Device and method for producing feed for livestock

Abstract

The present invention relates to a device for determining the particle size distribution in bulk material, such as milled or ground grain for animal feed. The device comprises an inlet for receiving at least a portion of the bulk material, a sorting mechanism for sorting the received bulk material. The sorting mechanism comprises at least a first sorting device for sorting the received bulk material into at least two sorted partitions, wherein the sorting device is capable of sorting different particle sizes and the at least two sorted partitions have different particle sizes. The invention also comprises: a motor or an actuator for vibrating the sorting device; a weighing system with at least one sensor for weighing the at least two sorted partitions sorted by the sorting mechanism; and a data output for generating output data indicating the weight of the at least two sorted partitions, thereby allowing the calculation of the particle size distribution in the bulk material received in the inlet and thus providing information about the particle size composition of the milled or ground grain.

Description

Technical Field

[0001] The present invention relates to the production of feed for livestock, such as grain pellets, and to the continuous monitoring of the particle size composition of the feed. More specifically, the present invention provides an apparatus, system and method for measuring and adjusting the particle size of feed for livestock. Background Art

[0002] Cereals have been used as feed for hundreds of years, both for humans and animals. Cereals are usually processed by milling or grinding into feeds with different particle sizes, which can then be further processed / pressed into pellets, which are easier for animal caretakers to handle and reduce the amount of dust that occurs when feeding the animals. Feed particle size refers to the average diameter of the individual particles of the feed, or in other words, the fineness of the ground feed. In recent years, studies have demonstrated the importance of the correct composition of the particle size of processed cereals used for animal feed. If the particle size of the processed cereals is too large, the animals cannot digest the cereals well and therefore take in less energy from the feed. If the particle size of the processed cereals is too small, the incidence of ulcers in pigs increases. In addition, dust with too small a particle size in the feed may increase respiratory problems in the animals and lead to dust accumulation in any equipment near the feeding pit.

[0003] When feeding animals such as pigs, the ideal particle size distribution of the feed also depends on the age of the animal being fed. Thus, young piglets will benefit more from being fed a finer ground grain feed than older pigs.

[0004] Currently, the measurement of particle size distribution during the production of animal feed from cereals is a manual process, i.e. a portion of the processed cereals is sorted and measured and the distribution of particle sizes is calculated. The particle size distribution depends on the processing equipment (e.g. hammer mill, grinder, etc.), the moisture content in the cereals to be processed and the solidification state of the cereals. Therefore, various parameters need to be adjusted during processing if the preferred particle size distribution is to be maintained in the resulting feed product.

[0005] Therefore, an improved device for measuring the particle size of processed grains for animal feed would be advantageous. In addition, a more efficient and / or reliable device, system and method for continuously controlling and adjusting the particle size during the processing of animal feed would be advantageous. The improved system can be used to produce a range of feed products with different particle size distributions suitable for different animals and animals of different ages, thereby optimizing the feeding of the animals. Summary of the invention

[0006] Therefore, based on the above description, it can be seen that the object of the present invention is to provide an apparatus, system and method for measuring and thereby allowing adjustment of the particle size composition of processed grains (such as milled or ground grains for animal feed), wherein the processed grains are provided as bulk grain materials or as pressed grain pellets.

[0007] In a first aspect, the present invention provides an apparatus for determining a particle size distribution in a bulk material, the apparatus comprising:

[0008] - an inlet for receiving at least a portion of the bulk material,

[0009] - a sorting mechanism, the sorting mechanism is used to sort the received bulk materials, the sorting mechanism comprises:

[0010] at least a first sorting device for sorting the received bulk material into at least two sorted partitions, wherein the sorting device is capable of sorting different particle sizes and the at least two sorted partitions have different particle sizes,

[0011] - a motor or an actuator for vibrating the sorting device,

[0012] - a weighing system comprising at least one sensor for weighing at least two sorted partitions sorted by the sorting mechanism, and a data output for generating output data indicating the weight of at least two sorted partitions, thereby allowing the calculation of the particle size distribution in the bulk material received in the inlet.

[0013] Such an apparatus for measuring the particle size of bulk material is advantageous because the weight data provided from the data output can be used to analyze the current particle size distribution of the bulk material fed into the inlet. Such detailed weight data can be used to generate an instantaneous image of a portion of the bulk material, or to generate a continuous analysis of the weight data during the continuous sorting of bulk material and the operating mode of the bulk material being sorted in the apparatus, thereby continuously ensuring the desired particle size composition.

[0014] The gravimetric data can be used for quality control of bulk materials and / or to record the particle size distribution of bulk materials in continuous processes or in batch processes.

[0015] Where the apparatus is used to measure the particle size of a bulk grain material suitable for animal feed, output data indicative of the weight of the sorted partitions may be used to label the bulk grain material and thereby demonstrate to an animal caretaker that the feed has a particle size distribution suitable for the desired feeding purpose.

[0016] In the context of the present invention, particle size is understood to be the average diameter of individual particles within a group or a subset (such as a sorted partition).

[0017] The sorting mechanism is suitable for sorting particles of different sizes, such as but not limited to sorting the particles into particle partitions or particle groups with an average diameter > 5 mm, another particle group with an average diameter > 4 mm, another particle group with an average diameter > 3 mm, another particle group with an average diameter > 2 mm, another particle group with an average diameter > 1 mm, another particle group with an average diameter > 0.5 mm, another particle group with an average diameter > 0.1 mm and a particle group with an average diameter < 0.1 mm.

[0018] In a preferred embodiment, the sorting mechanism comprises three sorting devices to sort the particles into four partitions, the first partition having an average diameter > 3 mm, the second partition having an average diameter between 3 mm and 2 mm, the third partition having an average diameter between 2 mm and 1 mm, and the fourth partition having an average diameter < 1 mm. The sorting devices are preferably sieves. This particular embodiment has proven suitable for evaluating the particle composition of feeds such as grain feeds for pigs or other animals.

[0019] In the context of the present invention, bulk material is understood to be a material comprising a number of smaller items, such as a quantity of grain to be processed and sorted, which is conveyed from a suitable storage container, such as a grain silo, to the present invention.

[0020] In the context of the present invention, a motor or actuator is understood to be a device suitable for generating vibrations in industrial applications, and vibration is understood to be a movement performed in two or more directions successively one after another, such as a movement in two opposite directions of the x-axis in a plane, or such as an alternating movement in the x-axis and the y-axis in a plane, or such as an alternating movement in the x-axis and the y-axis in a plane combined with a movement in the z-axis perpendicular to the plane.

[0021] In one embodiment, the device comprises at least a second sorting device, wherein the second sorting device receives the bulk material from the first sorting device so as to sort the bulk material to be sorted into at least three partitions. This embodiment is advantageous when it is necessary to describe the particle size distribution of the bulk material in more detail than two different particle sizes, such as describing the particle size distribution in the bulk material based on the weight of three, four or more sorted particle sizes.

[0022] In another embodiment, the device is arranged inside a frame or housing including a top portion and a bottom portion, the device is further arranged horizontally, and the inlet is located at the top portion, a first sorting device is located below the inlet for receiving bulk material from the inlet, a second sorting device is located below the first sorting device for receiving bulk material from the first sorting device, and wherein the particle size of the bulk material received in the second sorting device is smaller than the particle size of the sorted portion sorted by the first sorting device. This embodiment is advantageous for industrial applications because the horizontal arrangement saves space. In addition, it is easy to maintain and service different aspects of the device from the side of the device. In addition, when sorting particles, the particles have mass, and gravity can be used to let particles small enough to pass through the first sorting device fall downward. When arranging the next sorting device, the downward falling of the particles can be used, such as by arranging the next sorting device directly below the first sorting device. The horizontal arrangement also ensures that most of the material to be sorted eventually falls to the bottom of the device to facilitate the exit of the sorted bulk material.

[0023] In the context of the present invention, it should be understood that the housing can be a sealed housing with maintenance and operating hatches to prevent any dust that may be airborne due to vibrations inside the device from moving outside the housing and lodging on equipment near the device or entering the airway of an operator of the device.

[0024] In yet another embodiment, the sensor of the weighing system is located at the bottom part of the device and the bulk material to be sorted is weighed at the bottom part of the device in order to facilitate the movement of the sorted particles downwards through the device by gravity.

[0025] In a preferred embodiment, the at least two sorting devices include a first screen and a second screen, respectively, wherein the bulk material is transferred from the first screen to the second screen by vibration of the first screen and the second screen, the holes in the first screen being larger than the holes in the second screen, thereby allowing particles smaller than those retained in the first screen to be transferred from the first screen to the second screen. In this embodiment, the screen is a simple and effective method for sorting the bulk material into at least a first partition and a second partition having different particle sizes. In addition, the screen is easy to maintain and can be easily replaced with a screen of a different hole size if it is necessary to sort the bulk material into another particle size than before.

[0026] In another embodiment, the weighing system comprises a plurality of load cells for weighing respective ones of the at least two partitions in order to perform a rapid analysis of the particle size distribution. In an advantageous embodiment, the inlet also comprises a load cell in order to measure the weight of the bulk material to be sorted and to ensure the correlation between the bulk material to be sorted and the sum of the sorted partitions. This is particularly advantageous for ensuring and documenting the quality of the analysis performed by the device.

[0027] In a preferred embodiment, the device further comprises a separate container associated with each sorting device for receiving the sorted partitions from the sorting device. This embodiment is advantageous when sorting a plurality of smaller batches of bulk material representing a larger batch being processed, wherein the smaller sorted batches do not have to be sent back to the processing system.

[0028] In an advantageous embodiment, the sorting devices are tilted downwardly relative to the horizontal toward the container so as to displace any particles retained in the respective sorting devices toward said container by vibration. This embodiment is advantageous because it utilizes the simplicity of gravity in combination with the angle of the sorting devices and the vibration of the sorting devices to convey any particles that are too large to move through the sorting devices forward, such as toward the container or conveying device, to convey said particles toward the next stage in the processing system.

[0029] In a preferred embodiment, a chute is located below the downwardly inclined sorting device and the chute is downwardly inclined relative to the horizontal at an angle substantially opposite to that of the sorting device, so as to ensure that all particles that are too small to reach the lower end of the sorting device eventually rest on the chute, sliding in the opposite direction towards the upper end of the next sorting device, where the sorting process is repeated. This embodiment is advantageous in ensuring that the bulk material to be sorted is transferred through the entire length of each sorting device. If a particle is too large to fall through the sorting device, it will not reach the chute located below the sorting device, but will reach the end of the sorting device and eventually enter a container or onto a conveyor, or fall downward due to gravity, pass through the chute below and eventually reach the next processing stage.

[0030] In another embodiment, the device further comprises a cleaning mechanism for discarding the sorted partitions and cleaning the sorting mechanism, the cleaning mechanism comprising: a controller, a container attached to each sorting device, a tipping mechanism attached to each container, a motor, at least one cleaning unit (such as a brush) mechanically connected to the motor, an outlet,

[0031] Wherein the controller activates the tipping mechanism to tilt the container and discard the sorted partitions to the outlet, after which the cleaning unit cleans the sorting device after the sorted partitions have been discarded from the sorting device. This embodiment is particularly advantageous for integrating the device into a fully automatic processing system, wherein no operator is required to ensure that all particles from a batch of bulk material to be sorted are removed from the device before the next batch of bulk material is sorted.

[0032] In a preferred embodiment, the sorting mechanism comprises a separate motor or actuator for vibrating each sorting device, so that the sorting devices can vibrate at different frequencies. This embodiment is particularly useful for sorting bulk materials that tend to generate dust when vibrated, ensuring that the smallest particles do not become airborne due to excessive vibration, thereby avoiding the generation of excessive dust near and / or inside the device, which would normally require cleaning and maintenance.

[0033] In a further preferred embodiment of the device, the motor or actuator vibrates the sorting device with a frequency between 0.5 and 30 Hz, preferably between 1 and 20 Hz, most preferably between 4 and 10 Hz.

[0034] In an embodiment of the device, the first sorting device vibrates at a higher frequency than any subsequent sorting device.

[0035] In another embodiment of the device, the first sorting device vibrates at a lower frequency than any subsequent sorting device.

[0036] In an advantageous embodiment, the device further comprises an imaging device, such as a camera or a CCD sensor, a 3D scanner or a line scanner, wherein the imaging device is suitable for detecting color changes, size changes and / or reflectivity of the bulk material before and / or during and / or after sorting of the bulk material. This embodiment is particularly advantageous for detecting anomalies within the bulk material, such as foreign objects or objects whose size, color or reflectivity is different from what is expected. For example, the imaging device can detect parts of foreign objects, such as particles or plastics within bulk materials made of grain. The imaging device can further be connected to a controller, which outputs a signal notifying an operator of the presence of one or more foreign objects detected in the bulk material, or automatically discarding the foreign objects, such as by discarding a part of the bulk material in which the foreign objects have been detected.

[0037] In the context of the present invention, an abnormal condition is understood to be any structure, function or state that deviates from the normal usual range of variation.

[0038] In the context of the present invention, reflectivity is understood to be a measure of the proportion of light or other radiation that strikes a surface and is reflected by it.

[0039] In a preferred embodiment, the device further comprises a suction device for removing aerosolized particles from the environment around the sorting device. This embodiment is particularly useful for removing any particles from the environment that might otherwise contaminate or soil any elements around or inside the sorting device, such as equipment or cargo. This embodiment is further useful for ensuring a safe working environment for subjects, such as operators, who work or move in the area where the device is located.

[0040] In the context of the present invention, atomization is understood to be particles suspended in the air, such as dust particles that remain suspended in the air for several minutes or hours.

[0041] In yet another advantageous embodiment, the apparatus includes a vibration sensor configured to detect vibrations of the bulk material being sorted, such as a microphone or a piezoelectric sensor. The vibration sensor is particularly useful for detecting unexpected size changes of the bulk material within the sorting mechanism. The vibration sensor can be configured to detect any particles greater than a set threshold by detecting vibrations from larger particles during sorting. The microphone can be configured to obtain sound frequencies generated during the sorting process and detect specific sound frequencies generated by the larger particles. The vibration sensor can be further configured to send a signal to a peripheral device (such as a computing device) or an operator in response to detecting the larger particles.

[0042] In a second aspect, the invention relates to a processing system comprising an apparatus according to the first aspect of the invention and a computer system for receiving data from a data output indicating the weight of at least two sorted partitions of bulk material, thereby allowing calculation of the particle size distribution in the bulk material received in an inlet.

[0043] In the context of the present invention, it should be understood that the calculation can be performed by weighing each sorted partition of the bulk material sorted by the device and calculating their respective weight percentages relative to the total weight of the bulk material. When the weight percentages of each partition are calculated and the particle size of each partition is known, the particle size distribution of a subset of the batch can be calculated and the particle size distribution of the batch can be estimated, assuming that the subset of the batch is representative of the entire batch.

[0044] In a preferred embodiment, a processing system has a target range of particle size distribution of a ground bulk material at multiple processing stages, the processing system comprising:

[0045] a mill / grinder for grinding or milling a bulk material, the bulk material having a first particle size, and the ground bulk material having at least a second particle size, wherein the at least second particle size is smaller than the first particle size,

[0046] - a conveying device for conveying the ground bulk material to the device for determining the particle size distribution in the ground bulk material according to the first aspect of the invention,

[0047] wherein the particle size distribution target of the milled bulk material is maintained by adjusting one or more operating parameters of the mill based on the particle size distribution data of the milled bulk material when the particle size distribution is not within the particle size distribution target range, and wherein the mill / grinder and the device for determining the particle size distribution are only two of more stages in the processing system. The present invention is particularly useful for automating the process of continuously adjusting the particle size of the milled / ground bulk material, such as in the first stage of processing grain for animal feed, where a specific particle size distribution is required. Another advantage is that the particle size distribution can be monitored for changes during changes in the bulk material provided to the mill / grinder, or due to other factors, such as wear equipment that may require maintenance. Therefore, with respect to the use of the processed bulk material, the present invention enables the processed bulk material to have a higher consistency and quality.

[0048] In one embodiment of the invention, the operating parameters of the mill / grinding machine may be one or more of the following: adjusting the rotational speed of the mill, changing the hole size of the screen, or adding a second bulk material to adjust the composition of the bulk material fed into the mill. This is particularly advantageous because the processing of bulk materials requires more than one method of adjusting particle size to maintain a consistent high quality product with a specific particle size composition, thereby reducing the reliance on a consistent starting material. If the moisture content of the bulk material to be processed (such as grain) changes during continuous processing, the particle size distribution of the processed grain will change, and the processing system will detect the change in particle size distribution and adjust one or more of the above parameters.

[0049] In the context of the present invention, a sieve is understood to be a coarse screen which is usually present in mills or grinders for processing cereals, for example for separating cereals from chaff.

[0050] In another embodiment, the sorted bulk material is conveyed back to the bulk material processing system at a stage in the processing system after the means for determining the particle size distribution has sorted and weighed the milled / ground bulk material received from the inlet for further processing of the sorted bulk material. The invention is particularly advantageous for continuous control and adjustment of the particle size distribution of processed bulk material, wherein continuous monitoring of the particle size distribution does not lead to waste of the sorted and weighed bulk material, but ensures that the sorted and weighed bulk material is conveyed back to the processing system to eventually become a finished product, such as animal feed.

[0051] In yet another embodiment, the processing system further comprises a pellet press for pressing the milled / ground bulk material into pellets having a specific particle size composition based on the calculated particle size distribution data of the milled / ground bulk material.

[0052] In a third aspect, the present invention relates to a method of measuring particle size distribution in a bulk material, the method comprising the following steps:

[0053] - receiving at least a portion of the bulk material at an inlet;

[0054] - using a sorting mechanism to sort the received bulk materials, the sorting mechanism comprising:

[0055] at least a first sorting device for sorting the received bulk material into at least two sorted partitions, wherein the sorting device is capable of sorting different particle sizes and the at least two sorted partitions have different particle sizes,

[0056] - a motor or an actuator for vibrating the sorting device,

[0057] - providing a weighing system comprising at least one sensor for weighing at least two sorted partitions sorted by the sorting mechanism,

[0058] - providing a data output for generating output data indicative of the weight of the at least two sorted partitions, and

[0059] - Calculating the particle size distribution in the bulk material received in the inlet based on the data output provided.

[0060] In a preferred embodiment, when the ground bulk material is not within the target range, the method for controlling the particle size distribution target range of the ground bulk material further comprises one or more of the following steps:

[0061] - Adjust the speed of the mill,

[0062] - Change the mesh size, and / or

[0063] - Adding a second bulk material in order to adjust the composition of the bulk material fed to the mill.

[0064] In a more preferred embodiment, the method for producing pellets having a specific particle size distribution further comprises the following steps:

[0065] - providing a press for pressing granules from bulk materials,

[0066] - Pressing of ground bulk material into pellets suitable for animal feed.

[0067] In a fourth aspect, the present invention provides a method for producing animal feed from grain, the method comprising:

[0068] - grinding of grains,

[0069] - applying the method according to the third aspect to a portion of the cereal, and

[0070] - Production of animal feed, such as pellets, from cereals.

[0071] The first, second, third and fourth aspects of the invention may each be combined with any other aspect.These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS

[0072] The apparatus, system and method according to the present invention will now be described in more detail with reference to the accompanying drawings. The drawings illustrate one way of implementing the invention and should not be interpreted as limiting other possible embodiments falling within the scope of the attached claim set.

[0073] Figure 1 is a schematic diagram of an embodiment of a processing system.

[0074] Figure 2 is a schematic diagram of an embodiment of an apparatus for determining particle size distribution.

[0075] Figure 3 is another schematic diagram of an embodiment of an apparatus for determining particle size distribution.

[0076] Figure 4 is another schematic diagram of an embodiment of an apparatus for determining particle size distribution.

[0077] Figure 5 is another schematic diagram of an embodiment of an apparatus for determining particle size distribution.

[0078] Figure 6 is a schematic diagram of another embodiment of a processing system.

[0079] Figure 7 is a schematic diagram of another embodiment of a processing system.

[0080] Figure 8 is a schematic diagram of another embodiment of a processing system.

[0081] Fig. 9 is a schematic diagram of an embodiment of an apparatus for determining a particle size distribution, seen from a first angle.

[0082] Fig.10 is a schematic diagram of an embodiment of an apparatus for determining particle size distribution seen from a second angle.

[0083] Fig.11 is a flow chart of a method according to the present invention.

[0084] Fig.12 is another flow chart of the method according to the present invention. DETAILED DESCRIPTION

[0085] Figure 1 is a schematic diagram of an embodiment of a process system PROC.SYS. for processing bulk materials, such as grain into animal feed. Figure 1 There is an inlet IN for receiving bulk material, such as grain. The bulk material is transferred from the inlet IN to a conveying device T in order to convey the bulk material to a mill MILL, where the bulk material is milled or ground into milled or ground bulk material. The milled or ground bulk material is transferred from the mill MILL back to the conveying device T and is conveyed to a device DEV for determining the particle size distribution of the milled or ground bulk material. The device DEV outputs data OD to a computer COM, the output data OD comprising information about the particle size distribution of the milled or ground bulk material, or at least data indicating the weight of different parts of the ground bulk material sorted into different particle size parts, thereby allowing the computer COM to calculate the particle size distribution. The milled or ground bulk material is then transferred from the device DEV to the conveying device T, and the processed bulk material, such as bulk animal feed, can be transferred from the conveying device to an outlet OUT.

[0086] Alternatively, only a portion of the ground bulk material from the mill MILL is controlled, for example, by a valve system, so that the valve system is manually or automatically controlled to direct a portion of the ground bulk material from the mill MILL to the device DEV for determining the particle size distribution of a sample of the ground bulk material. Thus, only a limited portion (e.g. 1-10 kg) of the ground bulk material can be directed to the inlet of the device DEV.

[0087] It should be understood that Figure 1 The outlet OUT mentioned in the embodiment of the invention may be a packaging device for packaging batches of processed bulk material, for example into animal feed packages.

[0088] Figure 2is a schematic diagram of an embodiment of a device DEV for determining the particle size distribution of bulk material, such as the particle size distribution of milled or ground cereals for animal feed. The embodiment comprises an inlet 2 located at the top of the device DEV. A sensor 5 is located on the inlet 2. Below the inlet 2, a sorting mechanism 1 is located. The sorting mechanism comprises a first sorting device 10, which is located in an inclined position relative to a horizontal axis below the inlet 2. At the lower end of the first sorting device 10, below the first sorting device 10, a first container 30 is located. The first container 30 comprises a hinge or tilting mechanism 30'. Directly below the first sorting device 10, a first chute or slide 20 is located in an inclined position relative to the horizontal axis, the inclination being substantially opposite to the first sorting device 10, thereby having opposite ends oriented upward and downward relative to the first sorting device 10. Below the first chute 20, a second sorting device 11 is located in an inclined position, substantially parallel to the first sorting device 10. At the lower end of the second sorting device 11, below the second sorting device 11, a second container 31 is positioned. The second container 31 comprises a hinge or a tipping mechanism 31'. Directly below the second sorting device 11, a second chute or slide 21 is located in an inclined position, substantially parallel to the first chute 20. Below the second chute 21, a third sorting device 12 is located in an inclined position, substantially parallel to the first sorting device 10 and the second sorting device 11. At the lower end of the third sorting device 12, below the third sorting device 12, a third container 32 is positioned. The third container 32 comprises a hinge or a tipping mechanism 32'. Directly below the third sorting device 12, a third chute or slide 22 is located in an inclined position, substantially parallel to the first chute 20 and the second chute 21. Below the third chute 22, a fourth sorting device 13 is located in an inclined position, substantially parallel to the first sorting device 10, the second sorting device 11 and the third sorting device 12. At the lower end of the fourth sorting device 13, below said fourth sorting device 13, a fourth container 33 is positioned. Said fourth container 33 comprises a hinge or a tipping mechanism 33'. Directly below the fourth sorting device 13, a fourth chute or slide 23 is located in an inclined position, substantially parallel to the first chute 20, the second chute 21 and the third chute 22. Below the fourth chute or slide 23, a weighing system 50 is positioned, said weighing system 50 comprising a weighing container 55, which is attached to sensors 60, 60' for weighing the weighing container 55. The weighing container 55 has a hinge or a tipping mechanism 55'. Below the weighing system 50, a bottom container 70 is positioned.

[0089] It should also be understood that Figure 2 The illustrated embodiment may have more or fewer sorting devices than shown for sorting bulk materials into more or fewer containers, such as but not limited to:

[0090] - a sorting device for sorting bulk material into two partitions,

[0091] - two sorting devices for sorting bulk materials into three partitions,

[0092] - three sorting devices for sorting bulk materials into four partitions,

[0093] - four sorting devices for sorting bulk materials into five zones,

[0094] - five sorting devices for sorting bulk material into six zones, or

[0095] - Six sorting devices for sorting bulk material into seven zones.

[0096] Figure 3 1 is another schematic diagram of an embodiment of a device DEV for determining a particle size distribution of a bulk material 100, such as a particle size distribution of milled or ground grains for animal feed. The embodiment comprises an inlet 2 at the top of the device DEV for receiving the bulk material 100. The bulk material 100 is transferred from the inlet 2 to the sorting mechanism 1 and sorted into a first sorted bulk material 200 by a first sorting device 10. The bulk bulk material 100 is sorted into a first sorted bulk material 200 that cannot pass through the first sorting device 10 and a first remaining bulk material 110 that passes through the first sorting device 10. The first sorted bulk material 200 that does not pass through the first sorting device 10 is conveyed to a first container 30. The second sorting device 11 receives the first remaining bulk material 110 to sort the first remaining bulk material 110 into a second sorted bulk material 210 that cannot pass through the second sorting device 11 and a second remaining bulk material 120 that passes through the second sorting device 11. The second sorted bulk material 210 that has not passed through the second sorting device 11 is conveyed to the second container 31. The third sorting device 12 receives the second remaining bulk material 120 to sort the second remaining bulk material 120 into the third sorted bulk material 220 that cannot pass through the third sorting device 12 and the third remaining bulk material 130 that passes through the third sorting device 12. The third sorted bulk material 220 that has not passed through the third sorting device 12 is conveyed to the third container 32. The fourth sorting device 13 receives the third remaining bulk material 130 to sort the third remaining bulk material 130 into the fourth sorted bulk material 230 that cannot pass through the fourth sorting device 13 and the fourth remaining bulk material 140 that passes through the fourth sorting device 13. The fourth sorted bulk material 230 that has not passed through the fourth sorting device 13 is conveyed to the fourth container 33. The fourth chute or slide 23 receives the fourth remaining bulk material 140 and transfers the fourth remaining bulk material 140 to the weighing container 55 .

[0097] It should be understood that the first sorted bulk material 200, the second sorted bulk material 210, the third sorted bulk material 220, the fourth sorted bulk material 230 and the fourth remaining bulk material represent five sorting partitions of the bulk material 100, and the five sorting partitions of the bulk material 100 are characterized in that they have significantly different particle sizes relative to each other.

[0098] In a specific embodiment for sorting five partitions, the first partition can have a particle size greater than 5 mm, more particularly greater than 3 mm, the second partition can have a particle size between 1 mm and 4 mm, more particularly between 2 mm and 3 mm, the third partition can have a particle size between 0.5 mm and 3 mm, more particularly between 1 mm and 2 mm, the fourth particle size is between 0.1 mm and 1 mm, more particularly between 0.3 mm and 0.4 mm, and the particle size of the fifth partition is lower than that of the fourth partition, for example, the particle size is lower than 0.35 mm.

[0099] Figure 4 is another schematic diagram of an embodiment of a device DEV for determining the particle size distribution of bulk material 100, such as the particle size distribution of milled or ground grain for animal feed. This embodiment shows how the first container 30 contains the first sorted bulk material 200, the second container 31 contains the second sorted bulk material 210, the third container 32 contains the third sorted bulk material 220, the fourth container 33 contains the fourth sorted bulk material 230, and the weighing container 55 contains the fourth remaining bulk material 140, after the device DEV has sorted the bulk material to be sorted. The weighing container 55 is part of a weighing system 50, which further comprises a sensor 60, 60' attached to the weighing container 55 for weighing the weighing container 55. The weighing container 55 has a hinge or a tipping mechanism 55' for emptying the fourth remaining bulk material 140 into a bottom container 70 located below the weighing container 55 after weighing.

[0100] Figure 5 is another schematic diagram of an embodiment of an apparatus DEV for determining a particle size distribution of a bulk material 100, such as a particle size distribution of milled or ground cereals for animal feed. Figure 5 The weighing system 50 is shown simultaneously weighing a fourth sorted bulk material 230. The fourth sorted bulk material 230 has been emptied from the fourth container 33 into a weighing container 55 which can measure the weight of said fourth sorted bulk material 230 by using sensors 60, 60'. Figure 5 A fourth remaining bulk material 140 contained in the bottom container 70 is further shown.

[0101] It should be understood that the weighing system 50 is capable of weighing each sorted partition individually. After weighing one partition in the weighing container 55, the partition is emptied into the bottom container 70, after which another sorted partition can be emptied from one of the containers 30, 31, 32 or 33 into the weighing container 55.

[0102] Figure 6 is a schematic diagram of an embodiment of a processing system PROC.SYS. for processing bulk material, such as processing grain into animal feed pellets. The system PROC.SYS. has an inlet IN for receiving bulk material, such as grain. The bulk material is conveyed from the inlet IN to a conveying device T in order to convey the bulk material to a mill MILL, where the bulk material is milled or ground into milled or ground bulk material. The milled or ground bulk material is conveyed from the mill MILL back to the conveying device T and is conveyed to a device DEV for determining the particle size distribution of the milled or ground bulk material. The device DEV outputs data OD to a computer COM, said output data OD comprising information about the particle size distribution of the milled or ground bulk material. The milled or ground bulk material is then transferred from the device DEV to a conveying device T from which the processed bulk material, such as bulk animal feed, can be conveyed to a pellet processing device PELL in order to press the processed bulk material into pellets, such as pellets suitable for animal feed.

[0103] Figure 7 is a schematic diagram of an embodiment of a processing system PROC.SYS. for processing bulk material, such as processing grain into animal feed. The system PROC.SYS. has an inlet IN for receiving bulk material, such as grain. The bulk material is conveyed from the inlet IN to a conveying device T in order to convey the bulk material to a mill MILL, where the bulk material is milled or ground into a milled or ground bulk material. The milled or ground bulk material is conveyed from the mill MILL back to the conveying device T and is conveyed to a device DEV for determining the particle size distribution of the milled or ground bulk material. The device DEV outputs data OD to a computer COM, the output data OD comprising information about the particle size distribution of the milled or ground bulk material. The computer COM can use the information about the particle size distribution of the milled or ground bulk material to adjust the mill MILL, thereby adjusting the particle size distribution of the milled or ground bulk material by sending a feedback signal FB to the mill MILL. The milled or ground bulk material is transferred from the device DEV to a conveying device T from which the processed bulk material, such as bulk animal feed, can be conveyed to a pellet processing device PELL in order to press the processed bulk material into pellets, such as pellets suitable for animal feed.

[0104] Figure 8is a schematic diagram of an embodiment of a processing system PROC.SYS. for processing bulk material, such as processing grain into animal feed. The system PROC.SYS. has an inlet IN for receiving bulk material, such as grain. The bulk material is conveyed from the inlet IN to a first conveying device T1 in order to convey the bulk material to a mill MILL, where the bulk material is milled or ground into milled or ground bulk material. The milled or ground bulk material is conveyed from the mill MILL back to a second conveying device T2 and is conveyed to a device DEV for determining the particle size distribution of the milled or ground bulk material. The device DEV outputs data OD to a computer COM, the output data OD comprising information about the particle size distribution of the milled or ground bulk material. The milled or ground bulk material is then transferred from the device DEV to a third conveyor T3 from which the processed bulk material, such as bulk animal feed, can be conveyed to a pellet processing device PELL in order to press the processed bulk material into pellets, such as pellets suitable for animal feed.

[0105] It will be appreciated that the device DEV for determining the particle size distribution may have one or more motors attached to the sorting devices in order to vibrate all sorting devices at the same frequency, or to vibrate the sorting devices at individual frequencies.

[0106] Fig. 9 is a schematic diagram of an embodiment of an apparatus DEV for determining a particle size distribution, seen from a first angle. Fig. 9 A device DEV is shown embedded in a frame 6 in a horizontal arrangement. A first sorting device 10 is located at the top portion. At the front portion of the frame 6, a first container 30 is located below the first sorting device 10. A second sorting device 11 is located below the first sorting device 10. A motor 80 is attached to the second sorting device 11 and the frame 6. The motor 80 is adapted to vibrate one or more of the sorting devices 10, 11, 12, 13. At the front portion of the frame 6, a second container 31 is located below the second sorting device 10. A third sorting device 12 is located below the second sorting device 11. A motor 81 is attached to the third sorting device 12 and the frame 6. The motor 81 is adapted to vibrate one or more of the sorting devices 10, 11, 12, 13. At the front portion of the frame 6, a third container 32 is located below the third sorting device 12. A fourth sorting device 13 is located below the third sorting device 12, and a weighing mechanism 50 is located below the fourth sorting device.

[0107] Fig.10is a schematic diagram of an embodiment of a device DEV for determining a particle size distribution seen from a second angle. The figure shows the device DEV embedded in a frame 6 in a horizontal arrangement. A first sorting device 10 is located at the top portion. At the front portion of the frame 6, a first container 30 is located below the first sorting device 10. A second sorting device 11 is located below the first sorting device 10. A motor 80 is attached to the second sorting device 11 and the frame 6. The motor 80 is suitable for vibrating one or more of the sorting devices 10, 11, 12, 13. At the front portion of the frame 6, a second container 31 is located below the second sorting device 10. A third sorting device 12 is located below the second sorting device 11. At the front portion of the frame 6, a third container 32 is located below the third sorting device 12. A fourth sorting device 13 is located below the third sorting device 12, and a weighing mechanism 50 is located below the fourth sorting device.

[0108] Fig.11 is a flow chart of a method for measuring particle size distribution in a bulk material, the method comprising the steps of:

[0109] S1 - receiving at least a portion of the bulk material at an inlet,

[0110] S2-sorting the received bulk materials using a sorting mechanism, the sorting mechanism comprising:

[0111] at least a first sorting device for sorting the received bulk material into at least two sorted partitions, wherein the sorting device is capable of sorting different particle sizes and the at least two sorted partitions have different particle sizes,

[0112] - a motor or an actuator for vibrating the sorting device,

[0113] S3-providing a weighing system including at least one sensor for weighing at least two sorted partitions sorted by the sorting mechanism,

[0114] S4-providing a data output for generating output data indicating the weight of the at least two sorted partitions, and

[0115] S5 - Calculate the particle size distribution of the bulk material received in the inlet based on the data output provided.

[0116] Fig.12 is a flow chart of a method for controlling a target range of particle size distribution of a milled bulk material using multiple processing stages, the method comprising:

[0117] S10- defining a target range of particle size distribution of the ground bulk material,

[0118] S20-grinding / milling a bulk material, the bulk material having a first particle size, and the milled bulk material having at least a second particle size, wherein the at least second particle size is smaller than the first particle size,

[0119] S30—conveying the ground bulk material to the device for determining the particle size distribution in the ground bulk material according to the first aspect of the present invention,

[0120] S40-determining the particle size distribution in the ground bulk material, and

[0121] If the particle size distribution in the milled bulk material is OK within the target range, then continue CONT milling / grinding the bulk material, and

[0122] If the particle size distribution in the milled bulk material is not within the target range NO:

[0123] S50 - Adjusting one or more operating parameters of the mill / grinding machine based on the particle size distribution data of the milled bulk material in relation to a target range of the particle size distribution.

[0124] Briefly, the present invention relates to an apparatus for determining the particle size distribution in bulk material, such as milled or ground cereals for animal feed. The apparatus comprises an inlet for receiving at least a portion of the bulk material, a sorting mechanism for sorting the received bulk material. The sorting mechanism comprises at least a first sorting device for sorting the received bulk material into at least two sorted partitions, wherein the sorting device is capable of sorting different particle sizes and the at least two sorted partitions have different particle sizes. The invention further comprises a motor or actuator for vibrating the sorting device, a weighing system having at least one sensor for weighing the at least two sorted partitions sorted by the sorting mechanism, and a data output for generating output data indicating the weight of the at least two sorted partitions, thereby allowing the calculation of the particle size distribution in the bulk material received at the inlet and thus providing information about the particle size composition of the milled or ground cereals.

[0125] Although the present invention has been described in conjunction with specific embodiments, it should not be interpreted as being limited in any way to the examples presented. The scope of the present invention is set forth by the appended claims. In the context of the claims, the terms "comprise" or "include" do not exclude other possible elements or steps. In addition, references such as "one" and the like should not be interpreted as excluding multiple. The use of reference numerals in the claims regarding the elements shown in the figures should not be interpreted as limiting the scope of the present invention. In addition, the individual features mentioned in different claims may be advantageously combined, and mentioning these features in different claims does not exclude that the combination of features is impossible and advantageous.

Claims

1. A device for determining the particle size distribution in a bulk grain material for animal feed, the device comprising: - a guide adapted to guide a sample of bulk grain material for animal feed from an associated device, - an inlet for receiving a sample of the bulk cereal material, - a sorting mechanism, the sorting mechanism is used to sort the samples of the received bulk grain materials, the sorting mechanism comprising: at least a first sorting device for sorting the sample of the received bulk cereal material into at least two sorted partitions, wherein the first sorting device is capable of sorting different particle sizes and the at least two sorted partitions have different particle sizes, and - a motor or an actuator for vibrating said first sorting device, a weighing system comprising at least one sensor for weighing the at least two sorted partitions sorted by the sorting mechanism, and a data output for generating output data indicative of the weight of the at least two sorted partitions, thereby allowing calculation of the particle size distribution in the sample of bulk cereal material received in the inlet, and A suction device configured to remove aerosolized particles during sorting.

2. The device according to claim 1 comprises at least a second sorting device, wherein the second sorting device receives bulk grain material from the first sorting device.

3. The device according to claim 2, wherein: The device is arranged inside a frame or shell including a top part and a bottom part, and the device is further arranged horizontally, the inlet is located at the top part, the first sorting device is located below the inlet, and is used to receive a sample of bulk grain material from the inlet, and the second sorting device is located below the first sorting device, and is used to receive bulk grain material from the first sorting device, and wherein the particle size of the bulk grain material received in the second sorting device is smaller than the particle size of the sorted part sorted by the first sorting device.

4. The device according to claim 1, wherein: The sensor of the weighing system is located at a bottom portion of the device and wherein a sample of the bulk cereal material to be sorted is weighed at the bottom portion of the device.

5. The device according to claim 2, wherein: The first sorting device and the second sorting device include a first sieve and a second sieve, respectively, wherein the sample of the bulk grain material is transferred from the first sieve to the second sieve through vibration of the first sieve and the second sieve, and the holes in the first sieve are larger than the holes in the second sieve, thereby allowing particles smaller than the particles retained in the first sieve to be transferred from the first sieve to the second sieve.

6. The device according to claim 2 further includes a separate container associated with each of the first sorting device and the second sorting device, for receiving the sorted partitions from the first sorting device and the second sorting device.

7. The device according to claim 6, wherein: The first and second sorting devices are inclined downwardly relative to a horizontal plane toward the container so as to transfer any particles retained in the respective sorting devices toward the container by vibration.

8. The device according to claim 7, wherein: The chute is located below the downwardly inclined first and second sorting devices, and wherein the chute is downwardly inclined relative to a horizontal plane at an angle substantially opposite to that of the first and second sorting devices.

9. The device according to claim 1, wherein: The weighing system comprises a plurality of load cells for weighing corresponding ones of the at least two sorted zones, or wherein the weighing system comprises a single load cell for weighing all the zones of the at least two sorted zones sequentially.

10. The device according to claim 2, wherein: The motor or actuator is arranged to vibrate the first sorting device or the second sorting device at a frequency between 0.5 and 30 Hz.

11. The device according to claim 10, wherein: The motor or actuator is arranged to vibrate the first sorting device or the second sorting device at a frequency between 1 and 20 Hz.

12. The device according to claim 10, wherein: The motor or actuator is arranged to vibrate the first sorting device or the second sorting device at a frequency between 4 and 10 Hz.

13. Apparatus according to any preceding claim, further comprising an imaging device configured to detect anomalies in the bulk grain material.

14. The device according to claim 13, wherein: The parameters used to detect anomalies within the bulk grain material can be selected from one or more of size, shape, color or reflectivity.

15. The apparatus of any one of claims 1 to 12, further comprising a vibration sensor configured to detect vibrations generated by the sample of bulk grain material during sorting of the sample of bulk grain material.

16. The device according to any one of claims 1 to 12, further comprising a cleaning mechanism, which is suitable for discarding the sorted partitions and cleaning the sorting mechanism.

17. A processing system comprising: - a device according to any one of claims 1 to 16, and - A computer system for receiving from said data output data indicative of the weight of said at least two sorted partitions, thereby allowing calculation of a particle size distribution in a sample of bulk cereal material received in said inlet.

18. The processing system of claim 17, comprising a target range of particle size distribution for a milled bulk grain material having a plurality of processing stages, the processing system comprising: a mill or grinder for milling or grinding a bulk cereal material, the bulk cereal material having a first particle size, and the milled bulk cereal material having at least a second particle size, wherein the at least second particle size is smaller than the first particle size, - a conveying device for conveying ground bulk grain material to the device according to any one of claims 1 to 16, wherein, when the particle size distribution is not within the particle size distribution target range, the particle size distribution target of the ground bulk grain material is maintained by adjusting one or more operating parameters of the mill based on the particle size distribution data of the ground bulk grain material, and wherein the mill / grinding mill and the device for determining the particle size distribution are only two of more stages in the processing system.

19. A method of measuring particle size distribution in a bulk grain material, the method comprising the steps of: - providing a guide adapted to obtain a sample of the bulk grain material from the associated device, - receiving samples of bulk grain materials at the inlet; - sorting the received bulk grain material sample using a sorting mechanism, the sorting mechanism comprising: at least a first sorting device for sorting the sample of the received bulk cereal material into at least two sorted partitions, wherein the first sorting device is capable of sorting different particle sizes and the at least two sorted partitions have different particle sizes, - a motor or an actuator for vibrating said first sorting device, - providing a weighing system comprising at least one sensor for weighing at least two sorted partitions sorted by the sorting mechanism, - providing a suction device configured to remove aerosolized particles during sorting, - providing a data output for generating output data indicative of the weight of the at least two sorted partitions, and - calculating, based on the data output provided, a particle size distribution in a sample of said bulk cereal material received in said inlet.

20. The method of measuring particle size distribution in bulk grain material according to claim 19, further comprising the steps of: - provide imaging equipment, - Detecting any anomalies within a sample of bulk cereal material before, during or after sorting of said sample of bulk cereal material.

21. The method according to claim 20, further comprising: - In response to detecting an abnormal condition within a sample of the bulk cereal material, discarding at least a portion of the bulk cereal material.

22. The method according to claim 20 or 21, further comprising: - In response to detecting an abnormal condition within a sample of said bulk cereal material, outputting a signal.

23. A method for producing animal feed from grain, the method comprising: - milling the cereals to produce milled cereals, - measuring the particle size distribution of the sample of milled cereals according to the method of claim 19, 20, 21 or 22, and - producing animal feed or animal feed pellets from said milled cereals.

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