1. Field of the Invention
This invention relates to a system and method for spraying granulated materials, such as animal bedding or litter, with a low-shear tolerant treatment fluid, such as a fluid containing biological components (probiotics/bacteria).
2. Description of Related Art
Granulated materials, such as animal bedding and litter products, are frequently treated with a fluid during processing. These fluids may add a variety of compounds that enhance the functionality of the granulated material. For example, bacterial compositions or pH indicators may be added to cat litter to help control odor during use or to provide a visual indicator of the cat's health based on the pH of its urine. These compositions are typically sprayed onto the granulated material during processing. A centralized spray nozzle will spray the product onto the granulated material as it passes by the nozzle on a conveyor. Conventional sprayer systems have numerous problems, including uneven dispersion an over saturation of part of the granulated material which can lead to clumping of the material during processing that results in jamming storage hoppers and packaging equipment.
The functionality of conventional fluid transfer systems in general are predicated on flow rate, particle size, and pressure. The flow rate and mean droplet size are important to prevent clumping and ensure uniform dispersion of the fluid to granulated compounds such as cat litter. Large particles will induce clumping and non-uniform coverage rates. Small particles, like mist, will induce non-uniform coverage rates due to non-penetration of the granular parison. Misted fluids pose an inhalation risk to production personnel. High pressure and/or high flow rates have minimal effect of the transfer of most fluids. When the fluid is a sensitive, low-shear tolerant agent, such as a biological, these attributes become very critical to their viability and functionality during they conveyance. Dramatic fluctuations in these attributes generate shear forces which are detrimental to delicate biological organisms used in today's green/environmentally friendly world. Current application processes use standard sprayer systems that are not configured to address issues with localized saturation or to minimize shear forces to allow effective spraying of low-shear tolerant compositions. Bacterial compositions are particularly sensitive to shear forces and can be damaged or destroyed during the spraying process, rendering them less effective or useless for their intended purpose (e.g. odor control in cat litter). There is a need for a spraying system that will minimize shear forces while still delivering the desired flow rate and achieve uniform dispersion and particle (or droplet) size, while reducing the risks of downstream clumping and inhalation exposure for workers.
According to one preferred embodiment of the invention, a fluid conveyance system is provided that allows the transfer of bulk sensitive, low-shear tolerant agents (such as biological materials, encapsulated materials and the like) from a holding tank at a high velocity and low flow rate with medium pressure through at least two wide angle nozzles for uniform application to granulated materials, such as animal bedding and litter materials. By splitting the flow of fluid into a minimum of two streams via multiple spray nozzles, the shear forces and pressure are reduced while maintaining the same total flow rate. The splitting of the fluid flow also reduces over saturation of the fluid's treatment agents or components in a localized area and minimizes inhalation risks for personnel working near the spray area.
According to another preferred embodiment, the fluid conveyance system preferably comprises a conveyor or chute to transport the granulated material under the spray nozzles, with the conveyor or chute being configured to distribute the granulated materials into a wider, thinner laminar plane on the conveyor or dispersion plate of the chute. This increases application coverage as more of the granulated material will be contacted by the spray. The falling parison of flowing cat litter (or other material to which the sprayed agents are to be applied) is generally very tight and dense, so a thinner distribution helps with achieving uniform coverage of the sprayed fluid.
According to another preferred embodiment, the fluid conveyance system includes various lateral and cross bars to support the spray nozzles over the conveyor. These bars are adjustable to alter the height above and angle of the spray onto the conveyor or chute. According to another preferred embodiment, the fluid conveyance system includes various adjustable lateral and cross bars to support a portion of the conveyor or chute under the spray nozzles and allow for adjustment of the angle and distance between the spay nozzles and surface of the conveyor or chute. According to another preferred embodiment, the fluid conveyance system includes a blow-off nozzle to direct compressed air at the end of each spray nozzle to aid in cleaning the ends of the spray nozzles and avoid accumulation of dried spray fluid on the ends of the spray nozzles during periods of shut-down.
The fluid conveyance systems according to the invention are useful in achieving uniform application of low-shear tolerant agents, such as probiotics, vitamins, nutrients, deodorizers, pH indicators, medical compounds, reactive compounds, and other additives to cat or animal litter and animal bedding. The conveyance systems according to the preferred embodiments reduce downstream processing issues, such as jammed hoppers and packaging equipment, clumping of the granulated material, oversaturation, non-uniform coverage, and aerosolization and inhalation risks of potentially harmful agents, while ensuring biological viability (if the fluid being sprayed contains biological components) and uniform dispersion over the granulated materials and increases process efficiency by reducing over spray.
The device of the invention is further described and explained in relation to the following drawings wherein:
Spray bar 26 is supported a distance above the conveyor or chute 12 by upper support assembly 23. Upper support assembly 23 preferably comprises support bars 16, adjusting bars 18, lateral support bars 22, and cross support bars 24. Attached to side walls 14 are at least one and preferably a plurality of support bars 16. Adjusting bars 18 may also be attached at the upper end of one or more support bars 16. Preferably fluid conveyance system 10 comprises at least four support bars 16, two spaced laterally apart from each other on each side of conveyor 12. Lateral support bars 22 connect the upper ends of the support bars 16 on each side of the conveyor 12. Cross bars 24 connect a lateral bar 22 on one side of conveyor 12 to another lateral bar 22 on the other side of conveyor 12. Spray bar 26 is attached to at least one and preferably at least two cross bars 24. A plurality of latching holes 20 are provided at the upper and lower ends of support bars 16, on adjusting bars 18, side walls 14, lateral bars 22, cross bars 24 and spray bar 26 to facilitate adjustable attachment of the these components. This allows the height of spray bar 26 above conveyor 12 to be adjusted, as well as the angle of spray bar 26 relative to the conveyor 12 (as support bars 16 may be set at different heights, for example). Additionally, spray bar 26 may be configured at an angle across conveyor 12 (such as by attaching one end of spray bar 26 to a cross bar 24 at a point closer to a sidewall 14 than the other end of spray bar 26 is attached). Any conventional attachment mechanism, such as nuts and bolts, that allow releasable attachment of these parts may be used. Most preferably, the support bars 16 are not perpendicular to the conveyor 12, but are disposed at an angle θ1 relative to the conveyor that is between 30-80 degrees.
Spray bar 26 comprises at least two and preferably three or more spray nozzles 28 that are oriented toward conveyor 12. The fluid to be applied to the granulated material is supplied to spray bar 26 from a holding tank (not shown) (using conventional attachments, pumps, and other equipment as necessary to provide a pressurized spray of the fluid to spray nozzles 28) and dispersed onto the granulated material on conveyor 12 as it passes under the spray nozzles 28. The size of spray nozzles 28 is preferably limited to producing volume mean diameter range between 25-100 microns. The volume mean diameters are a function of pressure/nozzle size/flow rate combinations, as will be understood by those of ordinary skill in the art. The fluid travels at a high velocity and low flow rate with medium pressure through at least two spray nozzles 28, which are preferably wide angle nozzles. By using at least two spray nozzles 28, the shear forces on the fluid are reduced and the pressure is reduced, while maintaining the same total flow rate that would be achieved by a single nozzle as used in the prior art. Splitting the flow across at least two spray nozzles 28, also reduces the chances over oversaturating part of the granulated material, which reduces clumping during further processing. Typically the granulated materials will pass under spray nozzles 28 on conveyor 12 at a high rate, such as approximately 200 pounds per minute. The fluid conveyance system 10 is capable of dispersing the fluid through the spray nozzles 28 to achieve a uniform dispersion, with damaging or destroying any low-shear tolerant components of the fluid and without over-saturation problems faced by prior art systems.
Attached to side walls 114 or to a central portion of the underside of a dispersion plate (surface that supports granulated material) of chute 112 are at least one and preferably a plurality of adjusting bars 118. Adjusting bars 118 are attached at the upper end of one or more support bars 116. Preferably fluid conveyance system 110 comprises at least two support bars 116 spaced laterally apart from each other on the under each side of chute 112. A plurality of latching holes 120 are provided along the length of adjusting bars 118 and support bars 116 to facilitate adjustable attachment of the these components. This allows the lower end of chute 112 to be adjusted, changing the angle and distance of the chute surface relative to spray nozzles 128 and relative to the horizontal (ground). A cross support bar (not shown) may be attached to adjusting bars 118 on the underside of chute 112 to further support chute 112. A mounting bar 124 is preferably attached to a stable structure in the area where system 110 will be used, such as the floor, a wall, or another piece of granulated material processing equipment. Conventional attachment points 130 are provided on mounting bar 124 to connect mounting bar 124 with each support bar 116 to support a lower end of chute 112. The upper end of chute 112 is similarly attached to a stable structure in the area where system 110 will be used, such as the floor, a wall, or another piece of granulated material processing equipment, using conventional attachment points 130 and brackets 131.
A bracket 138 holds each spray nozzle 128 securely on a support member 142. Most preferably, the spray nozzles 128 are aligned along a central longitudinal axis of spray bar 126 with each spray nozzle 128 being slightly forward of the spray nozzle below it, as seen in
Each spray nozzle 128 is disposed at an angle α1 relative spray bar 126 (measured from a longitudinal axis of the spray nozzle) of between around 30 to 60° and most preferably between around 40 to 50°. This angle aids in complete coverage of the dispensed product, while minimizing overspray which could lead to product clumping, damaging other processing components and non-homogenous finished product. While other parameters may be changed alter the width of the spray 134 across chute 112 (such as distance between spray nozzle 128 and chute 112), changing the angle α1 allows for spray width adjustments. With an angle α1 range of 30-60°, the distance the fluid travels between the nozzle 128 and chute 112 can be varied up approximately 73%, which allows for variation in the width of spray 134 at the surface of chute 112 to be varied by around 58%, without requiring movement of spray bar 126 or adjustment of chute 112. With an angle α1 range of 40-50°, the distance the fluid travels between the nozzle 128 and chute 112 can be varied up approximately 19%, which allows for variation in the width of spray 134 at the surface of chute 112 to be varied by around 19%, without requiring movement of spray bar 126 or adjustment of chute 112. These angles (with corresponding changes in angle β) allow for fine tuning of the width of spray 134 at the surface of chute 112 to ensure all granulated material is being sprayed without having overspray issues. Allowing the width of spray 134 to be adjustable also provides flexibility in changing production feed rates for the granulated material being sprayed.
Most preferably, an air nozzle mounting bracket 136 is used for mounting each blow-off nozzle. Each air nozzle mounting bracket 136 comprises a rear portion 135 and a front portion 137. Disposed near a forward end of each air nozzle mounting bracket 136 is a blow-off nozzle 132. Blow-off nozzle 132 is most preferably disposed on front portion 137 and slightly forward from the forward most end of spray nozzle 128. Rear portion 135 is preferably substantially parallel to a longitudinal axis of spray nozzles 128. Front portion 137 is preferably disposed at an angle α2 relative to the rear portion 135 (and toward the spray nozzles 128) between around 135 to 170° and most preferably between around 150 to 160°. This angle, in combination with the forward positioning of blow-off nozzle 132 relative to spray nozzle 128, aids in pointing the end of blow-off nozzle 132 directly at the end of the corresponding spray nozzle 128, so that air blown through blow-off nozzle 132 is directed to the forward end of spray nozzle 128. Tubing 146 connects each blow-off nozzle 132 to a supply of compressed air (or other gas). A solenoid valve or other type of actuator controls the flow of gas from the supply of compressed gas through the blow-off nozzle 132 so that air (or other gas) is blown onto the end of spray nozzle 128 to clean off and dry the spray nozzle 128 when fluid is not being sprayed onto the granulated material. This aids in cleaning the spray nozzles 128 and keeping them from becoming clogged or fouled, particularly if a biologocial agent is being sprayed. Typically, a flow of air or gas for approximately 20 second to 2 minutes is sufficient to clean the nozzles and the flow of air or gas may be automatically or manually shut-off after such time. The cleaning process is preferably repeated each time the spray of fluid through spray nozzles 128 is stopped.
Each mounting bracket 136 is preferably pivotally attached to spray bar 126 or otherwise attached in a manner that allows slight positional adjustment of mounting bracket 136 once system 110 is installed for use, without requiring a positional change in spray bar 126 once attached to the ceiling or other structure and without requiring changes to upper support assembly 23 or overhead support assembly 323 (if they are used). A support member 142 is attached to each mounting bracket 136 so that any positional adjustment in a mounting bracket 136 will similarly change the position of a corresponding spray nozzle 128, and maintain the relative positioning of blow-off nozzles 132 to the spray nozzles 128. Alternatively, support members 142 may be separately pivotally attached to spray bar 126 to allow the angle α1 to be adjusted to change the width of spray 134 at the surface of chute 112 after installation. It is preferred that mounting brackets 135 (or support members 142 if separately attached to spray bar 126) be adjustable by at least around +/−5° after nozzle assembly 122 is installed without requiring positional movement of spray bar 126, chute 112, or upper support assembly 23 or overhead support assembly 323 so that the width of the spray 134 may be adjusted without significant disruption or shutdown of operations, but greater adjustability, even up to the full 30-60° or 40-50° ranges for α1, may be used. Slots in rear portion 135 of bracket 136 may also be used for lateral positioning adjustments relative to spray bar 136 (and spray nozzles 128 if support members 142 are not attached to brackets 136).
After passing through fluid sprays 134, the granulated material exits chute 112 and proceeds to other processing systems or operations, such as packaging. Typical manufacturing equipment, such as blowers, augers, and conveyors may be used to move the granulated material onto chute 112 and to move it from chute 112 to other downstream processing systems. Alternatively the entire system 310 may be disposed within a housing such that mounting bars 325 are attached to an interior upper surface of the housing and mounting bar 124 is attached to an interior sidewall of the housing. Apertures through the housing are provided to allow granulated material to enter the housing (from chute 312 or otherwise) on conveyor or chute 12, 112 and to exit the housing after being sprayed. The holding tank for the fluid to be sprayed and the supply of compressed air may be stored within the housing or outside the housing. If stored outside, additional apertures for tubing 144, 146 are provided.
If a stationary chute 12, 112 is used with systems 10, 110, 210, or 310 instead of a moving conveyor, the chute 12, 112 is preferably disposed at an angle θ2 relative to horizontal (ground level) of around 70 to 90° and most preferably around 80 to 85°. This angle may be achieved by adjusting the height of attachment at the upper end of chute 12, 112 or, more preferably, by adjusting the placement of adjusting bars 118 relative to support bars 116 on lower support assembly 123. This angle aids in facilitating gravity feed of the granulated material down the chute 12, 112 so that the material continues to move under spray nozzles 128 to be coated with the spray fluid. This angle also reduces the depth of the product out flow onto the chute 12, 112 to enhance pressurized fluid coverage on the finished product.
Most preferably, the spray nozzles 28, 128, and 228 are configured and oriented relative to the surface of conveyor or chute 12, 112, so that the spray of fluid relative to the chute surface (angle β as shown on
Any fluid conveyance system 10, 110, 210, or 310 may optionally include a controller to initiate the spray of fluid through spray nozzles 28, 128, or 228 and the flow of air through blow-off nozzles 132. Such a controller may control the flow of fluid or air by controlling the valves connected to the nozzles. The controller may be a simple timer that periodically actuates the spray of fluid and then the spray of air following cessation of fluid spray that is set for predetermined time intervals to correspond to production of the granulated material to be sprayed. The controller may be a stand-alone controller for the fluid conveyance system or may be connected to or part of another controller for the processing of the granulated material. The spray of fluid and air may also be manually controlled.
The features and optional components of any fluid conveyance system described herein, such as overhead support assembly 323, upper support assembly 23, lower support assembly 123, nozzle assembly 122 or 222, and blow-off nozzles 132, may be used with any of the embodiments (e.g. 10, 110, 210, or 310) even if not specifically described herein with that particular embodiment.
A method of spraying fluid onto a granulated material according to a preferred embodiment of the invention comprises diverting the granulated material onto a conveyor or chute and distributing it into a wider, thinner laminar plane, and passing the granulated material under at least two spray nozzles. The granulated material is then sprayed with the fluid from the at least two nozzles to achieve uniform coating of the fluid on the granulated material. The height/distance of the spray nozzles above the conveyor or chute, and angle of spray, may be adjusted as needed to achieve uniform dispersion. Most preferably various components of the systems 10, 110, 210, and/or 310 are adjusted as described above in order to alter the distance of the spray nozzles from the conveyor or chute and to alter the angle of spray. By using at least two spray nozzles and thinning the layer of granulated material on the conveyor or chute, the method reduces shear forces while maintaining the same total flow rate achievable with a single spray nozzle, and reduces inhalation risks and downstream processing issues. Optionally, the method may also include periodic activation of the fluid spray to correspond to operating parameters in the manufacture of the granulated materials, for example the spray of fluid may be alternately activated and deactivated if it is desired to coat only some of the granulated material with the fluid spray which may then be mixed with uncoated granulated material. The method also preferably comprises actuating a flow of compressed air or other gas through a nozzle located adjacent to each spray nozzle to direct a stream of air or other gas onto the spray nozzle to clean the spray nozzle once the spray of fluid has ceased. This cleans the spray nozzles and prevents them from becoming clogged with dried spray during periods of operational shut-down or other temporary cessation of spraying.
Those of ordinary skill in the art will also appreciate upon reading this specification and the description of preferred embodiments herein that modifications and alterations to the device may be made within the scope of the invention and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventors are legally entitled.
This application claims the benefit of U.S. Provisional Application Ser. No. 62/020,662 filed on Jul. 3, 2014.
Number | Date | Country | |
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62020662 | Jul 2014 | US |