Automated on-farm production unit for multiple dairy products on demand

Abstract

The invention relates to an automated on-farm production process for several types of dairy products on demand, comprising the following automated steps: electronically receiving a dairy product order from a consumer; filling a tank (10) with milk directly from 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 a processing step adapted to the ordered dairy product; storing the processed contents of the batch of containers in a controlled atmosphere module (24); and, upon request from the consumer on-site, packaging the processed contents of the batch of containers in a form presentable to the consumer. Figure for the abstract: Fig. 1

Description

Title of the invention: Automated on-farm production unit for multiple dairy products on demand. Technical field

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

[0002] Dairies implement large-scale industrial processes to produce a whole range of dairy products ready for sale in supermarkets. Dairies are generally located some distance from the production farms, and they are supplied with raw milk by refrigerated tanker trucks that collect the milk from the farms.

[0003] Dairy products from local production involve essentially manual processes, as industrial processes are not adapted to the small quantities produced individually by farms.

[0004] Many milk producers are giving up on local production due to a lack of time to devote to the essentially manual processes involved. Summary

[0005] Generally, an automated production unit for several types of dairy products on demand is envisaged, comprising a raw milk receiving tank directly from milking; a plate manipulator robot configured to move in a service corridor; arranged along the corridor, several processing modules capable of receiving plates transferred by the manipulator robot, including a plate storage module; a container storage module, configured to receive a plate transferred by the robot from the plate storage module, and to place the containers on the plate; a filling module, configured to receive a plate transferred by the robot from the container storage unit, and to fill the containers from the receiving tank;and at least one main processing module, configured to receive a plate transferred by the robot from the filling module, and apply a processing step adapted to the dairy product requested by the consumer.

[0006] The production unit may further include a packaging module configured to receive a plate transferred by the robot at the end of the cycle, and to remove finished products conveyed on the plate to make them available to the consumer in appropriate packaging.

[0007] The plate storage module can also be configured to wash the plates.

[0008] The production unit may include a controlled atmosphere module configured to receive and store a plate transferred by the robot from the main processing module pending transfer of the plate to the packaging module, the robot being programmed to transfer the plate to the packaging module upon request from the consumer on site.

[0009] The receiving tank can be configured to perform a pasteurization, curdling, or turbining function depending on the type of dairy product required, the installation including an input distribution unit, configured to dose into the tank an additive specific to the type of dairy product required.

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

[0011] The main processing module may include a draining module or a pressing module.

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

[0013] The container storage and filling modules can each include a CNC type machine for, respectively, individually positioning the containers on the plate and moving a dairy product dosing nozzle from container to container.

[0014] The production unit can be entirely carried out in a transportable enclosed shelter.

[0015] An automated on-farm production process for several types of dairy products on demand is further provided, comprising the following automated steps: receiving an order for a dairy product electronically from a consumer; filling a tank with milk directly from the milking; filling a batch of containers from the tank; routing the batch of containers through at least one processing module configured to apply a processing step adapted to the dairy product ordered; storing the processed contents of the batch of containers in a controlled atmosphere module; and, upon request from the consumer on-site, packaging the processed contents of the batch of containers in a form presentable to the consumer. Summary description of the drawings

[0016] Embodiments will be set forth in the following description, which is not exhaustive and relates to the accompanying figures, among which:

[0017] Fig. 1 represents a schematic top view of a small-scale automated dairy production unit;

[0018] [Fig. 2] is a perspective view of an embodiment of a plate-manipulating robot; and

[0019] [Fig.3] is a perspective view of an embodiment of the production unit filling module. Detailed description

[0020] The embodiments described below aim at the production of dairy products that is both local, small-scale, and fully automated. Production is carried out by a production unit preferably entirely contained within a transportable enclosed shelter, for example, a shipping container, which is installed on-site at the dairy farmer's farm. The production unit can thus be supplied directly with milk from milking, thereby ensuring optimal raw milk quality.

[0021] The small scale of automated production opens up certain possibilities that are not conceivable in large-scale production. In particular, the production unit can work on demand, namely taking an order from a consumer electronically, organizing production, and delivering the product when the consumer comes to the location.

[0022] Figure 1 illustrates a top view of one embodiment of such a production unit. The unit includes a receiving tank 10 supplied by a pipe 12. When the unit is placed on the farm, the pipe 12 can be connected to receive milk directly from milking.

[0023] The tank 10 can be a single unit and configured to carry out several possible pretreatments, depending on the dairy products to be produced, including pasteurization, curdling, or churning for ice cream production. Alternatively, several tanks 10 can be provided, each performing a different pretreatment, which allows different batches of dairy products to be started in parallel.

[0024] An input dispenser 14 is connected to the tank 10 to dose various additives required by the dairy product being manufactured, such as starter cultures for yogurt and cheeses, rennet for cheeses, ingredients for ice creams.

[0025] Several processing modules are installed around the tank 10, each designed to carry out one or more steps in the manufacturing process of a dairy product. The unit includes, for example, a incubation module 16 for making yogurt, among other things, a draining module 18 for making different types of cheese, a pressing module 20 for making pressed-curd cheeses, and several controlled-atmosphere modules 22, 24, and 26. Module 22 replicates the conditions of a ripening cellar, module 24 is a refrigerator, and module 26 is a freezer. A packaging module 28 is provided to offer the finished dairy product in ready-to-carry packaging, for example, several pots arranged in a box.

[0026] The modules just described carry out known steps in the dairy product manufacturing processes, and it is known how to automate them, the main difficulty of automation being the transport of dairy products from one step to another.

[0027] To ensure the transport of dairy products in the production unit described here, with a view to small-scale production, all the modules are organized along a service corridor 30 in which a handling robot 32 moves.

[0028] The dairy products are to be transported in pots directly from the tank 10. The pots are adapted to the manufacturing process of the required dairy product. The pots are placed on corresponding trays which the robot 32 transfers from one module to another according to the manufacturing process required for the required dairy product. Each module is designed to receive one or more trays in slides.

[0029] To manage the transport by pots on trays, three additional modules are provided. A module 34 stores the trays on slides and also acts as a dishwasher to wash the trays returning from a production cycle.

[0030] A module 36 stores new pots and distributes them onto a plate presented to it. The new pots, made of flexible material, can be stacked between parallel tubes that hold the pots in place by friction. A CNC (Computer Numerical Control) type machine can be configured to pick up each pot by suction or gripping and place it in a free opening in the plate. The new pots are preferably stored above the plate, opening downwards, so that the machine picks up each pot from the bottom of the stack from the inside, turns it over, and places it on the plate.

[0031] A module 38 is configured to fill the pots on a plate presented to it. It may include a dosing nozzle connected to the tank 10, which is moved by a CNC machine to fill the pots one after the other.

[0032] Preferably, as shown, the modules are housed in cabinets of the same dimensions, so as to be interchangeable, and are arranged on either side of the aisle 30. Although a spatial arrangement of individual modules is shown, several modules can in fact be incorporated into the same cabinet, or even be combined with other modules. For example, the pressing performed by module 20 may simply be an extension of the draining performed by module 18, since pressing is merely an accelerated draining operation.

[0033] Figure 2 is a partial perspective view of one embodiment of the manipulation robot 32. The robot comprises a parallelepiped carriage 40 that slides vertically on a beam 42. One end of the beam 42 slides on a rail 44 along the axis of the service corridor. Preferably, as shown, the rail 44 is located at a height rather than on the ground. The carriage 40 has a slightly shorter length. to the width of the corridor, a width slightly less than the width of the modules, and a height suitable for giving it satisfactory rigidity.

[0034] The trolley is shown placing a plate fitted with pots 46 onto slides on the upper part of one of the modules, for example, the refrigeration module 24. To handle the plates, the trolley includes a pair of transverse telescopic arms 48 on which two opposite edges of a plate can bear. The arms are configured to fully extend or retract a plate to one side or the other of the trolley in order to deposit or retrieve the plate in a module located on either side of the aisle. The lifting or lowering of a plate is achieved by a vertical movement of the trolley along the beam 42.

[0035] Transferring a plate from one module to another is carried out more specifically as follows. The beam 42 slides longitudinally along the rail 44 until the carriage 40 is aligned with the module where the plate is to be retrieved. The carriage is moved vertically along the beam 42 until the telescopic arms 48 are slightly below the plate to be retrieved. The arms 48 are extended and enter the module beneath the plate. The carriage is lifted along the beam 42 to sufficiently detach the plate from its guides. The telescopic arms are retracted, pushing the plate into the center of the carriage.

[0036] Next, the beam 42 slides until the carriage 40 is aligned with the module where the plate is to be placed. The carriage is moved vertically along the beam 42 until the telescopic arms 48 are slightly above the slides where the plate is to be placed. The arms 48 are extended and enter the module, presenting the plate above the slides. The carriage is lowered along the beam 42 to place the plate onto its slides. The telescopic arms are retracted to begin a new transfer operation.

[0037] Some of the modules are normally closed to perform their function, in particular the controlled atmosphere modules. To allow the transfer of plates, these modules are closed by an upper half-door and a lower half-door which slide vertically - to open the lower half of the module, the lower half-door is raised to overlap with the upper half-door, and to open the upper part of the module, the upper half-door is lowered to overlap with the lower half-door.

[0038] Figure 3 is a perspective view of an embodiment of a pot filling module 38. The plate, fitted with its pots 46, is placed on slides. To ensure relatively precise positioning, the plate may have, as shown, openings at its corners that fit over cones on the slides. The pots are filled individually from the tank 10 by a dosing nozzle 50 moved by a two-axis CNC machine 52a, 52b. Of course, The machine knows the type of plate and the positions of the pots on the plate. A centralized control system can be configured to track each plate and thus know at any given time which type of plate is in which module and at what position. Alternatively, the plates can have an identifier, such as a barcode, which is read at the entrance of each module.

[0039] As shown, the plate 46 has notches on the edge of the pot receiving holes, notches which are flush with the circumference of the holes. These notches allow robotic grippers to extract the pots into a subsequent processing module, such as the packaging module 28.

[0040] Considering again [Fig.1], we set out below some examples of processes for manufacturing different dairy products, in a non-exhaustive way, and we present some more detailed examples of the operation of certain modules.

[0041] As previously mentioned, a consumer can place an order for dairy products electronically, for example on a website, using a mobile application, or via a screen located on-site. The order can include different types of dairy products. The system then suggests delivery dates based on its stock and / or production capacity.

[0042] To make yogurt, for example, the tank 10 is used in pasteurization mode. After pasteurization, the dispenser 14 adds yogurt starter. The module 38 receives a tray of empty pots and fills the pots from the contents of the tank 10. After filling, the tray is transferred to the incubator 16.

[0043] After curing, the tray is transferred to refrigerator 24 while awaiting the scheduled delivery date with the consumer. Before or after curing, the tray may pass through the packaging module 28 to seal the jars.

[0044] On the delivery date, the consumer goes to the production unit and places their order, for example by entering a code on an interface or using a mobile application. The tray of yogurt pots is then removed from the refrigerator and transferred to the packaging module 28, where the pots corresponding to the order are placed in a box along with any other products ordered. The box may be presented to the consumer through a hatch.

[0045] The empty plate is returned to the storage / dishwasher module 34, where it will be washed when a sufficient number of empty plates have been returned or when the stock of clean plates is insufficient.

[0046] Alternatively, to free up the tray immediately, the yogurt pots can be packed in 28 as soon as they come out of the incubator, in which case the package is transferred to the refrigerator awaiting delivery while the tray returns to the dishwasher.

[0047] For cheesemaking, the vat 10 is used in curdling-only mode for raw milk cheese, or in pasteurization and curdling mode. The distributor 14 adds the ferments and rennet at the appropriate time and at the required temperature, depending on the processing technology specific to each category of cheese.

[0048] For example, in the case of a lactic curd, after 18 to 24 hours of curdling, the plate receives micro-perforated molds designed to drain the whey into module 36. The plate is transferred to the draining module 18 where the curd continues to drain by gravity. The whey from this draining can be collected in a tank via a drain 18-1.

[0049] To prevent whey leakage into channel 30 during transfer, the plate can be fitted with a collection tray attached beneath it. This tray can be equipped with a drainage mechanism that is activated when the tray is inserted into the module, with module 18 then configured so that the contents of the tray flow into 18-1. This solution keeps module 18 clean and reduces cleaning requirements.

[0050] When the plate and its tray are returned to the dishwasher, the drainage mechanism is also activated, so as to evacuate the whey residue and allow the circulation of the wash water.

[0051] Alternatively, if leaks are permitted in corridor 30, the corridor can be lined and fitted with a drain to evacuate any runoff occurring during transfers. This is facilitated when the robot's travel rail is located at a height, thus freeing the corridor from any obstructions. The corridor can be cleaned regularly and automatically using jets. Steam can be used to disinfect the different areas.

[0052] The recovered whey can be used. For example, the sweet whey from rennet-based coagulations can be returned to tank 10 for the production of whey cheeses such as Sérac or Ricotta by thermocoagulation.

[0053] After draining in step 18, the tray generally undergoes further handling. Depending on the product to be obtained, the contents of the micro-perforated molds are i) transferred into airtight containers (ready-to-eat soft cheese), ii) rotated in their molds to perform a second draining phase, or iii) unmolded. The required handling can be carried out by the robotic gripper available in module 36, to which the tray is then transferred after draining.

[0054] To facilitate handling, it can be provided that only half of the plate's capacity is occupied by the pots or molds, the other half of the plate being adapted for the required handling. In this case, the robotic gripper has access to all locations on a single plane. Then, the other half of the plate can i) have openings to receive the airtight pots for transferring the contents, ii) have openings to receive a second set of micro-perforated molds for turning the contents over, or iii) be flat to receive the demolded contents. The molds Empty micro-perforated trays can remain in place and be reused after the tray has passed through the dishwasher saddle 34.

[0055] In case i), the sealed pots contain ready-to-eat cottage cheese - the tray can be transferred to the refrigerator 24 hours before delivery.

[0056] In case ii) the plate returns to the draining module 18. Since this two-phase draining process is generally used for salted cheeses, the draining module 18 can be configured to salt the contents of the pots on the surface during each of the two draining phases. The salting can be carried out using a dosing unit mounted on a CNC machine.

[0057] After the second draining phase, demolding takes place, which corresponds to case iii).

[0058] In case iii), after demolding, the plate is transferred to the ripening cellar 22.

[0059] After a programmed maturation period, the plate can be transferred to the refrigerator 24 awaiting delivery.

[0060] The handling of unmolded cheeses, for example to package them for delivery in 28, can be carried out using a robotic spatula or suction cup.

[0061] In the case of a pressed cheese, between draining in 18 and ripening in 22, the plate is transferred into the pressing module 20. The pressing module may include a series of cylinders the size of the pots, which exert programmed pressure on the upper faces of the cheeses, for a programmed duration.

[0062] Pressing extracts more whey, which falls onto the collection tray. As in the draining module 18, the tray discharge mechanism is activated when the plate is inserted. The drained whey is collected in a reservoir, from where it can be returned to the processing tank 10.

[0063] The draining module 18 and the pressing module 20 can be combined into a single unit. Therefore, if only draining is required, pressing is not activated. However, since the draining operation is relatively lengthy, it is preferable to use two separate modules to improve production rates.

[0064] With regard to hygiene, the equipment must be washed regularly. Since most of the manufacturing process steps are carried out here on dairy product contained in containers (pots, molds) or poured onto trays that have been washed in a dishwasher, there is little equipment to wash. In practice, it is sufficient to wash the circuit running from the inlet of tank 10 to the dosing nozzle of the filling module 38. For this, a closed-loop CIP (Clean In Place) system can be used with alternating basic phases (chlorinated alkaline solution) and acidic phases, preceded and followed by rinses with clean water, in pipe 12, the tank 10 and up to the dosing nozzle of module 38. The dosing nozzle can, during washing, be positioned above a drain 38-1.

Claims

Demands

1. An automated production unit for several types of dairy products on demand, comprising: a tank (10) for receiving raw milk directly from milking; a robot manipulator (32) for plates (46) configured to move longitudinally in a service corridor (30); arranged at the edge of the corridor, several processing modules having slides configured to receive plates transferred transversely by the robot manipulator, including: a plate storage module (34); a container storage module (36), configured to receive a plate transferred by the robot from the plate storage module, and to place the containers on the plate; a filling module (38), configured to receive a plate transferred by the robot from the container storage unit, and to fill the containers from the receiving tank;and at least one main processing module (16), configured to receive a plate transferred by the robot from the filling module, and apply a processing step adapted to the dairy product requested by the consumer.

2. Production unit according to claim 1, further comprising a packaging module (28) configured to receive a plate transferred by the robot at the end of the cycle, and to remove finished products conveyed on the plate to make them available to the consumer in appropriate packaging.

3. Production unit according to claim 1, wherein the plate storage module (34) is also configured to wash the plates.

4. Production unit according to claim 2, comprising a controlled atmosphere module (24) configured to receive and hold a plate transferred by the robot from the main processing module pending transfer of the plate to the packaging module, the robot being programmed to transfer the plate to the packaging module upon request from the consumer on site.

5. Production unit according to claim 1, wherein the receiving tank (10) is configured to perform a function of pasteurization, curdling, or turbining depending on the type of dairy product requested, the installation includes an input distribution unit (14), configured to dose into the tank an additive specific to the type of dairy product requested.

6. Production unit according to claim 5, wherein the main processing module includes a drying module (16).

7. Production unit according to claim 5, wherein the main processing module comprises a draining module (18) or a pressing module (20).

8. Production unit according to claim 4, wherein the controlled atmosphere module comprises a refrigeration module (24), a freezing module (26) or a cellar (22).

9. Production unit according to claim 1, wherein the container storage (36) and filling (38) modules each comprise a CNC type machine for, respectively, individually positioning the containers on the plate and moving a dairy product dosing nozzle from container to container.

10. Production unit according to claim 1, entirely made in a transportable enclosed shelter.

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