METHOD AND MOULDING DEVICES FOR MOULDING THREE-DIMENSIONAL PRODUCTS

Abstract

The invention provides a method for moulding three-dimensional products from a mass of foodstuff starting materials which are suitable for consumption, in particular a meat mass. The method comprises the steps of filling a mould cavity, which is open on one side, with the mass of foodstuff starting materials which are suitable for consumption, which mould cavity is defined by a boundary comprising walls and base, in order to mould a moulded three-dimensional product, and the removal of the moulded three-dimensional product from the mould cavity. In the method according to the invention, during removal the adhesion forces between the moulded product and the boundary are eliminated virtually simultaneously along all the interfaces.

Claims

1-62. (canceled)

63. A mass feed member for feeding a meat mass to a mould cavity in an outer circumference of a rotatable drum of a moulding device, which drum is rotatable in a direction of rotation in said moulding device, said mass feed member comprising: a housing with an inlet side and a drum side which faces the drum; a through-passage provided in the housing for the meat mass to pass from an inlet towards an outlet located on the drum side; a flexible plastic plate adapted to be pressed against the outer circumference of the drum and to flexibly bear in a sealing mariner against the outer circumference of the drum; a plurality of rigid lamellae which lamellae are arranged at a side of the flexible plate facing away from the drum, are spaced apart in said direction of rotation of the drum, and extend transversely with respect to the direction of rotation of the drum, wherein said lamellae are embodied to impart to said flexible plastic plate lines of rigidity, which lines of rigidity are spaced apart in said direction of rotation of the drum, an excess-pressure device acting on said plurality of rigid lamellae to press said flexible plastic plate against the outer circumference of the drum.

64. The mass feed member according to claim 63, wherein the drum side of the mass feed member, as seen in the direction of rotation of the drum, extends on either side of the outlet, over a distance which covers at least one mould cavity.

65. The mass feed member according to claim 63, wherein a cutting device is provided in the through-passage on the drum side.

66. The mass feed member according to claim 63, wherein the excess-pressure-device comprises compressed air or pressurized water or other liquid.

67. The mass feed member according to claim 63, wherein the excess-pressure-device comprises at least one pressure cushion.

68. A moulding device for moulding three-dimensional products from a meat mass suitable for consumption, comprising: a rotatable moulding drum having a longitudinal axis and axial ends, said drum comprising: a cylindrical drum wall having an outer peripheral cylindrical surface, multiple mould cavities formed in the outer peripheral surface of the drum wall, which mould cavities define the shape of the products which are to be produced, the mould cavities being open on one side and defined by a boundary comprising walls and base, a drum drive, adapted to rotate the rum in a direction of rotation about the longitudinal axis thereof, a mass feed member arranged at a mass feed position along the outer peripheral cylindrical surface of the moulding drum and adapted to feed said meat mass to passing mould cavities, which mass feed member comprises: a housing with an inlet side and a drum side which faces the drum; a through-passage provided in the housing for the meat mass to pass from an inlet towards an outlet located on the drum side; a flexible plastic plate adapted to be pressed against the outer circumference of the drum and to flexibly bear in a sealing manner against the outer circumference of the drum; a plurality of rigid lamellae which lamellae are arranged at a side of the flexible plate facing away from the drum, are spaced apart in said direction of rotation of the drum, and extend transversely with respect to the direction of rotation of the drum, wherein said lamellae are embodied to impart to said flexible plastic plate lines of rigidity, which lines of rigidity are spaced apart in said direction of rotation of the drum, an excess-pressure device acting on said plurality of rigid lamellae to press said flexible plastic plate against the outer circumference of the drum.

69. Moulding device according to claim 68, further comprising a pressurized fluid feed member in fluid communication with the boundary of a mould cavity and a further excess-pressure device for supplying a further pressurized fluid, which pressurized fluid feed member is adapted to apply the further pressurized fluid for eliminating adhesion forces between the boundary of a mould cavity and a moulded product, to assist the removal of moulded product from the one or more mould cavities at a product removal position along outer peripheral cylindrical surface of the moulding drum.

70. Moulding device according to claim 68, further comprising a reduced-pressure-device for forming a reduced pressure in the mould cavities, the boundary of the mould cavities at least in part being provided with a number of pore openings which are in communication with the reduced-pressure-device.

71. Moulding device according to claim 69, further comprising a reduced-pressure-device for forming a reduced pressure in the mould cavities, the boundary of the mould cavities at least in part being provided with a large number of fine openings which in communication with the reduced-pressure-device.

72. Moulding device according to claim 69, further comprising an end piece at one of the axial ends of the drum and wherein a fluid communication is formed by a connecting passage in communication with the boundary of a mould cavity and an opening in said end piece of the drum.

73. Moulding device according to claim 70, further comprising an end piece at one of the axial ends of the drum and wherein a fluid communication is formed by a connecting passage in communication with the boundary of a mould cavity and an opening in said end piece of the drum.

74. Moulding device according to claim 69, wherein the pressurized fluid feed member comprises an air compressor adapted to provide pressurized air to the distribution channel of mould cavities that arrive at the product removal position.

75. Moulding device according to claim 68, wherein the moulding device further comprises a discharge belt arranged beneath the drum to receive products dropped from mould cavities passing a product removal position above the discharge belt.

76. Moulding device according to claim 68, wherein the mould cavities are distributed about the drum wall in peripheral direction and in a direction of rotation of the drum.

77. Moulding device according to claim 68, wherein the boundary of the mould cavity comprises a porous plastic or porous sintered metal forming a porous structure of intercommunicating pores opening out in said one or more mould cavities.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0093] It will be understood that the abovementioned mass feed member is also suitable for use in moulding devices with a rotating moulding drum, other than the embodiments discussed above.

[0094] The invention is explained below with reference to the appended drawing, in which:

[0095] FIG. 1 shows a perspective view of an embodiment of a moulding device of the invention;

[0096] FIG. 2 shows a side view of the embodiment shown in FIG. 1;

[0097] FIG. 3 shows an exploded perspective view of an embodiment of a moulding device with insert;

[0098] FIG. 4 shows a view of an embodiment of an insert with mould cavity;

[0099] FIG. 5 shows a cross section through an embodiment of a moulding device according to the invention, illustrating its operation;

[0100] FIG. 6 shows a detail of the embodiment shown in FIG. 5;

[0101] FIG. 7 shows another embodiment of a moulding device in accordance with the invention;

[0102] FIG. 8 shows an embodiment of a moulding device with release device in accordance with the invention;

[0103] FIG. 9 shows the release device presented in FIG. 8 in more detail;

[0104] FIG. 10 shows the operation of the release device illustrated in FIG. 8;

[0105] FIG. 11 diagrammatically depicts an embodiment of a moulding device with mass feed device in accordance with the invention;

[0106] FIG. 12 shows a detail of the mass feed device shown in FIG. 11;

[0107] FIG. 13 illustrates the operation of the mass feed device;

[0108] FIG. 14-15 show diagrammatic cross sections through various embodiments of a mould cavity with associated boundary;

[0109] FIG. 16-17 show detailed structures of various pore forms of a boundary of a mould cavity;

[0110] FIG. 18 shows a detailed view of an embodiment of a boundary of a mould cavity with a passage structure;

[0111] FIG. 19 diagrammatically depicts an embodiment of the method according to the invention;

[0112] FIG. 20 diagrammatically depicts another embodiment of the method according to the invention; and

[0113] FIG. 21-23 show various embodiments of a moulding surface according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0114] FIG. 1 diagrammatically depicts a perspective view of an embodiment of a moulding device 10 according to the invention, while FIG. 2 shows a side view of this device.

[0115] The moulding device 10 comprises a frame 14 which can be moved with the aid of wheels 12. A moulding drum 16 is mounted on the frame 14 in such a manner that it can be rotated about a horizontal axis and is coupled to a drive, for example an electric motor. The moulding drum 16 comprises mould cavities, which are not visible in FIGS. 1 and 2. A mass feed member 18 for feeding mass which is to be moulded to the mould cavities of the moulding drum comes into close contact with the outer circumference of the moulding drum 16. The mass is fed from a displaceable storage device 19 with introduction funnel 20 and then via a releasable connecting pipe 22 to the mass feed member 18 by means of an (optionally continuously) operating pump (not shown). In the vicinity of the underside of the moulding drum 16, there is a release device 24 for releasing moulded products from the mould cavities of the moulding drum 16, as well as a discharge belt 26 beneath it. Via this discharge belt 26, the products can be fed to other processing stations, for example a protein-coating device, a freezing device or a packaging installation. The moulding device 10 also comprises a control unit 28 for controlling the various components. With a view to making the device, in particular the moulding drum 16 and the mass feed member 18, accessible for maintenance and cleaning purposes, the mass feed member 18 is secured to a subframe 30, which can be rotated about a pivot pin 34 with the aid of a piston/cylinder assembly 32, so that the mass feed member 18 can be moved out of a working position illustrated in FIGS. 1 and 2 into an at-rest position (not shown) at a distance from the moulding drum 16 after coupling 36 between connecting pipe 22 and mass feed member 18 has been released.

[0116] In the embodiment shown in FIGS. 3a) and b), rectangular recesses 42 are provided in the outer circumference 40 of the moulding drum 16, which is in this case hollow. Exchangeable inserts 44 of corresponding dimensions can be secured in these recesses 42.

[0117] For this purpose, bores 46 are provided at the corners of an insert 44, aligned with threaded holes 47 in the base 48 of the recess 42, and bolts 50 can be fitted into them. In the base 48 of a recess 42 there is an opening 52 which is in communication, via one or more axial connecting passages and distribution device (not shown), with an opening 54 in an end piece 56 of the moulding drum 16. This opening 54 is in communication with excess-pressure means (not shown), such as a compressor, for supplying a forcing fluid via a flexible hose 57, and with reduced-pressure means (not shown), for example a vacuum pump, via a flexible hose 58. In its top side, the insert 44 comprises a mould cavity 60 of a shape which corresponds to the shape of the product which is to be produced.

[0118] In the embodiment shown in FIG. 4, the insert 44 together with spacer 62, forms an assembly 64. Insert 44 comprises the mould cavity 60 delimited by vertical walls 66 and base 68, while spacer 62 is a flat plate in which there is a through-opening 72, the dimensions of which are larger than the mould cavity 60.

[0119] The insert 44 is made from a porous material, such as sintered steel. The pores are denoted by reference numeral 73. They open out in the base 68 and peripheral wall 66. Therefore, in the assembled state, there is a space between the underside of this insert 44 and the base 48 of the recess 42, this space also being delimited by the peripheral wall 74 of the opening 72 in spacer 62, which space is in communication with, on the one hand, the pores 73 in the insert 44 and, on the other hand, the opening 52, so that during operation the mould cavity 60 can be efficiently evacuated, and during the release operation a forcing fluid can be supplied between product and boundary. The insert 44 is a rectangular body with a flat underside and sides, apart from the top side 75, which is curved. The radius of curvature of the curved upper side 75 is identical to the radius of curvature of the moulding drum 16.

[0120] FIG. 5 illustrates the way in which this embodiment of a device 10 according to the invention operates. The mass which is to be moulded is forced into the mould cavity 60, which is in a filling position, via the mass feed member 18, while air is being sucked out of this mould cavity 60 through the pores in the insert 44 in question, the opening 52 and a connecting passage 76 with the aid of reduced-pressure means. This mould cavity 60 is filled during the rotation (direction of rotation indicated by an arrow) of the moulding drum 16 past the filling position. As a result of further rotation, a mould cavity 60 moves into a release position where a moulded product 78, under the force of gravity, drops out of the mould cavity 60 onto a discharge belt 26 moving beneath it. The release is assisted by supplying compressed air or other pressure medium, for example water, to the mould cavity 60 via the connecting passage 76 and the porous insert 44. The compressed air is supplied by excess-pressure means (not shown).

[0121] FIG. 6 shows the latter aspect in more detail. From the connecting passage 76, compressed air is passed through the opening 52 in the base 48 of the recess 52 in the drum 16 into distribution space 82, from where the compressed air (indicated by arrows) forces its way through the pores in the boundary of the insert 44 and expels a product.

[0122] For the sake of simplicity, FIG. 3-6 in each case illustrate a combination of excess-pressure means and reduced-pressure means.

[0123] As will be clear from the general description given above, the two aspects can also be employed separately.

[0124] FIG. 14 shows an embodiment of a mould cavity 60 with a permeable boundary with a complete pore structure for the base 68 and peripheral wall 66. In addition to the pores 73, passages 200 are provided in the base 68. In the situation illustrated, the pores 73 are fed with a gaseous forcing fluid, such as compressed air, via a separate feed 202. The passages 200 are provided with a liquid forcing fluid, such as water, via a separate feed 204. As an alternative to a separate supply, it is also possible to use a mixture of liquid and gaseous forcing fluids.

[0125] FIG. 15 shows yet another embodiment, in which the boundary of a mould cavity 60 is of layered structure. An innermost boundary layer 206 comprises a pore structure, while the outermost boundary layer 208 is provided with passages 200. A forcing fluid is introduced into a distribution chamber 212 via feed 210. From there, the fluid flows through the passages 200 and then via the pores 73 and into the mould cavity.

[0126] FIGS. 16 and 17 show two different pore structures. One is composed of sintered, substantially round metal grains (FIG. 16) and one is composed of sintered, irregularly shaped metal particles. In the case of the pore structure shown in FIG. 17, the risk of a meat mass or small pieces of meat sticking in the pores is lower than in the case of the structure shown in FIG. 16, since the depth of penetration of the mass is lower on account of the relatively high resistance caused by the irregular nature of the pores.

[0127] FIG. 18 shows a boundary part with irregular passages 200 which taper from the outside towards the mould cavity 60.

[0128] FIG. 19 shows a boundary of a mould cavity 60 in which the boundary comprises a coating layer 220 which is given a surface charge by a reversible chemical reaction, repelling the oppositely charged particles (indicated as dipoles) from the product starting material.

[0129] FIG. 20 illustrates a method in which an additional electromagnetic repulsion force is generated in order to release a product from the mould cavity 60 with the aid of an electromagnet 222.

[0130] FIG. 7 shows another embodiment of a moulding device 10 according to the invention, in which components which correspond to those shown in FIG. 1-6 are denoted by the same reference numerals. The moulding drum 16 comprises recesses 42 which are distributed over its circumference and in which a filler piece 81 is positioned. In this case, the mould cavity 60 is delimited by the top side 83 of filler piece 81 and side walls 84 of the recess 42. The top side 83 in this case has a surface which is provided with a contour, so that an attractively shaped appearance can be imparted to the product. The mould cavities 60 of the moulding drum 16 can once again be selectively coupled to either reduced-pressure means or feed means, as described for a different embodiment with reference to FIGS. 5 and 6. For this purpose, an opening 52, which is aligned with bore 85 in filler piece 81, is provided in the base 48 of the recess 42. A web or strip 86 is wound around the moulding drum 16. This strip 86 has a sandwich structure and comprises an upper layer 88 made from a plastics material, in which flexible premoulds 90 are provided, substantially corresponding to a mould cavity 60, and a lower layer 92, which during operation is in contact with the outer circumference of the moulding drum 16 and is made from a more rigid material, in which there are round openings 94, the diameter of which in this case substantially corresponds to that of the premoulds 90 and therefore to that of the mould cavities 60. The two layers 88 and 82 are connected to one another in a suitable way. One end 96 of the web 86 of a sandwich structure is provided with securing means which interact with securing features on the drum 16. An example is a row of small openings 98 which are positioned over short projections on the drum 16.

[0131] The free end 102 of the web may be fixed to the drum 16 or to itself, for example using adhesive tape or the like. To protect the web 86, there is a wear-resistant material, for example stainless steel, protective strip 104, in which openings 106 which likewise correspond to the flexible premoulds are provided. One end of the protective strip 104 has a flanged edge 108 which, during operation, engages in an axial groove 110 provided in the outer circumference of the drum 16. The other end 112 has spring securing means 114 at its corners, and these means can be fixed to projections on the drum 16, so that the protective strip 104 can be clamped taut around the drum 16 and in this way also holds the flexible strip 86 beneath it in place.

[0132] During operation, at the filling position the flexible premoulds 90 in the mould cavities 62 are filled with mass or a portion of mass, it being possible for the air which is present beneath the flexible premould 90 in the mould cavity 60 to be sucked out, for example via the central bore 85 in filler piece 81 and opening 52 connected to it in the base 48 of recess 42, which opening can be connected to reduced-pressure means via an axial connecting passage in the manner described above. At the release position (FIG. 8), the flexible premould 90 is pushed out of the mould cavity 60 with the aid of compressed air, which is led to the mould cavity 60 in the manner which has likewise already been described, and the moulded product 78 can be released, if desired with the assistance of a release device, for example a spindle belt which is to be described below.

[0133] The release device 24 shown in FIG. 8-10 is arranged beneath the moulding drum 16 at the release position and in the situation illustrated comprises an endless conveyor. This conveyor comprises two endless chains 120 which are arranged parallel to one another and are guided in a fixed path over toothed wheels 122. Toothed wheels 128 arranged on a common driven axle 126 engage in the vicinity of the centre of a top part 124, moving towards the drum 16, of the conveyor. A drive unit is denoted overall by reference numeral 130. The links 132 of the chains 120 (cf. FIG. 10) are lengthened on the inner side by an extension piece 134 which projects inwards. Extension pieces 134 of corresponding links 132 of the two endless chains 120 are connected to one another by thin transverse spindles 136, in such a manner that the transverse spindles 136, at the reversing point, pass through the centre of the axis of the toothed wheel 122 in question. This results in the formation of a pointed nose which is responsible for further removing moulded products 78 from the mould cavity 60.

[0134] FIG. 11 diagrammatically depicts an embodiment of a mass feed member 18, in which identical components are once again denoted by identical reference numerals. The mass feed member 18 comprises a virtually semicircular housing 140 with a through-passage 142 extending in the radial direction (cf. also FIG. 13) with an inlet 144 for the mass which is to be moulded from a storage device 19 and an outlet 146 for the mass to pass to a mould cavity 60. Side walls 148 and 150 of the housing 140 are provided with openings 152 extending in the radial direction.

[0135] Radially movable lamellae 154, for example made from metal, are arranged between corresponding openings 152 in the side walls 148,150. The central part of the mass feed member 18 comprises a filler block 156 which is fixedly connected to the housing and in which the through-passage 142 is provided. That side of the mass feed member 18 which faces towards the moulding drum 16 comprises a plate 158 made from a flexible plastic, for example Teflon, in which the outlet 146 to a mould cavity 60 is provided. Between the inner wall of the housing 140 and the lamellae 154 there is a pressure cushion 160 which can be pressurized using a suitable pressure medium, such as compressed air or pressurized water or other liquid. In this way, during operation, the Teflon plate 158 is pressed onto the moulding drum 16 in such a manner as to form a seal, the lamellae 154 forming a large number of ribs which extend in the axial direction of the moulding drum 16 and impart the required rigidity, while the Teflon plate 158 is able to adapt to possible deviations in the radius of the moulding drum 16. On one side of the through-passage 152 there is a cutting blade 170 for cutting through tough pieces, such as muscle fibres.

[0136] In the embodiment of the moulding drum 16 illustrated in this figure, there are provided, in its outer wall, recesses 42 which have a widened base 162, extend in the longitudinal direction and into which corresponding inserts 44 with a mould cavity 60 can be pushed from the corresponding end of the moulding drum 16.

[0137] FIG. 21 shows a perspective illustration of an exchangeable moulding drum 16 as an embodiment of a moulding surface according to the invention. The moulding drum 16, which can rotate about an axle 250, comprises a cylindrical drum wall 252.

[0138] The outer side of the cylindrical drum wall 252 comprises recesses 42. In each recess 42 there is an insert 44, which insert 44 comprises a mould cavity 60 which is defined by a boundary provided with holes, namely walls 66 and base 68. In the embodiment illustrated, all the mould cavities 60 are identical in shape. It is also possible for the shape of the mould cavities to differ, for example for each annular drum-wall part to have identically shaped mould cavities, while the shape of the mould cavities differs from one annular drum-wall part to another. It is therefore relatively easy to make a range of products of different shapes and then package these products.

[0139] FIG. 22 shows a moulding drum similar to that shown in FIG. 21, except for the fact that the exchangeable inserts 44 are elements which extend in the longitudinal direction of the drum and are each provided with four mould cavities 60.

[0140] FIG. 23 shows a particularly preferred embodiment of a moulding drum 16 according to the invention which can be exchanged in its entirety. The moulding drum 16 comprises a piece of porous metal, the surface pores of which have been sealed at the outer surface and the inner surface. The mould cavities 60 are formed by spark erosion, with the result that the boundary, comprising base 68 and side walls 66, has acquired the porous structure, since the pores are uncovered as a result. It is easier to replace one moulding drum with another than to exchange the removable inserts as used in the embodiments shown in FIGS. 21 and 22.