Automatic preparation station for frozen foods

Abstract

The invention relates to a station including one or more loading positions, a feeder for feeding empty boxes to the loading positions, a loading robot with a gripper for picking up and transferring groups of frozen food into the boxes, a scale for automatically weighing the boxes, and a dispenser for automatically depositing individual units of frozen food into the loaded boxes. This conditioning station is controlled to slightly underload the boxes so that at the end of the loading by the loading robot, the individual units of frozen food do not have to be removed from the boxes and so that after deposition by the dispenser, the weight of the loaded boxes is equal to or greater than a predefined set value within a predefined tolerance. This allows the loading to be automated and the weight of the boxes of frozen food to be optimized.

Description

[Technical field]

[0001] The invention can be included in the food sector, in particular in the frozen food sector. More specifically, the object of the invention relates to a preparation station for preparing frozen food, in particular frozen hamburger patties, including beef, chicken, turkey, pork or vegetable hamburger patties. [Background technology]

[0002] In the food industry, and in particular in the finishing and packaging of previously frozen foods, installations are known for the in-line packaging of prepared, deep-frozen hamburger patties intended for distribution on a large scale to a wide range of points of sale around the world, where the hamburger patties are packaged to be sent to the point of sale where they are finished.

[0003] The packaging of frozen hamburgers is particularly delicate because it is performed manually on the hamburger processing line itself by dedicated workers who manually package a specific number of units in horizontally or vertically oriented stacks into boxes.

[0004] As this is a job carried out in a food processing and freezing facility, the working conditions are extreme since, on the one hand, it involves working at low temperatures and, on the other hand, the continuous handling of deep-frozen products, which makes the workers more susceptible to extreme cold, even though they are protected against said conditions by various PPE such as gloves and gowns.

[0005] Therefore, in this sector, these types of work are particularly dangerous and therefore should be optimized so that, on the one hand, production in general is optimized and non-added-value human work is amortized, and, on the other hand, work in dangerous conditions is eliminated from a purely ergonomic point of view. Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention overcomes the aforementioned drawbacks by providing an automatic preparation station for frozen food products, such as frozen hamburger patties, which makes it possible to combine automation of packaging with optimization of the contents of the packaging material (generally a box). [Means for solving the problem]

[0007] The conditioning station comprises one or more loading positions to which empty boxes are fed by a box feeder. There is also at least one scale for automatically weighing the boxes, preferably one scale at each corresponding loading position, and at least one loading robot with a gripper for picking up groups such as stacks of frozen food products and transferring them to a box at the loading position in synchronism with the feeder. The conditioning station is controlled to underload the boxes so that after loading by the loading robot or robots, the weight of the box is not so high as to exceed a predetermined lower limit set value plus a predetermined tolerance, i.e. so that there is no need to remove individual units from the frozen food products. In particular, the arrangement seeks to ensure that at the end of loading by the loading robot, the loaded box has a weight selected from the following: - Below the lower limit, and - above the lower set point by an amount not exceeding the tolerance so that individual units do not have to be removed from the frozen food.

[0008] Advantageously, the conditioning station further comprises at least one dispenser for automatically depositing one or more individual units of frozen food into the loaded box, the arrangement then seeking to ensure that after deposition by the dispenser, the weight of the loaded box is equal to or greater than a predetermined lower set point, within a predetermined tolerance range.

[0009] The conditioning station can work with various formats of frozen food, especially frozen hamburgers, in boxes for different sizes and different weights, both vertical and horizontal stacking, but exclusively one format at a time. The frozen food is loaded automatically, i.e. without human intervention. The frozen food is loaded into the boxes according to previous specifications, i.e. to reach a number, height and weight within pre-specified ranges, by number of units of frozen food (e.g. hamburgers), by thickness of the stacked units, i.e. total height, by weight, or by some or all combinations thereof.

[0010] It may optionally include a frame intended to introduce a grid pattern into the box once in the loading position and before it is loaded, to facilitate filling, the grid pattern dividing the box into cells and thus defining a predefined loading format. In this way, the loading robot can deposit the frozen products into the box, into the cells, according to a predefined arrangement according to the configuration of the grid pattern, thus simplifying the orderly loading of the frozen products into the box. Similarly, the frame may be configured to clamp a liner, typically a plastic bag, into the box without it collapsing or falling into the box.

[0011] The automation of loading is accomplished accurately, quickly, and in compliance with volume and weight specifications, without manual tasks such as removing individual units of frozen food from loaded boxes because they are overweight.

[0012] The above-mentioned advantages and features, as well as other advantages and features, will be more fully understood in the light of the following detailed description of embodiments, which refers to the following figures, which are to be read as illustrative and non-limiting, in which: [Brief description of the drawings]

[0013] [Figure 1] 1 shows a schematic top perspective view of a conditioning station of the present invention; [Diagram 2] FIG. 1 shows a detailed view of the support and substack configuration. [Diagram 3] 1 shows a detail of one of the grippers. [Figure 4] 1 shows details of the frame and grid pattern. [Explanation of symbols]

[0014] 1. Frozen Foods / Frozen Hamburgers 2 boxes 3 Groups / Stack 4. Conveyor Belt 5 Grouping device / stacker 6 Stacked Hamburger Supports 7 Empty Box Feeder 8 Loading Position 9. Loading Robot 10 Gripper 11. Substack 12 Separation means 13. Nails 14 Side hatch 15 Lower Hatch 16 Actuators 17 Frame 18 Grid Pattern 19 Plastic Liner / Bag 20 distributor 21 Tank 22 Upper Plate 23 Lower Plate 24 Upper through hole 25 Retaining plate 26 Cells 27 Frame 28 Internal tubular section 29 First Drive Unit 30 Connecting Rod 31 Closure 32 Second Drive Unit 33 Laser 34 meters DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] A detailed description of a preferred exemplary embodiment according to the first aspect of the present invention of an automatic preparation station for a frozen product (1), which is a frozen hamburger steak (1) without loss of generality, is provided below with the aid of the above mentioned figures 1 to 4.

[0016] In the presented example described below, the conditioning station of the invention is installed in a frozen hamburger patty (1) production facility, where the hamburger patty (1) is preferably first formed and then frozen, so that it arrives at the conditioning station in a frozen state and is packaged in boxes (2) according to predetermined weight requirements. For this purpose, the conditioning station comprises two sub-stations: - A packaging substation where groups of frozen hamburgers (3) are automatically loaded into boxes (2): - a finishing sub-station, in which the weight of the boxes (2) loaded with frozen hamburger patties (1) is automatically checked and, if necessary, said weight is adjusted by incorporating one or several loose frozen hamburger patties (1).

[0017] In the production facility, hamburger patties (1) are prepared and then frozen. The frozen hamburger patties (1) pass a visual verification system (not shown) that checks pre-specified format requirements such as shape, orthogonal dimensions, thickness, etc., and separates the frozen hamburger patties (1) into passable and failable hamburger patties based on pre-set criteria. The visual verification can be performed after the hamburger patties (1) have been frozen, as just explained, but it is also preferred to perform it before freezing. In general, it is important to perform the visual verification both before and after freezing for different reasons. In particular, the visual verification after freezing is more important, since the hamburger patties (1) may be damaged and deformed during freezing, which may cause problems in the operation of the station.

[0018] The frozen and, if necessary, inspected hamburgers (1) are transported on a conveyor belt (4) and arrive at the packaging station in a neat, aligned position.

[0019] The packaging sub-station comprises a grouping device (5), e.g. a stacker (5), which receives the frozen hamburger patties (1) via a conveyor belt (4) and forms one or more groups (3), e.g. stacks (3) receiving the frozen hamburger patties (1) supported on respective supports (6), which are preferably inclined. The number of groups (3), in particular stacks (3), may depend on the size of the hamburger patties (1). In the figure, by way of example, the grouping device (5) shown forms five stacks (3).

[0020] The packaging sub-station further comprises at least one feeder (7) for feeding empty boxes (2) to one or more loading positions (8) of the packaging sub-station. Without loss of generality, the feeder (7) may be of the type feeding already formed boxes (2) or of the type feeding corrugated sheets to form the boxes (2).

[0021] Likewise, the packaging substation comprises at least one loading robot (9) with a gripper (10) for removing a substack (11) of hamburgers (1) from the stack (3) and transferring it to a box (1) in synchronism with the feeder (7). By way of example, in the illustrated embodiment there are two loading robots (9) arranged on either side of a single feeder (7) and two loading positions (8), allowing the simultaneous operation of the two loading robots (9). The invention is applicable, without loss of generality, both to the case of a single loading robot (9) and to the case of more than two loading robots (9), for example three loading robots (9).

[0022] Preferably, the packaging sub-station comprises detection means (not shown) for determining the number of hamburgers (1) stacked in each stack (3) and the thickness, i.e. the total height, of each stack (3). When the number of hamburgers (1) and the height of the stack (3) meet the predetermined stacking requirements, e.g. when the stack (3) reaches a preset number of hamburgers (1) or a preset maximum height, a separating means (12) separates the hamburgers (1) forming a sub-stack (11) from said stack (3) and separates them from the remaining hamburgers (1) of the stack (3). The separating means (12) may comprise a claw (13) mounted on the support (6) which moves the sub-stack (11) upwards and separates them from the stack (3) which is continuously formed as the hamburgers (1) are fed.

[0023] At this point, the gripper (10) of the loading robot (9) picks up the substack (11) and introduces it into the box (2). Preferably, the gripper (10) has a side hatch (14) that closes and encloses the substack (11). If the hamburgers (1) are stacked horizontally in the box (2), the side hatch (14) opens to allow the hamburgers (1) to drop from the substack (11) into the box (2). If they are stacked vertically, the gripper (10) has a bottom hatch (15) that opens to allow the hamburgers (1) to drop. Although typically any box type (2) is intended to be filled only horizontally or only vertically, the loading robot (9) is preferably configured for horizontal and vertical loading, for example including both a side hatch (14) and a bottom hatch (15). The gripper (10) can be suitably configured depending on the particular shape of the hamburgers (1). For example, it can be configured to capture round hamburgers (1) as well as oval hamburgers (1).

[0024] The figures show a preferred example of the operation of the grippers (10) described below. Each gripper (10) has an outer tubular frame (27) and two inner tubular parts (28) concentric with the frame (27) and movable by a first drive (29), such as by a connecting rod (30), so as to open the side hatches (14), which allows the grippers (10) to approach and capture the substacks (11), and then close the side hatches (14) to hold the frozen hamburger patties (1) without damage. This configuration also serves to unload the substacks (11) in the case of horizontal filling, as explained above. It is only necessary to position the grippers (10) horizontally on the boxes (2) and open the side hatches (14). In the case of vertical filling, the grippers (10) can also include a closure (31) for opening and closing the lower hatch (15) by means of a second drive (32). Once the gripper (10) is loaded, it is moved towards the box (2) and positioned vertically on the box (2) as required, at which point the second drive (32) drives the closure (31) to open the lower hatch (15) and drop the substack (11). The inside of the tubular portion (28) is designed and dimensioned to allow the hamburger (1) to drop perfectly vertically, avoiding friction on the walls, while at the same time accommodating the tolerance differences of the hamburger (1), said tolerances being matched, if necessary, with those of the grid pattern (18) to avoid jamming when loading the box (2).

[0025] In the example shown in the figure, as the sub-stack (11) grows as the frozen hamburger patties (1) are accumulated on the support (6), a laser (33) emitted from a meter (34) measures the stopping position of the sub-stack (11) so that, when it reaches a predetermined position, the separating means (12), and if necessary the claws (13), are driven by a signal sent by the meter (34) to the drive device (16) to push the claws (13) towards the sub-stack (11) and separate the sub-stack (11) into two parts, so that, as explained above, the gripper (10) of the loading robot (9) performs the collection operation of the sub-stack (11) from its position on the support (6) and performs the remaining loading operation.

[0026] The loading robot (9) deposits the sub-stacks (11) of hamburgers (1) into the boxes (2) according to preset parameters related to the number of loaded hamburgers (1) and the weight of the loaded boxes (2). For example, both the number of hamburgers (1) and the weight of the loaded boxes (2) may be within preset ranges. In this regard, the packaging sub-station may further include a packaging scale (not shown) for measuring the weight of the boxes (2) as they are filled.

[0027] Optionally, the packaging substation further comprises a frame (17) intended to introduce into the box (2) once at the loading position (8) and before loading, a grid pattern (18) with cells (26) defining a predetermined loading format, in order to compartmentalize the box (2) and facilitate its filling. In this way, the orderly loading of the hamburgers (1) into the box (2) is simplified, since the loading robot (9) can alternatively deposit the substacks (11) into each compartment created by the grid pattern (18). The frame (17) can optionally be configured to clamp a liner (19), typically a plastic bag (19), in the box (2) without it collapsing or falling into the box (2), where, for example, the frame can comprise a hold-down plate (25) for clamping the liner (19). The presence of the frame (17) and the grid pattern (18) serves two purposes: Firstly, the grid pattern (18) together with its cells (26) are arranged according to the loading format of the selected box (2) and in particular how the product is to be loaded into that box (2). Similarly, the cells (26), in addition to acting as guides for the frozen burgers (1) to enter or fall into the box (2) in their correct place during the loading operation, also maintain the frozen burgers (1) in the correct position once loaded, preventing the substack (11) from collapsing and thus interfering with the subsequent loading operation of the frozen burgers (1) into the empty cells (26) waiting to be loaded. Secondly, the frame (17), in addition to holding the grid pattern (18) in the correct position and allowing it to rise and fall according to the cycle during the loading operation, clamps the bag (19) in the box (2) by the upper edge of the box (2). This clamp is important to prevent the bag (19) from collapsing into the box (2) if the bag (19) is not fully seated within the box (2) or if there is a gap between the inside of the box (2) and the bag (19), which is often the case when a plastic bag (19) is placed in a receptacle.

[0028] For its part, the finishing sub-station includes a finishing scale (not shown) that measures the weight of the box (2) loaded into the finishing station, and a dispenser (20) configured to introduce a precise number of frozen hamburgers (1) into the loaded box (2) after loading by the loading robot (9). The sub-station is programmed to slightly underload the box (2), i.e., such that the number of hamburgers (1) and / or the length of the sub-stack (11) taken in each run by the loading robot (9) is such that the weight of the box (2) at the end of loading does not exceed a certain set point so that individual frozen hamburgers (1) would need to be removed. However, the finishing station is programmed to ensure that the weight of the box (2) after loading by the loading robot (9) is not less than, i.e., not less than, a predetermined weight value. This allows the following: once the box (2) has been weighed by the finishing scale, the frozen hamburgers (1) do not have to be removed (manually) from the loaded box, but rather individual hamburgers (1) can simply be added as required by the dispenser (20) (i.e. the exact number required).

[0029] Preferably, the packing scale is the same as the finishing scale. Specifically, based on the weight discrepancy, the station determines how many hamburger patties (1) need to be included by the dispenser (20).

[0030] The figure shows that the loaded box (2) at the packaging station is moved to the position of the dispenser (20). Alternatively, although not shown, the dispenser (20) can be arranged to introduce the hamburger patties (1) into the loaded box (2) at the loading position (8) without the need to move the loaded box (2).

[0031] Although a single dispenser (20) is shown in the figures, in other embodiments there may be multiple dispensers (20) associated with the loading robot (9).

[0032] Also preferably, the distributor (20) is configured to be loaded by a loading robot (9). For example, the distributor (20) comprises a tank (21), for example a vertical tank (21), which is vertically loaded, for example, by the loading robot (9). By way of example, as shown in the figure, the distributor (20) comprises two overlapping plates (22, 23), for example two circular plates (22, 23), namely an upper plate (22) having a number of upper through-holes (24) for receiving the frozen hamburger patties (1) coming from the tank (21) and a lower plate (23) having at least one lower through-hole (not shown) for dropping the frozen hamburger patties (1) into the box (2) to be loaded. The upper plate (22) is rotatable relative to the lower plate (23) along a vertical axis coaxial with the two plates (22, 23) so as to face the hamburger (1) with the lower through-hole, and preferably also rotatable relative to the tank (21) so as to receive the hamburger (1) from the tank (21) into the upper through-hole (24).

[0033] Further, optionally, the dispenser 20 incorporates a timer (not shown) that determines the residence time of the frozen hamburger 1 in the tank 21. This is important due to hygiene considerations. The hamburger 1 must remain in the tank 21 for a predetermined maximum time, e.g. 30 minutes, after which it must be discarded. The timer is associated with an alarm (not shown) that indicates the residence time and / or issues an alarm message to indicate that the predetermined maximum time is being approached or exceeded.

Claims

1. A preparation station for frozen food (1), comprising: one or more loading positions (8), at least one feeder (7) for feeding empty boxes (2) to said loading position (8); at least one loading robot (9) equipped with a gripper (10) for picking up groups (11) of said frozen food products (1) and transferring them synchronously with said feeder (7) to said boxes (2) at said loading position (8); a scale for automatically weighing said box (2); at least one dispenser (20) for automatically depositing one or more individual units of said frozen food (1) into said loaded box (2); The adjustment station checks whether the loaded box (2) is: - weight below a certain lower limit, and a weight that exceeds said lower set limit by no more than a predetermined tolerance, so as not to require the removal of individual units from said frozen food product (1); and controlling the loading of said box (2) to have a weight selected from The conditioning station is further controlled such that the weight of the loaded box (2) after deposition by the dispenser (20) is equal to or greater than the predetermined lower set point within the predetermined tolerance range. A conditioning station.

2. 2. The conditioning station according to claim 1, characterized in that the distributor (20) is adapted to be loaded by the loading robot (9).

3. 3. Regulating station according to claim 2, characterized in that said distributor (20) comprises at least one tank (21) which is loaded by said loading robot (9).

4. The distributor (20) - an upper plate (22) having a number of upper through-holes (24) for accommodating the units of said frozen product (1) coming from said tank (21), and a lower plate (23) having at least one lower through hole for dropping said units (1) of frozen product into said box (2); 4. A conditioning station according to claim 2 or 3, characterized in that it comprises two overlapping plates (22, 23) comprising:

5. 5. The adjusting station according to claim 4, characterized in that the upper plate (23) is rotatable relative to the lower plate (23) according to a vertical axis coaxial with the two plates (22, 23) so as to bring the unit of frozen product (1) facing the lower through-hole.

6. 6. The conditioning station according to claim 5, characterized in that the upper plate (22) is further rotatable relative to the tank (21) in order to receive a unit of frozen product (1) from the tank (21) into the upper through-hole (24).

7. The preparation station according to any one of claims 1 to 6, characterized in that it further comprises a grouping device (5) for receiving the units of frozen food (1) and for forming, with the received units of frozen food (1), one or more groups (3) to be transferred by the loading robot (9) into the boxes (2).

8. 8. A conditioning station according to claim 7, characterized in that the grouping device (5) comprises respective supports (6) for supporting the groups (3).

9. 9. Adjustment station according to claim 8, characterized in that the support (6) is inclined.

10. 10. The conditioning station according to any one of the preceding claims, further comprising detection means for determining the number of individual units of frozen food product (1) grouped in each group (3) and the total thickness of each group (3).

11. A conditioning station according to any one of the preceding claims, further comprising separating means (12) for isolating the frozen foods (1) forming a subgroup (11) from each group (3) and for separating the frozen foods (1) of the subgroup (11) with respect to the remaining frozen foods (1) of the group (3).

12. 12. The adjusting station according to claim 11, characterized in that the separating means (12) comprise a claw (13) mounted on the support (6), which claw (13) moves the subgroup (11) upwards and makes it independent of the group (3).

13. 13. The adjustment station according to claim 11 or 12, further comprising an emitter (34) for irradiating a laser (33) for detecting a stop position of the sub-stack (11), characterized in that the station is configured such that when the meter (34) detects that the stop position has reached a predetermined position, the separating means (12) is activated.

14. A conditioning station according to any one of the preceding claims, characterized in that the gripper (10) comprises a side hatch (14) enclosing and closing the subgroup (11) of frozen food products (1).

15. 15. A conditioning station according to claim 14, characterized in that the side hatches (14) are controlled to open in order to deposit the subgroups (11) horizontally in the box (2).

16. 16. Adjustment station according to claim 14 or 15, characterized in that the gripper comprises an outer tubular frame (27) and two inner tubular parts (28) concentric with the frame (27) and movable by a first drive (29) for opening and closing the side hatch (14).

17. The adjustment station according to any one of claims 14 to 16, characterized in that the gripper (10) further comprises a lower hatch (15) that opens to allow the subgroup (11) to be dropped vertically into the box (2).

18. 18. Adjustment station according to claim 17, characterized in that the gripper (10) additionally further comprises a closure (31) for opening and closing the lower hatch (15) by means of a second drive (32).

19. A conditioning station according to any one of the preceding claims, characterized in that it further comprises a frame (17) intended to introduce into the box (2) once it is placed in the loading position (8) a grid pattern (18) defining a predetermined loading format, in order to partition the box (2) during loading.

20. 20. Conditioning station according to claim 19, characterized in that the frame (17) is configured to clamp a bag (19) in the box (2).

21. A conditioning station according to any one of the preceding claims, characterized in that the frozen food product (1) comprises a frozen hamburger steak (1).

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