CFD Simulation of an Industrial Spiral Refrigeration System

In the food industry, heating and cooling are key processes where CFD can play an important role in improving quality, productivity and reducing energy costs. Cooling products after baking is crucial for storage and transportation; the product has to be cooled efficiently to a specified temperature (often to fulfill regulatory requirements) whilst preserving its quality. This study involves the analysis of spiral cooling refrigerators used in cooling food products, in this case, Cornish Pasties. Three separate sets of CFD models were developed and validated against experimental data taken in the laboratory and measurements taken in use in industry. In the first set of models a full CFD model was developed of a refrigeration spiral including the pasties, and used to study the heat transfer from the products to the air. Further simulations were carried out on individual pasties to explore the pasty cooling and heat transfer to the air in more detail, with the pasty geometry being determined from MRI scans. In the final set of simulations, Image Based Meshing (IBM) was used to determine the interior structure of the pasty and develop a full heat conduction model of the interior, which was compared with separate laboratory experiments using jets of cold air to cool the pasty. In all cases, good agreement was obtained between the CFD results and experimental data, whilst the CFD simulations provide valuable information about the air flows and cooling in the industrial system.