Hemp processing system and method

Abstract

A system (100) and method for processing fibrous plant materials, such as hemp or flax. The plant material processing system (100) comprises an inline, multistage fragmentation or shredding apparatus (102) which is provided for fragmenting the plant material by pressing, separating, breaking and / or dislodging of the plant material. A screening apparatus (104) is provided for receiving the fragmented plant material and screening same based on size and / or type.

Description

[0001] HEMP PROCESSING SYSTEM AND METHOD

[0002] BACKGROUND TO THE INVENTION

[0003] This invention relates to the processing of raw plant material, such as hemp. More particularly, the present invention relates to a system and method for processing hemp and other fibrous plant materials.

[0004] Hemp or (industrial hemp) stems or stalks typically comprise a hollow inner core, hurd (which is a coarse core material) and fibrous material. Typically, to arrive at a commercially valuable product, the fibres need to be separated from the hurd.

[0005] The hurd and fibres have various known commercial uses. Coarse fibres, for example, are typically used in the manufacture of hemp bioplastics and insulation, while fine fibres are used in manufacturing of niche paper products and hemp bioplastics.

[0006] Coarse hurd, on the other hand, is used in manufacturing hempcrete blocks and animal bedding, while finer hurd is used in the manufacture of hemp lime plaster.

[0007] In the field of hemp processing, “decortication” is a process of separating the hurd material and fibres of the hemp stems.

[0008] Commercial decortication plants are typically quite involved, complex and expensive, and do not provide a solution to smaller- to medium-scale hemp processing, typically, such as required in third world countries. These more complex machines provide a means for wet and dry decortication.

[0009] It has been found that smaller-scale decortication machines are often inefficient, does not provide a means for properly processing dry hemp and does not provide for adequate separation of the hurd and fibres, thereby rendering the overall process inefficient. Furthermore, hemp used in smaller-scale or batch processes are typically not pre-processed, and the stems therefore have varying sizes, which, again, negatively impacts on the efficiency of the decortication process.

[0010] It is accordingly an object of the invention to provide a plant material processing system and method that will, at least partially, address the above disadvantages.

[0011] It is also an object of the invention to provide a plant material processing system and method which will be a useful alternative to existing systems and methods.

[0012] SUMMARY OF THE INVENTION

[0013] In accordance with a first aspect of the invention there is provided a plant material processing system, comprising: an inline, multistage fragmentation / shredding apparatus provided for fragmenting the plant material by pressing, separating, breaking and / or dislodging of the plant material; a screening apparatus for receiving the fragmented plant material and screening same based on size and / or type.

[0014] The plant material may be hemp, flax or substantially similar plant materials.

[0015] The processing system according to the first aspect of the invention may furthermore comprise an infeed arrangement for feeding unprocessed plant material towards the fragmentation / shredding apparatus and an outfeed arrangement for feeding fragmented plant material from the screening apparatus.

[0016] The fragmentation / shredding apparatus may comprise a decortication apparatus and / or a separation apparatus.

[0017] The fragmentation / shredding apparatus may include one or more of: a guide stage; a crushing stage; a cutting stage; and a breaking stage.

[0018] The fragmentation / shredding apparatus may comprise a drive motor and / or gearbox unit for driving one or more of the stages, directly or indirectly. The motor may be an electric, pneumatic, hydraulic or internal combustion motor.

[0019] Each stage may be provided substantially in line. The fragmentation / shredding apparatus may define a travel direction. Consecutive stages of the fragmentation / shredding apparatus may be arranged downstream with regards to the travel direction.

[0020] The guide stage may define an entry into the fragmentation / shredding apparatus and may comprise a first set of parallel infeed or guide rollers defining a first roller gap therebetween. A diameter of the rollers may be about 220 mm.

[0021] A first roller forming part of the first set of infeed or guide rollers may be directly driven by the motor and / or gearbox unit by means of a direct mechanical coupling. A second roller forming part of the first set of infeed or guide rollers may be directly driven by the first roller by means of a direct mechanical coupling, such as a first set of gears in mesh.

[0022] The crushing stage may comprise a second set of parallel infeed or guide rollers defining a second roller gap therebetween. The second roller gap may be smaller than the first roller gap and the second set of infeed or guide rollers may be configured as crushing rollers, operatively, at least partially, to crush the plant material.

[0023] The cutting stage may comprise a third set of rollers. The third set of rollers may comprise a guide roller and cutting or slitter roller. The guide roller and cutting or slitter roller may be spaced apart by a third gap, which may be a clearance gap. The cutting or slitter roller may comprise parallel and spaced apart ring-shaped cutting formations. The cutting formations may take the form of cutting blades, spaced apart by spacers. The cutting or slitter roller may comprise between 150 and 200 cutting blades. The cutting blades may have an outer diameter of about 1 18 mm and a cutting blade angle of 20 degrees. A base of the cutting blade may be about 3 mm wide and may taper towards a cutting edge.

[0024] The cutting stage may include a scraper assembly arranged proximate the cutting or slitter roller. The scraper assembly may comprise a plurality of scraper blades arranged between the ring-shaped cutting formations of the cutting or slitter roller.

[0025] The breaking stage may comprise at least a first set of breaking rollers.

[0026] The breaking stage may furthermore comprise at least a first set of dislodging rollers.

[0027] The breaking stage may comprise a plurality of sets of breaking rollers and dislodging rollers. At least some of the sets of breaking rollers and dislodgement rollers may be arranged sequentially.

[0028] Each breaking roller may comprise between 10 and 20 radially extending breaking segments. Breaking rollers of a set of breaking rollers may be arranged in meshed fashion.

[0029] Each breaking roller may comprise a central hub with a plurality of radially extending segments fixed thereto. Support braces may be sandwiched between adjacent segments. Segments may have a radial dimension of about 30 mm and may have rounded outer edges. Segments may be supported on the hub at a radius of about 30 mm, resulting in a total breaking roller radius of about 60 mm.

[0030] The dislodging rollers may take the form of ripping rollers. Each ripping roller may comprise between 10 and 20 radially extending ripping segments.

[0031] Each dislodging roller may comprise a central hub with a plurality of radially extending segments received within radially extending slots thereof and fixed thereto. Segments may have a radial dimension of about 40 mm and may have squared outer edges. Segments may be supported on the hub at a radius of about 20 mm, resulting in a total dislodging roller radius of about 60 mm.

[0032] Ripping rollers of a set of dislodgement rollers may be arranged in meshed fashion.

[0033] A first roller forming part of each of the second and further stages may be driven by means of a mechanical coupling to a roller of an upstream stage. The mechanical coupling may typically take the form of a set of sprockets connected by means of a chain or a set of pulleys connected by a belt. First and second rollers of each stage may be linked by means of a direct mechanical coupling, such as a set of gears arranged in mesh. The first roller of each stage may operatively rotate in a first direction, while the second roller of each stage may operatively rotate in a second, opposite direction. The first and second roller of each stage may rotate at similar speeds in opposite directions. The first and second stages may be driven the same speed (tangential speed and rotational speed). The slitter and breaking rollers may be driven at speeds (tangential and rotational speeds) higher than that of the first and second stages.

[0034] The screening apparatus may comprise a sorting grid which is arranged relative to an outlet of the fragmentation / shredding apparatus. The sorting grid may be arranged in declining or sloping fashion. The sorting grid may be associated with a predetermined aperture size, selected based on a predetermined and allowable fragment size of fragmented plant material. In use, material fragmented by the fragmentation / shredding apparatus may be cast over an upper surface of the screening apparatus. The screening apparatus may separate fragmented or processed material into a first stream, namely a screened material stream, and a second stream, namely a rejected material stream. The screened material stream may be received by the outfeed arrangement. The screening apparatus may separate the fragmented or processed material by allowing material below a predetermined size to pass through the apertures.

[0035] The sorting grid may be a vibrating grid. The sorting grid may be associated with a cam action which provides the grid with a shaking action.

[0036] The infeed arrangement may comprise an infeed conveyor for conveying unprocessed plant material towards the fragmentation / shredding apparatus. The infeed arrangement may furthermore comprise an infeed cover or guide, which takes the form of an inlet or input to the fragmentation / shredding apparatus. The infeed cover or guide may comprise a mouth portion and which converges towards a throat portion.

[0037] The outfeed arrangement may comprise a collection apparatus, typically in the form of a collection conveyor, arranged proximate the screening apparatus and configured for collecting fragmented and screened plant material from the screening apparatus.

[0038] In some variations, the collection conveyor may serve as an outfeed conveyor for feeding fragmented or processed and screened plant material out of the system. In other variations, the outfeed arrangement may include a separate outfeed conveyor for feeding fragmented or processed and screened plant material out of the system.

[0039] The collection conveyor may be situated vertically lower than the fragmentation / shredding apparatus and my pass, at least partially underneath, the fragmentation / shredding apparatus. The collection conveyor may have a travel direction opposite to a travel direction of the fragmentation / shredding apparatus. Yet furthermore, the outfeed arrangement may include a link conveyor arranged between the collection conveyor and outfeed conveyors, such that material is unloaded from the collection conveyor onto the link conveyor and unloaded from the link conveyor onto the outfeed conveyor.

[0040] The collection and outfeed conveyors may be arranged out of alignment, such that travel directions associated with the collection and outfeed conveyors differ. The outfeed conveyor may extend laterally relative to the system and may operatively unload fragmented and / or processed and screened plant material to a side of the system.

[0041] Further in accordance with the first aspect of the invention, the system may comprise a pretreatment subsystem which may include a raw material de-baler and a feedstock stream regulator.

[0042] Yet further in accordance with the first aspect of the invention, the system may comprise a secondary processing subsystem. The secondary processing subsystem may comprise a hurd processing subsystem and a fibre processing subsystem. The hurd processing subsystem may comprise a hurd screening arrangement, a hurd milling arrangement, optionally in the form of a hammer mill, and / or a hurd bagging or baling arrangement. The hurd processing subsystem may also include various conveyors and transfer arrangements, holding silos and the like. The fibre processing subsystem may comprise a fibre combing and cleaning arrangement and / or a fibre compressing and baling arrangement. The fibre combing and cleaning arrangement may comprise one or more conveyor arrangements comprising holding, transfer and combing components (optionally in the form of rollers).

[0043] In accordance with a second aspect of the invention there is provided a plant material processing method, comprising the steps of: providing a plant material processing system in accordance with the first aspect of the invention; feeding plant material into an inline, multistage fragmentation / shredding apparatus and using same to fragment the plant material by pressing, breaking, fragmenting, separating, dislodging and / or shredding the plant material; using a screening apparatus to screen the fragmented plant material based on size and / or type; collecting screened material from the screening apparatus.

[0044] The fragmentation or shredding of the plant material may involve at least some of the substeps of: crushing the plant material; cutting the plant material; breaking the plant material; and / or dislodging the plant material.

[0045] The method may comprise the secondary hurd processing steps of: screening the hurd; milling the hurd using a hammer mill; and bagging or baling the hurd.

[0046] Furthermore, the method may include the secondary fibre processing steps of: combing and cleaning the fibre; and compressing and baling the fibre.

[0047] In accordance with a third aspect of the invention there is provided a plant material processing system, comprising: a decortication apparatus, for receiving the plant material and stripping same; a separation apparatus for receiving stripped material and crushing same into separate pieces; and a screening apparatus for receiving the crushed material and screening same based on size and / or type.

[0048] The plant material may be hemp, flax or substantially similar plant materials.

[0049] The screening apparatus may comprise at least a first screening subsystem.

[0050] The first screening subsystem may comprise a first sieve.

[0051] The first sieve may take the form of a roll sieve. The roll sieve may define an axis of rotation, about which, the roll sieve is driven operatively to rotate, at a predetermined rotational speed. The axis of rotation may be arranged substantially horizontally.

[0052] The roll sieve may be associated with a first open end, through which crushed material may be received, and a second open end.

[0053] The roll sieve may comprise a plurality of apertures associated with a first aperture size. The first aperture size may be in the range of 10 mm to 20 mm. Typically, the first aperture size may be 14 mm.

[0054] The roll sieve may be associated with a first collection arrangement, arranged, operatively to collect particles or fragments screened by the roll sieve. The first collection arrangement may be arranged below the roll sieve to collect particles or fragments falling through the apertures under gravity, from the roll sieve. The roll sieve may be configured to allow at least a portion of hurd particles to pass through the apertures.

[0055] The roll sieve may be associated with a second collection arrangement, which may be arranged in communication with the second open end. The roll sieve may be configured to allow particles not passing through the apertures to be displaced substantially in the direction of the axis of rotation, and to be deposited through the second open end, to be collected by the second collection arrangement.

[0056] The screening apparatus may comprise a second screening subsystem. The second screening subsystem may comprise a screen drawer apparatus. The screen drawer apparatus may be associated with a third collection arrangement for collecting screened or separated particles, and a fourth collection arrangement for collecting remaining particles. The second collection arrangement of the roll sieve may be provided in communication a feed portion of the screen drawer apparatus, to allow particles to be fed from the roll sieve to the screen drawer apparatus.

[0057] The decortication apparatus may comprise first and second intake rollers, with which plant material is fed into to the decortication apparatus. The first and second rollers may be driven at a predetermined rotational speed, through a variable speed drive (VSD), by a motor. The predetermined rotational speed may be adjusted by the VSD, based on a thickness of material fed into the decortication apparatus.

[0058] The predetermined rate of rotation may be varied between 10 Hz (600 rpm) and 15 Hz (900 rpm). Typically, the rate of rotation may be relatively higher when relatively thinner material is fed into the decortication apparatus, and relatively lower when relatively thicker material is fed into the decortication apparatus. The rate of rotation may be about 13 Hz (780 rpm) when relatively thicker material is fed into the decortication apparatus.

[0059] The first and second intake rollers may be arranged in vertically stacked orientation relative to each other. The first roller may be a bottom roller, and the second roller may be a top roller. The bottom roller may comprise horizontally extending angle iron sections, while the top roller may comprise horizontally extending flat bar sections.

[0060] The first and second rollers may define a predetermined intake spacing therebetween.

[0061] The separation apparatus may comprise a mechanical means of breaking or crushing the material received from the decortication apparatus. The separation apparatus may comprise a hammer mill. The hammer mill may be provided with a screen. The screen may be associated with openings of about 50 mm in size.

[0062] Material, particles or fragments collected in the first or third collection arrangements may be further processed by a further crushing apparatus, which is associated with an adjustable screen, which may be adjusted to screen material, particles or fragments based on size. The adjustable screen may be adjusted to screen material, particles or fragments in sizes varying between 5 mm and 30 mm, typically between 6 mm and 20 mm.

[0063] The decortication, separation and screening apparatuses may be arranged in series, and such that material may continuously be fed from the one to the other.

[0064] In accordance with a fourth aspect of the invention there is provided a plant material processing method, comprising the steps of: providing a plant material processing system in accordance with the first aspect of the invention; feeding material into a decortication apparatus of the system, and decorticating the material; collecting the decorticated material and feeding same to a separation apparatus; using the separation apparatus to separate the material, and collecting the separated material; feeding at least a portion of the separated material to a screening apparatus; and collecting screened material from the screening apparatus.

[0065] BRIEF DESCRIPTION OF THE DRAWINGS

[0066] The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings in which:

[0067] Figure 1 shows a perspective view of a plant material processing system in accordance with a first aspect of the invention, from which certain details have been omitted for greater clarity;

[0068] Figure 2 shows a perspective view of the system of Figure 1 in use, installed in a shipping container;

[0069] Figure 3 shows a first side view of the system of Figure 1 ;

[0070] Figure 4 shows a second side view of the system of Figure 1 ;

[0071] Figure 5 shows a top view of the system of Figure 1 ;

[0072] Figure 6 shows a top view (from which certain details have been omitted for greater clarity) of an inline, multistage fragmentation / shredding apparatus forming part of the system of Figure 1 ;

[0073] Figure 7 shows a side view of the apparatus of Figure 6;

[0074] Figure 8 shows a perspective view of a scraper forming part of the of the apparatus of Figure

[0075] 6;

[0076] Figure 9 shows a perspective view of a cutting or slitter roller forming part of the apparatus of Figure 6;

[0077] Figure 10 shows a detailed view of the roller of Figure 9;

[0078] Figure 11 shows a perspective view of a breaking roller forming part of the apparatus of Figure 6;

[0079] Figure 12 shows a side view of the roller of Figure 1 1 ;

[0080] Figure 13 shows perspective view of a dislodging roller forming part of the apparatus of

[0081] Figure 6;

[0082] Figure 14 shows a side view of the roller of Figure 13;

[0083] Figure 15 shows a perspective view of a primary conveyor used for combing and cleaning fibres received as a product after processing by the processing system of Figure 1 ; Figure 16 shows a perspective view of a secondary conveyor used for combing and cleaning fibres received as a product after processing by the processing system of Figure 1 ;

[0084] Figure 17 shows a schematic perspective view of the processing system of Figure 1 including further subsystems;

[0085] Figure 18 shows a schematic representation of a hemp processing system, in accordance with a second aspect of the invention;

[0086] Figure 19 shows a side view of a decortication apparatus forming part of the system of Figure 18; and

[0087] Figure 20 shows a front view of a roll sieve forming part of a screening apparatus of the system of Figure 18.

[0088] DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0089] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms "mounted", "connected", "engaged" and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings and are thus intended to include direct connections between two members without any other members interposed therebetween and indirect connections between members in which one or more other members are interposed therebetween. Further, "connected" and "engaged" are not restricted to physical or mechanical connections or couplings. Additionally, the words "lower", "upper", "upward", "down" and "downward" designate directions in the drawings to which reference is made. The terminology includes the words specifically mentioned above, derivatives thereof, and words or similar import. It is noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the," and any singular use of any word, include plural referents unless expressly and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items. Referring to figures 1 to 17, in which like numerals indicate like features, a non-limiting example of a plant material processing system (or simply “system”) in accordance with a first aspect of the invention is generally indicated by reference numeral 100.

[0090] The system 100 can be used to process various forms of plant material and is especially suited to processing fibrous plant material. Throughout this disclosure, processing of hemp will be used as a non-limiting example of the type of plant material that may be processed using the system 100. Other types, including flax and the like, are also feasible.

[0091] As will become clear from what follows, the processing of the hemp relates to the decortication, stripping, separation, and / or screening of particles or fragments of hemp. Specifically, the system 100 is used to separate hurd from fibres, such that these two species of particles or fragments of hemp stems can be used separately.

[0092] The system 100 includes an inline, multistage fragmentation / shredding apparatus 102 (or simply “shredding apparatus”) (best shown in figures 6 and 7, where some details were omitted to show main components of the shredding apparatus 102 more clearly).

[0093] As discussed more fully below, the shredding apparatus 102 is used to process the plant material from an initial state, into a fragmented or shredded state. It will be appreciated that the different stages of the shredding apparatus 102 perform different processing functions.

[0094] The system 100 also includes a screening apparatus 104 with which the processed or fragmented plant material (processed by the shredding apparatus 102) is screened and sorted according to size, shape or type.

[0095] Furthermore, the system 100 also includes an infeed arrangement 106 for feeding unprocessed plant material towards the shredding apparatus 102 and an outfeed arrangement (generally indicated and referred to by reference numeral 108) for feeding processed or fragmented plant material from the screening apparatus 104.

[0096] The infeed and outfeed arrangements (106, 108) are arranged to facilitate continuous and automated operation of the system 100. Raw plant material is therefore operatively fed onto the infeed arrangement 106, and material which has been fragmented or processed and screened (or separated) is disposed by the outfeed arrangement 108 whereafter it may be further used, processed or stored.

[0097] The infeed arrangement 106 comprises an infeed conveyor 110 of the known kind for conveying unprocessed plant material towards the shredding apparatus 102, and an infeed cover or guide 1 12, which defines an inlet or input to the shredding apparatus 102. The infeed guide 1 12 comprises a mouth portion which converges towards a throat portion.

[0098] The outfeed arrangement 108 comprises a collection apparatus in the form of a collection conveyor 114, arranged below the screening apparatus 104, with which fragmented or processed and screened plant material from the screening apparatus 104 is collected. The collection conveyor 114 passes or runs, at least partially, underneath the shredding apparatus 102. The collection conveyor 1 14 has a travel direction opposite to that of the shredding apparatus 104. This layout ensures a relatively compact overall footprint of the system 100.

[0099] The outfeed arrangement 108 furthermore includes a link conveyor 116 which runs perpendicular to the collection conveyor, to convey the plant material received from the collection conveyor 114 to a side of the system 100 (and therefore out from underneath the shredding apparatus 102).

[0100] Lastly, the outfeed arrangement 108 includes an outfeed conveyor 1 18 which receives fragmented or processed plant material from the link conveyor 116 and conveys the material to a final location.

[0101] The screening apparatus 104 comprises a sorting grid of the known kind, which is arranged relative to an outlet 120 of the shredding apparatus 102. The sorting grid is arranged in declining or downward sloping fashion which allows fragmented or processed material from the shredding apparatus 102 to flow from the outlet 120 under gravity along a surface of the screening apparatus.

[0102] The sorting grid is associated with a predetermined aperture size, selected based on a predetermined and allowable fragment size of fragmented or processed plant material. The sorting grid may be a vibrating grid.

[0103] In use, material fragmented processed by the shredding apparatus 102 is cast over the upper surface of the screening apparatus 104 and the screening apparatus 104 separates the fragmented processed material into a first stream, namely a screened material stream, and a second stream, namely a rejected material stream. The screened material stream is collected by the collection conveyor 1 14 while the rejected stream may be stockpiled towards a rear end of the system 100. The screening apparatus separates the fragmented or processed material by allowing material below a predetermined size to pass through the apertures.

[0104] The shredding apparatus includes a guide stage 122, a crushing stage 124, a cutting stage 126 and a breaking stage 128. In some embodiments of the invention, some of the stages may be omitted, or some of the stages may be combined into a single multifunctional stage. Further stages may be added. The stages are provided substantially in line such that material travels or is displaced through the stages in a travel direction, indicated by the arrow 130.

[0105] The guide stage 122 defines an entry 132 into the shredding apparatus 102 and comprises a first set 134 of parallel rollers being infeed or guide rollers defining a first roller gap (not indicated) therebetween. Typically, the diameter of the rollers may be about 220 mm. The first set 134 serves to guide and / or pull material from the infeed conveyor 110 into the shredding apparatus 102. The shredding apparatus 102 comprises a drive motor and / or gearbox unit 136 which drives the stages of the shredding apparatus. The motor may be an electric, pneumatic, hydraulic or internal combustion motor. As discussed more fully below, the different stages are linked or coupled by means of mechanical couplings, allowing a single motor unit 136 to drive all the stages. That said, in an alternative, yet less desirable embodiment, some or all of the stages may be individually driven by individual motor and / or gearbox units. It will be appreciated that the use of a single unit 136 typically fixes relative rotational speeds between the different stages. Mechanical couplings between the stages and / or the unit 136 are not shown in the figures.

[0106] A first roller 138 forming part of the first set 134 is directly driven by the motor and / or gearbox unit 136 by means of a direct mechanical coupling.

[0107] A second roller 140 forming part of the first set 134 is directly driven through the first roller 138 by means of a direct mechanical coupling, such as a first set of gears in mesh. The first and second rollers (138, 140) naturally rotate in opposite rotational directions.

[0108] The motor is mounted towards a first side 142 of the shredding apparatus 102. Typically, the stages are coupled together on the first side 142 of the shredding apparatus 102. More particularly, a roller forming part of each of the second and further stages is driven by means of a mechanical coupling by a roller of an upstream stage. The mechanical coupling typically takes the form of a set of sprockets connected by means of a chain or a set of pulleys connected by a belt. The coupled rollers of the different stages are therefore driven in the same rotational directions, albeit not necessarily at the same rotational speed (predetermined relative rotational speeds are achieved by using sprockets of varying and predetermined size).

[0109] On the other hand, first and second rollers of each stage are coupled by means of a direct mechanical coupling, such as a set of gears arranged in mesh. This mechanical coupling is typically located on an opposite, second side 144 of the shredding apparatus 102. The first and second rollers of each stage may therefore operatively rotate in opposite directions but, typically at the same rotational speed. The first and second rollers of each stage may rotate at similar speeds in opposite directions. Rotational or tangential speeds of different stages or sets of rollers may differ.

[0110] The crushing stage 124 comprises a second set of parallel rollers 146 defining a second roller gap therebetween. The second roller gap is smaller than the first roller gap such that the second set 146 operatively, at least partially, crushes the plant material therebetween.

[0111] The cutting stage 126 comprises a third set of rollers 148, namely a guide roller 150 and a cutting or slitter roller 152. The slitter roller 152 is shown in more detail in figures 9 and 10. The guide roller 150 and slitter roller 152 are set up to define a clearance gap therebetween, to avoid contact and inhibit the blades (discussed below) from becoming dull. The slitter roller comprises a large number of (typically between 150 and 200) parallel and spaced apart ring-shaped cutting formations or blades 154. The blades 154 are spaced apart by spacers 156.

[0112] The cutting or slitter roller 152 may comprise between 150 and 200 cutting blades 154. The cutting blades 154 have an outer diameter of about 118 mm and a cutting blade angle of about 20 degrees.

[0113] The cutting stage 126 includes a scraper assembly 158, which is shown in figure 8. The scraper assembly 158 has been omitted from all other figures but is generally situated above the slitter roller 152. The scraper assembly 158 comprises a plurality of spaced apart scraper blades 160, which are shaped and sized to fit between the cutting blades 154 of the slitter roller 152 and to scrape, remove or dislodge accumulated debris, fragments or materials.

[0114] The breaking stage 128 comprises a number of sets of rollers. In the example embodiment, the breaking stage 128 comprises a first, second and third breaking roller set 162 (individual breaking roller sets denoted by different suffixes) and a first and second dislodging roller set 164 (individual dislodging roller sets denoted by different suffixes).

[0115] The breaking stage 128 therefore commences with two consecutive sets of breaking rollers 162 performing a primary breaking function. These are followed by a first set of dislodging rollers 164.1 which serves to dislodge and separate (or rip apart) fragments of plant material. The first set of dislodging rollers 164.1 is followed by a final set of breaking rollers 162.3 which performs a final breaking step, while a final set of dislodging rollers 164.2 performs a final step of dislodgement or ripping apart before fragmented or processed plant material is displaced from the shredding apparatus 102.

[0116] Each set of breaking rollers 162 is made up of two parallel breaking rollers 166, which are shown in more detail in figures 1 1 and 12. The breaking roller 166 comprises between 10 and 20 (typically 14 or 15) radially extending, and equidistantly spaced breaking segments 168. The breaking segments 168 of the rollers 166 of a particular set 162 are arranged in meshed fashion (without there being any contact between segments 168 of opposing rollers 166). The segments 168 are supported on a central hub 170 and are spaced apart, and supported, by braces 172 which are sandwiched between the segments 168. An outer diameter defined by the segments 168 is about 120 mm, with each segment 168 extending about 30 mm radially from the hub 170.

[0117] Each set of dislodging rollers 164 is made up of two parallel dislodging or ripping rollers 174, which are shown in more detail in figures 13 and 14. Each dislodging roller 174 comprises between 10 and 20 radially extending, and equidistantly spaced ripping segments 176. The ripping segments 176 of the rollers 174 of a particular set 164 are arranged in meshed fashion (without there being any contact between segments 176 of opposing rollers 174). The segments 176 are supported on a slotted central hub 178. An outer diameter defined by the segments 176 is about 120 mm, with each segment 176 extending about 40 mm radially from the hub 178. Edges of the ripping segments 176 are squared.

[0118] It will be appreciated that the system 100 provides a compact solution with which to process plant material. The inline, multi-staged nature of the shredding apparatus 102 results in a less labour-intensive process which does not require human intervention between different processing functions. Also, since the shredding apparatus 102 comprises various stages, including crushing, cutting, breaking and ripping stages, processing of the plant material into useful fragments may be achieved.

[0119] In some cases, as shown in figure 17, the system 100 may comprise further components, such as a pretreatment subsystem 200 including a raw material de-baler (shown schematically by reference numeral 202) and a feedstock stream regulator 204 which extends over the infeed conveyor 110 to regulate raw material being fed into the system. Furthermore, the system 100 may include a secondary processing subsystem 220 including a hurd processing subsystem 222 and a fibre processing subsystem 224.

[0120] In use, raw hurd which separates from the fibre falls through the screening apparatus 104 and is transported via the outfeed arrangement to a hurd pre-screening device 226 and a hurd triple-deck screening apparatus 228. These hurd screening devices may firstly remove waste and debris from the hurd (that accumulates during the decortication process) and secondly separate the hurd into courser hurd (used for the manufacture of hempcrete, poultry and equestrian bedding and the like) and finer hurd (used for pet bedding, packaging applications and the like). A hammer mill 230 may further be employed to crush oversized hurd fragments into more desirable fragment sizes. Processed hurd is transported via a chute or pipe 232 (by air) towards a hurd silo 234. Finally, a hurd bagging and / or baling arrangement 235 packages the hurd into transportable units. It will be appreciated that the outfeed conveyor 118, the pre-screening device 226, an entry to the triple-deck screening apparatus 228, the hammer mill 230 and the silo 234 may all be arranged in direct material flow communication, even though not necessarily shown as such in figure 17.

[0121] Material rejected by the screening apparatus 104 predominantly comprises of fibres (decorticated fibre), even though some hurd fragments may still be entangled therewith. Primary and second fibre cleaning arrangement (shown schematically in figure 17 by reference numerals 236 and 238 and shown in more detail in figures 15 and 16) are used to remove most if not all remaining hurd from the fibres. The primary fibre cleaning arrangement 236 comprises an entry 240 for receiving material from the screening apparatus 104 onto a drag / lattice conveyor 242. The lattice conveyor 242 is sized such that hurd is allowed to pass therethrough onto a collection structure 244 below the lattice conveyor 242. The arrangement 236 furthermore comprises a number of combing and cleaning rollers (246, 248) (which may contain ribs, bristles and the like). The combing and cleaning rollers (246, 248) may remove a portion of hurd fragments from the fibres. The secondary fibre cleaning arrangement 238 also comprises a drag / lattice conveyor 242, a collection structure 244 below the lattice conveyor 242 and a number of combing and cleaning rollers (246, 248) (which may contain ribs, bristles and the like which are finer or smaller than those of the primary arrangement 236). A further portion of hurd fragments may now be removed from the fibres. The hurd fragments collected by the collection structure 244 may be fed back to the hurd processing subsystem 222, while the cleaned and combed fibres are transported to a fibre compressing and baling arrangement 250.

[0122] It is believed that the system 100 used in accordance with the processes and steps outlined herein, can result in cost efficient processing of hemp, resulting in end products in the form of:

[0123] - 20 to 30 mm hurd, typically used the manufacture of hempcrete block making and animal bedding;

[0124] - 6 to 10 mm hurd, typically used in the manufacture of hemp lime plaster;

[0125] - Coarse fibre, typically used in the manufacture of hemp bioplastics and insulation materials;

[0126] Fine fibre, typically used in the manufacture of niche paper products and also hemp bioplastics.

[0127] The above ranges may vary and overlap.

[0128] In use, the system 100 may typically fit into, and be housed within, a standard shipping container 180. This facilitates easy transportation of the system 100 and allows the system 100 to be moved onto a location where processing needs to take place. This enables use and deployment in rural areas.

[0129] It will be appreciated that the above description only provides an example embodiment of the first aspect of the invention and that there may be many variations without departing from the spirit and / or the scope of the invention.

[0130] In some variations, the collection conveyor may serve as an outfeed conveyor for feeding processed and screened plant material out of the system. In other variations, the outfeed arrangement may include a separate outfeed conveyor for feeding processed and screened plant material out of the system.

[0131] It will easily be understood from the present disclosure that the particular features of the present invention, as generally described and illustrated in the figures, can be arranged and designed according to a wide variety of different configurations. In this way, the description of the present invention and the related figures are not provided to limit the scope of the invention but simply represent selected embodiments.

[0132] The skilled person will understand that the technical characteristics of a given embodiment can in fact be combined with characteristics of another embodiment, unless otherwise expressed or it is evident that these characteristics are incompatible. Also, the technical characteristics described in a given embodiment can be isolated from the other characteristics of this embodiment unless otherwise expressed.

[0133] Referring next to figures 18 to 20, in which like numerals indicate like features, a non-limiting example of a hemp processing system in accordance with an alternative aspect of the invention is generally indicated by reference numeral 10.

[0134] As will become clear from what follows, the processing of the hemp relates to the decortication, stripping, separation, and / or screening of particles or fragments of hemp. Specifically, the system 10 is used to separate hurd from fibres, such that these two species of particles or fragments of hemp stems can be used separately. The material, or hemp, processed by the system 10 is generally indicated by reference numeral 12. Different suffixes used with the reference numeral 12 indicate separated or screened or processed particles, fragments or fines produced by or associated with different stages or processes of the system 10. Arrows indicate streams of material 12.

[0135] The system 10 comprises a number of stages or different or separate apparatuses. These stages or apparatuses are arranged in series, and such that the material 12 can be processed in continuous fashion. However, advantageously, the different stages and apparatuses are still separate from each other to allow ease of handling, mobility, transportability, and the like.

[0136] A first stage or apparatus of the system 10 comprises a decortication apparatus 14. A second stage or apparatus of the system 10 comprises a separation apparatus 16. A third stage or apparatus of the system 10 comprises a screening apparatus 18.

[0137] It will be appreciated from what follows that the system 10, and particularly the inclusion of the second and third stages, is particularly suitable for processing wet or dry material 12, despite its relative simplicity. It has been found by the inventors, that simple decortication of dry material 12 without implementing separation and screening as provided for herein, does not allow for production of suitable or desirable end products. That said, the system 10 as outlined and described herein is still less complex and less expensive than typical or conventional processing plants.

[0138] The decortication apparatus 14 comprises a first intake roller 20 and a second intake roller 22, which are used to feed the material 12 into the decortication apparatus 14. The first and second intake rollers (20, 22) are operatively driven at a predetermined rotational speed, through a variable speed drive (VSD) 24, by a motor 26. The first and second intake rollers (20, 22), naturally, rotate in opposite directions, to allow feeding of the material 12 into the decortication apparatus 14.

[0139] The VSD 24 is used to adjust the rotational speed of the intake rollers (20, 22). Typically, the rotational speed is adjusted based on the thickness of the material, such as the thickness of stems of the material. The inventors found that feeding thicker material 12 at comparably lower speeds improves the operation and efficiency of the decortication apparatus 14. The predetermined rotational speed is adjusted using the VSD 24.

[0140] Typically, the first and second intake rollers (20, 22) are driven at a rate of between 10 Hz (600 rpm) and 15 Hz (900 rpm). For example, when comparatively thinner stems are processed, the intake rollers (20, 22) are driven at about 15 Hz, while, when thicker stems are processed, the intake rollers are driven at about 13 Hz. These slight variations in the rotational speed of the intake rollers (20, 22) have been found to be particularly beneficial in ensuring effective use of and processing with the decortication apparatus 14. Moreover, the use of the motor 26 and VSD 24, allows the rotational speed of the intake rollers (20, 22) to be adjusted and varied independently of a rotational speed of processing rollers or blades 28 of the decorticator. The rotational speed of the processing roller 28 may therefore stay relatively constant, irrespective of the thickness of the material 12. It will be appreciated that, instead of providing separate drive motors for the intake and processing rollers (20, 22, 28), a suitable gearbox arrangement coupled with a single motor may instead be provided to facilitate the driving of the intake rollers (22, 28) at varying rotational speeds relative to the rotational speed of the processing rollers 28.

[0141] The intake rollers (20, 22) are arranged in vertically stacked orientation relative to each other and define a predetermined intake spacing 30 therebetween. The first roller 20, which is a bottom roller, comprises horizontally extending angle iron sections (not shown in detail), while the second roller 22 which is a top roller comprises horizontally extending flat bar sections (again, not shown in detail).

[0142] The predetermined intake spacing 30 is selected to exert a suitable gripping force on the material 12, thereby forcing same into the decortication apparatus 14. The predetermined spacing 30 may be adjustable. As the material is fed through the processing rollers 28, the material 12 is, at least partially crushed and separated or stripped (the fibres and hurd are stripped, to a degree, from each other and from the core). Material 12.1 expelled from the decortication apparatus 14 therefore takes the form of at least partially crushed and stripped fragments or particles made up from hurd and fibres of varying size. The hurd and fibres are typically not yet separated to a degree suitable for commercial use.

[0143] The material 12.1 is therefore now introduced into the separation apparatus 16, which typically takes the form of a mechanical breaking or crushing apparatus. In the example shown and described herein, the separation apparatus 16 comprises a hammer mill, which includes a hammer mill screen 32. The hammer mill is used to further crush the material 12.1 received from the decortication apparatus 14, thereby further to separate fibres and hurd in the material 12.1. The material 12.2 flowing from the hammer mill itself has therefore further been crushed, separated and further processed compared to the material 12.1 flowing from the decortication apparatus 14.

[0144] The hammer mill screen 32 is located downstream of the hammer mill itself, and therefore screens the material 12.2 into a first and second output streams (12.3 and 12.4) of material. The first output stream 12.3 comprises material allowed to pass through the hammer mill screen, and comprises, predominantly, of hurd. The second output stream 12.4 comprises a mixture of hurd (typically larger particles) and fibres. The hammer mill screen is typically associated with openings of about 50 mm in size.

[0145] The second output stream 12.4 is fed to the screening apparatus 18. The screening apparatus typically comprises two distinct and separate screening subsystems, namely a roll sieve 34 and a screen drawer apparatus 36, which are again, arranged in series.

[0146] The roll sieve 34 comprises a substantially cylindrical drum 38 (although a cross section of the drum need not be circular, and can, as shown, be polygonal) which defines an axis of rotation 40 about which the drum 38 is driven to rotate, by a motor-gearbox unit 42.

[0147] The drum is rotated at a predetermined rotational speed, which promotes displacement of material through the roll sieve 34. The axis of rotation 40 is substantially horizontal, or may be arranged at a slight decline, to promote displacement of materials in a direction substantially along the axis of rotation 40.

[0148] The drum 38 has a first open end 43, through which the second output stream 12.4 is introduced into the drum 38.

[0149] A surface of the drum comprises a plurality of openings or apertures having a size of about 14 mm. Dynamic interaction between the material in the drum 38 and the surface thereof, causes the material to be further separated, and causes particles (typically hurd) of a predetermined size to fall through the apertures. These particles therefore take the form of a third output stream 12.5. A first collection arrangement 44 is provided underneath the drum 38, to collect this third output stream of material 12.5.

[0150] Remaining material not forming part of the third output stream 12.5, is displaced, again through dynamic interaction with the drum 38, in a direction substantially in the direction of the axis of rotation 40. This material is displaced from the drum 38 through a second open end 45 of the drum 38, as a fourth output stream 12.6 of material. This material, predominantly, comprises fibres, but still includes some pieces of hurd which has not yet been separated from the fibres.

[0151] The second screening subsystem is introduced to remove (at least a substantial amount of) the remaining hurd from the fourth output stream 12.6.

[0152] In some cases, a second collection arrangement is provided to collect (albeit temporarily) the fourth output stream 12.6. Alternatively, the fourth output stream 12.6 may be fed directly to an input portion of the second screening subsystem. The screen drawer apparatus 36 comprises at least one, but in some cases more than one inclined stages (46.1 , 46.2) of screen drawers 48, again driven by motor-gearbox units 42. The screen drawers 48 are mounted to a frame 50.

[0153] A third collection arrangement 52 is provided to collect a fifth stream of material 12.7 (predominantly hurd) screened from by the screen drawers 48, while a sixth stream of material 12.8 (predominantly fibres) is collected at an output end 54 of the screen drawer apparatus 36 by a fourth collection arrangement 56.

[0154] It will be appreciated that the first, third and fifth output streams of material (12.3, 12.5 and

[0155] 12.7) comprises predominantly of hurd fragments or particles (of varying sizes), while the sixth stream of material 12.8 predominantly comprises fibres, which may now be collected and stored.

[0156] The collected hurd (from the first, third and fifth output streams of material (12.3, 12.5 and

[0157] 12.7)) may also be collected, and fed into a further hammer mill (as a secondary crushing step) to further crush and reduce the size of the particles or fragments. An adjustable screen with sizes ranging between 6 mm and 20 mm is now used to finally screen the hurd into different sizes.

[0158] It will be appreciated that the provision of separation and screening stages as part of the system 10 facilitates proper processing of hemp, and particularly, of dry hemp, even though making use of fairly inexpensive hardware. Particularly, the separation and screening stages provide a means of effectively separating and classifying hurd and fibres.

[0159] It is believed that the system 10 used in accordance with the processes and steps outlined herein, can result in cost efficient processing of hemp, resulting in end products in the form of:

[0160] - 20 to 30 mm hurd, typically used the manufacture of hempcrete block making and animal bedding;

[0161] - 6 to 10 mm hurd, typically used in the manufacture of hemp lime plaster;

[0162] - Coarse fibre, typically used in the manufacture of hemp bioplastics and insulation materials;

[0163] Fine fibre, typically used in the manufacture of niche paper products and also hemp bioplastics.

[0164] The above ranges may vary and overlap.

[0165] It will be appreciated that the different apparatuses of the system 10 may be arranged in series, to allow material 12, and the various streams of material discussed herein, to be fed through the system 10 continuously and automatically. For example, the collection arrangements may comprise chutes that feed onto stockpiles or onto conveyor arrangements, as the case or requirement may be. The apparatuses may, however, still be individual and separate apparatuses which allows for ease of transportation and maintenance, and flexibility in terms of layout and deployment. It will be appreciated that the above description only provides an example embodiment of the invention and that there may be many variations without departing from the spirit and / or the scope of the invention. For example, the first screening subsystem may comprise alternative forms of sieves, such as sieves in the form of vibration screens, and the like. Furthermore, it is believed that the system may be used in the processing of other materials, such as flax.

[0166] It will easily be understood from the present disclosure that the particular features of the present invention, as generally described and illustrated in the figures, can be arranged and designed according to a wide variety of different configurations. In this way, the description of the present invention and the related figures are not provided to limit the scope of the invention but simply represent selected embodiments.

[0167] The skilled person will understand that the technical characteristics of a given embodiment can in fact be combined with characteristics of another embodiment, unless otherwise expressed or it is evident that these characteristics are incompatible. Also, the technical characteristics described in a given embodiment can be isolated from the other characteristics of this embodiment unless otherwise expressed.

Claims

CLAIMS1 . A plant material processing system, comprising: an inline, multistage fragmentation apparatus provided for fragmenting the plant material by pressing, separating, breaking and / or dislodging of the plant material; a screening apparatus for receiving the fragmented plant material and screening same based on size and / or type.

2. The plant material processing system according to claim 1 , wherein the plant material comprises a fibrous plant material selected from the list comprising hemp and flax.

3. The plant material processing system according to claim 1 , further comprising an infeed arrangement for feeding unprocessed plant material towards the fragmentation apparatus and an outfeed arrangement for feeding fragmented plant material from the screening apparatus.

4. The plant material processing system according to claim 1 , wherein the fragmentation apparatus comprises a decortication apparatus and / or a separation apparatus and wherein the fragmentation apparatus comprises a drive motor and / or gearbox unit for driving one or more of the stages, directly or indirectly, the motor being one of an electric, pneumatic, hydraulic and internal combustion motor.

5. The plant material processing system according to claim 1 , wherein the fragmentation apparatus includes one or more of: a guide stage; a crushing stage; a cutting stage; and a breaking stage.

6. The plant material processing system according to claim 5, wherein each stage is provided substantially in line, wherein the fragmentation apparatus defines a travel direction and wherein consecutive stages of the fragmentation apparatus are arranged downstream with regards to the travel direction.

7. The plant material processing system according to claim 5, wherein: the guide stage defines an entry into the fragmentation apparatus and comprises a first set of parallel infeed or guide rollers defining a first roller gap therebetween; the crushing stage comprises a second set of parallel infeed or guide rollers defining a second roller gap therebetween, the second roller gap being smaller than the first roller gap and the second set of infeed or guide rollers being configured as crushing rollers, operatively, at least partially, to crush the plant material; the cutting stage comprises a third set of rollers comprising a guide roller and cutting or slitter roller, the guide roller and cutting or slitter roller being spaced apart by a third gap,being a clearance gap and wherein the cutting or slitter roller comprises parallel and spaced apart ring-shaped cutting formations; and the breaking stage comprises at least a first set of breaking rollers and at least a first set of dislodging rollers.

8. The plant material processing system according to claim 7, wherein the cutting formations take the form of cutting blades, spaced apart by spacers, and wherein the cutting or slitter roller comprises between 150 and 200 cutting blades.

9. The plant material processing system according to claim 7, wherein the cutting stage includes a scraper assembly arranged proximate the cutting or slitter roller, the scraper assembly comprising a plurality of scraper blades arranged between the ring-shaped cutting formations of the cutting or slitter roller.

10. The plant material processing system according to claim 7, wherein the breaking stage comprises a plurality of sets of breaking rollers and dislodging rollers, wherein at least some of the sets of breaking rollers and dislodgement rollers are arranged sequentially.1 1 . The plant material processing system according to claim 7, wherein each breaking roller comprises a central hub with between 10 and 20 radially extending breaking segments fixed thereto or extending therefrom, wherein support braces are sandwiched between adjacent breaking segments and wherein the breaking rollers of a set are arranged in meshed fashion.

12. The plant material processing system according to claim 7, wherein the dislodging rollers take the form of ripping rollers, wherein each dislodging roller comprises a central hub with between 10 and 20 radially extending ripping segments received within radially extending slots thereof and fixed thereto and wherein the dislodging rollers of a set are arranged in meshed fashion.

13. The plant material processing system according to claim 1 , wherein the screening apparatus comprises a sorting grid which is arranged relative to an outlet of the fragmentation apparatus, the sorting grid arranged in declining or sloping fashion and associated with a predetermined aperture size, selected based on a predetermined and allowable fragment size of processed plant material and wherein the sorting grid comprises a vibrating grid.

14. The plant material processing system according to claim 3, wherein: the infeed arrangement comprises: an infeed conveyor for operatively conveying unprocessed plant material towards the fragmentation apparatus;an infeed cover or guide, which takes the form of an inlet or input to the fragmentation apparatus, the infeed cover or guide comprising a mouth portion which converges towards a throat portion, the outfeed arrangement comprises: a collection apparatus in the form of a collection conveyor, arranged proximate the screening apparatus and configured for collecting fragmented and screened plant material from the screening apparatus, the collection conveyor optionally having a travel direction opposite to a travel direction of the fragmentation apparatus whilst being situated vertically lower than the fragmentation apparatus and passing, at least partially, underneath, the fragmentation apparatus.

15. The plant material processing system according to claim 14, wherein the collection conveyor serves as an outfeed conveyor for feeding fragmented and screened plant material out of the system.

16. The plant material processing system according to claim 14, wherein the outfeed arrangement further comprises an outfeed conveyor for feeding fragmented and screened plant material out of the system and optionally, a link conveyor arranged between the collection conveyor and outfeed conveyor, such that material is operatively unloaded from the collection conveyor onto the link conveyor and unloaded from the link conveyor onto the outfeed conveyor, and wherein the collection and outfeed conveyors are arranged out of alignment, such that travel directions associated with the collection and outfeed conveyors differ, optionally such that the outfeed conveyor extends laterally to the travel direction of the fragmentation apparatus.

17. The plant material processing system according to claim 1 , further comprising a pretreatment subsystem including a raw material de-baler and a feedstock stream regulator.

18. The plant material processing system according to claim 1 , further comprising a secondary processing subsystem comprising a hurd processing subsystem and a fibre processing subsystem.

19. The plant material processing system according to claim 18, wherein the hurd processing subsystem comprises: a hurd screening arrangement; a hurd milling arrangement in the form of a hammer mill; and a hurd bagging or baling arrangement.

20. The plant material processing system according to claim 18, wherein the fibre processing subsystem comprises: a fibre combing and cleaning arrangement; and a fibre compressing and baling arrangement.21 . The plant material processing system according to claim 19, wherein the fibre combing and cleaning arrangement comprises one or more conveyor arrangements comprising holding, transfer and combing components.

22. A plant material processing method, comprising the steps of: providing a plant material processing system in accordance with claim 1 ; feeding plant material into an inline, multistage fragmentation apparatus and using same to fragment the plant material by pressing, breaking, fragmenting, separating, dislodging and / or shredding the plant material; using a screening apparatus to screen the fragmented plant material based on size and / or type; collecting screened material from the screening apparatus.

23. The plant material processing method according to claim 22, wherein the fragmentation or shredding of the plant material involves at least some of the sub-steps of:- crushing the plant material;- cutting the plant material;- breaking the plant material; and / or- dislodging the plant material.

24. The plant material processing method according to claim 22, comprising secondary hurd processing comprising: screening the hurd; milling the hurd using a hammer mill; and bagging or baling the hurd.

25. The plant material processing method according to claim 22, comprising the secondary fibre processing steps of: combing and cleaning the fibres; and compressing and baling the fibres.

26. A plant material processing system, comprising: a decortication apparatus, for receiving the plant material and stripping same; a separation apparatus for receiving stripped material and crushing same into separate pieces; and a screening apparatus for receiving the crushed material and screening same based on size and / or type.

27. The plant material processing system according to claim 26, wherein the plant material comprises a fibrous plant material selected from the list comprising hemp and flax.

28. The plant material processing system according to claim 26, wherein the screening apparatus comprises at least a first screening subsystem in the form of a first sieve.

29. The plant material processing system according to claim 28, wherein the first sieve takes the form of a roll sieve which: defines a substantially horizonal axis of rotation about which the roll sieve is driven operatively to rotate, at a predetermined rotational speed; is associated with a first open end, through which crushed material is operatively received and a second open end; comprises a plurality of apertures associated with a first aperture size, being in the range of 10 mm to 20 mm; is associated with a first collection arrangement, arranged operatively to collect particles or fragments screened by the roll sieve, which first collection arrangement is arranged below the roll sieve to collect particles or fragments falling through the apertures under gravity from the roll sieve; is associated with a second collection arrangement, which is arranged in communication with the second open end, wherein the roll sieve is configured to allow particles not passing through the apertures to be displaced substantially in the direction of the axis of rotation, and to be deposited through the second open end, to be collected by the second collection arrangement.

30. The plant material processing system according to claim 28, wherein the screening apparatus comprises a second screening subsystem in the form of a screen drawer apparatus, wherein: the screen drawer apparatus is associated with a third collection arrangement for collecting screened or separated particles; the screen drawer apparatus is associated with a fourth collection arrangement for collecting remaining particles; a feed portion of the screen drawer apparatus is provided in fluid flow communication with a second collection arrangement of the first sieve, to allow particles operatively to be fed from the first sieve to the screen drawer apparatus.

31. The plant material processing system according to claim 26, wherein the decortication apparatus comprises first and second intake rollers, with which plant material is fed into to the decortication apparatus, wherein the first and second intake rollers are arranged in vertically stacked orientation relative to each other to define an intake spacing therebetween, wherein the first roller comprises horizontally extending angle formations and wherein the second roller comprises horizontally extending flat formations.

32. The plant material processing system according to claim 26, the separation apparatus comprises a mechanical means of breaking or crushing the material received from the decortication apparatus.

33. The plant material processing system according to claim 32, wherein the separation apparatus comprises a hammer mill provided with a screen associated with openings of about 50 mm in size.

34. The plant material processing system according to claim 26, comprising a further crushing apparatus which is associated with an adjustable screen operatively used to screen material, particles or fragments based on size.

35. The plant material processing system according to claim 26, wherein the decortication, separation and screening apparatuses are arranged in series, such that material is operatively continuously be fed from the one to the other.

36. A plant material processing method, comprising the steps of: providing a plant material processing system in accordance with claim 26; feeding plant material into a decortication apparatus of the system, and decorticating the material; collecting the decorticated material and feeding same to a separation apparatus; using the separation apparatus to separate the material, and collecting the separated material; feeding at least a portion of the separated material to a screening apparatus; and collecting screened material from the screening apparatus.

37. The plant material processing method according to claim 36, wherein the decortication device comprises first and second intake rollers, and wherein the method comprises driving the first and second rollers a predetermined rotational speed through a variable speed drive (VSD) by a motor, the predetermined rotational speed adjusted by the VSD based on a thickness of material fed into the decortication apparatus.

38. The plant material processing method according to claim 37, wherein the predetermined rotational speed is varied between 10 Hz (600 rpm) and 15 Hz (900 rpm) and wherein the rotational speed is relatively higher when relatively thinner material is fed into the decortication apparatus, and relatively lower when relatively thicker material is fed into the decortication apparatus.

Images