Milker Unit Backflushing and Teat Dip Isolation Under Pressure
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Solution Overview
Problem
Existing automatic teat dip applicators and milker unit backflushing systems fail to prevent contamination of dairy milk lines by teat dip compositions and backflushing fluids due to differential pressures, leading to inefficiencies and health risks in dairy animal milking processes.
Innovation Solution
A system that automatically backflushes milker units and applies teat dip near the end of milking, using a safety valve to isolate the milker unit from the dairy system, ensuring uniform dip distribution and preventing contamination by utilizing a block-bleed-block valve arrangement to manage pressure differentials and a teat dip manifold for consistent distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic teat dip applicators and backflushing systems are used, then operator effort is reduced and productivity is improved, but contamination of dairy milk lines occurs due to differential pressures
Solution Approach 1:
The system divides the fluid delivery system into separate independent channels: a first fluid delivery system for teat dip composition and a second fluid delivery system for backflushing fluid. Each system has its own pump, valves, and delivery mechanisms, preventing cross-contamination while maintaining automated operation. The milker unit is also segmented with separate inlet and outlet ports for different fluids.
Solution Approach 2:
The patent introduces an intermediary control system that manages pressure differentials between the two fluid systems. Control valves and pressure regulation mechanisms act as intermediaries to ensure that backflushing fluid pressure never exceeds teat dip pressure, preventing contamination while maintaining efficient automated operation.
2Manufacturing precision
If teat dip is applied automatically before detachment, then uniform dip coverage is achieved, but chemical consumption increases
Solution Approach 1:
The system applies teat dip composition to the teats before the milker unit is detached from the animal. This preliminary application ensures that the dip is already in place on the teat surface, creating a protective barrier before milking begins. The timing is controlled to optimize both coverage uniformity and chemical efficiency.
Solution Approach 2:
The system dynamically adjusts delivery parameters including flow rate, pressure, and timing of dip application. By optimizing these parameters, the system achieves uniform dip coverage while minimizing the total volume of chemical required. Pressure regulation ensures consistent application without excessive chemical use.
3Reliability
If backflushing is performed to remove disinfectant solution, then hygiene is improved, but water and chemical consumption increases
Solution Approach 1:
The backflushing system operates periodically rather than continuously, delivering backflushing fluid at controlled intervals to remove disinfectant solution and milk residue from the milker unit. This periodic action maintains hygiene standards while minimizing water and chemical consumption compared to continuous rinsing systems.
Solution Approach 2:
The system is designed to efficiently discard used backflushing fluid after it has performed its cleaning function, while recovering and recirculating clean water and chemicals where possible. The periodic backflushing replaces thorough but wasteful continuous rinsing, maintaining hygiene with reduced resource consumption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively reduces operator effort, ensures consistent and uniform teat dip application, minimizes chemical and water consumption, and prevents contamination of the dairy milk lines, thereby improving dairy herd health and hygiene.
Implementation Method 1
differential pressures that develop in dipping and backflushing devices that are connected to milk lines
Implementation Method 2
block-bleed-block valve arrangement to manage pressure differentials
Implementation Method 3
teat dip manifold for consistent distribution
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A dip applicator for dairy animals, the dip applicator comprising: a housing in fluid communication with a downstream portion of a milker unit and a teat cup of the milker unit, and defining a dip fluid inlet (188), a dip fluid outlet (190) in fluid communication with the teat cup, a dip fluid conduit extending between the dip fluid inlet and the dip fluid outlet, and a vent (B5, B6) disposed between the dip fluid inlet and the dip fluid outlet and in fluid communication with the dip fluid conduit; and a safety valve in fluid communication with the dip fluid conduit, and including a dip piston (268) for movement between a milking position and a dipping position, and the dip piston engages and closes the dip fluid inlet as the dip piston moves from the dipping position to the milking position, and the dip piston blocks the vent when the dip piston is in the dipping position.