Automatic production line able to fill, freeze, cook, slice and cut meat and similar products

Abstract

The system in question is about an automatic production line that enables the filling, freezing, cooking, slicing and cutting processes of meat and similar products to be carried out on a single line, and comprises chain driven roller conveyor (1), product shocking and freeze forming mould (2), mould cover (3), mould front cover mounting unit (4), mould rear cover mounting unit (5), mould product filling unit (6), product shocking and freezing unit (7), hot water spray unit (8), mould cover opening unit (9), X1 axis mechanism (10), Y1 axis mechanism (11), cutting blade unit (12), Y2 axis mechanism (13), cooking unit (14), X2 axis mechanism (15), heat insulation panel (16), conveyor belt unit (17), hot water spray units (18), hot air blowing unit (19), heat sensor unit (20), and cutting width adjustment blade (21).

Description

[0001] AUTOMATIC PRODUCTION LINE ABEE TO FILL, FREEZE, COOK, SLICE AND CUT MEAT AND SIMILAR PRODUCTS

[0002] The system in question is about an automatic production line that enables the filling, freezing, cooking, slicing and cutting processes of meat and similar products to be carried out on a single line with zero-touch, with less energy consumption, fewer personnel and less cost, in a fully automatic manner.

[0003] With said system, meat and similar products such as veal meat, sheep meat, pork meat, poultry meat, vegan meat are produced on an automation line with zero-touch, with less energy consumption, fewer personnel and less cost. The disadvantages of similar systems are as follows; the product is produced with multiple machines, personnel, labour and costly facilities that take up a larger area. For example, if we take a facility with a meat slicer and doner cutting machine that produces a similar product as a basis, a larger filling and freezing mould is used for meat and similar products to increase production capacity. These large moulds take up a lot of space and filling the product is very difficult. In the current sector, there is a filling unit and machine that takes up a lot of space and is costly for filling the product. In addition, the products filled in the moulds are very difficult to transport (move) due to the size and weight of the mould. Freezing these product-filled moulds requires very high-cost, large-area could storages.

[0004] The large moulds used to increase production capacity have an average volume of 300 kg. Shocking meat and similar products with a volume of 300 kg takes approximately a minimum of 3 days. This period requires both a very large cold storage and greatly increases energy consumption and costs. In addition, a separate large cold storage is required for the storage and stacking of the shocked and frozen product. This separate cold storage also takes up too much space, causes too much energy consumption and increases costs. In addition, the empty weight of these large-volume moulds is an average of 100 kg. A minimum of 3 moulds are required for one cutting station in a shift. Each mould takes up an average of 1 m2of space. A minimum of 3 m2of cold storage space is required for one shift. When the product is filled, the weight of the mould becomes an average of 400 kg. It is quite difficult to carry and move this large and heavy mould. It also requires a lot of personnel to carry and move it. In addition, carrying these heavy moulds carries a high risk factor due to the possibility of causing a work accident.

[0005] In order for the mould filled with the product that has been shocked and frozen to be attached to the slicing, cutting or doner robot, its covers must be opened. However, opening the covers is quite difficult since the mould is frozen together with the product. In order for the covers of the frozen mould to be opened, the ice on its surface must be thawed. For this, a staff member sprays hot pressurised water onto the mould covers. During this time, the ground becomes slippery and this causes loss of time. It causes risks such as personnel slipping and falling or being harmed by hot water and threatens the work safety of the personnel.

[0006] The product removed from the mould must be carried and placed in a slicing, cutting or doner robot. A separate lift and similar machine is used to carry this large-volume product and place it in the machine to be cut. This also increases the facility cost. There is also a need for personnel to use this machine and provide this process. In addition, it takes a lot of time to carry and place the large-volume heavy product in the machine. Since the product is heavy, it is quite risky and dangerous to carry and place it in the machine. It threatens the life safety of the personnel and increases the risk of work accidents.

[0007] Powerful ovens / grills are needed to cook large-volume products. There is a metal apparatus located in a certain part of the product (usually in the middle) that allows the product to be attached to the machine to be cut and to remain fixed. This apparatus must be removed from the machine after the cutting is finished. These powerful ovens / grills cause the metal apparatus to become very hot. When the personnel remove this apparatus from the machine, the risk of injury is high because the apparatus is very hot. This situation threatens the health of the personnel and increases the risk of work accidents. The moulds from which the product is removed must be washed and disinfected in order to be used again. The washing and disinfection of these large-volume moulds also requires a large section and personnel in the facility. This situation increases the company's expenses and the need for facility size.

[0008] In the current sector, in order to provide the same production as our invention’s system, it is necessary to create a high-capacity facility, use powerful ovens / grills and large-volume machines. These high-capacity facilities in the current sector require more personnel and more energy than our invention’s system, and the cost of establishing this facility is very high. The risk of work accidents in these facilities is very high and the probability of the products produced being hygienic is lower.

[0009] In current systems, the cylindrical meat product must be shaved to equalise its diameter at the beginning of the cutting. This shaving process causes product loss.

[0010] With our system, which is the subject of our invention, quality products are produced with less energy and manpower in a hygienic manner without human touch. It is an automatic product processing line that malfunctions less than existing systems, causes less product loss, provides more energy savings, produces higher quality and hygienic products with less personnel, and minimises the risk of work accidents. Said system can be used in factories and restaurants that perform advanced production.

[0011] The invention is explained below, with reference to the attached figures.

[0012] These figures are;

[0013] Figure 1- Top right perspective view of automatic production line for meat and similar products

[0014] Figure 2- Top left perspective view of automatic production line for meat and similar products

[0015] Figure 3- Multiple back top perspective views of automatic production line for meat and similar products Figure 4- Multiple left top perspective views of automatic production line for meat and similar products

[0016] Figure 5- Multiple left perspective views of automatic production line for meat and similar products

[0017] Figure 6- Detail A perspective view of automatic production line for meat and similar products

[0018] Figure 7- Detail B perspective view of automatic production line for meat and similar products

[0019] Figure 8- Detail C perspective view of automatic production line for meat and similar products

[0020] Figure 9- Detail D perspective view of automatic production line for meat and similar products

[0021] The parts in the figures are numbered one by one, and the parts corresponding to these numbers are explained below:

[0022] I - Chain driven roller conveyor

[0023] 2- Product shocking and freeze forming mould

[0024] 3- Mould cover

[0025] 4- Mould front cover mounting unit

[0026] 5- Mould rear cover mounting unit

[0027] 6- Mould product filling unit

[0028] 7- Product shocking and freezing unit

[0029] 8- Hot water spray unit

[0030] 9- Mould cover opening unit

[0031] 10- XI axis mechanism

[0032] I I - Y1 axis mechanism

[0033] 12- Cutting blade unit

[0034] 13- Y2 axis mechanism

[0035] 14- Cooking unit

[0036] 15-X2 axis mechanism

[0037] 16- Heat insulation panel 17- Conveyor belt unit

[0038] 18- Hot water spray unit for cleaning

[0039] 19- Hot air blowing unit

[0040] 20- Heat sensor unit

[0041] 21- Cutting width adjustment blade

[0042] 22- Product

[0043] The invention is an automatic production line system for meat and similar products, comprising chain driven roller conveyor (1), product shocking and freeze forming mould (2), mould cover (3), mould front cover mounting unit (4), mould rear cover mounting unit (5), mould product filling unit (6), product shocking and freezing unit (7), hot water spray unit (8), mould cover opening unit (9), XI axis mechanism (10), Y1 axis mechanism (11), cutting blade unit (12), Y2 axis mechanism (13), cooking unit (14), X2 axis mechanism (15), heat insulation panel (16), conveyor belt unit (17, hot water spray units for cleaning (18), hot air blowing unit (19), heat sensor unit (20), and cutting width adjustment blade (21).

[0044] The product (22) to be produced with our system, which is the subject of the invention, starts with the automatic movement of the product shocking and freeze forming mould (2) on an automation line with a chain driven roller conveyor (1). The product shocking and freeze forming mould (2) is a metal apparatus into which the meat and similar products (22) to be cut are filled. This metal mould (2) allows the product (22) to be cut to be frozen and to take a rectangular shape. The mould (2) is connected to the chain of the conveyor (1) in order to move synchronously. The chain driven roller conveyor (1) ensures that the moulds (2) stop and move in the necessary areas at the stations on the line. The moulds (2) advance on the line according to the production process conditions by means of this conveyor (1) and all operations are carried out on this line. First of all, the mould covers (3) are attached to the front and back parts of the mould (2) moving on the automatic line, by means of an automatic mechanism in mould front cover mounting unit (4) and mould rear cover mounting unit (5) located on the line. This process is done so that the meat and similar products (22) to be filled do not flow out of the mould (2) and take the form of the mould (2). The mould (2), whose cover (3) is closed, moves on the line and the mould stops at product filling unit (6), the product (22) is automatically filled into the mould (2) without human touch. The filled product (22) continues to move on the line with the mould (2), the product automatically moves to product shocking and freezing unit (7).

[0045] In the product shocking and freezing unit (7), the product (22) inside the mould (2) is shocked and frozen and waits there for a while (the cooking and cutting time of the product in the mould at the end of the line). The purpose of shocking and freezing the product (2) is to ensure that the product (22) takes the form of the mould (2) and has a homogeneous structure. In addition, this process prevents the product (22) from thawing easily and the product (22) from scattering during cutting. The shocked and frozen product (22) moves on the line to be cooked and cut.

[0046] In order for the shocked and frozen product (22) to be cut, the mould covers (3) must first be opened. This process is very difficult since the mould (2) is shocked and frozen. Therefore, in order for the covers (3) to be opened easily, pressurised hot water is sprayed onto the mould covers (3) with the nozzle in the hot water spray unit (8). Then, by means of the mould cover opening unit (9) on the same line, the mould covers (3) are automatically opened for cutting. The full mould (2), whose covers (3) are opened, moves along the line and comes to cutting blade unit (12).

[0047] The product (22) in the mould (2) is cooked in cooking unit (14) with a cooking device similar to a grill, stove, radiant or oven, and is cut step by step from top to bottom with the Y2 axis mechanism (13), which is the mechanism that allows the cutting blade unit (12) to move up and down on the vertical axis with a band saw, knife or a different mechanism in the cutting blade unit (12); for this cutting process, the product (22) is pushed forward with the XI axis mechanism (10) and is brought closer to the blade part as much as the cutting thickness. This process is repeated until the frozen product (22) in the mould (2) is completely cut and the product (22) is sliced by means of the band saw in the cutting blade unit (12). The surface temperature of the product (22) is measured by means of the heat sensor unit (20) connected to an apparatus and it is determined whether the product (22) is ready for cutting and whether it is cooked or not. With the help of this unit, the product (22) cannot be cut without being cooked. In this way, a higher quality cooked product (22) is produced.

[0048] The XI axis mechanism (10) ensures that the product (22) is cut to the desired thickness; the thickness of the cooked product can be adjusted by means of this mechanism. The up and down movement of the XI axis mechanism (10) on the vertical axis is also provided by the Y1 axis mechanism (11). By means of the Y1 axis mechanism (11), the mould (2) filled with product (22) is passed to the cutting blade unit (12), the XI axis mechanism (10) remains behind the mould (2) and the product (22) is pushed inside the mould (2). The cutting width adjustment blade (21) connected to the cutting blade unit (12) cuts the rectangular product (22) from a predetermined point from top to bottom in a way that will be the thickness to be cut, and ensures that the product (22) is cut to the desired width, the slice width of the product (22) advancing inside the mould (2) is adjusted at the desired range, and it is divided to the desired width from top to bottom.

[0049] There is an X2 axis mechanism (15) that adjusts the proximity or distance of the cooking unit (14) to the product (22) that is being cooked and advanced inside the mould (2) to be cut. This mechanism carries the cooking unit (14) and moves it forward or backward on the horizontal axis, bringing it closer to or away from the product (22). In this way, a more optimum quality and faster cooking is ensured according to the type of product (22) to be cut. There is a heat insulation panel (16) that prevents heat transfer, during the cooking of the product (22), between the place where the mould (2) is stored and needs to remain cold during cutting and the place where it is cooked and needs to remain high, and maintains and insulates the temperature of the places on the line that need to remain cold and hot.

[0050] The cooked, cut and sliced product (22) falls onto the conveyor belt (17) and is transferred to the freezing and packaging sections of the facility. The emptied mould (2) moves on the line to return to the filling section and be used again. There are hot water spray units for cleaning (18) that allow the mould (2) to be washed and cleaned automatically on the line without touching. This unit (18), located in the return section of the conveyor (1) of the line, washes and cleans the mould (2) with hot pressurised water by means of the nozzle and disinfects the mould (2) for reuse. Hot air blowing unit (19), which ensures that the washed and disinfected mould (2) is dried and that water droplets do not leave stains on the mould (2), is also located on the line.

[0051] While a product (22) in the mould (2) is being cut on the same line, the product (22) in another mould (2) that is filled is shocked at the same time.

[0052] The system that is the subject of the invention cannot be limited to what is described here and to the model shown in the picture. Changes can be made to the shape of the invention without depending on the material and size, the places of the parts used can be changed, the number of parts used can be changed, different parts with similar features can be used instead of the used parts, and the system can be used without some parts if desired.

[0053] For example;

[0054] - Instead of the chain driven roller conveyor (1), a different similar system can be used on the automation system.

[0055] - Instead of the band saw in the cutting blade unit (12), the product (22) can be sliced with a knife or a different mechanism.

[0056] - If the filling of the product (22) into the mould (2) is desired to be done manually rather than automatically, the mould product filling unit (6) can be lifted from the line and the filling can be done manually.

[0057] - Instead of the product shocking and freezing unit (7) being separate in modules, a single large freezing chamber can be made for the cutting line modules placed side by side.

[0058] - Instead of the XI axis mechanism (10) pushing the product (22) in the mould (2) being separate in multiple modules, the XI axis mechanism (10) in the cutting line modules placed side by side can be used synchronously with a single mechanism in all lines as a single piece.

[0059] - Instead of pushing the product (22) in the mould (2), the product (22) can be left fixed and the knife can be brought closer to the product (22) with another mechanism. The cutting width adjustment blade (21) can be used with a circular, flat or ultrasonic similar mechanism.

[0060] The shape of the product shocking and freeze forming mould (2) can be in different shapes such as square, triangle etc., other than rectangular.

Claims

CLAIMS1) Production line for meat and similar products, comprising: chain driven roller conveyor (1) that allows the moulds (2) to stop and move forward in the required areas at the stations on the line, product shocking and freeze forming mould (2), which is a metal apparatus into which the meat and similar products (22) to be cut are filled, mould covers (3) that allow the front and back of the mould (2) to be closed by means of the mould front cover mounting unit (4) and mould rear cover mounting unit (5), mould front cover mounting unit (4) and mould rear cover mounting unit (5), which enable the automatic mounting of the covers (3) of the mould (2), product filling unit (6) where the product (22) is automatically filled into the mould (2) whose covers (3) are closed, without human contact, product shocking and freezing unit (7), which allows the product (22) inside the mould (2) to be frozen and take the shape of the mould (2) and have a homogeneous structure, hot water spray unit (8) from which pressurised hot water is sprayed onto the mould covers (3) so that the mould covers (3) can be opened easily, mould cover opening unit (9) that automatically opens the mould covers (3) for cutting,- XI axis mechanism (10) that determines the thickness of the product (22) to be cut by pushing the product (22) inside the mould (2),Y1 axis mechanism (11) that allows the mould (2) filled with product (22) to be passed to the cutting blade unit (12), cutting blade unit (12) that enables the product (22) inside the mould (2) to be cut,Y2 axis mechanism (13) that allows the cutting blade unit (12) to move up and down on the vertical axis, cooking unit (14) that enables the product (22) inside the mould (2) to be cooked with a cooking device,- X2 axis mechanism (15) that adjusts the proximity or distance of the cooking unit (14) to the product (22) that is advanced to be cooked and cut in the mould (2),heat insulation panel (16) that prevents heat transfer, during the cooking of the product (22), between the place where the mould (2) is stored and needs to remain cold during cutting and the place where it is cooked and needs to remain high and maintains and insulates the temperature of the places on the line that need to remain cold and hot, conveyor belt (17) that transfers the cooked, cut and sliced product (22) to the desired point in the facility, hot water spray unit for cleaning (18) that allows the mould (2) to be washed and cleaned automatically on the line without touching it, hot air blowing unit (19) that ensures that the disinfected mould (2) is dried and that water droplets do not leave stains on the mould (2), heat sensor unit (20) that measures the surface temperature of the product (22) and determines whether the product (22) is ready for cutting and whether it is cooked or not, and cutting width adjustment blade (21) that is connected to the cutting blade unit (12) and ensures that the product (22) to be cut is cut to the desired width by making a line on the product (22) from a predetermined point, from top to bottom, in the thickness to be cut, that the slice width of the product (22) advancing in the mould (2) is adjusted within the desired range, and that it is divided to the desired width from top to bottom.

Images