Systems and methods for controlling water quality in food processing

Abstract

A chiller bath includes a tank for holding a volume of chiller water; a dosing system for dosing a first solution and a second solution into the chiller water, arranged to create a plurality of zones within the volume of water, wherein each zone has a higher concentration of either the first or the second solution than surrounding portions of the volume of water; and a meat or poultry immersion arrangement for immersing and moving carcasses in the chiller water. A method for reducing bacterial load on meat or poultry includes generating a plurality of zones within a chiller bath containing water by dosing a source of alkalinity and antimicrobial into the water, wherein the plurality of zones comprises at least one alkaline zone with a pH above 8.5, and at least one antimicrobial zone with pH below 8.5; and submersing meat or poultry in the bath. The zones can also be generated using spray nozzles in a meat or poultry operation.

1 . (canceled) 
     
     
         2 . A chiller bath comprising:
 a tank for holding a volume of chiller water, the tank comprising a bottom and walls defining a first end and a second end;   one or more water lines operatively connected to one or more pumps for pumping water into the tank and creating a direction of flow of water from the first end to the second end, the one or more water lines comprising a make-up water inlet at the first end of the tank;   a dosing system for dosing a first solution and a second solution into the chiller water, the dosing system arranged to create a plurality of zones within the volume of water, wherein each zone has a higher concentration of either the first or the second solution than surrounding portions of the volume of water; and   a meat or poultry immersion arrangement for immersing and moving meat or poultry carcasses in the chiller water in a flow direction from the second end of the tank to the first end of the tank.   
     
     
         3 . The chiller bath of  claim 2 , further comprising a drain at the second end of the tank and a recirculation line for circulating the chiller water in the tank, the recirculation line having a first end in fluid communication with the drain and a second end disposed at the first end of the tank, the recirculation line comprising a pump arranged to create a recirculating water flow from the first end to the second end of the recirculation line and from the first end of the tank to the second end of the tank. 
     
     
         4 . The chiller bath of  claim 3 , wherein the dosing system comprises a first dosing pump operatively connected to a first inlet, and a second dosing pump operatively connected to a second inlet, wherein the first and second inlets are in the recirculation line. 
     
     
         5 . The chiller bath of  claim 3 , wherein the dosing system comprises a first dosing valve operatively connected to a first inlet, and a second dosing valve operatively connected to a second inlet, wherein the first inlet is in the recirculation line and the second inlet is in the tank adjacent the first end. 
     
     
         6 . The chiller bath of  claim 2 , wherein the dosing system comprises a first dosing valve operatively connected to a first inlet, and a second dosing valve operatively connected to a second inlet, wherein the first and second inlets are in the one or more water lines. 
     
     
         7 . The chiller bath of  claim 2 , wherein the dosing system comprises a first dosing valve operatively connected to a first inlet, and a second dosing valve operatively connected to a second inlet, wherein the first inlet is in the one or more water lines and the second inlet is in the tank adjacent the first end. 
     
     
         8 . The chiller bath of  claim 7 , wherein the one or more water lines comprises a cold water line connected to a cooling system, wherein the dosing system comprises a first dosing valve operatively connected to a first inlet, and a second dosing valve operatively connected to a second inlet, and wherein one or both of the first and second inlets are in the cold water line. 
     
     
         9 . The chiller bath of  claim 2 , wherein the dosing system comprises a first dosing valve operatively connected to a first inlet, and a second dosing valve operatively connected to a second inlet, wherein the first and second inlets are in the tank adjacent the first end. 
     
     
         10 . The chiller bath of  claim 2 , wherein the dosing system comprises a first dosing valve operatively connected to a first inlet, and a second dosing valve operatively connected to a second inlet, wherein the first inlet comprises a plurality of nozzles positioned on a spray bar extending across the tank in a direction transverse to the direction of flow of water. 
     
     
         11 . The chiller bath of  claim 2 , wherein the dosing system comprises a first dosing valve operatively connected to a first inlet, and a second dosing valve operatively connected to a second inlet, wherein the first and second inlets are positioned along the bottom or walls of the tank within the volume of chiller water. 
     
     
         12 . The chiller bath of  claim 2 , wherein the dosing system comprises a first dosing valve operatively connected to a first inlet, and a second dosing valve operatively connected to a second inlet, wherein each of the first and second inlets comprise a plurality of inlet ports disposed along the walls and the bottom of the tank. 
     
     
         13 . The chiller bath of  claim 2 , wherein the dosing system comprises a first dosing valve operatively connected to a first inlet, and a second dosing valve operatively connected to a second inlet, wherein each of the first and second inlets comprise a plurality of inlet ports disposed in a U-shaped area along the walls and the bottom of the tank, wherein the U-shaped area approximately corresponds to a cross section of the tank in a direction transverse to the recirculating water flow. 
     
     
         14 . The chiller bath of  claim 2 , wherein the first solution is a peracid. 
     
     
         15 . The chiller bath of  claim 14 , wherein the peracid comprises peracetic acid and creates at least one peracid zone. 
     
     
         16 . The chiller bath of  claim 15 , wherein the pH of the at least one peracid zone is about 4 to about 8.5. 
     
     
         17 . The chiller bath of  claim 15 , wherein the second solution is a source of alkalinity. 
     
     
         18 . The chiller bath of  claim 17 , wherein the source of alkalinity creates at least one alkaline zone. 
     
     
         19 . The chiller bath of  claim 18 , wherein the alkaline zone has a pH of about 8.5 to about 13. 
     
     
         20 . The chiller bath of  claim 14 , wherein the peracid has a concentration of about 25 to about 150 ppm within the peracid zone when measured under acidic conditions. 
     
     
         21 . The chiller bath of  claim 17 , wherein the peracid is added continuously and the source of alkalinity is added intermittently. 
     
     
         22 . The chiller bath of  claim 17 , wherein the peracid is added continuously, the source of alkalinity is added continuously, or both. 
     
     
         23 . The chiller bath of  claim 17 , wherein the source of alkalinity and the peracid are added alternatingly or intermittently. 
     
     
         24 . The chiller bath of  claim 17 , wherein the source of alkalinity and the peracid are added into a water input line. 
     
     
         25 . The chiller bath of  claim 17 , wherein the source of alkalinity is added at intervals determined based on a flow rate of water in the chiller and volume of the chiller. 
     
     
         26 . The chiller of  claim 17 , wherein the peracid is added at intervals determined based on a flow rate of water in the chiller and volume of the chiller. 
     
     
         27 . The chiller bath of  claim 17 , wherein the source of alkalinity and the peracid are added to create plug flows of source of alkalinity and of peracid in the water input line. 
     
     
         28 . The chiller bath of  claim 2 , wherein the meat or poultry carcasses are moved in the chiller bath in a first direction, and the plurality of zones move in a second direction opposite of the first direction. 
     
     
         29 . The chiller bath of  claim 18 , wherein the chiller bath comprises from one to four peracid zones and from one to four alkaline zones.