Vertical foodstuff production system and method therefor

Abstract

A method (200) for producing foodstuffs comprises inserting (215) foodstuff (160) into an attachable foodstuff container (105); agitating (215) the foodstuff container by a vibration device (120); ope

Description

Description Field of the invention The field of the invention relates to a vertical foodstuff production system and method for processing foodstuffs. Background of the invention Industrial food production is a very large multinational business area in which complex and highly automated manufacturing systems are used to process a large range of foodstuffs. One very common range of products are condiments, sauces and powders. These are produced in continuous or semi-continuous processes and packaged for transportation or further handling. In general, in the manufacture and packaging of food products, food manufacturers ensure that there is a clear division between the processing stage and the packaging stage, due to the nature of the products and each specifically designed for the specific role. Hence, for example, a dairy-produce process would require a specific range of processing machinery and a different range of packaging machinery to the machinery used to produce a powdered or non-dairy liquids processing system. The raw materials, sometimes referred to as infeed materials, of such processes are often themselves foodstuffs in sauce or powdered form that must be introduced into the food packaging processing system by a variety of means and using a range of packaging materials. These raw food material inputs must be checked and monitored for contamination or damage and often they must be pre-processed, so that they are in a suitable condition for input into the upstream packaging and distribution process. Beyond the complexity of an industrial scale production system, with its usual health and safety considerations for the workforce, the foodstuff industry must also meet rigorous standards of cleanliness in order to prevent contamination of food products, failure of which may result in injury to consumers. These stringent requirements mean that processes must be tightly controlled and great care taken in order to ensure the safety of the product and its packaging. Moreover, the processes must be efficient and low-cost. This combination of requirements presents a very specific set of problems to the foodstuff manufacturer. Manufacturers of machines for processing foodstuffs focus on specific functions in their processing systems that are common to many types of foodstuffs so as to serve the largest possible market. However, manufacturers of foodstuffs often find that their production systems require bespoke systems and solutions tailored to their specific foodstuff requirements. These requirements are often non-standard with the result that processing systems built out of of-the-shelf components are generally not optimal. In continuous or semi-continuous manufacturing or packaging processes, anything that causes the manufacturing or packaging process to stop causes severe problems with regard to efficiency and cost (e.g., particularly requiring machine operatives becoming involved). Furthermore, halting the manufacturing or packaging process is often not possible. Hence, it may be necessary to create storage capacity or buffers at places in the process in order to accumulate materials, thereby allowing the process to continue without a full re-start. The inventor has identified and appreciated that it would be beneficial if the individual functions of a foodstuff production process could be improved to more efficiently process foodstuff products and thereby to increase overall productivity and reduce machine operative involvement, whilst at the same time maintaining food safety and minimising contamination. Summary Examples herein described provide a method for producing foodstuffs in a vertical foodstuff production system as described in the accompanying claims. Specific examples are set forth in the dependent claims. These and other aspects will be apparent from and elucidated with reference to the embodiments described hereinafter. Brief description of the drawings Further details, aspects and example embodiments will be described, by way of example only, with reference to the drawings. In the drawings, like reference numbers are used to identify like or functionally similar elements. Elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. FIG. 1 illustrates a simplified drawing of one example of a vertical foodstuff production system according to some example embodiments. FIG. 2 illustrates one example of a flow chart of a method for a vertical foodstuff production system according to some example embodiments. Detailed description A vertical foodstuff production system that is not part of the claimed invention is described that comprises: an attachable foodstuff container selectable from a plurality of attachable foodstuff containers is configured to receive foodstuff, in a condiment, a sauce or a powder form, and comprises at least one vibration device and an egress component, wherein the attachable foodstuff container is agitated by the at least one vibration device after receiving foodstuff. A docking station comprises a connecting chute that is spring-loaded to press against the egress component of the attachable foodstuff container, wherein following the egress component being opened the foodstuff drops due to gravity from the attachable foodstuff container into the docking station. A detachable centrifugal sieving device is coupled to the docking station and is arranged to sieve the gravity-driven foodstuffs received via the docking station, wherein the detachable centrifugal sieving device comprises an inverter controlled electric motor arranged to control a centrifugal motor speed applied to the detachable centrifugal sieving device in a sieving process. An inline output filter is coupled to the detachable centrifugal sieving device via a mechanical coupling and is configured to receive and filter the sieved foodstuffs, wherein the inline output filter is formed of a sieve integrated into tubing. A metal detector is coupled to the inline output filter and configured to remove any metallic contamination in the sieved, filtered foodstuffs. A mechanical receptacle comprises a tote bag arranged to receive a finished foodstuff product comprising the sieved filtered, metallic-contamination removed, foodstuffs. A weighing scale is arranged to weigh the tote bag in the mechanical receptacle. A sensor is configured to identify when the tote bag is full. A controller is coupled to at least one of the sensor and weighing scale, and configured to automatically stop the vertical foodstuff production system when a full tote bag is detected in response to at least one of the sensor and weighing scale. In this manner, the advantageous high level of integration of the individual functions of in-feed, sieving, filtering, monitoring I detecting of metallic components and packaging results in a significant productivity gain and improved foodstuff production. Additionally, in this manner, the filtering process can be adapted to meet the demands of a range of applications and foodstuff types. Furthermore, the vertical foodstuff production system is advantageously designed such that a range of centrifugal sieving devices can be attached to the docking point. In this manner the flexibility of the vertical foodstuff production system process can be significantly increased. As the inline output filter is formed of a sieve integrated into tubing, it may be integrated into the piping of the system, thus allowing for an extremely compact design. In this manner, the filtering process can be easily adapted to meet the demands of a variety of applications and foodstuff types. As the foodstuff may be in a condiment, a sauce or a powder form, the flexibility of the vertical foodstuff production system can be significantly increased. In some advantageous examples, the vibration device may be a pneumatic device driven by compressed air. In this manner the vibration device can be easily integrated into the vertical foodstuff production system processes and / or repaired by unskilled workers. In further examples, a weight of the filled tote bag may be monitored or the tote bag may be sensed and when a full bag is detected or the weight of the filled tote bag exceeds a predetermined threshold, the process is automatically stopped. In this manner a loss of production is avoided and waste is reduced. In an aspect, a method for producing foodstuffs in a vertical foodstuff production system is described. The method comprises mounting an attachable foodstuff container, selectable from a plurality of attachable foodstuff containers, into the vertical foodstuff production system, where the attachable foodstuff container comprises at least one vibration device and an egress component. The method then comprises inserting foodstuff in a condiment, a sauce or a powder form into the attachable foodstuff container. The method then comprises agitating the attachable foodstuff container by the at least one vibration device; and opening the egress component and dropping the foodstuff due to gravity from the attachable foodstuff container into a docking station. The method then comprises sieving foodstuffs in a detachable centrifugal sieving device received via the docking station, wherein the detachable centrifugal sieving device comprises an inverter controlled electric motor arranged to control a centrifugal motor speed applied to the detachable centrifugal sieving device in a sieving process. The method then comprises receiving and filtering the sieved foodstuffs by an inline output filter formed of a sieve integrated into tubing. The method then comprises passing the sieved, filtered foodstuffs through a metal detector and removing any detected metallic contamination in the sieved filtered foodstuff; and collecting the sieved, filtered, contaminated metal removed, foodstuffs product in a tote bag. The method then comprises identifying when the tote bag is full in response to at least one of a sensor or a weighing scale identifying a weight of the tote bag. In this manner an efficient gravity driven process is defined that allows the efficient processing of foodstuffs whilst simultaneously incorporating required safety features for detecting contamination of the product. In this manner, an efficient vertical (e.g., gravity-driven) foodstuff production process is described that allows the efficient processing of foodstuffs, whilst simultaneously incorporating required safety features for detecting any potential contamination of the product. Referring first to FIG. 1, a simplified example of a vertical foodstuff production system 100 for processing a foodstuff, for example in a condiment, a sauce or a powder form, according to aspects of the current invention wherein a foodstuff container or intermediate bulk container (IBC), (hereinafter referred to as an attachable foodstuff container 105), is selected from a plurality of attachable foodstuff containers. The attachable foodstuff container 105 is lifted into position and fixed above the vertical foodstuff production system 100. In one example, each attachable foodstuff container 105 includes a vibration device 120. In operation, the attachable foodstuff container 105 is being agitated by the vibration device 120, once the attachable foodstuff container 105 is opened at the base, and the foodstuff starts to drop into a centrifugal sieving device 130. This design advantageously removes a need in the previous design whereby a separate vibration device is attached to the selected attachable foodstuff container 105 during the setup process and then detached at the end of the process. Hence, a significant reduction in the setup time is achieved. In operation, the attachable foodstuff container 105 is opened at the base by adjusting an egress component 108. In one example, the egress component 108 may be a component that opens up a diameter of one or more holes to form a sieve. In a second example, the egress component 108 may be a cover and the adjustment comprises a removal of the cover. A skilled artisan will be able to appreciate that other forms of egress component 108 may be used to enable the foodstuff 160 to be able to flow gravity-driven, once agitated by the vibration device 120. A docking station 112 comprises a connecting chute 111 that is spring-loaded to press against the egress component 108 of the attachable foodstuff container 105, and enable foodstuff 160 to pass through, gravity driven, to a centrifugal sieving device 130. In some examples, the centrifugal sieving device 130 is a variable speed centrifugal sieving device configurable to sieve the foodstuff at a constant or variable rate, appropriate to the process. In this example, the centrifugal sieving device 130 is driven by an inverter controlled electric motor 121, which may be a highly integrated type such that the inverter is mounted close to or on or in the motor, thereby removing a need in the previous design for an electrical cabinet near to the production process. The inverter-controlled motor 121 allows a very accurate control of motor speed, and hence of the sieved process. In some examples, the sieving speed may also be adjusted in real time driven based on a characteristic of the process or mix of the foodstuff, determined by controller 192, for example by monitoring a motor current that would indicate a state of the foodstuff mix. In some examples, the centrifugal sieving device 130 may also allow other ingredients or foodstuffs to be added via further openings, or alternatively other foodstuff may be added by changing the attachable foodstuff container or it may be the case that the sieving process is required simply in order to produce a homogeneous product. After the foodstuff 160 is processed in the centrifugal sieving device 130 the sieved foodstuff 161 enters an inline output filter 150 formed of a sieve integrated into tubing to which it is coupled via a mechanical coupling 140, again via a gravity driven approach. This mechanical coupling 140 allows the inline output filter 150 and / or the centrifugal sieving device 130 to be readily exchanged as required by the process and foodstuff being processed, thereby further increasing the flexibility of the process. In accordance with this example, the inline output filter 150 may be constructed such that a filter mesh or sieve is integrated into a metal pipe or tube, hence simplifying the construction of the inline output filter 150 and allowing, in conjunction with the mechanical coupling 140, the filter process to be easily adapted to the foodstuff by simply exchanging one inline output filter for another. In some examples, a further vibration device may be optionally attached to the inline output filter 150 or the mechanical coupling 140, in order to continue movement of the foodstuff through the vertical foodstuff production system 100 and improve the throughput of the inline output filter 150 by creating an active filter process. The active filter is advantageous when the foodstuff has a consistency that tends to prevent the free flow of product 161, 162. After passing through the inline output filter 150, the homogeneity and quality of the product the sieved and filtered / sieved foodstuff 162 is further increased and is arranged to pass through a metal detector 170 where any metallic contamination is identified and removed. The residual foodstuff (e.g., in a condiment, a sauce or a powder form) 162 finally falls into a tote bag 190, which is held in a suitable mechanical receptacle 195 that is itself resting on a weighing scale 191. In some examples, a controller 192 is coupled to a sensor 193 and / or the weighing scale 191 and is configured to automatically stop the process when a full tote bag 190 is detected. In some examples, the weight of the filled tote bag is monitored and when a full bag is detected or the weight of the filled tote bag exceeds a predetermined threshold, the process is automatically stopped. In this manner a loss of production is avoided and waste is reduced. Alternatively, once the tote bag has reached a specified, predetermined weight the process may be stopped manually, and the tote bag removed. Referring now to FIG. 2, a flow chart 200 illustrates a method for a vertical foodstuff production system according to a second aspect. At 210, the flow chart 200 starts with mounting an attachable foodstuff container, selected from a plurality of attachable foodstuff containers, such as attachable foodstuff container 105 in FIG. 1, at a top of a vertical foodstuff production system. The attachable foodstuff container 105 comprises at least one vibration device 120 and an egress component 108 mechanically connected to a base of the attachable foodstuff container 105. The egress component 108 is opened to allow the foodstuff to fall down into a first stage of the process, where the gravity transferred foodstuffs 160 from the attachable foodstuff container 105. At 215, the process is started by re-filling the foodstuff in the attachable foodstuff container or, if the foodstuff is filled, then the vibration device 120 in the attachable foodstuff container 105 is activated. At 218, the egress component of the attachable foodstuff container is opened to start the gravity driven foodstuff flow. Once the process is running the flow rate of foodstuff, for example in this case a powder, is checked at 220 by a suitable measurement device, which is connected via a communications link to a controller of the process, such as controller 192 in FIG. 1, which may be a programmable logic controller (PLC) or programmable controller (PC). A PLC or PC is an industrial computer that has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, machines, robotic devices, or any activity that requires high reliability, ease of programming, and process fault diagnosis. Following the flow rate being checked at 220, a determination is made at 220 as to whether the flow rate is acceptable. If the flow rate at 220 is within a pre-defined range, then the process moves to 235 where the foodstuff is being transferred to the centrifugal sieve via gravity. However, if the flow rate at 220 is not within a pre-defined range, a determination is made as to whether the attachable foodstuff container 105 is empty at 225. If the attachable foodstuff container 105 is empty at 225 the vibration device is de-activated at 230 and the process moves back to 215. Here, either a new attachable foodstuff container is mounted and the process re-started or a re-fill of the foodstuff is performed. If the attachable foodstuff container 105 is not empty at 225, then the vibration device’s agitation speed may be adjusted (for example by adjusting the inverter-controlled motor 121 in FIG. 1) to agitate the foodstuff differently to a desired flow rate and the process loops to 215. At 235 the foodstuff transfers to / falls into the centrifugal sieving device due to gravity, where it is sieved and subsequently gravity fed into an inline output filter formed of a sieve integrated into tubing (to facilitate ease of replacement for other sieve / filter designs) at 240. The sieved / filtered foodstuff now passes through a metal detector at 245, in which any metallic contamination is detected and removed at 250, and then finally into a suitable package in this example a tote bag at 255. In one example, the tote bag is held in a mechanical receptacle, which itself sits on a weighing scale. When the weight of the tote bag is determined as reaching a threshold / limit, or a sensor determines that the tote bag is full of the sieved and filtered foodstuff product, then the tote bag is removed and likely replaced with an empty tote bag at 260. By way of an exemplary embodiment, with reference to FIGs 1 and 2 a vertical production system 100 for processing foodstuffs 160, in a condiment, a sauce or a powder form, according to some aspects is presented which integrates several functions including multiple sieving processes, contamination detection and packaging into one highly optimised process. In the foregoing specification, it will be evidentto a skilled person that that various modifications and changes to the example embodiments herein described may be made therein without departing from the scope as set forth in the appended claims, and that the claims are not limited to the specific examples described above. It is envisaged that the vertical production system discussed herein may be utilised in any type of vertical, e.g., gravity-driven, foodstuff production process. Any arrangement of components to achieve the same functionality is effectively ‘associated’ such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as ‘associated with’ each other such that the desired functionality is achieved, irrespective of architectures or intermediary components. Likewise, any two components so associated can also be viewed as being ‘operably connected,’ or ‘operably coupled,’ to each other to achieve the desired functionality. Furthermore, those skilled in the art will recognize that boundaries between the abovedescribed operations merely illustrative. The multiple operations may be combined into a single operation, a single operation may be distributed in additional operations and operations may be executed at least partially overlapping in time. Moreover, alternative embodiments may include multiple instances of a particular operation, and the order of operations may be altered in various other embodiments. ln the claims, the word ‘comprising’ does not exclude the presence of other elements or steps than those listed in a claim. Furthermore, the terms ‘a’ or ‘an,’ as used herein, are defined as one or more than one. Also, the use of introductory phrases such as ‘at least one’ and ‘one or more’ in the claims should not be construed to imply that the introduction of another claim 5 element by the indefinite articles ‘a’ or ‘an’ limits any particular claim containing such introduced claim element to inventions containing only one such element, even when the same claim includes the introductory phrases ‘one or more’ or ‘at least one’ and indefinite articles such as ‘a’ or ‘an.’ The same holds true for the use of definite articles. Unless stated otherwise, terms such as ‘first’ and ‘second’ are used to arbitrarily distinguish between the elements such terms 10 describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements.

Claims

1. A method (200) for producing foodstuffs in a vertical foodstuff production system (100), the method comprising:mounting (210) an attachable foodstuff container (105), selectable from a plurality of attachable foodstuff containers, into the vertical foodstuff production system (100), where the attachable foodstuff container (105) comprises at least one vibration device (120) and an egress component (108);inserting (215) foodstuff (160) in a condiment, a sauce or a powder form into the attachable foodstuff container (105);agitating (215) the attachable foodstuff container (105) by the at least one vibration device (120);opening (218) the egress component (108) and dropping the foodstuff (160) due to gravity from the attachable foodstuff container (105) into a docking station;sieving (235) foodstuffs (160) in a detachable centrifugal sieving device (130) received via the docking station (112), wherein the detachable centrifugal sieving device (130) comprises an inverter controlled electric motor (121) arranged to control a centrifugal motor speed applied to the detachable centrifugal sieving device (130) in a sieving process;receiving and filtering (240) the sieved foodstuffs (160) by an inline output filter (150) formed of a sieve integrated into tubing;passing the sieved, filtered foodstuffs (160) through a metal detector (245) and removing (250) detected metallic contamination in the sieved filtered foodstuffs (160);collecting the sieved, filtered, contaminated metal removed, foodstuffs (160) in a tote bag (255); andidentifying when the tote bag (190) is full in response to one of: a sensor, a weighing scale identifying a weight of the tote bag.

2. The method (200) for producing foodstuffs in a vertical foodstuff production system (100) of claim 1, further comprising:determining (220) whether a foodstuff flow rate is above a threshold (220) flow rate; and in response thereto:if the flow rate is not above the threshold (220) flow rate, the method further comprises:determining whether the attachable foodstuff container (105) is empty (225) and in response thereto, either adjusting the agitation (260) of the at least one vibration device or replacing the attachable foodstuff container (105) or addingfoodstuff (160) into the attachable foodstuff container (105) if the attachable foodstuffcontainer (105) is empty; orif the flow rate is above the threshold (220) flow rate, deactivating (230) the at least one vibration device (120).

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