product rd session 5 jan 2013
TRANSCRIPT
-
7/29/2019 Product RD Session 5 Jan 2013
1/21
Product Research & DevelopmentSession 5
Case Study of
Pushcart for Vending Ice-CreamCtd.
Department of Chemical Engineering
2nd
Semester 2012-2013
V. M. Naik
-
7/29/2019 Product RD Session 5 Jan 2013
2/21
Recapitulation of Case Study of a Push Cart for Ice-cream, Which
Was too Heavy; Which Could not Keep Ice-cream Frozen
++
A Combination of Back of the
Envelope Reality Checks,Laboratory Reality Checks, and
Simulation Studies with a Simplified
Theoretical Model Revealed :
1. The so called eutectic coolant wasnot an eutectic at all
2. Even if we had a good eutectic
coolant the push cart would not
perform satisfactorily in aggressive
temperature conditions
Way-forward:
1. Develop thermally efficient pushcart design
2. Develop non - corrosive and non - toxic eutectic system
-
7/29/2019 Product RD Session 5 Jan 2013
3/21
Ideas Evaluated Using the Theoretical Model
Increase Mass of PG-Water
Change the Composition of PG-Water
Use a New Genuine Eutectic Coolant with
Lower Melting temperature Increase Cooling Surface Area by Putting
Frozen Eutectic in Small Ampoules
None of Them Exhibited Satisfactory Performance
-
7/29/2019 Product RD Session 5 Jan 2013
4/21
Ideas Evaluated Using the Theoretical Model
Increase Mass of PG-Water
Change the Composition of PG-Water
Use a New Genuine Eutectic Coolant with
Lower Melting temperature
Increase Cooling Surface Area by Putting
Frozen Eutectic in Small Ampoules
None of Them Exhibited Satisfactory Performance
The Theoretical Model Was No Goodto Solve the Problem!
-
7/29/2019 Product RD Session 5 Jan 2013
5/21
Ideas Evaluated Using the Theoretical Model
Increase Mass of PG-Water
Change the Composition of PG-Water
Use a New Genuine Eutectic Coolant withLower Melting temperature
Increase Cooling Surface Area by Putting
Frozen Eutectic in Small Ampoules
None of Them Exhibited Satisfactory Performance
The Theoretical Model Was No Good
to Solve the Problem!
However the Exercise of Developing the Model
Provided Vital Physical Insights for Creative
Thinking
-
7/29/2019 Product RD Session 5 Jan 2013
6/21
The Novel Design Invention
HEAT SHIELDHEAT SINK
Time (hours)
0 2 4 6 8 10 12 14
Ice-CreamT
emperature(degC)
-21
-20
-19
-18
-17
-16
Heat Sink
Heat Shield
-
7/29/2019 Product RD Session 5 Jan 2013
7/21
Next Challenge
Search for a Non Toxic, Non Corrosive Pure
Chemical, or Develop a Genuine Eutectic System
with High l, Which Melts between ~ 20 and - 26
Deg C
-
7/29/2019 Product RD Session 5 Jan 2013
8/21
A So Called Rigorous Rational Approach Was
Impossible
C1 C2 ..
Cm
L1
L2
.
.
Ln
56 Million Components in
CAS Registry Would Lead to
!256!2
!56
M
M
Binary Combinations
This Was Not a Rational Optimization Problem, Either!
-
7/29/2019 Product RD Session 5 Jan 2013
9/21
This Was a Creative Discovery Problem!
Use ofHeuristic Insights about Phenomenology ofSolid-Liquid Phase Equilibria, SimplifiedTheoretical Thumb Rules, and a Hypothetico-Deductive Approach Was the Best Way Forward.
-
7/29/2019 Product RD Session 5 Jan 2013
10/21
The Magical Non-corrosive Non-toxic Eutectic System
First Ever In The World Of Ice-Creams
E3
Temp
SALT I
WATER
E
SALT II
E21
COMMERCIALEUTECTIC
PREVIOUS
COOLANT(PG 35 %)
NEW
EUTECTIC
DSC
Temperature
-35 -30 -25 -20 -15 -10
HeatFlow
inDSC
New
Eutectic
PG35%
CORROSION
-
7/29/2019 Product RD Session 5 Jan 2013
11/21
Technology Development and Transfer
Involved Many Additional Steps:
Safety Clearance for the New Eutectic
Securing Intellectual property Rights
Building a Prototype Push Cart Testing the Push Cart Under Laboratory Torture
Conditions
Debugging the Technology through Next Cycle of
Development Market Trials
-
7/29/2019 Product RD Session 5 Jan 2013
12/21
Full-Scale Prototype Trials Revealed That Mark I
Needed Improvements
-
7/29/2019 Product RD Session 5 Jan 2013
13/21
Demonstration Of The Performance In The Field
-
7/29/2019 Product RD Session 5 Jan 2013
14/21
The Happy End
-
7/29/2019 Product RD Session 5 Jan 2013
15/21
New Challenge :Bigger Issues Faced by Ice-Cream Distribution
& Retailing Technologies
> 4KW H energy spent during vending,
per kg ice-cream sold
11 Kg weight pushed for ~ 5 hrs, during
vending, per kg of ice-cream sold
CAN WE VEND ICE-CREAM AT 1/2 THEENERGY CONSUMPTION, USING
PUSHCARTS WHICH WEIGH 1/2
Chart 3
-
7/29/2019 Product RD Session 5 Jan 2013
16/21
New Challenge :Bigger Issues Faced by Ice-Cream Distribution
& Retailing Technologies
> 4KW H refrigeration energy spent to
enable vending, per kg ice-cream sold
11 Kg weight pushed for ~ 5 hrs, during
vending, per kg of ice-cream sold
CAN WE VEND ICE-CREAM AT 1/2 THE
ENERGY CONSUMPTION, USINGPUSHCARTS WHICH WEIGH 1/2
Key Issue : Reduction in Cooling Requirement;
Reduction in Heat Ingress During Vending
-
7/29/2019 Product RD Session 5 Jan 2013
17/21
Modeling Had Revealed That > 85 % Heat Ingress
Was Through Walls of Container
What Could Be the Way Forward?
-
7/29/2019 Product RD Session 5 Jan 2013
18/21
Modeling Revealed That > 85 % Heat Ingress Was
Through Walls of Container
Way Forward: Search For a Super Insulation
Fi ld T i l f V S i l t d
-
7/29/2019 Product RD Session 5 Jan 2013
19/21
Field Trial of Vacuum Super-insulated
Vending Pushcart
LONG
THIN
FRP NECK
10e-6 TORR
VACUUM
ZIRCONIUMGETTER
AMPOULE
ARRAYS
METAL
CONTAINERS
LID
SUPPORT
MULTILAYER
SUPER-INSULATION
BASIC CONCEPT
-
7/29/2019 Product RD Session 5 Jan 2013
20/21
Superior Performance at 1/3rd Refrigeration
Requirement
-25
-23
-21
-19
-17
-15
-13
-11
0 2 4 6 8 10 12 14
Vending Time,Hrs
Ice-creamT
emperature,D
egC
Current Best Practice
New Insulation
Technology
Jaipur
2000
-
7/29/2019 Product RD Session 5 Jan 2013
21/21
Next Session
Soft Learnings from the Case Study of
Pushcart for Vending Ice-Cream