阅读说明：本技术 用于自动清洗浸泡罐的方法和系统 (Method and system for automatically cleaning an immersion tank ) 是由 C·戈尼 D·W·汤普森 J·P·舍尔 于 2020-02-07 设计创作，主要内容包括：一种用于自动清洗浸泡罐(14)的方法包括：基本上包封浸泡罐(14)的内部容积(30)；增加浸泡罐(14)的内部容积(30)中的温度和湿度；然后将清洗溶液施加到浸泡罐(14)的内表面；以及从浸泡罐(14)的内表面冲洗掉清洗溶液和污垢。(A method for automatically cleaning an immersion tank (14) comprising: substantially enclosing an internal volume (30) of the steeping tank (14); increasing the temperature and humidity in the interior volume (30) of the steeping tank (14); then applying a cleaning solution to the interior surface of the soak tank (14); and rinsing the cleaning solution and dirt from the interior surface of the soaking tank (14).)

1. A method for automatically cleaning an immersion tank, the method comprising:

substantially enclosing an interior volume of the steeping tank;

increasing the temperature and humidity in the interior volume of the steeping tank; then the

Applying a cleaning solution to the interior surface of the soak tank; and

rinsing the cleaning solution and dirt from the interior surface of the soak tank.

2. The method of claim 1, wherein substantially enclosing the interior volume of the steeping tank comprises closing a hood and/or cover over an upper opening of the steeping tank.

3. The method of claim 1, wherein increasing the temperature and humidity in the interior volume of the steeping tank comprises spraying hot water through a nozzle into the interior volume of the steeping tank.

4. The method of claim 3, wherein applying a cleaning solution to the interior surface of the soaking tank comprises spreading the cleaning solution through the nozzle onto the interior surface of the soaking tank.

5. The method of claim 4, wherein the nozzles are arranged such that cleaning solution is applied to substantially all of the interior surfaces of the soaking tank.

6. The method of claim 4, wherein rinsing the cleaning solution and dirt from the interior surface of the soaking tank comprises spraying water through the nozzle onto the interior surface of the soaking tank.

7. The method of claim 6, wherein:

the steeping tank comprises an auger oriented in a longitudinal direction in an interior volume of the steeping tank; and is

Adjacent ones of the nozzles are spaced apart in the longitudinal direction by a distance less than a pitch of the auger.

8. The method of claim 1, wherein the temperature and humidity are increased in each portion of the interior volume of the soak tank for at least two minutes before the cleaning solution is applied to the interior surface of the soak tank.

9. The method of claim 1, further comprising draining the cleaning solution and soil from the interior volume of the soaking tank.

10. The method of claim 1, further comprising axially translating at least one nozzle along the tank, wherein the adding, applying, and/or rinsing steps are performed sequentially at different axial locations along the tank using the at least one nozzle.

11. Method according to any one of claims 1 to 10, wherein the steeping tank is a poultry chiller.

12. A system for automatically cleaning an immersion tank, the system comprising:

a steeping tank comprising a tank defining an interior volume and an upper opening in communication with the interior volume;

one or more hoods and/or covers configured to selectively cover the upper opening to substantially enclose the interior volume; and

at least one nozzle configured to:

injecting hot water into the interior volume to increase the temperature and humidity in the interior volume;

spreading a cleaning solution onto the interior surface of the soak tank; and is

Spraying water onto the interior surfaces of the soak tank to remove cleaning solution and dirt from the interior surfaces.

13. The system of claim 12, wherein the at least one nozzle comprises a plurality of nozzle clusters distributed axially along the tank, each nozzle cluster comprising a plurality of nozzles.

14. The system of claim 13, wherein each nozzle cluster comprises:

a main conduit having an inlet;

a first secondary duct extending laterally away from a first side of the main duct;

a second subsidiary duct extending laterally away from an opposite second side of the main duct;

a first nozzle at an end of the first secondary duct and a second nozzle at an end of the second secondary duct,

wherein the nozzle clusters are positioned such that the first nozzles are adjacent a first side of the upper opening and the second nozzles are adjacent an opposite second side of the upper opening.

15. The system of claim 14, wherein the first nozzle and the second nozzle each comprise a spreading characteristic that provides substantially 360 degrees of coverage from a location of the nozzle.

16. The system of claim 14, wherein each nozzle cluster comprises:

a third secondary duct extending laterally away from a second side of the main duct and spaced apart from the second secondary duct;

a third nozzle at an end of the third secondary conduit,

wherein a first nozzle cluster is positioned such that the first nozzle is adjacent to a first side of the upper opening and the second and third nozzles are adjacent to a second side of the upper opening, and a second nozzle cluster adjacent to the first nozzle cluster is positioned such that the first nozzle is adjacent to the second side of the upper opening and the second and third nozzles are adjacent to the first side of the upper opening.

17. The system of claim 14, wherein the first and second secondary conduits each extend outwardly and downwardly from the main conduit such that when liquid supply is stopped, substantially all of the liquid in the conduits is discharged through the nozzle.

18. The system of claim 14, further comprising:

a hot water header in fluid communication with an inlet of the main conduit;

a first control valve between the hot water header and the inlet of the main pipe to selectively supply hot water to the nozzle clusters;

a wash solution header in fluid communication with an inlet of the main conduit; and

a second control valve between the wash solution header and the inlet of the main conduit to selectively supply wash solution to the nozzle clusters.

19. The system of claim 12, further comprising a rail under the one or more hoods and/or covers and a carriage connected to the rail, wherein the at least one nozzle is connected to the carriage, wherein the carriage and the nozzle are configured to travel axially along the tank on the rail to sequentially spray hot water and wash solution at different axial locations along the tank.

20. The system of claim 12, wherein the at least one nozzle is retained within an at least partially spherical nozzle mount retained in a socket, and wherein the nozzle mount is rotatable and/or translatable in the socket such that the nozzle is articulated to sequentially direct the hot water and/or wash solution to different interior surfaces in the interior volume of the tank.

21. The system of any one of claims 12 to 20, wherein the steeping tank is a poultry chiller.

Background

Many food processing operations employ large tanks in which the edible product is deposited at an inlet end of the tank, soaked in a fluid in the tank, mechanically transported along the length of the tank, and removed from the tank at an outlet end. The product, when immersed in a fluid, may be refrigerated, thawed, cooked, flue cured, or otherwise altered depending on the purpose of the processing operation. Products may range from freshly slaughtered poultry, cooked ham, frozen meat, soy protein, bagged legumes, or many other food products. During the processing of the product, fats, greases, product debris or other substances may contaminate the fluid in the tank and deposit on the mechanical surfaces of the tank or within the tank. These surfaces must be cleaned periodically to avoid culturing microorganisms that can contaminate the product.

In particular, the poultry processing industry employs poultry chillers to remove body heat from animal products shortly after evisceration. Poultry chillers employ a variety of mechanisms for cooling the product, including immersion in cold water and/or exposure to cold air. The amount of poultry processed in modern facilities dictates that these chillers be physically large. Immersion coolers are typically 8 to 12 feet in diameter and over 60 feet in length.

In immersion chillers, when the product is immersed in cold water, some fats, oils, blood, residual feathers and/or other materials may become dislodged from the product and deposit on mechanical surfaces within the tank. These surfaces include, but are not limited to, the interior surfaces of the tank and the surfaces of moving parts such as augers, agitators or paddles that move the product within the tank. The chiller must be cleaned periodically to prevent contamination of the poultry product by harmful pathogens. Typically, the cleaning is performed daily, but in some cases with additional sterilization steps, it is less frequent.

Cleaning has historically been a manual process. Most immersion coolers have a large upper opening that is accessible from an elevated aisle (elevated walk) along the side of the cooler. With the opening covered, the washing worker opens the cover to provide access to the interior of the cooler. The worker then power washes the interior of the chiller with hot water to remove most of the visible dirt. Because the top of the cooler is open, the air that is jet heated and humidified within the cooler quickly rises through the open top of the cooler and is distributed throughout the room in which the cooler is located. The cooler dry air from the room falls down through the opening into the cooler. After the initial wash, the worker applies chemical foam to the equipment to break down the remaining fouling membrane. Finally, they thoroughly flush the cooler with a high pressure spray bar. This process is time consuming, unpleasant for the workers, and consumes large amounts of hot water.

It is desirable to automate the cleaning process, but reproducing the manual process using a limited number of fixed spray stations has proven challenging. In the case of attempts, the cleaning efficacy has been low, partly because it is difficult to reach all surfaces with direct jets from a limited number of fixed points. Additional challenges arise due to the relatively long distance from the stationary nozzles outside the cooler to somewhere within the cooler. Water exiting such nozzles at relatively high temperatures may cool due to evaporation before it impacts the distant wall. The water may no longer be warm enough to melt or soften the fat deposited on the walls. In addition, the velocity of the jet decreases due to the resistance interaction with the air. To improve efficacy, larger amounts of water have been applied over longer exposure times, but this approach can result in unacceptable water consumption or operating costs.

When manually cleaning the cooler, workers may reach inside the cooler with their spray bars to get closer to the soiled surface, but this creates a safety hazard because the moving mechanisms inside the cooler are often rotating or otherwise moving in order to expose all of the soiled surface. In an automated process, extending the spray nozzles into the chiller requires complex mechanisms that increase the equipment and maintenance costs of the system.

The present invention overcomes the limitations of automatic cleaning by adding a process step in which the cooler is filled with hot, humid air for a period of time. The inventors have discovered this phenomenon when attempting to develop an automated high pressure spray system and spreading a tarpaulin over the cooler to reduce stray sprays that splash out of the cooler. The resulting hot and humid conditions soften or melt any fat that may have condensed on the cooler surfaces, making it possible to quickly remove contaminants from these surfaces with a relatively low velocity water jet. It is possible to create conditions within the encapsulated cooler that are too hostile to the exposure of workers. Coolers treated with such aggressive heat and humidity soften the fats to such an extent that they can be cleaned effectively, even in cases where the water jets do not directly impact the entire inner surface of the cooler, but only reach certain parts of the cooler surface by indirect splashing. The invention can reduce water consumption, labor cost and cleaning time.

Disclosure of Invention

Some embodiments of the invention relate to a method for automatically cleaning an immersion tank. The method comprises the following steps: substantially enclosing an interior volume of the steeping tank; increasing the temperature and humidity in the interior volume of the steeping tank (e.g., within a predetermined amount of time); then applying a cleaning solution to the interior surface of the soak tank; and rinsing the cleaning solution and dirt from the interior surface of the soak tank.

In some embodiments, substantially enclosing the interior volume of the steeping tank comprises closing a hood and/or cover over the upper opening of the steeping tank.

In some embodiments, increasing the temperature and humidity in the interior volume of the steeping tank comprises spraying hot water through a nozzle into the interior volume of the steeping tank.

Applying the cleaning solution to the interior surface of the soaking tank may include spreading the cleaning solution through a nozzle onto the interior surface of the soaking tank. The nozzles may be arranged such that the cleaning solution is applied to substantially all of the interior surfaces of the soaking tank.

Rinsing the cleaning solution and dirt from the interior surface of the soaking tank may include spraying water through a nozzle onto the interior surface of the soaking tank. The steeping tank may include an auger oriented in a longitudinal direction within the interior volume of the steeping tank. Adjacent ones of the nozzles may be spaced apart in the longitudinal direction by a distance less than the pitch of the auger.

In some embodiments, the temperature and humidity are increased in each portion of the interior volume of the soaking tank for at least two minutes before the cleaning solution is applied to the interior surface of the soaking tank.

In some embodiments, the method further comprises draining the cleaning solution and the soil from the interior volume of the soaking tank.

In some embodiments, the steeping tank is a poultry chiller.

Some other embodiments of the present invention are directed to a system for automatically cleaning an immersion tank. The system comprises: a steeping tank comprising a tank defining an interior volume and an upper opening in communication with the interior volume; a plurality of hoods and/or covers configured to selectively cover the upper opening to substantially enclose the interior volume; and at least one nozzle configured to: injecting hot water into the interior volume to increase the temperature and humidity in the interior volume; spreading a cleaning solution onto the interior surface of the soak tank; and spraying water onto the interior surfaces of the soak tank to remove the cleaning solution and dirt from the interior surfaces.

In some embodiments, the at least one nozzle comprises a plurality of nozzle clusters distributed axially along the tank, each nozzle cluster comprising a plurality of nozzles.

In some embodiments, each nozzle cluster comprises: a main conduit having an inlet; a first secondary duct extending laterally away from a first side of the primary duct; a second subsidiary duct extending laterally away from an opposite second side of the main duct; a first nozzle at an end of the first secondary duct and a second nozzle at an end of the second secondary duct. The nozzle clusters may be positioned such that a first nozzle is adjacent a first side of the upper opening and a second nozzle is adjacent an opposite second side of the upper opening.

The first and second nozzles may each include a spreading characteristic that provides substantially 360 degrees of coverage from the location of the nozzle.

In some embodiments, each nozzle cluster comprises: a third secondary duct extending laterally away from the second side of the main duct and spaced apart from the second secondary duct; a third nozzle at an end of the third secondary conduit. The first nozzle cluster may be positioned such that the first nozzle is adjacent to a first side of the upper opening and the second and third nozzles are adjacent to a second side of the upper opening, and the second nozzle cluster adjacent to the first nozzle cluster may be positioned such that the first nozzle is adjacent to the second side of the upper opening and the second and third nozzles are adjacent to the first side of the upper opening.

In some embodiments, the first and second subsidiary ducts each extend outwardly and downwardly from the main duct such that when liquid supply is stopped, an obtuse angle is defined between each of the first and second subsidiary ducts and the main duct and/or substantially all of the liquid in the ducts is discharged through the nozzle.

In some embodiments, the system further comprises: a hot water header in fluid communication with the inlet of the main conduit; a first control valve between the hot water header and the inlet of the main pipe to selectively supply hot water to the nozzle clusters; a wash solution header in fluid communication with the inlet of the main conduit; and a second control valve between the wash solution header and the inlet of the main conduit to selectively supply wash solution to the nozzle clusters.

In some embodiments, the system further comprises a rail under one or more hoods and/or covers and a carriage connected to the rail, wherein at least one nozzle is connected to the carriage. The carriage and nozzles may be configured to travel axially along the tank on rails to sequentially spray hot water and wash solution at different axial locations along the tank.

In some embodiments, the at least one nozzle is retained within an at least partially spherical nozzle mount that is retained in the socket. The nozzle mount may be capable of rotating and/or translating within the socket such that the nozzle is articulated to sequentially direct water and/or cleaning solution to different interior surfaces within the interior volume of the tank.

In some embodiments, the steeping tank is a poultry chiller.

Further features, advantages and details of the present invention will be appreciated by those of ordinary skill in the art from a reading of the figures and the detailed description of the preferred embodiments that follow, such description being merely illustrative of the present invention.

Drawings

FIG. 1 is a perspective view of a chiller according to some embodiments of the present invention.

Fig. 2 is a side view of the cooler of fig. 1 with portions of the side walls removed.

Fig. 3 is an end view of the cooler of fig. 1.

Fig. 4 is a cross-sectional view of the cooler of fig. 1.

Fig. 5 is a top view of the cooler of fig. 1.

FIG. 6 is a top view of a nozzle cluster and piping that may be used with the chiller of FIG. 1.

Fig. 7 is a perspective view of the nozzle cluster and tubing of fig. 6.

Fig. 8 is a side view of the nozzle cluster and tubing of fig. 6.

Fig. 9 is an end view of the nozzle cluster and tubing of fig. 6.

Fig. 10A is a side perspective view of a ball and socket nozzle assembly.

Fig. 10B is another (opposite side) perspective view of the ball and socket nozzle assembly of fig. 10A.

Fig. 11A is a side perspective view of the yoke and nozzle mount assembly of the ball and socket nozzle assembly of fig. 10A and 10B.

Fig. 11B is another (opposite side) perspective view of the yoke and nozzle mount assembly of fig. 11A.

Fig. 12 is a perspective view showing the multiple ball and socket nozzle assemblies of fig. 10A and 10B joined together.

FIG. 13 is a side view of a traveling nozzle cluster.

Detailed Description

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

It will be understood that when an element is referred to as being "coupled" or "connected" to another element, it can be directly coupled or connected to the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly coupled" or "directly connected" to another element, there are no intervening elements present. Like numbers refer to like elements throughout. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Furthermore, spatially relative terms, such as "below," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s), as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the exemplary term "below" can encompass both an orientation of above and below. It is possible to orient the device in other ways (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Well-known functions or configurations may not be described in detail for brevity and/or clarity.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises," "comprising," "includes" and/or "including," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

It is noted that any one or more aspects or features described with respect to one embodiment may be incorporated in a different embodiment, although not specifically described with respect thereto. That is, the features of any embodiment and/or all embodiments can be combined in any manner and/or combination. The applicant reserves the right to alter any originally filed claim or submit any new claim accordingly, including the right to be able to modify any originally filed claim to depend from and/or incorporate any feature of any other claim, although not originally claimed in that manner. These and other objects and/or aspects of the present invention will be explained in detail in the specification set forth below.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

As used herein, the term "nozzle" means a device for introducing liquid into a tank in a manner such that the liquid is encouraged to disperse throughout the intended portion of the inner surface in the tank.

The present invention relates to the cleaning and disinfection of steeping tanks for food processing applications (and in particular, for poultry cooling). The present invention is applicable to a variety of types of steeping tanks, including poultry chillers. Chillers may be broadly classified as soak chillers, in which the product is soaked in cold water, air chillers, in which cold air is circulated around the product, and other types of chillers, in which heat is removed from the product, such as by evaporation or radiation. The present discussion focuses on immersion coolers, as immersion coolers are most commonly used outside europe. However, the principles disclosed may be readily applied to other types of steeping tanks by one of ordinary skill in the art.

Even within the category of immersion cooling, a variety of configurations are employed. The most common in recent years are the so-called auger coolers (auger coolers), in which the product is advanced through a water tank by rotating the auger, and the oscillator coolers (rocker coolers), in which the product is kept suspended in the water contained in the tank by the oscillating movement of an agitator (dasher) inside the tank. So-called drag chillers (drags) are still being produced in which the product is advanced along the length of the tank by paddles extending into the water, which are mechanically urged to move from one end of the tank towards the other. All of these are suitable applications for the present invention.

The present invention works by creating temperature and humidity conditions adjacent to the soiled surface that soften the accumulated fat making it easier to remove from the surface. In some cases, the fat may be completely melted. A relatively low velocity water stream or water jet is sufficient to remove the fouling loosened by heat and humidity in this way.

According to an embodiment of the present invention, the problems of poor efficacy and excessive time and water consumption are solved in an automated system for washing poultry chillers by creating temperature and humidity conditions within the soiled chiller that soften and release fats and other contaminants from the interior surfaces in combination with washing the surfaces with a spray of water and/or a cleaning solution.

Referring to fig. 1, an auger-type chiller system 10 is shown including a chiller 12, the chiller 12 including a tank 14, the tank 14 having a side wall 16, an inlet end wall 18, an end wall bulkhead 20 above the inlet end wall 18, and a drain fitting 21. The auger drive mechanism is not shown so that features relevant to the present invention can be more clearly seen. The cooler is fitted with a hood 22 to at least partially cover the upper opening 23, which hood 22 serves to keep foreign objects outside the cooler during operation and to contain warm, moist air inside the cooler during washing. Some of the cowls on the left end of the cooler have been removed to expose clusters 24 of spray nozzles 26 mounted beneath the cowls. The cooler may be longer or shorter than that shown in the drawings and will have an outlet end wall not shown in the drawings.

Fig. 2 shows the auger-type cooler 12 of fig. 1 with some wall panels removed to reveal the interior of the tank 14 having an interior surface, an auger 28, and an interior volume 30. A plurality of injection nozzles 26 are mounted below the hood 22. The nozzle 26 is connected to a pipe system which supplies water and/or cleaning agent to be dispersed in the inner volume 30.

Fig. 3 shows an end view of the cooler 12.

Fig. 4 shows a cross section through the cooler 12. The nozzles 26 are positioned and directed such that the spray from at least one nozzle will impact most, if not all, of the soiled surface. In some embodiments, the nozzle 26 may have a spreading characteristic that provides nearly 360 degrees of coverage from the location of the nozzle 26. In the illustrated embodiment, the auger 28 is rotatable to expose multiple surfaces to one or more nozzles in turn. As shown in fig. 6, the spacing D1 and D2 between adjacent nozzles 26, as measured along the axial length of the cooler, should be less than the pitch P of the auger 28, as shown in fig. 2. This spacing will help ensure complete coverage of the inner surfaces, including the auger surfaces, by the jets.

The nozzle may be mounted adjacent to a structural member (such as a rod or beam) extending from the tank and/or a structural component of the encapsulation system. Such structural members may be attached to a nozzle or a piping system. In other embodiments, the nozzles and tubing may be supported from outside the cooler. In some embodiments, the nozzle may be attached to and/or penetrate the canister.

Internal components such as augers may prevent the spray of liquid from reaching some internal surfaces. Movement of the internal components (such as rotation of the auger) may eliminate some of the resulting jet shadow. However, some internal components, such as the auger shaft 32, will not move relative to the spray nozzle, and thus spray shadows persist even as the auger rotates. See fig. 4 (the dashed and shaded portions show the jet shading). To provide coverage for such spray shadows, the lateral spacing of the spray nozzles 26 should provide overlapping coverage from adjacent nozzles to ensure that the spray from at least one nozzle can access a majority of the interior surface. To provide overlapping coverage, the lateral spacing D3 of fig. 6 may be 1/3 to 2/3 the width of the chiller tank.

In embodiments involving other types of coolers, such as oscillator or drag coolers, different moving parts, such as stirrers or paddles, may move through their normal range of motion to intercept the spray from the nozzle. In such embodiments, the spacing of the spray nozzles will be distributed in a manner that minimizes the amount of interior surface area that the spray is permanently obscured.

In a preferred embodiment, a hood, cover, panel, curtain and/or other device (collectively referred to herein as a hood and/or cover) is used to enclose the chiller to retain warm moist air inside the chiller. Such a cover does not necessarily completely seal the cooler, but merely needs to contain most of the heat and moisture in the tank. The tank walls, hoods, covers, panels and other containment features should cover at least 90% of the surface area defining the interior volume of the cooler. In a preferred embodiment, the encapsulating features should cover at least 95% of the surface area bounding the interior volume. As shown in fig. 3, the containment feature may be configured to be open to provide maintenance and inspection access to the canister. At the end of the tank, a panel 20 may be employed to bridge the space between the end wall of the tank and the hood, as shown in figure 1.

Fig. 5 shows a top view of the cooler of fig. 1. The hood 22 and cover 34 at the left end of the cooler have been removed to expose the clusters 24 of nozzles 26 and ducts 36. For clarity, the auger is not shown.

Referring to fig. 7, the piping system 38 may include valves 40 to control the distribution of liquid from a liquid header 42, which liquid header 42 supplies cleaning solution to one or more spray nozzles in a cluster. A separate control valve 44 controls the distribution of water from the water header 46 to the cluster nozzles. In other embodiments, a single three-way valve may control the supply of cleaning solution and water from the cleaning solution manifold to the cluster nozzle. In still other embodiments, the cleaning solution and water may be alternately delivered through a single liquid header. Such valves may be operated sequentially so that liquid is supplied to a nozzle or group of nozzles for a period of time and then stopped. The configuration of the valve is then changed to supply liquid to a different nozzle or group of nozzles directed towards a different section of the soiled surface. In some embodiments, the valves will be operated to sequentially direct liquid to a set of nozzles directed toward adjacent sections of the soiled surface so that the cleaning process progresses along the length of the chiller.

In other embodiments, for example as shown in fig. 13, a single nozzle or cluster(s) of nozzles may be advanced along the length of the chiller by physically moving the nozzles, such as on a track extending parallel to the length of the chiller. In such embodiments, multiple clustered nozzles with separate control valves may not be required.

The number of nozzles included in a cluster of nozzles fed through a single control valve will be determined by the flow characteristics of the nozzles and the flow rates of water and/or cleaning solution that can be fed. For example, if the nozzles require a flow rate of 15gpm to provide acceptable spreading and the supply rate of cleaning liquid is 45gpm, then there should be no more than 3 nozzles in the cluster. The size or flow rate (flow rate) of each nozzle should reflect the internal tank surface area covered by that nozzle. A flow of 1gpm will service about 3-8 square feet of interior surface.

Referring to fig. 6, in some embodiments, the respective nozzle clusters include a main or central tube (hub) or header 36p, and first and second secondary tubes or extensions 36s1 and 36s 2. The first secondary conduit 36s1 may extend away from the main conduit 36p in a first direction, and the second secondary conduit 36s2 may extend away from the main conduit 36p in a second, generally opposite direction. In some embodiments, additional secondary conduits (e.g., third secondary conduit or extension 36s3) may extend away from the primary conduit 36p (e.g., in the second direction). It will be appreciated that a respective nozzle cluster may include a greater or lesser number of secondary conduits and corresponding nozzles. The main conduit 36p includes an inlet 50, with the wash solution header 42 and the hot water header 46 in fluid communication with the inlet 50.

Referring to fig. 5 and 6, each nozzle cluster 24 may be positioned such that a first nozzle 26 connected to the first secondary conduit 36s1 is adjacent to one of the first side 23A and the opposing second side 23B of the upper opening 23, and such that a second nozzle 26 connected to the second secondary conduit 36s2, and optionally such that a third nozzle 26 connected to the third secondary conduit 36s3 is adjacent to the other of the first side 23A and the second side 23B of the upper opening 23.

Referring to fig. 9, in a preferred embodiment, the piping system will be configured to provide a continuous downslope from the inlet 50 to each nozzle. Such a configuration allows liquid in the tubing to be discharged through the nozzle without leaving liquid trapped in the tubing.

The cleaning solution or water sprayed onto the inner surface of the cooler will flow down the surface and collect in the bottom of the tank. From there, the liquid will flow out of the tank through a drain fitting 21 (fig. 1). Depending on the preference of the operator, the liquid may be discharged into a waste water system, or collected, filtered, or otherwise cleaned and reused.

The cleaning process is carried out through a series of sequential steps. The first step is to close a hood or cover or other feature to contain heat and humidity within the interior volume. Heat and humidity are then added to the interior volume. In some embodiments, this may be accomplished by spraying hot water through nozzles onto the interior surfaces of the cooler. Water in the range of 90 ° F to 160 ° F is effective. Water in the range of 120 ° F to 150 ° F may be preferred. In an alternative embodiment, low pressure steam may be injected into the interior volume to increase the temperature and humidity of the air within the chiller. In still other embodiments, heat may be applied to the outer surface of the tank wall. The air temperature within the enclosed volume should exceed 90 ° F and the humidity ratio should exceed 0.028 pounds of moisture per pound of dry air. Preferably, the air temperature should exceed 110 ° F and the humidity ratio should exceed 0.034 pounds of moisture per pound of dry air.

The conditions of warm air and high humidity should be maintained in the cooler for a period of time that allows fat that may be dirtying the interior surfaces to soften or melt and begin to flow toward the bottom of the cooler. In some cases, 2 minutes may be a sufficient duration. In the case of heavy fouling and/or low ambient temperatures, a soak time (soak time) of 5 minutes or more may be preferred. If the temperature and humidity are kept constant, it may not be necessary to spray water over the inner surface for the entire duration of the soaking time. Preferably, the duration of the spray application exceeds the time of one complete cycle of the internal mechanism. For example, in an auger-type cooler, the duration of the spray application should be long enough to allow the auger to rotate a full revolution.

After treatment with heat and humidity, a cleaning solution is applied to the interior surfaces of the chiller. This is achieved by spreading the washing solution through a nozzle, which may be the same nozzle for water or may be a different nozzle dedicated to the washing solution. The cleaning solution can be one of several commercially available types currently used in the poultry industry. Foaming solutions may be preferred because they can remain on the surface for longer before being discharged completely away. The cleaning solution should be left in place for the amount of time recommended by the manufacturer to dissolve and dissipate the soil on the interior surfaces. The chiller should remain fully enclosed to retain as much heat and humidity as possible.

The final step is to rinse any remaining soil and cleaning solution from the interior surface. This is accomplished by spraying hot water through a nozzle onto the interior surface. The water flushes dirt and cleaning solution into the bottom of the chiller tank and out through the drain. This step should continue until the drain is empty.

As previously described, the process may be applied sequentially along the length of the chiller. The first process step may be applied at one end of the cooler through a first cluster of nozzles, and then applied through an adjacent second cluster of nozzles, and so on, continuing along the length of the cooler. The progression from one cluster to an adjacent cluster is not a necessary aspect of the process and the suggestions are made here only for convenience. The progression from one cluster to another may be in any desired order.

Once the proper hot wet soak time is completed in a particular area of the chiller, the cleaning solution may continue to be applied. For example, hot water may be applied to a first end of the cooler through a first cluster of nozzles, and then through a second cluster of nozzles, and so on, continuing along the length of the cooler. Once the desired soaking time has elapsed at the first end of the cooler, the application of the cleaning solution may be started at that end, even though the thermo-wetting treatment is still being performed further along the cooler. Of course, care should be taken to prevent the water jets in another portion of the chiller from inadvertently rinsing the cleaning solution prematurely.

Also, once the cleaning solution set time has elapsed at this location, a final rinsing step may be initiated at the first end of the chiller, even though the cleaning solution is still being applied in other portions of the chiller.

In another embodiment, the nozzle through which water and/or cleaning solution is applied to the interior surface of the tank may generate a concentrated jet of fluid rather than a widely dispersed spray, and may further be articulated in a manner that allows the jets to be directed at multiple tank surfaces in sequence.

In addition to heat and humidity, the jet of fluid also provides high impact forces and momentum to remove dirt from the can surface. Jet velocities of 40 to 100 feet/second at the nozzle have proven effective, with velocities of 65 to 75 feet/second being preferred. Jet flows of 3 to 20 gallons per minute have proven effective, with flows of 4 to 10 gallons per minute being preferred.

In selecting the appropriate flow rate and velocity, the reduced flow may be offset by the increased velocity, and vice versa. Mass flow rate (m') multiplied by velocity squared (v)²) The product of (a) yields a power (P) term, which guides this balance, as shown in the following equation:

P = ½ m' v²

flow power of 150 to 1500 lb-ft/sec has proven effective, with 270 to 900 lb-ft/sec being preferred.

The way in which the fluid momentum is distributed over the surface area impinged by the jet may be additionally considered. Those skilled in the art will appreciate that the area may depend on the distance from the nozzle to the surface, the divergence angle of the jet, and the type of spray pattern, such as a solid jet (solid jet), a hollow cone, or a flat fan. The average momentum (M) is defined as the mass flow rate (M') multiplied by the average velocity over the impingement area. The average velocity at impact can be determined as the volumetric flow rate (V') divided by the impact area (a). Combining these concepts yields the equation:

M = m' V' / A

an average momentum of 0.013 to 0.075 pound-force has proven effective, with a momentum of greater than 0.036 pound-force being preferred.

The jet spray may have multiple modes to achieve different effects. A conical narrow jet spray with a spray angle of up to 5 degrees has proven effective for maintaining jet impact forces at distances of up to 12 feet from the spray surface. An elliptical cone shaped fan jet with a nominally (nominally) narrow minor axis angle is effective for jetting large surfaces while maintaining sufficient impact forces at moderate distances. With long axis angles of 30 to 90 degrees, fan-shaped jets with short axis angles of up to 5 degrees are effective, with long axis angles of 50 to 90 degrees providing a good compromise between surface coverage and jet impact forces.

A gimbal mount for the jet nozzle allows the jet to be directed at multiple surfaces within the tank. Referring to fig. 10 and 11, a universal joint nozzle assembly or universal joint system 101 may include a ball and socket arrangement in which a nozzle 102 is mounted in a spherical or partially spherical nozzle mount 104-a ball-the nozzle mount 104 fits against a socket 106, the socket 106 including an opening 110 and an edge 108 that substantially seals the spherical portion of the nozzle mount 104, the nozzle 102 obtaining a view of the interior 30 of the tank 14 through the opening 110 (fig. 2). Ball mount 104 may be substantially spherical or only the portion of the mount adjacent to socket edge 108 may be spherical. A biasing member, such as a spring 112, is provided to maintain secure contact between the spherical portion of the nozzle mount 104 and the socket 106.

The jet nozzle 102 may be attached to the nozzle mount 104 by a threaded engagement, a clamp, a retaining plate (retaining plate), or other known attachment mechanism. Fig. 10A and 11A illustrate the use of the support plate 114 and the fastener 116. In an alternative embodiment, the ball mount itself may contain an internal channel that defines the nozzle.

A fluid supply member, such as a hose (not shown), may be connected to the fitting 103 on the inlet end of the nozzle 102 to supply fluid to the nozzle 102. The fluid supply member must accommodate the range of motion of the nozzle in operation.

A further feature is attached to the ball mount 104 to cause it to rotate about its center of sphere relative to the socket 106. Such features may include a yoke 120 attached to the nozzle mount 104 by a shaft 122, the shaft 122 allowing the nozzle mount to rotate about the axis of the shaft 122. In turn, the yoke may be attached to the socket or socket assembly 106 by a second shaft 124 oriented at an angle relative to the first shaft 122. The yoke 120, along with the ball mount 104, is rotatable together about a second shaft 124 relative to the socket 106. In a preferred embodiment, the two shafts are perpendicular to each other.

In other embodiments, the gimbal system may include a backing plate having an edge similar to an edge of the socket that engages the spherical portion of the nozzle mount. The backing plate is attached to the socket such that the nozzle mount is captured therebetween while still being able to rotate about its spherical center relative to the socket.

The nozzle 102 directs a jet of fluid through an opening 110 in the socket 106 towards the interior surface of the canister. The ball 104 may swivel horizontally through a range of 30 degrees within the socket 106 and vertically through a range of up to 45 degrees. Preferably, the nozzle 102 is oriented to direct fluid flow through the socket opening 110 throughout this entire range of motion, however, in some embodiments, the nozzle 102 may be blocked by portions of the socket 106 during certain portions of its range of motion.

In some embodiments, the ball 104 may be intentionally swiveled far enough within its range of motion that the tip of the nozzle 102 is no longer directed through the opening 110 in the socket 106. When the cleaning system is not in use, the nozzle 102 may be stowed in such a position to eliminate the possibility of cleaning solution leaking into the tank during processing operations.

The nozzle 102 may be articulated using linkages 126, 128 connected to the nozzle 102 or the nozzle housing 104 such that pushing the end of the linkage 126 or 128 in a substantially linear motion by means of a linear actuator will cause the nozzle 102 to pivot about an axis. Separate linkage mechanisms may be provided to pivot the nozzle about different axes, such as the x and y axes. The linear actuator may comprise a 3-or 4-bar linkage, a hydraulic cylinder, a jack screw, or other such known mechanisms.

In other embodiments, the nozzle may be articulated using a rotary actuator that rotates the nozzle mount relative to the yoke and rotates the yoke relative to the socket. The rotary actuator may include a stepper motor, a hydraulic actuator, or a gear engaging teeth on the housing or other such known mechanisms.

Referring to fig. 1, 10A and 10B, the nozzle assembly 101 may be installed in the tank wall 16 such that the socket 106 is flush or substantially flush with the inner face of the tank wall 16. Alternatively, the nozzle assembly 101 may be mounted on a mounting structure or surface (such as the arch 25 of the support cover 34) or at the top of the tank wall 16 over the upper opening 23.

As previously described with reference to fig. 6, the axial spacing between adjacent nozzle assemblies 101 should be less than the pitch P of the auger 28, as shown in fig. 2.

Referring to fig. 12, in some embodiments, two or more nozzles 102 may be coupled together such that a set of actuators 129 causes the coupled nozzles to move in series as they direct jets of fluid relative to the plurality of interior surfaces.

In other embodiments, the nozzle may be installed in a gimbal system similar to that described above, but without the ball and socket. In such embodiments, the nozzle mount need not have any spherical portion. Instead of being located adjacent to the socket, the nozzle mount and/or yoke of this embodiment is attached to any convenient fixed structure to obtain a view of the interior surface of the tank. The nozzle and mounting assembly must not interfere with the operation of the tank or the movement of any components within the tank. In operation, the actuator will cause the nozzle to pivot about one or more axes, thereby directing a fluid jet to sweep across the interior surface of the tank.

Referring to fig. 13, in other embodiments, a single nozzle or a single clustered nozzle 24 travels along the length of the tank 14 above the upper opening 23 but below any hood or cover (which is the same or similar to those shown in fig. 1 and 2, but is not shown in fig. 13 to more clearly show the system in travel). While the previously described embodiment uses a plurality of clustered nozzles at fixed locations to provide spray coverage for substantially all of the interior surfaces, the embodiment uses a single nozzle or a single clustered nozzle 24 that moves to different stations in the tank 14 to provide coverage. In some embodiments, the nozzles or cluster nozzles 24 may continuously eject fluid as they travel along the tank 14. This embodiment employs methods similar to those previously described for spraying water into the substantially encapsulated portion of the tank to increase heat and humidity, followed by application of a cleaning agent to the interior tank surface and application of a final rinse.

The piping that supplies fluid to the traveling nozzle 24 must be flexible enough to accommodate the range of motion of the nozzle 24 within or above the tank. For example, the fluid may be supplied through a hose 130 wound around a spool 132. As the nozzle 24 moves along the tank 14 away from the spool 132, the spool 132 rotates to unwind an additional length of hose 130 sufficient to reach the nozzle 24. In other embodiments, the hose may be suspended from the overhead rail at spaced intervals. The support points may be advanced along the rail as required to reach the advancing nozzle, while the hose simply hangs between the support points with any slack.

The traveling nozzle 24 may be supported and guided by a guide rail 134 mounted above the upper opening 23 of the tank 14. In some embodiments, power to move the nozzle 24 may be supplied from an external source, such as a pull cable 136 attached to a nozzle carriage 138. The cable 136 may be pulled by a winch. In other embodiments, the pressure and flow of the fluid will be utilized to provide a motive force to advance the nozzle along the length of the chiller. In still other embodiments, rotation of the auger 28 in the tank 14 may propel the nozzle clusters along the tank. Those skilled in the art will appreciate that many other ways can be used to drive the traveling nozzle or nozzle cluster.

It will be appreciated that it is an object of the present invention to provide an automated process for removing most, but not necessarily all, of the foulants from a poultry chiller. After the automated process is complete, it may be necessary to manually wash certain locations locally or for a particularly severe build-up of dirt.

The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.