System and method for manufacturing shaped ice

Abstract

A method of manufacturing uniform ice objects includes placing an ice block in a freezer; cutting the ice block into sub-blocks, in the freezer; trimming all sides of each sub-block to ensure smooth, straight cuts on all sides thereof, in the freezer; cutting each trimmed sub-block into sheets, in the freezer, to define a final height of ice objects; cutting each sheet into loins, in the freezer, to define a width of the ice objects; cutting each loin into the ice objects, in the freezer; loading the ice objects in tubs, in the freezer; relocating the tubs of ice objects from the freezer to a refrigerator; removing snow from the ice objects and packaging the ice objects, in the refrigerator; and returning the packaged ice objects to the freezer.

1 .- 20 . (canceled) 
     
     
         21 . A method of manufacturing uniform ice objects, comprising:
 (a) placing an ice block in a freezer;   (b) cutting each trimmed sub-block into sheets to define a final height of ice objects;   (c) cutting each sheet into loins to define a width of the ice objects;   (d) cutting each loin into the ice objects;   (e) loading the ice objects in containers; and   (f) packaging the ice objects.   
     
     
         22 . The method of  claim 21 , wherein step (a) further comprises tempering the ice blocks in the freezer for at least about 12 hours. 
     
     
         23 . The method of  claim 21 , further comprising maintaining the freezer at a temperature of at least about 5° F. and not greater than about 15° F. 
     
     
         24 . The method of  claim 21 , further comprising forming the ice objects with respective dimensions that vary from each other by not greater than about 0.1 inches. 
     
     
         25 . The method of  claim 21 , wherein steps (b) through (d) comprise cutting with a band saw. 
     
     
         26 . The method of  claim 25 , wherein steps (b) through (d) comprise cleaning a blade of the band saw with polymer blade cleaners on opposed sides of the blade. 
     
     
         27 . The method of  claim 26 , wherein steps (b) through (d) comprise lubricating the blade with a food grade white oil. 
     
     
         28 . A method of manufacturing uniform ice objects, comprising:
 (a) placing an ice block in a freezer that is maintained at a temperature of at least about 5° F. and not greater than about 15° F.;   (b) cutting each trimmed sub-block into sheets to define a final height of ice objects;   (c) cutting each sheet into loins to define a width of the ice objects;   (d) cutting each loin into the ice objects, such that the ice objects are formed with respective dimensions that vary from each other by not greater than about 0.1 inches; and   (e) packaging the ice objects.   
     
     
         29 . The method of  claim 28 , wherein step (b) comprises cutting with an electric chain saw. 
     
     
         30 . The method of  claim 29 , wherein steps (b) through (d) comprise cutting with a band saw. 
     
     
         31 . The method of  claim 30 , wherein steps (b) through (d) comprise cleaning a blade of the band saw with polymer blade cleaners on opposed sides of the blade. 
     
     
         32 . The method of  claim 31 , wherein steps (b) through (d) comprise lubricating the blade with a food grade white oil. 
     
     
         33 . A method of manufacturing uniform ice objects, comprising:
 (a) placing an ice block in a freezer that is maintained at a temperature of at least about 5° F. and not greater than about 15° F.;   (b) cutting the ice block into sub-blocks;   (c) trimming all sides of each sub-block to ensure smooth, straight cuts on all sides thereof;   (d) cutting each trimmed sub-block into sheets to define a final height of ice objects;   (e) cutting each sheet into loins to define a width of the ice objects;   (f) cutting each loin into the ice objects;   (g) loading the ice objects in containers;   (h) removing snow from the ice objects and packaging the ice objects.   
     
     
         34 . The method of  claim 33 , wherein step (a) further comprises tempering the ice blocks in the freezer for at least about 12 hours. 
     
     
         35 . The method of  claim 33 , further comprising forming the ice objects with respective dimensions that vary from each other by not greater than about 0.1 inches. 
     
     
         36 . The method of  claim 33 , wherein step (b) comprises cutting with an electric chain saw. 
     
     
         37 . The method of  claim 33 , wherein steps (c) through (f) comprise cutting with a band saw. 
     
     
         38 . The method of  claim 37 , wherein steps (c) through (f) comprise cleaning a blade of the band saw with polymer blade cleaners on opposed sides of the blade. 
     
     
         39 . The method of  claim 38 , wherein steps (c) through (f) comprise lubricating the blade with a food grade white oil. 
     
     
         40 . The method of  claim 21 , wherein:
 step (g) comprises loading no more than about 50 pounds of the ice objects in each container; and   steps (g) and (h) comprise retaining the ice objects in the containers for not greater than about 30 minutes prior to packaging.