Continuous Flow Poultry Meat Deboning via Pneumatic Transfer
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Solution Overview
Problem
Existing meat processing systems for poultry face issues with clogs, feed capacity, consistency, and labor costs due to the need for manual smoothing of meat on conveyor belts, which limits their efficiency and effectiveness.
Innovation Solution
An automated continuous flow deboned poultry processing system that uses a batch supply stage connected through a transfer stage to a feed stage, employing vacuum and pressure differences to smoothly transfer meat from a small high-pressure tank to a larger tank, ensuring a consistent flow without harming the meat, and then pushing it onto a conveyor belt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual smoothing is used to create consistent meat flow on conveyor belts, then meat consistency is improved, but labor costs and operational complexity increase
Solution Approach 1:
The patent replaces manual mechanical smoothing operations with an automated pneumatic system. Meat is conveyed through a pressurized air stream in a controlled flow channel, where the air flow automatically smooths and distributes the meat evenly on the conveyor belt without human intervention, thus maintaining manufacturing precision while eliminating labor requirements.
Solution Approach 2:
The system enables self-service operation where the pneumatic conveying system automatically regulates and smooths the meat flow through the flow channel. The controlled air pressure and flow channel geometry work together to self-regulate the meat distribution, eliminating the need for external manual smoothing operations.
2Manufacturing precision
If mechanical rollers are used to smooth meat on conveyor belts, then meat consistency is improved, but risk of product damage and contamination increases
Solution Approach 1:
The patent replaces direct mechanical contact with rollers by using a pneumatic field (pressurized air stream) to convey and smooth the meat. This non-contact mechanism eliminates mechanical stress that could damage the product and removes the risk of contamination from roller surfaces, while still achieving consistent meat flow through the controlled air stream and flow channel geometry.
3Adaptability or versatility
If batch processing is used for poultry meat, then processing flexibility is maintained, but production efficiency and continuity deteriorate
Solution Approach 1:
The patent implements continuous processing by maintaining a constant pneumatic flow through the system. The pressurized air stream continuously conveys meat through the flow channel and onto the conveyor belt without interruption, eliminating the start-stop nature of batch processing. This continuous action improves productivity while the system remains adaptable to different processing requirements through adjustable air pressure and flow channel design.
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 converts batch input into continuous flow output, maintaining meat quality and reducing labor costs by ensuring a constant operating flow and preventing clogs, thereby improving the efficiency and consistency of the processing.
Implementation Method 1
A vacuum is then pulled onto a small batch tank and the poultry is then transferred via vacuum into a gravity separating small volume batch tank
Implementation Method 2
Gravity makes the poultry meat fail to the bottom of the tank while a vacuum is pulled on the top of the tank
Implementation Method 3
the small batch tank is then pressurized to 12 psi to become a high pressure tank in relation to the pressure of a larger feed tank
Implementation Method 4
the 10 psi pressure pushes the meat out a flow tube onto the conveyor without harming the meat product
Data Source
AI summary
A deboned poultry meat batch to continuous feed system using a hopper input transferring the meat through a vacuum fill to a low pressure gravity separation small volume batch tank. The low pressure gravity separation small volume batch tank is connected through a rotary valve to a larger lower pressure level-maintenance tank with a tight parameter pressure regulation system to maintain a consistent flow output.