Patent Application
20240074418
The present disclosure relates to a system and method for rearing insects. In particular, the present disclosure relates to a system and method for rearing insects utilising a centralised harvesting unit for providing a continuous loop production cycle.
Production facilities for rearing insects usually require a large amount of manual labour or have various sub-stations which are interconnected by a complex logistics system. Depending on the type of insect, certain parameters like feedstock and climate have to be monitored and the facility has to be cleaned periodically. Current systems use multiple disconnected rooms and/or compartments with different climates for different age larvae. The larvae are grown in crates. The crates are removed regularly from the room for example in order to perform an operation like feeding or harvesting the insects or to clean the rooms. After performing such an operation, the crates return to a room or compartment. In current systems the logistics between the rearing or breed rooms and a processing section is largely performed manually. This may lead to downtimes of the rearing facility and thus to reduced output.
Rearing insects needs to be done in a controlled manner so that the outflow of product is consistent to reduce the load on equipment and logistic systems further down the line. The system needs to be able to run continually and not stop for cleaning. The system should also protect against excessive cross contamination between the insects. The present invention has been made in view of the above problems.
The invention provides a way of connecting at least one rearing room together with a central harvesting unit and/or swap area comprising at least two crate collection devices. This allows a constant flow of product from the at least one rearing room to a central harvesting area while allowing all areas of the rearing room to be cleanable without stopping the production. The room may be subdivided in separate compartments. The compartmentalisation protects the different zones of the room from cross contamination. At most, a single room may be lost if a disease, invasive insect species or parasitic outbreak occurs. Failures in certain equipment in the rearing system such as dosing stations will have reduced downtime as all crates can be redirected to any dosing station due to the interconnectivity.
In particular, the present disclosure relates to a system for rearing insects, comprising at least one room for storing a plurality of crates for storing insects to be reared, a dosing station for filling insects and/or feed to the crates, an automated central harvesting unit including a harvesting station for unloading the insects from the crates for subsequent processing of the insects and/or a plurality of further processing stations, and a crate collection system for transferring the crates between the at least one room and the central harvesting unit comprising a plurality of crate collection devices for at least collecting crates in or from the at least one room, and a connection for connecting the at least one room and the central harvesting unit. The connection may be any means for transferring the crates between the at least one room and the central harvesting unit, including a path for allowing an automated guided vehicle to move from the at least one room to the central harvesting unit, a conveyor line connecting the at least one room to the central harvesting unit, connection lines with automated crate handling devices like a shuttle, a shuttle-satellite, and/or a robotic arm etc. The crates are used in a continuous loop in the system.
The at least one room may be subdivided in separate compartments. The system may further comprise a climate system adapted to individually control the climate conditions for the at least one room and/or each compartment.
The central harvesting unit may further include, as a further processing station, a washing station for cleaning and, preferably, for drying empty crates and/or a weighing station for measuring the weight of a crate. The central harvesting unit is preferably followed by a separation process to separate insects from rearing residue.
The central harvesting unit preferably comprises a bypass for allowing an individual crate on the central harvesting unit to bypass one or several of the processing stations.
The crate collection devices of the collection system may directly or indirectly connect the at least one room with at least one of the processing stations. The connection between the at least one room and/or central harvesting unit and/or processing stations may be stationary or mobile as the crate collection devices may use automated guided vehicles for transporting individual crates or stacks of crates.
The transporting or the transferring of the crates by or along the connection is preferably automated.
“Stationary” means in this sense for example a fixed arranged pathway or arrangement of means along which the crates are transferred or transported, as for example rails or conveyers. Instead “mobile” means for example a flexible pathway on the ground.
The system may further comprise a controller for controlling rearing of insects in individual crates or sets of crates by automatically controlled transporting of the crates or sets of crates. The transport may include a transport between the at least one room and the central harvesting unit and the processing stations, the controller being configured such that the system provides for a regular output of reared insects.
The invention further provides a system for rearing insects, comprising at least one room, at least one compartment of a room and/or at least one lane for storing a plurality of crates for storing the insects to be reared, at least one swap area, leaving space for crates to be temporarily stored, and a collection system for transporting the crates between rooms, compartments, and/or lanes and the swap area or vice versa.
The swap area may be provided in at least one of the compartments and/or adjacent to the at least one room and/or within the reach (operating distance) of the crate collection system.
The swap area may have a size for storing crates of an entire lane, of a compartment and/or of a room.
Moreover, the invention provides a method for operating an insect rearing system, in particular the system according to the invention. That is, the system may comprise at least one room for storing a plurality of crates for rearing the insects, a dosing station for filling insects and/or feed to the crates, a central crate harvesting unit including a harvesting station for unloading the insects from the crates for subsequent processing of the insects and/or comprising a plurality of further processing stations, and a crate collection system for transferring the crates between the at least one room and the central harvesting unit comprising a plurality of crate collection devices for collecting crates in or from the at least one room. The crates may be transferred between the at least one room and the central harvesting unit via a connection.
For operating the system, a path of the crates through the rearing system is automatically individually controlled to
The crates may be used inside the system in a continuous loop.
The method may further comprise a step of washing and drying the crates and/or weighing after harvesting the insects.
The crates may be automatically transported between the processing stations performing the respective method steps, between the at least one room and the central harvesting unit and/or between the plurality of crate collection devices by using a connection such as conveyor belts or automated guided vehicles.
The invention is further described in more detail with reference to the figures. Therein,
Unless indicated otherwise, the same reference numerals denote the same or similar elements. The examples shown in the figures below are compatible with each other. The terms “central handling unit” and “central harvesting unit” refer to the same element and may be used interchangeably throughout the specification.
Each room 1 is accessible via a collection system device 21 forming part of a collection system 2. The collection system 2 may also be understood as a logistics system or a logistics aisle. The device 21 may e.g. be an automated forklift or any other transport or conveying means for extracting one or a plurality of crates from the room 1 or compartments 11 or lanes 12. A single or plurality of collection system devices 21 may service one or a plurality of rooms 1. I.e., depending on the configuration, a single collection system device 21 may serve a plurality of rooms 1 or a plurality of collection system devices 21 may serve a single room 1. According to the invention as defined in claim 1, at least two collection devices may be provided.
From the crate collection devices 21 the crates are transferred via a connection station 4 to the central handling unit 3.
The system of
The central handling unit 3 is also provided in such a way that each of the connection stations 4 can be bypassed. The movement direction of the crates is not fixed and may be changed at any time according to the rearing requirements. The central handling unit 3 is further connected to at least one filling station 5 or dosing station for filling feed and/or insect larvae into the crates. In addition or alternatively, feedstock may be provided to the crates inside the connection station 4. The system may further comprise a weighting station for determining the total weight of the crates and/or the weight of the added feedstock and/or insects. The weighting station may be provided separately or may be included in any one of the processing stations.
Depending on the insect type reared and its specific requirements, the crates are collected via the collection system 2 and transferred to the central handling unit 3 for re-feeding at the filling station 5 or directly at the connection station 4, or unloaded at the harvesting station 7. I.e., re-feeding may be performed through a crate collection device such as a collection system device 21, in a connection line between the room 1 and the processing stations, in the central handling unit 3 or at a separate re-feeding station.
In addition to the harvesting station 7, a separate rejection station 8 may be provided. There, crates which do not meet the required quality standards (i.e. weight) can be ‘parked’ to be inspected by an operator or automatically checked. Furthermore, contaminated crates may be emptied at the rejection station 8. In the central handling unit 3 a device may be foreseen to separately harvest crates not meeting the quality requirements.
A washing station 6, which can be bypassed via the bypass or re-batch line 31, is provided for cleaning used crates before (re-)filling. All processing stations 5, 6, 7, 8 can be bypassed through a bypass line 31.
The crates are transported from the room 1 to the connection station 4. This can be done, e.g. by a collection system device 21 or manually. Examples are given throughout the specification. In case pallets are used, the connection station 4 may also comprise a de-palletiser or de-stacker in order to singularise the crates. The connection station 4 may also comprise a connection device 41 such as a robot arm for moving crates. The connection device 41 can move crates coming from the rooms 1 (section 42) to the processing stations 5, 6, 7, 8 (section 43) and vice versa. Thus, the processing stations may directly be connected to the rooms. The connection station 4 may be supported by manual intervention, e.g. using manual pallet trucks to move crates or stacks of crates. At reference numeral 43, e.g. a central handling unit 3 according to
The central handling unit 3 according to the disclosure may also comprise stackers and destackers for stacking and destacking or isolating of crates. Furthermore, the crates may be turned during transportation, e.g. for facilitating emptying or cleaning of the crates. Furthermore, a dryer may be provided for drying the crates after the washing.
With this system, a regular output of insects may be provided, since the central handling unit 3 is capable of automatically and centrally managing the crates according to the type and state of the insects. Thus, with different climate conditions and/or feedstock, depending on the content of the respective crate, a quasi-continuous rearing output may be provided by circulating the crates. Crates may also be inspected in the central handling unit using an automated inspection camera to determine the status and rearing stage of the insects within.
If deemed necessary after a rearing cycle or in case of contamination of a compartment 11 and/or room 1, the crates as well as the lanes 12 and/or compartments 11 and/or rooms 1 may be cleaned from larvae, residue, contaminants or feed. Empty rooms and/or compartments and/or lanes might be also needed for other operational actions like maintenance. Therefore, swap areas are provided as shown in the example
This may further help providing the functionality of quasi-continuously or regularly outputting insects. With the swap areas, the downtime of compartment 11 or lanes 12 may be minimised or in other words the crate using time may be optimised.
The term continuously may be understood as performing harvesting in regular intervals. The intervals may be fixed or may be adapted according to the requirements of the insects. In other words, the system and method proposed herein may ensure a constant product flow. In the different example embodiments, insect harvesting is for example performed 14 hours a day or 7 hours a day, wherein the remaining 10 hours or 17 hours, respectively, can be used for cleaning or no movement of crates is performed. Depending on the facility, insect type and other circumstances, the harvesting times may vary. All embodiments of the present disclosure may be employed regardless of the rearing cycles.
According to an example of the present disclosure, a system or facility for rearing insects comprises a plurality of crates for storing the insects which are reared. The crates are preferably rectangular and stackable and set up to be picked up by e.g. a forklift or any automated device. The following example will be explained using crate measuring 800×600×290 mm, but the present disclosure is not limited to these dimensions and shapes. The crates preferably allow air circulation for providing optimal climate conditions to the insects. Furthermore, the crates are filled with feedstock and insect larvae, wherein the feedstock is varied according to the reared insects. The filling can be performed at a filling station or dosing station 5 which is configured to provide both insects and feed or at a plurality of stations, one providing insects while the rest provide feed. A mixture of insects and feed may also be provided at one of the stations. The station for providing additional feedstock and/or the station for providing insects may also be integrated into a connection station 4. Additionally, a weighting station may be provided to determine the weight of the crates and/or the weight of the added insects and/or feedstock. The weighting station or stations may be provided separately or may be included in any of the processing stations.
The filled crates are then stored in a rearing room 1 which is subdivided in compartments 11 and lanes 12 as explained above in conjunction with the figures. The system according to the present disclosure comprises at least one rearing room 1. The compartments 11 or rooms 1 may be climatised differently depending on the type of insect and development stage. Thus, a rearing facility is capable of simultaneously rearing different kinds of insects and different development stages while providing a continuous output.
At the end of a rearing cycle, the crates are transported to a harvesting station 7, where the insects are unloaded and processed further. In addition, a station for removing the insect skins, e.g. for mealworms, may be provided.
After emptying or harvesting, respectively, at the harvesting station 7, the crates are transported to a washing station 6, where residues are removed from the crates and the crates are cleaned and prepared to be filled again. The crates are therefore used in a closed loop inside the system. However, at any point, crates may be manually removed and/or added to the system, particularly the central handling unit.
Depending on the type of insect, the crates may, during a rearing cycle, be transported to a filling station in fixed intervals or when deemed necessary for providing additional feedstock. The climate conditions as well as the development stage of the insects may be monitored during rearing.
In order to transport the crates between the processing stations, i.e. the filling station 5, the washing station 6, the harvesting station 7 and the rejection station 8, a central handling unit 3 is provided. The central handling unit 3 is accessible from all of the rooms 1 and connects with all of the processing stations 5, 6, 7, 8 and is thus capable of centrally managing the complete rearing facility having a plurality of rooms 1. A connection station 4 may be needed to connect the central handling unit 3 to the collection system 2. The central handling unit 3 may be designed as a loop and may be operated uni- or bidirectionally. The connection between the processing stations 5, 6, 7, 8 within the central handling unit 3 and/or the collection system 2 may be fixed. In the case automated guided vehicles are used, they may also freely move inside the facility or move on previously set tracks. All processing stations 5, 6, 7, 8 can be accessed or bypassed by the central handling unit 3 as also shown in
The system also comprises a controller which controls rearing of insects in individual crates or sets of crates. In particular, the controller controls the central handling unit 3. The controller may further control at least one of the processing stations 5, 6, 7, 8 and/or the connection station 4. The controller may also control and/or monitor climate conditions inside the rooms 1 and/or compartments 11. The controller may therefore also be configured such that the system provides a regular output of reared insects. Also, a control system comprising one or a plurality of controllers may be provided for controlling at least one of the central handling unit 3, the processing stations 5, 6, 7, 8, the collection system 2, the connection station 4 or the collection system devices 21.
The example described above can also implement the features described in conjunction with all figures and vice versa.
A central handling unit 3 as described above and as preferred may handle up to thirty-six rooms 1. An insect rearing facility may contain a plurality of central handling units 3. A room 1 may consist of two (2) to seventy-two (72) compartments 11. Each compartment 11 may have between two (2) and twenty-four (24) lanes 12. Each lane 12 may have between two (2) and sixty-four (64) crate stacks. Depending on the height of the crate stacks, each compartment 11 may for example house hundred twenty (120) to twenty-five thousand (25′000) crates. It is understood that the crate numbers per compartment may vary with different crate sizes. If separate feeding stations are provided, the number of feeding stations may correspond to the number of rooms 1 or may be any other number sufficient for providing feed to the insects. As noted above, the feeding stations may also be partially or completely integrated into connection stations 4 or filling stations 5. The given numbers are purely exemplary and not to be understood as limiting.
The following will give an overview of exemplary configurations according to the present disclosure. These configurations are compatible with all examples described above.
According to the disclosure, crates may be stored in a room on the ground, on pallets, on support elements with or without pallets, in a rack system or other suitable means. The crates may be stacked and the stacked crates may be stored in lanes. The room may be climatised. Moreover, the compartments, lanes or even crates may be singularly climatised according to the requirements of the reared insects. The rooms, compartments or lanes may have insects of different life stages.
The crate collection system with multiple crate collection devices interconnects rooms, processing stations, the central handling unit and/or swap areas. Crate collection devices such as the collection system devices describe above may move freely or on fixed pathways. Freely moving devices preferably are automated guided vehicles (AGVs). Fixed pathways may e.g. be confined by rails or other means guiding a shuttle-satellite system, an automated storage and retrieval system (AS/RS), or conveyor belt system. The crate collection devices can be used to transport crates to a swap area, to a non-central feed dosing unit or inspection station or the central handling unit.
The connection station (also referred to as “connection”) interconnects rooms, processing stations and/or the central handling unit. The connection may be a connection formed by collection system devices or other means. The connection may be performed freely or on fixed pathways. Freely moving devices preferably are AGVs or pallet trolleys. Fixed pathways may be confined by rails, guide means or similar. The connection can be provided as a stationary system such as a conveyor belt or hanger system, a shuttle system, a pusher system or a robotic arm. The connection may also include stacking and de-stacking of the crates by a de-stacker, stacker or a robotic arm.
The central handling unit may be a separated connecting unit or comprise at least one of the following: a harvesting station for unloading insects from the crates followed by separating insects from frass, a dosing station for filling insects and/or feed to the crates, a crate washer (and possibly dryer) of crates, weighing means for determining the weight of crates, observation means such as a camera, a crate (de-)stacker, a reject line or rejection station, a bypass for one or more particular processing stations or a station for removal of frass. The dosing station may be separately provided. Automated transport of crates may be performed by AGVs or a conveyor belt system.
Depending on the configuration, the following options are possible. The elements have been described in detail above.
When using stacks of crates without pallets and a shuttle-satellite for crate transport, de-stacking may be performed before, within or after the connection station. When using an AGV for crate transport, de-stacking may be performed before the connection station or the connection station may be omitted and the AGVs may transport the crates to de-stacking. Subsequently, the crates are moved to the central handling unit.
When using stacks on pallets in an AS/RS, the following configurations are possible. The crates may be de-palletised, de-stacked and given to the connection station and subsequently the central handling unit. Alternatively, the crates may be de-palletised, given to the connection station, be de-stacked and then moved to the central handling unit. As a further alternative, the complete pallets may be transported to the connection station and afterwards de-palletised, de-stacked and brought to the central handling unit.
The same procedures as with the AS/RS may apply to stacks of crates and AGVs for transportation.
In case single big boxes for rearing insects are used, transportation from the room to the central handling unit may directly performed via shuttle satellites, AS/RS or AGVs.
The AGVs described herein may e.g. be a pallet truck, a move-lift truck or a wheeled pallet.
The present disclosure also relates to a corresponding method for rearing insects or a method for operating an insect rearing system, preferably as described above.
The system of a facility thus consists of a plurality of rooms 1 as well as processing stations 5, 6, 7, 8 with respective actions such as filling, feeding, tipping, cleaning and re-batching. By the central handling unit 3, a constant product flow is ensured. The crates do not leave the system during normal operation and rather form a rearing loop. The rearing cycles vary according to the reared insects. Black soldier flies may have a rearing cycle of 4 to 16 days, while mealworms may take up to 45 days until they are ready for processing.
If automated guided vehicles (AGVs) or shuttle satellites are used in the central handling unit 3, the number thereof may be adapted to the number of rooms 1. The crates or stacks of crates may also be positioned on pallets which are configured to be picked up by the collection system 2, which transfers it to the central handling unit 3.
The examples above refer to the division in rooms, compartments and lanes. However, any further subdivision or no subdivision at all is also encompassed by the present disclosure and may be used with the system and method presented herein.
Preferably, the crates are stored as stacks. Furthermore, stackers and de-stackers may be provided in the system to form stacks of crates or isolate crates depending on the stage of processing. In particular, for feeding, adding insects, harvesting, rejecting and washing, the crates need to be de-stacked. Alternatively, pallets may be used.
With the system and method as described above it is possible to provide a constant product flow by having a central handling unit or central harvesting unit which centrally manages the crates according to the stored insects and/or development stages. Multiple rooms can be connected with the central handling unit and the facility allows cleaning and maintaining of areas after or during a rearing cycle without halting the production. By providing at least two collection devices interconnecting the processing stations and connecting the processing stations with the room(s), a regular or continuous output of insects may be ensured. The subdivision in compartments also prevents cross contamination between compartments or rooms. If one of the processing stations fails or requires maintenance, crates may also be redirected to other processing stations by the central handling unit.
Other aspects, features, and advantages will be apparent from the summary above, as well as from the description that follows, including the figures and the claims.
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. It will be understood that changes and modifications may be made by those of ordinary skill within the scope of the following claims. In particular, the present invention covers further embodiments with any combination of features from different embodiments described above and below.
Furthermore, in the claims the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. A single unit may fulfil the functions of several features recited in the claims. The terms “essentially”, “about”, “approximately” and the like in connection with an attribute or a value particularly also define exactly the attribute or exactly the value, respectively. Any reference signs in the claims should not be construed as limiting the scope.
| Number | Date | Country | Kind |
|---|---|---|---|
| 20217492.6 | Dec 2020 | EP | regional |
This application is the United States National Phase of International Application No. PCT/EP2021/086723 filed Dec. 20, 2021, and claims priority to European Patent Application No. 20217492.6 filed Dec. 29, 2020, the disclosures of which are hereby incorporated by reference in their entireties.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2021/086723 | 12/20/2021 | WO |
