Related Commercial Resources

CHAPTER 34

ICE MANUFACTURE
Ice Makers ..................................................................................................................................... 34.1
Thermal Storage............................................................................................................................ 34.3
Ice Storage .................................................................................................................................... 34.4
Delivery Systems ........................................................................................................................... 34.5
Commercial Ice ............................................................................................................................. 34.6
Ice-Source Heat Pumps................................................................................................................. 34.6

M OST commercial ice production is done with ice makers that

produce three basic types of fragmentary ice (flake, tubular,
and plate), which vary according to the type and size required for a
flakes present the maximum amount of cooling surface for a
given amount of ice.
When used as ingredient ice in sausage making or other food
particular application. Among the many applications for manufac- grinding and mixing, flake ice provides rapid cooling while mini-
tured ice are mizing mechanical damage to other ingredients and wear on mixing/
cutting blades.
• Processing: fish, meat, poultry, dairy, bakery products, and hydro-
Some flake ice machines can produce salty ice from seawater.
cooling
These are particularly useful in shipboard applications. Other flake
• Storage and transportation: fish, meat, poultry, and dairy products ice machines require adding trace amounts of salt to the makeup
• Manufacturing: chemicals and pharmaceuticals water to enhance the release of ice from the refrigerated surface. In
• Others: retail consumer ice, concrete mixing and curing, and off-
peak thermal storage Fig. 1 Flake Ice Maker
ICE MAKERS
Flake Ice
Flake ice is produced by applying water to the inside or outside
of a refrigerated drum or to the outside of a refrigerated disk. The
drum is either vertical or horizontal and may be stationary or fixed.
The disk is vertical and rotates about a horizontal axis.
Ice removal devices fracture the thin layer of ice produced on the
freezing surface of the ice maker, breaking it free from the freezing
surface and allowing it to fall into an ice bin, which is generally
located below the ice maker.
Thickness of ice produced by flake ice machines can be varied by
adjusting the speed of the rotating part of the machine, varying
evaporator temperature, or regulating water flow on the freezing
surface. Flake ice is produced continuously, unlike tubular and plate
ice, which are produced in an intermittent cycle or harvest opera-
tion. The resulting thickness ranges from 0.04 to 0.18 in. Continu-
ous operation (without a harvest cycle) requires less refrigeration
capacity to produce a ton of ice than any other type of ice manufac-
ture with similar makeup water and evaporating temperatures. The
exact amount of refrigeration required varies by machine type and Fig. 1 Flake Ice Maker
design. Typical flake ice machines are shown in Figures 1 and 2.
All water used by flake ice machines is converted into ice; there- Fig. 2 Disk Flake Ice Maker
fore, there is no waste or spillage. Flake ice makers usually operate
at a lower evaporating temperature than tube or plate ice makers,
and the ice is colder when it is removed from the ice-making sur-
face. The surface of flake ice is not wetted by thawing during
removal from the freezing surface, as is common with other types of
ice. Because it is produced at a colder temperature, flake ice is most
adaptable to automated storage, particularly when low-temperature
ice is desired.
Rapid freezing of water on the freezing surface entrains air in
the flake ice, giving it an opaque appearance. For this reason,
flake ice is not commonly used for applications where clear ice is
important. Where rapid cooling is important, such as in chemical
processing and concrete cooling, flake ice is ideal because the

The preparation of this chapter is assigned to TC 10.2, Automatic Icemak-

ing Plants and Skating Rinks. Fig. 2 Disk Flake Ice Maker

34.1
Copyright © 2006, ASHRAE
34.2 2006 ASHRAE Handbook—Refrigeration

rare cases, the presence of salt in the finished product may be a cylinder that can be cut to desired lengths. The refrigerant tem-
objectionable. perature outside the tube is continually dropping, with an initial
temperature of 25°F and a terminal suction temperature ranging
Tubular Ice from 20 to –5°F. At the end of the freezing cycle, the circulating
Tubular ice is produced by freezing a falling film of water either water is shut off and ice is harvested by introducing hot discharge
on the outside of a tube with evaporating refrigerant on the inside, or gas into the refrigerant in the freezing section. To maintain gas tem-
on the inside of tubes surrounded by evaporating refrigerant on the perature, typical discharge gas pressure is 180 psia. This releases the
outside. ice from the tube; the ice descends to a motor-driven cutter plate that
Outside Tube. When ice is produced on the outside of a tube, the can be adjusted to cut ice cylinders to the length desired (up to
freezing cycle is normally 8 to 15 min, with the final ice thickness 1.5 in.). At the end of the defrost cycle, the discharge gas valve is
0.2 to over 0.5 in., following the tube’s curvature. The refrigerant closed and water circulation resumes.
temperature inside the tube continually drops from an initial suction These units can use refrigerants R-717 and R-22; R-12 may be
temperature of about 25°F to the terminal suction temperature in the found in older units. Again, capacity increases as terminal suction
range of 10 to –15°F. At the end of the freezing cycle, the circulating pressure decreases. A typical unit with 70°F makeup water and R-
water is shut off, and hot discharge gas is introduced to harvest the 717 as the refrigerant produces 43 tons of ice per 24 h with a termi-
ice. To maintain proper harvest temperatures, typical discharge gas nal suction pressure of 40 psia and requires 74.5 tons of refrigera-
pressure is 160 psia. This drives the liquid refrigerant in the tube up tion. This equates to 1.73 tons of refrigeration per ton of ice. The
into an accumulator and melts the inside of the tube of ice, which same unit produces 66 tons of ice per 24 h with a terminal suction
slides down through a sizer and mechanical breaker, and finally pressure of 30 psia and requires 135 tons of refrigeration. This
down into storage. The defrost cycle is normally about 30 s. The unit equates to 2.04 tons of refrigeration per ton of ice.
returns to the freezing cycle by returning the liquid refrigerant to the Tubular ice makers are advantageous because they produce ice at
tube from the accumulator. higher suction pressures than other types of ice makers. They can
This type of ice maker operates with R-717, R-404A, R-507, and make relatively thick and clear ice, with curvatures that help prevent
R-22. R-12 may be found in some older units. Higher-capacity units bridging in storage. Tubular ice makers have a greater height
of 10 tons per 24 h and larger usually use R-717. Unit capacity requirement for installation than do plate or flake ice makers, but a
increases as terminal suction pressure decreases. A typical unit with smaller footprint. Provision must be made in the refrigeration sys-
70°F makeup water and R-717 as the refrigerant produces 19.3 tons tem high side to accommodate the volume of refrigerant required
of ice per 24 h with a terminal suction pressure of 38.5 psia and for the proper amount of harvest discharge gas. Ice temperatures are
requires 35.7 tons of refrigeration. This equates to 1.85 tons of generally higher than with flake ice makers.
refrigeration per ton of ice. The same unit produces 41.6 tons of ice Supply Water. Supply water temperature greatly affects capac-
per 24 h with a terminal suction pressure of 21 psia and requires ity of either type of tubular ice maker. If supply water temperature
80 tons of refrigeration. This equates to 1.92 tons of refrigeration is reduced from 70 to 40°F, ice production of the unit increases
per ton of ice. Figure 3 shows the physical arrangement for an ice approximately 18%. In larger systems, the economics of precooling
maker that makes ice on the outside of the tubes. water in a separate system with higher suction pressures should be
Inside Tube. When ice is produced inside a tube, it can be har- considered.
vested as a cylinder or as crushed ice. The freezing cycle ranges
from 13 to 26 min. Tube diameter is usually 0.9 to 2 in., producing Plate Ice
Fig. 3 Tubular Ice Maker Plate ice makers are commonly defined as those that build ice on
a flat vertical surface. Water is applied above freezing plates and
flows by gravity over the freezing plates during the freeze cycle. Liq-
uid refrigerant at a temperature between –5 and 20°F is contained in
circuiting inside the plate. The length of the freezing cycle governs
the thickness of ice produced. Ice thicknesses in the range of 0.25 to
0.75 in. are quite common, with freeze cycles varying from 12 to
45 min. Figure 4 shows a flow diagram of a plate ice maker using
water for harvest. All plate ice makers use a sump and recirculating
pump concept, whereby an excess of water is applied to the freezing
surface. Water not converted to ice on the plate is collected in the
sump and recirculated as precooled water for ice making.
Ice is harvested by one of two methods. One method involves
applying hot gas to the refrigerant circuit to warm the plates to 40 to
50°F, causing the ice surface touching the plate to reach its melting
point and thereby release the ice from the plate. The ice falls by
gravity to the storage bin below or to a cutter bar or crusher that fur-
ther reduces the ice to a more uniform size. Plate ice makers using
the hot-gas method of harvesting can produce ice on one or two
sides of the plate, depending on the design.
In the second method of harvesting ice, warm water flows on the
back side of the plate. This heats the refrigerant inside the plate
above the ice melting point, and the ice is released. Ice makers using
this approach manufacture ice on one side of a plate only. Harvest
water is chilled by passing over the plates. It is then collected in the
sump and recirculated to become precooled water for the next batch
of ice.
For plate ice makers, freezing time, harvest time, water, pump, and
refrigeration are controlled by adjustable electromechanical or elec-
Fig. 3 Tubular Ice Maker tronic devices. Using the wide variety of thicknesses and freezing
Ice Manufacture 34.3

Fig. 4 Plate Ice Maker

Fig. 4 Plate Ice Maker

times available, plate ice makers can produce clear ice. Thus, the See Chapter 34 of the 2003 ASHRAE Handbook—HVAC Applica-
plate ice maker is commonly used in applications requiring clear tions for more information.
ice.
Because of the harvest cycle involved, plate ice makers require Scale Formation
more refrigeration per unit mass of ice produced than flake ice Performance of all ice makers is affected by the characteristics of
makers. This disadvantage is offset by the ability of plate ice mak- the inlet water used. Impurities and excessive hardness can cause
ers to operate at higher evaporating temperatures; thus, connected scale to be deposited on the freezing surface of the ice maker. The
motor power per ton of refrigeration is usually less than that of deposit reduces the heat transfer capability of the freezing surface,
flake ice makers. During the harvest cycle, the suction pressure thereby reducing ice-making capacity. Deposited scale may further
rises considerably, depending on the design of the ice maker. reduce ice-making capacity by causing the ice to stick on the freez-
When a common refrigeration system is used for multiple refrig- ing surface during the harvest process. The rated capacity of all ice
erated requirements, a stable suction pressure can be maintained makers is based on the substantial release of all the ice from the
for all the refrigeration loads by using a dedicated compressor for freezing surface during the removal period. Because the process of
the ice machine, or by using a dual pressure suction regulator at freezing water tends to freeze a greater proportion of pure water on
each ice machine to minimize the load placed on the suction main the ice maker’s freezing surface, impurities tend to remain in the
during harvest. This may occur in large processing plants, refrig- excess or recirculated water. A blowdown, or bleedoff, whereby a
erated warehouses, and so forth. Large plate ice makers can be portion of the recirculated water is bled off and discharged, can be
arranged such that only sections or groups of plates are harvested installed. The bleedoff system can control the concentration of
at one time. Properly adjusting the timing of harvesting each sec- chemicals and impurities in the recirculated water. The necessity of
tion can reduce the fluctuation in suction pressure. a bleedoff system and the effectiveness of this concept for control-
Plate ice makers using the water harvest principle rely on the ling scale deposits depend on local water conditions. Some refrig-
temperature of the water for harvesting. A minimum of 65°F is usu- eration system loss occurs because recirculated water that is bled off
ally recommended to minimize both harvest cycle time and harvest to drain is precooled. Water that is bled off may be passed through
water consumption. For installations in cold-water areas, or where a heat exchanger to precool incoming makeup water. Water condi-
wintertime inlet water temperatures are low, it is advisable to pro- tions, treatment, and related problems in ice making are covered in
vide auxiliary means of warming the inlet water to 65°F. Chapter 48 of the 2003 ASHRAE Handbook—HVAC Applications.
Ice Builders
THERMAL STORAGE
Ice builders comprise various types of apparatus that produce ice
on the refrigerated surfaces of coils or plates submerged in insu- Interest in energy conservation has renewed interest in using ice
lated tanks of water. This equipment is commonly known as an ice to provide thermal storage of cooling capacity for air-conditioning
bank water chiller. Ice built on the freezing coils is not used as a or process applications. The ice is produced and stored using lower
manufactured ice product but rather as a means of cooling water cir- off-peak and weekend power rates. During the day, stored ice pro-
culating through the tank as the ice melts from the coils. The ice vides refrigeration for the chilled water system. The design and
builder is most often used for thermal storage applications with features of thermal storage equipment are covered in Chapter 34 of
high peak and intermittent cooling loads that require chilled water. the 2003 ASHRAE Handbook—HVAC Applications.
34.4 2006 ASHRAE Handbook—Refrigeration

ICE STORAGE Fig. 5 Ice Rake System

Fragmentary ice makers can produce ice either on a continuous
basis or in a constant number of harvest cycles per hour. The use of
the ice is generally not at a constant rate but on a batch basis.
Batches vary greatly, based on user requirements. The ice must be
stored and recovered from storage on demand. Labor savings, eco-
nomics, quantity of ice to be stored, amount of automation desired,
and user delivery requirements must all be considered in ice storage
and storage bin design.
Ice makers can produce ice 24 h a day. Making ice during off-
shifts and weekends, as well as during work shifts, can lead to con-
siderable savings in total ice-making and refrigeration system
requirements. In addition, by using electrical power during off-peak
hours, peak loads on the power system are reduced during the day.
Many power companies offer reduced rates during off-peak hours.
Ice storages vary in type from short- to prolonged-term. Degree
of automation for filling and discharge ranges from manual shovel-
ing to a completely automatic rake system.
Short-term storage generally requires provision for one day’s
ice production. The ice maker is mounted over a bin, and ice falls
by gravity into the bin. The bin is an insulated, airtight enclosure
with one or more insulated doors for access. Ice is removed by
shoveling or scooping. In such storage, the subcooling effect of the Fig. 5 Ice Rake System
ice generally offsets the heat loss through the insulated bin walls
without excessive melting. In most situations, it is not necessary to
provide refrigeration units in an ice storage bin where ice produc- of steel framework and panels, with the complete unit installed in a
tion is being used on a daily basis and ambient temperatures are refrigerated room. The second type constructs an insulated enclo-
reasonable. sure around the ice bin and rake system. This type can be installed
Prolonged ice storage requires a refrigerated, airtight, insulated inside a building or outside, depending on the weather protection
storage bin. Some designs provide for false walls and floor, which provided. For either type, the ice makers are mounted outside of the
produce an envelope effect that allows cold air to circulate com- refrigerated space. Figure 5 shows the arrangement of components
pletely around the mass of ice in storage. If wet ice is placed in a bin for a typical rake system.
refrigerated to a temperature below 32°F, it will freeze together and Once fragmentary ice comes to rest in the storage bin, it will not
may be difficult to remove. flow freely, and a mechanical force is necessary to start it moving.
Time and pressure affect the storage quality of fragmentary ice. The deeper the ice is stored, the greater the pressure on ice near the
Even though a bin is refrigerated to a temperature well below 32°F, bottom. Ice near the bottom tends to fuse together faster. Rake sys-
pressure can cause local melting near the bottom. Thus, there are lim- tems work from the top of the ice; they continuously level and fill
its to the size and configuration of a gravity-filled storage bin. Ice the storage bin, as well as automatically remove the ice on demand.
falling from an ice maker forms a cone directly underneath the drop The systems operate in nonrefrigerated or refrigerated bins; because
in the bin. With slight variation because of the type of ice, the angle most users of large storages also want ice to be dry for ease of han-
of repose is approximately 30°. Fusion of ice under pressure limits dling, large automated storages are usually refrigerated.
the practical ice storage depth to 10 to 12 ft. To use the bin’s volume The ice rake itself consists of a structural steel mechanism with
more efficiently, a leveling screw mounted in the overhead can be drive. It operates similarly to the tracks of a crawler tractor. By
used to carry the ice away from the top of the ice cone. means of a hoist and timer, the rake is raised or lowered to automat-
There is also a practical limit to the size of a storage bin from ically maintain its position suspended over, and in close contact
which ice can be manually removed through refrigerator doors. The with, the ice level. Wide scraper conveyors, mounted across the
simplest device used to remove ice from a bin is a screw conveyor tracks along the full width of the bin, spread the ice out and drag it
with a trough at floor level, which is equipped with gratings and toward the back of the bin during the filling mode. To dispense the
removable sectional covers. The removable covers protect the screw ice at delivery, the scraper conveyors reverse direction and drag the
from ice blockage when the conveyor is not running. The gratings ice to the opposite end of the bin, dropping it into a screw conveyor
are for personnel protection. mechanism. From this point, the ice is transferred to the external
delivery system of screw conveyors.
Ice Rake and Live Bottom Bins Some rake systems have features that allow ice deliveries from
The ice rake system is used for larger and fully automated stor- the bin to be remotely controlled and volumetrically metered. Ice
ages. These storages generally have a 10 to 300 ton capacity for a deliveries can be recorded on digital counters at the storage bin,
single rake system. Depending on plant demands, combinations of remote stations, and control centers. Accuracy is in the range of
rake systems can be developed into an integrated production, stor- ±2%. Another method of metering ice from a rake system storage
age, and delivery system. Such a mechanism could have capabilities involves the screw conveyor delivering the ice to a weigh belt. As
of up to 1000 tons of storage with multiple screw or pneumatic con- the ice passes along the moving belt, it is electronically weighed
veying delivery systems. A range of delivery rates, up to 60 tons of and the weight is recorded. Selection of the belt material carrying
ice per hour, can be achieved. Advantages include elimination of the ice is critical in preventing ice from sticking to the belt. The
labor for storing and transporting ice, longer and more effective weigh belt is often installed in a refrigerated area adjacent to the
distribution systems, faster delivery and termination of ice flow, less ice storage.
waste of ice, and the elimination of physical contamination. Another type of ice storage with delivery system capabilities is
Storages that incorporate rake systems are of two basic types. the live bottom type, with multiple screws arranged in various con-
One type encloses the ice storage and rake system in an arrangement figurations on the bottom of the storage bin. Because of ice fusion,
Ice Manufacture 34.5

these bins are limited to short-term storage. Success of this type of Screw and Belt Conveyors
bin depends on the type and quality of fragmentary ice being Screw conveyors are the most popular of all the conveyances
stored and the ability of the design to overcome particle fusion. used for transporting ice. They are manufactured in sizes of 4 in.
Particle fusion may result in ice bridges forming over the top of the diameter and up, as well as in various screw pitches. Most ice-
screws; then the screws will bore holes in the ice rather than empty conveying operations use 6, 9, and 12 in. diameter screws.
the bin. The sizing and drive power requirements of screw conveyors are
Primarily for the consumer bagged-ice industry, a bin and auto- determined by the ice delivery rate, inclination of the conveyor, and
matic storage system is used in which the entire floor moves, carry- conveyor screw pitch. With fragmentary ice, selection of an under-
ing the ice load into slowly rotating beaters. As the ice breaks loose, sized conveyor results in excessive conveyor speed or requires that
it drops to a screw conveyor, which feeds an ice bagger. This type of the conveyor run too full of ice. These conditions can produce
bin is located in a refrigerated room, and the ice makers are located excessive fines.
away from the bin. The ice makers must be shut off so that no ice can When screw conveyors transport ice through high-ambient
flow into the storage during the discharge and bagging process. inside areas or outside in the weather (e.g., in icing fishing vessels),
The ice silo is used for long- or short-term storage with capacities it is advisable to insulate the screw conveyor trough and provide the
in the range of 20 to 100 tons. The silo tank comprises a cylindrical conveyor with insulated covers. Rain is as problematic as sunshine
part and a tapered, conical part leading the ice to the outlet at the bot- for contributing to ice meltage and delivery difficulties. For this rea-
tom of the tank. From this point, the ice is transported by a screw son, most screw conveyors operating in the weather are provided
delivery system. A rotating flexible chain arrangement is provided with sectional and removable covers.
in the silo to assist in ice removal and to partially overcome the Belt conveyors are often used when excess moisture has to be
fusion problem. The ice maker is mounted over the top of the silo, removed from the ice or to minimize the fines. The mesh belts
and the ice falls into the storage. No leveling of ice is required in the allow snow and excess water to fall through. Stainless steel, gal-
bin because the silo’s diameter is sized to be compatible with the ice vanized steel, or high-density polyethylene are commonly used for
maker. The larger the ice storage, the higher the silo. As a result, belting.
proper ice discharge becomes more critical in the design when con-
sidering the fusion of ice and the fact that the ice must finally pass Pneumatic Ice Conveying
through a relatively small opening at the bottom of a tapered zone.
Pneumatic ice conveying systems have proved desirable, eco-
nomical, and practical for transporting fragmentary ice distances of
DELIVERY SYSTEMS 100 ft or more and when multiple delivery stations must be served.
The location of ice manufacture is rarely the location of ice A pneumatic system is advantageous when delivery stations are in
usage. Usually it is necessary to move ice from the ice machine or different directions or at different elevations, when delivery through
storage bin to some other area where it will be used; thus, a con- a pressure hose is needed, or when flexibility is required for future
veying system is required. Most conveyor applications use screws, changes or addition of delivery stations.
belts, or pneumatic systems. Great care must be taken in selecting The basic principle of conveying ice by a pneumatic system
the size and type of conveyor to be used because no matter what involves a rotary blower, which delivers air to a rotary air-lock valve
type of fragmentary ice is being handled, problems such as fines, or conveying valve. Ice is fed into the conveying valve, and com-
freeze-up, and ice jams can be encountered with an improperly pressed air conveys the mixture of air and ice at high velocity
designed system. Fines, or snow, are small particles of ice that chip through thin-walled tubing (aluminum, stainless steel, or plastic).
off the larger pieces during harvesting, crushing, or conveying Figure 6 shows the diagrammatic arrangement of pneumatic system
operations. components.

Fig. 6 Typical Flake Ice Pneumatic Conveying System

Fig. 6 Typical Flake Ice Pneumatic Conveying System

34.6 2006 ASHRAE Handbook—Refrigeration

Delivery rates between 10 and 40 ton/h and conveying distances tainer to remove water. Because of its suspension in water, ice is car-
up to 600 ft are common. Delivery distances exceeding 600 ft can be ried to all parts of the container. The ice solidifies as water drains
achieved at reduced delivery rates, with the maximum practical dis- from the container. The product is then completely surrounded with
tance being approximately 1000 ft. Conveying pressures range from ice, the voids are filled, and potential hot spots are eliminated.
4 to 10 psig, depending on the delivery rate and the maximum dis- Drained water can be collected and returned to the mixing tank.
tance the ice is to be conveyed. The air velocity required to keep ice
in suspension in the conveying line will vary among the different COMMERCIAL ICE
types of fragmentary ice. A pneumatic system cannot satisfactorily
convey all sizes of fragmentary ice. The manufacturer of the ice- Commercial ice is primarily used for human consumption. It is
making equipment should be consulted for recommended line veloc- also called packaged or consumer ice and is used for cooling bev-
ities. Sometimes, storage bins for ice plants using a pneumatic deliv- erages and for other applications in restaurants, hotels, and similar
ery system are refrigerated to ensure cold, free-flowing ice with institutions. This use requires packaging at the ice plant for storage
minimum moisture. Because the ice remains in the tubing a very and eventual distribution. In bagged form, commercial ice is also
short time, tubing insulation is seldom needed or used. However, in available for sale in grocery stores and in automatic, coin-operated
warm climates, shading the conveying line reduces the solar load. vending machines. When the ice is to be used in beverages, ice pro-
The tubing typically used has a diameter of 4 to 8 in. and requires duced by plate or tube ice makers is preferred because of its clear
minimum support, making installation easy and economical. appearance and the fact that it can be made in greater thicknesses.
Rake systems are often used to store packaged ice and convey it into
Multiple delivery points are served by automatic Y-type diverter
the packaging system.
valves or multiple-way slide valves, either air or electrically oper-
Packaging. A packaging system normally comprises an ice bag-
ated. Pneumatically blown ice can be delivered under pressure out
ger and a bag closer. These components are available from ice pack-
of the end of a hose. An alternative method of delivery is a cyclone
aging equipment manufacturers in various types and sizes. In the
receiver, which takes the ice at high velocity, dissipates the air, and
bagging process, the ice is fed from the ice storage bin into the bag-
drops the ice by gravity. Combinations of hose stations and cyclone
ging machine by a screw or belt conveyor. The bagging machine
delivery stations in the same system are common.
meters ice into a bag placed below its discharge chute. The amount
When a pneumatic conveying system is used in areas of high
of ice measured into the bag can be determined by weight, volume,
ambient and wet-bulb temperatures on an application requiring
or sight approximation, depending on the equipment used.
higher conveying pressures, a heat exchanger is often used to cool
When packaging by weight, the ice bag is placed on a weighing
and dehumidify the pneumatic air before it enters the conveying
table on the bagging machine. Ice is then dispensed into the ice bag
valve. The heat exchanger is provided with a cooling coil, either
until the desired weight is in the bag. At this point, a switch mounted
refrigerant- or chilled-water-cooled, a demister or other means of
on the scale stops the flow of ice.
separating moisture from the air, and a condensate trap to expel
The volumetric bagging machine deposits the ice in a rotating
entrapped moisture. Geographical location, system pressure, and
chamber, which is adjustable in volume. After a predetermined vol-
quality and use of ice at the delivery point must be considered when
ume of ice enters the chamber, the ice is discharged into the bag below.
determining whether to use a heat exchanger.
Because the shape and size of the ice is not constant, the volumetric
Slurry Pumping chamber is usually set to produce a 3 to 5% overage by volume. There-
fore, the proper minimum weight of ice in the bag is ensured.
A mixture of particle ice and water can be pumped as a slurry,
The bag closer consists of a mechanical unit that ties and seals the
which has some advantages for transporting ice. Generally, the
top of the bag with a wire ring, wire twist tie, or plastic clip. Smaller
slurry is approximately 50% water and 50% ice, but for specialized
bagging operations do not use a bag closer, and the bags are manually
application, mixtures of up to 80% ice and 20% water can be suc-
closed with plastic ties, wire rings, staples, and so forth. In more
cessfully pumped. Delivery distances of 800 ft have been achieved
elaborate systems, the bag is formed from roll stock, filled with ice,
with delivery rates of 60 tons of slurry mix per hour. This practice
automatically removed from the bagging machine, and automati-
has been extensively used in the produce industry and has potential
cally closed before it is dropped onto a conveyor, which carries the
in concrete cooling, chemical processing, and other ice or chilled-
bagged ice to the refrigerated storage room. The degree of automa-
water applications. Ice slurry mixes are of particular interest where
tion for the bagging and closing operation is determined by the num-
there is a need for low-temperature chilled water at or near 32°F. In
ber of bags of ice to be produced per day, bag size, and cost-benefit
converting ice to water, the absorption of latent heat at the usage
relationship between automated equipment and reduced labor costs.
point enables more cooling to be done with a slurry mix than with
Ice bags are made of plastic, most often polyethylene, or, very
straight chilled-water cooling. Pumping volumes and line sizes are
rarely, heavy moisture-resistant paper. Plastic bags are used in most
minimized, and ice meltage during mixing and pumping does not
modern plants.
normally exceed 1 to 3%. The system is capable of automation for
Storage. Packaged ice must be stored in a refrigerated ware-
continuous operation.
house or room before distribution. The ice storage area is sized to
The basic system for slurry pumping includes a mixing tank, in
meet the daily production of the plant and distribution requirements.
which the ice and water are mixed. The ice is carried by any of the
Generally, a bag ice storage facility can store 3 to 7 days’ produc-
conventional conveying methods from the ice storage bin to the slurry
tion. Although the ice will not melt at a storage temperature below
mix tank. Agitators in the tank operate continuously to maintain a
32°F, it is important that storage be maintained at a temperature
mixture with uniform consistency. Pumps discharge the slurry mix
between 10 and 25°F. The lower temperature subcools the ice and
through pipelines to the point of use. The pumps are of the centrifugal
avoids meltage during distribution. Depending on the type and qual-
type, modified for pumping slurry. When the icing cycle at the usage
ity of the ice, bagged ice can contain some water (from 0 to 5%). For
points is intermittent, a recirculating system returns unused slurry to
this reason, provision is made in the storage room refrigeration sys-
the mixing tank. Thus, the slurry is kept moving at all times, and the
tem for the product load of refreezing the water.
possibility of ice blockage in the lines is minimized. The temperature
of the slurry solution in the tank is maintained at 32°F.
The fresh produce industry offers a unique application for slurry
ICE-SOURCE HEAT PUMPS
mixes. Body icing of the fresh produce, which is generally of non- Ice-making systems can be configured to provide heating alone,
uniform size and configuration, is achieved by applying slurry to the or heating and cooling, for a building or process. Conversion of
dry packed product. Drain holes are provided in the shipping con- water to ice occurs at a relatively high evaporator temperature and
Ice Manufacture 34.7

coefficient of performance compared to air-source heat pumps oper- the evaporator component of the heat pump. The second approach
ating at low ambient temperatures. Systems can provide necessary uses a fragmentary type of ice maker as the evaporator, with a mix-
heating, with the resulting ice disposed of by melting with low- ture of ice and water stored in a tank. Many variations, combinations,
grade heat, such as solar. In addition, ice can be used for useful cool- and adaptations may be developed from these basic systems. The
ing through daily, weekly, or seasonal storage. requirement for thermal storage of a large quantity of ice dictates
The concept was originally considered mainly for residential new planning in architectural building design. Heating and cooling
heating and cooling, but installations are proving feasible for larger system designs for the building are also influenced.
structures, such as office buildings. Energy consumption savings
from the coefficient of performance of a conventional heat pump BIBLIOGRAPHY
system are achieved. Using off-peak night and weekend rates can
reduce power costs, and ice produced is used for building cooling Dorgan, C.E. 1985. Ice-maker heat pumps operation and design. ASHRAE
requirements. As a result, a system can be developed that consumes Transactions 91(1B):856-862.
less energy, at a lower utility rate. Dorgan, C.E., G.C. Nelson, and W.F. Sharp. 1982. Ice-maker heat pump
Ice-source heat pumps follow two basic approaches. The first performance—Reedsburg Center. ASHRAE Transactions 88(1):1271-
involves using the ice builder principle, with coils in a large tank, as 1278.

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