Installation of arthropod breeding facilities in multi-level modules

Abstract

The present invention relates to the field of large-scale arthropod rearing, particularly of insects, for the production of animal or human food. An arthropod rearing installation comprising racking for storing arthropod growth modules and equipment for periodically performing at least one rearing treatment, as well as means for moving the modules, characterized in that said modules consist of multi-tiered monolithic blocks, each having a plurality of superimposed transverse platforms joined by fixed spacers defining at least one lateral slot between each of said transverse platforms; the means for moving the modules comprise a support interacting directly with the bottom of said modules, without the interposition of a pallet; said modules are handled, as such, and in a closed loop, between the racking and the various processing equipment.Figure from the summary: 1.

Description

Title of the invention: Arthropod rearing installation in multi-stage modules. Field of the invention

[0001] The present invention relates to the field of large-scale rearing of arthropods, in particular insects for the purpose of producing food for animals or humans.

[0002] Insects have a number of characteristics that make them well-suited for use in animal feed. Indeed, insects have a high protein content, while also being rich in other beneficial nutrients such as fats, minerals, and vitamins. Protein concentration levels in insect meal intended for animal feed range from 55% to 75%. Insects are characterized by a higher feed conversion ratio and can therefore become a very valuable feed source for livestock. Insects are a natural component of the diet of animals such as carnivorous fish (for example, insects can provide up to 70% of the nutritional requirements of trout) or poultry.

[0003] Moreover, these products also have a well-balanced nutritional profile to meet human dietary needs.

[0004] These considerations have led to the development of automated mass production of food from arthropod farming, and more particularly from insects, in industrial sites organized into complementary spaces specializing in hatching, rearing, collecting mature animals and processing them to extract compounds of interest.

[0005] These industrial sites must be optimized to offer the best health guarantees, and ensure the appropriate climatic conditions to allow optimal and reproducible larval growth in all seasons. State of the art

[0006] To install such production sites, European patent EP2986107 proposed an insect rearing system comprising a plurality of crates, a climate zone with a ventilation system arranged to accommodate the crates in the climate zone, a conveyor system for retrieving crates from the climate zone and optionally returning them there, and an observation system along the conveyor system for obtaining observations. This solution is not satisfactory for high-volume production because the flow of crates is limited by the bottleneck formed by the conveyor, which is designed to move a crate. one after the other, from a defined starting point to a second defined arrival point, each of the crates must then be handled individually, one by one, to be transported to the next area.

[0007] European patent EP3282837 proposes a solution in which the production site comprises two zones: - The first zone, divided into silos for storing larvae at different stages of maturity, includes: • shelving for storing pallets on which stacks of livestock crates are stored; • an automated device configured for moving elementary units between the first zone and a second zone; • an interface with the second zone, for sending and retrieving pallets. The insects grow in this first zone under controlled and optimized environmental conditions (defined by environmental parameters including temperature, humidity, etc.).

[0008] The first zone implements an automated device for the retrieval of pallets and sending them to the second zone, so that no or almost no rearing operations need to be carried out in the first zone according to the teaching of this prior art patent.

[0009] The rearing modules, in this case crates, are stacked and grouped on pallets for the multiple movements between the two aforementioned zones. These movements are carried out by stacker cranes normally used for transporting pallets. The interface zone is an area intended for the placement of a pallet supporting stacks of crates and for depalletizing or unbundling the rearing crates for shipment to the second zone.

[0010] This patent proposes a solution based on a group of palletized modules.

[0011] This solution is also unsatisfactory because it requires multiple steps to form stacks of modules, group several stacks of modules to place them on a pallet to allow movement with a pallet jack, then, for certain operations, depalletizing to separate the stacks of modules, and sometimes separating the modules within a stack to access the rearing medium and larvae. These steps are tedious and require either a large workforce or complex and multiple robotic equipment for preparing the stacks of modules, grouping them on pallets, and separating the stacks of modules, resulting in lost time and reduced throughput, leading to a loss of productivity.

[0012] Furthermore, grouping several stacked modules to form multiple stacks on a pallet results in loads that are difficult to transport. Moreover, in the prior art, the formation and movement of stacks of these containers presents risks of falls and therefore production interruptions. Solution provided by the invention

[0013] In order to remedy the problems of the prior art, the present invention relates in its most general sense to an arthropod rearing installation comprising shelving for the storage of arthropod growth modules and equipment for carrying out at least one rearing treatment episodically, as well as means for moving the modules characterized in that - said modules are made up of multi-stage monolithic assemblies each having a plurality of superimposed transverse platforms joined by immovable spacers (except in the event of destruction of the module) delimiting at least one lateral slot between each of said transverse platforms; - the means of movement include a support interacting directly with the bottom of said modules, without the interposition of a pallet; - said modules are handled, as such, and in a closed loop, between the shelving and the various processing equipment.

[0014] For the purposes of this patent, "monolithic" means a rigid assembly with parts that cannot be separated except by destruction, forming a single block that can be manipulated as a whole without the possibility of manipulating some of its parts separately (except in the case of dismantling or destruction).

[0015] According to a first variant, the installation further comprises a means of emptying said multi-stage monolithic modules by tilting them as a whole, without any separation of the stages of said modules.

[0016] According to another variant, it further comprises a means of filling said modules by feeding through a set of conduits which discharge onto each of said trays of the multi-stage module a flow of rearing medium and / or larvae

[0017] Preferably, said plates have a central convex area (11).

[0018] According to a particular embodiment, said shelving units have parallel rails whose spacing is between the diameter of said central zone and the width of the lower transverse platform, directly and without recourse to an intermediate pallet.

[0019] Advantageously, said means of movement comprise supports having a width less than the gauge of said rails.

[0020] The invention also relates to a breeding module consisting of a multi-tiered monolithic block having a plurality of superimposed transverse platforms joined by spacers defining at least one lateral slot between each of said transverse plates.

[0021] The central surface of said plates of said module is preferably convex.

[0022] According to an advantageous embodiment, the rearing module according to the invention consists of a non-reversible, non-destructive assembly of a plurality of trays extended by spacers. These spacers are fixed to the trays at both ends by deformable clipping means.

[0023] The invention also relates to a method for rearing arthropods characterized in that rearing medium is deposited on the trays of rearing modules made up of multi-stage monolithic blocks each having a plurality of superimposed transverse trays joined by spacers delimiting at least one lateral slot between each of said transverse trays, in that said rearing medium is inoculated by pouring arthropods at an early stage of growth, and in that said rearing modules are moved episodically, without dismantling and in a closed loop, between racks suitable for storing said arthropod rearing modules, and equipment for carrying out at least one rearing treatment episodically by means of movement comprising a support interacting directly with the bottom of said modules, without interposition of a pallet.

[0024] Advantageously the process includes a step of filling said rearing modules consisting of inserting into the slots of said rearing modules ramps fed by dosing systems to deposit on the trays the rearing medium and / or the arthropods at an early stage of growth.

[0025] Preferably, it also includes a step for emptying said rearing modules consisting of tilting said rearing modules to ensure the discharge of the contents of the trays onto a collection means. This tilting can be applied to several rearing modules simultaneously.

[0026] Advantageously, the process includes, before each new treatment, a quality control step of the contents of the rearing modules extracted from the racks.

[0027] According to a particular embodiment, the rearing modules whose contents do not conform during said quality control step are directed to an evacuation area comprising a dedicated tipper to undergo an emptying and transfer step to a waste disposal site.

[0028] Detailed description of non-limiting examples of embodiment

[0029] The present invention will be better understood upon reading the following description, with reference to the accompanying drawings illustrating non-limiting examples of embodiments where: - [Fig.1] [Fig.1] represents a perspective view of a breeding module; - [Fig.2] [Fig.2] represents a median cross-sectional view of the breeding module; - [Fig.3] [Fig.3] represents a view of a tray before assembly of the breeding module; - [Fig.4] [Fig.4] represents a side view of a breeding module; - [Fig. 5] [Fig. 5] represents a median cross-sectional view of the breeding module arranged on a rack; - [Fig.6] [Fig.6] represents a median cross-sectional view of the rearing module on the support of a shuttle; - [Fig.7] [Fig.7] represents a median cross-sectional view of the rearing module arranged on a belt conveyor; - [Fig.8] [Fig.8] represents a schematic view of the rearing module at the beginning of emptying; - [Fig.9] [Fig.9] represents a schematic view of the rearing module in an intermediate emptying situation - [Fig. 10] [Fig. 10] represents a schematic view of the rearing module in an emptying situation - [Fig. 11] [Fig. 11] represents a schematic view of the rearing module during filling - [Fig. 12] [Fig. 12] represents a schematic view of the breeding cycle. General principles

[0030] The industrial production of food from the rearing of arthropods and -in the example described by way of non-limiting reason - of insects takes place in largely automated facilities designed to create the optimal conditions to allow massive passage from the developmental stage of the egg, the ootheca or the neonate larva to the adult insect, via the larva (or maggots or wingless) and the nymph or pupa.

[0031] Typically, these facilities are organized into several buildings with racks for storing rearing modules loaded with an inoculated rearing medium, in a climatic atmosphere conducive to rearing, and handling equipment for episodic treatments.

[0032] The invention aims to optimize large-scale production by simplifying handling both to save time and increase production, to allow the use of reliable and economical equipment, as well as to guarantee sanitary conditions reducing the risks of infection or development of pathogens. Production cycle

[0033] Unlike most prior art industrial production solutions that operate in a linear fashion, the installation according to the invention operates in a closed loop, particularly with regard to the circulation of the rearing modules. All the processes, from filling a rearing module to retrieving the mature insects and reintroducing the rearing module into the rearing circuit, are carried out in a closed loop, according to a cycle of a few days (typically 6 to 20 days).

[0034] This cycle comprises a succession of steps: - storage of breeding modules filled with the inoculated breeding medium in shelving at a breeding site in a controlled atmosphere (temperature, humidity, controlled light, atmosphere controlled in terms of chemical and / or biological composition); - transfer to processing equipment; - emptying of the rearing module for recovery of the rearing medium and insects by tipping; - washing and rinsing of the emptied breeding module; - injection of the rearing medium into the rearing module; - inoculation of larvae from neonates or young larvae of pregrowth; - and resumption of the aforementioned storage stage, with the breeding modules being continuously recycled (except for occasional breakages).

[0035] The efficiency of the installation is therefore conditioned in particular by: - the configuration of the breeding modules; - the operating mode of some of the handling and transport equipment. The general organization of the infrastructure (buildings, storage racks) is generic. Growth stages

[0036] Optionally, the cycle is broken down into a pregrowth stage followed by an incubation stage.

[0037] During the pregrowth stage, the rearing module (100) is loaded with a first rearing medium adapted to young larvae and is inoculated with larvae at the neonate (newborn) stage. When these young larvae have reached a predetermined reference size, the rearing module is emptied and the young larvae are retrieved to inoculate a new rearing module previously loaded with a new rearing medium adapted to this second stage of maturity. Livestock modules

[0038] In order to optimize both storage space and handling equipment, the livestock modules according to the invention have a multi-tiered configuration which allows storage on racks and handling in a single rigid and monolithic block, not requiring a pallet or additional support for movement.

[0039] In the non-limiting example described with reference to Figures 1 to 4, the module has six levels (1 to 6). Each level has a convex transverse base (10) surrounded by a border with grooves (15). Consecutive levels are separated by spacers (20). The cross-section of the module is typically 1200 x 1000 mm, and the height of the borders (15) is 160 mm. The elements are made by plastic injection molding.

[0040] The edges (15) have grooves to increase rigidity and strength when the module is loaded, while reducing the module's weight. The bottom (10) of the trays also has reinforcing ribs to stiffen the rearing module.

[0041] The bases (10) have a domed shape with a central hemispherical area (11) with a circular cross-section and a diameter of 600 mm, and a central elevation h of 50 mm. The culture medium (13) is deposited on the base (10). The convex shape of this central area (11) helps to limit deflection, better distribute the material deposited on the tray (10), and increase the deflection tolerance (to allow the satellites (30) to pass under the lower tray of the stack during storage / retrieval).

[0042] The rearing trays are assembled to form monolithic modules of six trays by forcefully clipping the spacers (20) located in the corners with a space of 172 mm between two consecutive trays (10). The elements are connected only by the four spacers and do not rest on each other along their entire edges.

[0043] The modules cannot be disassembled. In the non-limiting example described, the spacers are clipped in place between the trays in a non-reversible manner.

[0044] The spacers (20) are configured to ensure between two consecutive trays a lateral slot with a height between 0.5 and 2 times the height of the edges (15), for example a lateral slot of 160 mm between two consecutive trays (10) of a module, in order to ensure good air circulation, and to allow the pouring of the contents for emptying the module, as well as filling as will be explained below. Module manipulation

[0045] Figures 5 to 7 illustrate the methods of handling the modules. The bottom of the modules rests on racks in a climate-controlled space with rails (41, 42) on which it rests on either side of the convex zone (11). These rails (41, 42) are spaced to allow the passage of the support (43) which is positioned under the bottom of the rearing module, without any intervening pallet, ensuring the removal of the modules or their insertion into a rack. This support (43) extends a mobile satellite moving in a direction perpendicular to a guided shuttle to move the modules to a conveyor and place them on it. A plurality of shuttles and satellites allows all the modules to be moved to conveyors.

[0046] The conveyors then move the modules between the different processing and rearing stations. The width of the conveyors corresponds to that of the rails (41, 42) of the racks. Emptying of the breeding modules

[0047] Figures 8 to 10 illustrate the process of emptying the modules after the insects have matured. The module (100) is placed in an emptying unit comprising a frame (50) and a tray (51) that are fixed together and pivotally operated around a transverse axis. During storage on the racks and during transport, the modules (100) are positioned vertically, with the trays horizontal. To unload the rearing medium and the larvae, the module is tilted through a 120° rotation to allow the contents of the trays to flow by gravity onto a ramp (51), passing through the slots formed between the edges (15) and the adjacent tray by means of the spacers (20). Optionally, several modules can be emptied simultaneously. Filling the breeding modules

[0048] Figure 11 illustrates the filling process of the modules (100). This is carried out by a system of ramps (61) that dispense the rearing medium onto trays (60) and / or a similar system of ramps that dispenses the young larvae onto trays (60). This system is positioned between a standby position where the ramps are away from the module (100), and a filling position where the ramps (60) are inserted into the module (100), between the trays (10), through the slots created by the spacers between consecutive trays. In the example described, the ramp system (61) is fixed, and the rearing modules (100) are moved using a shifter to allow filling. Optionally, several filling modules (100) can be filled simultaneously by a multi-ramp system (61), for example, three sets of six ramps (61).

[0049] The injection consists of filling the empty modules (100) with rearing medium from the rearing medium preparation area. The injection line simultaneously fills three adjacent modules (100) with a quantity and / or composition controlled rearing environment. The injection line includes 18 metering pumps discharging their contents into ramps (60).

[0050] Inoculation consists of depositing doses of insects into the trays (10) of the multi-stage modules (100). These doses are partly conveyed by gravity to the trays (10) and a compressed air blowing allows the doses to be expelled into the rearing modules and prevents the accumulation of material in the lower part of the inoculation chutes.

[0051] The rearing modules are moved sideways via a shifter (rail conveyor) which transports the three modules (100) constituting the batch. This shifter moves on an axis perpendicular to that of the handling circuit and allows each tray of the rearing modules (100) to be brought under its rearing medium injection nozzle (60), and then its larval inoculation nozzle. These nozzles are located above each tray (10) of the modules (100), and therefore enter the modules (100).

[0052] The shifter moves to the injection start position. Position sensors send information as soon as the rearing modules are sufficiently shifted (i.e., as soon as the trays (10) of the modules (100) begin to be under the injection nozzles). Module (100) is moved during the injection sequence to distribute the rearing medium into the rearing modules (from the injection start position to the injection end position). Inoculation is performed at the end of the injection, and then module (100) is returned to its original, unshifted position.

[0053] This process allows the rearing medium to be well distributed over all the trays (10) of the modules (100).

[0054] Nature of the treatments carried out by the equipment

[0055] The installation according to the invention makes it possible to carry out a processing cycle applied to each module or group of modules by episodic outputs according to a predetermined sequence of the storage and rearing racks, according to a sequence illustrated by [Fig.12],

[0056] The main treatments are described below. The core of the cycle consists of storing the rearing modules in the racks provided in a climate-controlled environment (step 110). As previously explained, upstream, the mature rearing modules (100) are emptied by the tipper (step 120) and, if necessary, washed (step 130). The empty rearing modules (100) thus prepared undergo an injection step of rearing medium (140) followed by an inoculation step (150) with young neonate larvae, or with larvae that have reached a reference size (160). These young larvae injected in step (160) come either from the hatching phase or from a sieving step (170). The sieving unit itself is fed by a hopper receiving the contents poured into the tipper during the emptying stage (120) of the rearing modules extracted from the racks

[0057] Furthermore, before each new treatment, the rearing modules extracted from the racks in batches of three rearing modules are subject to a quality control (180) by weighing, measuring temperature or other rearing parameters, visual inspection (190) and / or optical control by a camera and an automatic image interpretation system.

[0058] The rearing modules (100) whose contents do not conform are directed to a non-conforming evacuation zone comprising a dedicated tipper to undergo an emptying step (120) and transfer to a waste disposal site (200).

[0059] Step 180: Weighing on the shuttle and optionally temperature measurement: At each batch exit, the module is weighed on the shuttle and the temperature under each tray of each rearing module is measured. The batch mass is compared to a threshold mass. If the batch mass is less than the threshold value, the batch is considered compliant and is sent as planned on the handling circuit. If it is greater than the threshold value, the batch is considered non-compliant and will be sent to the inspection area. Temperature can be used as a supplementary indicator to verify compliance, in addition to mass.

[0060] Weighing by rearing module at the handling circuit entrance: Batches arriving on the handling circuit are weighed module (100) by module (100) on a weighing table. This weighing of the rearing module (100) allows for a more precise conformity check than weighing on the shuttle. For each module (100), the measured mass is compared to a threshold mass. If the mass is less than the threshold value, the module is considered compliant. Otherwise, the module is considered non-compliant and is sent to the non-conforming waste disposal area for destruction of its contents.

[0061] Non-conforming disposal zone (Step 200): The non-conforming branch is used to destroy the contents of the rearing modules declared non-conforming. These rearing modules are emptied by tipping using a tipper, the operation of which is described above. Their contents are emptied, removed, and shredded.

[0062] Triple tipper (step 120): When a batch arrives in front of the conforming tipper, the conforming tipper turns the entire batch over to collect its contents, performing several tipping motions, for example three consecutive tipping motions, to ensure complete emptying, and then sets it down. The module (100) is then sent to the injection and inoculation station.

[0063] Weighing at the exit of the handling circuit: At the exit of the handling circuit, the modules (100) are weighed again one by one.

[0064] Handling circuit exit: The module (100) is sent to storage.

[0065] Operator conformity control: An operator checks batches detected as non-conforming by the shuttle following a measured mass exceeding a threshold mass for to decide on the next steps in their treatment. This discrepancy may actually be due to an abnormal growth. The operator performs a visual and tactile inspection to verify the growth status of each tray in the rearing modules (100).

Claims

Claims

1. - Arthropod breeding installation comprising: - racks for storing arthropod breeding modules and equipment for episodically carrying out at least one breeding treatment; - breeding modules (100) consisting of multi-tiered monolithic blocks each having a plurality of transverse trays (10) superimposed and joined by irremovable spacers delimiting at least one lateral slot between each of said transverse trays (10); - as well as means for moving said modules (100) comprising a support interacting directly with the bottom of said modules (100), without the interposition of a pallet; characterized in that - said moving means being configured to manipulate said modules (100) as they are in a closed loop, between the racks and the different treatment equipment - said trays (10) have a curved central zone (11);and in that - said shelves have parallel rails (41, 42) whose spacing is between the diameter of said central zone (11) and the width of the lower transverse plate (10).;

2. 2 - Arthropod breeding installation according to claim 1 characterized in that said rails (41, 42) are spaced to allow the passage of the support (43) which is positioned under the bottom of the breeding module, without any intermediate pallet, to ensure the removal of the modules or their insertion into a rack.

3. 3 - Arthropod breeding installation according to the preceding claim characterized in that said support (43) extends a mobile satellite moving in a perpendicular direction a guided shuttle to ensure the movement of the modules to a conveyor and place them on it.

4. 4 - Arthropod breeding installation according to claim 1 characterized in that it further comprises a means for emptying said multi-stage monolithic breeding modules (100) by tilting as a whole, without any separation of the stages of said modules (100).

5. 5 - Arthropod breeding installation according to claim 1 characterized in that it further comprises a means for filling said breeding modules (100) by a supply via a set of conduits discharging onto each of said trays (10) of the multi-stage module (100) a flow of breeding medium and / or larvae.

6. 6 - Arthropod breeding installation according to claim 4 characterized in that said movement means comprise supports having a width less than the spacing of said rails (41, 42).

7. 7 - Arthropod breeding module consisting of a multi-stage monolithic block having a plurality of transverse plates (10) superimposed and joined by irremovable spacers delimiting at least one lateral slot between each of said transverse plates (10), intended for an arthropod breeding installation comprising shelves having parallel rails (41, 42), characterized in that the lower plate (10) has a central zone (11) curved with a diameter less than the spacing of the parallel rails (41, 42) of said installation, the width of said lower plate (10) being greater than or equal to the spacing of said parallel rails (41, 42)

8. 8 - Arthropod breeding module according to the preceding claim, characterized in that it is constituted by a non-reversible assembly without destruction of a plurality of trays extended by spacers, at least one of the ends of which has a deformable clipping means.

9. - Arthropod breeding module according to the preceding claim, characterized in that each of the trays has a curved transverse bottom (10) surrounded by a border comprising grooves (15).

10. - Arthropod breeding module according to the preceding claim, characterized in that the bottom (10) of said trays has reinforcing ribs to stiffen the breeding module.

11. 11 - Method for rearing arthropods comprising steps: - of depositing the rearing medium on the trays of rearing modules constituted by multi-tiered monolithic rearing modules (100) each having a plurality of superimposed transverse trays and joined by spacers delimiting at least one lateral slot between each of said transverse trays; - of inoculating said rearing medium by pouring arthropods at an early stage of growth; - of episodic movements of said rearing modules, without disassembly, and in a closed loop, between shelves suitable for storing said arthropod growth modules, and equipment for episodically carrying out at least one rearing treatment by movement means comprising a support interacting directly with the bottom of said modules, without the interposition of a pallet;characterized in that it comprises, before each new treatment, a step of quality control of the contents of said breeding modules (100) extracted from racks, the breeding modules (100) whose contents are not compliant during said quality control step being directed towards an evacuation zone comprising a dedicated tipper to be subject to an emptying step (120) and transfer to waste disposal (200).;

12. 12 - Method for breeding arthropods according to the preceding claim, characterized in that it comprises a step of filling said breeding modules (100) consisting of inserting into the slots of said breeding modules (100) ramps (61) supplied by dosing systems to deposit the breeding medium and / or the arthropods at an early stage of growth on the trays.

13. 13 - Method for breeding arthropods according to claim 12 characterized in that it comprises a step of emptying said breeding modules (100) consisting of tilting said breeding modules to ensure that the contents of the trays are discharged onto a collection means.

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