ES2909001T3 - Device, system and method for filling containers with solid food products - Google Patents

Abstract

A device (1) for filling at least one container (10) with a first volume of solid food product, the device (1) comprising: a pump (4) operatively connected to a product tank (2) containing the food product solid, at least one filling head (8) operatively connected to the pump (4); a valve (7) configured to selectively connect the pump (4) to the product tank (2) or to the filling head (8); and a control unit (9) configured to control the valve (7) to connect the pump (4) to the product tank (2) or to the filling head (8), and to control the pump (4) to supply the first volume of solid food product to the filling head (8), characterized in that the control unit (9) is further configured to control the pump (4) to draw from the product tank (2) a larger volume of solid food product than the first volume and to expel an excess volume back to the product tank (2).

Description

DESCRIPTION

Device, system and method for filling containers with solid food products

technical field

The invention relates to a device, system and method for filling containers. More specifically, the present invention relates to a device, system and method for filling containers with food particles.

Background art

Today there are several known techniques for filling containers with liquid food products, such as soups, purees, juices and sauces. Liquids or substances that have a sufficiently low viscosity can be moved from a product tank to a container using standard pumps, in combination with standard volume measurements to control the amount of product being filled.

However, filling containers with food products in the form of food particles such as mushrooms, fruit, peas or beans is normally done in two stages; first, the solid part of the food product (ie the mushrooms/fruits/etc.) is introduced, before carrying out a second stage of filling with brine or syrup or the like. Especially the first part has proven to be very difficult to automate due to air pockets occupying an unknown amount of volume between the individual food particles. Today, solid food products are often packed in volumetric bag fillers or manually filled. Even for automatic filling processes, a manual adjustment after filling is often necessary. Weight fillers can also be used for some types of solid foods, providing better filling accuracy. To some extent, prior art systems can successfully fill packages with food particles. However, such machines cannot be used to accurately fill sticky, irregularly shaped, somewhat brittle, spongy or moist food particles or pieces without the need for manual adjustment after filling.

Documents US 4606174 A and US 4608810 A describe filling devices according to the preamble of claim 1.

Summary

It is an object of the invention to overcome, at least partially, one or more of the limitations of the prior art identified above. In particular, it is an object to provide a device, method and system for filling containers with solid food products in an improved and more precise manner.

Food particles, such as sliced mushrooms, are preferably transported on a conveyor to a filling tank. Advantageously, the mushrooms should contain as little water/moisture as possible when they reach the filler. According to some embodiments described herein, from the filling tank, the mushrooms are sucked into a piston pump controlled by a servo motor. When filling the piston pump from the tank, the piston stroke is approximately 40-80% longer, such as 50% longer than is necessary for the desired fill volume. A retract stroke to the nominal, or desired, fill volume is made before changing the connection from the tank piston pump to the fill nozzle. The retraction stroke compresses the product on the piston and expels the air between the food particles. The profile and acceleration of the piston movement can be controlled to precisely control the filling process. During filling, that is, when the piston pump discharges the desired filling volume into the filling nozzle, the piston pump can be emptied through a filling head that can cut off food particles when closed, if necessary. Brine/liquid can be added to the container using another filler.

According to a first aspect of the invention, the above and other objects of the invention are achieved, in whole or at least in part, with a device for filling at least one container with a first volume of solid food product. The device comprises a pump operatively connected to a product tank containing the solid food product, at least one filling head operatively connected to the pump; a valve configured to selectively connect the pump to the product tank or to the fill head; and a control unit configured to control the valve to connect the pump to the product tank or to the filling head, and to control the pump to supply the first volume of solid food product to the filling head, where the control unit is further configured to control the pump to draw from the product tank a larger volume of solid food product than the first volume and to expel the excess volume into the product tank.

The flow of product in and out of the pump is advantageous because it makes the product more homogeneous, which means that air is expelled so that volumetric measurements are standardized and the product is easier to handle.

The pump may be an alternative pump.

The reciprocating pump is advantageous in that it can be easily scaled depending on the first volume to be filled. The pump may comprise a piston.

The piston is advantageous in that it increases the efficiency of the pump.

The device may comprise a motor to drive the piston, such as a servo motor.

The motor is advantageous in that it allows higher piston speed and automatic control. This is especially true when the control unit is used to control the piston movement according to a software profile tailored for the filling of specific food particles. In this way, potentially any solid product having a corresponding software profile for piston movement stored in the control unit or some external memory accessible by the control unit can be accurately filled into a container described above. The software profile has the function of controlling the movement of the motor and therefore of the piston.

The excess volume of solid food product drawn from the product tank can be between 40-80% of the first volume to be filled.

This range is advantageous because the inventors of this application have found that it maximizes exhaust air while maintaining high speed and efficiency.

The first volume to be filled may correspond to the volume of solid food product to be filled in a single container. This volume is advantageous in that it allows for a simpler fill head and easier operational connection between the fill heads and the tank, resulting in a simpler valve.

According to a second aspect, a system for filling at least one container with solid food product is provided. The system comprises a device according to the first aspect; a product tank containing the solid food product; at least one nozzle for pouring liquid into the at least one container; and a sealer for sealing the at least one container. Optionally, the system also comprises a heater to sterilize the at least one container.

The system is advantageous in that it allows efficient cooperation of different components and produces a complete sterilized package of ready-to-eat foods.

The system may comprise at least one liquid tank operatively connected to the at least one nozzle. The liquid tank has the advantage that it feeds the nozzle(s) in a simple and efficient way.

The system may comprise a conveyor belt to supply the product tank with solid food product.

The conveyor belt has the advantage that it can transport any solid food product quickly.

According to a third aspect, a method for filling at least one container with a solid food product is provided. The method comprises the steps of introducing into a pump a larger volume of solid food product than a first volume to be filled; return excess volume to a product tank; and supplying to a filling head the first volume of solid food product to be filled.

The flow of product in and out of the pump is advantageous because it makes the product more homogeneous, which means that air is expelled so that volumetric measurements are standardized and the product is easier to handle.

The method may comprise a step of supplying the product tank with solid food product.

The method may comprise a step of pouring liquid into the at least one container.

The method may comprise a step of sealing the at least one container.

The method may comprise a step of sterilizing the at least one container.

Still other objects, features, aspects, and advantages of the invention will become apparent from the following detailed description, as well as from the drawings.

Brief description of the drawings

Embodiments of the invention will now be described, by way of example, with reference to the accompanying schematic drawings, in which

Figure 1 is a schematic view of a device for filling at least one container with a solid food product according to one embodiment;

Figure 2 is a schematic view of a device for filling at least two packages with a solid food product according to another embodiment;

Figure 3 is a schematic view of a system for filling at least one container with a solid food product according to one embodiment; Y

Figure 4 is a schematic illustration of a method for filling at least one container with a solid food product according to one embodiment.

Detailed description

With reference to Figure 1, a device 1 for filling at least one package 10 with a first volume of solid food product, ie food particles, is illustrated. The container 10 can be a cardboard box, a metal can, a plastic bottle, or any other food-grade packaging. In the most preferred embodiment, the package 10 is a sterilizable carton designed for non-perishable products that are traditionally packaged in cans, jars, or bags (foods such as vegetables, beans, tomatoes, pet food, soups, and sauces). Such a carton is commercially available and is known as Tetra Recart®.

For the device 1 of Figure 1, the food particles may comprise, for example, mushrooms, fruit pieces, or meat pieces. Solid food is heterogeneous and comprises pieces or particles of product with air pockets in between. The solid food product can have a certain amount of liquid, for example between 0-20%, as long as the result is heterogeneous. The solid food product is usually packed in brine or another type of liquid, such as syrup, which is added to at least one container 10 at a later stage, as discussed below with reference to Figure 3.

The device 1 comprises a pump 4 operatively connected to a product tank 2 containing the solid food product, ie the solid part of the food product. The pump 4 may be a reciprocating pump capable of drawing the solid food product from the product tank 2. An advantage of a reciprocating pump is that it is very practical for scaling variations in the fill volume of the solid food product. The scaling can be e.g. eg, slave scaling . Thus, one device 1 can be used for any number of fill volumes or container volumes. One skilled in the art will appreciate that the volume of the container 10 is not necessarily the same or even proportional to the fill volume.

Pump 4 preferably pumps at a speed and acceleration that is fast and efficient, but without causing any damage to the product. Pump 4 preferably works automatically.

The purpose of the pump 4 is to attract the solid food product from the product tank 2 and then to deliver the attracted solid food product to the container 10. The fill volume, i.e. the volume of solid food product that is supplied to the container 10, it is hereafter indicated as a first volume.

Another function of the pump 4 is to temporarily store the solid food product as the amount of product to be filled is measured. Therefore, the pump 4 is made of a material suitable for periodically containing solid food products, such as a plastic, glass or metal and shaped, e.g. eg, substantially like a ball, box, cylinder, or tube.

Pump 4 is configured to accommodate a volume of solid food product greater than the first volume, i.e. the volume to be filled into container 10. By drawing solid food product into pump 4, a larger volume of solid food product than the first volume enters pump 4. The excess volume, that is, the difference between the volume drawn and the first volume, is then discharged from pump 4 to product tank 2.

The excess volume is, therefore, the difference between the input/attracted volume and the first volume to be filled. Expelling the excess volume into product tank 2 does not necessarily mean that the product reaches product tank 2. Instead, the excess volume of the output product can be accommodated, e.g. e.g. in connection pipes.

This process compresses the solid food product to mainly discharge the air from the air pockets, to achieve a more homogeneous and compact solid food product. This means that by drawing in additional volume and then expelling additional volume, even though the resulting volume of the product is the same as without the additional steps, the resulting content actually fills the volume efficiently and can be used as a fair measure.

In one embodiment, the volume drawn is 40-60% greater than the first volume to be filled. In another embodiment, the drawn volume is approximately 50% greater than the first volume to be filled.

The device 1 further comprises at least one filling head 8 operatively connected to the pump 4. The filling head 8 is configured to dispense the solid food product delivered by the pump 4 into the at least one container 10. The filling head 8 can be e.g. g., a nozzle, a funnel, or a pipe opening.

The filling head 8 preferably ensures that all the solid food product delivered by the pump 4 is filled into the at least one container 10, either through the use of a feedback system, such as sensors, or simply by the design of the head. filler 8 so that spills and losses are avoided.

Device 1 further comprises a valve 7 configured to selectively connect pump 4 to product tank 2 or fill head 8. Valve 7 is preferably a passive component that does not impact flow. The valve 7 can be, for example, a branch with a mechanical switch or a set of plugs that block different paths according to their positions. Valve 7 may allow flow into or out of one or more than one pump 4.

Valve 7 preferably connects pump 4 to product tank 2 to allow the flow of solid food product between product tank 2 and pump 4 while product is drawn into pump 4 and excess volume of product is expelled. to product tank 2, as described above. This process typically takes about half a second in modern filling operations.

Note that valve 7 allows product flow from product tank 2 to pump 4 and from pump 4 to product tank 2. In different embodiments, valve 7 may be arranged to allow both directions of flow to the pump. same time or to switch between allowing the two directions at different times.

Once the excess volume of product is expelled from pump 4, valve 7 preferably switches to connect pump 4 to fill head 8 to allow flow between pump 4 and fill head 8. This allows the filling head 8 fill container 10 with the correct amount of solid food product contained in pump 4. This process usually takes about half a second in a modern filling operation.

In the embodiment shown in figure 1, the pump 4 comprises a piston 5 to control the flow of solid food product between the product tank 2 and the pump 4.

During a stroke, piston 5 will initially drive the flow of solid food product towards pump 4 and, by changing direction, pushing piston 5 forward, the product is ejected from pump 4, either into product tank 2 or to the filling head 8.

The piston 5 preferably moves at a speed and acceleration that is fast and efficient, but without damaging the product.

The device 1 may further comprise a motor 6 for driving the piston 5. The motor 6 may be integrated in or arranged adjacent to the piston 5 and may be arranged to drive one or more than one piston 5. The motor 6 may be controlled via hand or automatically. The motor 6 can be e.g. g., a stepper motor or an electric motor and is preferably a servo motor.

Device 1 also comprises a control unit 9 configured to control valve 7 to connect pump 4 to product tank 2, control pump 4 to draw from product tank 2 a larger volume of solid food product than the first volume to fill, and then expel the excess volume into product tank 2, control valve 7 to connect pump 4 to fill head 8, and control pump 4 to supply the first volume of solid food product to fill head 8 .

The control unit 9 can be further configured to control the operation of one or more pistons 5 and/or one or more motors 6 so that the pistons 5 cooperate with the pumps 4.

The control unit 9 can be further configured to control the operation of one or more filling heads 8 to activate the filling of the solid food product, to monitor and react to the feedback system, and/or to control the processing means, as shown. previously analyzed.

The control unit 9 can be implemented as one or more processors (CPU) or programmable logic controllers (PLC). It can be a single unit or divided into several parts. A control unit 9 can be configured to control the operation of any number of valves 7, pumps 4, pistons 5, motors 6 and/or filling heads 8.

The control unit 9 can be fully automatic using feedback systems to control the device 1 in the most efficient way. The control unit 9 may have semi-manual control of variations, such as container volume control using a user interface, such as a control panel.

Control unit 9 is preferably configured to precisely control the movement profile of piston 5; in terms of speed and acceleration, as well as in terms of defining the final positions of the piston 5 (ie the final position corresponding to the largest volume, and the intermediate position corresponding to the first volume to be filled). As the piston 5 is preferably driven by a servomotor, the control unit 9 communicates with the servomotor to follow a software profile adapted to each type of food particles that are filled. Such control will improve the filling operation in terms of accuracy and speed.

Figure 2 shows another embodiment of device 1, where two devices 1 are arranged with certain shared components to increase efficiency. The person skilled in the art will realize that any number of devices 1 can be provided with any number of shared components.

Figure 2 shows two pumps 4, each comprising a piston 5. Although not shown, two or more pumps 4 may be arranged to share the same piston 5. Only one of the pistons 5 is provided with a motor 6, which in this embodiment it is configured to actuate both pistons 5.

Two fill heads 8 are shown, each filling a respective container 10. A fill head 8 may be arranged, e.g. with several nozzles or openings, each one being configured to fill a container 10.

In one embodiment, the first volume to be filled corresponds 7 to the volume of solid food product to be filled in a single container 10. In this case, it is preferred to use one filling head 8 per container 10 to be filled.

It is preferred that the first volume to be filled expelled by each pump 4 does not change between the pump 4 and the corresponding containers 10 to be filled. To that end, it is beneficial to maintain the same number of pumps 4 and fill heads 8 while scaling system 20. Each fill head 8 can be configured to fill exactly one volume to fill any number of containers 10, using known methods for ensuring that each package 10 receives the same amount of solid food product.

Figure 2 further shows two valves 7, each being connected to a respective pump 4 and a respective filling head 8. However, each of the valves 7 is connected to the same product tank 2 (not shown). The person skilled in the art will realize that more than one valve 7 can share any two or more connections.

However, it is preferred that the valves 7 maintain a direct connection between a pump 4 and a corresponding filling head 8 to ensure that the first volume to be filled expelled by each pump 4 does not change, as discussed above.

In figure 2 a control unit 9 is shown to control two valves 7 and a motor 6. Although all these components can be controlled by a control unit 9, each one, the person skilled in the art will realize that they can be more efficient to have a control unit 9 which controls all the components as needed.

Figure 3 shows a system 20 for filling at least one container 10 with a solid food product. The system 20 comprises a device 1 for filling at least one container 10 with a first volume of solid food product similar to the device 1 of Figure 1 and will therefore not be described further.

System 20 comprises a product tank 2 containing the solid food product. The product tank 2 is connected to the pump 4 through a valve 7, as described above. The product tank 2 can be any tank suitable for storing solid food product, made of a material suitable for containing solid food product, such as a plastic, glass or metal and shaped, e.g. eg, substantially like a ball, box, cylinder, or tube.

The product tank 2 can be any size, such as 0.1-5 liters, 5-10 liters, 10-20 liters and 20-100 liters. Regardless of size, it may eventually need to be replenished. The provisioning can be done by hand or automatically. If done automatically, any device suitable for transporting solid food products can be used, such as screws, vibrating funnels or a conveyor belt 3.

It may be beneficial to process the solid food product before it is stored in the product tank 2. For example, a dryer 13 may be provided together with a suitable conveying device to dry the product as it is stored. Other processing stations 11-15 are also possible. Other examples of processing include molding, grinding, cutting, or coating.

However, a dryer 13 is not necessary for the system 20 described. The conveyor or any other type of transport must ensure in said embodiments that the food particles are completely drained when they reach the filling device 1. When a conveyor is used, it may have holes to drain the food product.

After the at least one container 10 is filled, further processing may be beneficial. The embodiment of figure 3 shows a conveyor belt 3 with packages 10 being processed in a specific order at different processing stations 11-15. The different processing stations 11-15 can be processed in any order and any station can be skipped. Any number of packages 10 can be processed at one time by each processing station 11-15 and any number of processing stations 11-15 can process the same package 10 at the same time.

The different processing stations 11-15 may be parts of different machines or integrated into a single machine. The packages 10 can be transported in some way, e.g. eg by hand or by conveyor belt 3, between the different processing stations 11-15. Additionally or alternatively, the different processing stations 11-15 can be transported to the container 10; additionally or alternatively, the different processing stations 11-15 may be arranged to process the package 10 without the need for transportation.

A spout 11 can be used to pour liquid into at least one container 10. The liquid can be e.g. g., brine or a syrup. The nozzle 11 can be any opening suitable for supplying liquid to a container 10, similar to how the filling head 8 supplies solid food product.

The nozzle 11 may be operatively connected to at least one liquid tank 12. The liquid tank 12 may be any tank suitable for storing liquid, made of a material suitable for containing liquid, such as a plastic, glass or metal and shaped, p. eg, substantially like a ball, box, cylinder, or tube. Different liquid tanks 12 may comprise different liquids. Liquid tank 12 may or may not be integrated with nozzle 11. A liquid tank 12 may be centrally connected to any number of nozzles 11, additionally or alternatively, each nozzle 11 may have its own liquid tank 12.

A sealer 14 may be used to seal the at least one container 10. The sealer 14 may use, e.g. eg, adhesives, pressure, fasteners, heat, or electricity to seal the container 10. The container 10 may need to be folded before sealing 170, which may be done by the sealer 14 or another processing station.

A heater 15 may be used to sterilize the at least one container 10. The heater 15 may heat the container 10 to between 100 and 130°C.

The control unit 9 of the device 1 for filling at least one container 10 can furthermore be used to control any number of components of the system 20, such as the different processing stations 11-15 and/or the conveyor belt(s). s) 3. A feedback system can be implemented at the systematic level to allow the control unit 9 to automatically control the system 20.

The system 20 may further comprise a user interface (not shown) to allow a user to interact with the control unit 9 and, in turn, with the system 20. The user interface may be configured, e.g. eg, to allow a user to vary the first volume of solid food product or excess volume/stroke length, to adjust the speed of filling operations, or to stop or resume filling operations.

Figure 4 shows a method 100 for filling at least one container 10 with a solid food product. Method 100 may comprise any number of steps that may be performed in any order or omitted in whole or in part. Therefore, each stage will be described individually.

A supply step 110 comprises supplying the product tank 2 with solid food product. This step 110 can be carried out by hand or with any device suitable for transporting solid food products, such as a conveyor belt 3. This step 110 can be carried out continuously or periodically.

An introduction step 120 comprises introducing into a pump 4 a larger volume of solid food product than a first volume to be filled. This step 120 can be performed by the pump 4, driven by means of a piston 5.

A return stage 130 comprises returning the excess volume to the product tank 2. This stage 130 can be performed by the pump 4. As explained above, the excess volume is the difference between the input volume and the first volume to fill. Returning excess volume to a product tank 2 does not mean that the returned product is to arrive at product tank 2. Instead, the returned product may be housed, e.g. e.g. in connection pipes.

A supply step 140 comprises supplying a filling head 8 with the first volume of solid food product to be filled. This step 140 can be done using any operative connection between the pump 4 and the fill head 8, such as a tube, and can be operated, e.g. e.g. by pump 4.

A filling step 150 comprises filling the at least one container 10 with a solid food product. This step 150 can be done with the fill head 8. Any number of containers 10 can be filled 150 with a fill head 8. In this case, the fill head 8 may need to ensure that each container 10 is filled 150 with the correct amount of solid food product.

Note that the correct amount to fill in each container 10 is not the first volume to fill, the first volume to fill is the sum total of the volume filled in all containers 10 by the fill head 8 at this stage 150.

A pouring step 160 comprises pouring liquid into the at least one container 10. This step 160 can be performed with a nozzle 11, the liquid being supplied by a liquid tank 12, as previously discussed. The resulting mixture of solid and liquid food product is the food product sold to customers, such as mushrooms or chickpeas in brine or fruit in a sugar solution.

A sealing step 170 comprises sealing the at least one container 10. This step 170 can be performed with a sealer 14 using, e.g. g., adhesives, pressure, fasteners, heat, or electricity. The container 10 may need to be folded before sealing 170, which should be considered as part of this stage 170.

A sterilizing step 180 comprises sterilizing the at least one container 10. This step 180 may be performed by a heater 15 heating the container 10 after it is sealed 170, the resulting increased heat and pressure sterilizing the container 10 and its contents.

From the above description, it follows that although various embodiments of the invention have been described and shown, the invention is not limited thereto, but can also be embodied in other ways within the scope of the subject matter defined in the following claims.

Claims (17)

1. A device (1) for filling at least one container (10) with a first volume of solid food product, the device (1) comprising: a pump (4) operatively connected to a product tank (2) containing the solid food product, at least one filling head (8) operatively connected to the pump (4); a valve (7) configured to selectively connect the pump (4) to the product tank (2) or to the fill head (8); Y a control unit (9) configured to control the valve (7) to connect the pump (4) to the product tank (2) or to the filling head (8), and to control the pump (4) to supply the first volume of solid food product to the filling head (8), characterized by what the control unit (9) is further configured to control the pump (4) to draw from the product tank (2) a larger volume of solid food product than the first volume and to expel an excess volume back to the product tank (two). 2. The device (1) according to claim 1, wherein the pump (4) is a reciprocating pump. The device (1) according to claim 1 or 2, wherein the pump (4) comprises a piston (5). The device (1) according to claim 3, further comprising a servo motor (6) to drive the piston (5). 5. The device (1) according to claim 4, wherein the control unit (9) is further configured to regulate the movement and/or speed of the piston (5) in relation to a software profile adapted for the filling of specific food particles. 6. The device (1) according to any one of the preceding claims, wherein the excess volume of solid food product drawn from the product tank (2) is between 40-60% of the first volume to be filled. 7. The device (1) according to any one of the preceding claims, wherein the first volume to be filled corresponds to the volume of solid food product to be filled in a container (10). A system (20) for filling at least one container (10) with solid food product, the system (20) comprising: a device (1) according to any one of the preceding claims; a product tank (2) containing the solid food product; at least one nozzle (11) to pour liquid into the at least one container (10); Y a sealer (14) for sealing the at least one container (10). The system (20) according to claim 8, further comprising at least one liquid tank (12) operatively connected to the at least one nozzle (11). The system (20) according to claim 8 or 9, further comprising a conveyor belt (3) for supplying the product tank (2) with solid food product. 11. A method (100) for filling at least one container (10) with a first volume of a solid food product, the method (100) comprising the steps of: controlling a pump (4) to draw from a product tank (2) a volume of solid food product greater than the first volume; controlling the pump (4) to return (130) the excess volume to the product tank (2); connect the pump (4) to a filling head (8) and controlling the pump (4) to supply (140) to the filling head (8) the first volume of solid food product to be filled. 12. The method (100) according to claim 11, further comprising regulating the movement and/or speed of a piston (5) in the pump (4) in relation to a software profile adapted for particle filling of specific foods. The method (100) according to claim 11 or 12, further comprising a step of filling (150) the at least one container (10) with the solid food product. 14. The method (100) according to any of claims 11-13, further comprising a step of supplying (110) the product tank (2) with the solid food product. 15. The method (100) according to any one of claims 11-14, further comprising a step of pouring (160) liquid into the at least one container (10). 16. The method (100) according to any one of claims 11-15, further comprising a step of sealing (170) the at least one container (10). 17. The method (100) according to any one of claims 11-16, further comprising a step of sterilizing (180) the at least one container (10).