Abstract:
An apparatus for rapidly producing cryogenically frozen dessert particles is disclosed. The machine comprises a refrigerated mixer, a plurality of hoses connecting the refrigerated mixer to a filling head, a bath having a housing and a tank for liquid nitrogen, a bath belt rotatably engaged to the housing, a cluster cylinder rotatably engaged to the housing, and a delivery belt. The method of employing the apparatus comprises the steps of placing a mix into the refrigerated mixer, pumping the mix through the plurality of hoses into the filling head, allowing the mix to stream into liquid nitrogen in a tank in the bath, carrying the particles formed out of the liquid nitrogen by means of a conveyor belt, breaking up clumps of particles and transporting the particles to a channel guide for weighing and packaging.

Description:
FIELD OF THE INVENTION 
     The present invention relates to an apparatus and method for rapidly freezing and packaging dessert particles such as cream, ice cream or flavored water. 
     BACKGROUND OF THE INVENTION 
     U.S. Pat. No. 3,832,864 discloses a quick freezing machine having an insulated tank for holding liquid nitrogen and an endless slack conveyor belt supported between opposite sides of the tank with all but the endmost portions fully immersed in the bath. U.S. Pat. No. 3,857,974 (the &#39;974 patent) discloses a method and apparatus of cryogenic freezing of discrete particles of homogenized egg yolk and egg white. A peristaltic pump causes the discrete particles to fall into liquid nitrogen, and the frozen particles, ranging in size from 3 mm to 7 mm, are removed from the liquid nitrogen by a screw conveyor. UK Patent GB 2 092 880 discloses an apparatus for freezing drops of cream into solid pellets carried by flowing liquid nitrogen. U.S. Pat. No. 4,479,363 discloses a method of freezing a continuous pulsating stream of a liquid such as cream into discrete spheroidal bodies. U.S. Pat. No. 5,126,156 discloses a method of dripping an alimentary composition from a feed tray into liquid nitrogen to form beads. 
     What is needed beyond the prior art is a method of rapidly freezing and packaging dessert particles such as cream, ice cream, or flavored water. 
     SUMMARY OF THE INVENTION 
     The invention which meets the needs identified above is a machine for rapidly producing cryogenically frozen dessert particles comprising a refrigerated mixer, a plurality of hoses connecting the refrigerated mixer to a filling head, a bath having a housing and a tank for liquid nitrogen, a bath belt rotatably engaged to the housing, a cluster cylinder rotatably engaged to the housing, and a delivery belt. The method of employing the apparatus comprises the steps of placing a mix into the refrigerated mixer, pumping the mix through the plurality of hoses into the filling head, allowing the mix to stream into liquid nitrogen in a tank in the bath, carrying the particles formed out of the liquid nitrogen by means of a conveyor belt, breaking up clumps of particles and transporting the particles to a channel guide for weighing and packaging. 
     The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings wherein like reference numbers represent like parts of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 depicts a left side perspective view of the machine; 
     FIG. 2 depicts a left side perspective view of a bin; 
     FIG. 3 depicts a perspective view of the bottom of a bin; 
     FIG. 4 depicts a detailed view of the bottom of a bin; 
     FIG. 5 depicts a left side view of the machine; 
     FIG. 6A depicts a front view of the guide channels; 
     FIG. 6B depicts a scoop marked for a volumetric gallon; and 
     FIG. 7 depicts a flow chart of the process. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1 depicts machine  100  having refrigerated mixer  200 , filling head  300 , bath  400  and post cooler  500 . Refrigerated mixer  200  has first container  210 , second container  220 , third container  230  and fourth container  240 . First container  210  has first lid  212 , first pipe  214 , first valve  216 , first hose  218  and first electrical connection  264 . Second container  220  has second lid  222 , second pipe  224 , second valve  226 , second hose  228  and second electrical connection  266 . Third container  230  has third lid  232 , third pipe  234 , third valve  236 , third hose  238  and third electrical connection  268 . Fourth container  240  has fourth lid  242 , fourth pipe  244 , fourth valve  246 , fourth hose  248  and fourth electrical connection  270 . Each of first container  210 , second container  220 , third container  230  and fourth container  240  are refrigerated, have an internal rotatable mixing arm (not shown), a pump (not shown) and are connected to power supply  260  by connecting wires  262  which are connected to first electrical connection  264 , second electrical connection  266 , third electrical connection  268  and fourth electrical connection  270 . In the preferred embodiment, refrigerated mixer  200  is made of stainless steel. 
     Filling head  300  has first bin  310 , second bin  320 , third bin  330 , fourth bin  340  and filling head support  350 . First bin  310  has first connector  312  for removable engagement of first hose  218 . Second bin  320  has second connector  322  for removable engagement of second hose  228 . Third bin  330  has third connector  332  for removable engagement of third hose  238 . Fourth bin  340  has fourth connector  342  for removable engagement of fourth hose  248 . First bin  310 , second bin  320 , third bin  330  and fourth bin  340  are removably engaged to filling head support  350 . First leg  352 , second leg  354 , third leg  356  and fourth leg (not shown) are fixedly engaged to filling head support  350  and removably engaged to housing  10  of bath  400 . 
     Bath  400  has housing  10 , tank  410 , bath belt  420  and cluster cylinder  430 . Housing  10  has first aperture  12  beneath filling head  300 . Bath belt  420  is removably and rotatably engaged to first roller  422 , second roller  424 , third roller  426  and fourth roller  428 . Housing  10  has second aperture (not shown) whereby bath belt  420  and fourth roller  428  extend outward from housing  10 . Cluster cylinder  430  has a plurality of cluster cylinder arms  432 . Cluster cylinder  430  is rotatably engaged to housing  10 . 
     FIG.  2  and FIG. 3 depict first bin  310 . First bin  310  has first bin side  314 , second bin side  318 , third bin side  316 , fourth bin side  320 , bin top  312 , first connector  322 , bin bottom  324  and a plurality of bin holes  326 . First bin  310  is representative of second bin  320 , third bin  330  and fourth bin  340  and, hereinafter, references to first bin  310  shall include references to second bin  320 , third bin  330  and fourth bin  340 . 
     FIG. 4 depicts a detailed view of first bin bottom  324  of first bin  310  and bin holes  326 . In the preferred embodiment, bin bottom  324  has approximately 1800 bin holes  326  arranged into an approximate 20×90 pattern with each of said bin holes  326  having an approximate ⅛ inch diameter. In other embodiments, first bin bottom  324  may have any number of bin holes  326 . 
     FIG. 5 depicts machine  100  in operation. Tank  410  is filled with liquid nitrogen. First bin  310 , second bin  320 , third bin  330  and fourth bin  340  are filled with mix  450  which falls through bin holes in bin bottoms as shown in FIG.  3  and FIG. 4 for first bin  310 . In the preferred embodiment mix  450  is an ice cream mix. Alternatively, mix  450  may be flavored water. Further in the alternative, mix  450  may be any milk, cream or water based mix capable of producing a dessert product. When mix  450  contacts the liquid nitrogen in tank  410 , mix  450  freezes into particles. The weight of mix  450  in first bin  310  causes mix  450  to fall in unbroken streams through first bin holes  326  in first bin bottom  324  of first bin  310 . The unbroken liquid streams fall into the liquid nitrogen and freeze into particles  470 . Particles  470  consist of a mixture of roundish particles and irregularly shaped particles including “popcorn.” Particles  470  fall through the liquid nitrogen for a distance of 2-4 inches and come to rest on bath belt  420 . The depth of the liquid nitrogen in tank  410  varies between 2-4 inches because the liquid nitrogen evaporates during the operation, and liquid nitrogen must be added periodically to maintain the depth. As bath belt  420  moves, particles  470  that have landed on bath belt  420  are moved under other falling particles  470 , and a “piling on” effect occurs. This “piling on” effect causes clumping of particles  470 . Furthermore, the “piling on” effect causes masses of particles  470  to rise several inches above bath belt  420 . Bath belt  420  carries particles  470  up and out of the liquid nitrogen. Clumps of particles  470  and masses of particles  470  are broken up by cluster cylinder arms  432  protruding from cluster cylinder  430 . In addition, large particles  470  are broken up by cluster cylinder arms  432  into smaller particles  470 . Particles  470  fall from bath belt  420  onto travel belt  520 . Travel belt  520  is rotatably engaged in post cooler  500 . Clumps of particles  470  are further broken up by falling from bath belt  420  to travel belt  520 . Additional travel belts  520  may be included in post cooler  500  so that clumps of particles  470  will fall from a first travel belt to a second travel belt and then from a second travel belt to a third travel belt. Each time particles  470  fall, additional clumps of particles  470  that are clumped or stuck together are further broken up. 
     Referring to FIG. 6A, when particles  470  emerge from post cooler  500 , particles  470  fall off travel belt  520  onto guide  600 . Guide  600  is made from base  610 , a first guide  612 , a second guide  614 , a third guide  616  and a fourth guide  618 . First guide  612  and second guide  614  are fixedly engaged to base  610  creating a channel so that particles  470  falling from travel belt  520  will be guided between first guide  612  and second guide  614  to first opening  624  at the end of base  610 . Third guide  616  and fourth guide  618  are fixedly engaged to base  610  creating a channel so that particles  470  falling from travel belt  520  will be guided between third guide  616  and fourth guide  618  to second opening  626  at the end of base  610 . Base  610  is slanted out away from post cooler  500 . Particles  470  are manually pushed off the slanted surface of guide  600  into first insulated chest  630  and second insulated chest  632 . 
     Referring to FIG. 6B, first insulated chest  630  and second insulated chest  632  are removed from beneath guide  600  and scoop  640  is used to transfer particles  470  to a plastic bag (not shown) by pouring the contents of scoop  640  into the plastic bag. Scoop  640  holds a volumetric gallon. Mark  644  on scoop  642  indicates when a volumetric gallon has been placed into scoop  640 . Title 21 of the Code of Federal Regulations Part 135, Subpart B, Sec. 135.110 states that “ice cream contains not less than 1.6 pounds of total solids to the gallon, and weighs not less than 4.5 pounds to the gallon.” The plastic bags are weighed to ensure that each bag contains at least 4.5 pounds of particles  470 . The plastic bags are sealed using a heat sealing device (not shown). A single small hole is poked in each bag using a stainless steel needle (not shown) in order to allow residual nitrogen gas and expanding air to escape. The plastic bags are placed into a cardboard box (not shown) with six bags per box. The boxes are then placed into a freezer room (not shown) and stored. 
     FIG. 7 depicts a flow chart for the method of rapidly producing cryogenically frozen dessert particles. Referring to FIG. 1-6 and FIG. 7, the process begins ( 702 ). Initially N is set equal to 1, where N equals the number of flavors to be produced. First container  210  is filled with mix  450  ( 706 ). A determination is made as to whether another flavor is to be produced. If another flavor is to be produced, then N is set equal to N+1, the process returns to step  706 , and second container  220  will be filled. In the preferred embodiment, N will not be greater than 4; however, additional containers could be added to increase the number of flavors that can be combined in one production run. If another flavor is not to be produced, then a determination is made as to whether the flow rate is within limits ( 712 ). The mix is pumped from first container  210  (and any other containers that have been filled with mix  450 ) to first bin  310  (and to any other bins receiving mix from a container). The limits are determined for mix  450  so that the depth of mix  450  in filling head  300  is not less than that depth sufficient to cause mix  450  to fall in unbroken streams through first bin holes  326  of first bin  310 . In addition, the upper limit is established so that the depth of mix  450  in filling head  300  will not overflow filling head  300 . If the flow rate is not within limits, then the flow is adjusted ( 714 ). The flow rate may be adjusted either by opening or closing first valve  216  or controlling the pump speed of first container  210  (and likewise for each of the other containers and corresponding valves). If the flow rate is within limits, then the liquid mix is streamed into tank  410  ( 716 ). The depth of liquid nitrogen in tank  410  is monitored ( 718 ) A determination is made as to whether the depth of liquid nitrogen is within limits ( 720 ). If the depth of liquid nitrogen is not within limits, then liquid nitrogen is added to bath ( 722 ). The limits for the depth of liquid nitrogen in tank  410  are that the depth of liquid nitrogen in tank  410  will be greater than or equal to 2 inches above bath belt  420  and less than or equal to 4 inches above bath belt  420 . If the depth of liquid nitrogen is within limits, then additional liquid nitrogen is not added. Next, particles  470  are collected ( 724 ) and particles  470  are bagged ( 726 ). Each bag is weighed ( 728 ). A determination is made as to whether the bag weight is equal to or greater than 4.5 pounds. If the weight is less than 4.5 pounds, then particles are added ( 732 ). If the weight is greater than or equal to 4.5 pounds, then the bag is sealed and placed in a cardboard box ( 734 ). When the box is filled with six bags, the box is sealed and stored ( 736 ). The process stops ( 740 ). It will be understood from the foregoing description that various modifications and changes may be made in the preferred embodiment of the present invention without departing from its true spirit. It is intended that this description is for purposes of illustration only and should not be construed in a limiting sense. The scope of this invention should be limited only by the language of the following claims.