Patent Application
20180280899
The object of the present invention is a method and a modular and easily transportable plant intended for dosing, mixing and packaging powdery products, granular products and other products having similar characteristics and comprising a carrying structure incorporating a plurality of modules interacting with one another to obtain a mixed and packaged product ready to be sold, and comprising as a main particularity the incorporation of cooling and drying means for cooling and drying the mixed product.
The present invention is comprised in the technical field of industrial plants for manufacturing, mixing and packaging powdery products such as those used in the agri-food industry, without this limiting the application thereof to other products having similar characteristics in other industrial manufacturing sectors.
Conventionally, in plants and machines for mixing powdery products different processing phases the product to be mixed goes through in the vertical direction, i.e., the product goes from one phase to another due to gravity, from the upper part of the plant to the lower part, are described, as is described, for example, in Spanish patent document with application number P0381423, which describes a machine for treating or mixing powdery products, granular products or doughy products.
To solve this problem, European patent document EP2465780 describes a mobile dosing, mixing and packaging plant which, as it can be a mobile plant capable of dosing, mixing and packaging powdery products, granular products or the like, can be transported in a certified shipping transport container measuring 40 feet, and where its entire structure, including all the necessary machinery, elements and tools, are distributed horizontally. Furthermore, this document describes a mobile plant the operative control of which is done remotely, assuring complete control over the product and the traceability thereof, being provided with real time connection with a control center arranged for such purpose in another location other than that of the mobile plant itself.
Nevertheless, the plant described in EP2465780 is not provided with cooling and drying means for cooling and drying the mixed product, so its functionality is limited. This is essentially because this patent only allows mixing powders, where it is desirable to perform processes of another type.
An object of the present invention is a method and a modular mobile plant which, based on concept described in patent document EP2465780, improves its functionality and modularity such that possible uses thereof and, therefore the versatility thereof, are increased, becoming a multifunctional plant. In that sense, the present invention describes a multifunctional plant that mixes products of any type, not just powdery products like in patent document EP2465780. The present invention also allows granulating mixed products.
A modular, mobile mixing and packaging plant for powdery or granular products comprising a carrying structure having dimensions suitable for being introduced in a standard shipping container and internally housing a receiving and manual weighing module, a material loading module, a mixing module and a packaging module, where there are incorporated automatic dosing modules for the automatic dosing prior to introducing the formula and furthermore incorporating an automatic formula loading module with an automatic bag opening system for automating the loading of raw material into the plant.
Furthermore, the mobile plant also incorporates a liquid injection module for injecting liquids into a powder mixture, maintaining a final powder state. The module is automated, such that it is possible to automatically dose the liquids into the mixture, up to ten liquids, according to what is previously required by the end user, with the ability to inject up to 50% liquid into the powder such that the powdery form is maintained after the injection with the conditions and parameters required by the final formulation, such as temperature, stirring and pre-mixture of liquids.
Finally, the plant incorporates a packaging module depending on the type of packaging the end user requires, including, in a non-limiting manner, a big bag bagging module, a European type bag bagging module or a module for bagging any other type of package (such as sachets, for example). Furthermore, the packaging module can incorporate an automatic palletizing module for any client needing end of line automation.
In all the described modules, a series of basic conditions are met to assure compatibility with the plant as a whole, because all the modules must be transportable in a maritime transport container measuring 20 or 40 feet, depending on the type of module, with all the necessary machinery, auxiliary elements and tools included.
On the other hand, the modules must be connectable plug and play type modules, i.e., they must be able to be connected with the CPU managing the plant as a whole for immediate use, which includes that the modules must be compatible both electrically and pneumatically.
In addition to the described modules, the multifunctional plant is most advantageous precisely because of the incorporation of means for cooling and/or drying the mixture in the mixing module, more specifically, the mechanical part of the mixer has been modified, utilizing its movements, to incorporate a flow of a fluid (preferably air) from the fixed mechanical part until extracting it through the involute of the lower part or lower side area of the container, all in an automated manner. In the present invention, it is essential to obtain air recirculation in the container, and particularly in the involute of the lower part thereof.
More specifically, the advantages of the solution described in the present invention are the following:
In summary, by adding automatic suction to the container and the fixed part of the installation, the mixing equipment therefore goes from being a mixer to being a (a) fluidized bed dryer; or (b) a pelletizer or granulator; or (c) a cooler; or (d) a vacuum dryer. The equipment of the present invention therefore becomes multifunctional equipment with this innovation.
The foregoing is described in the different aspects indicated in the independent claims attached to the present specification. In the same manner, the dependent claims show particular practical embodiments of the invention.
More specifically, in a first aspect of the invention the modular mobile mixing and packaging plant for powdery or granular products comprises a carrying structure having dimensions suitable for being introduced in a standard shipping container and internally housing a receiving and manual weighing module, a material loading module, a mixing module, and a packaging module, wherein the mixing module comprises means for cooling and/or drying the mixture contained in said module.
In a particular embodiment, the present invention incorporates at least one additional module selected from: an automatic liquid dosing and injection module or a big bag packaging module, wherein said additional modules can be inserted and be connected with a control PLC of the modular plant.
In another particular embodiment, the liquid injection module is configured for dosing liquid amounts of any viscosity into the mixing tank of the mixing module by means of a pump, with the flow rate thereof being controlled by means of a plurality of loading cells.
In another particular embodiment, the liquid injection module comprises a cylindrical liquid compartment with a frustoconical bottom and dual chamber prepared for introducing thermal oil distributing the heat of thermal resistors.
In another particular embodiment, the liquid compartment has a hygienic gantry where there is supported an agitator rotary support with agitator scrapers which are made of white, food-grade plastic and withstand service temperatures of 60° C. and peaks of up to 100° C.
In another embodiment of the invention, the liquid compartment comprises at least one inclined cover in the upper part.
In one embodiment of the invention, the liquid compartment comprises an outlet for the product with a sanitary bottom valve; and wherein upper openings will have safety sensors in at least one cover; and wherein each of the supports of the liquid compartment comprises a loading cell that allows reading the weight of the product.
In one embodiment of the invention, the liquid injection module comprises a heating system that carries out the function of keeping the product at the desired temperature, if required, by means of a dual chamber around the liquid compartment in which a thermal oil will circulate and in which thermal resistors will be installed; and wherein the outside of the liquid compartment is insulated.
In one embodiment of the invention, to load the thermal oil, the equipment has a compartment also acting as an expansion vessel, such that the oil enters a dual chamber of the liquid compartment where it is heated by means of thermal resistors; and wherein the outlet for the oil is located in the lower part, where there is a gear pump that continuously recirculates the thermal oil while it is hot through the oil circuit.
In another particular embodiment, the temperature of the product inside the liquid compartment and the temperature of the thermal oil are controlled by temperature probes.
In another particular embodiment, dosing is performed by means of a pump such that its inlet is connected to a bottom valve of the liquid compartment; and wherein the inlet of the pump is always below the outlet of the bottom valve.
In another particular embodiment, the big bag module (400) comprises: (a) a structure (401) capable of being introduced in a 20″ container without deformations, protecting and providing support to the different auxiliary machines and equipment for performing the different processes; (b) receiving the mixed product in a hopper (402) and dosing for packaging; (c) a dosing valve (403) installed after the hopper (402) for dosing the already mixed product; (d) an in-line metal detector (404) with rejection means; and (e) a batch bagging module (405), with labeling and weight control (406).
In a second aspect of the invention, the method of mixing and packaging powdery or granular products in the modular mobile plant object of the invention comprises the steps of: receiving and manual weighing, loading material, mixing and packaging; and wherein said steps are controlled by a PLC remotely connected with a central server providing the instructions and orders for mixing and configuring the end product, and further comprising at least one step of drying and cooling the mixed product in the actual mixing module.
In a particular embodiment of the method of the invention, said method comprises at least one additional step selected from: automatic dosing, injecting liquids, and bagging; wherein said additional modules can be inserted and be connected with a control PLC of the modular plant.
Finally, a third aspect of the present invention claims a computer program with instructions configured for being executed by one or more processors, which instructions, when executed by the plant of the invention, causes said plant to carry out the method object of the present invention.
Throughout the description and claims the word “comprises” and variants thereof do not seek to exclude other technical features, additives, components, or steps. For those skilled in the art, other objects, advantages, and features of the invention will depend in part on the description and in part on putting the invention into practice. The following examples and drawings are provided by way of illustration and are not intended to limit the present invention. Furthermore, the present invention covers all the possible combinations of particular and preferred embodiments herein indicated.
A series of drawings which help to better understand the invention and which are expressly related to an embodiment of said invention presented as a non-limiting example thereof is very briefly described below.
As can be seen in
The carrying structure (1) is formed by various square tubes (11) supported at several height-adjustable support points (12), several hinges (13) and a set of stairs (14) with a safety railing (15). This structure will have dimensions that are not larger than the measurements of a standard container measuring 40 inches, such that the total dimensions allow the transport thereof in a standard transport container (generally a shipping container measuring 40 feet).
In a practical embodiment, the structure (1) will be built with square stainless steel tube. The ground of the structure will be formed by rolled carbon steel profiles. The profiles and crossbeams of the structure will be made of square stainless steel tube. The structure (1) will be supported by six height-adjustable support points on which there is supported a diamond plate where objects and staff move about. One side (16) will fold in three sections and will also be built with square tube and diamond plate. The aforementioned hinges will fold the aforementioned sides using a number of capstans for easy installation and positioning.
The set of access stairs (14) will be built with stainless steel, except for the tread of the steps, which will also be built from stainless steel anti-skid plate. A rectangle will be arranged at the end of the set of stairs to provide access to the upper part of the platform. The top of the platform and set of access stairs have a protective railing (15) along the entire perimeter, built with square stainless steel tube.
The automatic dosing modules perform dosing prior to introducing the formula and furthermore incorporating an automatic formula loading module with an automatic bag opening system to automate the loading of raw material into the plant. These automatic dosing modules are connected in the receiving and weighing module (2).
Furthermore, the mobile plant also incorporates a liquid injection module for injecting a liquid into a powder mixture (
More specifically, the liquid injection module (300) serves for dosing liquid amounts of any viscosity into the mixer by means of a pump (318), preferably a lobe pump, without ruling out pumps of any other type, where the flow rate is controlled by means of a plurality of loading cells (320). The liquid injection module performs the following phases during the process:
The liquids are homogenized by means of the agitator formed by the agitator rotary support (326) and the agitator scrapers (327) because when there is more than one liquid, the exact amount with the same proportion of each ingredient must be previously homogenized and then dosed in that manner. The liquid injection capacity reaches up to a percentage of 50% (it will normally be a lower percentage) with respect to the powder such that the powdery form is maintained after the injection with the conditions and parameters required by the final formulation, such as temperature, stirring and pre-mixture of liquids.
As can be seen in the following table, the liquid injection module (300) comprises the following elements in the particular non-limiting embodiment shown in
In a particular embodiment, the liquid compartment (305) is a cylindrical type compartment with a frustoconical bottom and dual chamber prepared for introducing thermal oil distributing the heat of resistors (306), which in this particular embodiment have a power of 3 kW each.
The liquid compartment (305) has a hygienic gantry where there is supported an agitator rotary support (326) with agitator scrapers (327) which are made of white, food-grade plastic and withstand service temperatures of 60° C. and peaks of up to 100° C. Furthermore, it comprises at least one cover (307) in the top part making cleaning and inspections easier, furthermore having a certain inclination as shown in
The outlet for the product with a bottom sanitary valve (317). The upper openings will have safety sensors (323) in at least one cover (307). Each of the supports of the liquid compartment (305) has a loading cell (320) that allows reading the weight of the product.
The heating system performs the function of keeping the product at the desired temperature, if necessary, by means of a dual chamber around the liquid compartment (305) in which the thermal oil will circulate and in which the resistors (306) will be installed. The outside of the liquid compartment (305) is insulated.
To load the thermal oil, the equipment has a compartment also acting as an expansion vessel. The oil enters the dual chamber of the tank where it is heated by means of thermal resistors (306). The outlet for the oil is located in the lower part, where there is a gear pump (315) that continuously recirculates the thermal oil while it is hot through the oil circuit (313).
Both the temperature of the product inside the liquid compartment (305) and the temperature of the thermal oil are controlled by temperature probes (324).
The dosing system allows effectively dosing the product contained in the liquid compartment (305) towards the mixing tank (41) of the mixing module of the plant of
Finally, the frame is formed by a tubular structure 325 to prevent flat surfaces and therefore the accumulation of dirt and to make cleaning of all the surfaces easier. The structure incorporates wheels 322 with the possibility of fixing and height-adjustable feet 321 to provide stability to the assembly.
Finally, the plant incorporates a packaging module depending on the type of packaging required by the end user, including, in a non-limiting manner, a big bag bagging module, a European type bag bagging module or a module for bagging any other type of package (such as sachets, for example). Furthermore, the packaging module can incorporate an automatic palletizing module for that client needing end of line automation.
In a particular embodiment, the plant of
The arrangement of this plant is a horizontal container measuring 20 feet which, once at its destination will be installed vertically and will be located after the mixing module (4). The big bag module (400) is made up of three blocks which are placed on top of one another vertically and all the installations are connected with quick connect adaptors without requiring in situ installations, because everything is ready to be assembled and with all installations for starting up in one day. The quick connections and electric power are provided from the general distribution board of the plant of
Therefore, once the mixing of the product in the mixing module (4) has ended, said product goes to the packaging module (5) which, in this embodiment, comprises a system for taking the powder after mixing to the big bag module (400). The capacity to be achieved is approximately 1000 kg/h, depending on the products.
Packaging is done for four or five 200 kg batches combined with one another. The module is designed to be contained and transported in a 20″ open top container with all the necessary machinery, auxiliary elements and tools included. It has been designed to be installed vertically, under cover, protected from the elements, in a ventilated site and located on even ground suitable for the described loads.
This design is established so that it can be divided into three blocks of a height of about 2.3 m each (in any case, less than 2.4 m, which is the maximum height of the containers) and so that they can be handled with an electric fork lift during assembly and installation. Suitable transport and operation is thereby assured, in addition to achieving safety and traceability in the process so that staff working at the plant cannot make mistakes and making it easier to follow the manufacturing sequence as it has been projected, and implementing the necessary surveillance and control means from the central office.
The big bag module (400) comprises the following elements:
The production parameters to be achieved are 1 Tm/h in 4 or 5 batches per bag. The times in the different phases are 12 minutes at most, so said cycle at most will continue to be maintained to assure the indicated capacity. For complete certification and combination with an existing plant of mixtures, in this non-limiting example the times will be (they logically may vary according to the desired installation):
Generally, all the general services of the installation will be connected with those of the plant of
| Number | Date | Country | Kind |
|---|---|---|---|
| 201700326 | Mar 2017 | ES | national |
