IES950939A2 - A process and apparatus for deboning meat carcasses - Google Patents

Abstract

The invention concerns a process and apparatus for handling and deboning meat carcasses. The process comprises identifying and classifying the carcass according to predetermined characteristics and recording details of the carcass. The carcass is vertically suspended from a first overhead rail assembly, and is moved to a sorting station where the carcass is sorted depending upon characteristics. The carcass is then directed along one of a number of second overhead rail assemblies to a succession of deboning stations positioned at intervals along the second overhead rail assemblies. At the deboning stations the height and position of the carcass is adjusted relative to the overhead rail as required. Tension is applied to parts of the carcass at certain of the deboning stations so as to enable an operator to complete the removal of muscle from the bone to which it is attached, without the need for the operator to substantially handle the carcass. The specification discloses apparatus for carrying out the above process. Also disclosed is apparatus for deboning the carcass including hook or gripper means for attachment to the carcass, and an adjustable backrest for supporting the carcass <Fig.1>.

Description

Technical Field The present invention relates to a process and apparatus for deboning 10 meat carcasses. The invention is concerned mainly with the handling and deboning of beef carcasses, but is not restricted thereto and applies also to carcasses of lamb, venison and other quadrupeds.

Background Art The invention is particularly applicable to meat factories where carcasses of animals, and in particular beef carcasses, are fed from an abattoir to a boning hall where muscles and other portions of meat are removed from the bones of the carcass. Traditionally, this work was done by boning operators using a knife. The carcass was quartered and quarters were laid on a work table where the operator carried out the deboning operation.

More recently, the deboning operation has become partly automatic. It is known for the carcasses to be hung vertically from an overhead monorail system, by means of which the carcass are moved to a boning station, with the aid of hooks and grippers so that the operator can debone the carcass.

For example, U.S. Patent No. 4,797,975 discloses a semi-automatic process in which the carcass is moved from an initial position as far as a suspending station forming part of a closed loop equipped with an overhead rail and a plurality of means of suspension for quarters travelling continuously along the rail. After the quarter has been suspended from a means of suspension, the quarter hanging vertically at a constant height is moved in front of a plurality of treatment stations 1578S OPEN TO PUBLIC INSPECTION UNDER SECTION 28 AND RULE 23 JNL No /7½ OF - 2 '0509 J 9 which are arranged at intervals along the path forming a closed loop. Removal of the muscles from the quarter is performed successively at each station, permitting a vertical movement in both directions which is controlled by each operator at each treatment station so as to enable him to adopt the ergonomic position which is best suited to his task and to change his position continually in relation to the quarters which move in front of his station. At the last treatment station, the bones remaining after the removal of all the muscles from each quarter are then released so as to permit the means of suspension thus released to grasp a new quarter to be treated. This patent also discloses a processing plant comprising a constant height overhead rail arrangement forming a closed loop and on which a plurality of arms for suspending at regular intervals are suspended at regular intervals. The plant comprises means for continuously driving the set of arms along the closed loop of the overhead rail and a plurality of stationary treatment stations arranged along at least one portion of the closed loop and outside the latter. Each station comprises a platform equipped with manually-controlled means of automatic vertical movement. A removal system, for example in the form of conveyor belts, is arranged under the path of the arms in order to receive the muscles removed by the operators at the various treatment stations.

DE 3011026 discloses a carcass cutting station with angular and height adjustment for ergonomically correct positioning.

U.S. 4,381,582 B and EP 0049689 A, each describes apparatus for gripping and conveying meat carcasses.

In the known deboning plants as described above, typically there is a single overhead rail loop by means of which the carcasses are fed to a succession of deboning stations positioned at intervals along the closed loop. At the deboning stations, operators, typically using a knife, remove the muscle from the carcass. Although the operator is aided in this by means of hooks and grippers which apply tension to the muscle, it is necessary for the operator to grip the carcass with one hand while holding the knife in the other hand. Because the operator is handling a plurality of carcasses, this can cause crosscontamination of the carcasses by bacteria. This can be particularly - 3 -850839 troublesome where touching and handling of bones are concerned because it is found that the bacteria count on bones increases very quickly after slaughter.

Furthermore, carcasses, within a given grade, being delivered from an abattoir to the boning hall, can vary quite considerably in terms of their characteristics. For example, they can vary in weight, conformity, shape, size, lean to fat ratio etc. The meat industry is a highly competitive industry, and it is important to secure a maximum yield of a particular quality of meat from the carcass. Also, different customers frequently require different characteristics. The maximum yield can be achieved if the carcass is selected depending upon the particular characteristics required by a particular customer, as this enables the carcass to be processed with optimum utilisation of the raw material.

Object of the Invention Thus, it is an object of the invention to provide means for the pre-selecting and sorting of the carcasses depending upon predetermined characteristics. It is also an object of the invention to provide a process and apparatus for deboning the meat carcass with minimal contact of the carcass by the operator to avoid cross-contamination. It is also an object of the invention to provide means for positioning the carcass at a boning station in the most ergonomically efficient position for the operator. It is also an object of the invention to provide an improved process for the dissection of the bone skeleton of the carcass to facilitate its subsequent processing.

Summary of the Invention Accordingly, the invention provides a process for handling meat carcasses and the deboning thereof which comprises: a) identifying and classifying the carcass according to predetermined characteristics and recording details of the carcass; b) vertically suspending the carcass from a first overhead rail - 4 8509J8 assembly; c) moving the carcass to a sorting station where the carcass is sorted depending upon characteristics; d) directing the carcass from the sorting station to one of a plurality of second overhead rail assemblies; e) moving the carcass along the selected second overhead rail assembly to a succession of deboning stations positioned at intervals along the second overhead rail assemblies; f) adjusting the height and position of the carcass relative to the overhead rail as required at each deboning station; and g) applying tension to parts of the carcass at certain of the deboning stations so as to enable an operator to complete the removal of muscle from the bone to which it is attached, without the need for the operator to substantially handle the carcass.

The invention also provides apparatus for handling and deboning meat carcasses comprising: a) a first overhead rail assembly from which a carcass may be vertically suspended; b) means for moving the carcass along the first overhead rail assembly; c) a control system for controlling the movement of carcasses along the first overhead rail assembly; d) a sorting station to which the carcasses are fed by the first overhead rail assembly and including means for identifying and selecting each carcass depending upon its characteristics; e) a plurality of second overhead rail assemblies, each connected to the first overhead rail assembly, and to a selected one of which a carcass may be dispatched; 950939 - 5 f) switching gate means connected between the first rail assembly and the second overhead rail assemblies by means of which a carcass may be passed to a selected second overhead rail assembly; and g) a succession of boning stations positioned at intervals along each second overhead rail assembly.

The invention also includes means for positioning the carcass at individual boning stations, and means to assist in the removal of muscle from the carcass.

Brief Description of the Drawings Figure 1 is a schematic diagram, in plan, of overhead rail assemblies for handling carcasses according to the invention; and Figure 2 is a side perspective view of deboning apparatus located at a saw station; and Figure 3 is a side view of deboning apparatus at a deboning station.

Detailed Description of the Preferred Embodiment While the present invention is susceptible of embodiment in many forms, there is shown in the drawings and will hereinafter be described one presently preferred embodiment with the understanding that the present specification is to be considered as an exemplification of the invention, which is not intended to limit the invention to the specific embodiment illustrated.

Referring to Figure 1 of the drawings, this is a schematic diagram, in plan, showing rail assemblies for conveying carcasses of animals, in particular beef carcasses which have been pre-cut into quarters, comprising front and hind quarters, to a plurality of work stations from where the meat is separated from skeletal bones of the carcass. The rail assembly, which is in the form of a continuous loop, comprises an overhead conveyor rail from which the carcass is hung by means of hooks which travel along the rail, in well known manner, to convey the 950939 - 6 quarters to particular work stations.

The overhead conveyor rail is positioned, at ceiling height, in a boning hall where the work stations are located. Essentially, there is a first overhead conveyor rail assembly 1 which conveys the carcass quarters to one of three second overhead rail assemblies, A, B or C.

Carcass quarters, either hind quarters or forequarters, pass from a slaughtering plant (not shown) along a rail 2 which joins in to the beginning of the continuous rail assembly 1 at 3. The carcass quarters are suspended on hooks which are inserted in an incision in the quarter in well known manner. From here the quarters pass adjacent a sorting station 4, which comprises a microprocessor. The number of the carcass and its characteristics and classification are entered into the microprocessor. The microprocessor thereafter controls the routing of the quarter to one of the second overhead rail assemblies A, B or C.

From the sorting station 4, the quarter enters the boning hall proper through an opening in an end wall 5 of the boning hall. The quarter continues along the overhead rail 1 in the direction of the arrow d. At this point there is a slight fall in the rail, in the direction of the arrow d, so that the carcasses quarter can travel under gravity, to reach one of three switching gate means 6a, 6b or 6c. The switching gate means operate in well known manner to direct the carcass quarter to one of the second overhead rail assemblies A, B or C. The switching gate means 6 are controlled by the microprocessor of the sorting station 4 to direct particular carcass quarters through a particular gate 6, depending upon its characteristics.

In the particular embodiment shown there are three second overhead rail assemblies (A, B & C), but it will be appreciated that there can be any number of these assemblies, from two upwards. Each of the second overhead rail assemblies is of substantially similar configuration, and for the sake of convenience, only assembly A will be described hereinafter. Similar reference numerals are used to denote similar parts in each of second overhead rail assemblies A, B and C.

Assuming that the carcass quarter to be boned, has been shunted at gate 6A to the overhead rail A, it passes to a first working station 7. 950939 - 7 The work station 7 is a preparation station where certain preliminary preparation work is carried out on the carcass quarter e.g. the removal of flaps of tissue, the removal of fillets and so on.

From work station 7 the quarter passes to a second preparatory workstation 8. This is an optional workstation which is used only where the specification of meat required involves more opening-up of the carcass at this stage.

From here the carcass quarter passes to a saw workstation 9. Here a portable saw is used to sever or partly-sever a part of the skeletal structure of the quarter, e.g. the back bone in the case of a hind quarter.

From workstation 9, the quarter passes to workstation 10, where the first substantial separation of bone and meat takes place. At this station the pelvis bone and backbone are separated from the carcass, in the case of hind quarters. In the case of fore quarters it is the rib and neck bones which are removed.

The system is designed for automatic bone release from the carcass after workstation 10. The main overhead rail A extends between workstations 8 and 9 with the carcass suspended from hook 23 (see Fig. 3). A dedicated gripper or hook 46 is suspended from a loop rail between stations 9 and 10. At station 9 it is applied on the bones which are to be separated from the quarter at station 10 (ribs and necks and pelvis and backbones respectively). Hook 23 is transferred along with the quarter on its loop rail and is automatically positioned in front of a pushing arm at station 10. The quarter is restrained as the operator, aided by the tension on the bones, removes them. The bones on hook 23 are transferred to a bone cutting station at which they are reduced in size and dropped on the conveyor belt - either for edible purposes or inedible ones (see description below).

The bones removed from the carcass at workstation 10 are placed on a conveyor belt 11, shown in broken lines in Figure 1. The conveyor belt 11 conveys the bones to an automatic bone cutting machine 12 (known per 950939 - 8 se) where the bones are cut to desired size. The cut bones are separated. Bones for inedible purposes are placed on a conveyor 13, which conveys them to a chute for disposal. Bones for edible purposes are conveyed by a conveyor 14 to receiving means (not shown) where they are further processed or packaged.

From workstation 10, the now partly deboned carcass, still suspended from the overhead rail by a hook, is conveyed along the overhead rail A to a further preparation workstation 15, where further preparatory work is carried out prior to final deboning.

The quarter is suspended on hook 23 as it enters station 15. A second hook (not shown) is applied into the meat of the quarter. The second hook enters station 16. The bone into which hook 23 is applied is being restrained as the meat on the second hook is pressed in a forwardly direction away from the second hook. The operator makes a few strokes with his knife and separates the meat from the bone. Hook 23 now only contains the bone and is transferred on a loop rail 53 away from 16 to a bone release station. The bones are the Tibia and Femur from hindquarters and the Ulna-Radius, Humerus and the Scapula from forequarters.

After the bone has been automatically released from hook 23, the now empty hook is automatically transferred to a waiting position on the loop rail before station 15. Hook 23 will now become the second hook as it is applied into the meat of the quarter.

The carcass then passes to a final workstation 16 where all remaining bones are removed from the quarter.

After the workstation 16, the deboned carcass, still suspended by a hook from the overhead rail is passed from the second rail assembly back into the first rail assembly 1. The deboned carcasses are conveyed to breaker stations 17A, 17B or 17C. At breaker station 17A, deboned carcasses from overhead rail assembly A, are removed from the suspension hooks onto a moving stainless steel belt 18A. Likewise, deboned carcasses from overhead rails B and C are transferred onto belts 18B and 18C, respectively. The now empty hooks continue along 950939 - 9 the overhead rail 1 back to the beginning of the loop at 3.

As the deboned carcass passes along the belts 18, it is jointed and trimmed by operators positioned to each side of the belts 18. The trimmed meat pieces travel down the belt 18 and are transferred to a food grade conveyor 19 which travels transversely of the ends of the belts 18. The conveyor 19 conveys the meat pieces to packaging and cartoning stations (not shown). Fat pieces and trims removed from the meat joints are placed on lower level conveyors 21, from where they are conveyed to a transverse conveyor 22 for separation and further processing.

Referring now to Figure 2 of the drawings, this shows apparatus for supporting a carcass quarter 22 during the sawing step at the first working station 7. The apparatus comprises a backrest 20.

As shown in the drawings, the carcass quarter 52 (in this case a hind quarter) is suspended by a hook 23 from the overhead rail A. The overhead rail comprises spaced-apart parallel rail members 24, 25. The hook 23 is attached, at its upper end to a bogey 26 which has wheels 27, by means of which the hook and bogey may travel along the overhead rails 1 and A, in well-known manner. The hook 23 is pivotally connected to the bogey 26. The overhead rails are suspended from the ceiling of the boning hall.

The backrest 20 comprises a downwardly extending longitudinal member 28 which is pivotally connected, by a pivot 30, at its upper end to a bracket 29. A rod 31 of a hydraulically-operated ram 32 is pivotally connected, by pivot 33, to the member 28. The ram 32 is pivotally suspended from the ceiling of the boning hall. By operating the ram 32, the member 28 can be caused to swing, in an arc, about pivot 30.

An extension arm 34 is pivotally connected, at its upper end, by pivot to the lower end of member 28. A second hydraulic ram 36 is pivotally connected between a bracket 37 on the arm 34, and a bracket 38 extending laterally from the end of member 28. Operation of the ram causes the arm 34 to swing in an arc about pivot 35, and relative to the member 28. 950939 - 10 A curved rest 39 is fitted to the end of the arm 34 and is adapted to support the lower end of the carcass quarter 52. A second curved rest 40, which is adapted to support the carcass quarter 52, midway of its length, extends forwardly of the member 28 and is attached to the member 28 by a horizontally-disposed rod 41, which extends through the member 28. The rod 41 can slide lengthways through the member 28, and is fixed in position by a screw 42. Thus, the distance by which the rest 40 extends forwardly of the member 28 can be adjusted to suit the size of the carcass quarter 22.

The purpose of the back rest 20 is to support the carcass quarter in a desired orientation while preliminary sawing of the bone structure takes place.

The articulation of the member 28 and arm 34 by the rams 32, 36 enables the operator to achieve very accurate positioning of the carcass 52 so that sawing can take place in an ergonomically efficient manner with a minimum of handling of the carcass by the operator.

Figure 3 shows a deboning apparatus of the kind used at workstation 10, where a substantial part of the bone structure is removed from the carcass.

The apparatus comprises a backrest 20. The backrest 20 is adapted to support the carcass quarter 52 in an inclined position, and is substantially similar in construction to the backrest 20 described above in relation to Figure 2, and like parts are denoted by like reference numerals. In the particular, arrangement shown the second curved rest 40 has been omitted.

At workstation 10, the pelvic bone of the hindquarters 52 is first removed from the carcass, and then the backbone is removed. Figure 3 shows the method used for removing the backbone 43.

As shown in Figure 3, the carcass quarter 52 is supported in an inclined position by the backrest 20, with the weight of the carcass partly held by the hook 23 and partly by the curved rest 39. A restraining bar 44, mounted on a bracket 45, pushes against the front 950939 - 11 of the quarter 52 to keep it in position and to prevent it coming off the hook 23.

A meat hook 46 is attached to the bone 43 to be removed. The meat hook is attached by a flexible chain 47 to pulling means (not shown). Tension is applied to the hook 46 by pulling on the chain 47. Tension can also be maintained, or increased, by lowering the arm 34. In this way the operator can apply and increase tension as and when required. All the operator needs to do is to sever the connecting tissue between the bone 43 and the muscle of the carcass by means of a boning knife. The tension applied to the bone will ease the bone from the carcass with a minimum of effort on the part of the operator. Because the carcass is held by the backrest 20, a minimum of handling of the carcass, and virtually none of the bone, is required by the operator.

At all of the stations, hydraulic means, are provided for raising and lowering of the overhead rails. In an automatic mode of the system the upper and lower positions are determined by a sensor. However, the operator has the facility to switch the system to manual mode in which case the height of the rails, and thus the height of the carcass 52 can be determined by the operator.

Thus, the operator has complete control of the height of the carcass, and its angle of inclination at the workstation. He can also adjust the tension applied to the carcass at will. In this way a ergonomically efficient and hygienic method of deboning is achieved.

From the foregoing, it will be apparent that numerous modifications and variations can be effected without departing from the true spirit and scope of the novel concept of the present invention. It will be appreciated that the present disclosure is intended to set forth exemplifications of the invention which are not intended to limit the invention to the specific embodiments illustrated. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.

Claims (5)

1. A process for handling meat carcasses and the deboning thereof which comprises: a) identifying and classifying the carcass according to predetermined characteristics and recording details of the carcass; b) vertically suspending the carcass from a first overhead rail assembly; c) moving the carcass to a sorting station where the carcass is sorted depending upon characteristics; d) directing the carcass from the sorting station to one of a plurality of second overhead rail assemblies; e) moving the carcass along the selected second overhead rail assembly to a succession of deboning stations positioned at intervals along the second overhead rail assemblies; f) adjusting the height and position of the carcass relative to the overhead rail as required at each deboning station; and g) applying tension to parts of the carcass at certain of the deboning stations so as to enable an operator to complete the removal of muscle from the bone to which it is attached, without the need for the operator to substantially handle the carcass.

2. The invention also provides apparatus for handling and deboning meat carcasses comprising: a) a first overhead rail assembly from which a carcass may be vertically suspended; b) means for moving the carcass along the first overhead rail assembly; 950939 - 13 c) a control system for controlling the movement of carcasses along the first overhead rail assembly; d) a sorting station to which the carcasses are fed by the first overhead rail assembly and including means for identifying and selecting each carcass depending upon its characteristics; e) a plurality of second overhead rail assemblies, each connected to the first overhead rail assembly, and to a selected one of which a carcass may be dispatched; f) switching gate means connected between the sorting station and the second overhead rail assemblies by means of which a carcass may be passed to a selected overhead rail assembly; and g) a succession of boning stations positioned at intervals along each second overhead rail assembly.

3. Apparatus as claimed in Claim 2 including a boning station having a hook or gripper suspended from a loop rail adjacent the boning station, which is adapted for attachment to a bone of a carcass suspended by a hook from a second overhead rail, means for pulling on the hook or gripper, and a backrest for the carcass which is pivotally adjustable to position the carcass in a desired position.

4. Apparatus as claimed in Claim 3, wherein the backrest comprises a downwardly extending longitudinal member pivotally connected to a support at its upper end, means for pivoting the member, an extension arm pivotally connected to the lower end of the member, and means for pivoting the extension arm relative to the member, and a rest on the end of the extension arm adapted to support the carcass.

5. Apparatus for handling and deboning meat carcasses substantially as hereinbefore described with reference to and as illustrated in Figure 1, and/or Figures 2 and 3, of the accompanying drawings.