Parallel-Station Chick Processing Facility for High Throughput
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Solution Overview
Problem
Existing facilities for processing newly hatched chicks are slow, stressful for the animals, prone to bruising and skeletal injuries, and pose health risks for operators, with inefficient vaccine administration methods that require manual handling and non-continuous dispensing of veterinary fluids.
Innovation Solution
A facility with multiple identical processing stations on linear conveyors allows high-speed processing of chicks, reducing stress and injuries, and includes automated vaccine administration and controlled dispensing of veterinary fluids, ensuring homogeneous distribution and continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling and processing of chicks is used, then operator skill and practice can minimize stress, but processing speed remains low and requires single operator per batch
Solution Approach 1:
The processing line is divided into multiple independent processing stations (vaccination station, weighing station, etc.) that operate simultaneously. Each station handles a portion of the total processing load, allowing parallel processing of chicks across multiple stations rather than sequential handling by a single operator.
Solution Approach 2:
Manual handling operations are replaced with automated mechanical systems including automated conveyors, robotic positioning systems, and automated vaccination devices. This substitution eliminates the need for highly skilled manual operations while maintaining animal welfare standards.
2Productivity
If single operator processes entire batch on same workstation, then operational simplicity is maintained, but processing time becomes relatively long
Solution Approach 1:
The facility is segmented into multiple processing stations arranged along a conveyor system. Each station performs a specific function (vaccination, weighing, marking) and operates independently, allowing simultaneous processing operations that dramatically increase throughput.
Solution Approach 2:
The processing system transitions from a single-workstation linear approach to a multi-dimensional conveyor system where multiple stations operate in parallel across different spatial positions. This dimensional expansion enables simultaneous multi-stage processing.
3Ease of operation
If conventional conveyor design with changes of direction is used, then chick transport is achieved, but significant stress and skeletal injuries occur
Solution Approach 1:
The conveyor system uses gentle curved transitions instead of sharp angular changes of direction. This curvature allows chicks to move smoothly along the conveyor path without sudden directional changes that cause stress or skeletal injuries.
Solution Approach 2:
The conveyor design incorporates cushioning elements and padded surfaces at critical transition points to protect chicks from impacts and stress during transport. This beforehand cushioning prevents injuries before they occur.
4Productivity
If continuous conveyor processing is implemented, then processing speed increases, but homogeneous distribution of vaccine droplets becomes difficult to maintain
Solution Approach 1:
The vaccine dispensing system incorporates sensors and feedback mechanisms that monitor droplet distribution in real-time. The system automatically adjusts dispensing parameters to maintain homogeneous vaccine distribution across all containers while operating at high processing speeds.
Solution Approach 2:
The system dynamically adjusts vaccine dispensing parameters (droplet size, dispensing rate, container spacing) based on real-time conditions. This parameter optimization ensures uniform vaccine distribution across all containers regardless of conveyor speed.
5Ease of manufacture
If predetermined storage volume supply to nozzles is used, then vaccine dispensing is simplified, but continuous processing of containers is prevented
Solution Approach 1:
The vaccine dispensing system is designed to continuously supply containers with vaccine droplets without interruption. Multiple nozzles are positioned along the conveyor path, and the system maintains continuous dispensing operation as containers pass through, enabling uninterrupted processing.
Solution Approach 2:
The system pre-positions multiple vaccine containers along the conveyor path before they reach the dispensing point. This preliminary arrangement ensures that vaccine is always available for immediate dispensing onto the next container, eliminating gaps in continuous processing.
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
Achieves processing rates of over 12,000 chicks per hour with reduced stress and operator health risks, while ensuring effective and uniform vaccine application.
Implementation Method 1
a spray nozzle, which dispenses droplets of a veterinary fluid onto the surface of containers conveyed by the conveyor
Data Source
AI summary
The invention relates to a facility for high-speed processing of newly hatched fowl.According to the invention,said facility comprises at least one first linear conveyor (10), which defines a conveying axis (11) along which a plurality of processing stations (13) are arranged,at least some of said processing stations (13) being identical so that the fowl of a single first container in motion can receive the same processing by being shared across the various identical processing stations (13),at least each one of said identical processing stations (13) comprising a chute (15) for conveying fowl thus processed to second containers (16),said facility comprising stationary supports for supporting said second containers, which are placed level with a second conveyor (17) located under said first conveyor (10), so that each second container can be moved, when it is full, to said second conveyor (17) in order to be discharged.