Portable basket colony for growing and transport and method of use
11390472 ยท 2022-07-19
Inventors
- Doug Foreman (Springdale, AR, US)
- Stephen Brannan (Wesley, AR, US)
- James Ruff (Farmington, AR, US)
- David Lee Mantooth (Fayetteville, AR, US)
- Thoodorc Burnett (Fayetteville, AR, US)
Cpc classification
B65G61/00
PERFORMING OPERATIONS; TRANSPORTING
B66F9/00
PERFORMING OPERATIONS; TRANSPORTING
A01K31/18
HUMAN NECESSITIES
A01K31/005
HUMAN NECESSITIES
B65G47/26
PERFORMING OPERATIONS; TRANSPORTING
B66F19/00
PERFORMING OPERATIONS; TRANSPORTING
B65G67/02
PERFORMING OPERATIONS; TRANSPORTING
International classification
A01K45/00
HUMAN NECESSITIES
B65G67/02
PERFORMING OPERATIONS; TRANSPORTING
B65G47/26
PERFORMING OPERATIONS; TRANSPORTING
B65G61/00
PERFORMING OPERATIONS; TRANSPORTING
B66F9/00
PERFORMING OPERATIONS; TRANSPORTING
B65G47/08
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A colony basket and method of using the same for handling poultry from DOC through the growing process and on to a production facility comprising a harvesting system, a loading system, a transport system, an unloading and storing system, hanging system and cleaning system. The system and method performs the steps of harvesting and colonizing live poultry into a singly stackable and transportable colony basket, stacking and loading the trays on a transport, unloading and temporarily storing the poultry for subsequent processing.
Claims
1. A rack assembly for transferring colony baskets from a colony to a transport comprising: a transfer rack conveyor assembly positioned adjacent an exit end of a colony; a colony basket rack support configured to one or more of vertically elevate and lower within the transfer rack conveyor assembly to a level of the colony to receive a colony basket being conveyed out of the exit end of the colony; said colony having a conveyor conveying the colony basket out of the exit end of the colony to be received on the colony basket rack support within the transfer rack conveyor assembly; and an actuatable extension arm rotatable upward about a pivot to laterally engage the colony basket and said actuatable retention arm configured to extend a retention bar extending therefrom to contact and move the colony basket from the transfer rack conveyor assembly to a transport; a transfer conveyor positioned between the exit end of the colony and the transfer rack conveyor assembly, where said transfer conveyor is configured to convey the colony basket from the exit end of the colony, where the retention bar has engagement members for engaging side walls of the colony basket.
2. The rack assembly as recited in claim 1, where the actuatable extension arm and retention bar are longitudinally extendable and retractable during retrieval and insertion of a basket responsive to being actuated.
3. The rack assembly as recited in claim 2, comprising: a plurality of colony basket rack support configured to one or more of vertically elevate and lower within the transfer rack conveyor assembly to a level of the colony to receive a colony basket being conveyed out of the exit end of the colony.
4. The rack assembly as recited in claim 1, where the engagement members are received in receptors of the colony basket.
5. A method for transferring colony baskets from a colony to a transport comprising: positioning a transfer rack conveyor assembly adjacent an exit end of a colony; one or more of vertically elevating and lowering a colony basket rack support within the transfer rack conveyor assembly to a level of the colony to receive a colony basket being conveyed out of the exit end of the colony; conveying the colony basket out of the exit end of the colony to be received on the colony basket rack support within the transfer rack conveyor assembly; actuating an extension arm to rotate about a pivot to laterally engaged the colony basket and to extend a retention bar to contact and move the colony basket from the transfer rack conveyor assembly to a transport; one or more of vertically elevating and lowering the colony basket received on and while supported by the colony basket rack support within a transfer rack conveyor assembly to a level where a top rim flange of the colony basket is at one or more of the level of the colony and another level of the colony; conveying another colony basket out of the exit end of the colony to be received on top of the colony basket thereby forming a basket stack being supported by the colony basket rack support within the transfer rack conveyor assembly; and actuating the extension arm to rotate about the pivot to laterally engaged the colony basket and to extend the extension bar to contact and move the basket stack from the transfer rack conveyor assembly to the transport, where the one or more of vertically elevating and lowering a colony basket rack support within the transfer rack conveyor assembly to a level of the colony is, one or more of vertically elevating and lowering a plurality of colony basket rack supports to a level of the colony to receive a plurality colony baskets being conveyed out of the exit end of the colony, and where the retention bar has engagement members for engaging side walls of the colony basket.
6. The method of transferring colony baskets as recited in claim 5, comprising: receiving the engagement members into colony basket receptors.
7. The method of transferring colony baskets as recited in claim 5, comprising: actuating the extension arm to rotate upward about a pivot to laterally engage and actuating to rotate downward about the pivot to laterally disengage the sidewall.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) For a better understanding of the present invention, reference may be made to the accompanying drawings in which:
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(23) While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description presented herein are not intended to limit the invention to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
(24) According to the embodiment(s) of the present invention, various views are illustrated in
(25) One embodiment of the technology is a single colony basket design adapted to be used throughout poultry processing from the hatchery, through growing and to production. The colony basket includes components designed for the growing process and components designed for transport. The colony basket is adapted for an automated loading system including a stackable tray design, a transport system, and unloading and storing system.
(26) The details of the invention and various embodiments can be better understood by referring to the figures of the drawing.
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(45) The process can begin at the hatchery where a grouping of birds (for example DOC) are gathered and placed into a colony basket. A plurality of baskets can be stacked on over top of another for transport. A netting material can be shrouded over each colony basket to assist in containing the birds. The grouping of birds and their respective colony basket in which they are placed can remain in the same colony basket throughout the process until they are removed as broilers at the kill station. This reduces the handling of the birds to avoid injury and helps to prevent the spread of bacteria or disease between bird groupings. The grouping of DOC can be transported to a growing house in the same colony basket in which they were originally placed at the hatchery, where the poultry are grown for future processing. At the growing location there can be a series of growing colony racks for housing the colony baskets with the original grouping of birds placed therein at the hatchery. At the growing facility, the colony baskets can be integrated with water and feed channels and watering and feed troughs. The colony baskets can have a specific configuration to integrate with the watering and feeding systems as outlined herein in order to assist poultry going through the growth process and assist the operators at the growing facility for attending to the birds. When the poultry have completed the growth process, now in the broiler stage, they can be transported to a location for processing as a final food product. A transport can arrive at the growing location to receive the poultry that have completed the growth process. The transport system can be a truck and trailer combination. The trailer can be a standard flatbed trailer on which colony baskets containing the fully grown poultry can be loaded. The colony baskets containing the original grouping of birds, or some subset thereof, can be transferred from the colony racks of the colony system to the flatbed of the transport. A netting material can be shrouded over each basket before it is stacked in order to assist in retaining the bird. The colony baskets can be stacked one atop another. The transport can be loaded with the fully grown birds and transported along a travel route to an unloading station at a processing facility. The transfer system for transferring the colony baskets from the colony racks to the flatbed can be automated as described herein.
(46) The unloading station can include an automated unloading system for automatically unloading a colony basket stack from the trailer for storage in an adjacent storage area of the processing facility. Tray stacks can be conveyed to a storage location having a climate controlled storage facility for housing the poultry in the stacked configuration prior to the rendering process. The storage area can be operated on a first in first out system such that a given colony basket stack does not dwell in the storage area for an extended period of time. The storage area can also have a system for controlling and tracking the weight of the tray stacks which could ultimately provide weight information regarding the fully grown poultry.
(47) Within the storage facility there can be an automated unstacking system for unstacking the colony basket stacks for conveyance through the processing facility. There can be a stunning system utilized including a gaseous environment for stunning the poultry or it can include an electric shock stunning system or a combination of the two. If a gaseous environment stunning system is utilized, the gaseous environment can be a multi-stage stunning system where the first stage(s) can be a combined induction phase and the second stage(s) can be the combined stunning phase. This system can generally be referred to as a controlled atmosphere stunning system or CAS. Once the colony baskets containing the original grouping of birds/poultry have transitioned through the stunning system, the poultry can be unloaded from the trays at an unloading station. The unloading station can comprise an automated unloading system which is operable to tilt the colony baskets sufficiently to remove the stunned poultry from the colony baskets. This is the first point in the process that the birds are removed since their original placement into the colony basket at the hatchery as DOC. Once removed from the colony baskets, the stunned poultry can be conveyed to a shackling station where the poultry can be hung from a shackle conveyor for being conveyed to a plant evisceration facility.
(48) As described the colony baskets can be stackable. Further the colony basket can have an interwoven wire mesh elevated floor above the colony basket bottom floor where the mesh openings are sufficiently large for debris to pass therethrough and also providing a means for the bird to grasp hold in order to stabilize itself and the mesh floor can be flexible in order to avoid injury to the birds. The frame of the colony baskets include various portions including perimeter top and bottom rim flanges and upright vented side walls. The upward facing surface portion of the upper perimeter top rim flange can be designed to be complimentary with respect to the downward facing portion of the bottom perimeter rim flange. This complimentary configuration can be designed such that the trays interlock when they are stacked thereby resisting longitudinal and latitudinal movement of the trays with respect to each other.
(49) The stackable tray can be constructed having a top rim flange and a bottom rim flange, which defines the longitudinal and latitudinal dimensions of the tray. The top and bottom rim flanges can have L-shaped cross sections. The inner perimeter of the top rim flange can define an upper opening or upward facing opening through which birds can be easily inserted. The bottom rim flange defines the perimeter of the lower or downward facing opening closed off by the solid floor. The solid floor can have elevators for elevating the mesh floor proximately above the solid floor. The mesh flooring is designed with vented openings where the openings are sufficiently large to allow debris to pass there through. The flexible mesh floor design provides for a surface that can be grasped by the talons of a bird without injury. Upright side walls can be attached around the perimeter of the tray and attached to support members. The inner perimeters of the top rim flange and the bottom rim flange, which define the upper and lower openings respectively, can have substantially the same geometry.
(50) The top rim flange can include stabilization standoffs which can extend vertically. The top rim flange can have on an upper surface a vertical standoff. The flange and the complementing recessed receptacle on the underside of the colony basket when engaged, one with respect to the other in a stackable fashion, they can resist longitudinal and latitudinal shifting of trays, one with respect to the other. Also, the stabilization standoffs can be placed along the latitudinal and longitudinal sides of the top rim flange. The spacing between the longitudinal, the latitudinal, and the corner upright support ribs define the vented openings of the tray. The spacing between the support members and the height of the support members can be optimized depending on the type of bird being contained within the stackable trays.
(51) For stacked colony baskets the uppermost colony basket can have a top cover or a netting installed of the uppermost colony basket. The top cover can have a mesh screen for covering the opening of the uppermost tray. The perimeter of the mesh screen can be defined by the top cover flange. The top cover flange can have recessed receptacles for interfacing with the raised standoffs of the uppermost tray.
(52) The colony basket stacks can be transitioned to the transport and loaded on the flatbed by way of a transfer rack or loading dock or other means for loading the colony basket stacks. Vertically protruding standoffs can be provided on the flatbed for and dimensioned to be received by the recessed receptacles of the lower most colony basket in a stack. The transport can have a shroud covering for better controlling the environmental exposure of the poultry. The shroud covering can be supported by transport side rails. One or both of the side panels of the shroud covering can be a retractable curtain for exposing the flatbed from either side. The shroud covering can also have a rear transport cover opening and or a side transport cover opening through which colony baskets can be loaded.
(53) The stacked colony baskets can be loaded through the transport cover opening by sliding them along tray tracks which extend along the flatbed. The trailer can be a standard trailer; however, the trailer can have side railings for supporting shroud covering. The top surface of the flatbed can have raised standoffs that conform to the recessed receptacles on the underside of the tray to restrict lateral sliding or movement of the bottom most tray.
(54) The various poultry handling examples shown above illustrate a novel system and method for handling poultry. A user of the present invention may choose any of the above chicken handling embodiments, or an equivalent thereof, depending upon the desired application. In this regard, it is recognized that various forms of the subject chicken handling could be utilized without departing from the spirit and scope of the present invention.
(55) As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. It is accordingly intended that the claims shall cover all such modifications and applications that do not depart from the spirit and scope of the present invention.
(56) Other aspects, objects and advantages of the present invention can be obtained from a study of the drawings, the disclosure and the appended claims.