Multifunctional automated multi cassette filling and stacking line of kasmar cheese and pasty foods with robotic arm

Abstract

The present invention relates to a production line (10) for the portioning and weighing of pasty products, especially kashar cheese, placing them in multiple molds (15) and transporting these multiple molds (15) in the production of pasty foods, and to a production method. The production line (10) and production method, which are the subject of the invention provide a significant improvement in the food sector by offering many advantages such as minimizing hygiene problems, increasing space efficiency, reducing manpower needs and saving energy.

Description

[0001] MULTIFUNCTIONAL AUTOMATED MULTI CASSETTE FILLING AND STACKING LINE OF KASHAR CHEESE AND PASTY FOODS WITH ROBOTIC ARM

[0002] Field of the Invention

[0003] The present invention relates to a production line and method for portioning and weighing pasty products, placing them in molds and transporting these molds in the production of pasty foods, especially kashar cheese.

[0004] In particular, the invention relates to a production line and method designed for the production of kashar type cheeses, which is designed to ensure that the products in the form of dough in the production process of kashar type cheeses are processed into certain weights and placed in molds, and then these molds are transported in an orderly manner, which automatically directs the mold trays to the weighting machine with the feeding-grading line and provides an orderly stacking process so that the trays can be collected and transported again after filling.

[0005] State of the Art

[0006] In the current state of the art, after the scalding process, the cheese dough at certain temperatures is portioned into the desired weights in the grading machine and then placed on the deck mold carts by hand. The products are kept in the production area for a while and their temperature is reduced before being transported to the ripening rooms. However, this process causes the products to be kept in an uncontrolled and irregular manner, causing hygiene, cost and quality problems. In addition, the time lost here causes disruptions in the production line and the need for excess manpower.

[0007] The removal of the cheese molds by hand is done after approximately 8-10 hours. At this stage, the dismantled molds are washed in a separate section and then manually stacked on multi-layer mold carts to prepare them for the next production stage. However, production with this method is inadequate in industrial application; hygiene problems reach unacceptable levels in terms of today's production technologies. In the mass production of kashar type products, difficulties related to placing portioned products into molds and movement in subsequent production steps are tried to be overcome by using multiple mold trays. Weighing and filling technologies in the industry have been designed and deployed to accommodate these multiple molds. However, in practice, there are significant deficiencies in the feeding of multiple mold trays into the filling process and their collection and re-stacking at the process exit. Feeding, collecting and stacking trays based on human power creates heavy loads and workload that are not suitable for manual handling. This situation causes food spoilage and waste as well as hygiene problems.

[0008] It is known that there are elevator systems that work with various techniques for feeding and collecting multiple mold trays to the next processes. However, it is also known that existing fully automatic mold feeding and stacking systems take up a large amount of space in terms of area and height. At this point, cartesian stacking technologies developed as an alternative to two-stage elevator systems attract attention. In both systems, a certain ceiling height is required for the tower structures. This situation offers an important development area in terms of increasing efficiency, ensuring hygiene and reducing labor costs in industrial production processes. Integration of automated systems is essential to optimize the process and eliminate such problems.

[0009] One of the structures developed for the purpose of stacking multi-mold trays is the invention subject to the patent application numbered TR2013 / 03057 and titled "Removing kashar cheese from multi-molds and empty mold stacking system". The present invention relates to a system for removing kashar cheese from multiple molds and stacking empty molds, which enables the rested kashar cheese poured into multiple molds to be automatically removed from multiple molds at once and the emptied multiple molds to be stacked before cleaning.

[0010] Another study is the invention that is the subject of the utility model application numbered TR 2012 / 08410 and titled “Stacking unit”. The invention relates to a stacking unit that basically provides fast, standard and automatic processing of cheese products, including a filling conveyor on a cheese line direction and a filling machine where the cheese filling process is carried out, characterized in that the stack waiting conveyor comprises a lifting tower for lifting the cheese molds onto the conveyor, a stack opening tower for opening the stacks waiting on the conveyor and sending them to said filling conveyor and said filling machine, a stacking tower for re-stacking the filled cheese molds, and a stacking conveyor, the stacking conveyor comprising a lowering tower for lowering the whey-discharged cheese molds onto a plane or cart.

[0011] Today, the continued competitiveness of commercial products in the market is possible through the implementation of the right digital solutions. Existing technologies and solutions for the movement of mold trays in the production line of kashar type products are inadequate in managing the costs of mass production and poor quality. For this fundamental reason, it has become necessary to develop a sustainable solution that is compatible with the flow of molded trays in the production line in the industrial production of kashar type products and has a communication and machine learning infrastructure with other technologies available in the production line. As a result, the need for a multifunctional automatic multi-cassette filling and stacking line of Cheddar cheese and pasty foods with robotic arm that eliminates the disadvantages of the existing technique and the inadequacy of the existing solutions necessitated a development in the relevant technical field.

[0012] Brief Description of the Invention

[0013] The present invention relates to a production line and method for the production of pasty foods, in particular Cheddar cheese, which meets the above-mentioned requirements, eliminates all disadvantages and brings some additional advantages, for the production of doughy foods, especially Cheddar cheese, and for the production line and method for the production of pasty products in the form of dough, weighting them, taking them into molds and transporting these molds.

[0014] Based on the state of the art, the object of the invention is to increase food safety and prevent food waste by providing an uninterrupted and efficient production chain without human intervention thanks to the developed production line.

[0015] The object of the present invention is to reduce product losses by preventing microbiological spoilage of high protein foods such as cheese by improving hygienic conditions in the production line.

[0016] Another object of the present invention is to provide a safer production environment by minimizing the risks of contamination from contact surfaces and personnel.

[0017] Another object of the present invention is to ensure that the production process continues without interruption thanks to the automatic system carried out without the use of human hands and power, thus reducing both time loss and the need for manpower.

[0018] Another object of the present invention is to shorten the total production time by ensuring time and energy efficiency and to enable more efficient use of resources.

[0019] Another object of the present invention is to provide an area gain of approximately 10 m2and to increase the efficiency of the production facility by optimizing the use of existing space in the developed production line. Another object of the present invention is to eliminate the ceiling height requirement thanks to the cartesian stacking technology, thus making it more suitable for existing facilities.

[0020] Another object of the present invention is to eliminate the need for two operators by automating mold feeding and transfer operations, to reduce labor costs, to reduce the number of personnel and to increase the overall productivity of the enterprise.

[0021] Another object of the present invention is to provide advantages in terms of both hygiene and efficiency thanks to automatic feeding of the weighing machine without touching it.

[0022] Another object of the present invention is to create a fluid workflow on the line by automatically collecting and stacking the products.

[0023] Another object of the present invention is to ensure that products are transported and stored safely through remote access and modified atmosphere applications, thus increasing product quality while meeting hygiene requirements.

[0024] Another object of the present invention is to ensure that food products remain fresh for a longer period of time by improving the production to meet the hygiene requirements with the modified atmosphere application.

[0025] Another object of the present invention is to enable the mass production process to continue uninterruptedly thanks to the system structure of the developed method that does not require an operator.

[0026] The structural and characteristic features of the present invention will be understood clearly by the following drawings and the detailed description made with reference to these drawings and therefore the evaluation shall be made by taking these figures and the detailed description into consideration.

[0027] Brief Description of the figures

[0028] In order to understand the advantages of the present invention with its structure and additional elements, it shall be evaluated with the following defined figures.

[0029] Figure-1 is the schematic general view of the production line from above,

[0030] Figure-2 is the schematic general view of the production line from the side, Figure-3 is the schematic general view of the conveyor group,

[0031] Figure-4 is the schematic general view of the gripper, Figure-5 is the schematic general view of the multiple mold.

[0032] Reference Numbers

[0033] 10. Production line

[0034] 11 . Outlet throat group

[0035] 12. Grading filling group

[0036] 13. Conveyor group

[0037] 14. Gripper

[0038] 15. Multiple mold

[0039] 16. Carrier equipment

[0040] 17. Carrier robot

[0041] 18. Discharging / feeding area

[0042] 19. Filling / stacking area

[0043] D1 : Multi-mold filling process travel distance

[0044] Detailed Description of the Invention

[0045] In this detailed description, a production line (10) and production method for portioning and weighing pasty products in the production of pasty foods, primarily kashar cheese, which is the subject of the invention, taking them into multiple molds (15) and transporting these multiple molds (15) are explained only as an example for a better understanding of the subject and in a way that does not create any limiting effect.

[0046] The production line (10) and production method, which are the subject of the invention shown in Figure 1 , provide a significant improvement in the food sector by offering many advantages such as minimizing hygiene problems, increasing space efficiency, reducing manpower needs and saving energy. These innovations will help businesses both reduce costs and improve product quality. At the entrance part of the aforementioned production line (10); on the one hand, there is the filling / stacking area (19) where the multiple molds (15), which exit from the grading filling group (12) and contain products, are picked up by the carrier robot (17) with the gripper (14) mechanism over the conveyor group (13) and left to be stacked; on the other hand, there is the discharging / feeding area (18) where the stacks of multiple molds (15) are ready to be conveyed to the grading filling group (12) by the conveyor group (13). Between the aforementioned filling / stacking area (19) and the discharging / feeding area (18), a carrier robot (17) is positioned, which controls the mechanical movement of the gripper (14) mechanism and ensures that multiple molds (15) are held by the gripper (14) and moved in the desired axis. There is a grading filling group (12) in the middle section of the production line (10) shown in Figure 2, in order to transfer the cheese dough into the multiple mould (15) by portioning it into the desired weight. At the front part of the mentioned grading filling group (12), there is the outlet throat group (11) which transmits the cheese dough to the grading filling group (12) at the desired speed and volume. The conveyor group (13) shown in Figure-3 ensures the entry and exit of multiple molds (15) to the mentioned grading filling group (200) at the desired speed. At the front of the carrier robot (17) shown in Figure 4, a gripper (14) suitable for its shape and weight is positioned to lift and lower multiple molds (15) in the vertical direction. The stacks of multiple moulds (15) located in the filling / stacking area (19) are transported by the carrier equipment (16). The cheese doughs, which are positioned in the multiple moulds (15) shown in Figure 5, portioned in the desired weight, melted at a certain temperature and with a tendency to stick, gain the desired semi-hard form depending on time and cooling.

[0047] In the aforementioned production line (10), the main measurement path of the multi-mold filling process movement distance (D1 ) between the discharging / feeding area (18) and the filling / stacking area (19) is reduced to the distance between the mold inlet and the product outlet of the conveyor group (13), which is positioned relative to the grading filling group (12), which transitions to a compact structure with the multi-axis motion function of the carrier robot (17). The carrier robot (17), which is positioned on the conveyor group (13) to provide the function of feeding and collecting multiple molds (15) from a single point, provides multi-axis electro-mechanical control of the gripper (14) mechanism and ensures the movement of multiple molds (15) from the discharging I feeding area (18) to the filling / stacking area (19) at the shortest movement distance (D1) and with the desired flexibility under process conditions.

[0048] In the method of the invention developed for portioning and weighing the products in dough form in the production of pasty foods, especially kashar cheese, for taking them into multiple molds (15) and for transporting these multiple molds (15), the stacked multiple molds (15) are made ready for use in the discharging / feeding area (18). The carrier robot (17) places the empty multiple moulds

[0049] (15) stacked on the carrier equipment (16) one by one on the conveyor group (13) at the appropriate processing speed. The multiple molds (15) on the conveyor group (13) are advanced in accordance with the process time in the grading filling group (12). Then, in the grading filling group (12), the product is filled into multiple molds (15). Then, the filled multiple moulds (15) are taken from the conveyor group (13) by the carrier robot (17) and placed on the carrier equipment

[0050] (16) in the filling / stacking area (19). When the desired stacking height is reached, a new stacking is started on the empty carrier equipment (16). If necessary, the empty carrier equipment (16) is carried to the filling / stacking area (19) by the carrier robot (17) with the gripper (14) mechanism.

[0051] In the shortening of the transport distance of the aforementioned multiple molds (15), the functionalization of the use of the working area and the elimination of the need for an operator; the multi-axis motion function that the carrier robot (17) adds to the gripper (14) mechanism with electro-mechanical control enables the gripper (14) mechanism to move the handling equipment (16) to the desired position in the working area like multiple molds (15).

Claims

CLAIMS1. A production line (10) for the portioning and weighing of pasty products, especially kashar cheese, placing them in multiple molds (15) and transporting these multiple molds (15) in the production of pasty foods, characterized by comprising;- A gripper (14) positioned at the front of a carrier robot (17) for lifting and lowering multiple moulds (15) in a vertical direction;- The carrier robot (17) positioned between a filling / stacking area (19) and a discharging / feeding area (18) to control the mechanical movement of the gripper (14) mechanism, to hold the multiple molds (15) by the gripper (14) and move them in the desired axis, and to perform the feeding and collecting function of the multiple molds (15) from a single point.

2. Production line (10) according to claim 1 , characterized by comprising; a compact conveyor group (13) for the inlet and outlet of multiple molds (15) at the desired speed to and from the grading filling group (12).

3. Production line (10) according to claim 1 , characterized by comprising; a carrier equipment (16) for transporting multiple stacks of molds (15) in the filling / stacking area (19).

4. Production line (10) according to claim 1 , characterized by comprising; the multi-axis motion function of the carrier robot (17) and the compact conveyor group (13) comprises a multi- mold filling process travel distance (D1) reduced to the distance from the mold inlet to the product outlet positioned relative to the grading filling assembly (12).

5. A production method for the portioning and weighing of pasty products, especially kashar cheese, placing them in multiple molds (15) and transporting these multiple molds (15) in the production of pasty foods, characterized by comprising the process steps of;- the carrier robot (17) placing the empty multiple moulds (15) stacked on the carrier equipment (16) one by one on the conveyor group (13) at the appropriate processing speed.- then, the filled multiple moulds (15) being taken from the conveyor group (13) by the carrier robot (17) and being placed on the carrier equipment (16) in the filling / stacking area (19),- when the desired stacking height is reached, a new stacking being started on the empty carrier equipment (16).

6. Production line (10) according to claim 5, characterized by comprising; the process step of transporting empty carrier equipment (16) to the filling / stacking area (19) by the carrier robot (17) with the gripper (14) mechanism.

7. Production line (10) according to claim 5, characterized by comprising; the process step wherein the carrier robot (17) adds a multi-axis motion function to the gripper (14)mechanism by electro-mechanical control, and the gripper (14) mechanism moves the conveying equipment (16) to a desired position in the work area, such as multiple molds (15).

8. Production line (10) according to claim 5, characterized by comprising; the process step of feeding and collecting multiple molds (15) to the conveyor group (13) by a carrier robot (17) from a single point.

9. Production line (10) according to claim 5, characterized by comprising; the process step of multi-axis electro-mechanical control of the movement of the gripper (14) mechanism by the carrier robot (17).

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