AU2023202055A1 - An apparatus for and a method of deshelling nuts - Google Patents

Abstract

The invention relates to an apparatus for deshelling nuts. The apparatus includes a feeder configured to feed an individual unshelled nut into a deshelling assembly; a cutter assembly for cutting a groove along an equator of the shell of a nut, the cutter assembly including a cutting means; wherein the deshelling assembly includes a gripper wherein the individual unshelled nut is gripped in order for the cutting means to cut a groove along the nut's equator thereby defining a half shell on either side of the groove; and a splitter, wherein the groove is engaged on either side thereof by the splitter to apply equal but opposite tensile forces on each side of the groove so as to pull apart the half shells, thereby deshelling the nut to expose a kernel. The invention extends to a method of deshelling nuts using the aforementioned apparatus. 32 10 52 46 46 44- 56 14 16 15234 20 ] 12 Fig. 1

Description

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AN APPARATUS FOR AND A METHOD OF DESHELLING NUTS FIELD OF THE INVENTION

[0001] This invention relates to an apparatus and a method using the apparatus to deshell

nuts, preferably macadamia nuts.

BACKGROUND TO THE INVENTION

[0002] Macadamias were first introduced into South Africa around the beginning of the 1960s.

Since then, the South African macadamia industry has grown to such a large extent

that it competes with Australia as being the largest producer of macadamia nuts.

[0003] South African production of macadamia nuts has increased more than 20 fold in the

last 20 years, from 1211 tons of nut in shell to 56550 tons in 2018. The total annual

production value for 2018 was around R4.2 billion (http://www.samac.orq.za/industry

overview).

[0004] Macadamia handlers use the International Nut and Dried Fruit Council Foundation's

(INC) international macadamia specification as a guide concerning deshelled

macadamia nuts for sale around the world. In terms of the INC's proposed

specification, the following "style" sizing parameters apply, wherein reference is made

to the size of the kernel of the macadamia nut and the percentage of whole kernels as

well as the number of pieces of loose shell together with the kernel for each of the

styles. In short, the INC guide is as follows: Sizing Style 0 Greater than 20mm with min 95% wholes See definition of whole kernel Style 1 16mm &21mm with min 90% wholes Style S1 13mm to 17mm 95% wholes Style 2 Greater than 13mm with min 50% wholes and large pieces ranging in size Styfre ha13mm upwads Styie 3 Greater than 13mm with min 15% whales Style 4L Greater than 13mm with min 90% halves Style 4S 9-15mm with min 50% halves Style05h-13.mmlargeschips Style S5-9mm chips and pieces Style 7 3-6 m chips Style 6 (Meal) Less then 4mm

Loose Shell Max 1 piece larger than 2mm per 100kg for style 0 to 4 and max 2 pieces per 100kg of kernel for other styles

[0005] For purposes of this specification, a "whole kernel" is defined per the INC definition,

namely kernels that are not split or separated into halves, with not more than 25% of

the kernel missing provided that the kernel contour is not materially affected by the

missing portion. Furthermore, reference to an unshelled nut shall include within its

scope the shell of the nut, alternatively referred to herein as a nutshell. Reference to a

"nut" shall mean a nut which is still shelled. The nutshell has an inner surface. The

unshelled nut contains a kernel.

[0006] In terms of the South African Macadamia organisation, macadamia kernels are classed

according to certain kernel standards, namely SAMAC First Grade, Commercial Trade

and Local market grade.

[0007] The most sought after of kernels is the first-grade kernel which have a uniform, normal,

natural cream colour.

[0008] Commercial grade kernels are kernels having some discolouration, onion rings and a

791 (cultivar) spot. These immature kernels are to be used in food ingredients and they

may not be sold as a snack and must be labelled as commercial grade.

[0009] Accordingly, the value of a processed macadamia nut is increased if a clean whole

kernel can be extracted from the shell of the nut. Furthermore, the value of half kernels

is greater than that of broken kernels.

[0010] A common form of equipment used on macadamia nuts includes a cracking apparatus

which has two opposed blades that are brought together at high speed in a rotary

device to split the shell of the nut. This form of equipment is commonly referred to as

the "shaw cracker". The shaw cracker has the disadvantage that splitting the nut by

compression between two blades results in brittle failure of the nutshell, which results

in a highly energetic shock to the kernel thereby impacting upon its integrity.

[0011] Other known techniques include "roll crackers" wherein nuts are passed through rollers

that exert a compressive force on the shell of the nut. This compression force may still

cause the nutshell to split due to brittle failure and is likely to result in a low recovery

of whole kernels.

[0012] A further disadvantage concerning equipment commonly used to deshell nuts is that

the end product of the deshelling process results in a mixture of kernels, whole or

otherwise, and shells, which shells then have to be separated out. Prior art equipment

used to deshell nuts tend to shatter the shell of the nut causing a large number of small

shell fragments which have to be removed manually or by electronic sorters which are

costly. Irrespective of the method used to remove the shells, because they are so

small, the risk of having some shell fragments in the final product is unavoidable and

quite high.

[0013] Accordingly, it is not desirable to have the shells mix with the kernels of the nuts, as

the shells may have residual pesticides, fertilisers and the like on the surface thereof

which may be transferred to the kernels. The presence of shells in the final product

reduces the value of the kernels. An additional disadvantage results from impacted

shells i.e. small fragments of shell that are lodged in the kernel. Such fragments may

damage the teeth and/or gums of a consumer eating the kernel.

OBJECT OF THE INVENTION

[0014] It is an object of the invention to provide a nut deshelling apparatus and a method for

the deshelling of a nut, preferably a macadamia nut, which at least partially overcomes

the disadvantages of the current deshelling equipment and methods.

SUMMARY OF THE INVENTION

[0015] According to the present invention there is provided an apparatus to deshell nuts, the

apparatus including: a. a feeder configured to feed an individual unshelled nut into a deshelling assembly; b. a cutter assembly for cutting a groove along an equator of the shell of a nut, the cutter assembly including a cutting means; wherein the deshelling assembly includes: c. a gripper wherein the individual unshelled nut is gripped in order for the cutting means to cut a groove along the nut's equator thereby defining a half shell on either side of the groove; and d. a splitter, wherein the groove is engaged on either side thereof by the splitter to apply equal but opposite tensile forces on each side of the groove so as to pull apart the half shells, thereby deshelling the nut to expose a kernel.

[0016] The nut is preferably a macadamia nut. "Macadamia nut" means, for purposes of this

specification, the seed of the plant Macadamia integrifolia, tetraphylla and ternifolia

and their hybrids.

[0017] In an embodiment of the invention, the feeder includes a receptacle, preferably a

hopper, which is filled with unshelled nuts.

[0018] The feeder, in an embodiment of the invention, includes a rotating disc. The hopper is

configured to accommodate the rotating disc therein. Preferably, the rotating disc is at

an angle in the hopper to allow the nuts to accumulate towards the bottom of the disc

in the hopper.

[0019] The rotating disc is provided with a supporting plate underneath. The rotating disc has

notches along the outer periphery thereof configured to accommodate a single nut, the

single nut being received within the notch and being supported by the supporting plate

while in the notch.

[0020] The supporting plate is preferably fixed relative to the rotating disc.

[0021] In terms of an embodiment of the invention, the feeder further includes a feeder wheel,

which transfers an individual nut from the notch in the rotating disc into the deshelling

assembly.

[0022] The feeder wheel includes several sets of multiple fingers and is rotatable about a

feeder wheel axis which is perpendicular to a plane in which the feeder wheel is

orientated.

[0023] One or both fingers of a set may be movable from an open condition, wherein a nut

may be received between the fingers, and a retaining condition wherein the nut is

retained between the fingers. The open condition also allows for the nut, once it has

been presented to the feeder wheel and retained between the fingers, to open in order

to transfer the nut into the deshelling assembly.

[0024] In an embodiment of the invention, the fingers are weakly biased towards each other

such that they are easily forced to the open condition as a nut first makes contact with

a finger.

[0025] In an alternate embodiment, the opposed fingers, which are biased towards each other

may be moved to the open condition by a cam follower, the cam follower being

actuated by its contact with a static cam. In this way, the fingers of the feeder wheel

are not forced open by contact with a nut and are able to accommodate different sized

nuts more easily.

[0026] The deshelling apparatus may include an ejector assembly for the ejection of mis-sized

nuts which are not received by the feeder wheel.

[0027] It will be appreciated by those skilled in the art that the hopper and method of

separating nuts into individual nuts and transferring them to the deshelling assembly

may be achieved by other mechanically equivalent methods.

[0028] Accordingly, in another embodiment of the invention, the feeder includes a drum

having a continuous side wall and a base. The drum may be filled with nuts.

[0029] The drum includes one or more blades disposed within the drum at the base thereof

to sweep the nuts around the drum.

[0030] The blades are preferably arranged in a propeller configuration and rotate around a

central stem driven by any suitable drive means.

[0031] The base of the drum is provided with an aperture therein to allow the blades to sweep

the nuts over nut retainers located on a conveyor beneath the base of the drum. The

conveyor conveys the nut retainers to the deshelling assembly.

[0032] A nut retainer, according to an embodiment of the invention includes a nut retaining

assembly and a blank which acts as a spacer. Both the nut retaining assembly and the

blank are located on and engage with a conveyor chain which moves in a direction

towards the deshelling assembly and then loops back towards the feeder after a nut is

presented to the feeder wheel and picked up.

[0033] The nut retaining assembly comprises a block with an aperture therein to receive a

nut. The assembly further includes first and second orienting rollers, such that the nuts

are supported at 4 points.

[0034] The rollers roll on a static rail and are caused to rotate by the movement of the

conveyor chain.

[0035] In use, a nut, located in the aperture, will be supported at 4 points on the rollers and

will be caused to rotate (horizontally and vertically) by the nut's contact with the surface

of the orienting rollers as they roll, such that the nut will favourably be orientated upon

its approach to the feeder wheel i.e. with the nuts principle axis horizontal and

transverse to the direction of travel along the conveyor.

[0036] In an embodiment of the invention, the gripper of the deshelling assembly comprises

a first cone configured apart from, but directly opposite to, a second cone, there being

a space between them to receive a nut.

[0037] The first cone and the second cone are movable between an open condition wherein

a nut may be received between them and an intermediate condition wherein a nut is

secured between them whilst at least the equator of the nut remains exposed.

[0038] In an embodiment of the invention the first cone is movable relative to the second cone

from the open condition to the intermediate condition.

[0039] In a form of the invention the first cone is biased towards the second cone. The cones

may be configured to spring, in a controlled manner, to the intermediate condition

thereby imparting a force on the nut which may help the kernel to be released from the

inner surface of the nutshell. The cones may further be configured to control the force

with which they spring to the intermediate condition. A dampening device to dampen

the force with which the cones spring to the intermediate position may also be

employed. The controlled springing of the cones to the intermediate position is to

ensure that the kernel or nutshell is not fractured.

[0040] In one embodiment of the invention, both cones are rotatable relative to the deshelling

assembly and each other so that the nut may be rotated about an axis substantially

perpendicular to the plane defined by the equator of the nut.

[0041] Each cone may be provided with retaining formations such as ribs or ridges on an inner

surface thereof to keep the nut, and the exposed equator of the nut, in place between

the cones. One or both cones are driven by an internal gear and pinion or by friction

against a static rubber strip, so that the nut rotates as it passes the cutter assembly.

[0042] For purposes of the invention, it will be appreciated that one need not use conically

shaped members to grip the nut. Any other suitable shape (e.g. half spheres) are

possible without departing from the spirit and the scope of the invention.

[0043] The cutter assembly of the apparatus comprises one or more cutting means, preferably

one or more saw blades, which cutting means cuts a groove along the exposed equator

of the nut, preferably along the entire equator.

[0044] In a preferred form of the invention, the groove is cut along the equator of the nut to a

depth of between 1mm to 2.5mm, preferably 2mm. The groove is not, in a preferred

embodiment, cut entirely through the nutshell.

[0045] In an embodiment of the invention, where the cutter assembly comprises one or more

saws, the cutter assembly includes a saw assembly, a saw cam assembly and a guide

assembly for each saw. The saw assembly includes a housing for the guide assembly.

The guide assembly includes a guide member, having an edge, proximate to the saw

blade of the saw, wherein the edge of the guide member is located in close proximity

and adjacent to a nut held between the first cone and second cone. In a preferred

embodiment of the invention a single saw is used.

[0046] The saw including the guide member is preferably biased towards the nut.

[0047] In use, a nut, held between the first cone and second cone will be brought to bear

against the edge of the guide member, and as it travels along the edge of the guide

member, and depending on the size of the nut, the guide assembly will cause the saw

to rock about a pivot of the guide assembly in order to accommodate the size and

shape of the nut. The saw assembly is therefore caused to rock upwardly and

downwardly by the guide assembly as differently sized nuts bear against the guide

assembly.

[0048] Where multiple saws are used, each saw may be mounted on a pivot shaft about which

the saw rotates. The saw blade is driven by a shaft allowing for the saw to rock about

a pivot of the guide assembly.

[0049] The saw assembly and guide assembly are configured to be interoperable therefore to

ensure that a groove of a substantially uniform depth is cut into the nutshell as it passes

the one or more saws.

[0050] Once the groove has been cut into the shell, it will be appreciated that there is a half

shell on either side of the groove.

[0051] The splitter of the deshelling assembly grips the nut on either side of the groove. A first

tensile force and a second tensile force, which are equal and opposite, is applied to

each half shell respectively. The half shells are pulled apart by the splitter.

Advantageously pulling either side of the shell apart reduces the potential for impacted

shells commonly resulting from current apparatus such as roller and blade cracker

deshellers which tend to push the shell into the kernel.

[0052] In an embodiment of the invention, the splitter includes a first set of jaws and a second

set of jaws, each of the jaws in the set of jaws having a gripping surface.

[0053] The jaws are, in an embodiment of the invention, movable between a retracted position

and a forward position. In the retracted position the jaws are located behind the first

and second cones respectively. In the forward position, the jaws are in front of the

cones such that the gripping surface of each jaw in the set of jaws may be brought to

bear on either side of the groove cut into the nutshell. Furthermore, each jaw is

movable from an open position (to allow access to the equator of the nutshell) to a

closed position wherein each jaw is brought to bear on and engage with and grip the

nutshell on either side of the groove cut into the nutshell.

[0054] The jaws are preferably biased in a closed position once a groove has been cut into

the nutshell.

[0055] In a preferred form of the invention the deshelling assembly may include a first product

outlet for the kernels of nuts that have been deshelled, and a second product outlet for

the shells of the nut. Two trampoline chutes are provided for each stream respectively.

Preferably, the nutshell halves are retained by the splitter jaws long enough for the

kernel to be released into a first trampoline chute.

[0056] In an embodiment of the invention, a plurality of deshelling assemblies is mountable

upon a rotatable carousel wherein a first deshelling assembly is presented to receive

a first nut from the feeder wheel. As the carousel rotates, a second deshelling

assembly is presented to receive a second nut from the feeder wheel and so on.

Preferably between 6 to 12 deshelling assemblies may be mounted on the carousel.

More preferably, 9 deshelling assemblies may be mounted on the carousel.

[0057] The carousel rotates continuously about a carousel axis perpendicular to the plane of

the feeder wheel.

[0058] The feeder wheel and the carousel are configured to rotate about their respective axes

at a rotational speed that is in sync.

[0059] According to an alternate embodiment of the invention, the deshelling apparatus

includes an impactor assembly. It will be appreciated that the kernel of a nut tends to

grow and attach itself to an inner surface of the nutshell. The impactor assembly

provides for the kernel to be loosened from the inner surface of the nutshell.

[0060] The impactor assembly may be located prior to the feeder wheel of the feeder.

[0061] The impactor assembly may include an impacting member which impacts upon a nut

which is accommodated in the notch of the rotating disc of the feeder. Preferably the

impactor assembly includes a hammer.

[0062] According to a further aspect of the invention, the apparatus as described herein may

be used to deshell a nut.

[0063] According to a further aspect of the invention there is provided a method of deshelling

a nut, the method comprising:

a. feeding a single unshelled nut into a feeding assembly as described herein;

b. presenting the nut to a deshelling assembly wherein the nut is gripped by a

gripper including a first cone configured apart from, but directly opposite to, a

second cone, there being a space between the first cone and the second cone

for receiving an unshelled nut and exposing an equator of the nut;

c. cutting a groove around the exposed equator of the nut by a cutter assembly

having a cutting means thereby defining a half shell on either side of the groove;

d. engaging either side of the groove by means of a splitter and applying an equal

but opposite tensile force on each side of the groove to pull apart the half shells,

thereby deshelling the nut to expose a kernel.

[0064] The first cone and the second cone are configured to spring, in a controlled manner,

to an intermediate condition wherein the unshelled nut is secured between them whilst

at least the equator of the nut remains exposed to the cutting means.

[0065] The splitter comprises a set of jaws which are moveable to a retracted position, in

exercising the method, wherein the jaws are located behind the first cone and the

second cone, respectively, of the gripper gripping the nut, and then a forward position,

wherein the jaws are located in front of the first cone and second cone, respectively,

of the gripper gripping the nut, such that the jaws are configured, in the forward

position, to be brought to bear on either side of the groove cut into the nutshell.

[0066] Each jaw of the set of jaws are moved between an open position and a closed position,

wherein in the closed position each jaw engages with and grips the nutshell on either

side of the groove cut into the nutshell.

[0067] According to yet a further aspect of the invention, a method of deshelling nuts is

provided, the method comprising the steps of:

a. separating the nuts into individual nuts;

b. optionally orienting the nuts with their principle axes horizontal and transverse

to the direction of travel towards the deshelling assembly;

c. feeding an individual nut into a deshelling assembly;

d. cutting a groove into the shell of the individual nut along an equator thereof;

e. splitting the shell of an individual nut having a groove cut into the equator

thereof by applying equal and opposite tensile forces on either side of the

groove to pull a first half and second half of the nutshell apart.

[0068] The method may further include the step of providing an impact force upon a nut to

promote separation of the kernel of the nut from an inner surface of the nutshell, prior

to the nut being fed into the deshelling assembly.

[0069] In an embodiment of the invention the product stream of kernels and shells are

separated from each other. This may be achieved in any suitable way. For example,

the kernels may be diverted into a first trampoline chute while the shells are diverted

into a separate second trampoline chute by retaining the shells in the splitterjaws until

after then kernel has dropped. It is envisaged that the apparatus shall also be provided

with a vacuum chute to vacuum shells, resulting from the cutting of the shells, into a

container.

BRIEF DESCRIPTION OF THE FIGURES

FIGURE 1: Is a perspective view of the deshelling apparatus according to example 1 of the

invention.

FIGURE 2: Is a perspective view of the impactor of the deshelling apparatus according to

example 1 of the invention.

FIGURE 3: Is a further perspective view of the impactor assembly of the deshelling apparatus

according to example 1 of the invention.

FIGURE 4 : Is another perspective view of the impactor assembly of the deshelling apparatus

according to example 1 of the invention.

FIGURE 5 : Is a perspective view of the feeder wheel of the deshelling apparatus according

to example 1 of the invention.

FIGURE 6 : Is a perspective view of a plurality of deshelling assemblies mounted upon a

carousel of the deshelling apparatus according to example 1 of the invention.

FIGURE 7 : Is a perspective view of a deshelling assembly of the deshelling apparatus

according to example 1 of the invention.

FIGURE 8 : Is another perspective view of a deshelling assembly of the deshelling apparatus

according to example 1 of the invention.

FIGURE 9 : Is a perspective view of a part of the cutter assembly of the deshelling apparatus

according to example 1 of the invention wherein the saw and guide assembly is shown.

FIGURE 10 : Is a perspective view of the deshelling apparatus of the invention according to

example 1 of the invention without the carousel of the invention shown in the Figure 5.

FIGURE 11 :Is a perspective view of the deshelling apparatus according to example 2 of the

invention.

FIGURE 12 Is a perspective view of the feeder of the deshelling apparatus according to

example 2 of the invention.

FIGURE 13 : Is a perspective view of the nut retainer of the deshelling apparatus according

to example 2 of the invention.

FIGURE 14 : Is a perspective view of the nut retaining assembly of the nut retainer of the

deshelling apparatus according to example 2 of the invention.

FIGURE 15 : Is a perspective view of the feeder wheel of the deshelling apparatus according

to example 2 of the invention.

FIGURE 16 : Is a perspective view of the carousel and a number of deshelling assemblies

thereon according to example 2 of the invention.

FIGURE 17 : Is a perspective view of a deshelling assembly of the deshelling apparatus in

accordance with example 2 of the invention.

FIGURE 18 : Is a perspective view of the gripper of the deshelling assembly according to

example 2 of the invention.

FIGURE 19 : Is a bottom perspective view of the cutter assembly according to example 2 of

the invention.

FIGURE 20 : Is a top perspective view of the cutter assembly according to example 2 of the

invention.

FIGURE 21 : Is a perspective view of a first component of the splitter's jaw assembly of the

deshelling assembly according to example 2 of the invention.

FIGURE 22 : Is a perspective view of the second component of the splitter's jaw assembly

according to example 2 of the invention.

FIGURE 23 : Is a perspective view of the static cams and drive strips of the deshelling

apparatus according to Example 2 of the invention.

FIGURE 24 : Is a perspective view of the saw cam assembly of the deshelling assembly

according to Example 2 of the invention.

FIGURE 25 : Is a perspective view of the saw assembly of the deshelling assembly according

to Example 2 of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0070] The order of the components of the deshelling apparatus will be explained with

reference to the journey of a nut that is to be shelled through the deshelling apparatus.

Example 1

[0071] A deshelling apparatus according to the invention is designated by the numeral 10.

[0072] Referring to Figure 1, the deshelling apparatus 10 includes a feeder 12 comprising a

hopper 14, a rotating disc 16, having notches 18 on the periphery thereof, and a

supporting fixed plate (not shown).

[0073] The rotating disc 16 is at an angle as shown in Figure 1 to accumulate nuts to be

deshelled (not shown) at the bottom of the hopper 14.

[0074] The rotating disc 16 rotates in an anti-clock wise direction as shown in Figure 1. In use,

an individual nut is separated from the rest of the nuts in the hopper 14 and is retained

in one of the notches 18.

[0075] The individual nut is carried along, in its notch 18, by the rotating disc 16 where the nut

approaches the impactor assembly 20.

[0076] Referring to Figures 2 and 3, the impactor assembly includes a main body 22 having

a pinion 24 and shaft 26. The pinion 24 is driven by a large spur gear (not shown)

provided under the rotating disc 16 and the support plate (not shown).

[0077] The hammer body 22b is provided with a helical ridge 28 terminating in a hammer

surface 30. In use, the pinion 24, engaged by the large spur gear (not shown), causes

the hammer body 22b to rotate upwardly as a result of the helical ridge 28 and one or

more fixed cam arms 32 (Figure 4) on which the helical ridge 28 travels. The hammer

body 22b is spring loaded to a hammer position wherein the hammer surface 30 can

impact upon a nut. As the helical ridge 28 travels along the one or more fixed cam

arms 32, the hammer body 22b is lifted upwardly to then spring back to the hammer

position.

[0078] It will be appreciated that the assembly used to impact a nut may be configured

differently without departing from the feature that the nut is struck in order to loosen

the kernel of the nut from an inner surface of the shell.

[0079] Once the nut has been impacted, it will travel in its notch 18 to the feeder wheel 34.

Referring to Figure 5, the feeder wheel 34 includes fixed fingers 36 and movable

fingers 38. The movable fingers 38 are biased towards the fixed fingers 36. As a nut

approaches the feeder wheel 34, it will be retained between the fixed fingers 36 and

movable fingers 38 by forcing them apart to accommodate the nut.

[0080] The feeder wheel 34 rotates about a shaft 40 which is provided with a pinion 42 and is

caused to rotate in sync with the rotation of the carousel 44 (Figure 1) and the rotating

disc 16.

[0081] Referring to Figures 1 and 6, the carousel 44 has a plurality of deshelling assemblies

46 mounted thereon. In use, the carousel 44 rotates anti clockwise and in sync with

the feeder wheel 34, such that a single nut is presented to a single deshelling assembly

46 on the carousel 44 as it rotates.

[0082] Referring to Figures 7 and 8, the deshelling assembly 46 includes a gripper comprising

a first cone 48 opposite to a second cone 50, which cones are spaced apart in an open

condition to receive a nut (not shown). It will be appreciated that the gripper may be

modified such that the shape of the cones are changed to any other suitable shape to

accommodate different types and shapes of unshelled nuts.

[0083] The first cone 48 is biased towards the second cone 50. The first cone 48 is caused

to move away from the second cone 50, to receive a nut between the two cones by

means of a first cam 52 (Figure 1) and first cam follower 54. Thereafter the first cone

48 is caused to spring back towards the second cone 50 to an intermediate position

wherein the nut is securely held and the equator of the nut is exposed for cutting into.

The cam 52 is mounted on a frame of the deshelling apparatus. The fist cone and

second cone spring to the intermediate position in a controlled manner thereby

preventing or substantially minimising the fracturing of the nutshell and/or the kernel.

[0084] At this point the jaws 49a and 49b are in a forward and open condition as shown in

Figure 7.

[0085] The deshelling assembly 46 is caused to move towards a cutter assembly 56 including

two saws 58 such that a groove may be cut into the equator of the nut which is retained

between the first cone 48 and the second cone 50.

[0086] The second cone 50 includes a shaft (not shown) and a pinion 51 (shown in Figure 7)

such that the second cone 50 is rotatable about an axis defined by the plane in which

the shaft and pinion 51 lie. The pinion is driven by a fixed gear which is connected to

the frame of the deshelling apparatus.

[0087] Referring to Figure 9, a first saw 58 and its guide assembly 60 forms part of the cutter

assembly 56. The guide assembly 60 includes a guide member 62. In use, and when

the first saw is presented with a nut, retained between the first cone 48 and second

cone 50, the nut will be brought to bear upon an edge of the guide member 62. As the

carousel 44 rotates, the deshelling assembly 46 moves with the carousel thereby

forcing the nut to travel along the guide member 62. As the nut travels on the edge of

the guide member 62, and depending on the size of the nut, the guide member 62 may

cause the guide assembly 60 to rock about a pivot 64 of the guide assembly 60 to

accommodate variances in the size of the nuts being deshelled.

[0088] As the nut moves, the nutshell comes into contact with the blade of a first saw 58 and

the blade of a second saw, also designated by the number 58.

[0089] The cutter assembly allows for a groove of substantially the same depth to be cut into

the nutshell.

[0090] Once a groove has been cut into the nutshell, thereby defining two halves of a shell,

one on either side of the groove, the deshelling assembly rotates with the carousel 44

past the cutter assembly 56.

[0091] Once past the cutter assembly 56, the jaws 49a and 49b move forward towards each

other and spring to a closed position wherein each jaw engages with and grips the two

half shells respectively.

[0092] Having regard to Figures 7 and 8, it will be appreciated that the jaws 49a and 49b are

movable between a retracted position and a forward position. Furthermore, each jaw

is movable from an open position (to allow access to the equator of the nutshell) to a

closed position wherein each jaw engages with and grips the nutshell on either side of

the groove.

[0093] In an example of the invention and having regard to Figures 7 and 8, a splitter is shown

including a jaw assembly (shown in part) which includes a first pair of cam followers

66a and a second pair of cam followers 66b which engage with a second cam 68 which

is shown in Figure 10. The second cam 68 is also fixed to the frame of the deshelling

apparatus.

[0094] As the carousel 44 rotates towards the feeder wheel 34, cam followers 66a and 66b

engage with the second cams 68a and 68b respectively to keep the pair of jaws 49a

and 49b in a retracted and open position.

[0095] The jaws 49a and 49b remain in the above condition until the deshelling assembly 44

passes the cutting assembly 56 and a groove has been cut into the nutshell.

[0096] Referring to Figure 1 and 10, after the jaws 49a and 49b have engaged the shell, the

first and second pair of cam followers 66a and 66b re-engage with the second cams

68a and 68b such that the jaws 49a and 49b are caused to move from the forward

closed position to the retracted position thereby pulling each half of the nutshell apart.

[0097] Once the half shells have been pulled apart, the first cam 52 engages the first cam

follower 54 of the first cone thereby to move the first cone 48 to the open position such

that the kernel and the half shells are freed.

[0098] Preferably, the kernel shall fall into a product outlet and the half shells shall be directed

to a shell outlet such that shells and kernels are separated by the deshelling apparatus.

[0099] Once the kernels and shells are freed, and as the carousel rotates, the second pair of

cam followers 66a and 66b cause the jaws 49a and 49b to move to the retracted open

position.

[0100] It will be appreciated by the skilled person that the manner in which parts such as the

jaws, cones and the like are caused to move between conditions may be achieved in

other suitable ways without departing from the spirit and scope of the invention.

Example 2

[0101] Example 2 demonstrates another embodiment of the invention without departing from

the spirit and scope of the invention.

[0102] A deshelling apparatus according to an alternate embodiment of the invention is

designated by the numeral 100. The static cams and drive strips referred to herein

below are detailed in Figure 23.

[0103] Referring to Figures 11 and 12, the deshelling apparatus 100 includes a feeder 102

comprising a drum 104 having a base 106 and a continuous side wall 108.

[0104] The drum 104 includes six blades 110 disposed within the drum 104 at the base 106.

[0105] The six blades 110 are preferably arranged in a propeller configuration and rotate

around a central stem 112 driven by any suitable drive means (not shown).

[0106] The base 106 of the drum 104 is provided with an aperture 114 therein to allow the

blades 110 to sweep nuts in the drum 104 over nut retainers 116 located on a conveyor

118 beneath the base 106 of the drum 104. The conveyor 118 conveys the nut

retainers 116 to the deshelling assemblies 400.

[0107] Referring to Figures 13 and 14, the nut retainer 116 includes a nut retaining assembly

120 and a blank 122. Both the nut retaining assembly 120 and the blank 122 are

located on and engage with a conveyor chain 124 which moves in a direction towards

the feeder wheel 220 and then loops back towards the feeder 102 after a nut is

presented to the feeder wheel 220 (Figures 11 and 15) and picked up.

[0108] The nut retaining assembly 120 includes an aperture 126 therein to receive a nut. The

assembly 120 further includes first 128 and second 130 orienting rollers, wherein four

points of support 132 are provided to cradle the nut. The points of support 132

preferably lie underneath the aperture 126.

[0109] The orienting rollers 128 and 130 are caused to rotate by static support rails (not

shown).

[0110] In use, a nut, located in the aperture, will be positioned such that it is at least partially

supported by the orienting rollers 128 and 130 and will be caused to rotate (horizontally

and vertically) by the nut's contact with the surface of the orienting rollers 128 and 130

as they roll such that the nut will favourably be orientated (i.e. with its principle axis

horizontal and transverse to the direction of travel) upon its approach to the feeder

wheel 220.

[0111] In this example 2, an impactor assembly is not included in the deshelling apparatus.

[0112] Referring to Figure 15, the feeder wheel 220 is similar to that described in paragraphs

[0079] and [0080] herein. In this embodiment however the moveable fingers 222 and

fixed fingers 224 are biased toward each other by a torsion spring 225. As the nut

approaches the feeder wheel 220, the fixed cam 226 pushes the cam follower 228 so

that the moveable finger 222 is in an open position to receive a nut. At bottom dead

centre, when the nut in the retaining assembly 116 is between the fingers, the cam 226

releases the fingers 222 towards the fixed fingers 224 so that the nut will be retained

between the fixed fingers 224 and moveable fingers 222.

[0113] Referring to Figure 11 and Figure 16, the carousel 300 has a plurality of deshelling

assemblies 400 mounted thereon. In use, the carousel 300 rotates anti clockwise and

in sync with the feeder wheel 220 such that a single nut is presented to a single

deshelling assembly 400 on the carousel 300 as it rotates.

[0114] Referring to Figures 17 and 18, the deshelling assembly 400 includes a gripper 402

comprising a first cone 402a opposite to a second cone 402b, which cones 402a and

402b are spaced apart in an open condition to receive a nut (not shown). The cones

402a and 402b are inter-operably connected by a gear segment 404 such that they

move symmetrically from an open condition to a closed condition, and vice versa.

[0115] The first cone 402a is biased towards the second cone 402b by means of a spring 406.

The first cone 402a is caused to move away from the second cone 402b to receive a

nut between the two cones by means of a cam (not shown) and a cam follower 408.

Thereafter the first cone 402a is caused to spring back, in a controlled manner, towards

the second cone 402b by the spring 406 to an intermediate position wherein the nut is

securely held and the equator of the nut is exposed for cutting into. The cam is mounted

on a frame of the deshelling apparatus 100.

[0116] The first cone 402a and second cone 402b include a shaft (not shown) and a cylindrical

drive surface (not shown) such that the cones 402a and 402b are rotatable about an

axis defined by the plane in which the shaft and cylindrical drive surface lie. The cones

402a and 402b are driven by a fixed rubber strip (not shown) which is connected to the

frame of the deshelling apparatus 100.

[0117] The deshelling assembly 400 is caused to move towards a cutter assembly 600

(Figures 19 and 20) such that a groove may be cut into the equator of the nut which is

retained between the first cone 402a and the second cone 402b.

[0118] In this Example 2, the cutter assembly 600 has been modified from the cutter assembly

in Example 1, while retaining the spirit and scope of the invention.

[0119] Referring to Figures 19, 20, 24 and 25, the cutter assembly 600 comprises a saw

assembly 660 (Figure 25) and a saw cam assembly 664 (Figure 24). The saw

assembly 660 and saw cam assembly 664 pivot on the same axis in fixed bearings

525 (Figure 11) of the deshelling apparatus 100. Relative to the saw cam assembly

664, the saw assembly 640 is biased downward by a rubber buffer 640d and supported

by an adjustable stop 635 (Figure 25) which bears on the stop flange 640e (Figure 24).

[0120] Components of the cutter assembly are all inter-operable to ensure that the saw of the

saw assembly is in contact with the shell of a nut for a maximum period as it cuts a

groove along the equator of the nut at a consistent depth. The inter-operability of the components also allows for the accommodation of different sized nuts within defined tolerances so as to achieve grooves having a substantially uniform depth into the shell of the nuts regardless of size differences. Expanding upon the components of the cutter assembly:

[0121] The saw assembly 660 (Figure 25) includes a housing 662 which accommodates the

guide assembly 640.

[0122] The saw cam assembly 664 includes a rotating disc cam plate 664a having a groove

provided along the periphery of the disc cam plate 664b. The cam 664b is part of the

carousel 300. The groove 664b has a wave pattern as shown in Figure 20 and Figure

24. The saw cam assembly 664 further includes a cam follower arm 664c. It also

includes the dampener 640d which includes a buffer in the form of a resiliently

deformable cone, and a stop flange 640e.

[0123] A roller 664d at an end of the cam follower arm 664c is received within the groove

664b. The cam follower arm 664c includes a cam follower shaft 664e at the other end

thereof. The cam follower shaft 664e is fixedly attached to the arm 665 such that as

the disc cam plate 664a rotates about its axis, the cam follower arm 664c follows the

pattern thereby causing the saw cam assembly 664 to undulate smoothly up and down.

The undulation of the saw assembly 660 is synchronised with the passage of a nut

along the trajectory towards, past and away from the cutter assembly 600.

[0124] In order to accommodate a variance of 1mm to 2mm between the size of the nuts

passing through the cutter assembly, the guide assembly 640 plays an important role.

[0125] The guide assembly 640 includes a first guide member 640a and a second guide

member 640b having the disc shaped saw 661 between them. The saw 661 is

connected to a drive shaft 640c which is connected to the motor 620 to cause the saw

661 to rotate. The first guide member 640a and second guide member 640b operate in the same manner as described in paragraph [0087] insofar as the rocking action of the guide assembly 640 is concerned.

[0126] In order to accommodate variances in the size of a nut by a few millimetres, and still

obtain substantially uniform grooves cut into a nutshell irrespective of such variances,

the first guide member 640a and second guide member 640b are connected fixedly to

each other and other components of the saw assembly 660 (Figure 25). If a nut is

larger than a certain minimum diameter, its shell will bear against at least one of the

guide members, causing the saw assembly 660 to move up relative to the saw cam

assembly 640, thereby compressing the dampener 640d, and so the groove is cut only

to the depth determined by the guides.

[0127] In use, a nut held within the deshelling assembly 400 will have its equator, preferably

its minor equator, presented to the saw 661 as the saw assembly 660 undulates

upwards to accommodate the nut. As the nut is presented to the saw 661, and if the

nut is slightly larger than other nuts, said nut will bear against the guide members 640a

and 640b, as it continues its trajectory, such that the saw assembly 660 is caused to

rock upwardly to accommodate the variance in size of the nut, which rocking is

dampened by the resiliently deformable cone.

[0128] As the nut continues its trajectory beyond the saw 661, the saw assembly 660 will rock

back to a resting position which is achieved by a stop member 635 bearing against a

stop flange 640e provided for on the bracket 665 of the saw cam assembly 664.

[0129] Once a groove has been cut into the nut, thereby defining two halves of a shell, one

on either side of the groove, the deshelling assembly 400 rotates with the carousel 300

past the cutter assembly 600 and the separation of the nutshell from the nut kernel

takes place.

[0130] The splitter of the deshelling assembly is like the splitter exemplified under example 1

in that each jaw in the set of jaws is movable from a retracted position and a forward position, as well as an open position (to allow access to the equator of the nutshell) to a closed position wherein the jaws engage with and grip the nutshell on either side of the groove. The jaws operate in the same manner as described in paragraph [0092], however the jaw assembly has been modified to have fewer components making it a smaller unit.

[0131] The jaw assembly includes two major components.

[0132] The first is the component 800 responsible for moving the jaws 820a and 820b from a

retracted position to a forward position and vice-versa. Referring to Figure 21 the jaws

820a and/or 820b may be moved to the retracted position by means of a cam (not

shown) and cam follower 840 (on the first set of jaws 820a) arrangement, wherein the

cam is on the deshelling apparatus 100. The jaws 820a and 820b are connected by a

gear linkage 860 so that when the cam and cam follower 840 co-operate together, the

jaws 820a and 820b will move in sync from a retracted position to a forward position

and vice-versa.

[0133] The first component 820 further includes a first cam 880a and a second cam 880b on

either side of the jaws 820a and 820b, which cams engage with corresponding cam

followers 900a and 900b on the second component 900 shown in Figure 17 and Figure

22.

[0134] The second component of the jaw assembly 900 is that which controls the movement

of the jaws from an open position to a closed position, thereby allowing either side of

the nutshell to be engaged and gripped.

[0135] Referring to Figure 22, the second component 900 includes oppositely disposed first

920a and second 920b frames, each frame accommodating the gripper 402 and the

first component 800 between them. Each frame is also provided with an aperture cam

follower 940a and 940b in a wall 960 thereof, which aperture cam follower 940a and

940b is dimensioned and configured to receive the first cam 880a and second cam

880b of the first component 800.

[0136] The first frame 920a and second frame 920b are inter-operably connected by means

of a gear linkage 980. Either of the first frame 920a or second frame 920b are provided

with a cam follower 990 corresponding to a cam on the deshelling apparatus 100.

When the cam and cam follower 990 co-operate together, the first and second frames

920a and 920b are caused to rock backwards or forwards. The backwards and

forwards movement causes the jaws 820a or 820b to open and close via the cam 880a

and 880b and aperture cam follower 940a and 940b in the wall 960 of either frame,

which in turn will cause the corresponding jaws 820a and 820b to open and close.

[0137] Each set of jaws 940a and 940b remain in a retracted condition until the deshelling

assembly 400 passes the cutting assembly 600 and a groove has been cut into the

nutshell.

[0138] Once a groove has been cut into the nutshell, each of jaws 940a and 940b are caused

to move from the retracted open position to the forward position in order to close and

bear upon either side of the groove cut into the nutshell.

[0139] As the carousel 300 rotates, the jaws 940a and 940b and the cups 402a and 402b are

caused to retract, thereby pulling on either side of the nutshell to split the nutshell into

two halves thereby freeing the nut kernel.

[0140] Preferably, the kernel shall fall into a product outlet, i.e. a first trampoline chute, and

the half shells shall be diverted to a shell outlet i.e.; a second trampoline chute, such

that shells and kernels are separated by the deshelling apparatus. This is achieved by

retaining the shells in the splitter jaws until after the kernel falls into the product outlet.

[0141] The desheller 100 includes fixed cams and drive strips 500 shown in Figure 23.

[0142] The gripper fixed cam 505 (Figure 23) controls the gripper cam followers 408 (Figure

18). Gripper fixed cam 505 is cut away at the transfer point from the feeder wheel 220

so the grippers are released to hold the nut.

[0143] The splitter cam 515 has a back face (as shown in Figure 23) which controls the cam

followers 840 (Figures 17 and 21), and a front face which controls the cam followers

990 (Figures 17 and 22).

Claims (18)

Claims:

1. An apparatus to deshell nuts, the apparatus including:

(a) a feeder configured to feed an individual unshelled nut into a deshelling assembly;

(b) a cutter assembly for cutting a groove along an equator of the shell of the individual

unshelled nut, the cutter assembly including a cutting means; and

wherein the deshelling assembly includes:

(c) a gripper wherein the individual unshelled nut is gripped in order for the cutting means

to cut a groove along the unshelled nut's equator thereby defining a half shell on either

side of the groove; and

(d) a splitter, wherein the groove is engaged on either side thereof by the splitter to apply

equal but opposite tensile forces on each side of the groove so as to pull apart the half

shells, thereby deshelling the unshelled nut to expose a kernel.

2. The apparatus of claim 1, wherein the feeder includes a feeder wheel having several sets

of multiple fingers, one or both fingers in the set of multiple fingers being moveable

between an open condition, for receiving an unshelled nut between the fingers, and a

closed position, wherein the unshelled nut is retained between the fingers.

3. The apparatus of claim 1, wherein the cutting means includes at least one saw blade and

the cutter assembly includes a saw assembly and a guide assembly.

4. The apparatus of claim 3, wherein the guide assembly includes a guide member for the

at least one saw blade, the guide member being proximate to the at least one saw blade

and being in close proximity and adjacent to the individual unshelled nut gripped by the

gripper.

5. The apparatus of claim 3, wherein the saw assembly and the guide assembly are

configured to be interoperable such that differently sized unshelled nuts are

accommodated whilst still cutting a substantially uniform groove in the nutshell.

6. The apparatus of claim 5, wherein the saw assembly is caused to rock upwardly and

downwardly by a guide member of the guide assembly, the guide member having an edge

which bears against the individual unshelled nut.

7. The apparatus of claim 1, wherein the gripper includes a first cone configured apart from,

but directly opposite to, a second cone, there being a space between the first cone and

the second cone for receiving an unshelled nut.

8. The apparatus of claim 7, wherein the first cone and the second cone are moveable

between an open condition, for receiving an unshelled nut, and an intermediate position

wherein the unshelled nut is secured between them whilst at least the equator of the

unshelled nut remains exposed to the cutting means.

9. The apparatus of claim 8, wherein the first cone and the second cone are configured to

spring, in a controlled manner, to the intermediate condition thereby imparting a force on

the shell of the unshelled nut in order to facilitate a kernel of the unshelled nut to be

released from an inner surface of the shell.

10. The apparatus of claim 8, wherein at least one cone is rotatable relative to the deshelling

assembly and the other cone, thereby rotating the unshelled nut about an axis

substantially perpendicular to a plane defined by the equator of the unshelled nut, as the

unshelled nut passes by the cutter assembly.

11. The apparatus of claim 1, wherein the splitter comprises a set of jaws moveable between

a retracted position, wherein the jaws are located behind a first cone and a second cone,

respectively, of the gripper gripping the nut, and a forward position, wherein the jaws are

located in front of the first cone and second cone, respectively, of the gripper gripping the

nut, such that the jaws are configured, in the forward position, to be brought to bear on

either side of the groove cut into the nutshell.

12. The apparatus of claim 11, wherein each jaw of the set of jaws is moveable between an

open position and a closed position, wherein in the closed position each jaw is brought to

bear, engage with and grip the nutshell on either side of the groove cut into the nutshell.

13. The apparatus of claim 12, wherein the jaws are moved to the retracted position

subsequent to each jaw being brought to bear, engage with and grip either side of the

groove cut into the nutshell, thereby imparting a first tensile force and a second tensile

force on either side of the groove cut into the nutshell thereby pulling apart the half shells

of the unshelled nut.

14. A method of deshelling a nut, the method comprising:

(a) feeding a single unshelled nut into a feeding assembly of an apparatus of claim 1;

(b) presenting the unshelled nut to a deshelling assembly wherein the unshelled nut is

gripped by a gripper including a first cone configured apart from, but directly opposite

to, a second cone, there being a space between the first cone and the second cone

for receiving an unshelled nut and exposing an equator of the unshelled nut;

(c) cutting a groove around the exposed equator of the unshelled nut by a cutter assembly

having a cutting means thereby defining a half shell on either side of the groove;

(d) engaging either side of the groove by means of a splitter and applying an equal but

opposite tensile force on each side of the groove to pull apart the half shells, thereby

deshelling the unshelled nut to expose a kernel.

15. The method of claim 14 wherein the first cone and the second cone are configured to

spring, in a controlled manner, to an intermediate condition, wherein the unshelled nut is

secured between them whilst at least the equator of the unshelled nut remains exposed

to the cutting means.

16. The method of claim 14, wherein the splitter comprises a set of jaws which are moved to

a retracted position, wherein the jaws are located behind the first cone and the second

cone, respectively, of the gripper gripping the unshelled nut, and then a forward position,

wherein the jaws are located in front of the first cone and second cone, respectively, of

the gripper gripping the unshelled nut, such that the jaws are configured, in the forward

position, to be brought to bear on either side of the groove cut into the nutshell.

17. The method of claim 16, wherein each jaw of the set of jaws is moved between an open

position and a closed position, wherein in the closed position each jaw, engages with and

grips the nutshell on either side of the groove cut into the nutshell.

18. The apparatus of claim 1 or the method of claim 14, wherein the unshelled nut is a

macadamia nut.

HG Molenaar & Co (Pty) Ltd. Patent Attorneys for the Applicant/Nominated Person SPRUSON&FERGUSON