Abstract:
A chiller for reducing the temperature of previously eviscerated whole birds and the like, includes a tank having a bird outlet end, a bird inlet end, an inlet end plate, an outlet end plate, and a water reservoir between the ends. The poultry chiller also includes water circulation means for introducing water into the reservoir at the bird outlet end of the tank, draining water at the bird inlet end of the tank, and forming a movement of water generally from the bird outlet end toward the bird inlet end of the tank. The chiller further includes a motive device for urging the birds from the bird inlet end to the bird outlet end of the tank, the motive device being in driven relationship with a power means. A transverse wall having a lower portion, a central portion, and a top edge, is disposed at the bird inlet end of the tank substantially parallel to the inlet end plate such that a sump is formed between the lower portion of the transverse wall and the inlet end plate.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a division of U.S. patent application Ser. No. 10/350,443 filed Jan. 24, 2003 now U.S. Pat. No. 6,658,886. 
    
    
     TECHNICAL FIELD 
     The present invention generally relates to poultry chillers for reducing the temperature of whole birds after the birds have been eviscerated on a poultry processing line. More particularly, the invention relates to a sump compartment formed integrally with the poultry chiller. 
     BACKGROUND OF THE INVENTION 
     It is desirable to reduce the temperature of chickens and other types of poultry after the birds have been processed, or defeathered, eviscerated and are otherwise oven-ready before the birds are packaged for delivery to the retail customer. A conventional poultry chiller  10 , as shown in  FIG. 1 , is the “auger-type” poultry chiller  10  which includes a trough-shaped, half-round tank  12  filled with cold water in which an auger  20  provides positive movement of the birds through the tank  12 . The cooling effect for the water and the birds was originally provided by crushed ice added to the water. As shown in  FIG. 2 , later designs include a counter-flow recirculation of the chilled water through the tank  12  with the water being chilled by a refrigerated heat exchanger  24  instead of using ice. The water is introduced at one end of the tank  12 , the outlet end  16 , and flows progressively to the other end, the inlet end  14 , where it is recirculated through the heat exchanger  24 . In the mean time, the birds are continually delivered to the inlet end  14  of the tank  12  and moved under the influence of the rotating auger  20  in the counter-flow direction and are lifted from the outlet end  16  of the tank  12  for further processing. A prior art poultry chiller of this general type is disclosed in U.S. Pat. No. 5,868,000, and a heat exchanger for the water refrigeration system suitable for this purpose is shown in U.S. Pat. No. 5,509,470. 
     As noted, chilled water is added to the tank  12  at the outlet end  16 , where the birds have been chilled and are being lifted out of the tank  12 . The water flows in the opposite direction of movement of the birds and the auger  20  of the tank  12 , thereby insuring that the birds are always flowing into the cleanest and coldest water and that there is always a temperature drop between the temperature of each bird and the temperature of the water about each bird. 
     During operation, the recirculation pump  22  removes the warmer water from the inlet end  14  of the tank  12 . As shown in  FIG. 2 , a suction header  30  connects the inlet of recirculation pump  22  to a sump  26 . The sump  26  is positioned at an overflow recess in the sidewall of the chiller tank  12  and is below the typical operational water level within the tank  12 . A typical sump can measure about 4 feet high and from 2 to 4 feet in width. The sump  26  helps to insure that the inlet of the suction header  30  does not become blocked by birds in the tank and that adequate chill water is present for the recirculation pump  22  to maintain proper suction. A suction valve  42  is disposed in the suction header  30  in close proximity to the sump  26 . The outlet of recirculation pump  22  discharges the chill water into a fill header  32  that includes a heat exchanger  24  for chilling the water. After having passed through the heat exchanger  24 , the chill water continues down the fill header  32  and enters the tank  12  at the outlet end  16 . A fill valve  44  is disposed in the fill header in close proximity to the tank  12 . 
     Side mounted sumps, such as the sump  26 , tend to cause operational problems in typical chillers  10 . For example, although the warmer water side discharge opening in the wall of tank  12  that is in fluid communication with the side mounted sump  26  is typically rather large, and the sump is approximately 2 to 4 feet wide and 4 feet tall, it is possible for birds to migrate to this portion of the tank  12  wall and be sucked up against the edge of the opening without passing through the opening. If enough birds migrate to the opening into the side mounted sump  26 , partial blockage of the access of recirculation water to the suction header  30  can occur. In turn, the performance of the recirculation pump  22  is affected in that chill water flow rate throughout the poultry chiller  10  is reduced. Eventually, the birds will be urged away from the opening to the side mounted sump  26  by the outer periphery of an oncoming flight of the auger  20 . However, because full 360° flights on typical augers  20  are frequently longitudinally displaced by 4 feet or more and the auger  20  rotated on the order of 1 turn every 4 minutes, the birds partially blocking the side mounted sump  26  inlet can remain there for extended periods of time prior to being displaced and the reduced flow of recirculation water continues. 
     Also, as previously noted, the chill water becomes progressively warmer as it moves from the outlet end  16  to the inlet end  14  of the tank  12 . Generally, the temperature of the water in front of a flight is colder than the water behind the flight, as much as 2° F. As the auger  20  rotates, the last auger flight funnels water into the side mounted sump  26  sometimes from in front of the flight and other times from behind the flight as the flight passes by the warmer water side discharge opening. This means that when the individual flight  20 A funnels water into the side mounted sump primarily from behind the individual flight  20 A, the inlet temperature of chill water at the heat exchanger  24  will be warmer than when the majority of water funneled into the side mounted sump  26  is from in front of the individual flight  20 A. These temperature variations mean that frequent adjustments must be made to the heat exchanger  24  to maintain a constant chill water temperature in the fill header  32 . 
     To maintain proper sanitary conditions, poultry chillers  10  typically are cleaned on a daily basis. As shown in  FIG. 2 , prior art poultry chillers  10  include a clean-up tank  28  that holds cleaning solution that is used for cleaning the chill water circulation system of the poultry chiller  10  during shut down of the chiller. Usually, the clean-up tank  28  can be mounted either to the side of the poultry chiller  10  in a manner similar to that of the sump  26 , or it may be free standing. Clean-up tanks  28  typically are on the order of 300 to 500 gallons and are connected to the chill water system by a recirculation header  34  and control valves  46  and  48 . As shown in  FIG. 2 , a first portion  34   a  of the recirculation header  34  taps into the suction header  30  between the suction valve  42  and the recirculation pump  22 . A recirculation suction valve  46  is used to either line up or isolate the clean-up tank  28  from the suction header  30 . A second portion  34   b  of the recirculation header  34  taps into the fill header  32  upstream of the fill valve  44  and includes the recirculation fill valve  48  that can be used to either line up or isolate the clean-up tank  28  from the fill header  32 . 
     To clean the poultry chiller  10 , the tank  12  is drained of water and birds and cleaning personnel clean the auger  20  and the inside of the tank  12  with hot water and cleaning solution under high pressure. The chill water system is cleaned by shutting the suction valve  42  and the fill valve  44  to isolate the chill water system from the tank  12 . A mixture of cleaning solution and hot water is mixed in the clean-up tank  28  by cleaning personnel. The clean-up tank  28  is then aligned with the chill water system by opening the recirculation suction valve  46  and the recirculation fill valve  48 . The recirculation pump  22  is now aligned to take suction off the clean-up tank  28 , thereby pumping the solution of hot water and cleaning solution through the suction header  30 , recirculation pump  22 , heat exchanger  24 , fill header  32 , and the recirculation header  34 . Note however, the portion of the suction header  30  disposed between the suction valve  42  and the side mounted sump  26 , indicated by reference numeral  50 , is not cleaned during recirculation of the cleaning solution from the clean-up tank  28 . As such, this portion of the suction header  30  must be cleaned by cleaning personnel, as is the side mounted sump  26 . 
     A number of problems are common to the side mounted sump  26  and the clean-up tank  28  when the clean-up tank  28  is mounted directly to the side of the tank  12 . When mounted to the side of the tank  12 , the sump  26  and clean-up tank  28  interfere with the routine of the cleaning personnel, and take up space along the side of the poultry chiller  10  which is frequently at a premium. Also, side-mounting the sump  26  and clean-up tank  28  can interfere with the placement of a cat walk (not shown) along the upper edge of the tank  12 , as is common in the manufacture of poultry chillers  10 . Also, manufacturing the sump  26  and the clean-up tank  28  adds to the overall cost of producing the poultry chiller  10  in that the construction of the typically rectangular boxes requires significant man hours. Additionally, because the clean-up tank  28  is independent of the sump  26 , the suction portion  34 A of the recirculation header  34  and the recirculation inlet valve  46  are required. If a single tank were used that served both functions, a common portion of suction piping and a single isolation valve could be used. 
     From the foregoing, it can be appreciated that it would be desirable to have an integral sump compartment for use for with the poultry chiller that can function as both a sump for the recirculation pump suction and as a clean-up tank. Thus, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies. 
     SUMMARY OF THE INVENTION 
     Briefly described, an embodiment of a poultry chiller for reducing the temperature of previously eviscerated whole birds and the like, includes a tank having a bird outlet end, a bird inlet end, an inlet end plate, an outlet end plate, and a water reservoir between the ends. The poultry chiller also includes water circulation means for introducing water into the reservoir of the tank at the bird outlet end of the tank, draining water at the bird inlet end of the tank, and forming a movement of water generally from the bird outlet end toward the bird inlet end of the tank. A motive device for urging the birds from the bird inlet end of the tank to the bird outlet end of the tank is included, the motive device being in driven relationship with a power means. A transverse wall having a lower portion, a central portion, and a top edge is disposed at the bird inlet end of the tank and is substantially parallel to the inlet end plate such that a sump is formed between the lower portion of the transverse wall and the inlet end plate. 
     Other systems, methods, features, and advantages of the present poultry chiller will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the poultry chiller, and be protected by the accompanying claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The poultry chiller can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principle of the poultry chiller. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
         FIG. 1  is a perspective view of a prior art poultry chiller. 
         FIG. 2  is a top view schematic diagram of a prior art poultry chiller. 
         FIG. 3  is a top view schematic diagram of a poultry chiller including an embodiment of an integral sump compartment in accordance with the present invention. 
         FIG. 4  is a perspective view of a bird inlet end of a poultry chiller including an embodiment of an integral sump compartment in accordance with the present invention. 
         FIG. 5  is a side perspective partially cut-away view of a bird inlet end of a poultry chiller including an embodiment of an integral sump compartment in accordance with the present invention. 
         FIG. 6  is a side perspective partially cut-away view of a bird inlet end of a poultry chiller including an embodiment of an integral sump compartment in accordance with the present invention. 
     
    
    
     Reference will now be made in detail to the description of the poultry chiller as illustrated in the drawings. While the poultry chiller will be described in connection with these drawings, there is no intent to limit the poultry chiller to the embodiment or embodiments disclosed therein. On the contrary, the intent is to cover all alternatives, modifications, and equivalents included within the spirit and scope of the poultry chiller as defined by the appended claims. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now and more detailed to the drawings, in which like numerals indicate like parts throughout the several views,  FIG. 3  illustrates a schematic diagram of a poultry chiller  100  including an integral sump compartment  160 , as viewed from the top. The poultry chiller  100  includes a semi-cylindrical water reservoir or tank  102 , an auger  120  having a helical blade structure  124  disposed about an auger shaft  122 , and a water circulation means, or chill water system  130 . 
     The auger  120  is positioned longitudinally in the tank  102  and supported at its opposing ends. An electric motor or other conventional power means (not shown) is provided to rotate the auger  120 . The auger  120  includes a helical blade structure  124  formed around the auger shaft  122 . During operation of the poultry chiller  100 , birds are urged from the bird inlet end  104  of the tank  102  to the bird outlet end  106  of the tank  102  as the chill water flows in the opposite direction. As shown, the poultry chiller  100  includes an integral sump compartment  160 , according to the present invention. The integral sump compartment  160  is disposed between the inlet end plate  108  and the transverse wall  150 . The above noted chill water system  130  includes a recirculation pump  131 , a heat exchanger  148 , a suction header  136  having a suction valve  142 , a fill header  138  having a fill valve  144 , and a recirculation header  140  having a recirculation valve  146 . The suction header  136  takes suction from the integral sump compartment  160  and the recirculation header  140  is in fluid communication with both the fill header  138  and the integral sump compartment  160 , such that the contents of the integral sump compartment  160  can be continually recirculated by the recirculation pump  131 . 
     Referring now to  FIG. 4 , a preferred embodiment of the transverse wall  150  according to the present invention is shown. The transverse wall  150  includes a lower portion  152 , a central portion  154 , and a top edge  156 . The transverse wall  150  is disposed at the bird inlet end  104  of the poultry chiller  100  such that the transverse wall  150  is substantially parallel to the inlet end plate  108 . As shown, the outer periphery  155  of the transverse wall  150  is substantially similar to the cross section of the tank  102 . The lower portion  152  of the transverse wall forms a water-tight solid partition between the integral sump compartment  160  ( FIG. 3 ) and the remainder of the tank  102 . The central portion  154  of the transverse wall  150  defines a water passage for allowing the free flow of water from the portion of the tank  102  that includes the helical blade structure  124  ( FIG. 3 ) into the integral sump compartment  160 . As well, the central portion  154  preferably includes an auger aperture  157  configured to allow the auger shaft  122  to extend therethrough. As shown, the water passage formed in the central portion  154  is comprised of a plurality of apertures, such as radial slots, that allow the free flow of water therethrough while preventing the passage of birds from the portion of the tank  102  that is used to chill the birds into the integral sump compartment  160 . As such, the central portion  154  prevents the birds from potentially blocking the inlet to the suction header  136 . Preferably, a stiffening member  158  is provided along the top edge  156  to lend rigidity to the transverse wall  150 . Support bars  151  can be used to help secure the transverse wall  150  within the tank  102 . 
       FIG. 5  is perspective side view of the bird inlet end  104  of a poultry chiller  100  including a transverse wall  150 . For ease of description, a side wall of the tank  102  has been omitted. Dashed line  103  indicates a typical water level in the poultry chiller  100  that is maintained while chilling birds within the tank  102 . As shown, the water level during regular operations is maintained preferably above the auger shaft  122 . Preferably, a substantial portion of the central portion  154  of the transverse wall  150  is disposed below the normal water lever  103 . As such, the transverse wall  150  does not impede the flow of water from the bird outlet end  106  ( FIG. 3 ) to the bird inlet end  104  of the tank  102 . Therefore, the recirculation pump  131  is able to take suction through the suction header inlet  137 , which is disposed within that portion of the tank  102  that acts as the integral sump compartment  160 . 
     Typically, poultry chillers  100  are cleaned daily, or after each operational run. First, the tank  102  is drained through the tank drain  114 . As shown, the tank drain  114  is disposed in the lower portion  152  of the transverse wall  150  and extends through the integral sump compartment  160  and through the inlet end plate  108 . The tank drain  114  is not in fluid communication with the integral sump compartment  160 , and therefore drains the entire tank  102  with the exception of that portion disposed between the lower portion  152  of the transverse wall  150  and the inlet end plate  108 , which comprises the integral sump compartment  160 . That portion of the tank  102  which functions as the integral sump compartment  160  is indicated by dashed line  153 . Preferably, the integral sump compartment  160  will have drain fittings (not shown) that allow the integral sump compartment  160  to be drained independently of the remainder of the tank  102 . Numerous configurations of the water passage through the central portion  154  are possible. Note, the surface level of the volume of water within integral sump portion  160  will be determined by the lower most aperture of the water passage. 
     As shown, the tank drain  114  extends through the integral sump compartment  160  and is covered by a false bottom  118 . The false bottom  118  simplifies the cleaning of the integral sump compartment  160  by reducing the number of surfaces that can trap foreign matter. As well, the poultry chiller  100  includes deflector means for preventing birds from entering the integral sump compartment  160  during operations, and thereby possibly blocking the suction header inlet  137 . During operations, it is possible for the helical blade structure  124  ( FIG. 3 ) to urge a bird upwardly along the surface of the transverse wall  150 , thereby increasing the risk that the bird will be pushed over the top edge  156  of the transverse wall  150  and into the integral sump compartment  160 . Preferably, the deflector means, shown as a grill  159 , can be disposed between the top edge  156  of the transverse  150  and the inlet end plate  108 . The grill  159  not only prevents those birds that are disposed in the chiller  100  from entering the integral sump compartment  160 , but also prevents birds that are frequently moved above the poultry chiller  100  during production from being inveterately dropped into the integral sump tank  160 . 
     OPERATION 
     During a typical processing run for chilling birds, the birds are placed in the bird inlet end  104  of the poultry chiller  100  on the auger side of the transverse wall  150 . The auger  120  is rotated such that the helical blade structure  124  engages the birds, thereby urging them from the bird inlet end  104  to the bird outlet end  106  of the poultry chiller  100 . As the birds are urged from the bird inlet end  104  to the bird outlet end  106 , chill water flows in the opposite direction. The counter flow of chilled water opposite to that of the birds insures that the birds are always flowing in the cleanest and coldest possible chill water, and that a temperature differential is always experienced by the birds relative to the chill water as the birds move from the bird inlet end  104  to the bird outlet end  106 . Once the chill water has traveled the length of the helical blade structure  124 , it then flows through the water passage in the transverse wall  150  and into the integral sump compartment  160 . The chill water is then removed from the integral sump compartment  160  and recirculated back to the bird outlet end  106  of the poultry chiller  100 , where it is then reintroduced into the tank  102 . The recirculation pump  131  takes suction on the chill water by way of the suction header  136 , which includes a suction header inlet  139  disposed in the integral sump compartment  160 . The recirculation pump  131  then discharges the chill water through a outlet  134  into the fill header  138 , which includes a heat exchanger  148  for regulating the temperature of the chill water. From the heat exchanger  148 , the chill water travelers through the fill header  138  and into the bird outlet end of the tank  106 . In this manner, chill water is continuously recirculated through the poultry chiller  100  during routine chilling operations. 
     In order to maintain sanitary operating conditions, poultry chillers  100  are routinely cleaned. After a production run has been completed, any straggler birds are removed from the chiller  100  and the tank  102  is drained through the tank drain  114 . In an preferred embodiment of the present invention, draining the tank  102  through the tank drain  114  will leave chill water remaining in the integral sump compartment  160 , that volume of water being indicated in  FIG. 5  by dashed line  153 . The integral sump compartment  160  will also be drained through independent drain valves (not shown) prior to cleaning the poultry chiller  100 . After the tank  102  has been drained, clean-up personnel spray down the tank  102  and the auger  120  with hot water, to be followed by a rinse down with cleaning solution, and a final rinse with water. The integral sump compartment  160  and chill water system  130  are cleaned by recirculating cleaning solution through the chill water system  130  using the recirculation pump  131 . 
     To clean the integral sump compartment  160  and chill water system  130 , clean-up personnel place cleaning solution in the empty integral sump compartment  160  and then fill the remaining volume of the integral sump compartment  160  with the appropriate amount of hot water. The integral sump compartment  160  is filled until water starts to flow out of the integral sump compartment  160  and into the tank  102  through the water passage of the central portion  154  of the transverse wall  150 . After an adequate amount of cleaning solution and water has been mixed in the integral sump compartment  160 , the fill valve  144  is closed and the recirculation valve  146  is opened to align the outlet  134  of the recirculation pump  131  with the integral sump compartment  160 . With the chill water system  130  piping so aligned, the recirculation pump  131  is started. Typically, the recirculation pump  131  is run for 30 to 40 minutes, thereby recirculating cleaning solution through the suction header  136 , the recirculation pump  131 , the heat exchanger  148 , a portion of the fill header  138 , and the recirculation header  140 . After the cleaning solution has been circulated for an adequate amount of time, the recirculation pump is secured and the cleaning solution is drained from the integral sump compartment  160 . The integral sump compartment  160  is then filled with fresh water which is then recirculated through the chill water system  130  to remove any residual cleaning solution. After draining the integral sump compartment  160 , the recirculation valve  146  is closed and the fill valve  144  is opened, thereby realigning the fill header  138  with the bird outlet end  106  of the tank  102 . 
     Preferred embodiments of the integral sump compartment  160  according to the present invention offer a number of advantages over existing configurations of sumps and clean-up tanks. Because embodiments of the present integral sump tank  160  serve as both a sump for the recirculation pump  131  and as a clean-up tank, only the suction header  136  is necessary for both normal chilling operations and clean-up operations. Therefore, the present integral sump compartment  160  reduces the amount of piping, fittings, and valves, required for these operations in existing systems. For example, existing clean up tanks  28  (FIG.  2 ), whether side-mounted or remotely located from the tank  102 , require at least one extra run of piping and one extra valve ( 34   a  and  46 , respectively) in order to be aligned with a suction header, as shown in FIG.  2 . Also, as described above, clean-up operations using the integral sump compartment  160  clean the entire suction header  136 . This reduces the expense and man hours required for clean-up operations in that manual cleaning of portions of the suction header is not required, as in existing systems. Also, embodiments of the integral sump compartment  160  of the present invention do not interfere with the placement of cat walks along the tank  102  and do not require excess floor space because the integral sump compartment is disposed at the bird inlet end  104  of the tank  102 . The water passage formed in the central portion  154  of embodiments of the transverse wall  150  also creates a larger water return area for the chill water system  130  than do existing side mounted sumps. Therefore, the likelihood that birds will possibly block the water passage is reduced as is the potential for fluctuation of the inlet water temperatures to the heat exchanger  148 . 
     Another preferred embodiment of a poultry chiller  100  having an integral sump compartment  160  includes an inlet chute  162  as shown in FIG.  6 . Preferably, the inlet chute runs from the inlet end plate  108  to the transverse wall  150  and assists in loading birds into the poultry chiller  100 . As shown, the inlet chute  162  is separated from the integral sump compartment  160  by a longitudinal wall  164  to prevent birds from entering the integral sump compartment  160 . 
     It should be emphasized that the above-described embodiments of the present poultry chiller  100  having an integral sump compartment  160 , particular, any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the poultry chiller  100 . Many variations and modifications may be made to the above-described embodiments of the poultry chiller  100  without departing substantially from the spirit and principles of the poultry chiller  100 . All such modifications and variations are intended to be included herein within the scope of this disclosure of the poultry chiller  100  and protected by the following claims.