Abstract:
A processing chamber effective for workers to perform therein a selected task upon an edible product. The processing chamber comprises a floor, walls, and a ceiling joined together to be impermeable to water. The processing chamber further comprises a washing system which, when activated at regular intervals in the absence of the workers, directs a pressurized fluid toward at least one object within the processing chamber. The pressurized fluid washes away debris and sanitizes the at least one object. Upon sanitizing, the workers re-enter the chamber to perform the selected task upon the edible product.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S)  
       [0001]    Applicant claims the priority date of U.S. Provisional Application 60/299,544 filed on Jun. 20, 2001. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present invention relates to a chamber used in the food industry. In particular, the present invention relates to a processing chamber for use in a livestock processing facility.  
           [0003]    During the processing of edible products for human consumption, it is extremely important that proper sanitation methods be practiced in order to maintain high quality products for the consumer that are free from bacteria, pathogens and other micro-organisms. Products containing bacteria and pathogens, if consumed, can lead to sickness, malaise and the spread of other diseases.  
           [0004]    Conventional processing facilities currently employ a variety of methods to maintain the sanitization of the facilities. These methods, however, are inefficient in that a considerable amount of “down time” takes place in order to maintain the strict sanitization requirements, often imposed by both the USDA and the FDA. Thus, in order to maximize production, the intervals between cleansing are maximized or lengthened to a point where the likelihood of contamination at the end of the interval is substantially greater than the likelihood of contamination at the beginning of the interval.  
           [0005]    Conventional processing facilities typically perform “washdowns” between shifts or at the end of the day. A shift can typically last for 8 hours or more. However, it has been shown that bacteria and other pathogens within such facilities increase at an exponential rate after about four hours, vastly increasing the chance that the carcasses may be infected with such pathogens.  
         BRIEF SUMMARY OF THE INVENTION  
         [0006]    A processing chamber effective for workers to perform selected tasks upon a an edible product. The processing chamber comprises a floor, a ceiling and sidewalls joined together to be impermeable to water, and an automatic washing system effective for sanitizing or sterilizing the processing chamber. The washing system is activated at regular intervals in the absence of the workers to direct pressurized water toward at least one object within the processing chamber. Upon sanitizing or sterilizing, workers re-enter the processing chamber to perform the selected tasks upon the edible products. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    [0007]FIG. 1 is a perspective view of an outward structure of a processing chamber of the present invention.  
         [0008]    [0008]FIG. 2 is a perspective view of the processing chamber of the present invention during the processing of carcasses.  
         [0009]    [0009]FIG. 3 is a perspective view of the processing chamber of the processing area of the present invention during a washing cycle.  
         [0010]    [0010]FIG. 4 is a perspective view of the processing chamber of the processing area of the present invention.  
         [0011]    [0011]FIG. 5 is a perspective view of an alternative embodiment of the processing chamber of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0012]    A processing chamber of the present invention is generally indicated at  10  in FIG. 1. In the preferred embodiment of the present invention, the processing chamber is used as a carcass work-up chamber within a livestock processing facility. A full and detailed description of the livestock processing facility employing the processing chamber of the present invention is included in U.S. Application No. (H565.12-01), incorporated herein by reference. Alternative embodiments of the present invention include use of the processing chamber within any facility for processing edible products where sterilization is preferred or required to minimize the spread of pathogens onto the edible products. Examples of such edible products include, but are not limited to, fruits and vegetables. For the sake of convenience, the preferred embodiment of the carcass work-up chamber will be discussed herein, but it should be understood that any edible food product can be replaced with the animal carcasses throughout the present description.  
         [0013]    The processing chamber (also termed a carcass work-up or slaughter chamber, as is known in the art)  22  of the present invention comprises supporting sidewalls  32 , which may be constructed inline, “L”-shaped, “U”-shaped, or any other shape depending on the particular use for the processing chamber  22 . The sidewalls  32  may be constructed of concrete, cinder blocks, bricks or other similar masonry, and a floor  34  preferably constructed of split-pavers as is well known in the art. It should be noted, however, that alternative constructions of the floor  34 , including cement, gratings or any USDA-FDA approved material, are within the scope of the present invention. The sidewalls  32  support a plurality of cross-beams  36  which in turn support a center support beam  38 . Stainless steel panels  40  are attached to the center support beam  38  to form a stainless steel ceiling. Alternatively, the ceiling can also be constructed of a single rounded, or semi-cylindrical panel as shown in FIG. 2. The sidewalls  32  preferably comprise top panels  42  and bottom panels  44 . The top panels  42  are joined to the ceiling panels  40  and the bottom panels  44  are joined to the floor  34  to make the slaughter chamber  22  preferably water impermeable, and alternatively water resistant. Dimensions of the slaughter chamber  22  will vary depending on the edible product being processing, including fruits, vegetable and carcasses. While it is preferable that ceiling panels  40  and side panels  42  and  44  are constructed of stainless steel, it is well within the scope of the present invention to construct each panel  40 ,  42  and  44  of various other materials including, but not limited to, aluminum or any other USDA-FDA approved material.  
         [0014]    Preferably, the floor  34  is provided with a continuous gutter drain  46 , with strategically located drain points. These drains are connected to a process drainage system  48 . The drain system  48  of the slaughter chamber  22  may be designed to match any general guideline directed by the United States Department of Agriculture, the Food Safety Inspection Service or any other regulating body for food safety. The floor  34  has the same grade throughout, having a sloped center gutter  46  connected to the drainage system  48 .  
         [0015]    Referring to FIG. 1, the slaughter chamber  22  further includes a plurality of work stations  50  at which workers perform a variety of tasks on the edible products. When disemboweling or eviscerating carcass  26 , these stations  50  are located at various positions and heights throughout the processing chamber  22 . The work stations  50  are either located on the floor  34  or on a raised platform  52 , and may include tables on which sets the edible product to be processed. Preferably, each work station is constructed of stainless steel, but also may be manufactured from food grade plastic. Sinks  54  constructed of either stainless steel or food grade plastic indicate the general area where a worker stands to perform the selected task upon the carcass  26 . FIG. 3 includes a depiction of two carcasses  26  hanging from the hanging system  28  on the overhead conveyer  30 , with workers  56  performing different tasks upon on the carcass  26  at each station  50 . Such tasks include, but are not limited to, leaf pulling, eviscerating, and splitting. The inspections include the head inspector, viscera and rail inspection. In operation, the carcass  26  is transported by the overhead conveyer system  30  past a worker  56 . The worker stops the carcass  26 , performs a selected task upon the carcass  26 , and then the carcass  26  passes to the next station  50 . The worker need not travel with the carcass  26  because of the design of the “walking-beam” overhead conveyer system  30 .  
         [0016]    The slaughter chamber  22  further comprises an automated washing system  58  for removing waste products at regular intervals from the slaughter chamber  22 , thus improving sanitary conditions of the processing facility  10 . The automated washing system  58  preferably comprises a plurality of nozzles  60  attached to a water conduit  62  running outside the slaughter chamber  22 . Preferably each nozzle  60  may rotate, emitting a pressurized jet of water in various directions to clean the inside of the slaughter chamber, as best illustrated in FIG. 4. Upon pumping water through the conduit  62 , each nozzle  60  spews out a jet of water in various directions, increasing the effectiveness and thoroughness of the washing system  58 . Water pressure supplied to each nozzle  60  may be within the range of 5 to 2,500 pounds per square inch depending on the application of a foaming agent, water or cleaning agent. Preferably, water pressure is above 50 pounds per square inch, and more preferably between 1,200 to 1,500 pounds per square inch. The spray nozzles  60  are strategically located to provide the most efficient wash-down process, utilizing large and small nozzles. Alternatively, it would be within the scope of the present invention to position a plurality of stationary nozzles  60  within the slaughter chamber, each nozzle  60  directed at a specific point, such as a ceiling panel  40 , the floor  34  or wall panel  42  or  44 , or at a specific work station  50 .  
         [0017]    The slaughter chamber  22  is a self-contained chamber, with the stainless steel construction of the ceiling panels  40  and sidewall panels  42  and  44  preventing contamination of waste products and water into other areas of the livestock processing facility  10 . Apertures  64  are located throughout the slaughter chamber  22  to position light fixtures, utility outlets and spray nozzles  60  at strategic locations. The slaughter chamber  22  may be constructed in various configurations, including various widths, lengths, heights, and shapes, depending on the facility and the preferred process to be utilized.  
         [0018]    The slaughter chamber  22  further comprises a second overhead conveyer system  66 , as best illustrated in FIG. 5. The second conveyor system  66  comprises a series of hooks  68  for attaching certain body parts harvested from each carcass  26 . The hooks  68  carry the harvested body part, by way of the second overhead conveyer system  66 , to the offal room  24  or packaging area  18  of the facility  10  where the harvested part can be further processed or packaged for shipment.  
         [0019]    For sanitation reasons, the slaughter chamber  22  is periodically washed and sterilized to remove bodily material and fluids generated by disemboweling the carcasses  26 . These bodily materials and fluids can contaminate other carcasses  26  traveling through the evisceration portion  22  by either direct contact or by airborne micro-organisms. With the present invention, the cleaning and sterilization of the slaughter chamber  22  can be accomplished quickly and effectively. Preferably, there are two multi-step cycles for cleaning and sterilization that include mid-shift cycles performed two or three times a day and an end-of-shift cycles performed once a day or five times a week.  
         [0020]    To operate the automatic, self-cleaning system  58 , introduction of additional carcasses  26  into the slaughter chamber  22  is momentarily stopped, and the remaining carcasses  26  already within the slaughter chamber  22  are processed past each of the stations  50 . Each worker then exits the slaughter chamber area  22 . A four cycle cleaning system is then initiated. Pumps (not shown) connected to the conduits  62  located outside the slaughter chamber  22  are activated.  
         [0021]    During mid-shift cycles, pumps supply the nozzles  60  with water to flush the immovable objects within the chamber, which include the ceiling panels  40 , sidewall panels  42  and  44 , the floor  34 , the work stations  50  and sinks. Immovable objects may also include any objects within the chamber  22  used during processing that are not easily removed from the chamber  22 , including tables (not shown), the hanging system  28 , and conveying systems  58  and  66 . The first cycle flushes the chamber  22  and immovable objects for about a minute with raw, cold water. Upon flushing, the second cycle begins washing down the chamber  22  and immovable objects. The second cycle lasts approximate a minute and includes a cleaning agent being pumped through the nozzles  60  at approximately 110° F. The cleaning agent is directed onto the same items as did the previous cycle to flush the slaughter chamber  22 .  
         [0022]    Upon washing, the third cycle is initiated wherein water at approximately 185° F. is pumped through the system for about half a minute to sterilize the ceiling  40 , floor  34 , sidewalls  42  and  44  and work stations  50  of the slaughter chamber  22 . Preferably, the first and third cycles use a substantially aqueous solution to flush and rinse the slaughter chamber  22 . However, it is well within the scope of the present invention to use other solutions, which include, but are not limited to, sanitation solutions, anti-bacterial solutions, chlorinated solutions such as bleach, bromine solutions, and any USDA-FDA approved agent. Additionally, the term cleaning agent as used herein means any type of solution, including an aqueous solution, that will aid in the removal of surface debris including, but not limited to, detergents, soap, bleach, and any USDA-FDA approved agent.  
         [0023]    Finally, the fourth part of the mid-shift cycles includes dry air being pumped through the slaughter chamber  22  to remove excess water. The air may be heated to increase its water retaining capacity. The temperature of the dry air will vary based upon volume of airflow provided and conditions of supply air such as humidity. After being sent through the processing chamber, the drying air can either be vented to the atmosphere or used elsewhere in the processing facility  10 . Upon completion of the fourth cycle, the slaughter chamber  22  is ready for workers to re-enter and resume processing carcasses.  
         [0024]    The end-of-shift cycles include five cycles, with the fifth cycle preferably occurring once per week, unless otherwise directed by quality assurance personnel or USDA-FDA regulations. Similar to the first mid-shift cycle, the end-of-shift cycle begins with a one minute flush of cold water to remove debris within the chamber and the immovable objects. The second cycle then directs a cleaning agent, such as a foam, within the chamber and onto the immovable objects for approximately a minute. The foam is emitted at a low pressure and then allowed to soak for approximately three minutes during the third cycle. The fourth cycle then spews water at approximately 185° F. within the chamber and onto the immovable objects for half a minute. This sterilizes the chamber  22 . After a three minute cooling period, the chamber and immovable objects are then sprayed with sanitizing agent at 110° F., and allowed to dry.  
         [0025]    The self-containment of the slaughter chamber  22  ensures that all the of water, bodily matter and fluids exit the slaughter chamber  22  during wash down through the drainage system  48 , thus preventing any other areas of the processing facility  10  from being contaminated with the aforementioned waste products. These waste products, which include the contaminants along with the water emitting from the nozzles  60 , wash and flow into the drainage system  48 . From there, the waste products gravitationally flow toward the waste removal area  14 . Preferably, the cleaning cycle is repeated at a regular interval of four hours, and should last between 10-15 minutes, which can easily be correlated to correspond with the workers&#39; break time. Thus, when all of the workers leave for a lunch or coffee break, the slaughter chamber can be cleaned and sanitized in about 10-15 minutes, and be ready for processing of additional carcasses when the workers come back from break.  
         [0026]    Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.