Abstract:
A mobile system for processing raw ears of corn includes a first mobile processing trailer for receiving raw unhusked ears of corn, holding the ears and disbursing them to a husker for removing corn husks and corn silk from the ears. A conveyer takes the husked ears of corn to a second trailer for further processing. The second mobile processing trailer includes multiple cutting machines to remove the corn kernels from the cob and a saw to slice the fresh ears of corn into mini cobs. A conveyer takes the sliced cobs to a holding bin for transportation to a cannery while a second conveyer removes the corn kernels from the second trailer to a third trailer for washing and cooling. The third trailer includes a pair of rotating sieves and a cooling tank to clean and chill the corn kernels. The chilled kernels are then transported via a conveyer to transportation receptacle for transportation to a cannery for further processing.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. application Ser. No. 09/887,584, filed Jun. 22, 2001 now abandoned. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to a system and method for processing fresh corn and in particular to a self-contained mobile processing plant for processing fresh corn in proximity to the field in which it is grown. 
     BACKGROUND OF THE INVENTION 
     In the prior art, fresh ears of corn have been typically processed by harvesting the corn in the field with standard prior art corn strippers and then transporting corn to central canneries where the corn is processed and packaged as cobs or where fresh corn kernels are cut from the cob and packaged. 
     The desired portion of the fresh corn, the kernels, comprise approximately 25% to 30% by weight of the total fresh corn harvested in the field. The waste portion, the shucks and cobs, comprise approximately 70% of the weight. Because conventional canneries may be many miles from the field in which the corn is grown, the unprocessed raw corn must be transported from the field to the cannery. As a result, 70 to 75 percent (when processing only the corn kernels) of the hauling charges incurred are attributable to the transportation costs of the waste cobs and shucks. Moreover, additional hauling charges will be incurred for transporting the waste away from the cannery. 
     Additionally, there are numerous canneries located in agricultural areas that are capable of freezing and/or canning fresh produce; however, there are substantially fewer canneries that contain equipment that is capable of husking, slicing cobs and cutting the kernels corn from the cob. Transportation expenses and the need to minimize transport time restrict the potential growing area for fresh green corn to geographic areas in general proximity to canneries with husking, slicing and cutting capabilities. 
     The present invention provides an efficient means to process corn at the harvest site in preparation for packaging, to reduce the costs associated with transporting the corn to a cannery and to expand the potential growing areas for fresh green corn. 
     SUMMARY OF THE INVENTION 
     The present invention comprises a self-contained mobile fresh corn processing system that may be transported in proximity to the field in which the corn is grown. In the present invention, raw ears of unhusked corn are received by a hopper which continuously feeds the ears of corn into a first processing trailer. The first processing trailer holds the ears and disburses them onto a first conveyer. The first conveyer feeds the raw ears of corn into a husker where the corn husks and silks are removed. The ears are then transported via a conveyer to a second trailer for further processing. 
     Upon entrance to the second trailer, the corn ears can be selectively separated into two groups. The first group of ears can be directed to a mechanism to slice the cobs into “mini” cobs for packaging “corn-on-the-cob” while the second group of ears can be directed to cutting mechanisms to remove the corn kernels from the cobs. The slicing and cutting functions can be performed simultaneously or separately, depending on the product demand. Further, the step of selectively separating the cobs into multiple groups can be manually or automatically performed. The corn husks, silk, cob and stalks are removed from the first and second trailers to a trash trailer by a series of trash conveyer belts. These trash particles can be used for fertilizer or stored as silage. 
     The sliced or mini-cobs are transported via a conveyer from the second processing trailer to transportation totes where the cobs are transported to a cannery for packaging. The cut kernels are cleaned and chilled in a third processing trailer and finally directed to transportation totes for delivery to a cannery for packaging. 
     The present system presents advantages over conventional systems because the geographic growing area for fresh corn is substantially expanded. In the present invention, the husking, cutting and slicing functions are accomplished in proximity to the field in which the corn is grown; therefore, conventional canneries may be used for final processing of the output product from the present invention. As noted in the background section, there are numerous canning facilities located in agricultural areas; however, only a limited number of those include the capability for husking, cutting kernels, and slicing cobs. By expanding the number of canneries capable of processing the corn, the area for growing fresh corn is increased. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A more complete understanding of the invention may be had by reference to the following Detailed Description when taken in conjunction with the accompanying drawings in which: 
     FIG. 1 is a plan view of the self-contained mobile corn processing system of the present invention; 
     FIG. 2 is an elevation view of a portion of FIG. 1 illustrating the cob conveyer and entrance area where a cobs enter into second trailer. 
     FIG. 3 is a section view taken along line  3 — 3  of FIG. 1; 
     FIG. 4 is an elevation view of a portion of FIG. 1 illustrating the cob conveyer and saw. 
    
    
     DETAILED DESCRIPTION 
     Reference is now made to the Drawings wherein like reference characters denote like or similar parts throughout the four Figures. The present invention comprises a self-contained mobile fresh corn processing system that may be transported in proximity to the field in which the corn is grown. Referring to FIG. 1, the system includes three self-contained movable semi-trailers  10 ,  12  and  14  such as are typically manufactured and conventionally used to transport goods on the highways, wherein corn processing equipment is contained inside or thereon the semi-trailers. First trailer  10  comprises a storage area  26  and husker  20  to remove the corn silks and husks. Second trailer  12  contains multiple corn cutters  36 , wherein the ears are processed to strip the kernels from the cob, and a saw housing  44 , where fresh corn ears are cut into mini corn cobs in preparation for packaging. Third trailer  14  comprises a first sieve  58 , a cooling water tank  60 , a second sieve  62 , and chiller  76 , all operable to wash and cool the cut corn kernels. Power supply  74 , also located on trailer  14 , provides power to the corn processing equipment. The corn processing equipment is conventional equipment similar to that located in fixed canneries; however, the equipment has been modified so as to be self-contained in the mobile trailers. 
     The first trailer  10  receives fresh unhusked corn from a harvester (not shown). The harvester may be any conventional corn harvester that strips the ears of unhusked corn from the stalk and discards the stalk. Corn is preferably fed into the first trailer  10  from hopper  16 , whereby the flow of corn into storage area  26  can be continuous and easily regulated. Hopper  16  is a conventional type hopper capable of holding approximately 2000 pounds of corn ears. Corn may be fed into the hopper  16  directly from the harvester or alternatively from a transportation buggy filled by the harvester in the field. Hopper  16  directs ears of corn into storage area  26  of trailer  10  and provides distinct advantages in that the rear doors to storage area  26  are not required to be opened each time corn is loaded into storage area  26 . Thus, cobs will not fall from first trailer  10  when the storage container&#39;s doors are opened and trailer  10  can be continually fed. In an alternative embodiment, the first trailer  10  can be fed directly from the harvester&#39;s dump box or from the transportation buggy that is filled by the harvester in the field without using hopper  16 . 
     The trailer storage area  26  functions as a holding bin with a vibrating floor  18  (commonly known in the trade as a walking floor). Floor  18  feeds the unhusked corn to a cleated first conveyer (not shown) that transports the corn to husker  20 , where the corn is further processed. Power source  74 , located on the third trailer  14 , directs power to a motor (not shown) to operate a bidirectional hydraulic pump (not shown), which moves floor  18 . 
     Husker  20  removes the corn shucks and corn silks by counter-rotating rubber grip rollers. The components of the husker  20  are conventional equipment well known to those skilled in the art, and of the type manufactured by CCM, Hughes, or FMC. After the husker processes the corn, the shucks and waste cob are carried by a trash conveyer belt  22  (located under first trailer  10 ) to a main trash conveyer  23  and inclined cleated conveyer  25 , which deposits the waste inside trash container or trailer  82 . The waste cobs and shucks may be returned to the fields and plowed under as fertilizer or transported to storage and used for silage. 
     The husked ears of corn are transported from husker  20  to trailer  12  via conveyer  24  to feed the ears of corn onto belt  28 . Belt  28  directs the ears inside trailer  12  where the husked ears are visually inspected for any ears that are unsatisfactory for processing. Unsatisfactory ears include those not fully developed, short ears or those that are not desirable for human consumption. After visual inspection, the ears are selectively separated into two groups. A first group of ears is directed onto conveyer  34 , which transports the ears toward saw housing  44  for subsequent cutting of ears into smaller cobs. A second group of ears is directed toward multiple corn cutters  36 , where the kernels are stripped from the cob. Any ears that proceed to the end of belt  28  that are not processed in either the first or second group are re-circulated back to belt  28  by return belt  30 . 
     The separation into the first and second groups depends on cob length and diameter. Cobs that have longer lengths and larger diameters are selected and included in the first group for processing as corn-on-the-cob. The larger “coblets” are preferable as in most cases the ear can be sliced into two equal sized portions. Cobs that are shorter in length and smaller in diameter are better suited for processing as corn kernels as in some cases the shorter length prevents the cob from being cut into normal or desired portions. 
     As seen in FIG. 2, cobs enter trailer  12  via conveyer  24 , which deposits the corn ears on feed conveyer  28 . Processing the first group of ears begins by operators taking the corn ears from feed conveyer  28  and placing them onto conveyor  34  as it moves in feed direction  78 . Any unsatisfactory cobs are removed from belt  28  and routed for trash. Normal operation requires three operators to direct the corn on the conveyer; however, a greater or fewer number of operators can be used depending on the output desired. In the preferred embodiment, operators stand outside trailer  12  on scaffolding (not shown) and reach through window openings  32  (FIG. 1) to visually inspect and place satisfactory cobs from belt  28  onto conveyer  34  as they move toward saw housing  44  (FIG.  1 ). 
     Conveyer  34  comprises multiple “U” shaped cups  54  located above and parallel to feed conveyer  28  and are designed to receive and support the ears of corn. Cups  54  can be plastic, metal or any other suitable material capable of supporting the ears of corn. Referring to FIGS. 2 and 3, as the corn cobs are placed onto conveyer  34 , they are supported by a pair of spaced apart and coaxially aligned cups  54  (best seen in FIG.  3 ). Cups  54  have a diameter D slightly larger than the diameter of a husked corn cob and the pair of cups  54 , when coaxially aligned, have a length shorter than that of a fully developed ear. This shorter cup length allows the cob ends to be sawed off to remove any remaining portion of the stalk and to provide a flat end. Further, the gap G between cups  54  provides a slot to allow saw  46 C to slice the cob into smaller portions (FIG.  3 ). Conveyer  34  is driven by a conventional type electrical motor  35  with adjustable speed capabilities. Power is supplied to the motor by remote power source  74  located on third trailer  14  (FIG.  1 ). 
     FIG. 3 illustrates the cobs being processed inside saw housing  44 . Three circular saw blades  46 L,  46 C and  46 R are rotated by motor  37  so that they continuously rotate as cups  54  transport the cobs through saw housing  44 . As explained earlier, when the cobs are processed through saw housing  44 , they are sliced in the radial direction, perpendicular to the length of the cob, into smaller portions by saw  46 C, which slices the middle portion of the cob. In addition to slicing the middle portion of the cob, the end portions are removed by blades  46 L and  46 R to discard any portion of the corn stalk that may remain on the cob and provide a smooth end. The cob ends fall downward and are directed toward trash belt  38  by deflectors  50 . The ends are removed from trailer  12  via conveyer  38  for storage in trash trailer  82 . 
     Referring to FIG. 4, after the cobs have been sliced, cups  54  carry the cobs away from saw housing  44  and drop the cobs onto transportation conveyer belt  52 . The cobs on conveyer belt  52  travel from trailer  12  to a lined container  84  (See FIG. 1) which can be stored on a flatbed trailer  88  for transporting the cobs. Container  84  contains a polyethyl liner and holds approximately 1000 pounds of cobs and are transported to a cannery for further processing. During normal operation, 6 containers (6000 pounds of corn cobs) can be filled per hour. The empty cups  54  on conveyer  34  continue in return direction  80  where they are eventually re-filled with ears of corn at the opposite end of the trailer. 
     Referring back to FIG. 1, when processing the second group, cobs are manually removed from feed conveyor  28  by operators standing adjacent cutting machines  36 . Trailer  12  comprises nine cutting machines  36  to receive the fresh ears of corn for processing. Each cutting machine can cut up to approximately 100-110 ears per minute. Referring to FIG. 2, Operators visually inspect and remove the satisfactory ears from conveyer  28  and place them in feed chutes  55  with the point end forward. The oriented corn is carried by an intake chain  56  to cutter mechanism  36  wherein a plurality of mechanical knives (not shown) follow the contours of the cob and remove the kernels from the cob in a longitudinal direction along the length of the cob. As seen in FIG. 3, a kernel chute  48  directs the kernels to a white PVC (food grade) kernel conveyor belt  40  for transporting the cut kernels to the rear of the trailer  12 . Cobs from the cutter  36  are released and directed from the cutter to trash belt  38  by chute  42 . The spent cobs are conveyed via trash belt  38  to the rear of second trailer  12  and then via conveyers  23  and  25  to trash trailer  82  (FIG.  1 ). 
     The separation the first and second groups can be performed by manual labor, whereby human operators direct the ears to the desired location as discussed above, or, in the alternative, separation can be performed automatically so that human operators are not required. In either case, the cobs are selectively placed onto the cob conveyer or into the corn cutter machine so that the lines are operating simultaneously or individually, whichever may be desired. 
     Automation can be performed by directing the cobs to a chamber or slot whereby the cobs can be weighed, imaged, optically scanned or examined by any other method capable of determining the characteristics of the cob (i.e., size, weight, color, etc.). This data can be analyzed to determine whether the cob is better suited for processing in the first group as “corn-on-the-cob” or if it is better suited for processing with the second group as cut corn kernels. In either case, after analysis has been performed, the cob can be directed toward the desired processing area. 
     Referring now to third trailer  14  in FIG. 1, corn kernels are delivered from trailer  12  by conveyor  57  for cleaning and cooling. Kernels are first directed inside rotating sieve  58 . Sieve  58  is a metal cylindrical container having a mesh diameter slightly larger than the diameter of a corn kernel. Chilled water is sprayed inside rotating sieve  58  to rinse and chill the kernels. As the corn is rotated by sieve  58 , the kernels are sifted through the mesh and fall onto a water filled tray (not shown) located below sieve  58 . The kernels slide down the tray into tank  60 , where they are further washed and cooled. Trash particles too large to pass through the mesh screen exit the opposite end of sieve  58  end and fall onto trash belt  70 , where the particles are directed to trash conveyor  72  for transportation from trailer  14 . Cooling tank  60 , which circulates chilled water, cools the corn to approximately 38-40 degrees Fahrenheit. Corn kernels are then pushed up a ramp onto second tray  71  from the bottom of tank  60  by high pressure water. Kernels flow down second tray  71  into a second rotating sieve  62  to drain any excess water that may remain on the corn kernels. Holding tank  64 , located directly below rotating sieve  62 , stores the excess water and directs the water for re-circulation. 
     The kernels exit the opposite end of rotating sieve  62  onto conveyer  66 , a food grade PVC conveyer. The kernels are transported via conveyer belt  66  to a transportation tote  86  located in loading trailer  68 . Transportation totes  86  may be any sanitary containers capable of bulk transportation of approximately 1500 to 1700 pounds of the kernel corn and juice. Typical containers may be stackable polymeric or stainless containers with suitable sealing lids or corrugated crates with plastic liners. The transportation totes  86  are loaded onto conventional tractor trailers and delivered to a cannery for further processing. If a cannery is not nearby, refrigerated tractor trailers may be used to transport the transportation totes  86  containing the kernel corn to more distant canneries. The refrigerated trailers transport the kernel corn at about 28 degrees to 30 degrees Fahrenheit. As noted in the Background and Summary of the Invention sections of this application, chilling of the corn and refrigerated transportation provide distinct advantages over prior art systems for processing kernel corn. 
     The cooling water is inspected and changed as needed for maintenance of sanitary conditions. Generally, the cooling water is changed at least daily. The cooling water is chilled by a conventional chiller  76  comprising a heat exchanger and compressor/condenser mounted on the front portion of the third trailer  14 . 
     Power is supplied to the various components by power supply  74 , most preferably a 250 horsepower engine mounted on third trailer  14 . 
     Although preferred embodiments of the present invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention. Such modifications may include, but are not limited to, the use of two or more husking and cutting trailers to increase the inlet kernel corn to the cooling trailer. Alternatively, if the harvesting area is located very near a cannery, the raw kernel corn may be processed as taught herein and transported in bulk containers without the chilling steps.