CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuing application claiming the benefit of U.S. application Ser. No. 13/068, 683 filed 17 May 2011. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates generally to an apparatus for the rapid chilling of food products and a method for seamless retrofitting of the apparatus to existing walk-in cooler arrangements. 
       BACKGROUND OF THE INVENTION 
       [0003]    Increased regulation in the food service industry has forced kitchens to meet new HACCP (Hazard Analysis and Critical Control Point) requirements regarding the rapid cooling of prepared foods for storage by large scale food service operations. Such operations include, for example, commissaries, hospitals, schools, prisons and correctional institutions, airport in-flight kitchens, convention centers, hotel banquets, cruise ships, and business cafeterias, to name a few. The term “cook-chill” is often used to describe a process of cooking or preparing food (usually in large volume) and then chilling it for refrigerated storage, to be reheated and served at a later time, typically within a few days. 
         [0004]    Efficient and rapid cooling of food generally prolongs storage life and therefore minimizes cooking and food preparation activities. This enables food preparation to be performed with a smaller staff and at convenient times, rather than requiring lengthy preparation before every mealtime. By employing a cook-chill process, large volumes of food can be prepared by skilled chefs and kitchen staff working ordinary day shifts, and the food can be readily available for night shift or weekend meals by simple reheating. 
         [0005]    Rapid chilling is needed to prevent irreversible deterioration of prepared foods. When left at the warm “danger zone” (temperatures usually in the range of 45.degree. to 140.degree.), cooked food deteriorates quickly due to the action of organisms and enzymic and chemical reactions. A reduction in the storage temperature slows the exponential multiplication of bacteria and other microorganisms and also slows the chemical and enzymic reactions. At normal refrigeration temperatures reactions and bacteria growth still take place, but at a much slower rate. 
         [0006]    Rapid chilling of cooked food maximizes shelf life without sacrificing its quality and physical appearance. Existing food safety guidelines require that certain hot food products be chilled from cooking temperatures of 140.degree. F. to 40.degree. F. in a specific period of time, typically about 90 minutes. A standard refrigerated room or storage refrigerator/freezer is designed for storage of food products, and is incapable of lowering the food product&#39;s initial temperature with sufficient rapidity to ensure against bacterial growth and chemical reactions. 
         [0007]    All commercial kitchens have one or more cold storage units including a walk-in cooler or a walk-in freezer or a combination of both. However, space limitations often limit the options for location of rapid chilling devices. Stand alone rapid chiller systems are often too large and sacrifices must be made of the size of the chilling system for installation in a limited space. 
         [0008]    It is therefore needed a Modular Chiller System that can be retrofitted to an existing cooler configuration through a seamless modular integration. 
         [0009]    It is further needed a standalone modular chiller system, more portable, and independent of the larger refrigeration system. 
       SUMMARY OF THE INVENTION 
       [0010]    The present invention , in one aspect, relates to a rapid chiller device, or “blast-chiller”, having separate novel components that are integrated into a Modular Chiller System when retrofitted to and existing walk-in cooler or refrigeration space. In this embodiment the Modular Chiller System is a separate section of an existing larger walk-in cooler or refrigerator. The system may also operate as a standalone system, existing independent of a larger refrigeration system. 
         [0011]    The method of integrating the Modular Chiller System into an existing walk-in cooler comprises the steps of 1.) selecting a portion of an existing walk-in cooler, 2.) installing walls and doors, by means known in the art, to define an existing Blast Chiller space within the cooler 3.) positioning a frame assembly of refrigeration and electrical components on one of the interior walls, 4.) positioning a controller unit on an exterior wall and interfacing the controller unit to the frame assembly, and 5.) positioning a remote condenser unit and interfacing the condenser unit to the frame assembly. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The invention is best understood from the following detailed description when read in connection with the accompanying drawings, which illustrate various embodiments of the present invention: 
           [0013]      FIG. 1  illustrates a Modular Chiller frame assembly of the present invention. 
           [0014]      FIG. 2  illustrates an exploded view of the Modular Chiller frame assembly of  FIG. 1 . 
           [0015]      FIG. 3  illustrates the airflow direction (indicated by arrows) of an operable Modular Chiller frame assembly as embodied in  FIG. 1 . 
           [0016]      FIG. 3A  illustrates a cross-section of frame assembly  20 F. 
           [0017]      FIG. 4  illustrates the Control Panel of the present invention used in conjunction with the Modular Chiller frame assembly of  FIG. 1  for retrofit to either an existing refrigerated room or integrated into a standalone blast chiller freezer. 
           [0018]      FIG. 5  illustrates an exploded view of the Control Panel of  FIG. 4 . 
           [0019]      FIG. 6  illustrates the electrical schematic of the control panel of  FIG. 5 . 
           [0020]      FIG. 7  illustrates and existing refrigerated room of which the Modular Chiller frame assembly of  FIG. 1  and Control Panel of  FIG. 4  are retrofitted into. 
           [0021]      FIG. 8  illustrates the refrigerated room of  FIG. 7  subsequent to panels being removed for the addition of a new Blast Chiller freezer enclosure. 
           [0022]      FIG. 9  illustrates the newly installed panels and doors creating a new Blast Chiller freezer enclosure in the larger refrigerated room. 
           [0023]      FIG. 10  illustrates the Modular Chiller frame assembly of  FIG. 1  installed in the new Blast Chiller freezer enclosure of  FIG. 9 . 
           [0024]      FIG. 11  illustrates the addition of the Control Panel and outside condenser unit to the Blast Chiller freezer enclosure of  FIG. 10 . 
           [0025]      FIG. 12  illustrates a cut-away view of the Blast Chiller freezer enclosure of  FIG. 10 . 
           [0026]      FIG. 13  illustrates two standalone Blast Chiller freezer enclosures with either a single or double entry, and retrofitted with the Modular Chiller system and control panel of the present invention. 
           [0027]      FIG. 14  illustrates an alternative embodiment of two standalone Blast Chiller freezer enclosures each fitted with multiple Modular Chillers and Control Panels. 
           [0028]      FIG. 15-18  illustrates multiple embodiments of the present invention retrofitted into larger refrigerated rooms. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]      FIG. 1  illustrates an embodiment of the Modular Chiller frame assembly  10  employing the principles of the present invention and having components as illustrated in  FIG. 2 . The assembly  10  includes a frame  20 F having a base panel  20 F 1 , side supports  20 F 2  extending upward from base panel  20 F 1  at one end, and a top panel  20 F 3  attached to side supports  20 F 2  at the opposite end, base panel  20 F 1  and top panel  20 F 3  being substantially parallel to each other. Base panel  20 F 1 , side supports  20 F 2 , and top panel  20 F 3  being in fixed relation to each other forming the frame  20 F. 
         [0030]    Base panel  20 F 1  may include legs  20 F 4  for separation of frame assembly  10  from the floor surface. Legs  20 F 4  can be height adjustable and the frame assembly  10  fabricated from stainless steel  304  or its equivalent. Base panel  20 F 1  may also include[s] a plurality of drainage holes  20 F 5  to channel condensation from evaporator assembly  20 E. A drain pan (not shown) may be either integrated into base panel  20 F 1  or be free standing in a location that would allow moisture through the drainage holes to enter the pan, and exit the pan via a drain connection to an outside location (not shown). 
         [0031]    Side support  20 F 2 , may include channels  20 F 2 A for fixing the Modular Chiller system components  25  within the frame  20 F. Means known in the art, such as screwing, riveting, bolting may be used for attaching components to frame  20 F. Defrost Heaters  20 D are attached to the evaporator assembly  20 E by any means known in the art, for example, hooks or clips. Frame assembly  20 F, further includes an air deflector  20 G mounted at the rear of frame  20 F as illustrated in  FIGS. 2 ,  3  and  3 A. Deflector  20 G includes diffusion panels  20 G 2  and  20 G 3  and center section  20 G 1 . Center section  20 G 1  separates outgoing cold air  38  produced by Modular Chiller System components  25  and transfers the cold air  38  over diffuser panels  20 G 2  and  20 G 3 . 
         [0032]    As illustrated in  FIGS. 3 and 3A , outgoing air  38  is further channeled by moving over surface  20 F 1 A and identical surface  20 F 1 B. Air deflector,  20 G, in the preferred embodiment, sits on and is secured to base panel  20 F 1  ( FIG. 3A ), and top panel  20 F 3  (not shown) in an identical manner, with the surface of deflectors  20 G 2  and  20 G 3  set off from and substantially parallel to the rear surface of evaporator  20 E. 
         [0033]    Deflector sections  20 G 2  and  20 G 3 , at their first and second ends, in the preferred embodiment are secured to the edge of panels  20 F 1  and  20 F 3  and are displaced from the rear of evaporator  20 E. Sections  20 G 2  and  20 G 3  terminate into opposite ends of center section  20 G 1  which angles inward into close proximity to the rear of evaporator  20 E. 
         [0034]    Top panel  20 F 3  further includes cutouts  20 M 1  and  20 N 1  for the passage of refrigeration line  20 M (liquid and gas lines) and electrical lines  20 N. In the preferred embodiment, modular chiller frame assembly  10 , and all internal components are mounted vertically to achieve a narrow frame base footprint and to produce a consistent air flow and heat transfer at every level of a food rack  15  placed in front of modular chiller frame assembly  10  ( FIG. 3 ,  12 ). 
         [0035]    As illustrated in  FIGS. 3 and 12 , fans  20 C pull hot air  39  from every level of rack  15  into chiller system components  25 , then cold air  38  is dispersed evenly and consistently throughout the refrigeration enclosure reaching the multiple levels of rack  15 . The channeling of cold air  38  is achieved over diffuser panels  20 G 2  and  20 G 3  and surfaces  20 F 1 A and  20 F 1 B. 
         [0036]      FIG. 13  illustrates a standalone version of the Modular Chiller assembly  10  integrated into a refrigeration space having an enclosure  42 A. It is understood that the refrigeration space can be any dimension, including a non-walkin enclosure having drawers or racks accessible therein. Further, subject invention contemplates the placement of chiller assembly  10  and control system  30  in locations deemed suitable by those skilled in the art. For example, chiller assembly  10  may be mounted off the floor directly to a sidewall of en enclosure  42 A. Further, control system  30  could be integrated within the enclosure  42 A for a “Flush” appearance. 
         [0037]    The Modular Chiller System assembly  10  includes chiller system components  25  (heat exchanger), known in the art, for the removal of warm air  39  and conversion to cold air  38 . These components include, but are not limited to, evaporator fans  20 C, defrost heater  20 D, evaporator  20 E, fan grilles  20 A, and condensing unit  50 . In the preferred embodiment, the condensing unit will be mounted outside of the refrigeration building. Hot air from the food placed in rack  15  is sucked through fans  20 C (intake) and transfers its thermal energy to evaporator  20 E (see  FIG. 12  for placement of rack  15 ). 
         [0038]    The evaporator  20 E may circulate any suitable coolant such as, e.g., chlorofluorocarbon freon (also known as  404 A). Circulating coolant evaporates due to the transfer of thermal energy from air heated by the hot food in rack  15  to the evaporator  20 E. The evaporated coolant circulates through the external condensing unit  50 , wherein it condenses and transfers its thermal energy. It is contemplated that the dimensions of the Modular Chiller Assembly  10 , can be modified to accommodate various sized refrigeration spaces, including portable refrigeration units, without departing from the spirit and scope of the invention. 
         [0039]      FIGS. 7 and 8  illustrates a typical refrigeration room  40  that is typical of the type of room retrofitted with the Modular Chiller system of the present invention. First, a portion  42  of the existing refrigeration room  40  is removed to accommodate retrofit of the Modular Chiller system. In the preferred embodiment, an area of 20 square feet would accommodate a universal roll in rack  15  (see  FIG. 12 ) capable of holding 20-30 food size pans, and approximately 220-330 lbs of food. To size the proper area of the room, a customer is first asked how many pounds of food is needed to be blast chilled (160 F down to 40 F degrees) and/or shock freezed (160 F down to 0 F degrees). 
         [0040]    A ninety minute cycle, to process up to 264 lbs of food, would require a 20 sqft space for a single rack system. The 20 sqft space would require a universal rack  15  which would hold up to 26 food pans. A minimum 30 inch door would be required for entry and exit of the food rack  15 . In the preferred embodiment, single rack spaces are partitioned in 20 sqft increments. As illustrated in  FIG. 16 , side by side spaces are broken out as 20 sqft spaces, each having a rack  15  capable of holding up to 440 lbs of food. 
         [0041]    A single rack  15 , in a 20 sqft space, holding up to 264 lbs of food would require an evaporator size of approximately 26,000 BTU/Hr at 15 F evaporator temperature and 110 F condensing temperature, to achieve the aforementioned blast chill/shock freeze requirements. A single rack  15 , in a 20 sqft space, holding up to 440 lbs of food would require an evaporator size of approximately 44,000 BTU/Hr at 15 F evaporator temperature and 110 F condensing temperature, to achieve the aforementioned blast chill/shock freeze requirements. 
         [0042]    The evaporator and condenser size can be determined for the size space, quantity of food and required chill/freeze times by means known in the art. Examples illustrated are preferred, for the chill/freeze requirements set forth in the preferred embodiments of subject invention, however, chill/freeze requirements and evaporator/condenser sizes can be determined for any size space by means known in the art. 
         [0043]    The panels are cut or removed by means known in the art, and new insulation panels are installed. Manufacturers, such as BARR, Inc provide panels for refrigeration systems that can be provided at custom sizes with all necessary hardware for installation. 
         [0044]    As illustrated in  FIG. 9 , new front panels  40 A (end walls), side panels  40 B (side-walls), and top panel  40 C (ceiling) create a smaller blast chiller freezer enclosure  90  within the larger refrigeration enclosure  95 , situated on floor  41 . To complete the new smaller blast chiller freezer enclosure  90  a door  42 A 1  or multiple doors  42 A 1  may be installed as illustrated in  FIG. 9  and  FIG. 15 . Top panel  40 C includes openings  40 C 1  for refrigeration lines  20 M and electrical lines  20 N. 
         [0045]    Next a location is chosen for the placement of Modular Chiller frame assembly  10  within enclosure  90 . Although frame assembly  10  can be placed against any interior wall  40 B or  40 A, placement against sidewall  40 B on the side of larger frame  95  sidewall  40 B is preferable for shorter runs of electrical and refrigeration lines, as indicated in  FIGS. 10 and 11 . As illustrated in  FIGS. 10 and 11 , refrigeration lines  20 M and electrical lines  20 N are routed through openings  40 C 1  for interface to remote condenser unit  50  and Controller unit  30 . 
         [0046]    Control unit  30 , in the preferred embodiment, as illustrated in  FIG. 4  and  FIG. 5 , includes a top section  33  and a side section  32 , the two sections being substantially perpendicular to each other. As illustrated in  FIG. 11 , in the preferred mounting location, top cover  30 G, which includes electrical panel  30 F ( FIG. 5 ), is mounted on top panel  40 C, with cable transition hole  30 E approximately over cutouts  40 C 1  to allow a direct passage of electrical lines  20 N through top panel  40 C and through cable transition hole  30 E. 
         [0047]    Side section  32  of control unit  30  rests against sidewall  40 A and includes an operator interface  30 A. The location of control unit  30  allows for a clean installation and effectively covers the presence of electrical lines. Electrical lines routed through cable transition hole  30 E are connected at terminal block  30 C and power terminal block  30 D. As illustrated in  FIGS. 11 and 12 , the intake provided by fans  20 A is coextensive with the position of rack  15  placed in front of frame assembly  10 . 
         [0048]    Referring to  FIG. 6 , operator interface and controller  30 A includes a microprocessor based programmable computer for controlling the operation of chiller system components  25 , to accomplish the rapid freezing of food product. Operator interface and controller  30 A may include[s] an industrial grade VFD (Vacuum Fluorescent Display) which allows the operator to view it from any angle. On screen programming via controller  30 A utilizes inputs from thaw probe(s)  20 J, air probe(s)  20 I, and food probe(s)  20 H, that sense temperature and provide inputs to the controller. 
         [0049]    Food probes may include heated tips, activated by the controller to allow for easy extraction of probes  20 H from frozen food. The controller may further have inputs from switches located on the blast chiller freezer enclosure doors  42 A 1  and evaporator doors  20 B. The controller  30 A can be programmed to start or stop the chiller system based on inputs indicating that the doors are opened or closed. Blast Chiller freezer enclosure  90  ( FIG. 9 ) can also include Ultra Violet lights for killing bacteria on the inside of the enclosure, programmable by the controller  30 A. 
         [0050]    The controller has inputs for various signals to generate alarms for conditions such as air temperature high or low, food to hot, and power failures. The controller further includes inputs for connection to external devices such as printers and computers for downloading and printing data. 
         [0051]    The chiller system components  25  operate whereby the input of a target temperature will control the chiller system components to freeze the contents of rack  15  within the specified time period. The controller  30 A is capable of storing hundreds of recipe freeze temperatures, and is programmable for rapid temperature pull down cycles, at intervals of (1,2,5, 10 . . . ) minutes, including start/stop cycle times. 
         [0052]    The controller  30 A can operate in either the manual or automatic mode. In the manual mode, the operator selects either a soft chill cycle, hard chill cycle, shock freeze cycle, or thaw cycle. In manual mode, temperature inputs are via air probes  20 I. The manual soft chill cycle will maintain the air temperature in chiller freezer enclosure  90  between 32 F and 35 F for approximately 90 minutes. After 90 minutes the controller goes into holding mode, maintaining the freezer enclosure  90  temperature at 38 F to 40 F. 
         [0053]    The manual hard chill cycle will maintain the air temperature in chiller freezer enclosure  90  between 0 F and 10 F for approximately 60 minutes. After 60 minutes the controller maintains the freezer enclosure  90  temperature at 32 to 35 F for another 60 minutes during the second part of the cycle. After the second cycle is complete the controller goes into holding mode maintaining the temperature at 38 F to 40 F. 
         [0054]    The manual shock freeze cycle will maintain the chiller freezer enclosure  90  temperature at −25 F for 240 minutes, then will hold the temperature at 0 F. The manual thaw cycle is set for six hours and maintains the chiller freezer enclosure  90  at 40 F to 50 F in order to thaw a product from 0 F to 36 F. At the end of the six hours the controller goes into holding mode maintaining the air cavity at 38 F to 40 F. 
         [0055]    In the automatic mode, the operator selects either a soft chill cycle, hard chill cycle, shock freeze cycle, or thaw cycle. In automatic mode, temperature inputs are via air probes  20 I and food probes  20 H. In the automatic soft chill cycle food probes  20 H are inserted into a hot product and the temperature of freezer enclosure  90  will be lowered to 32 F to 35 F, utilizing temperature inputs from air probes  20 I. When input from food probe is 40 F the controller goes into holding mode maintaining freezer enclosure  90  at 38 F to 40 F. 
         [0056]    In automatic hard chill mode food probes  20 H are inserted into a hot product and the temperature of freezer enclosure  90  will be lowered to 0 F to 10 F, utilizing temperature inputs from air probes  20 I. When food probe  20 H indicates a temperature of 55 F, at the center of the product, the controller  30 A moves the temperature in freezer enclosure  90  to 32 F to 35 F. Next, when food probe  20 H indicates a temperature of 40 F at the center of the product, controller  30 A readjusts the temperature within freezer enclosure  90  to 38 to 40 F. 
         [0057]    In the automatic shock freeze mode, the temperature of freezer enclosure  90  will be lowered to −25 F, utilizing temperature inputs from air probes  20 I. When food probe  20 H indicates a temperature of 0 F at the center of the product, controller  30 A readjusts the temperature within freezer enclosure  90  to 0 F. 
         [0058]    In the automatic thaw cycle mode, a thaw probe  20 J is inserted into a frozen product via a hole drilled into the product. Controller  30 A maintains the freezer enclosure  90  at 45 F, utilizing temperature inputs from air probes  20 I, until thaw probe  20 J reads a temperature of 36 F. At that point controller  30 A will maintain the temperature in the freezer enclosure  90  at 38 F to 40 F. 
         [0059]    It should be understood that the preceding is merely a detailed description of one embodiment of this invention and that numerous changes to the disclosed embodiment can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. Rather, the scope of the invention is to be determined only by the appended claims and their equivalents.
A method of integrating the Modular Chiller System into an existing walk-in cooler includes the steps of 1.) selecting a portion of an existing walk-in cooler, 2.) installing walls and doors, by means known in the art, to define an existing space within the cooler 3.) positioning a frame assembly of refrigeration and electrical components on one of the interior walls, 4.) positioning a controller unit on an exterior wall and interfacing the controller unit to the frame assembly, and 5.) positioning a remote condenser unit and interfacing the condenser unit to the frame assembly.