Automated units for producing a variety of on-demand dairy products on farms.

Abstract

The present invention relates to a method for automatically producing multiple types of dairy products on a farm on demand, the method comprising the following automated steps: receiving an electronic order for dairy products from a consumer; directly filling a tank (10) with milk after milking; filling a batch of containers (46) from the tank; passing the batch of containers through at least one processing module (16) configured to apply processing steps suitable for the ordered dairy products; storing the processed contents of the batch of containers in a controlled atmosphere module (24); and adjusting the processed contents of the batch of containers into a form suitable for presentation to the consumer, based on a request from a consumer on site.

Description

Technical Field

[0001] This invention relates to the automated production of dairy products, and more specifically to small-scale production. Background Technology

[0002] Dairy plants employ large-scale industrial processes to produce a range of dairy products ready for supermarkets. They are typically located some distance from the production farms and are supplied with raw milk via refrigerated tanker trucks that collect milk from the farms.

[0003] Locally produced dairy products are largely manual processes because industrial processes are not suitable for small-scale production on individual farms.

[0004] Many dairy farmers have abandoned local production because they do not have the time to invest in the largely manual processes involved. Summary of the Invention

[0005] Generally, an automated production unit is provided for on-demand production of various types of dairy products. The automated production unit includes: a tank for directly receiving raw milk after milking; a pallet-carrying robot configured to move longitudinally within a service aisle; multiple processing modules arranged at the edges of the aisle and having guides configured to receive pallets laterally conveyed by the transport robot. These modules include: a pallet storage module; a container storage module configured to receive pallets conveyed by the robot from the pallet storage module and arrange containers on the pallets; a filling module configured to receive pallets conveyed by the robot from the container storage module and fill containers from the receiving tank; and at least one main processing module configured to receive pallets conveyed by the robot from the filling module and apply processing steps suitable for dairy products requested by consumers.

[0006] The production unit may also include an adjustment module configured to receive a pallet delivered by a robot at the end of the cycle and retrieve the finished products conveyed on the pallet so that they are provided to consumers in appropriate packaging.

[0007] The pallet storage module can also be configured as a cleaning pallet.

[0008] The production unit may include a controlled atmosphere module configured to receive and hold a tray delivered by a robot from the main processing module, and then deliver the tray to an conditioning module, the robot being programmed to deliver the tray to the conditioning module based on a customer’s on-site request.

[0009] The receiving tank can be configured to perform pasteurization, curdling, or turbinating functions depending on the type of dairy product requested. The production unit includes an input dispensing unit configured to dispense additives specific to the type of dairy product requested into the tank contents.

[0010] The main processing module may include a heating module.

[0011] The main processing module may include a filtering module or a compression module.

[0012] The controlled atmosphere module may include a refrigeration module, a freezing module, or a maturation chamber.

[0013] The container storage module and the filling module may each include a CNC machine for individually positioning the containers on the tray and moving the dairy product dispensing nozzle from one container to another.

[0014] The production unit can be completely enclosed in a transportable shelter.

[0015] A method for automatically producing multiple types of dairy products on a farm on demand is also provided, the method comprising the following automated steps: receiving an electronic order for dairy products from a consumer; directly filling a tank with milked milk; filling a batch of containers from the tank; passing the batch of containers through at least one processing module configured to apply processing steps suitable for the ordered dairy products; storing the processed contents of the batch of containers in a controlled atmosphere module; and adjusting the processed contents of the batch of containers into a form suitable for presentation to the consumer, based on a request from a consumer on-site. Attached Figure Description

[0016] The following non-limiting descriptions are provided in connection with the accompanying drawings, including:

[0017] Figure 1 A schematic top view of a small-scale automated dairy production unit is shown;

[0018] Figure 2 This is a perspective view of a pallet-carrying robot; and

[0019] Figure 3 This is a perspective view of the filling module of the production unit. Detailed Implementation

[0020] The method described below is for the local, small-scale, fully automated production of dairy products. Production is ensured by a production unit, preferably fully enclosed in a transportable, enclosed shelter, such as a shipping container, installed on-site at the dairy producer's farm. Therefore, milk from the farm after milking can be directly supplied to the production unit, thus ensuring optimal raw milk quality.

[0021] Small-scale automated production opens up many possibilities that are difficult to achieve with large-scale production. Specifically, production units can operate on demand, that is, take electronic orders from consumers, organize production, and deliver products when consumers arrive at the site.

[0022] Figure 1 A top view of an embodiment of this production unit is shown. The unit includes a receiving tank 10 fed by a pipe 12. When the unit is placed on a farm, the pipe 12 can be connected to receive milk directly after milking.

[0023] Tank 10 can be a single tank configured to perform several possible pretreatments depending on the dairy product to be produced, including pasteurization, curdling, or whirlpooling. Alternatively, several tanks 10 can be provided, each performing a different pretreatment, thereby allowing the parallel commencement of production of different batches of dairy products.

[0024] The feed dispenser 14 is connected to the tank 10 to dispense various additives required for the preparation of dairy products, such as enzymes for yogurt and cheese, rennet for cheese, and ingredients for ice cream.

[0025] A plurality of processing modules are mounted around tank 10, each designed to perform one or more steps in the dairy product preparation process. This unit includes, for example, a heating module 16 for preparing yogurt, a filtering module 18 for preparing different types of cheese, a pressing module 20 for preparing pressed cheese, and several controlled atmosphere modules 22, 24, and 26. Module 22 reproduces the conditions of a maturation chamber, module 24 is a refrigerator, and module 26 is a freezer. An adjustment module 28 is provided to provide the final dairy product in a portable package, such as several cups arranged in a parcel.

[0026] The modules described above perform well-known steps in the dairy product preparation process, and how to automate them is also known. The main challenge in automation lies in transporting dairy products from one step to the next.

[0027] To ensure the transport of dairy products in the production unit described herein, all modules are managed along a service channel 30 in which a handling robot 32 moves, taking into account small-scale production.

[0028] It is configured to transport the dairy products in cups once the dairy products leave tank 10. These cups are suitable for the preparation process of the requested dairy products. These cups are arranged on corresponding trays, and robot 32 transfers the trays from one module to another according to the preparation process required by the requested dairy products. Each module is designed to receive one or more trays in a guide.

[0029] Three additional modules are designed to handle the transport of cups on trays. Module 34 stores the tray in a guide and also acts as a dishwasher to clean trays returning from the production cycle.

[0030] Module 36 stores new cups and distributes them onto a tray presented to it. New cups, made of a flexible material, can be stacked between parallel tubes that hold the cups in place by friction. A CNC (“Computer Numerical Control”) machine is configured to pick up each cup by suction or gripping and store it in an available hole in the tray. New cups are preferably stored on top of the tray with their openings facing down, allowing the machine to pull each cup from its interior from the bottom of the stack, flip it over, and place it on the tray.

[0031] Module 38 is configured to fill cups presented to its tray. The module may include a dispensing nozzle connected to tank 10, which is driven by a CNC machine to fill cups one after another.

[0032] Preferably, as shown, the modules are housed in racks of the same size for interchangeability and are positioned on either side of aisle 30. While the space management of the individual modules has been described, in practice, several modules can be combined into the same rack, or even merged with other modules. For example, the compression performed by module 20 may simply be an extension of the filtering performed by module 18, since compression is merely an accelerated filtering operation.

[0033] Figure 2 This is a partial perspective view of an embodiment of the handling robot 32. The robot includes a parallelepiped bracket 40 that slides vertically on a beam 42. One end of the beam 42 slides along the axis of the service passage on a guide rail 44. Preferably, as shown, the guide rail 44 is located overhead rather than on the ground. The bracket 40 has a length slightly smaller than the width of the passage, a width slightly smaller than the width of the module, and a height suitable for providing satisfactory rigidity.

[0034] The tray is shown as a guide in the upper part of one of the modules (e.g., refrigeration module 24) to place a tray equipped with cups 46. For handling the tray, the tray includes a pair of lateral telescopic arms 48 on which the two opposite edges of the tray can be supported. The arms are configured to fully extend or retract the tray on either side of the tray to store or retrieve the tray in or from a module located on either side of the passageway. The lifting or placing of the tray is ensured by the vertical movement of the tray along beam 42.

[0035] More specifically, the pallet is transferred from one module to another as follows. Beam 42 slides longitudinally along guide rail 44 until bracket 40 is aligned with the module from which the pallet will be retrieved. The bracket moves vertically along beam 42 until telescopic arm 48 is slightly below the pallet to be retrieved. Arm 48 extends and enters the module beneath the pallet. The bracket rises along beam 42 to fully lift the pallet away from its guide. The telescopic arm retracts, thus retracting the pallet back to the center of the bracket.

[0036] Then beam 42 slides until bracket 40 is aligned with the module on which the pallet will be placed. The bracket moves vertically along beam 42 until telescopic arm 48 is slightly above the guide on which the pallet will be placed. Arm 48 extends into the module, positioning the pallet above the guide. The bracket descends along beam 42 to place the pallet onto its guide. The telescopic arm retracts to begin a new transfer operation.

[0037] Some of these modules are typically closed to perform their functions, particularly the atmosphere control modules. To enable tray transfer, these modules are closed by vertically sliding top and bottom half-doors—to open the bottom portion of the module, the bottom half-door is raised to overlap with the top half-door, and to open the top portion of the module, the top half-door is lowered to overlap with the bottom half-door.

[0038] Figure 3 This is a perspective view of the cup filling module 38. A tray with its cups 46 is placed on a guide. To ensure relatively precise positioning, as shown, the tray may be fitted with holes at its corners that fit into cones on the guide. Cups are individually filled from tank 10 by dispensing nozzles 50 moved by a CNC machine with two axes 52a, 52b. Of course, the type of tray and the position of the cups on the tray are known to the machine. In practice, a centralized control system can be configured to track each tray and thus always know which type of tray is in which module and in which location. Alternatively, the tray may be equipped with an identifier such as a barcode, which is read at the entrance of each module.

[0039] As shown in the figure, the cup receiving hole of tray 46 has notches on its circumference. These notches allow the robotic gripper to remove the cups in subsequent processing modules (such as adjustment module 28).

[0040] refer to Figure 1 Below are some examples of processes used to prepare different dairy products, described in a non-exhaustive manner, and some more detailed examples of the operation of certain modules are presented.

[0041] As previously mentioned, consumers can order dairy products electronically, for example, using a mobile application on a website or a live display. Orders can include different types of dairy products. The system then suggests a delivery date based on its inventory and / or production capacity.

[0042] For example, to prepare yogurt, tank 10 can be used in pasteurization mode. After pasteurization, dispenser 14 adds yogurt enzyme. Module 38 receives a tray of empty cups and fills them from the contents of tank 10. After filling, the tray is conveyed to heater 16.

[0043] After heating, the tray is transferred to refrigeration unit 24 to await the delivery date agreed upon with the consumer. The tray can be sealed to the cup via adjustment module 28 before or after heating.

[0044] On the delivery date, the consumer visits the production unit and requests an order, for example, by entering a code on an interface or using a mobile application. The tray of yogurt cups is then removed from the refrigeration unit and conveyed to the conditioning module 28, where the cups corresponding to the order are placed in the package along with any other ordered products. The package can then be presented to the consumer through the hatch.

[0045] Empty pallets are returned to storage module / dishwasher 34, where they are cleaned when a sufficient number of empty pallets have been returned or when there is a shortage of clean pallets.

[0046] Alternatively, to release the tray immediately, the yogurt cups can be packaged in 28 as soon as they leave the heater. In this case, the package is conveyed to a refrigeration unit to await delivery, while the tray is returned to the dishwasher.

[0047] For cheese production, tank 10 can be used in either a curdling-only mode for raw milk cheese or in a pasteurization and curdling mode. Dispenser 14 adds enzymes and rennet at the appropriate time and temperature, depending on the processing technology specific to each cheese category.

[0048] For example, in the case of lactic acid coagulation, after 18 to 24 hours of coagulation, a tray is fitted with a microporous mold suitable for whey filtration in module 36. The tray is then conveyed to filtration module 18, where the coagulation continues to be filtered by gravity. The whey produced by this filtration process can be collected in a tank via outlet 18-1.

[0049] To prevent whey leakage into channel 30 during transport, the tray may be fitted with a collection container attached to the underside of the tray. This container may be equipped with a discharge mechanism that is activated when the container is inserted into the module, wherein module 18 is then configured to allow the container contents to flow into discharge outlet 18-1. This solution keeps module 18 clean and relaxes cleanliness restrictions.

[0050] When the tray and its container are returned to the dishwasher, the container's discharge mechanism is also activated to remove any residual whey and allow the wash water to circulate.

[0051] Alternatively, if leakage is permissible in channel 30, the channel may be cup-shaped and equipped with a drain to vent any spillage that occurs during transport. This is advantageous when the robot's transport rail is overhead, thereby clearing any obstructions from the channel. Jet jets can be used to clean the channel periodically and automatically. Steam can be used to sterilize different volumes.

[0052] The recovered whey can be recycled. For example, sweet whey from rennet-based coagulated products can be returned to tank 10 for the production of whey cheese, such as Sérac or Ricotta, via heat coagulation.

[0053] Following filtration in step 18, the trays typically undergo further processing. Depending on the product to be obtained, the contents of the microporous molds are either i) poured into cups (for ready-to-eat cottage cheese), ii) flipped in their molds for a second filtration stage, or iii) removed from the molds. The required processing can be performed by a robotic gripper available in module 36, in which the trays are conveyed after filtration.

[0054] For ease of handling, only half of the tray's capacity can be occupied by cups or molds, while the other half is managed for the required processing. In this case, the robotic gripper can reach all locations on a single plane. For this purpose, the other half of the tray can i) have holes to receive cups for pouring, ii) have holes to receive a series of microporous molds for flipping, or iii) be flat to receive the demolded contents. After the tray has traveled through the dishwasher 34, the empty microporous molds can remain in place and be reused.

[0055] In case i), the cup contains ready-to-eat cottage cheese, and the tray can be conveyed to the refrigeration unit 24 while awaiting delivery.

[0056] In case ii), the tray returns to the filtration module 18. This two-stage filtration process is typically used for salted cheese, and the filtration module 18 can be configured to surface-salt the contents of the cup during each of the two filtration stages. Salting can be performed using a dispensing unit equipped with a CNC machine.

[0057] After the second filtration stage, the product is demolded, which then corresponds to case iii).

[0058] In case iii), after demolding, the tray is transferred to curing chamber 22.

[0059] After the programmed curing period, the pallet can be transferred to refrigeration unit 24 to await delivery.

[0060] For example, robotic spatulas or suction pads can be used to process the unmolded cheese so that it can be packaged in 28 for delivery.

[0061] In the case of pressed cheese, between filtering in 18 and aging in 22, the tray is conveyed to pressing module 20. The pressing module may include a series of pistons, the size of which is comparable to a cup, which apply a set pressure to the upper surface of the cheese at a programmed time.

[0062] The pressing process extracts more whey, which falls into a collection container. Similar to the filtration module 18, the container discharge mechanism is activated when the tray is inserted. The filtered whey can be collected in a tank from which it can be returned to the processing tank 10.

[0063] The filtering module 18 and the pressing module 20 can be formed into a single unit. If only filtering is required, pressing is not activated. However, since the filtering operation is relatively time-consuming, it is preferable to provide two separate modules to improve productivity.

[0064] Regarding hygiene, regular equipment cleaning is required. Since most steps in the preparation process take place on dairy products conveyed in containers (cups, molds) or poured onto trays placed in dishwashers, the amount of equipment requiring cleaning is minimal. In practice, only the loop from the inlet of tank 10 to the dispensing nozzle of filling module 38 needs cleaning. This can be accomplished using a closed-loop CIP (clean-in-place) system, where an alkaline phase (chlorinated alkaline solution) and an acidic phase are alternately used, with rinsing with clean water before and after the process through pipe 12, tank 10, and up to the dispensing nozzle of module 38. During washing, the dispensing nozzle can be positioned above the outlet 38-1.

Claims

1. An automated production unit for multiple types of dairy products on demand, comprising: Tank (10), the tank being used to directly receive raw milk after milking; Pallet handling robot (32), the pallet handling robot being configured to move longitudinally in the service aisle (30); Multiple processing modules are arranged at the edge of the service aisle and have guides configured to receive pallets laterally conveyed by the pallet-handling robot. The multiple processing modules include: Pallet storage module (34); A container storage module (36) is configured to receive a pallet delivered from the pallet storage module by the pallet handling robot and to place a container on the pallet; A filling module (38) configured to receive a pallet delivered by the pallet handling robot from the container storage module and to fill the container from the tank; and At least one main processing module (16) is configured to receive a pallet delivered from the filling module by the pallet handling robot and apply processing steps suitable for dairy products requested by the consumer.

2. The production unit according to claim 1 further includes an adjustment module (28) configured to receive a pallet delivered by the pallet handling robot at the end of the cycle and retrieve the finished products conveyed on the pallet to provide them to the consumer in appropriate packaging.

3. The production unit according to claim 1, wherein the pallet storage module (34) is further configured to clean the pallet.

4. The production unit according to claim 2, comprising a controlled atmosphere module (24) configured to receive and hold a pallet delivered from the main processing module by the pallet handling robot, and then deliver the pallet to the conditioning module, the pallet handling robot being programmed to deliver the pallet to the conditioning module according to a field request from the consumer.

5. The production unit according to claim 1, wherein the tank (10) is configured to perform pasteurization, curdling or vortexing functions according to the type of dairy product requested, the production unit comprising an input dispensing unit (14) configured to dispense an additive specific to the type of dairy product requested into the contents of the tank.

6. The production unit according to claim 5, wherein the main processing module includes a heating module (16).

7. The production unit according to claim 5, wherein the main processing module includes a filtering module (18) or a pressing module (20).

8. The production unit according to claim 4, wherein the controlled atmosphere module includes a refrigeration module (24), a freezing module (26), or a curing chamber (22).

9. The production unit according to claim 1, wherein the container storage module (36) and the filling module (38) each include a CNC machine for positioning the containers on the tray individually and moving the dairy product dispensing nozzle from one container to another.

10. The production unit according to claim 1, wherein the production unit is completely enclosed in a transportable shelter.

11. A method for automatically producing multiple types of dairy products on a farm on demand, implemented by a production unit as described in any one of claims 1-10, comprising the following automated steps: Receiving electronic orders for dairy products from consumers; Milk after milking is directly filled into can (10); A batch of containers (46) are filled from the tank; The batch of containers is passed through at least one processing module (16), which is configured to apply processing steps suitable for the ordered dairy products. The processed contents of the batch of containers are stored in the controlled atmosphere module (24); as well as Based on requests from on-site consumers, the processed contents of the batch of containers are adjusted to a form suitable for presentation to the consumers.

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