Patent Application
20050112256
A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
1. Field of Invention
The present invention relates to harvesting and preparation of vegetables and other produce. More particularly, the present invention relates to methods for harvesting, washing, drying, and packaging of produce.
2. Discussion of Background
In the field produce and particularly vegetables are typically harvested or gathered and placed into containers called baskets, totes, crates, cartons, or bins (hereafter collectively referred to as “baskets”) for further processing. Such baskets can be relatively small and capable of being lifted and otherwise manually manipulated by a single worker or they can be of a size which can only be lifted by a machine. The produce is sometimes placed in these baskets in a random orientation and is sometimes stacked into the baskets in a uniform orientation. In either case, the produce is not processed further in the field packing baskets and is merely transported to a central location where they are removed from the baskets and processed, i.e., washed, dried, packaged (e.g., bagged salads), cooled, stored, and then shipped.
As a result of the above processing, produce undergoes a significant amount of handling during the period of time from which it is first harvested until it is finally displayed for sale. This transferring of the produce from machine to machine and container to container can result in significant damage and degrading of the produce and makes it less appealing to the consumer visually. In addition, the shelf-life of produce is also reduced when it has been subjected to excessive handling. Moreover, cellular damage to produce in turn results in the loss of cellular fluids and in an increased risk of microbiological decay. Furthermore, the lengthy process of repetitive transferring of produce among various containers and various machines expends a significant amount of time and labor, thereby increasing its eventual cost.
Mitchell et al. I, 5,992,042, the contents of which are incorporated herein by reference, discloses a dryer device that efficiently dries washed vegetables. And, Mitchell et al. II, U.S. Pat. No. 6,112,429, the contents of which are incorporated herein by reference, discloses significant advances in the processes of field harvesting, cleaning, and drying of vegetables. Each of these inventions address many of the issues discussed above.
The present inventors have realized the need to provide better cleaning, packaging, and drying of harvested vegetables. The present invention provides techniques for preparing vegetables for the washing, packaging, and drying processes. The techniques include removing a core of the harvested vegetable. The present invention allows for produce to retain its whole head structure or single leaf form, except for the de-cored end. The produce is field packed and maintained in totes for transport, washing, and drying, and packing (for both Retail and Foodservice produce) allows the product to be cleaned, dried and packaged while maintaining the whole head structure. This reduces costs and provides a cleaned product, and reduces retailers handling costs compared to other preparation techniques.
The whole head form saves having to reassemble the heads further reducing costs. The lengthy process of repetitive transferring of produce among various containers and various machines expends a significant amount of labor, (and causes shrinkage of the raw product) thereby increasing costs and reducing quality.
Core removal is preferably performed in the field during a harvest, but may be applied at another time or location such as a processing plant. The de-cored vegetable is subjected to washing fluid that cleans the vegetable as it flows through the vegetable (e.g., entering at the de-cored end and exiting a leafy end, and/or entering and exiting the de-cored and leafy ends of the produce during any of wash, rinse, and drying cycles).
The present invention includes a washing device that takes advantage of the physical characteristics of a removed core vegetable or produce by directing a flow of washing liquid through the core end into the vegetable for thorough cleaning and disinfecting. The present invention includes an entire process from harvest, through cleaning, and drying of the vegetable and packaging. The packing is accomplished by loading whole de-cored head vegetables or produce into a package (e.g., produce bag). In one embodiment, retail bags are loaded from the side with a reclosable zipper on the opposite side. The zipper is optional. The retail bags are loaded from the side instead of from the bottom. This is accomplished by a preformed loading devise that assists in sliding the product into a retail bag. The device holds the bag open while allowing the head to side into the bag. Foodservice is loaded by placing the bag over a ring. The ring holds the bag open during loading. Both Foodservice and retail bags have controlled atmosphere properties, which helps to extend the shelf life of the produce. The end result is a cleaner more healthy product having better consumer appeal and longer shelf life. The end result provides a ready to use whole de-cored heads or leaves in a sealed bag.
In one embodiment, the present invention is a wash device for washing cut vegetables in totes, comprising, a wash tank, a flow device configured to cause a flow of liquid through the tank, and a transport mechanism configured to place totes containing cut vegetables in the wash tank, wherein the transport mechanism is configured to move the totes through the wash tank in a pre-determined alignment direction, and the pre-determined alignment direction comprises an axial direction in which cut vegetables are to be located in the totes.
The present invention is embodied as method, comprising the steps of, cutting a product from a stalk from which it was grown, removing a core of the product, and placing the de-cored product in a tote in a pre-aligned direction relative to the tote, while maintaining the whole de-cored head structure.
The present invention also includes a method, comprising the steps of, cutting a product from a stalk from which is was grown, removing a core from a core end of the product, pre-washing the de-cored end of the product, loading the de-cored product in a tote in a pre-aligned direction relative to the tote, transporting the tote to a processing facility, washing the tote in a washing fluid, and spin drying the washed de-cored product in the tote. In one embodiment, the de-cored product is immersed in a tank of the washing fluid. In another embodiment, the de-cored product is subjected to a spray or a flow of washing fluid that has sufficient strength to cause at least some of the washing fluid to flow through the de-cored end and out a leafy end of the produce. The tote includes openings large enough to allow the flow of washing fluid and small enough to secure the produce in the tote. The washing fluid preferably comprises water and at least one of chlorine and anti-bacterial agents, and the step of washing comprises loading the tote on a transport mechanism configured to transport the tote through the tank of washing fluid.
Portions of both the wash device and method may be conveniently implemented in programming on a general purpose computer, or networked computers, and the results may be displayed on an output device connected to any of the general purpose, networked computers, or transmitted to a remote device for output or display. For example, the wash device may include electronic sensors for flow rates, and quality monitoring that are fed to a computer that sends control signals that increase or decrease flows, or add fresh water or anti-bacterial agents to the washing liquid.
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts, and more particularly to
At step 100, a produce item is cut from the stalk or plant from which it is grown. The cut product includes a butt, or core end, which begins at the cut portion and extends toward a generally leafy or open end of the product. The core is removed (step 110), for example, by using a stainless steel knife (e.g., a plug cutter having a tubular blade of a diameter approximately the size of an average outer core for the harvested product. The core may also be removed via a water knife, saw (e.g., Stainless Steel Saw) or other tools and the like. The core may be removed by a coring device or by cutting off the core across the bottom of a whole head produce. The de-coring can also be done by v-cutting the butt out of the produce. The de-cored product may also be topped (a cutting off of the top leaves of the produce) to remove any defects on the upper part of the leafs. The core and any topping is left to return to the soil. The cut end of the product is rinsed (step 115). The de-cored product is loaded into a tote with the cut de-cored ends of the product facing a pre-aligned direction within the tote (step 120), and then the product is washed in the totes (step 125). In one embodiment, discussed in more detail later, the de-cored product is loaded into the totes with the de-cored ends facing away from the center of the tote, in a outward direction.
The present inventors have determined that the manner in which the de-cored produce (e.g., heads packed in the tote increases the effectiveness of the wash). Preferably, heads are packed closely enough to prevent them from moving around but still allow flow of fluid through the product. This also allows for proper drying and more efficient unloading of the product when being packed.
Although the de-coring process is preferably performed in the field, it should be noted that the produce may be first loaded into the tote and then de-cored at a processing plant. However, such embodiments may require additional handling of the product that would likely increase cost and damage to the product.
At step 130, the totes, having been loaded with cut de-cored vegetables, are transported from the field to a processing plant for washing, drying, and packaging. The washing process (step 140) is performed by placing the totes in a wash tank in an orientation with the pre-aligned direction so that a flow of washing fluid in the tank (relative to the tote) is directed toward the cut and de-cored ends of the produce. Thus, when the cut de-cored vegetables are set in a pre-aligned direction in the totes (as shown in
As noted in Mitchell et al. II, more than one washing tank may be utilized, each tank having a different solution or other environmental characteristics. Any of the features in either Mitchell et al. I or Mitchell et al. II may also be applied to processing according to the present invention. Spray mechanisms may be placed between washing tanks to further clean the produce. In one embodiment, the tanks include different cleaning solutions (e.g., a chilled tap water wash and a separate chilled anti-bacterial solution at different temperatures).
A dwell time in which the produce is exposed to or immersed in the chilled solutions controls a temperature of the produce. The temperature of the produce is regulated as needed so that additional cooling is not needed. In several embodiments, equipment used to process the produce, and particularly the temperature of the washing fluid, is set to achieve and maintain the product in a temperature range that extends a shelf life of the product. For example, the temperatures of the water, equipment, and/or environment (e.g., ambient air temperature, conveyors, spin dryer, etc.) achieve a product temperature of approximately 33-38 degrees F.
In one embodiment, the totes are immersed in a wash tank without any special flow arrangements. The de-cored ends facilitate flow of water into previously enclosed or partially enclosed portions of the produce and allows the produce to “open” (spread the leafy portions apart). Additional cleaning flow occurs as the washing fluid splashes and eddies within and against the produce, and even more so when the washing fluid drains from the produce. As noted above, multiple tanks may be utilized with sprayers (spray bars) between tanks. (alternatively, a tote can be routed more than once through a single tank). Repeatedly immersing, draining and spraying of the de-cored produce provides for sufficient cleaning solution flow to provide a very clean product.
At step 150, the totes are loaded into a dryer. Preferably the dryer is a spin dryer similar in construction to that described in Mitchell et al. I, however, other dryers may be utilized. The totes are taken from the washing line and preferably loaded into the spin dryer so that an open end of the produce in the totes is facing outward (i.e., centrifugal forces push excess water out through the leafy end, if any, of the produce). The centrifugal force of the spin dryer is more effective with the de-cored produce compared to intact core produce because of easier flow through the vegetable (e.g., there is less vacuum holding water to the produce because the cut end can produce an open channel). Due to the greater efficiency of spin drying de-cored produce, the dryers may be run at a slower rpm compared to drying operations on cored produce (increasing the dryers' useful life and decreasing energy consumption). Optionally, the spin speed or cycle times of the drying operations may be reduced. After drying, the products are packaged (step 160) and then sold/delivered to a customer (step 170).
At step 330, with the cut de-cored produce is loaded in totes, the totes are then loaded onto a field conveyor belt and sprayers mounted around the conveyor belt perform a spray wash on the core and leafy ends (tops) of the produce. The initial spray wash is, for example, a chlorine solution which cleans excess dirt and plant liquid (“milk”), and reduces browning and discoloration of the produce.
At step 340, the totes are loaded onto a field trailer (preferably on pallets on the trailer). The field trailer provides for temporary storage and allows for larger bulk pickups of the loaded totes. On the field trailer, the loaded totes are covered (e.g., an opaque cover that protects from sunburn, windburn (particularly during transport), and keeps out dust and other foreign particles, reduces dehydration.). In one embodiment, the cover is a white plastic shroud strapped to the totes.
Again, the loaded totes are transported to a processing plant for washing, drying, packaging, and product distribution (steps 350, 360, 370, and 390).
Turning now to the washing process. The produce are placed in a pre-aligned direction in the totes.
As shown in
Although the present invention is preferably implemented with flows impacting each side of the tote (e.g.,
The whole head form of the produce also helps keep the produce in the tote during washing and drying, and makes it easier to remove from the tote for packing, either clam shell or bags. The whole head form can generally be described as a vegetable or produce in which a head (e.g., leafy portion of the vegetable remains together even though the core portion of the vegetable has been removed).
The transport mechanism 520 is, for example, as illustrated in
De-cored ends 575 of produce are illustrated in tote 570. A flow of washing fluid through the tank 510 is shown by the circled x's 580 (indicating a flow of washing fluid into the page of the drawing). The flow of washing fluid is consistent with the pre-aligned direction that produce was loaded into the totes, the de-cored ends 575 are facing flow of the washing fluid, and leafy ends 675 of the produce (not shown in
In one embodiment, the totes are open at a top of the totes. To prevent produce from floating out of the totes (or being expelled due to the flow of washing fluid, a top conveyor belt 590 rides on top of the totes. The top conveyor belt also helps maintain registration of the totes to the lower conveyor belt(s) (520A-520E).
The present invention refers to registration, a term which is used to describe maintaining a position of a tote on the conveyor belt (or other transport mechanism). In the context of the present invention, registration is enough holding power (e.g., traction) to move the tote through the wash tank (preferably, the totes maintain a same position on the belt(s), but some slippage or movement relative to the belt(s) is permissible). The use of stops, latches, or other gripping mechanisms may also be used to maintain a relatively stable position on the transport mechanism.
In one embodiment, the bottom conveyor belt is a single loop. Stops 592 are placed on the conveyor belt and maintain registration of the totes with the bottom conveyor belt. In one embodiment, stops are replaced by latches 594 that hook onto the tote and maintain registration with the conveyor belt. The latches 594 also eliminate the need for the top conveyor belt to maintain registration. In one embodiment, the top conveyor belt 590 is not used and the totes are fitted with top (e.g., grated wire or plastic top—not shown) to prevent the produce from leaving the tote. Another embodiment involves the use of any gripping mechanism on the bottom belt such as raised rubber “grip” sections placed to catch the bottom edge of the tote. This is enough to maintain placement and forward motion of the totes.
Preferably, the speed of the conveyor belts are variable (e.g., computer controlled). Inverters control the speed of the conveyor motors. A control panel may, for example, be placed inside the cabinet to prevent worker tampering. The variable speed of the conveyor belt is used to control a “dwell time” or the duration of the products exposure to the wash fluid and jets. This increases the effective range of products and product conditions to be processed by the same production line. For example, for a heavily soiled product, the production line would be set or otherwise programmed for a longer dwell time. Less soiled or more easily cleaned products would be set for relatively shorter dwell times.
The size and shape of the tank 510 may take many different configurations. As noted above, ramps may be included in the tank to facilitate movement of totes through (e.g., entry into and exit from) the tank.
In several embodiments, the washing device also includes a flow device that maintains a flow of washing fluid through the tank. In
In one embodiment, the flow is created only from immersion of the tote in the wash tank. The de-cored and leafy ends of the produce “fill” with washing fluid by being immersed. Because the butt end of the produce has been de-cored, the flow, or “filling” of the produce with washing fluid is more efficient and effective compared with immersion of intact core produce. Likewise, and flows maintained in the tank or caused by motion of the tote through the wash tank are also more effective at cleansing the produce.
In one embodiment, the totes are loaded exactly as described in Mitchell et al. II except that the produce has been de-cored or otherwise processed (e.g., field processing) as described elsewhere herein. Tote loading for this embodiment is shown in
Furthermore, variations in the direction and travel of the line (e.g., conveyor belt of
For the various embodiments employing a flow of washing fluid, many different types and variations of flow devices may also be utilized. The flow device may be, for example, a pump, waterwheel, or other device capable of maintaining a flow of washing fluid. The present inventors have realized that pump sizing ensures wash effectiveness across all product densities. Larger pumps create more turbulence in the lines. An APV pump model #18vs2 has been determined to provide needed size capacity. The size is 7.5 hp. Other makes/models of pumps having similar capacities would also provide the same level of effectiveness.
Apparatuses and configurations in which the flow is applied to the totes may also take many forms.
Input flow pipes 602C and 602D route a flow 612 of washing fluid into the wash tank 510. Nozzles 604C and 604D are fitted at ends of the input flow pipes 602 C and 602 D and provide a spray pattern directed at produce loaded in totes. The spray pattern from nozzles 604C and 604 D are directed toward cut de-cored ends of produce on the right side of tote 608.
Placement of the nozzles is made to maximize flow of washing fluid through the whole head de-cored produce (e.g., directing nozzles toward the totes, and, more specifically, toward de-cored ends of produce in the totes). The de-cored ends 575 of the produce are facing the flow of the washing fluid.
A drain (or central sump) 615 is located, for example, at a center of the wash tank and collects washing fluid that has run off the produce and feeds a return flow 620 back to a pump 630 or other mechanism that maintains the flow 610. The return line may, for example, drain into a filter to remove debris washed from the produce. The washing fluid may also be directed to a holding area (e.g., holding tank) where maintenance of the washing fluid (e.g., testing, temperature maintenance, adding additional fluid, etc.) is performed.
In this embodiment, the washing force is not a spray directed at the de-cored ends, but instead is a flow of washing fluid (or other cleaning solution) directed across the washing tank 510 from an end of pipes 635A and 635B to return pipes 650.
Although shown as 2 example supply pipes and at least one return pipe are shown in the figures, both the supply and return pipes may be embodied as a single large pipe or any number of smaller pipes.
The flow is sufficient to enter the de-cored ends of the produce and, at least to some extent, flow through the produce. In flowing through the produce, an “opening” of the leafs or leafy end of the produce occurs. Sediment, contaminants, and other debris between the leafs are washed away with the flow. The return pipes are capable of the same or better flows as the input pipes 635A and 635B.
The present invention provides for various configurations and processes for harvesting, washing, and packaging produce. In at least one embodiment, the produce is washed in the field twice and once in a remote processing plant. The produce may be double washed at the processing plant. Any combination of the field and plant washing as described herein may be utilized. The end result is a de-cored product that has been cleaned “triple washed,” dried, and packaged ready for use.
Portions of the present invention may be conveniently implemented using a conventional general purpose or a specialized digital computer or microprocessor programmed according to the teachings of the present disclosure, as will be apparent to those skilled in the computer art. For example, sensor data monitoring washing fluid quality, temperature, and flow rates (e.g., sensors mounted in the holding tank) may be fed to a computer programmed to evaluate those factors and make adjustments as needed. The adjustments may include changing water, adding chlorine, anti-bacterial agents, preservatives, coloring, sealants, or other chemicals, and/or raise or lowering the washing fluid temperature. The adjustments may be made, for example, via valves having electronic controls coupled to programming (e.g., allow the release of fresh water and/or chemicals, open/close drains, for example), and switches that control flow of pumping devices and heating/cooling elements.
Appropriate software coding can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will be apparent to those skilled in the software art. The invention may also be implemented by the preparation of application specific integrated circuits or by interconnecting an appropriate network of conventional component circuits, as will be readily apparent to those skilled in the art.
The present invention includes a computer program product which is a storage medium (media) having instructions stored thereon/in which can be used to control, or cause, a computer along with appropriate equipment infrastructure (wash tanks, transport mechanisms, etc) to perform any of the processes of the present invention. The storage medium can include, but is not limited to, any type of disk including floppy disks, mini disks (MD's), optical discs, DVD, CD-ROMS, micro-drive, and magneto-optical disks, ROMs, RAMs, EPROMs, EEPROMs, DRAMs, VRAMS, flash memory devices (including flash cards), magnetic or optical cards, nanosystems (including molecular memory ICs), RAID devices, remote data storage/archive/warehousing, or any type of media or device suitable for storing instructions and/or data.
Stored on any one of the computer readable medium (media), the present invention includes software for controlling both the hardware of the general purpose/specialized computer or microprocessor, and for enabling the computer or microprocessor to interact with a human user or other mechanism utilizing the results of the present invention. Such software may include, but is not limited to, device drivers, operating systems, and user applications. Ultimately, such computer readable media further includes software for performing the present invention, as described above.
In describing preferred embodiments of the present invention illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the present invention is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents which operate in a similar manner. For example, when describing a flow mechanism, a mechanical pump is discussed and illustrated, however, and other alternate mechanism capable of causing a flow of liquid (e.g., compressed air driven pump) may be utilized. The invention includes any and all modifications needed to adapt the teaching described herein to work with alternate mechanisms. All other described items, including, but not limited to washing tanks, pumps, totes, conveyor belts, nozzles, supply and return pipes, drains, anti-bacterial agents, chlorines, washing fluids, etc should also be consider in light of any and all available equivalents.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
