axis of the enclosure;

a plurality of fans arranged to blow air in a manner transverse to the longitudinal axis of said enclosure; and

a plurality of devices for holding comestibles to be frozen and moveable relative to said enclosure through said compartments.

28. The system of claim 27, wherein said device comprises a set of trolleys containing adjustment features enabling the placement of said comestibles in said trolleys to be changed depending on the size of said comestibles, wherein said trolleys comprise a solid panel on one side thereof such that when said trolleys are moved within said insulated enclosure said panel is oriented width-wise within said enclosures such that the longitudinal flow of air through said enclosure is substantially reduced.

29. The system of claim 27, wherein said enclosure comprises at least one container sized and adapted to be transported from one place to another.

30. A freezing system comprising first and second elongate insulated enclosures separated from each other by an evaporator, a fan blowing air through said evaporator to thereby provide a flow of cold air to said enclosures, and devices for carrying product moveable through said insulated enclosure.

31. The freezing system of claim 30, wherein said fan is oriented transverse to the longitudinal axis of said enclosures.

32. The freezing system of claim 31, wherein said devices comprise trolleys having a solid panel extending widthwise across said trolleys in a manner perpendicular to the direction of travel of said trolleys through said enclosures.

33. The freezing system of claim 31, wherein said devices comprise trolleys having a means for carrying product to be frozen and adjustment features for adjusting the location of said means for carrying product.

34. The freezing system of claim 30, wherein said first and second insulated enclosures comprises a modified shipping container adapted to be moved from one place to another.

35. A trolley for holding comestibles to be frozen by a freezing system, comprising:

a base,

a plurality of support rails,

structures extending above said base adapted to receive said plurality of support rails, said support rails for receiving either trays or bars for hooks holding product to be frozen, said structures having a plurality of closely spaced adjustment features for said support rails so as to enable said support rails to be placed at a multitude of different vertical positions in said trolley.

36. The trolley of claim 35, wherein said rails comprise an elongate member having a cross-section adapted to slidingly receive said tray or said bar.

37. The trolley of claim 35, further comprising a solid panel formed on at least one side of said trolley.

38. The trolley of claim 35, wherein said trolley receives at least one tray, and wherein the trolley further comprises a low friction material applied to at least one of said tray or said tray support rail enhancing the ability of said tray to be slid relative to said tray support rail.

39. The trolley of claim 35, wherein said trolley receives at least one tray, and wherein said tray and tray support rail comprise structures cooperating with each other to prevent substantial rotation of said tray relative to said tray support rail during sliding of said tray out of said trolley thereby easing the loading and unloading of said trays from said trolley.

40. A freezing system comprising:

an elongate insulated enclosure defining a longitudinal axis and having an entrance,

a heat exchanger comprising an evaporator positioned along one side of said enclosure and extending along the length of the insulated enclosure; and

one or more fans blowing air in said insulated enclosure through said evaporator in a manner substantially transverse to the longitudinal axis of said enclosure; and

an entrance vestibule exterior of said enclosure and proximate to said entrance, said entrance vestibule comprising an enclosure for receiving a product carrying device and at least one evaporator, said entrance vestibule chilling said product carrying device and comestibles loaded thereon and removing moisture from air surrounding said comestibles and moisture from said comestibles prior to movement of said product carrying device into said insulated enclosure thereby reducing the formation of frost in said insulated enclosure.

41. The freezing system of claim 40, wherein said evaporator is placed above said product carrying devices adjacent a top of said enclosure.

42. The freezing system of claim 40, wherein said evaporator is placed below said product carrying devices.

43. The freezing system of claim 40, wherein one wall of said insulated enclosure comprises said evaporator.

44. The freezing system of claim 40, wherein said product carrying devices comprise product carrying trolleys.

45. The freezing system of claim 40, wherein said product carrying devices comprise a set of trays attached to a mechanism moving said trays through said enclosure.

46. A freezing system comprising an insulated enclosure, a plurality of trolleys carrying product to be frozen on at least one tray through said enclosure, and at least one station provided with a mechanism for either automatically removing said tray from said trolley after said trolley has moved from said enclosure and/or automatically loading a tray loaded with product to be frozen onto said trolley.

47. The system of claim 46, wherein said at least one station comprises a platform moveable vertically relative to said trolley and extendible in a horizontal direction relative to said trolley to lift one of said trays from said trolley or place one of said trays onto said trolley.

48. A mechanism for moving a tray through an enclosure having pairs of opposite support frames, said trays extending between said opposite support frames, comprising:

a pair of main conveyor chains extending along the length of said frames;

a tray support pin extending from each of said chains and engaging said tray at opposite sides thereof; and

a direction reversing mechanism for each of said chains for reversing the direction of movement of the trays while the upper side of said trays remains upright, comprising

an end sprocket,

a guide placed on at least one of said support frames preventing said trays from rotating as said chain reverses direction on said sprocket, and

a secondary chain having a clips engaging with the side of said tray,

wherein as the tray support pin rotates around the end sprocket said clip engages and holds the tray level while moving freely up or down in time with, and being driven by, the attachment of said tray to said main conveyor chain via said tray support pin.

49. A blast freezer, comprising:

an insulated enclosure defining a longitudinal axis;

an evaporator having a longitudinal extent arranged generally in the direction of said longitudinal axis of said insulated enclosure adjacent to a wall of said insulated enclosure;

said evaporator diagonally oriented with respect to said enclosure and adjacent to one wall of said enclosure so as to maximize the capacity of said freezer for freezing product.

50. The freezer of claim 49, wherein said evaporator is positioned relative to said wall such that air is prevented from flowing over a first longitudinal edge of said evaporator;

said diagonal orientation of said evaporator relative to said enclosure thereby defining air plenums on opposite sides of said evaporator through which air may flow;

said evaporator having a second longitudinal edge on an opposing side of said evaporator from said first longitudinal edge, said second longitudinal edge spaced away from said first wall and a second wall of said enclosure; and

a fan positioned in said enclosure to direct the flow of air transverse to the longitudinal axis of said enclosure through said evaporator.

51. The freezer of claim 50, wherein said fan is placed between said evaporator and a corner of said enclosure defined by the intersection of said first and second walls.

52. The freezer of claim 50, wherein said freezer further comprises a product carrying device moveable through said enclosure and wherein said second longitudinal edge is placed closely adjacent to said product carrying device.

53. The freezer of claim 49, wherein said evaporator comprises a high surface area to depth ratio in which said evaporator has a width and a length to define a face area of said evaporator and a depth, and wherein said width and length are substantially greater than the depth of said evaporator.

54. The freezer of claim 49, wherein said evaporator comprises a pair of evaporators arranged in said enclosure such that they have a V configuration.

55. The freezer of claim 49, further comprising a product carrying trolley moveable within said enclosure.

56. The freezer of claim 55, wherein said trolleys are constructed an arranged so as to define spaces on opposite transverse sides thereof to thereby allow the passage of air on opposite sides of said trolley.

57. The system of claim 49, wherein said refrigeration system comprises an air-cooled condenser and an evaporator receiving a refrigerant from said condenser, said condenser placed at the exterior of said enclosure and said evaporator placed in the interior of said enclosure, and wherein said insulated enclosure comprises a shipping container modified to function as a freezer cell.

58. The freezer of claim 49, wherein said insulated enclosure comprises a modified shipping container.

59. The freezing system of claim 49, wherein said insulated enclosure comprises a shipping container adapted to be moved from one place to another.

60. A trolley for a freezing system comprising:

a plurality of trays adapted for holding product to be frozen;

a frame structure for receiving said plurality of trays; and

said frame structure comprising tray receiving features enabling said trays to be received in said trolleys in a multitude of vertical positions and thereby adjust the spacing of said trays from one another to thereby accommodate different sizes of product and maximize the carrying capacity of the trolley.

61. The trolley of claim 60, wherein said frame structure slideably receives said trays and wherein at least one of said trays and said frame structure further comprises a low friction material enhancing the ability of said tray to slide relative to said frame structure.

62. The trolley of claim 60, wherein said frame structure defines a rectangular base and four sides, and wherein at least one of said sides is enclosed by a substantially solid panel.

63. The trolley of claim 60, wherein said trays and frame structure comprises features mutually cooperating with each other to permit said tray to be substantially slid out of said trolley so that product can be unloaded from said tray without substantial rotation of said tray relative to said frame structure wherein loading and unloading of said tray may be improved.

64. A trolley for a freezing system comprising:

a plurality of trays adapted for holding product to be frozen;

a frame structure for receiving said plurality of trays; and

wherein said trays and frame structure comprises features mutually cooperating with each other to permit said tray to be substantially slid out of said frame structure so that product can be unloaded from said tray without substantial rotation of said tray relative to said frame structure wherein loading and unloading of said tray may be improved.

65. The trolley of claim 64, wherein said frame structure defines a rectangular base and four sides, and wherein at least one of said sides is enclosed by a substantially solid panel.

66. The trolley of claim 64, wherein said frame structure slideably receives said trays and wherein at least one of said trays and said frame structure further comprises a low friction material enhancing the ability of said tray to slide relative to said frame structure.

67. A self-contained, continuous throughput blast freezer system comprising:

an enclosure defining a longitudinal axis;

a self contained refrigeration system contained within said enclosure, comprising (1) an evaporator placed within said enclosure and said extending substantially along the length of said enclosure;

(2) an air-cooled condenser provided on the periphery of said enclosure; and

(3) refrigeration equipment circulating a refrigerant through said condenser and evaporator, and

product carrying devices for carrying product through said enclosure.

68. The system of claim 67, wherein said enclosure comprises a modified shipping container and wherein said air-cooled condensers are positioned on the exterior of said modified shipping container within the envelope of dimensions of a standard shipping container thereby facilitating transportation of said system by rail, truck and/or ship.

69. The system of claim 67, wherein said evaporator has a high surface area to depth ratio in which said evaporator has a width and a length to define a face area of said evaporator and a depth, and wherein said width and length are substantially greater than the depth of said evaporator.

70. A continuous throughput blast freezer system comprising:

an insulated enclosure defining a longitudinal axis and having an entrance and an exit;

an evaporator placed within said enclosure and said extending substantially along the length of said enclosure;

product carrying trolleys carrying product through said enclosure, said trolleys including one or more trays;

an unloading station unloading trays from said trolleys after said trolleys have exited from said enclosure;

a tray conveying system carrying trays to product unloading and product loading stations;

a trolley conveying system separately transporting trolleys from said station unloading trays to said entrance; and

a loading station loading trays loaded with product into said trolleys;

wherein a continual introduction of said trolleys into said entrance with product to be frozen, the movement of said trolleys within said enclosure between said entrance and said exit, and a continual removal of said trolleys from said enclosure at said exit, provide a continual production of frozen product by said freezing system.

71. The system of claim 70, wherein said trolley conveying system comprises set of roller aprons extending from said exit to said entrance.

72. A blast freezer system comprising:

an insulated enclosure having an entrance and an exit;

a means for cooling said enclosure;

product carrying trolleys carrying product through said enclosure from said entrance to said exit, said trolleys including one or more trays;

one or more stations for unloading trays from said trolleys after said trolleys have exited from said enclosure and for loading trays loaded with product into said trolleys.

73. The freezing system of claim 72, further comprising a set of roller aprons extending from said exit to said entrance.