IES84361Y1 - An apparatus for producing and handling a flowing substance - Google Patents
An apparatus for producing and handling a flowing substance Download PDFInfo
- Publication number
- IES84361Y1 IES84361Y1 IE2005/0294A IE20050294A IES84361Y1 IE S84361 Y1 IES84361 Y1 IE S84361Y1 IE 2005/0294 A IE2005/0294 A IE 2005/0294A IE 20050294 A IE20050294 A IE 20050294A IE S84361 Y1 IES84361 Y1 IE S84361Y1
- Authority
- IE
- Ireland
- Prior art keywords
- reservoir
- starter culture
- culture
- fermentation
- ingredients
- Prior art date
Links
- 239000000126 substance Substances 0.000 title claims description 13
- 239000007858 starting material Substances 0.000 claims abstract description 114
- 239000004615 ingredient Substances 0.000 claims abstract description 44
- 238000000855 fermentation Methods 0.000 claims abstract description 41
- 230000004151 fermentation Effects 0.000 claims abstract description 41
- 230000000717 retained Effects 0.000 claims abstract description 6
- 238000002360 preparation method Methods 0.000 claims abstract description 3
- 238000004519 manufacturing process Methods 0.000 claims description 63
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 46
- 235000013312 flour Nutrition 0.000 claims description 39
- 239000000203 mixture Substances 0.000 claims description 35
- 238000002156 mixing Methods 0.000 claims description 34
- 230000000977 initiatory Effects 0.000 claims description 21
- 238000000034 method Methods 0.000 claims description 18
- 230000001105 regulatory Effects 0.000 claims description 18
- 238000001816 cooling Methods 0.000 claims description 16
- 238000011068 load Methods 0.000 claims description 12
- 238000003860 storage Methods 0.000 claims description 11
- 206010040007 Sense of oppression Diseases 0.000 claims description 9
- 238000011049 filling Methods 0.000 claims description 9
- 239000007788 liquid Substances 0.000 claims description 6
- 238000007599 discharging Methods 0.000 claims description 4
- 230000000694 effects Effects 0.000 claims 1
- 238000004140 cleaning Methods 0.000 description 17
- 239000012530 fluid Substances 0.000 description 9
- 241001438449 Silo Species 0.000 description 4
- 244000005700 microbiome Species 0.000 description 4
- 238000005303 weighing Methods 0.000 description 4
- 239000002826 coolant Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- 230000003442 weekly Effects 0.000 description 3
- 235000008429 bread Nutrition 0.000 description 2
- 239000003599 detergent Substances 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 1
- 235000013365 dairy product Nutrition 0.000 description 1
- 238000011143 downstream manufacturing Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000008236 heating water Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000005416 organic matter Substances 0.000 description 1
- 235000014594 pastries Nutrition 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- 239000008237 rinsing water Substances 0.000 description 1
- 230000000630 rising Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
Abstract
ABSTRACT A system (1) for producing a dough starter culture is provided which comprises a plurality of reservoirs (15) pre-loaded with a small amount ("mother level") of a previously obtained starter culture. Into the reservoirs (15) are inoculated the ingredients required for the preparation of starter culture and the contents are left to ferment for a specified period of time to produce the required starter culture, which is then discharged as required from each reservoir (15). A "mother level" portion is retained in the reservoir and is used to produce a next batch of starter culture. The system (1) operates automatically and is programmable so that a first pre-set interval of time which is less then the fermentation time is allowed to elapse from the start of fermentation in a first reservoir (15) before the ingredients are delivered into a succeeding reservoir (15), and a second pre-ser interval of time is allowed to elapse after the starter culture is discharged from the first reservoir (15) before a next batch of the ingredients is delivered into the first reservoir ( 15).
Description
AN APPARTUS FOR PRODUCING AND HANDLING A FLOWING SUBSTANCE
The present invention relates to a system for producing and handling a flowing substance
and in particular to a system for producing and handling a starter culture such as, for
example, dough starter culture.
Starter culture is a very delicate substance comprising microorganisms which process
organic matter, to produce compounds useful in dairy, baking, brewing and many other
industries. Performance of these microorganisms, and therefore the quality of starter
culture, highly depends on temperature conditions of the environment in which the starter
culture is produced. Even slight fluctuations of this temperature may affect the process
and the characteristics of the final product may differ from the required ones.
Fermentation time is also a very important parameter and must be accurately controlled.
In a production line environment, such as for example, a bakery line, it is difficult to
provide a large-scale starter culture managing system without the need for a large number
of staff for such operations as control and monitoring of the process, cleaning, etc. On
the other hand, manual operations are prone to mistakes which put the production at risk.
Similar problems exist in production of any flowing substance in a controlled environment
on a large scale.
The present invention seeks to alleviate the above disadvantages.
Accordingly, the invention provides a system for producing and handling a flowing
substance comprising
a mixing vessel for mixing ingredients for use in subsequent preparation of a flowing
substance;
a first manifold for transferring the mixed ingredients from the mixing vessel into one of a
plurality of reservoirs where the mixed ingredients are combined with initiating culture;
a first regulating means for maintaining predetermined conditions in each reservoir in
order to produce a starter culture as a flowing substance having predetermined properties
from the initiating culture and the mixed ingredients;
a second manifold for transferring the starter culture from each reservoir to at least one
receiving container; and
an electronic control means operable to control the system to provide delivery of mixed
ingredients to each reservoir in a specified sequence so that a pre-set interval of time
elapses before the delivery of the mixed ingredients into a succeeding next reservoir, said
interval being less than the fermentation time of the starter culture in the preceding
reservoir.
Such arrangement of the system ensures availability of adequate supplies of starter
culture of required quality during a specified period of time, for example during a
production run of a bakery line, such as a five—day production week. Any number of
reservoirs greater than one may be employed in such a system. For example, eight
reservoirs have been found to suit a five-day production plan and a fermentation time of
twelve hours in each reservoir.
Conveniently, the system comprises a first measuring means at each of the reservoirs for
measuring required quantity of the ingredients delivered into each reservoir; a second
measuring means for measuring required quantities of the ingredients in the mixing
vessel; and a third measuring means for measuring quantity of the starter culture
delivered into the at least one receiving container.
Ideally, the system further comprises a second regulating means for maintaining
conditions of the ingredients being mixed in the mixing vessel and a third regulating
means for maintaining conditions of the starter culture in the at least one receiving
reservoir.
The system preferably comprises a first propelling means for transferring mixed
ingredients into each reservoir via the first manifold and a second propelling means for
transferring the starter culture produced in the reservoir into the receiving container via the
second manifold.
ideally, the first regulating means comprises a first temperature regulating means for
regulating processing temperature of the mixed ingredients and initiating culture being
processed in the reservoir; the second regulating means comprise a second temperature
regulating means for regulating temperature of the ingredients being mixed in the mixing
vessel; and the third regulating means comprise a third temperature regulating means for
regulating temperature of the starter culture in the receiving reservoir.
A temperature measuring means is ideally provided at each of the mixing vessel,
reservoirs and the at least one receiving vessel.
Preferably, the first and the second propelling means comprise first and second pumps
respectively.
Conveniently, the first temperature regulating means comprises heating means and
cooling means for regulating the temperature of the mixed ingredients and initiating
culture being processed in each reservoir. The heating means may comprise a heating
station having a water tank for heating water and a pipework which delivers the heat from
the water in the tank to the reservoirs. The cooling means may comprise a cooling
station which supplies a coolant to the tank via a cooling manifold.
In a preferred arrangement, the receiving container comprises a dosing vessel having
measuring means from which required quantities of starter culture are transferred to
further downstream processing steps. Such a closing vessel may be located in an area
remote from the reservoirs. However, a smaller tank may be located at each reservoir for
local discharge of the contents of each reservoir.
In one application, the ingredients being mixed in the mixing vessel comprise at least one
powdery ingredient and at least one liquid ingredient such as, for example, flour and water
respectively for subsequent production of a starter culture, and most ideally, a starter
culture for making dough for subsequent baking.
in a most preferred arrangement, the system comprises at least one storage container for
storage of the powdery ingredient, the storage container being connected to the mixing
vessel via a delivery means. The delivery means comprises a delivery manifold leading
from the storage container to the mixing vessel and liquid manifold for supplying a liquid
ingredient into the mixing vessel.
Ideally, the powdery ingredient is initially delivered from the storage container into an
intermediate dosage container prior to its transfer into the mixing vessel. From the
dosage container, the powdery ingredient is preferably delivered into the mixing vessel via
a weight-difference measurement (loss-in-weight) mechanism.
Ideally, the first measuring means comprise a plurality of first weighing mechanisms each
connected to one of the plurality of reservoirs; the second measuring means comprise a
second weighing mechanism connected to the mixing vessel; the third measuring means
comprise a third weighing mechanism connected to the at least one receiving vessel.
Advantageously, the system also includes a plurality of supply manifolds for delivering
cleaning and rinsing fluids from a cleaning station to a plurality of locations in the system,
and a plurality of return manifolds for collecting and returning said fluids from said plurality
of locations back to said cleaning station. The system preferably includes spray means
for spraying said fluids over components of the system at said plurality of locations.
Ideally, the electronic control means comprise a programmable logic controller (PLC)
suitably programmed to read input signals from any of the first, second and third weighing
means and from the temperature measuring means, to process the input signals and then
send, if required, relevant output signals to any of the delivery means, the first and second
propelling means and the first, second and third temperature regulating means to actuate
said means in a manner which ensures
provision of required quantities of ingredients in the mixing vessel;
maintenance of a pre-determined temperature of the ingredients being mixed in the mixing
vessel;
delivery of required quantities of mixed ingredients at required times from the mixing
vessel to the reservoir;
control of a pre-determined temperature of the mixed ingredients and initiating culture
being processed in the reservoir; and
provision of required processing time intervals, so as to obtain a starter culture having pre-
determined properties.
The PLC is linked to a real time clock for use in conjunction with the PLC program.
Ideally, the PLC is programmable to actuate the cooling station in order to lower the
temperature of the starter culture in a reservoir to retard or stop further fermentation in the
reservoir.
Ideally. the PLC is programmable to control the second propelling means to discharge
starter culture produced in each reservoir, save for a portion of the starter culture which
remains in the reservoir and is intended for a subsequent cycle of production of starter
culture in this reservoir, the remaining portion being sufficient to serve as initiating culture
for the subsequent cycle. Sensor means are provided connected between a reservoir
and the PLC for enabling the PLC to determine the quantity of starter culture in the
reservoir and preventing the quantity falling below a predetermined quantity on actuation
of the second propelling means. This ensures that sufficient starter culture is retained in
each reservoir to enable a desired amount of fresh culture to be prepared in that reservoir
within a predetermined time.
The PLC ideally controls the system in accordance with a previously entered quantity of a
starter culture to be produced during a production run of the system.
In another aspect the invention provides a method for producing dough starter culture in
the above described system having a plurality of reservoirs comprising the steps of:
a) pre-loading culture reservoirs with a desired amount of initiating culture maintained
at an oppression temperature;
b) filling at least one reservoir with a relevant amount of water/flour mix;
c) allowing the contents of the reservoir to ferment at a specified fermentation
temperature for a pre-set fermentation time interval;
d) cooling the obtained fermented starter culture to an oppression temperature to
stop the fermentation process;
e) discharging a desired first portion of the starter culture from the reservoir whilst
retaining a desired second portion therein. said retained second portion comprising
an initiating culture for subsequent production in the reservoir of a further batch of
starter culture upon introduction of a next load of water/flour mixture;
f) allowing a first pre-set delay interval to elapse after discharge before introducing
the next load of water/flour mix into the reservoir;
g) upon expiry of a second pre-set delay interval from the start of fermentation in the
first reservoir, filling a subsequent reservoir with the relevant amount of water/flour
mix;
h) repeating steps c) to f) in respect of said subsequent reservoir as if it were the first
reservoir;
Preferably, the above steps are carried out continuously during a production run of the
system.
Ideally, in the end of the production run a portion of the starter culture obtained in the last-
used reservoir is retained for use as an initiating culture in a subsequent production run of
the system. This portion of starter culture may be discharged locally into a smaller tank,
collected and kept at an oppression temperature pending a next production run.
In a most preferred arrangement the number of reservoirs is eight, the fermentation time is
preferably about twelve hours including filling and cooling time, the fermentation
temperature is about 21°C and the oppression temperature is about 16°C.
Ideally, the time allowed for discharging and using the produced starter culture from a
reservoir, the first pre-set delay interval and the second preset delay interval are each
about three hours.
The present invention will now hereinafter be described with reference to the
accompanying drawings which show, by way of example only, one embodiment of a
system for producing and handling starter culture in accordance with the invention.
In the drawings:
Figure 1 is a schematic plan view of a system according to the invention;
Figure 2 is an enlarged portion of Figure 1 showing a flour silo of the system;
Figure 3 is an enlarged portion of Figure 1 showing a receiving hopper for flour, a mixing
unit and a cleaning station of the system;
Figure 4 is an enlarged portion of Figure 1 showing a fermentation tank of the system;
Figure 5 is an enlarged portion of Figure 1 showing another two fermentation tanks of the
system and a portion of a manifold leading to further stages of handling of starter culture;
Figure 6 is an enlarged portion of Figure 1 showing two dosing stations of the system;
Figure 7 is a flow chart illustrating stages of a starter culture production cycle of two
fermentation tanks of an eight-tank system and a time sequence between the production
cycle;
Figure 8 shows two tables showing a 24 hour schedule of production cycles of eight
fermentation tanks in an eight-tank system for two subsequent days; and
Figure 9 shows a flow chart of a production cycle of a tank and its interactions with a
system control unit.
Referring to the drawings, the system for producing and handling starter culture according
to the invention is generally indicated by reference numeral 1 (see Figure 1). The system
1 is most suitable for and will be described in connection with producing and handling
starter culture for subsequent use in baking of bread, pastries etc. Of course, the system
of the invention is not limited for use only with such type of starter culture and, indeed, is
suitable for or can be suitably adapted to producing and handling any type of flowing
substances which require time- and condition-controlled environment.
The system 1 comprises a silo 2 in which a powdery ingredient, being flour in the present
case, is stored. The flour is discharged from an outlet at the bottom of the silo 2 and
received in a pneumatic conveying pipework 4. The flour passes through a sifter 3 into a
receiving hopper 5 where a required quantity of flour is accumulated for a batch of starter
culture. From the receiving hopper 5 the flour is discharged into a loss-in-weight screw
feeder 6a (Figure 3). A rotary valve 6 provides gradual feed of the flour from the hopper
to the screw feeder 6a. The screw feeder 6a delivers the flour into a mixing unit 7 in
The ratio between the
quantities of flour and water depends on the recipe and can be, for example, 50% of water
and 50% of flour.
example 21°C (70°F), by blending water from a mains water manifold 9, a chilled water
which the flour is blended with water to form a uniform mix.
Water temperature is maintained at a constant temperature, for
manifold 10 and a warm water manifold 11.
The quantity of water delivered into the
mixing unit 7 is controlled by a flow-meter 8.
After the mix of flour and water is blended in the mixing unit 7, the mix is pumped by a
pump 12 through a pipework 40 into a tank 15. The tank 15 is selected from several such
tanks employed in the system 1. The present system 1 has eight tanks 15 (although only
Each
tank 15 is installed on a load cell (not shown) which determines when the tank 15 is filled
three are shown), but of course any suitable number of tanks can be employed.
with the required quantity of the mix so that a signal can be given to the pump 12 to stop
feeding the mix into the tank 15.
In the herein described system 1 a certain amount of pre-prepared starter culture
(initiating culture) is pre-loaded in the tanks 15 at the beginning of a production cycle of
the tank before the flour/water mix is pumped into the tanks 15. This amount of starter
culture must not be less than a minimum amount for a given amount of flour/water mix.
This minimum amount of initiating culture is known as a “mother level”. The “mother
level" of starter culture depends on the recipe and can be, for example, 20% of an overall
volume of an initial mixture of the “mother level’’ of starter culture and the flour/water mix
to be fermented in a tank 15. Thus, a tank 15 pre-loaded with 20% of “mother level” of
initiating culture is filled with 80% of the flour/water mix to form the required overall
quantity of the initial mixture. Once the tank 15 is filled, the initial mixture of the “mother
level'’ of initiating culture and the flour/water mix is left to ferment in the tank for a specified
time according to the recipe, for example, twelve hours.
During the fermentation process, the temperature of the initial mixture in the tanks 15 is
maintained at a constant predetermined level, which may be for example 21°C (70°F), at
which microorganisms of the “mother level" of starter culture become active and start to
process the flour/water mix. This temperature of the contents of each tank 15 is achieved
and maintained at the same level by supplying passing heated water to the tanks 15 from
a water heater 16 via a heated water manifold 16a. During the fermentation process, the
initial mixture is transformed into a starter culture which should be of the same
characteristics as the initiating culture of the “mother level" in each tank 15.
In the herein described use of the system 1 for producing and handling starter culture, the
starter culture resulting from the fermentation process needs to be cooled at the end of
the fermentation process to an oppression temperature at which the microorganisms of
the starter culture are inactive. Such temperature may be for example about 16°C (60°F)
or less. A cooling station 17 is provided for lowering the temperature of the starter culture
in the tanks 15 to the oppression temperature. The station 17 supplies coolant to the
tanks 15 via a coolant supply manifold 17a.
The oppressed starter culture is discharged as required from each tank 15 via a discharge
pump 20. The discharge pump 20 transfers the starter culture via a starter manifold 21
to closing stations 25. Diverting valves 22 are provided in the manifold 21 for directing of
the starter culture into a correct manifold of the system.
At each of the dosing stations 25 the starter culture is received in a holding hopper 26.
The holding hopper 26 is installed on a measuring means, such as a load cell (not shown)
which determines when a batch of preset quantity of starter culture is delivered into the
holding hopper 26 so that a signal can be given to the respective pump 22 to stop feeding
the starter culture into the holding hopper 26. The holding hopper 26 stores the starter
culture until the batch is required for further steps to be carried using the starter culture.
For example, when a dough mixing system of a production line calls for ingredients for
dough, the holding hopper 26 discharges the batch of starter culture via an outlet manifold
28 to a required location.
During a production run, the starter culture produced in the tanks 15 is not completely
discharged from the tanks. A “mother level“ of the starter culture remains in each tank 15
for the next production cycle of the tank. At the end of a production period (perhaps a
week), some starter culture is cooled to 16°C (60°F) and placed into a storage container
29 for use at the beginning of the next production week as a “mother level” for the tanks
An example of a weekly scheme of operation of the system 1 for producing and handling
starter culture will now be described below with reference to Figures 7 and 8. The
scheme applies to an eight-tank system and can be altered to adapt to a system with
different number of fermentation tanks 15. The fermentation time of twelve hours
mentioned above for a single tank 15 is taken to include the time for filling the tank 15 with
flour/water mixture and for cooling the contents of the tank 15 at the end of the
fermentation process from 21°C (70°F) to 16°C (60°F).
limited to the scheme of operation described below and any other suitable way of
Of course, the system 1 is not
organising the sequence of the steps of its operation ensuring continuous supply of freshly
produced starter culture are possible.
At the start of a production week, the starter culture held over from the production run of
the preceding week is split to provide “mother levels" in the eight tanks 15. If this quantity
of starter culture is not sufficient to provide the necessary “mother levels” for all the tanks
, then the starter culture needs to be built up prior to placement into the tanks 15 by
adding a necessary amount of flour/water mix and fermenting for 12 hours in order to
obtain an amount of the starter culture sufficient to be split among the tanks 15.
Referring to Figure 7, at 100 Tank 1 is held pre-loaded with a “mother level'’ of starter
culture at the beginning of a production cycle. The “mother level” quantity of starter
culture is held at 16°C (60°F). At Time Zero, Tank 1 starts to be filled with flour/water mix
at 21°C (70°F) and should be filled within 1 hour. At 101, Tank 1 is filled and the
fermentation process begins. Ten hours later, at 102, the starter culture produced in
Tank 1 during the fermentation process of the mixture of the “mother level” of starter
culture with the flour/water mix is ready for use. At this stage the fermentation process is
oppressed by cooling the starter culture to 16°C (60°F). The cooling process should be
completed within one hour. This batch of starter culture is used within three hours. A
"mother level” of the starter culture should be left in the tank 15 for the next production
cycle of the tank 15. Upon expiry of said three hours for using the starter culture, another
three hours elapses before introducing the next batch of flour/water mix into the tank 15
for the next production cycle. At 104, Tank 1 is ready for the next production cycle.
At 200, three hours after the beginning of the production cycle of Tank 1 i.e. from Time
Zero, Tank 2, which is held pre-loaded with a “mother level” of starter culture, is filled with
flour/water mix at 21°C (70°F) within one hour. Steps 201 — 204, which are the same as
the steps 101 — 104 for Tank 1 are then followed.
Figure 8 shows 24 hour schedules for Day 1 and Day 2 of the production cycles illustrated
in Figure 7 for eight tanks. A production cycle of each subsequent tank starts three hours
after the beginning of the production cycle of a previous tank. The production cycles
which have not completed at the end of Day 1 will continue to run during Day 2 until
completed. The number of tanks in operation can be selected to match the need of
starter culture batches needed to keep the downstream bakery adaptably supplied.
At the end of the production week the starter culture may be used entirely from all the
tanks 15, except for one tank. The amount of the starter culture in the tank should be
sufficient to be split amongst the eight tanks 15 and used as a “mother level” in the tanks
during the production run of the next week. Alternatively, the remaining starter can be
built up later by adding a necessary amount of flourlwater mix as described above. The
starter culture remaining from the production run may be pumped into a storage container
and stored at 16°C (60°F) so that the tank can be cleaned.
The system is cleaned using the known Cleaning-in-Place (ClP) technology. A
commercially available ClP station 30 comprises a water tank 31 and a diluted detergent
tank 32. The system 1 is adapted to be compatible with a known ClP station, such as the
CIP station 30. Water and diluted detergent are mixed at the station and the mix is
delivered to the components of the system 1 to be cleaned via a CIP supply manifold 33.
After cleaning, the fluids are delivered back to the CIP station 30 via a CIP return manifold
34. Different components of the system 1 can be cleaned at different times and the
components not engaged in an on-going production run can be cleaned during this
production run. The manifolds 21 to the dosing stations 25 are cleaned only after a
production run is completed.
A pre-programmed cleaning cycle is performed by the CIP station 30 for cleaning the
tanks 15. The fluids are delivered into the tanks though spray balls 35 located at top
regions of the tanks 15. The spray balls 35 of each tank 15 wash all parts of the exterior
of the tank. The fluids are drained from the tanks 15 via the discharge pumps 20. After
passing through the discharge pumps 20 the fluids are directed by the diverting valves 22
into the return manifold 34 and are brought back to the CIP station 30. The CIP system
also provides hot or cold rinsing water to the tanks 15 in the described above manner.
Air blow manifold 36 is provided for air purge the components of the system 1.
Pipeworks 4 and 40 are also cleaned using a pre-programmed cleaning cycle by passing
cleaning and rising fluids through the pipeworks and returning these fluids back to the CIP
system 30.
The quantity of starter culture required weekly for a production run varies depending on
the quantity of dough being produced for this production run. ln the present system 1, a
weekly production plan of dough governs the quantity of starter culture produced by the
system 1.
The present system 1 is controlled using a programmable logic controller (PLC) which is
suitably programmed to read input signals from various system components such as
sensors, flow-meters, valves, pumps, load cells, etc., run control logic in respect of the
input signals and then send output signals to the system to actuate a relevant system
component and/or adjust relevant condition via a regulating device in order to ensure
relevant production output in accordance with pre-inputted parameters of the production
run. The PLC is linked to a real time clock for use in conjunction with the PLC program
for sending output signals to the system at relevant times. One example of the
interactions between the system and the PLC is shown in Figure 9.
The sensors include, for example, a temperature sensor for the water supplied into the
mixing unit 7, temperature sensors for measuring the temperature of the contents of the
tanks 15 and holding hoppers 26. Sensors on valves and pumps determine the
conditions of the valve or the pump, e.g. on/off, open/shut etc. Flow-meter 8 determines
the quantity of water delivered into the mixing unit 7. Measuring means such as load
cells (not shown) detennine the quantity of material delivered into the tanks 15 and
holding hoppers 26.
The regulating devices include, for example, flow-meters at water manifolds 9, 10 and 11
which blend water from these three manifolds to achieve a desired water temperature of
about 21°C (70°F) in the arrangement shown, heater 16 for maintaining the fermentation
temperature in the tanks 15, cooling station 17, valves, pumps, etc.
The PLC allows the system to operate automatically during a production run, which could
be a single run extending over several days. System conditions are operator-monitored
by the use of one or more screens. One screen shows tank conditions such as
“disabled”, “await filling", “scheduled”, “discharge", “cooling", “ferment”.
In the
mode “await filling" the tank is being filled and is waiting for the till cycle to complete within
If a tank is “disabled” then it is not included in the system for starter production.
the allowed time of 1 hour for this example. In the “scheduled” mode, the tank has been
scheduled for inclusion in the production system but has not yet received instructions for
next use. In the “discharge” mode the tank is in use for discharge of the starter culture. in
‘‘cooling'’ mode the tank, which has gone through the fermentation time at the temperature
of 21°C (70°F) is cooled to 16°C (60°F) to retard the fermentation.
tank is going through the fermentation process at 21°C (70°F).
In “ferment" mode the
Also within this screen it is
possible to view the quantity and temperature of the material in each tank and the
fermentation time elapsed.
A set of screens is also provided which allows changes to be made to the times and
temperatures of the tanks by manual intervention into the automatic run. This screen
optionally has password protection and will normally only be accessible to an authorised
person. For example, the fermentation temperature may be manually changed from 21°C
(70°F) to 24°C (75°F).
A further screen or set of screens allow system parameters such as for example agitator
speeds to be viewed and/or altered. Flour system screen allows such parameters as, for
example temperature and quantity of flour in the silo 2 to be viewed.
Another screen is provided for viewing and adjusting the ratio of water/ flour mix in the
mixing unit 7, although normally the settings are made and never changed. Also it is
possible to view the flow rates of flour and water.
A cleaning-in-place (CIP) control allows for the CIP system to be enabled or disabled.
Alarms screen shows any current and historic alarms that the system has experienced. It
displays current alarms highlighted. Alarms may signal when motor overload occurs or
when the temperature in tank 15 exceeds the permitted temperature. The alarms are
acknowledged and/or attended to or by an operator depending on their severity.
The system also comprises a computer and specialised software to allow scheduling of
starter production and graphic monitoring of the system. The computer does not in itself
carry out any control function. An operator inputs a production schedule for finished
products (eg. bread) for a time period such as a week. The software already contains
the recipes and calculates the amount of starter culture required and when it is required
during the production run. The production schedule when downloaded to the PLC sets
up particular quantities of starter culture that the tanks must produce to have sufficient
quantity of starter culture ready at the appropriate times.
It is thought that the present invention and its advantages will be understood from the
foregoing description and it will be apparent that various changes may be made thereto
without departing from the scope of the invention as defined by the appended claims, the
forms hereinbefore described being merely preferred or exemplary embodiments thereof.
Claims (5)
1. A system for producing and handling a flowing substance comprising a mixing vessel for mixing ingredients for use in subsequent preparation of a flowing substance; a first manifold for transferring the mixed ingredients from the mixing vessel into one of a plurality of reservoirs where the mixed ingredients are combined with initiating culture; a first regulating means for maintaining predetermined conditions in each reservoir suitable to allow a fermentation process to occur which results in the production after a specified time of a starter culture as a flowing substance having predetermined properties from the initiating culture and the mixed ingredients; a second manifold for transferring the starter culture from each reservoir to at least one receiving container; and an electronic control means operable to control the system to provide delivery of mixed ingredients to each reservoir in a specified sequence so that a first pre-set interval of time elapses from the start of fermentation in a first or subsequent reservoir before the delivery of the mixed ingredients into a succeeding next reservoir, that interval being less than the fermentation time of the starter culture in the preceding reservoir.
2. A system as claimed in Claim 1 in which the electronic control means is operable to control the system so as to effect discharge of a desired first portion of the starter culture from a reservoir whilst retaining a desired second portion therein, said retained second portion comprising an initiating culture for subsequent production in that reservoir of a further batch of starter culture upon introduction of a next load of the mixed ingredients; and to allow a second pre-set delay interval to elapse after the discharge before introducing the next load of the mixed ingredients into the reservoir, the electronic control means comprising a programmable logic controller (PLC), optionally, the PLC is pre-programmed with information specifying the required amount of starter culture required to be produced during a production run of the system; optionally, the system comprises eight reservoirs; optionally, the ingredients being mixed in the mixing vessel comprise at least one powdery ingredient and at least one liquid ingredient, the system comprising at least one storage container for storage of the powdery ingredient, the storage container being connected to the mixing vessel via a delivery means, the delivery means comprising a delivery manifold leading from the storage container to the mixing vessel and optionally, the system comprises a liquid manifold for supplying a liquid ingredient into the mixing vessel; optionally, the ingredients being mixed in the mixing vessel comprise flour and water; and optionally, the system comprises a first propelling means for transferring mixed ingredients into each reservoir via the first manifold and a second propelling means for transferring the starter culture produced in the reservoir into the receiving container via the second manifold; the PLC being programmed to control the second propelling means to discharge the starter culture produced in a reservoir, save for a portion of the starter culture which remains in the reservoir and is intended for a subsequent cycle of production of starter culture in this reservoir, the remaining portion being sufficient to serve as initiating culture for the subsequent cycle and in which a sensor means is provided connected between a reservoir and the PLC for enabling the PLC to determine the quantity of starter culture in the reservoir and preventing the quantity falling below a predetermined quantity on actuation of the second propelling means.
3. A method for producing a starter culture using the system of Claims 1 or 2 comprising the steps of providing a plurality of reservoirs: a) pre—loading the reservoirs with a desired amount of initiating culture maintained at an oppression temperature; b) filling at least one first reservoir with a relevant amount of water/flour mix; c) allowing the contents of the first reservoir to ferment at a specified fermentation temperature for a pre-set fermentation time interval; d) cooling the so obtained fermented starter culture in the first reservoir to an oppression temperature to stop the fermentation process; e) discharging a desired first portion of the starter culture from the first reservoir whilst retaining a desired second portion therein, said retained second portion comprising an initiating culture for subsequent production in the first reservoir of a further batch of starter culture upon introduction of a next load of water/flour mixture; f) upon expiry of a first pre-set delay interval from the start of fermentation in the first reservoir, filling a subsequent reservoir with a relevant amount of water/flour mix; g) allowing a second pre-set delay interval to elapse after the discharge before introducing the next load of water/flour mix into the first reservoir; 17 h) repeating steps c) to f) in respect of the subsequent reservoir as if it were the first reservoir; the method optionally comprising the step of retaining at the end of the production run a portion of the starter culture obtained in the last-used reservoir for use as an 5 initiating culture in a subsequent production run of the system, and optionally, the fermentation time is about twelve hours including filling and cooling time, the fermentation temperature is about 21°C and the oppression temperature is about 16°C.; and optionally, time allowed for discharging and using the produced starter culture from a reservoir, the first pre-set delay interval and the second preset delay 10 interval are each about three hours.
4. ' A system for producing and handling a flowing substance substantially as herein described with reference to and/or as shown in the accompanying drawings. 15
5. A method for producing a starter culture substantially as herein described with reference to the accompanying drawings. MACLACHLAN & DONALDSON
Publications (2)
Publication Number | Publication Date |
---|---|
IE20050294U1 IE20050294U1 (en) | 2006-10-04 |
IES84361Y1 true IES84361Y1 (en) | 2006-10-04 |
Family
ID=
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US5458415A (en) | Apparatus for making bread | |
US20050169099A1 (en) | Mixing system and process | |
US20130102071A1 (en) | System and method for preparing cell culture dish media | |
CA2607347C (en) | An apparatus for producing and handling a flowing substance | |
CN108142061B (en) | Fertilizer distribution system | |
DK175502B1 (en) | Method and apparatus for processing and dosing compound feed | |
IES84361Y1 (en) | An apparatus for producing and handling a flowing substance | |
IE20050294U1 (en) | An apparatus for producing and handling a flowing substance | |
US20220287315A1 (en) | System and method for batter mixing and application | |
US20220030831A1 (en) | System for feeding farm animals with a liquid containing full milk | |
CN206897335U (en) | Resin on-line mixing multi-channel intelligent measuring and dispensing system | |
CN105686032B (en) | A kind of method of water chestnut coating pan automation on line production | |
CN101998830A (en) | Metering and mixing machine and method for producing a solution | |
CN110128951B (en) | Gelatin bone meal automatic blending and pickling control system and process | |
CN108064530B (en) | Full-automatic fertilizer preparation system | |
WO2021097859A1 (en) | Automatic grouting system and grouting method therefor | |
GB2336093A (en) | A microbiologically stable slurry of soya flour in brine | |
CN110628596B (en) | Strain fermentation system and control method thereof | |
CN203816577U (en) | Automaticbatching device for sour soup beverages | |
US9604186B1 (en) | Automated multichannel media dispenser | |
CN117772067A (en) | Discharging control method, discharging control device, discharging control equipment and reaction kettle | |
CN106925157A (en) | A kind of medicine weighs dust pelletizing system | |
DE202006001483U1 (en) | Device for automatic production of agarose gel composition, comprises interchangeable supply containers, reception container exhibiting an outlet and a controllable and/or adjustable arrangement, and an operating unit and/or a display | |
US2987016A (en) | Ingredient handling | |
TR202019530U5 (en) | SOUR YEAST PROCESS TANK SYSTEM |