Abstract:
A system for loading retorts, sterilization systems, and the like. The preferred embodiment of the present system provides both loading and unloading modules, the loading module designed to automatically load fragile containers, in mass and layer by layer into a self-supporting cube array of stacked trays nested in a basket frame. The unloader module automatically unloads the cube array layer by layer after the contents of the cube array are processed in mass. The stack of trays, or batch cube remain as an intact, stacked unit throughout the entire retort process. A hydraulic ram which is associated with each the loader and unloader, lifting the batch cube from the basket frame and indexing the batch cube vertically during the loading/unloading process, respectfully. Each layer in the stack is either loaded or unloaded as that layer is positioned in the home position. Both the loader and unloader includes home position locating devices or tray supports that accurately position the batch cube so that product can be transferred onto or off of the conveyor. In the loader module, a multi-position container break is used to collate each layer prior to transfer into the batch cube system. There are a total of three break locations. A clearing assembly is provided to assure that no containers are left on the dead plate. Also taught is a tip indicator which detects when a container has been knocked over or otherwise improperly oriented during the loading process.

Description:
FIELD OF THE INVENTION 
     The present invention relates to loaders, and particular to a system for loading retorts, sterilization systems, and the like. The preferred embodiment of the present system provides both loading and unloading modules, the loading module designed to automatically load fragile containers, in mass and by layer into a unique self-supporting cube array of stacked trays (hereinafter referred to as batch cube which remain intact and are conveyed to and from the unloaders by a basket frame. The unloader module automatically unloads the containers after the cube array and its contents have been processed, in layer-by-layer fashion. 
     The batch cube remains intact as a stacked unit throughout the entire retort process, transported and enveloped by a basket frame. A hydraulic ram which is associated with each the loader and unloader, indexing the batch cube vertically during the loading/unloading process. Each layer in the stack of trays forming the batch cube is either loaded or unloaded as that layer is positioned in the home position. Both the loader and unloader includes home position locating devices or tray supports that accurately position the tray or cube array out of the basket frame and to the appropriate position so that product can be transferred onto or off of the conveyor. 
     In the loader module, a multi-position container break is used to collate product prior to transfer into the tray system. There are a total of three break locations. A clearing assembly is provided to assure that no containers are left on the dead plate. 
     Lastly, a tip indicator is taught wherein the unit is able to detect when containers which have been knocked over or are otherwise improperly oriented with regard to the cube array during the loading thereof. 
     BACKGROUND OF THE INVENTION 
     Most shelf stable products have historically been processed in metal cans or glass containers, which are typically processed in a mass in a retort basket or the like. These containers are very rigid and not prone to damage when using conventional retort basket loading techniques. These containers are rigid enough that each layer can be stacked in the basket upon the previous layer with no damage to the containers in the lower quadrant of the stack. Perforated layer pads or divider sheets are typically placed between each layer to separate same. 
     Because of consumer preferences and lesser costs, flexible and fragile containers have begun to be used in increasing numbers. This trend started in the mid 1980 s and has increased significantly starting in the late 1990 s. As the consumer demand for this type of packaging increases, food processors have been faced with the difficult chore of handling these containers at higher and higher line speeds. 
     Unlike a rigid container like a metal can or glass bottle, these containers cannot support the weight of additional containers being loaded one layer on top the next. Examples of fragile containers include plastic bottles, trays, cans, cups, and bowls, and various laminated packaging. The geometry of these packages can include cylindrical, rectangular, and various other irregular shaped containers. Since most production lines require elevated line speeds to be commercially feasible, the best method to transfer or load these types of containers is to do so in mass. However, the prior art fails to provide such a system. 
     Existing loading devices that have been used to handle flexible pouches and some fragile containers use a pick and place methodology, which may or may not allow for a full layer of containers to be handled at one time. In addition to handling the container, this type of handling approach also requires secondary handling of the trays. Each layer must be staged for loading or unloading and then collated into a formed stack. There is also additional handling, which must be done to manage the flow of racks between the unloader and loader. All of this secondary handling makes the equipment design more complex, more costly, and in many cases limits the operational speed of the line. 
     SUMMARY OF THE INVENTION 
     Unlike the prior art, the present invention seeks to provide a system for the loading and unloading of fragile containers which cannot be stacked upon one another which is reliable and fast in operation, and relatively cost effective to operate and maintain. 
     In this regard, the present invention provides a system for loading and unloading fragile containers for the retort or sterilization process in a manner that will eliminate the damaging vertical, downward forces that cause container deformation and do so at commercially accepted line speeds. The invention eliminates the unnecessary complexities and costs seen with secondary tray handling currently being utilized. 
     The present invention provides an apparatus suitable for handling multiple containers types including: plastic bottles, plastic cans, plastic cups, and various laminated packaging. The geometry of these packages can include cylindrical, rectangular, and various other irregular shaped containers. The containers can be handled either in lanes or in a nested pattern. The invention is applicable for any type of horizontal retort which uses square or rectangular baskets. 
     The methodology used in this invention is to handle the transfer one full layer at a time in a specialized, one piece, multi-layer transport and processing cube array. While the array is referred to as being a cube shape, this is not meant to be limiting, as the array can comprise any rectilinear or other configuration, depending upon the application. The number of containers to be treated in a layer is a function of the size of the container being loaded and the size of the cube or basket that will fit inside the retort or sterilizer. The methodology used in the invention allows the stack of trays that forms the batch cube to always stay together. 
     Thus, the need for secondary handling (i.e., stacking the goods to be treated upon one another in a layering manner) is completely eliminated. The batch cube can either be contained within a basket or basket frame, as illustrated in the preferred embodiment of the present invention. As will be shown, the trays can include lanes which allow the product to be staged by lanes or can have an open configuration which allows for a nested pattern of containers. 
     In either case, the cube of trays is indexed up and down and stops at the home position so that the layer of containers can be transferred. Each layer in the cube will visit the home position until the entire cube is emptied or filled. The side loading of the trays cube is what allows the cube to stay together as a unit and eliminates the need to stack and de-stack the cube like what is done with pick and place systems. 
     The invention includes both a loading module and unloading module. Both modules are almost identical with the exception of the direction of operation and a few components like the break feature. This fact aids in the economy of both the fabrication and the ongoing operation of the modules. Both modules are controlled by an independent PC or PLC. The PC or PLC controls allow for fully automatic operation of the machines. 
     Both the loader and unloader module include an independent, servomotor driven, linear motion mechanism used to push the containers into or out of the tray a Pusher. Another independent, servomotor driven, linear motion mechanism is used as a follower to assure that containers are not tipped during the transfer process a Follower. This feature is required if the modules are to be operated without the presence of a human operator. Both the Pusher and Follower are equipped with a breakaway mechanism that will trip in the event that a container is tipped over. Both breakaway mechanisms are equipped with a detection switch that sends a tipped container signal to the PLC or PC controlling the modules. 
     Both the loader and unloader module can include components for determining the accurate location of the tray cube, including proximity switches, photosensors, or other tracking means. The hydraulic ram mechanism is used to provide coarse positioning of the cube within the module, lifting the cube from the basket frame so that the tray to be loaded is in the appropriate position. Atray support mechanism is used for final and accurate positioning of the layer being loaded or unloaded. This part of the mechanism is essential to assure a final, accurate location prior to container transfer. The mechanism eliminates cumulative dimensional error within the cube and provides needed support for trays and basket frame so that deflection error is also eliminated. 
     A multi-position can brake is used in the loader module to allow proper staging of each layer of containers into the tray to be loaded. Unlike conventional brakes (which may use, for example, pick and place loading techniques), the present invention utilizes linear, horizontal motion to convey the product into the trays, which eliminates the damaging effects of a top pressure brake used for metal cans or other rigid containers. 
     A conveyor is used to transport the cubes to and from each module. This conveyor is oriented transverse to each module and straddles the hydraulic push mechanism. The push plate actuates up and down through the conveyor frame and allows the cube to be moved for positioning at the load or unload position. 
     The above components working together form a new and innovative loading/unloading system which is not contemplated or otherwise suggested by the prior art. 
     It is therefore an object of the present invention to provide a loading/unloading system for retorts or sterilizers which can accommodate the new generation of polymer, laminated, or other containers which cannot be stacked upon one another. 
     It is another object of the present invention to provide a loading/unloading module which automatically loads fragile containers to a multi-shelf, multi-channel cube of trays in a basket frame. 
     It is another object of the present invention to provide a tip mechanism which indicates if an object being loaded is improperly oriented. 
     It is another object of the present invention to provide a loader/unloader system which fully automates the process and limits secondary handling of the trays, and wherein the nested trays or batch cube remains intact through the treatment process. 
     Lastly, it is still another object of the present invention to provide a loader/unloader for fragile containers which is cost effective to implement and maintain, reliable in operation, while providing a speed and operational performance on par with loaders for rigid goods. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein: 
     FIG. 1 is a side, isometric view of the loader of the preferred embodiment of the present invention. 
     FIG. 1A is a partial, close-up, isometric view of the loader of FIG. 1, illustrating the tray positioner section, pusher section, brakes, and follower section of the device. 
     FIG. 2 is a close up, isometric view of the invention of FIG. 1, illustrating in detail the clearing assembly section of the system. 
     FIG. 3 is a close up, isometric view of the unloader of the preferred embodiment of the present invention. 
     FIG. 4 is a top, partially cut-away view of an exemplary layout of the batch retort loading/unloading system of the present invention. 
     FIG. 5 is a close-up, isometric view illustrating in detail the individual tray and basket frame forming batch-processing basket utilized with the invention of FIG.  1 . 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENT 
     The preferred embodiment of the present invention contemplates a batch loader and unloader for simultaneously processing a number of fragile containers through a retort, sterilization apparatus, or similar system. 
     Referring to FIG. 5 of the drawings, a batch-processing basket  14  in the form of a frame having a plurality of trays vertically situated therein in is utilized in the loading and conveying of the product for processing in the retort, sterilizer, or other process. As shown, a batch cube is securely held within the basket frame  11 , allowing the batch processing basket, once the trays have been loaded and positioned therein, to be oriented 360 degrees and remain intact. 
     Each tray  1  has first  2  and second  2 ′ ends, first  3  and second  3 ′ sides, a length  4 , a width  4 ′, and top  5  and bottom  5 ′ walls forming an enclosure  16  having a height  6  therein. The enclosure is divided equally via parallel vertical divider walls  7 ,  7 ′, forming individual cells  9 ,  9 ″ or linear compartments, each having sufficient width  8  and height  6  for receiving a row or line of product along the length  4  of the tray. In the preferred embodiment, the trays are formed of stainless steel with apertures  15 ,  15 ′ for providing uniform heat distribution and transfer to product situated therein. 
     Multiple trays are stacked  10  upon and affixed to one another forming a batch cube  13 , which is selectively enveloped by a basket frame  11  which includes a structure  12  to encapsulate the openings of the trays, as well as securing the trays in stacked configuration at any orientation, the trays together forming the batch processing basket  14 . In the example shown, six trays are stacked and secured to one another for placement into the basket frame to form the batch cube. 
     The basket frame has an open top  17  and bottom  18 , and which may include an H Frame  21  for distributing clamping force during the retort process, for use in a rotary retort. The floor  16  of a bottom tray situated in the base of the basket frame, is shown in a cut-away view. In loading or unloading the batch cube  13 , upward pressure  19  is provided to the floor  16  of the bottom tray while the basket frame is held stationary, so as to urge the batch cube  13  forming the stack of trays up  20  and out of the basket frame  11 , where the open ends  2 ,  2 ′ of the trays and compartments  9  are positioned so as to be accessible for loading or unloading product therein, as will be further discussed infra. 
     It is noted that the side walls  22 ,  22 ′,  22 ″,  22 ′ of the basket frame  11  may be clad with stainless sheeting having apertures therein similar to the walls forming the trays, for structural reinforcement and to keep product loaded in the trays from falling out during processing. 
     Loader Module 
     Referring to FIGS. 1,  1 A,  4  and  5 , a loader module  30  is provided having first  31  and second  32  ends, a flat upper work surface  33  having a generally rectilinear configuration having raised edges  42  at least partially thereabout, and a loader conveyor system  46  for conveying product from the first end  31  of the loader to the tray  39  to the actual loading area. The upper work surface  33  is supported in spaced relationship above the floor via legs  34 . 
     An opening  36  is formed through the medial portion  35  of the work surface  33  in the loader module for allowing the passage of the batch cube, so that a layer formed by one tray  39  can be indexed for loading, the tray emanating from the basket frame  37  hereunder, each of the trays in the stack of trays in the batch processing basket configured to be vertically indexed  38  through opening  36  via computer control, so that the product receiving compartments  9  for each tray may be positioned at work surface  33  level via a computer controlled lift mechanism  41 . 
     The lift mechanism  41  may be operated by, for example, a hydraulic ram/push plate  40 , servo motor, or the like, and is configured to raise  43  or lower  44 , the batch cube to facilitate the loading of product into each tray forming the batch processing basket  37 . The hydraulic ram/push plate  40  provides coarse positioning of the batch cube within the loading module. A tray support mechanism  23  locks to the batch cube and is powered by pneumatic cylinder  58 , providing a more accurate, final positioning prior to container transfer for each tray to be loaded, to eliminate cumulative dimensional errors while providing support to prevent deflection errors in the system. 
     The hydraulic ram/push plate is comprised of a hydraulic cylinder which is attached to a flat, push plate and to an anti-swivel linkage. The cylinder is encased in a flanged casing which is sunk into a hole placed in the floor and secured to the floor by means of top mounted flange. The push plate and controls are located above floor level. 
     The first end  31  of the loader module  30  receives product from an external conveyor  50 ′, wherein the product passes over a dead plate and on to the loader conveyor system  46  of the loader module. In the preferred embodiment of the present invention, the loader conveyor system  46  comprises a series of evenly spaced mini conveyor belts  46 ′, each belt having width to accommodate the width of a single line of the product to be conveyed, each belt separated by divider wall  47 ′ to maintain product  48  traveling along a belt in along a centered, single line  49  on each said belt, each belt configured to end  50  adjacent to the opening of each compartment  9  in the tray to be loaded  39 , thereby conveying  53  product to the opening of the compartment to be loaded. 
     In the present example, the exemplary tray  38  has fourteen compartments  9  for receiving a row of product; accordingly, there is provided fourteen mini conveyors belts  46 ′, situated in aligned fashion along the length of the conveyor area  46  from the first end  31  of the loader unit to the vicinity of the opening of the commensurate aligned compartment  9  in the tray in position to be loaded, which tray is a level in a batch cube in a basket frame which has been conveyed to the loader via conveyor and positioned and indexed via lift  41 . 
     For consistency of processing, it is important that each product to be treated is uniformly oriented, and each compartment of each tray has an equal number of product situated therein, so as to provide maximum efficiency and uniform heat transfer in the retort or sterilization process. Accordingly, the present invention includes means to monitor proper orientation, collation, spacing and number of items loaded. 
     With this in mind, the loader of the present invention includes first  51 , second  52  and third  65  computer controlled brake systems, each brake system comprising a line of transversely situated, individually computer controlled barriers in the form of vertically oriented rods  52 ′ having first and second positions, wherein in the first position each rod  52 ′ is situated in an open state adjacent to a divider wall as shown, and a second position  52 ″ whereby the rod is moved sideways  55  to a position medial to the conveyor path and between first and second divider walls about the conveyor path, so as to temporarily block further passage of product therethorough, thereby selectively regulating the feeding of product along the conveyor lines. 
     These break systems may work in cooperation with proximity detectors, which may be set to have the barriers (vertically oriented rods) moved from an open to closed position when it is detected that the mini conveyor belt beyond the barrier has full capacity product, or alternatively on a timing cycle, so as to facilitate loading of the desired number of product into the compartments  9  formed in the trays for receiving same. Further, other means of selectively preventing the continued passage of product along a conveyor may likewise be implemented, including without limitation, raised or lowered barriers, etc. 
     The barriers, which may be controlled via individual actuators or servos, are configured to provide uniform placement of product into a final loading area  60 . For example,  14  individual conveyor lines are shown in loading area  60 , conveyor line one  61  being the first line, having shown therein exemplary polymer bottles containing food therein for retort processing. As shown, conveyor line one  61  has a capacity of handling eighteen bottles, which is the predetermined amount of bottles which can be held in an upright position by the first compartment  9 ′ in tray  39 . 
     It is further noted that the system of the present invention may utilize other means of directing product to the loading area, including a single large conveyor belt with or without divider walls, depending upon the nature of the product being loaded, and the presently taught mini-conveyor belt/divider wall embodiment is provided for illustrative purposes only and is not intended to be limiting as to the scope of claims of the present invention. 
     Returning to the drawings, in the preferred embodiment of the present invention, product from external conveyor  50 ′ passes over a dead plate, through first brake  51  (which is in an open position), where the product is urged upon the plurality of adjacent mini conveyors comprising the loader conveyor system  46 . 
     The product advances down the loader conveyor system  46  until it reaches the second brake  52 , which is in a closed position  52 ″. Once the product or containers form a full layer behind second brake  52  (detected by full layer detector  56 , which comprises, for example, a line of proximity switches, light sensor, weight sensor, etc), second brake  52  is opened, so that the containers in the preliminary loading area  60  are allowed to advance to the final loading area  59 ; third brake  65  is closed to “park” the multiple lines of product to be loaded into the tray at their respective openings of the compartments in the tray to be loaded. 
     Thus, in the present example, once all fourteen mini conveyor belts  54  situated in the preliminary loading area  59  are stocked with the determined amount of product (in this exemplary case, eighteen bottles each), which comprises the exact amount of product to fill each compartment in the tray  39  to be loaded, thereby providing fourteen lines product to be loaded in the final loading area, each line having first  62  and second  63  ends. 
     Situated over the final loading area  60  is a pusher  70  for urging the product situated along the fourteen lines into respectively aligned and positioned fourteen compartments in the positioned empty tray  39 , While a follower  80  is provided to engage the second end  63  of each line of product for loading, the follower configured to support the each line of product in an upright position while the pusher urges same into each compartment  9  of the tray  39 . Upon initiation of the pusher  70  and follower  80 , the third brake  65  is opened to allow the product in the final loading area to be urged therein, as discussed below. 
     As shown, the pusher  70  and follower  80  are linear motion mechanisms each utilizing their own servo motors  71 ,  81  to push and support the product  48  ready for loading in the final loading area into the tray positioned for loading. The pusher comprises a plurality of aligned pusher paddles  72 ,  72 ′ situated in equidistant spacing on carriage  73 , each paddle aligned above a respective mini conveyor  54  in the final loading area  60 , so as to push  75  a line of product situated upon said mini conveyor into an aligned compartment in the empty tray  39 , positioned for loading. 
     The carriage  73  is transversally supported by pneumatic cylinder  57  which can raise  66  or lower  66 ′ the carriage and pusher paddles to allow the passage of product thereunder when the pusher is not in use, the vertical servo affixed to a linear track  74 , which in turn guides the carriage and pusher paddles below said linear track  74  by the servo motor  71 , and is computer controlled. As indicated, the carriage has situated along its length a pusher paddle  72  above each mini conveyor in the loading area, each pusher paddle configured to engage the first end  62  of the product to be urged  75  along the final loading area  60  and loaded into their respectively aligned compartment  9 ′ in the tray  39  to be loaded. 
     The follower  70  works in conjunction with the pusher, and likewise includes a carriage  82 , but instead of pusher paddles, the carriage  82  has situated thereon a number of follower arms  83  commensurate with the number of compartments  9 ′ in the tray to be loaded (in this case,  14 ), the follower arms  83  having first  84  and second  84 ′ ends, the first  84  ends engaged and supported by the carriage  82 , the second ends  84 ′ having an engagement end  85  for engaging the second end  63  of the row of product to be loaded to prevent same from tipping, each follower arm  83  further having a uniform length  86  to allow passage of a single engagement end completely through each respective compartment  9 ′ in the tray to be loaded. 
     Like the pusher  70 , the carriage  82  of the follower  80  is guided along a linear track  88  by a servo motor  89  so as to allow the engagement end  85  of each follow arm  83  to engage and support the second end of the row of product to be loaded while the pusher  70  is pushing or urging  75  the first end of the product to be loaded into the compartments of the empty tray  9  positioned for loading. During this operation, the follower  80  is retracting  87  the follower arms  83  at about the same speed that the pusher  70  is pushing or urging  75 , while maintaining the engagement end  85  of the follower arms against the product being loaded into the tray  39 . 
     Further provided in the present invention is a tip detector mechanism  77  for detecting when a container has tipped over from its upright position during loading into the tray. In accomplishing this feature, each pusher paddle  72  is pivotally affixed  76  to the carriage  73 , but held in a vertical position via a trip mechanism to a predetermined level of resistance  78 . If the pusher paddle is pushing a row of product into a tray and one of the product containers is tipped over, it provides resistance against said pusher paddle to further forward movement through the pusher s predetermined cycle, exceeding the trip force, causing the trip mechanism to release the pusher paddle, causing the pusher paddle to pivot, which pivot is detected by a light beam//sensor or mechanical switch, which alerts the operator of the tipped product and halts loading until the problem is corrected. Upon the operator reorienting the tip product and resetting the pusher paddle by re-orienting it vertically, the loader may be reactivated to complete the loading operation. 
     Likewise, the each follower arm is designed with a breakaway point which like the pusher, will trip in the event of a tipped container. In the even of a tripped arm, the follower trip switch or light beam/sensor will be interrupted to detect the tripped lane. 
     The pusher and follower are sequenced to move simultaneously, the pusher urging  75  the product into the tray, while the follower, contacting the product at the second end of the line, retracting  87  as the product is loaded into the tray. Once the product is fully loaded, the follower is fully retracted so that no portion of the follower arms is present in the tray, so that the batch cube in the basket frame  37  may be vertically sequenced  38  to position the next empty tray into position for loading, until the processing basket  37  is full. 
     Once the product containers are fully inside tray, the tray batch cube is vertically indexed  43  one position via lift mechanism  41 , and the next tray is staged for loading. The product is collated to the final loading area mini conveyor belts as discussed above, forming in this case fourteen lines of product, the pusher/follower urges the product into the tray compartments, the next tray is indexed into position, and the procedure is repeated until the entire batch cube of trays is loaded. 
     Again, the number of trays in a batch cube, and the number of compartments in each tray is dependent on both the size of the stack and the dimensions of the product containers to be processed, although the exemplary batch-processing basket of the present example is shown as a six-tray stack. Once the entire stack of trays forming the batch cube has been loaded, it is indexed away  24  from the loader module by means of the transverse mounted conveyor  104 ′ adjacent to the lift mechanism. The next basket frame and batch cube forming the batch processing basket is then loaded from the transverse conveyor  104 ′ and indexed into position. 
     Referring to FIG. 2, a clearing assembly  92  comprising a carriage transversally situated above the dead plate  64 , providing an independent, servomotor driven, linear motion mechanism to clear  90  product remaining on the dead plate after the loading cycle has been completed, conveying the product back to the external conveyor  50 ′, to prevent accumulation and blockage of loader. 
     Unloader Module 
     Continuing with FIGS. 3 and 4, the unloader  100  module operates in the same way as the loader module, but in reverse, and includes the same features and functional operation of the various elements, except it does not require the brake system of the loader module, and the follower of the loader module functions as and a pusher in the unloader module, as it is now used to urge processed product from each compartment in the tray being unloaded, and the pusher of the loader now becomes the follower in the unloader, as it is used to maintain the line of product being unloaded in an upright state. 
     A batch cube  101  in a basket frame forming a batch-processing basket  115  is conveyed  102  to a lift  103  at the unloader module  100  by means of a transverse exterior conveyor  104 . The stack of trays or batch cube  101  is lifted  116  from basket frame and positioned at the home or unload position and indexed upward  105  to load the first tray  106 . Once in position, a tray backstop  107  may be engaged and the tray support  108  is engaged to securely position the first tray for unloading. The pusher  113  advances  114  to engage product at the opening of the compartments  112 ′ of the tray to be unloaded, to support the product  117  therein as it is urged from the tray by the follower. 
     The follower arms  110  of the follower  109  are then advanced  114 ′ through each compartment  112  of the tray  106  being unloaded, while the pusher  113  is retracted  118  as the product  117  containers are removed from the tray onto the unloader conveyor  119  where the product is conveyed  120  to an exterior conveyor  121  system (again, the follower is used as the pusher in the unloader and the pusher is used as the follower in the unloader module, as opposed to visa-versa in the case of the loader module). Once the containers are fully outside the first tray in the batch cube, the follower  109  is retracted  122  fully so that the follower arms  110  are removed from the tray, the batch cube is vertically indexed  105  one position and the second tray  123  is staged for unloading. The same procedure is repeated until the entire stack of trays is unloaded. 
     Once the batch cube  101  has been unloaded, the lift  103  lowers the batch cube into the basket frame and loads same upon the transverse mounted conveyor  104 ′ where it is conveyed  124  away, perhaps to the loader module  30  for loading. The next batch-processing basket (having processed product in a stack of trays therein) to be unloaded is then indexed into position. 
     One may appreciate that the apparatus described is suitable for loading or unloading retort baskets, but it will be appreciated that it could also be so constructed as to be suitable for only either one of these operations as well. 
     Both the loader and unloader are designed for fully automatic operation and use a PC or PLC for control purposes. Both modules can therefore be used in a fully automated batch retort system (A.B.R.S.) or in a semi-automated retort system in which there is some operator involvement. 
     
       
         
               
             
               
               
             
           
               
                   
               
               
                 ELEMENTS 
               
               
                 of the Invention 
               
             
          
           
               
                 Element 
                 Description 
               
               
                   
               
               
                  1 
                 tray 
               
               
                  2 
                 first, second ends 
               
               
                  3 
                 first second sides 
               
               
                  4 
                 length, width 
               
               
                  5 
                 top wall, bottom wall 
               
               
                  6 
                 height 
               
               
                  7 
                 spaced vertical divider walls 
               
               
                  8 
                 width 
               
               
                  9 
                 compartments for receiving a row of product along length 
               
               
                  10 
                 fits in 
               
               
                  11 
                 basket frame 
               
               
                  12 
                 secured by frame 360 orientation intact 
               
               
                  13 
                 batch cube 
               
               
                  14 
                 batch processing basket (multiples tacked trays multiple rows 
               
               
                   
                 forming array 
               
               
                  15 
                 trays formed of stainless with apertures for heat transfer 
               
               
                  16 
                 floor of bottom tray (cutaway) 
               
               
                  17 
                 top 
               
               
                  18 
                 bottom 
               
               
                  19 
                 lifting pressure on bottom tray 
               
               
                  20 
                 urges top tray from frame 
               
               
                  21 
                 top bar which rides upon top tray, but is used to secure 
               
               
                  22, , , 
                 side walls 
               
               
                  23 
                 tray support mechanism 
               
               
                  24 
                 away 
               
               
                  25 
               
               
                  26 
               
               
                  27 
               
               
                  28 
               
               
                  29 
               
               
                  30 
                 loader module 
               
               
                  31 
                 first end 
               
               
                  32 
                 second end 
               
               
                  33 
                 upper work surface 
               
               
                  34 
                 legs 
               
               
                  35 
                 medial portion 
               
               
                  36 
                 opening 
               
               
                  37 
                 batch processing basket 
               
               
                  38 
                 vertically indexed 
               
               
                  39 
                 tray 
               
               
                  40 
                 hydraulic ram 
               
               
                  41 
                 lift mechanism 
               
               
                  42 
                 raised edges 
               
               
                  43 
                 raised 
               
               
                  44 
                 lowered 
               
               
                  45 
               
               
                  46 
                 loader conveyor system 
               
               
                  47 
                 divider wall 
               
               
                  48 
                 product 
               
               
                  49 
                 line 
               
               
                  50 
                 end 
               
               
                  50′ 
                 Exterior 
               
               
                  51 
                 first brake 
               
               
                  52 
                 second brake 
               
               
                  53 
                 conveying 
               
               
                  54 
                 respective mini conveyor 
               
               
                  55 
                 sideways 
               
               
                  56 
                 full layer detector 
               
               
                  57 
                 vertical servo 
               
               
                  58 
                 tray support servo 
               
               
                  59 
                 preliminary loading area 
               
               
                  60 
                 final loading area 
               
               
                  61 
                 conveyor line 1 
               
               
                  62 
                 first end of line to be loaded 
               
               
                  63 
                 second end 
               
               
                  64 
                 dead plate 
               
               
                  65 
                 third brake 
               
               
                  66 
                 raise or lower carriage 
               
               
                  67 
               
               
                  68 
               
               
                  69 
                 pivot 
               
               
                  70 
                 pusher 
               
               
                  71 
                 servo 
               
               
                  72 
                 pusher paddles 
               
               
                  73 
                 carriage 
               
               
                  74 
                 track 
               
               
                  75 
                 urge 
               
               
                  76 
                 pivotally affixed 
               
               
                  77 
                 trip detector mechanism 
               
               
                  78 
                 resistance 
               
               
                  79 
                 trip mechanism 
               
               
                  80 
                 follower 
               
               
                  81 
                 servo 
               
               
                  82 
                 carriage 
               
               
                  83 
                 follower arms 
               
               
                  84, 
                 first, second ends 
               
               
                  85 
                 engagement end 
               
               
                  86 
                 length 
               
               
                  87 
                 retracting 
               
               
                  88 
                 track 
               
               
                  89 
                 servo motor 
               
               
                  90 
                 clear 
               
               
                  91 
                 rigid pusher paddles 
               
               
                  92 
                 clearing assembly 
               
               
                  93 
               
               
                  94 
               
               
                  95 
               
               
                  96 
               
               
                  97 
               
               
                  98 
               
               
                  99 
               
               
                 100 
                 unloader 
               
               
                 101 
                 batch cube 
               
               
                 102 
                 conveyed 
               
               
                 103 
                 lift 
               
               
                 104 
                 conveyor 
               
               
                 105 
                 lifted 
               
               
                 106 
                 first tray 
               
               
                 107 
                 tray backstop 
               
               
                 108 
                 tray support 
               
               
                 109 
                 follower 
               
               
                 110 
                 follower arms 
               
               
                 111 
                 forward 
               
               
                 112 
                 compartment of tray 
               
               
                 113 
                 pusher 
               
               
                 114 
                 advances 
               
               
                 115 
                 batch processing basket 
               
               
                 116 
                 upward 
               
               
                 117 
                 product 
               
               
                 118 
                 retracted 
               
               
                 119 
                 conveyor 
               
               
                 120 
                 conveyed 
               
               
                 121 
                 exterior conveyor 
               
               
                 122 
                 retracted 
               
               
                 123 
                 second tray 
               
               
                 124 
                 conveyed 
               
               
                   
               
             
          
         
       
     
     The invention embodiments herein described are done so in detail for exemplary purposes only, and may be subject to many different variations in design, structure, application and operation methodology. Thus, the detailed disclosures therein should be interpreted in an illustrative, exemplary manner, and not in a limited sense.