Automatic Canning System for Tuna Steaks
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Solution Overview
Problem
The manual cutting and packaging of tuna steaks into glass jars in the food industry are labor-intensive and prone to compromising the integrity and quality of the product, despite the use of automated systems.
Innovation Solution
An automatic canning system featuring a vertical axis rotor with synchronized cutting and handling systems, including conveyor belts and pushing pistons, enables automated cutting of tuna steaks into fillets and packaging them into jars without damaging the product, utilizing various cutting methods like water, ultrasonic, or blade cutting systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cutting and packaging is used, then product integrity and quality are maintained, but labor costs and time consumption increase
Solution Approach 1:
The patent replaces manual mechanical cutting with automated cutting systems (blade cutting, water cutting, or ultrasonic cutting) that can precisely cut tuna steaks into fillets while maintaining product integrity. The automated systems use controlled mechanical or acoustic energy to cut the delicate tuna without the variability and potential damage associated with manual cutting.
Solution Approach 2:
The patent introduces specialized handling systems with support surfaces that cradle and stabilize the tuna steaks and fillets during the cutting and packaging process. These intermediary support structures prevent the delicate tuna from collapsing or being damaged while enabling automated manipulation and transfer to jars.
2Productivity
If automated cutting systems are used, then productivity increases, but product integrity may be compromised
Solution Approach 1:
The patent employs dynamic, synchronized movement between the rotor carrying the tuna steak, the cutting elements, and the jar positioning system. This coordinated dynamic operation allows high-speed automated cutting while maintaining precise control over the cutting process to prevent damage to the delicate tuna fillets.
Solution Approach 2:
The patent provides continuous support and cushioning for the tuna steak and fillets throughout the automated cutting process. Support surfaces are positioned to cradle the product before cutting, during cutting, and after cutting, preventing collapse or damage that could occur with high-speed automated handling.
3Reliability
If manual packaging is used, then product aesthetics are maintained, but labor costs increase
Solution Approach 1:
The patent replaces manual packaging with automated systems that precisely position tuna fillets in jars using controlled mechanical movement. The automated handling systems maintain product aesthetics by carefully placing fillets without crushing or mispositioning them, while eliminating the need for manual labor in the packaging process.
4Ease of manufacture
If automated handling systems are introduced, then labor costs decrease, but system complexity increases
Solution Approach 1:
The patent combines multiple functions into an integrated automated system where a single rotor simultaneously carries out cutting, handling, and packaging operations. The cutting elements, support surfaces, and jar positioning mechanisms are merged into one coordinated system that reduces overall complexity compared to separate manual operations for each function.
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 ensures the integrity and quality of the tuna fillets by automating the cutting and packaging process, reducing manual labor costs and time while maintaining product aesthetics, and can be adapted for other food products.
Implementation Method 1
a pushing piston (104) connected to the cutting system (102) and movable in a vertical direction parallel to the axis of rotation of the vertical axis rotor (106) and synchronized to it
Implementation Method 2
utilizing various cutting methods like water, ultrasonic, or blade cutting systems
Implementation Method 3
utilizing various cutting methods like water, ultrasonic, or blade cutting systems
Data Source
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AI summary
Automatic canning system (100) for a food product comprising: a vertical axis rotor (106) comprising a first circular plate (106a) having over its perimeter a plurality of housings (107); a first handling system (101) able to move a food product to be canned to the housings; a cutting system (102), comprising: a first cutting element (102a) placed at one end of the first handling system (101); a second cutting element (102b) and a third cutting element (102c) able to cut the food product to be canned; a second handling system (103) able to move jars (50) empty; a third handling system (105) able to move the jars (50) filled with the food product.