Method, computer program, and multifunctional, modular and mobile mixing and packaging plant

Abstract

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, wherein the mixing module comprises means for cooling and/or drying the mixture contained in said module.

Claims

1. 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 wherein said modules are connected to a control PLC which in turn is connected remotely with a central server arranged for providing the instructions and orders for mixing and configuring the powdery or granular product, wherein the mixing module comprises a mixture tank and means for cooling and/or drying the mixture contained in the mixing module; and wherein the means for cooling and/or drying the mixture are arranged to incorporate an air flow inside the mixing tank by using a plurality of movements of the mixing tank to obtain air recirculation in an involute of a lower part of the mixing tank.

2. The plant according to claim 1 incorporating 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 the control PLC of the modular plant.

3. The plant according to claim 2, wherein the big bag module comprises: (a) a structure capable of being introduced in a 20″ container without deformations; (b) receiving a mixed product in a hopper and dosing for packaging: (c) a dosing valve installed after the hopper for dosing the already mixed product; (d) an in-line metal detector with rejection apparatus; and (e) a batch bagging module, with labeling and weight control.

4. The plant according to claim 2, wherein 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.

5. The plant according to claim 4, wherein dosing is performed by means of a pump such that an inlet is connected to a bottom valve of the liquid compartment; and wherein the inlet of the pump is always below an outlet of the bottom valve.

6. The plant according to claim 4, wherein 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.

7. The plant according to claim 6, wherein the cylindrical 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.

8. The plant according to claim 6, wherein the cylindrical liquid compartment comprises at least one inclined cover in the upper part.

9. The plant according to claim 6, wherein the cylindrical 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 the liquid compartment comprises at least a support including a loading cell that allows reading the weight of the product.

10. The plant according to claim 6, wherein 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 cylindrical liquid compartment in which a thermal oil will circulate and in which thermal resistors will be installed; and wherein the outside of the cylindrical liquid compartment is insulated.

11. The plant according to claim 10, wherein for loading the thermal oil, the liquid injection module has a compartment that also works as an expansion vessel, such that the oil enters a dual chamber of the liquid compartment where it is heated by means of the 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.

12. The plant according to claim 6, wherein the temperature of the product inside the cylindrical liquid compartment and the temperature of the thermal oil are controlled by temperature probes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) 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.

(2) FIG. 1 shows a perspective view of the mobile mixing plant for powdery products and of its carrying structure as described in patent document EP2465780.

(3) FIG. 2 shows the plant of FIG. 1 in the transport position.

(4) FIGS. 3A-3E show a liquid injection module (in isometric, plan, elevational, profile, and internal views respectively) which is connected with the mobile mixing plant for powdery products of FIG. 1.

(5) FIG. 4 shows an isolated view of the big bag packaging module that is connected with the mobile mixing plant for powdery products of FIG. 1.

(6) FIGS. 5A-5D show views of the mixing tank (41) of the mixing module (4) in four basic operating positions.

DETAILED DESCRIPTION OF AN EMBODIMENT OF THE INVENTION

(7) As can be seen in FIG. 1, the modular mobile plant object of the present invention essentially comprises a carrying structure (1) and a receiving and weighing area (2), a loading area (3), a mixing area (4), a packaging area (5), a sewing and labeling area (6), a metal detection area (7), a palletizing area (8) and a cleaning area (9).

(8) 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).

(9) 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.

(10) 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.

(11) 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).

(12) Furthermore, the mobile plant also incorporates a liquid injection module for injecting a liquid into a powder mixture (FIGS. 3A-3E), 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. This liquid injection module is connected with the stirring tank (41) in the mixing module (4).

(13) 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: i. Loading the liquid compartment (305) with the liquid or liquids making up the raw material. ii. Stirring the liquid or liquids by means of an anchor-type agitator and comprising an agitator rotary support (326) and an agitator scraper (327). The liquid compartment (305) maintains or achieves optimal temperatures due to its dual chamber with resistors and temperature control by means of at least one temperature probe (324). iii. For controlling the amounts to be dosed, the liquid compartment (305) has a plurality of loading cells (320) commanding the pump (318), transferring the exact amounts required for the formula into the stirring tank (41) of the mixing module (4).

(14) 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.

(15) 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 FIGS. 3A-E:

(16) TABLE-US-00001 Reference Units Characteristic 301 1 Geared motor 302 2 Lifting loops 303 2 Liquid feed nozzles 304 1 Agitator connection neck 305 1 Liquid compartment 306 3 3000 W resistors 307 2 Cover of the liquid compartment (305) 308 1 Tubular wiring structure 309 1 Main distribution board 310 1 Rectangular structure for board (309) 311 1 Control of loading cells (320) 312 1 Oil compartment 313 1 Oil circuit 314 1 Gear pump support (315) 315 1 Gear pump of the circuit (313) 316 2 Feed hose 317 1 Bottom valve of tank (305) 318 1 Pump 319 1 Mobile structure of the pump (318) 320 3 Loading cells 321 4 Height-adjustable base 322 4 Wheels of the structure 323 1 Safety sensor 324 2 Temperature probe 325 1 Tubular frame 326 1 Agitator rotary support 327 8 Agitator scraper

(17) 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.

(18) 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 FIGS. 3A-3E.

(19) 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.

(20) 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.

(21) 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).

(22) Both the temperature of the product inside the liquid compartment (305) and the temperature of the thermal oil are controlled by temperature probes (324).

(23) 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 FIG. 1. Dosing is performed by means of a pump (318) controlled by a variable frequency drive. The inlet of the pump (318) is connected to the bottom valve (317) of the liquid compartment (305) by means of a flexible and hygienic connection. The inlet of the pump (318) is always below the outlet of the bottom valve (317). The outlet of the pump is connected with a feed hose with a connection compatible with an inlet of the mixing tank (41) of the mixing module (4) of the plant of FIG. 1.

(24) 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.

(25) FIGS. 5A-5D show different positions of the mixing tank (41) of the mixing module (4) of the plant of FIG. 1. a) If in the equipment in the mixing position, for example, its position is rotated +180° (FIG. 5A, i.e., inverting its position with respect to the horizontal defined by the floor of the plant), and a flow of a fluid (for example, dry air) is incorporated, the mixture of solids being processed will be dried. This furthermore makes the mixing tank (41) of the mixing module (4) a fluidized bed dryer by means of drying using air flow, and as indicated, air recirculation in the involute of the lower part of the container. b) If liquids are injected into the mixing tank (41) with said tank being in the horizontal position (i.e., at an angular position of 90° or of 270° with respect to the horizontal defined by the floor of the plant, or in other words, in a position parallel to the floor of the plant), as shown in FIG. 5B, through a liquid injection inlet (52) and blasts of air are furthermore provided through an air inlet (53) with a specific screen-type agitator as a mixing tool for this new application, creating a suction current at the bottom of container, the so-called pelletizing or granulating operations can be performed. c) As shown in FIG. 5C, if a mixture of solids with fats having a low melting point is processed in the equipment in which it is necessary to perform the mixture under controlled temperature and humidity conditions (where this operation is very delicate due to the temperature), it can be done by sending a cold fluid stream through the equipment and extracting it through the bottom of the container. The equipment therefore acts as a low-temperature cooler/mixer, even acting as equipment for cooling delicate solids such as fats. In this case, it must be taken into account that not only is the temperature important, but it is also necessary to take into account the humidity conditions of the air that is introduced in the container. Before the air is injected, it is sent through an air handling unit. d) As shown in FIG. 5D, the equipment can, through an opening in the bottom in a fixed or variable position, connect the outlet of the container to vacuum equipment (51), a vacuum dryer, or it can be subjected to vacuum mixing to prevent possible mixtures, with there being oxygen, which invalidate the mixture. The equipment therefore acts as a vacuum dryer or vacuum mixer.

(26) 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.

(27) In a particular embodiment, the plant of FIG. 1 for packaging big bags, as can be seen in detail in FIG. 4, allows the packaging module (5) to be able to pack 500 kg to 1000 kg bags. Nevertheless, in some particular embodiments products can be bagged in bags starting from 100 kg, and in some embodiments, also bags of 350 or 400 kg.

(28) 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 FIG. 1.

(29) 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.

(30) 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.

(31) 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.

(32) The big bag module (400) comprises the following elements: (a) A structure (401) capable of being introduced in a 20″ container without deformations, protecting and providing support for the different auxiliary machines and equipment for carrying out the different processes. (b) Receiving the mixed product in a hopper (402) and dosing for packaging. (c) Dosing valve (403) installed after the hopper (402) for dosing the already mixed product. (d) In-line metal detector (404) with rejection means. (e) Batch bagging module (405), with labeling and weight control (406).

(33) 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): Weighing will be done independently. Loading. Taking up bags: 1 min. Filling: 10 min. Connection/disconnection: 1 min. Total: 12 minutes. Mixing: Machine connection: 1 min. Mixing: 10 min. Disconnection: 1 min. Total: 12 minutes Lifting the product from mixing to the feed hopper (402) which complies with cycles that allow the goal of assuring 1000 kg/h Bagging: Continuously connected with the previous phase, packing must be done with each batch of about 200 kg going through a rotary installation and metal detector until amounting to 4-5 batches, depending on densities. This operation must be done in 1 hour. Five container changes (for each batch). Packaging of these five batches in one bag, going through a rotary installation and metal detector. For each bag, there is weight verification, labeling, and withdrawal of the bag, placing an empty bag to start a new packaging cycle (60 minutes per cycle of 1000 kg for five batches).

(34) Generally, all the general services of the installation will be connected with those of the plant of FIG. 1.