Automated Mould Opening and Closing Plant for Food Processing
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Solution Overview
Problem
Existing plants for treating food products, such as hams, require laborious and time-consuming manual operations to open and close mould elements, leading to high labor, energy, and cost expenditures.
Innovation Solution
A plant with automated apparatuses for opening and closing moulds, utilizing a system of interlocking tubular elements and automated conveying and actuating mechanisms to facilitate the extraction and reinsertion of pressing rods, allowing for automated operation and reduced manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operations are used to open and close mould elements, then operational simplicity is maintained, but productivity is reduced and labor costs increase
Solution Approach 1:
The automated apparatus is divided into separate functional modules: extracting devices for removing pressing rods from tubular elements, introducing devices for reinserting rods, and control systems. Each module operates independently but coordinates through the standardized rod interface, enabling high-speed automated operation without requiring an overly complex monolithic design
Solution Approach 2:
The pressing rods serve multiple functions: they provide compression force during food product processing, act as extraction points for automated handling, and serve as structural components connecting mould elements. This multi-functionality reduces the need for separate specialized components, balancing automation capability with device simplicity
2Productivity
If automated apparatuses are introduced for opening and closing moulds, then productivity increases and labor costs decrease, but device complexity increases
Solution Approach 1:
The mould elements are designed to be self-servicing through the automated apparatus: pressing rods are automatically extracted and reinserted without manual intervention, and the system self-regulates through feedback from sensors that monitor rod position and mould state. This reduces the need for complex external control systems while maintaining high productivity
Solution Approach 2:
The pressing rods are nested within tubular elements during storage and transport, and the automated extracting devices insert extraction tools into the rod ends. This nested arrangement compactly stores multiple components and simplifies the automated handling mechanism, as the system only needs to access the outermost rod ends rather than manipulating entire assemblies
3Loss of time
If manual mould operations are used, then energy consumption is lower, but time consumption increases
Solution Approach 1:
The automated apparatus operates in periodic cycles: extracting rods from multiple tubular elements simultaneously, transporting them in batches, and reinserting them in coordinated sequences. This periodic batch processing reduces peak energy demands compared to continuous operation while maintaining high overall throughput, as energy-intensive actions are concentrated in discrete time windows
Solution Approach 2:
The extracting and introducing devices are merged into a single integrated automated system that shares common components such as motors, control circuits, and structural support. This consolidation reduces total energy consumption compared to separate manual operations for each mould element, as the system performs multiple functions using a unified energy source and control architecture
Data Source
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AI summary
An apparatus (200) for opening a mould (1) suitable for containing a food product, the mould comprising at least one mould element (2) comprising a tubular element (3), inside which pressing elements (5) are slidable, each of which is fixed to a pair of rod means (7), said apparatus (200) comprising a mould opening station (201) in which an extracting device (50) is provided that is provided with gripping means (85) that is movable towards the rod means (7) to hook to the rod means (7) and drag the rod means (7) away from the mould (1), said pushing device (316) is drivable to move vertically along upright elements (307) of said apparatus (300) by movement means (312). An apparatus (300) for closing a mould (1) suitable for containing a food product, the mould comprising at least one mould element (2) comprising a tubular element (3), inside which pressing elements (5) are slidable each of which is fixed to a pair of rod means (7), the apparatus (300) comprises a pushing device (316), which is movable towards the mould (1) and is suitable for exerting a push on a pressing element (5) of the mould (1) to compress the food product in the mould (1), the pushing device (316) is drivable to move vertically along upright elements (307) of said apparatus (300) by movement means (312). A plant (100; 900) that comprises an apparatus (200) for opening a mould (1) arranged in a mould opening station (201) and/or an apparatus (300) for closing said mould (1) arranged in a mould closing station (301).