IE980721A1 - Food processing method and apparatus - Google Patents

Abstract

Food processing apparatus for placing different food products in one of a number of different trays comprises a tray loading station (1) at an infeed end of an elongate conveyor (2). A plurality of tray filling stations along the conveyor include gaps (6, 9, 11, 14, 16) for loading, for example of layered product, sauce filling stations (5, 8, 12, 13) dry ingredient filling station (7) and a multi-head weigher (10) for delivering a predetermined weight of product to a predetermined location on a tray, and at least are topping station (15). A multi-head sealing station (19) is used for sealing the trays which are then check weighed and diverted by a diverter (21) either along a conveyor (23) to a freezer (25) or along a re-work conveyor (30). <Fig. 1>.

Description

“Food Processing Method and Apparatus” Introduction The invention relates to a food processing method and apparatus and in particular to a food processing method and apparatus for placing a plurality of different food products using different types of trays.

Various food processing equipment and processes have been developed for highly 10 efficient production of a single food product or a small range of food products on a production line.

There is however a need for an improved food processing apparatus and method which will facilitate the efficient manufacturing on a single line of a range of food products. This invention is directed towards providing such an improved food processing method and apparatus.

Statements of Invention According to the invention there is provided a food processing apparatus for placing different food products in one of a number of different types of trays comprising:a tray loading station for receiving a number of different types of trays; an elongate conveyor along which the trays are led; a plurality of tray filling stations along the course of the conveyor; the tray filling stations including:- OPEN TO PUBLIC INSPECTION UNDER SECTION 28 AND RULE 23 layered product filling stations; sauce filling stations; dry ingredient filling stations; a multi-head weigher having means for delivering a predetermined weight of product to a predetermined position on the tray; and at least one topping station; an inspection station; a multi-head sealing station for sealing the different trays; and a check weigher station.

In one embodiment of the invention the apparatus includes :a reject conveyor system after the check weigher station; diverting means for diverting rejected trays onto the reject conveyor system; and control means for operating the diverting means when a tray below a check weight is detected.

Preferably the reject conveyor system includes at least one re-work station for adding product to a rejected tray and for delivery of the tray to the infeed to the inspection station.

Preferably the apparatus includes an interface control unit, the interface being movable along a track for viewing of the interface from different viewing positions. Ideally the interface control unit is mounted on a support arm which in turn is pivotally mounted for movement along an arcuate path of the track.

Preferably the apparatus includes:a tray detector at the inlet to the multi-head sealing station, the tray detector being adjustably mounted.

Preferably the tray detector is mounted on a threaded bar which is rotatable to move the tray detector linearly.

In a preferred embodiment the multi-head sealing station includes safety guards which are mounted for quick release and consequent rapid access to the sealing heads of the sealing station. Preferably the safety guards comprise at least two separately movable safety guard sections. Ideally the safety guards comprise:a pair of main side guard sections which are hingedly mounted for movement between the closed guarding and the open access positions; and a central section which is independently mounted for opening of the central section independently of the main side guard sections.

Preferably the central section extends for at least 50% of the height of the side guard stations. Ideally the side guards extend below the central section. Preferably the central guard section is hingedly mounted to one of the main guard sections.

The invention also provides a method for producing food products by placing different food products in one of a number of different types of trays using the apparatus of the invention, the method comprising the steps of:loading food-receiving trays at a tray loading station; leading the trays along on elongate conveyor; filling food products into the trays at a number of tray filling stations including: layered product filling stations; sauce filling stations; dry ingredient filling stations; a multi-head weigher having means for delivering a predetermined weight of product to a predetermined position on the tray; and at least one topping station; inspecting the filled trays; delivering the filled trays to a multi-head sealing station for sealing the different trays; and check weighing the individual filled trays.

Preferably the method includes the steps of: diverting trays below a pre-set weight onto a reject conveyor; and leading the rejected trays along the reject conveyor to a reworking station.

In a preferred arrangement the method includes the step of moving a tray detector at an infeed of the multi-head seeding station to a position corresponding with a desired tray type or size.

Preferably the method includes the step of turning the filled tray through substantially 90° for delivery to the multi-head sealing station.

Preferably the method also includes the steps of:delivering two lanes of filled trays to the multi-head sealing station; and converting the output from the multi-head sealing station to a single lane.

Preferably the method includes the step of turning the single lane output through substantially 180° for delivery to the check weighing station.

In another embodiment the method includes the step of turning an interface controller on a mounting means for viewing and input to the controller from different positions adjacent to the multi-head sealing stations.

The invention provides food products whenever produced using an apparatus of the invention and/or using the method of the invention.

Brief Description of the Drawings Fig. 1 is a schematic plan view of a food processing apparatus of the invention.

Fig. 2 is a plan view of portion of the apparatus of Fig. 1; Fig. 3 is a plan view of a diverting station forming part of the apparatus; Fig. 4 is a side view of an interface control unit forming part of the apparatus; Fig. 5 is a plan view of a tray infeed detector station used in the invention; Fig. 6 is a cross sectional view on the line VI - VI of Fig. 5 ; Fig. 7 is a front view of a sealing head guarding system used in the invention; and Fig. 8 is a plan view illustrating the operation of the guarding system of Fig. 7.

Detailed Description .

Referring to Fig. 1 of the drawings there is illustrated a food processing apparatus according to the invention for preparing one of a variety of different food products on one of a number of different types of trays. The apparatus comprises a tray loading station 1 for receiving a number of different types of trays. The trays include a container which is sealed by means of a crimp-on foil, a sealed-on plastic film or a sealing board.

The trays are loaded onto a elongate conveyor 2 which may be in a number of sections joined end to end as illustrated. At a spraying station 3 at least portion of some of the containers may be sprayed with an oil or water dosing spray which prevents food products from drying out on reheating. A first double head sauce filling station 5 is then provided on the line followed by a gap 6 at which various ingredients may be manually filled into the trays. A dry ingredient filling station 7 is then positioned for volumetric filling of dry ingredients such as rice and the like. A second sauce dosing station 8 which again has two dosing heads is then positioned on the line. After the second sauce dosing station 8 a gap 9 is provided which again may be used for manual filling of various ingredients into the containers. A multi-head weigher 10 is then provided on the line. The multi-head weigher 10 has means for delivering a predetermined weight of product such as a meat product to a predetermined position on the tray. This station is followed by a gap 11 which again may be used for manual filling of various ingredients. Third and fourth sauce dosing stations 12, 13 are then provided on the line with a gap 14 therebetween. Each of the sauce dosing stations 12, 13 has a dual dosing head. The gap 14 again provides an area for manual filling of various ingredients into the containers as required.

A topping station 15 is then provided for applying a topping to the materials in the container as desired, such as a crumb or cheese topping. Another gap 16 is provided to facilitate further manual loading of ingredients into the containers, if required. The trays are then delivered to a two lane out-feed conveyor section 17 which has an associated weighing and inspection station 18. The trays are loaded into a multi-head sealing station 19 for sealing, in a single station, two lanes of a number of different types of trays. A conveyor 20 delivers a single lane of the sealed containers to a check weighing station 22. After check-weighing the trays are led through a diverting station 21. Trays within a preset weight are delivered along a conveyor 23 to a freezer inlet 24 which feeds the trays along a conveyor belt 25 to a spiral freezer 26.

Trays that are not within the limits set at the check weighing station 22 are diverted as will be described in more detail below to a recycle conveyor 30 which delivers the trays to the station 18 for re-working and loading back onto the main conveyor for sealing.

It will be noted that the conveyor is turned through substantially 90° for delivery of the trays to the sealing station 19. The single lane conveyor 20 from the sealing station 19 is turned through approximately 180° for delivery to the check weighing station 22. In this way maximum space utilisation is achieved in a highly efficient manner while providing long conveyor sections which are more easily monitored and controlled to optimise the operation of the sealing station 19. Similarly, the conveyor 23 leading to the spiral freezer 25 is arranged to facilitate maximum inspection and control.

A visual indicator for line restart from the sealing head 19 is provided. This is important because of the length of the line and the fact that the sealing head is out of direct vision at the start of the line.

Referring in particular to Figs. 2 and 3 the diverting apparatus 21 comprises a conveyor 40 onto which a single lane of trays from the check weigher 22 are delivered. A pair of elongate arms 41, 42 extend along the length of the conveyor 40. The arms 41, 42 are pivotally mounted about pivots 43, 44 at a check weigher end of the conveyor 40 and are each connected at 45, 46 to the rod of a ram 50. -.....

The ram 50 is operated in response to a signal from the check weigher 22 to move the arms 41, 42 from an in-line position illustrated by full lines in Fig. 3 to a diverting position illustrated by interrupted lines. In the diverting position trays below a pre-set weight are delivered onto the recycle/rework conveyor 30.

Interface control means for controlling the operation of the line and especially the sealing station 19 is provided by an interface 60 which is mounted on a swing arm 61 for movement about a longitudinal axis in the direction of the arrows A. The swing arm 61 is in turn pivotally mounted for movement about another axis L.

The arm 61 is mounted by a roller wheel 63 engaging an arcuate track 64 defining a raceway for controlled movement about the interface 60 in the direction of the arrows B in Fig. 2.

The interface 60 is therefore readily movable in the region of the sealing station 19 for maximum viewing and accessibility for operation at all points in the local area of the sealing station 19.

The user interface 60 is therefore readily available at all stages in the production cycle and is particularly accessible at change-over from one set of sealing heads to another. Thus, the change-over time is optimised.

Referring in particular to Figs. 5 and 6 a tray infeed detector 71 is adjustably mounted at an infeed location 70 (see Fig. 2) to the sealing station 19. The detector 71 is fixedly mounted in a housing 73 which in turn is linearly adjustable by engagement between threaded rods 75 and the housing 73. The threaded rods 75 are operated by thumbscrews 76. This greatly improves the efficiency, particularly at changing-over from one tray to another, as the detector 71 is easily adjusted by simply operating the thumbscrews.

Referring in particular to Figs. 7 and 8 the multi-head sealing unit 19 is fitted with a guarding system 80 on both sides. Each guarding system 80 is mounted for quick release and consequent rapid access to the sealing heads at the sealing station. Thus, rapid access may be gained to deal with any breakdown in the operation of the machine and especially for efficient changing of one set of sealing heads corresponding to one tray to another set of sealing heads corresponding to another tray.

Each guarding system 80 comprises a pair of main guards 81, 82 which are hingedly mounted for rapid movement between the closed guarding and open access positions as illustrated in Fig. 8. Each guarding system 80 also includes a central section 85 which is independently mounted for opening of the central section 85 independently of the main side guard sections 81, 82. The central section 85 extends for at least 50% of the height of the side guard sections 81, 82 and facilitates ready access for rapid repair of any faults during operation.

The guarding sections 81, 82, 85 are rapidly released by operating levers 86.

Microswitches 87 are provided to provide signals to disable the sealing station 19 on opening of the guard sections.

The food processing apparatus and method of the invention are highly efficient in preparing a wide range of different products including layered products (for example lasagne) and ready mean products which may contain a wide range of different ingredients housed in a number of compartments in a tray. The line is arranged to provide optimum production of a wide range of different products in a wide range of different trays.

The invention is not limited to the embodiments hereinbefore described and may be varied in construction and detail.

Claims (23)

1. Food processing apparatus for placing different food products in one of a number of different types of trays comprising:a tray loading station for receiving a number of different types of trays; an elongate conveyor along which the trays are led; a plurality of tray filling stations along the course of the conveyor; the tray filling stations including: layered product filling stations; sauce filling stations; dry ingredient filling stations; a multi-head weigher having means for delivering a predetermined weight of product to a predetermined position on the tray; and at least one topping station; an inspection station; a multi-head sealing station for sealing the different trays; and a check weigher station.

2. Apparatus as claimed in claim 1 including:, a reject conveyor system after the check weigher station; diverting means for diverting rejected trays onto the reject conveyor system; and control means for operating the diverting means when a tray below a check weight is detected.

3. Apparatus as claimed in claim 2 wherein the reject conveyor system includes at least one re-work station for adding product to a rejected tray and for delivery of the tray to the infeed to the inspection station.

4. Apparatus as claimed in any preceding claim wherein the apparatus includes an interface control unit, the interface being movable along a track for viewing of the interface from different viewing positions.

5. Apparatus as claimed in claim 4 wherein the interface control unit is mounted on a support arm which in turn is pivotally mounted for movement along an arcuate path of the track.

6. Apparatus as claimed in any preceding claim including: a tray detector at the inlet to the multi-head sealing station, the tray detector being adjustably mounted.

7. Apparatus as claimed in claim 6 wherein the tray detector is mounted on a threaded bar which is rotatable to move the tray detector linearly.

8. Apparatus as claimed in any preceding claim wherein the multi-head sealing station includes safety guards which are mounted for quick release and consequent rapid access to the sealing heads of the sealing station. 5

9. Apparatus as claimed in claim 8 wherein the safety guards comprise at least two separately movable safety guard sections.

10. Apparatus as claimed in claim 9 wherein the safety guards comprise:10 a pair of main side guard sections which are hingedly mounted for movement between the closed guarding and the open access positions; and a central section which is independently mounted for opening of the 15 central section independently of the main side guard sections.

11. Apparatus as claimed in claim 10 wherein the central section extends for at least 50% of the height of the side guard stations.

12. Apparatus as claimed in claim 11 wherein the side guards extend below the central section.

13. Apparatus as claimed in any of claims 10 to 12 wherein the central guard section is hingedly mounted to one of the main guard sections.

14. Food processing apparatus substantially as hereinbefore described with reference to the accompanying drawings.

15. A method for producing food products by placing different food products in one of a number of different types of trays using the apparatus of any of claims 1 to 14, the method comprising the steps of:30 loading food-receiving trays at a tray loading station; leading the trays along on elongate conveyor; filling food products into the trays at a number of tray filling stations including: layered product filling stations; sauce filling stations; dry ingredient filling stations; a multi-head weigher having means for delivering a predetermined weight of product to a predetermined position on the tray; and at least one topping station; inspecting the filled trays; delivering the filled trays to a multi-head sealing station for sealing the different trays; and check weighing the individual filled trays.

16. A method as claimed in claim 15 including the steps of: diverting trays below a pre-set weight onto a reject conveyor; and leading the rejected trays along the reject conveyor to a reworking station.

17. A method as claimed in claim 15 or 16 including the step of moving a tray detector at an infeed of the multi-head sealing station to a position corresponding with a desired tray type or size.

18. A method as claimed in any of claims 15 to 17 including the step of turning the filled tray through substantially 90° for delivery to the multi-head sealing station.

19. A method as claimed in any of claims 15 to 18 including the steps of:delivering two lanes of filled trays to the multi-head sealing station; and converting the output from the multi-head sealing station to a single lane.

20. A method as claimed in claim 19 including the step of turning the single lane output through substantially 180° for delivery to the check weighing station.

21. A method as claimed in any of claims 15 to 20 including the step of turning an interface controller on a mounting means for viewing and input to the controller from different positions adjacent to the multi-head sealing station.

22. A method for producing food products substantially as hereinbefore described with reference to the accompanying drawings.

23. Food products whenever produced using an apparatus as claimed in any of claims 1 to 14 and/or using a method as claimed in any of claims 15 to 22.