Product RD Session 5 Jan 2013

7/29/2019 Product RD Session 5 Jan 2013

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Product Research & DevelopmentSession 5

Case Study of

Pushcart for Vending Ice-CreamCtd.

Department of Chemical Engineering

2nd

Semester 2012-2013

V. M. Naik


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


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


4/21




Use a New Genuine Eutectic Coolant with

Lower Melting temperature

Increase Cooling Surface Area by Putting



The Theoretical Model Was No Goodto Solve the Problem!


5/21




Use a New Genuine Eutectic Coolant withLower Melting temperature

Increase Cooling Surface Area by Putting



The Theoretical Model Was No Good

to Solve the Problem!

However the Exercise of Developing the Model

Provided Vital Physical Insights for Creative

Thinking


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


7/21

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


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!


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.


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


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


12/21

Full-Scale Prototype Trials Revealed That Mark I

Needed Improvements


13/21

Demonstration Of The Performance In The Field


14/21

The Happy End


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


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


17/21

Modeling Had Revealed That > 85 % Heat Ingress

Was Through Walls of Container

What Could Be the Way Forward?


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


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


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


21/21

Next Session

Soft Learnings from the Case Study of

Pushcart for Vending Ice-Cream

Documents

Product RD Session 5 Jan 2013