Rocker chiller with baffle assembly

Abstract

A rocker chiller includes a chilling tank and a baffle assembly. The baffle assembly includes a drive shaft, a baffle blade extending along a bottom of the tank and a plurality of spaced-apart and elongate baffle members extending in a radial direction from the drive shaft towards the bottom of the tank. The elongate baffle members contact the drive shaft at spaced-apart locations along the drive shaft and define a plurality of openings therebetween. The elongate baffle members are sized and shaped to push at least a majority of the carcasses laterally through the heat exchanging liquid in a direction generally orthogonal to a lengthwise forward movement of the carcasses from the first end of the tank to the second end of the tank.

Claims

1. A rocker chiller, comprising: a chilling tank having first and second opposing sides and first and second opposing ends spaced apart at a greater distance relative to a spacing between the first and second opposing sides, said tank including a curved bottom portion configured to hold heat-exchanging liquid at a liquid level in said tank and for receiving carcasses in the heat-exchanging liquid in said tank; a baffle assembly comprising a drive shaft having a longitudinal axis about which said baffle assembly may be at least partially rotated, and at least one baffle blade extending at least partially along a length of said curved bottom portion of said tank and parallel to said drive shaft, said drive shaft connected to a first of the at least one baffle blade by a first pair of support arms, which extend adjacent first and second opposing ends of the first baffle blade; and power means for oscillating each of said at least one elongated baffle blade side-to-side in a corresponding arc along said curved bottom portion of said tank; wherein said baffle assembly further comprises a plurality of spaced-apart and elongate baffle members extending in respective radial directions from said drive shaft towards the curved bottom portion of said tank, said plurality of spaced-apart and elongate baffle members contacting said drive shaft at spaced-apart locations along said drive shaft relative to the first pair of support arms and defining a plurality of openings therebetween, which extend below the liquid level in said tank, and being sized and shaped to push a plurality of the carcasses laterally through the heat exchanging liquid in a direction generally orthogonal to a lengthwise forward movement of the carcasses from the first end of said tank to the second end of said tank; wherein the plurality of openings between said plurality of spaced-apart and radially-extending baffle members are sized and shaped to enable passage of the heat-exchanging liquid therethrough as the plurality of spaced-apart and elongate baffle members and the first baffle blade oscillate back-and-forth in respective arcs through the heat-exchanging liquid; and wherein said plurality of spaced-apart and elongate baffle members are not joined at their distal ends by the first baffle blade.

2. The rocker chiller of claim 1, wherein all of the plurality of spaced-apart and elongate baffle members contact said drive shaft.

3. The rocker chiller of claim 2, wherein at least some of the plurality of spaced-apart and elongate baffle members extend parallel to each other.

4. The rocker chiller of claim 3, wherein all of the plurality of spaced-apart and elongate baffle members extend in respective planes that intersect the longitudinal axis of said drive shaft.

5. The rocker chiller of claim 1, wherein the plurality of spaced-apart and elongate baffle members operate collectively to engage the carcasses in repeated cycles of compression and expansion as the first baffle blade oscillates back-and-forth through the heat exchanging liquid.

6. The rocker chiller of claim 5, wherein the first baffle blade is a centrally-located baffle blade that sweeps equivalent length arcs on the first and second opposing sides of said tank during its back-and-forth oscillation through the heat exchanging liquid.

7. The rocker chiller of claim 1, wherein said plurality of spaced-apart and elongate baffle members are cylindrically-shaped rods.

8. The rocker chiller of claim 4, wherein all of the plurality of spaced-apart and elongate baffle members extend parallel to each other.

9. The rocker chiller of claim 4, wherein at least some of the plurality of spaced-apart and elongate baffle members extend parallel to each other and to the first pair of support arms.

10. The rocker chiller of claim 4, wherein all of the plurality of spaced-apart and elongate baffle members extend parallel to each other and to the first pair of support arms.

11. The rocker chiller of claim 1, wherein the plurality of openings are rectangular-shaped openings; and wherein lengths of the rectangular-shaped openings as measured in the radial direction from said drive shaft are greater than corresponding widths of the rectangular-shaped openings as measured along said drive shaft.

12. The rocker chiller of claim 1, wherein said drive shaft is connected to the first baffle blade by multiple pairs of support arms.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) The present disclosure will be better understood with reference to the following drawing figures. Similar reference numerals designate corresponding parts throughout the figures, and components in the figures are not necessarily to scale.

(2) FIGS. 1A, 1B and 1C are perspective sections of a rocker chiller, showing the elongate baffle assembly in its left, centered and right positions, respectively.

(3) FIGS. 2A, 2B, 2C, 2D, and 2E, 2F and 2G are perspective sections of portions of baffle assemblies that include baffles of different configurations that extend from the semi-cylindrical bottom wall upwardly toward the surface of the heat exchanging liquid.

(4) FIGS. 3A and 3B are end views of a baffle assembly with a carcass guide that directs the oncoming carcasses into the chilling heat exchanging liquid.

DETAILED DESCRIPTION

(5) Referring now in more detail to the drawings in which like numerals indicate like parts throughout the several views, FIGS. 1A-1C show a rocker chiller 10 that includes a semi-cylindrical tank 12 that is substantially filled with a body of heat exchanging liquid 14. The temperature of the heat exchanging liquid may vary in accordance with the carcasses being treated and the manner of treatment of the carcasses. For example, the heat exchanging liquid may be water with antimicrobial and other desirable additives. If the rocker chiller is to be used as a pre-chiller, in which the carcasses of chickens at 104° F. are going to be treated, the temperature of the heat exchanging liquid in the tank may be at about 60° F., a difference of about 44° F. If, however, the principles of the rocker chiller are used in a final chiller tank, the temperature of the heat exchanging liquid might be just above 32° F.

(6) In addition to the heat exchanging liquid 14 that substantially fills the tank 12, FIG. 1A shows that additional heat exchanging liquid may enter the tank by recirculation conduits 16 that direct a cold stream of makeup heat exchanging liquid along the length of the semi-cylindrical bottom wall 19 of the tank, preferably at the predetermined positions above the sweep of the baffle assembly 18, to be described hereinafter. The makeup liquid entering through the recirculation conduits will be at the desired temperature for the purpose of chilling the carcasses, and tends to urge the carcasses gathered at the upper facing surface of the baffle assembly along the length of the semi-cylindrical tank 12 toward the exit end 13 of the tank. This is disclosed in more detail in U.S. Patent Application Publication 2007/0169502 A1, dated Jul. 26, 2007, the disclosure of which is incorporated herein by reference.

(7) FIGS. 1A, 1B and 1C show the rocker chiller 10 with its baffle assembly 18 in different positions, with the lower edge portion of the baffle assembly to the left, centered and to the right, respectively. It will be appreciated that the baffle assembly 18 substantially divides the heat exchanging liquid 14 into two regions of variable volume depending on the position of the baffle assembly within its range of motion. Due to the design of the baffle, the heat exchanging liquid 14 may freely communicate between the two regions, but the carcasses 28 are at least partially confined to the region in which each was originally introduced. Carcasses in each region will be more or less densely gathered in the heat exchanging liquid as the volume of the region changes due to the motion of the baffle assembly 18. Alternate cycles of compression and expansion have beneficial effect on the carcasses as will be described more fully in this description.

(8) Baffle assembly 18 includes a drive shaft 20 that may extend at the liquid level along the length of the semi-cylindrical tank 12. Drive shaft 20 oscillates about the longitudinal axis 22, which may be the longitudinal axis for both the drive shaft 20 and the semi-cylindrical tank 12. A power means 23 is used to oscillate the drive shaft. An electric motor and gear box may function as the power means. In the embodiment illustrated in FIGS. 1A-1C, the baffle assembly 18 includes support arms 24 that are mounted at their upper ends to and extend radially downwardly from the drive shaft 20, with the support arms spaced along the drive shaft. Baffle 26 is formed of parallel spaced apart horizontal slats 30 that are supported at their ends by the radially extending support arms 24. The chilling liquid in the tank moves through the spaces 29 between the baffle slats 30 in response to the movement of the baffle 26. The spaces 29 between the baffle slats 30 are too small for most of the poultry carcasses to pass between the baffle slats. The lower edge portion of baffle assembly 18 may include one or more elongated baffle blades 21 that are supported by the radially extending support arms 24 and extend parallel to the drive shaft 20. The baffle blade 21 of FIGS. 1A-1C is sized, shaped and positioned by the support arms 24 so as to sweep closely adjacent the facing semi-cylindrical bottom wall 19 of tank 12.

(9) A conventional drive motor 41 and transmission 40 are connected to the drive shaft 20 of the rocker chiller and function as means for oscillating the baffle assembly 18 in an arc from side to side in the heat exchanging liquid 14 across the interior facing surface of the tank 12, as shown by arrow 17. When the baffle assembly oscillates, it sweeps from side to side and tends to engage and move the poultry carcasses 28 adjacent the side wall of the tank toward alignment with recirculation conduits 16 as indicated in FIGS. 1A and 1C.

(10) Poultry carcasses 28 are placed in the tank 12 with the carcasses being generally submerged in the heat exchanging liquid 14. Most of the carcasses tend to slowly sink toward the bottom of the heat exchanging liquid 14, adjacent the interior surface of the semi-cylindrical bottom wall of tank 12.

(11) With this arrangement, some of the carcasses 28 are engaged by the baffle 26 and move up with the movement of the baffle and become aligned with the streams of liquid emitted from the recirculation conduits 16 so that the recirculated heat exchanging liquid that may bear an antimicrobial is directed against the carcasses. The drive motor may operate to intermittently pause the baffle assembly 18 at its up positions at the sides of the tank when the baffle assembly is aligned with a recirculation conduit 16. The oncoming streams of heat exchanging liquid tend to urge the carcasses 28 along the length of the tank 12 toward the discharge end of the tank and to wash the carcasses with the heat exchanging liquid.

(12) As shown in FIGS. 1B and 1C the baffle 26 extends from the baffle blade 21 at the lower edge of the baffle 26 upwardly toward the drive shaft 20 and toward the surface of the heat exchanging liquid 14. The parallel slats 30 of baffle 26 have openings 29 extending between them for the passage of the heat exchanging liquid 14 through the baffle as the baffle moves from side to side. These parallel baffle slats 30, as well as the parallel baffle rods and the parallel baffle bars described hereinbelow and shown in the figures, may be collectively referred to herein as elongate baffle members.

(13) The baffle 26 includes openings extending therethrough that may be of various shapes, such as circular, non-circular, elongated, and polygonal. Other shapes of baffle openings may be suitable, as generally shown in FIGS. 2A-2G. The openings in the baffle 26 are sized and shaped for reducing the likelihood of the carcasses becoming caught in the openings of the baffle but permitting the heat exchanging liquid 14 in the tank 12 to move through the baffle. The baffle may be formed of sheet metal, expanded metal, woven wire, perforated sheet material, one or more slats or a plurality of parallel rods supported by adjacent ones of the support arms 24 or by a plurality of parallel rods extending radially out from the drive shaft 20 and joined or not at the distal ends by a baffle blade 21. The baffle may be made of materials that are stable and strong in the heat exchanging liquid. Further, the openings in the baffle may be larger than described above, with the spaces allowing movement of carcasses through the baffle. Preferably the openings in the baffle are of a size and shape so that the carcasses do not become caught in the baffle.

(14) As shown in FIG. 2A, the baffle 26A of baffle assembly 18A includes a perforated sheet 25A extending radially downwardly from drive shaft 20 that defines an array of openings 31A, with the baffle 26A forming an upward extension of baffle blade 21A. The perforated sheet may extend from the baffle blade 21A upwardly to the drive shaft 20. The radially extending support arms 24A support the baffle assembly from the drive shaft 20.

(15) As shown in FIG. 2B, the baffle 26B of baffle assembly 18B may be a perforated sheet 25B that extends radially from drive shaft 20 to baffle blade 21B. The perforated sheet 25B also defines an array of openings 31B, and the baffle 26B forms an upward extension of baffle blade 21B. The radially extending support arms 24B support the baffle assembly from the drive shaft 20.

(16) As shown in FIG. 2C, the baffle 26C of baffle assembly 18C includes a plurality of parallel spaced bars 27C mounted to and extending downwardly from the drive shaft 20. Spaces 29C are formed between the bars 27C and are sized as previously described, to retard the movement of the poultry carcasses from one side to the other side of the baffle as the baffle oscillates from side-to-side. The bars 27C are of a length so that the lower ends of the bars move closely adjacent the facing cylindrical surface of the tank so the carcasses are not likely to pass about the end of a bar.

(17) As shown in FIG. 2D, the baffle 26D of baffle assembly 18D includes a plurality of parallel spaced bars 27D mounted to and extending downwardly from the drive shaft 20 and joined (or not) at their lower ends to longitudinally extending baffle blade 21D. Spaces 29D are formed between the bars 27D and are sized as previously described, to retard the movement of the poultry carcasses from one side to the other side of the baffle as the baffle oscillates from side-to-side.

(18) As shown in FIG. 2E, the baffle 26E of baffle assembly 18E includes a plurality of horizontally extending parallel spaced bars 27E positioned between and parallel to the drive shaft 20 and baffle blade 21E. Spaces 29E are formed between the bars 27E and are sized as previously described, to retard the movement of the poultry carcasses from one side to the other side of the baffle 26E as the baffle oscillates from side-to-side. Radially extending support arms 24E support the baffle 26E and baffle blade 21E from the drive shaft 20.

(19) As shown in FIG. 2F, the baffle 26F of baffle assembly 18F includes at least one wide slat 30F positioned between the drive shaft 20 and the baffle blade 21F. Spaces 29F are formed on opposite sides of baffle slat 30F and are sized as previously described, to retard the movement of the poultry carcasses from one side to the other side of the baffle as the baffle oscillates from side-to-side. Radially extending support arms 24F support the baffle 26F and baffle blade 21F from the drive shaft 20.

(20) As shown in FIG. 2G, the baffle 26G of baffle assembly 18G includes a baffle board 30G mounted to the baffle blade 21G and to the radially extending support arms 24G. The upper edge 23G of the baffle board is spaced downwardly from the drive shaft 20 and forms an overflow space 29G above its upper edge for the movement of chilling liquid. As the baffle assembly 18G oscillates, the chilling liquid spills over the upper edge 23G of the baffle board 30G, causing turbulence of the chilling liquid about the poultry carcasses.

(21) While the baffle blades 21A-21G may provide structural and operational advantages in specific cases, it is not necessary to the general function of the baffle which is to allow heat exchanging liquid to pass through while retarding the passage of carcasses. For example, the baffle blade 21E could be replaced by additional parallel rods 27E of FIG. 2E while retaining adequate structural integrity, and the baffle would function as intended.

(22) In some cases, the baffle may be designed with sufficient structural integrity to eliminate the need for the baffle blade and even the support arms. FIG. 2B shows a perforated baffle 26B with a lip 21B at the lower edge. The lip provides sufficient rigidity to avoid excessive flexure under the loads imposed on the baffle by the oscillating motion. The support arms 24B of FIG. 2B have been reduced to flat ribs which carry the bending load where the baffle attaches to the central drive shaft 20.

(23) FIG. 2C shows an embodiment in which the baffle consists of a series of radially extending parallel rods 27C that span from the drive shaft 20 to a length that places the ends of the rods adjacent the inner surface of the tank 12. The spaces between the ends of the rods 27C and the tank 12 are small enough that carcasses cannot become wedged between rod and tank, but large enough that the rods do not touch the tank at any point in their range of motion. The rods are designed of such size and strength that each rod can bear the bending load imposed by the local resistance to the oscillatory motion of the baffle assembly. Neither baffle blade nor support arms are required in this embodiment. Note also that the lower edge of this baffle is not a continuous physical edge but rather an imaginary edge interpolated between the distal ends of rods.

(24) FIGS. 3A and 3B illustrate the positions of a baffle assembly 18 when the baffle assembly has moved from one side over to the other side of the semi-cylindrical tank 12. A carcass guide 40 extends upwardly from drive shaft 20. The carcass guide 40 may be a plate or other surface that extends in the opposite direction from the drive shaft 20 when compared to the radially extending support arms 24.

(25) The carcass guide may comprise a deflector plate 42 or other guide surface that functions to direct the oncoming carcasses 28 downwardly at a sloped angle into the heat exchanging liquid 14. As shown in FIG. 3A, the carcass guide 40 is positioned on the opposite side of the drive shaft 20 from the baffle assembly and the carcass guide moves to the opposite side of the drive shaft 20 in comparison to the movement of the baffle assembly. This causes the carcass guide 40 to deliver the carcasses to the heat exchanging liquid 14 on the side where the baffle assembly 18 is raised in the liquid 14. When the baffle assembly sweeps to the other side of the tank, as shown in FIG. 3B, the carcass guide will be extended upwardly to the opposite side in comparison with FIG. 3A, so as to direct the oncoming poultry carcasses 28 to where the baffle assembly has been raised. This tends to equally divide the oncoming carcasses on opposite sides of the baffle assembly over time.

(26) In the current invention, the baffle restricts carcasses from moving through the baffle assembly, and the poultry carcasses 28 tend to become more densely gathered in the turbulent heat exchanging liquid 14 when the baffle assembly 18 sweeps in that direction and less densely gathered on the trailing side of the baffle assembly as shown in FIGS. 1A, 1B and 1C.

(27) The contact of the carcasses with the surfaces of the tank 12, with the baffle assembly 18 and with one another creates a mild compression of each carcass, providing the benefit of massaging the meat of the carcasses. Repeated cycles of compression and relaxation cumulatively tend to help break down some of the cell structure of the carcasses, thereby tenderizing the meat and creating microscopic voids where moisture can be retained within the product.

(28) It is desirable to not only chill the carcasses but to massage the carcasses so that moisture will be retained in the product through the production process. The additional surface area of the baffle provides more contact with the carcasses thus promoting the massaging action.

(29) As the poultry carcasses gather more densely on the leading side of the baffle assembly, the heat exchanging liquid rushes through the baffle toward the opposite side of the tank. This is illustrated by the horizontal arrows 44 in FIG. 1B, showing how the water rushes from the right side, through the baffle of the blade assembly, and then into the left portion of the tank. The rush of heat exchanging liquid tends to push the carcasses against the baffle, further enhancing the massaging effect on the meat. In addition, heat exchanging liquid rushing past the carcasses as they accumulate adjacent the baffle enhances the heat exchange efficiency. This enhanced efficiency assures that the chilling function does not suffer significantly as a result of the asymmetrical distribution of carcasses within the heat exchanging liquid.

(30) A result of the new rocker chiller herein disclosed is the washing action of the more vigorous movement and more positively churning of the birds about in the heat exchanging liquid 14. This vigorous washing function of the carcasses tends to remove bits of organic matter that are usually carried by the carcasses into the heat exchanging liquid. This vigorous churning tends to get more of that substance off the birds and this may be important if the rocker chiller is functioning as a pre-chiller where the birds are first placed for treatment in the pre-chiller and then moved to the final chiller.

(31) When the rocker chiller disclosed herein is functioning as a pre-chiller, the temperature of the water in the pre-chiller is usually significantly higher than the temperature of the water in the final chiller, and at the higher temperature the compression and turbulence action experienced in the pre-chiller tends to remove more of the unwanted substances from the surfaces of the carcasses while the surfaces of the carcasses are relatively warm. The warmer surfaces of the carcasses are more subject to being cleansed by the turbulence of the water and the impact against the carcasses. The oil and bits of fat and organic matter on the meat tend to be washed off the carcasses in the chiller when the temperature of the carcasses is still above about 60° F. The combination of the higher temperature and the more vigorous impact and churning of the carcasses provides a cleaner carcass at the exit of the pre-chiller. Thus, these items, skin oil, bits of fat, organic matter, etc. tend to remain in the heat exchanging liquid of the pre-chiller, where it is not transferred to the subsequent main chiller, where disinfectant in the main chiller can be used at a lower concentration for providing the same cleaning results. A stronger dose of disinfectant in the pre-chiller allows a minimal dose of disinfectant in the final chiller.

(32) By scrubbing the birds in the pre-chiller, less organic matter is transferred into the final chiller and whatever chlorine or other disinfectant is used is more available to attack the microbes of the carcasses.

(33) The cycles of alternate compression and relaxation of the water on opposite sides of the baffle assembly as shown in FIGS. 1A, 1B and 1C tends to “massage” the soft tissues of the poultry carcasses and encourage moisture retention. The baffle assembly configuration increases and decreases liquid pressure on opposite sides of the baffle as it sweeps in opposite directions across the tank in a cycle pattern. This change in pressure is relatively small, only a few inches of water head, as shown in FIGS. 3A and 3B, but when the pressure change is applied repeatedly along the length of the travel of the carcasses, it tends to have an effect of compression and expansion of the bird carcasses, resulting in more water retention and expelling of undesirable surface tissues on the birds.

(34) Although preferred embodiments of the invention have been disclosed in detail herein, it will be obvious to those skilled in the art that variations and modifications of the disclosed embodiments can be made without departing from the spirit and scope of the invention as set forth in the following claims.