Method for harvesting biologics from eggs

A method for harvesting biologics from eggs by which an egg is de-capped by positioning the egg in a reference opening so as to expose an upper section of said egg, then, while said egg is positioned within the reference opening, cutting the upper section of the egg by moving a cutter member over the reference opening through the egg, and then removing the debris formed from the cut upper section. The biologics can then be harvested in various ways such as by inverting the egg to allow the biologics to drain for collection. An apparatus for carrying out the method is also provided.

BACKGROUND

The present invention relates to the production of biologics such as viruses for vaccines, and more particularly to the harvesting of such biologics from eggs. Specifically, the present invention relates to apparatuses and methods for opening avian eggs and removing the desired biologics from within.

One method of producing biologics is to use fertilized avian eggs. The desired biologics are grown within the egg and must be harvested therefrom for further processing. Although a preferred embodiment of the present invention is directed to biologics such as viruses, the invention is believed to be applicable to other biologics that can be grown in eggs, such as proteins.

One method of producing vaccines, such as influenza vaccines, is to use fertilized avian (chicken) eggs. The eggs are injected with the viruses and, after a sufficient time of incubation to allow the virus to multiply, the eggs are opened to harvest the viruses.

Harvesting typically involves the collection of the allantoic fluid that is contained in the allantoic sac of a fertilized egg. It is preferable to harvest just the allantoic fluid and avoid contamination from the embryo containing yoke. The viruses are then separated from the fluid, purified, and inactivated to produce the final vaccine as is known in the art.

There are various methods for removing the allantoic fluid. One is to take advantage of the air sac within the top section of the egg shell. The top section, also referred to herein as the “egg cap”, can be cut to provide access to the allantoic fluid within. Various means can be utilized to remove the allantoic fluid for further processing.

As can be appreciated, it is desirable to be able to produce large quantities of vaccines as fast as possible. The present invention provides an advantageous apparatus and method for harvesting the allantoic fluid for producing vaccines.

Embryonated eggs have proven to be a useful medium for the isolation and identification of animal viruses, for titrating viruses, and for cultivation of viruses in the production of viral vaccines. The embryo, chorioallantoic membrane, yolk sac, allantoic sac, and amniotic sac may be inoculated in eggs at various developmental stages providing the scientist with large array of tissue types for specific purposes.

The apparatus and method of the present invention can be adapted for recovering a number of biologically active molecules from the components of embryonated avian eggs (e.g., allantoic fluid, embryo, chorioallantoic membrane, etc.) in addition to the influenza virus. Exemplarily biologically active molecules that may harvested from avian eggs components include viruses and immunoglobulins such as, but not limited to, flaviviruses (e.g., yellow fever virus); arboviruses (e.g., Sindbis virus, Murray Valley encephalitis virus, and Getah virus); orbiviruses (e.g., Bluetongue virus); aphtoviruses (e.g., type C foot-and-mouth-disease virus); alpharetrovirus (e.g., avian leukosis virus); gammaretrovirus (e.g., reticuloendotheliosis virus); rubulavirus (e.g., mumps virus and Newcastle disease virus); avian adenovirus (e.g., chicken embryo lethal orphan virus (CELO) and related quail bronchitis virus); infectious bronchitis the virus; and immunoglobulins from aves inoculated with a variety of infectious agents and/or antigens.

The production of viruses for influenza vaccine production is one preferred use of the present invention. The influenza viruses are some of the most ubiquitous viruses present in the world, affecting both humans and livestock. Influenza infections result in an economic burden, severe morbidity, and even death in the very young, the elderly and immunocompromised individuals. According to statistics from the World Health Organization, looking just at the U.S.A., there are 25-50 million cases of influenza resulting in approximately 150,000 hospitalizations and from 30,000-40,000 deaths per year. The world inter-pandemic influenza burden may be as high as 1 billion cases of influenza with 3-5 million cases of severe illness. Extrapolation of these statistics predicts from 300,000-500,000 annual deaths attributed to influenza worldwide.

Influenza viruses are spread from person to person, primarily through direct respiratory droplet transmission (e.g., when an infected person coughs or sneezes in close proximity to an uninfected person). Indirect transmission is also possible and usually results from tactical transfer (e.g., handshake) of contaminated secretion from an infected person to an uninfected person's nasal or conjunctival epithelium.

The typical incubation period for influenza is one to four days, with an average of two days. Adults can be infectious from the day before symptoms begin through approximately five days after illness onset. Children can be infectious for >10 days after the onset of symptoms, and young children also can shed virus before onset of illness. Severely immunocompromised persons can shed virus for weeks or even months after infection.

Uncomplicated influenza illness is characterized by the abrupt onset of constitutional and respiratory signs and symptoms (e.g., fever, myalgia, headache, malaise, nonproductive cough, sore throat, and rhinitis). Among children, otitis media, nausea, and vomiting also are commonly reported with influenza illness. Uncomplicated influenza illness typically resolves after three to seven days for the majority of persons, although cough and malaise can persist for >2 weeks. However, among certain persons, influenza can exacerbate underlying medical conditions (e.g., pulmonary or cardiac disease), lead to secondary bacterial pneumonia or primary influenza viral pneumonia, or occur as part of a coinfection with other viral or bacterial pathogens. Young children with influenza virus infection can have initial symptoms mimicking bacterial sepsis with high fevers, and febrile seizures have been reported in up to 20% of children hospitalized with influenza virus infection. Influenza virus infection also has been uncommonly associated with encephalopathy, transverse myelitis, myositis, myocarditis, pericarditis, and Reye syndrome.

Accordingly, improved methods and apparatuses for producing vaccines are desired.

Preferred embodiments of the present invention relate to methods and apparatuses for separating the components of avian eggs. Eggs suitable for use in the methods and apparatuses of the present invention can be obtained from a number of avian species including, but not limited to, domesticated chickens (gallus), turkeys, geese, ducks, quail, and the like. The present invention is primarily used to collect allantoic fluid from embryonated chicken eggs, however, the disclosed apparatuses and methods are useful for separating yolk and embryo from embryonated eggs as well. The embryogenesis of chick egg development is well characterized in the art. The reader is referred to standard texts in the field of chick development for additional details of the structures and development of chick embryos (e.g., R. Bellairs and M. Osmund, The Atlas of Chick Development, 2nd ed., Elsevier, New York N.Y., 2005).

The allantoic fluid from avian eggs, in particular chicken eggs, can be inoculated with live virus from the othomyxoviridae family. The inoculated virus replicates in the egg while the eggs are incubated from two to three days depending on the viral strain used for inoculation. The influenza virus is subsequently isolated and purified from the allantoic fluid collected from the inoculated eggs.

The othomyxoviridae family includes four genera: influenza A, influenza B, influenza C, and thogotovirus (sometimes called influenza D). Influenza A and B are responsible for most epidemic human disease. Influenza A also infects swine, horses, sea mammals, and birds, including, domesticated poultry and waterfowl. Human infection with influenza A usually results in more sever disease symptoms than those following infection with the other genera of influenza. Influenza A is also the most disposed to significant antigenic changes from season to season through antigen drifts and antigenic shift. Influenza B appears to only infect humans. Influenza C has been isolated from both swine and humans it is thought to cause only mild respiratory illness and not epidemics. Thogotoviruses are tick born viruses which are genetically and structurally related to the influenza A, B, and C viruses.

All othomyxoviridae viruses are enveloped viruses with a negative single stranded RNA (nsRNA) genome. In particular, influenza A and B viruses each contain eight segments of nsRNA enveloped in a glycolipid membrane derived from the host cell's plasma membrane. More particularly, the influenza A and B viral genome consists of segments PB2, PB1, PA, NP, M, NS, HA and NA) that encode at least 10 polypeptides, including RNA-directed RNA polymerase proteins (PB2, PB1 and PA), nucleoprotein (NP), neuraminidase (NA), hemagglutinin (subunits HA1 and HA2), the matrix proteins (M1 and M2) and the non-structural proteins (NS1 and NS2) (Krug et al., In The Influenza Viruses, R. M. Krug, ed., Plenum Press, N.Y., 1989, pp. 89-152).

The inner surface of the glycolipid membrane contains virus specific proteins while the exterior surface is studded with virus specific neuramidase (NA) and hemagglutinin (HA) proteins. HA was named for its ability to agglutinate erythrocytes (red blood cells) by attaching to N-acetylneuraminic (sialic) acid containing glycoprotein or glycolipid receptor sites on the surface of respiratory epithelial cells. HA is also responsible for facilitating penetration of the influenza virus particle into the cell's cytoplasm by mediating fusion of the virus particle membrane with the cell's membrane of the endosome encapsulating the virus particle with the consequence being the subsequent release of the viral nucleocapsids into the cell's cytoplasm. The nucleocapsid segments contain the viral genetic material destined for migration into the cell's nucleus. The acidic interior of the endosome encapsulating the virus particle causes the HA to slightly alter its structure and merge with the endosomal membrane until a hole is formed in the endosome. Major epidemics are associated with changes in the antigenic structure of HA and it is also the principal viral antigen against which infected hosts produce neutralizing antibodies. HA is the most important antigen in defining the serological specificity of the different influenza strains. This 75-80 kD protein contains numerous antigenic determinants, several of which are in regions that undergo sequence changes in different strains (strain-specific determinants) and others in regions which are common to many HA molecules (common to determinants).

NA is a hydrolytic enzyme that removes the terminal sialic acid from the cell's hemagglutinin receptors resulting in destruction of the receptor activity. The roles NA plays in influenza infection are not completely understood, however it is thought that NA may allow the virus particle to penetrate the mucin layer in respiratory tract that would otherwise bind virus particles and prevent them from contacting the surface of respiratory epithelial cells. NA may also be important in the fusion of the virus particle with the cell membrane prior to viral entry into the cell.

Influenza C virus is also enveloped with a nsRNA genome. The genome is composed of only seven RNA segments however and it has only a single multifunctional surface glycoprotein called hemagglutinin-esterase-fusion protein (HEF). As the names implies, the HEF protein has three functions a receptor-binding activity, a fusion activity, and a receptor-destroying activity.

Both influenza A and B viruses are further separated into groups on the basis of antigenic characteristics. Influenza A viruses are divided into subtypes based on two proteins on the surface of the virus: the hemagglutinin (H) and the neuraminidase (N). There are 16 different hemagglutinin subtypes and 9 different neuraminidase subtypes, all of which have been found among influenza A viruses in wild birds. Wild birds are the primary natural reservoir for all subtypes of influenza A viruses and are thought to be the source of influenza A viruses in all other animals. Most influenza viruses cause asymptomatic or mild infection in birds. Infection with certain avian influenza A viruses (for example, some strains of H5 and H7 viruses) can cause widespread disease and death among some species of wild and especially domestic birds such as chickens and turkeys. Only one subtype of HA and one of NA are recognized for influenza B viruses.

Influenza viruses can change in two different ways. One is called “antigenic drift.” These are small changes in the virus that happen continually over time. Antigenic drift produces new virus strains that may not be recognized by the body's immune system. This process works as follows: a person infected with a particular flu virus strain develops antibody against that virus. As newer virus strains appear, the antibodies against the older strains no longer recognize the “newer” virus, and reinfection can occur. This is one of the main reasons why people can get the flu more than one time. In most years, one or two of the three virus strains in the influenza vaccine are updated to keep up with the changes in the circulating flu viruses. So, people who want to be protected from flu need to get a flu shot every year.

The other type of change is called “antigenic shift.” Antigenic shift is an abrupt, major change in the influenza A viruses, resulting in new hemagglutinin and/or new hemagglutinin and neuraminidase proteins in influenza viruses that infect humans. Shift results in a new influenza A subtype. When shift happens, most people have little or no protection against the new virus. While influenza viruses are changing by antigenic drift all the time, antigenic shift happens only occasionally. Type A viruses undergo both kinds of changes; influenza type B viruses change only by the more gradual process of antigenic drift.

Pigs can be infected with both human and avian influenza viruses in addition to swine influenza viruses. Infected pigs get symptoms similar to humans, such as cough, fever, and runny nose. Because pigs are susceptible to avian, human and swine influenza viruses, they potentially may be infected with influenza viruses from different species (e.g., ducks and humans) at the same time. If this happens, it is possible for the genes of these viruses to mix and create a new virus. For example, if a pig were infected with a human influenza virus and an avian influenza virus at the same time, the viruses could mix (reassort) and produce a new virus that had most of the genes from the human virus, but a hemagglutinin and/or neuraminidase from the avian virus. The resulting new virus would likely be able to infect humans and spread from person to person, but it would have surface proteins (hemagglutinin and/or neuraminidase) not previously seen in influenza viruses that infect humans. This type of major change in the influenza A viruses is known as antigenic shift. Antigenic shift results when a new influenza A subtype to which most people have little or no immune protection infects humans. If this new virus causes illness in people and can be transmitted easily from person to person, an influenza pandemic can occur.

The term “avian” as used herein, is intended to include males and females of any avian species, but is primarily intended to encompass domestic poultry which is commercially raised for eggs, meat, or as pets. The term “avian” is particularly intended to encompass various avian species including, but not limited to, chickens, turkeys, ducks, geese, quail, pheasant, ostrich, and, emu, etc. Accordingly, the term “avian egg” refers to an embryonated egg laid by a female of one of the aforementioned avian species, and more preferably to an embryonated egg from a chicken.

As used herein, the term “membrane” refers to any layer of tissue within an egg that delimits an internal structure or area within the egg. Exemplary membranes within an egg include, but are not limited to, the outer shell membrane, inner shell membrane, the chorioallantoic membrane (CAM), vitelline membrane (VM), and amniotic membrane (amnion).

The present invention, which will now be described in detail below, provides novel methods and apparatuses for harvesting biologics from eggs.

SUMMARY OF THE INVENTION

In broad terms, the invention provides a method for opening an egg. This includes positioning the egg in a reference opening so as to expose a section of egg to be opened; then, while the egg is positioned within the reference opening, creating an opening in the exposed section of egg by moving a cutter member over the reference opening into the egg; and then removing egg debris formed when opening said egg. Once the egg is opened, fluids from the egg can be collected by inverting the egg to allow the fluids to drain therefrom, and then collecting the fluids.

The invention also provides a method of collecting fluid from multiple eggs. In one form, the invention provides for moving at least a portion of the multiple eggs upwardly into reference openings, each of the reference openings being configured to expose a predetermined approximate amount of egg to be removed for opening said eggs; then moving a cutter member into said eggs to create openings in the eggs; inverting the opened eggs to allow fluid from within the eggs to drain therefrom; and then collecting the drained fluid.

An apparatus for carrying these methods is also provided. In one form, such apparatus includes at least one de-cap apparatus having a reference plate with at least one reference opening therethrough, the opening being configured for receiving the egg therein from a lower side of the plate and for stopping further upward movement of the egg within the opening when an upper egg section to be cut extends from the opening above the first plate; and a cutter member positioned above the reference plate wherein the cutter member is moveable across the reference opening so as to create an opening in the upper egg section. The apparatus further includes at least one tray configured for holding the multiple eggs therein; lifting arms configured to hold said eggs, the arms being operable to lift said eggs from said tray and move them to said de-cap unit and then return said eggs to said tray; a drainage pan configured to be combined with said tray to form a tray/pan assembly; an invert unit for inverting the tray/pan assembly so that the openings of the eggs therein face downward to allow the fluid to drain therefrom; a drainage trough for collecting draining fluids from the inverted eggs, the inverted tray/pan assembly being moveable over the trough; and a transport system for moving the tray and tray/pan assembly through the apparatus.

The apparatus and method of the present invention are useful for collecting viral laden allantoic fluid from avian eggs. The viral laden allantoic fluid can be subsequently processed using one or more clarification, centrifugation, purification, splitting, inactivating and/or adjuventation steps known in the art and routinely used in the production of immunogenic compositions and/or vaccines. In preferred embodiments, the influenza virus laden allantoic fluid collected according to the present invention is subsequently processed according to routine methods known in the art for producing influenza vaccines.

DETAILED DESCRIPTION OF THE INVENTION

The apparatuses and methods of the present invention will now be described with reference to the figures appended hereto. With initial reference toFIGS. 1,1A and1B, illustrated in the figures is an exemplary apparatus20for harvesting allantoic fluid from embryonated chicken eggs.FIG. 1shows the overall apparatus,FIG. 1Ashows the front section of the apparatus andFIG. 1Bshows the mid and back sections of the apparatus20. As will be described below in more detail, the apparatus20is formed of numerous sub-components and carries out numerous methods for completing the harvesting process. Many of these components and methods are believed to be novel in addition to the overall apparatus and process.

As is known in the art, the apparatus20is preferably enclosed within a clean environment, such as an enclosure of glass panels supplied with filtered air. Such enclosures are well known in the art and thus no further description is required. For purposes of describing the invention, the apparatus20can be broken down into major stations, each of which carries out a basic function or functions. A general description of the various stations is now provided, followed by a more detailed description of the individual stations.

An initial station is the egg loading station22or conveyor (left side ofFIG. 1) where multiple eggs can be placed into the apparatus20. Here, in the preferred embodiment, an operator manually loads trays36(FIG. 2) of eggs into the apparatus20. Each tray36of eggs, thirty-six eggs per tray, is then moved towards the right through the apparatus20to the other stations for further processing.

In an egg de-cap station24, an opening is created in the top portion of the egg shells (also referred to as “caps”). In the preferred embodiment described herein, the caps are cut and removed to create the opening in the eggs. The debris created by the opening process, e.g., the cut caps, is then discarded via a debris removal system.

The de-capped eggs are next inspected at an inspection station26. Here, operators can manually inspect each egg, discard rejected eggs, and remove any un-cut eggs for reprocessing.

After the inspection station26, the tray of de-capped eggs moves to an infeed pan and invert station28(FIG. 1). Here, a drain pan162for draining the allantoic fluid is placed on top of the tray36. The combined tray/pan is then inverted at this station, turning the eggs so that the openings in the eggs face downward to allow the allantoic fluid to drain therefrom (the semicircle29inFIG. 1represents the inversion motion).

Once inverted, the tray/pan unit moves through a drainage station30were the allantoic fluid drains by gravity from an opening in the bottom of the pan and is collected in a drainage trough188for further processing.

At an outfeed pan and invert station32, the tray/pan is re-inverted so that the drain pan is again on top of the tray36. The pan is then removed from the tray and directed to a rinse unit33via rails were the pan is rinsed and processed for reuse at the infeed pan and invert station28. The egg tray is then inverted over a waste collector, dumping the egg remains into the debris waste system.

Finally, at the tray outfeed station34, the used trays are transported from the apparatus20to a downstream tray washer (not shown) where the trays are processed for re-use. The above described process is a continuous one, with trays proceeding one after the other in a continuous feed through the apparatus.

Having described generally the overall apparatus20, a more detailed description of the apparatus20is now provided.

The eggs containing the viruses to be harvested are carried through the apparatus20on trays36as illustrated inFIGS. 2 and 2A. Each tray36is capable of holding 36 eggs in a 6×6 square matrix of individual egg support sections38. Each egg support section38includes an opening40in which the bottom of the egg rests against egg support edges40a, the opening40allowing an egg lifter arm122(FIG. 4) to pass through the opening40as explained in more detail below with regard to the egg de-cap station24. Tabs42extending upwardly along the sides of the individual egg support sections38protect the eggs and keep them from falling from the tray during handling. The tabs42should not bind or interfere with the processing of the eggs. Registration projections44help align the tray36with the drain pan162when placed on top of the tray36as further described below. Tray posts44aproject downward below the bottom face44bof the tray36and are used to control the movement of the tray as further described. The tray36includes notches46on two opposing sides as shown which are used to orient the trays in the apparatus20as described below. It is understood that other tray configurations may be used, and that the present invention is not limited to the processing of 36 eggs per tray.

With further reference toFIGS. 1 and 1A, at the tray loading station22, trays36with eggs21are manually loaded onto the tray loading plate48and onto the infeed conveyor50. The infeed conveyor50has rollers52positioned on both sides of the apparatus20on which the bottom edges of the trays36rest. The rollers52are rotatably driven to move the trays36towards the egg de-cap station24, and are linked to one another to be driven by a common driver and to ensure that the trays move simultaneously and therefore minimize harsh bumping into one another. The trays36are placed onto the infeed conveyor50such that the notches46in the sides of the trays36face one another, and are preferably placed onto the apparatus20one after the other to create a continuous feed of trays36in contact with one another. The rollers52can be powered in any known means such as by motor and chain or gear. Moreover, any suitable tray loading means, manual or automated, and any suitable tray conveyor means may be used. The length of the tray loading station is designed to accommodate the variations of the operators in placing trays into the apparatus20.

Tray stops54hold and release the trays36along the infeed conveyor50to control the position of the trays36in the egg de-cap station24. As shown inFIG. 1A, the tray stops54have a finger54athat can rotate on shaft54bbetween a down position which allows the tray to move forward, and an upward position as shown inFIG. 1Ato engage the tray posts44a(FIG. 2) and stop the forward movement of that tray and all trays behind it. The shaft54bcan be rotated between the two positions by any known means, such as by pneumatic actuators controlled by sensors that detect the trays. In a preferred embodiment, two fingers54aare provided on each shaft to engage two posts44aon the under side of the tray36. It is further understood that additional tray stops54are provided as needed to control the flow of trays into and through the egg de-cap station24, and that each can be independently controlled with use of a tray position sensor to track the position of a tray. The rollers52do not stop rotation when the tray stops are activated, but continue to rotate, simply sliding against the bottom of the tray36.

As seen inFIGS. 1 and 1A, the trays36move from the egg tray loading station22to the egg de-cap station24on the rollers52with the forward motion of the trays controlled by the tray stops54. In the preferred embodiment, at the egg de-cap station24there are two separate de-cap units56aand56bwhere the eggs are raised out of the trays36for de-capping. One of the de-cap units will cut the even rows of eggs in the tray, the other unit will cut the odd rows of eggs. The cut egg caps are then discarded via a debris removal system and the eggs are lowered back into the trays36for further processing. This section of the apparatus20is now described in further detail.

With further reference toFIGS. 1,1A and3, it is seen that the egg de-cap station24includes the first and second de-cap units56aand56bpositioned above the tray conveyor so that the trays36of eggs can move underneath them. Due to tolerances and space requirements, the apparatus of the illustrated embodiment cuts half of the eggs of a given tray36in the first de-cap unit56aand the other half in the second de-cap unit56b. Additional embodiments, not presently shown, contemplate the use of one or multiple de-cap units (e.g., units56a,56b. . .56n) in any arrangement at the de-cap station24depending on the particular embodiment and tray configuration. Alterations of the present invention from the presently illustrated two de-cap units56aand56bwill require modifications to the apparatus, not presently shown, of one or more of the subassemblies therein (e.g., modifications to the egg lifter arms122, reference plate60, de-cap plate70, and debris wiper plate88, etc.). With further reference toFIG. 3A, which shows the location of the trays36aand36brespectively underneath the first and second de-cap units56aand56b, it is seen that the eggs21in tray rows R2, R4, and R6are lifted from the tray for cutting in the first de-cap unit56a(the eggs lifted from the tray for cutting are not shown); the eggs in rows R1, R3, and R5are lifted from the tray for cutting in the second de-cap unit56b. With further reference toFIG. 3G(see the egg21), it is preferable to cut the upper section21aof the eggs at the air sac as is known in the art. The eggs21are cut and then lowered back into the trays for further processing. InFIG. 3A, the direction of flow for the trays is from right to left, from de-cap unit56ato unit56b(arrow57).

With reference toFIGS. 3 through 3M, the de-cap units56aand56bare now described. The two de-cap units are similar in construction and thus only one unit will be described. Exploded views of the de-cap units are shown inFIGS. 3B and 3C. Each of these de-cap units include three main components, a reference plate60, a de-cap plate70, and a debris wiper plate88. The reference plate60remains stationary. The de-cap plate70and debris wiper plate88form a single upper portion unit102, both of which plates70,88are movable relative to one another and the reference plate60. The reference plate60is described first.

To control where the cut is made on any given egg21, each egg is referenced, i.e., the section of the egg21to be cut (or “de-capped”) is fixed. In the illustrated embodiment, the referencing of each egg21is carried out with a circular reference opening58formed in the reference plate60.FIG. 3Bshows the relationship of the reference plate60to the rest of the de-cap unit;FIG. 3Cshows an isometric view of the reference plate60;FIG. 3Dshows an enlarged view of the reference opening58; andFIG. 3Eshows a cross-sectional view through the reference plate60with an egg positioned within the opening58.

An egg21is lifted upwardly from the underside of the tray36as oriented inFIGS. 3B,3D, and3E into the reference opening58until the egg21contacts the opening58, the opening58acting as a stop. A preferred diameter for the reference opening58(on the top face of the plate) is about 26 mm to facilitate a cut diameter of the egg of about 21 mm (a range from about 15 to about 35 mm depending on the egg size). It is understood that by changing the diameter of the reference opening58, the size of the upper section of an egg to be cut can be changed. It is further understood that eggs can vary in size and thus the reference opening58is chosen to provide the desired range of cut dimensions for a given range of egg sizes. Put another way, because the sizes of the eggs can vary, the size or configuration of the reference opening58allows a predetermined approximate amount of egg (within the desired range) to extend therethrough.

Due to the thickness of the reference plate60, and with particular reference toFIGS. 3D and 3E, the reference opening58is formed as an exit opening58aon the upper plate face60a, and extends downward through the plate60to an inlet opening58bin the lower plate face60b(the underside). Inlet opening58bis sufficiently larger in diameter to account for the curved surface of the egg and to allow the egg to extend fully into the reference opening58a, the angle through the plate opening58ato opening58bis preferably in the range from about 45° to about 120°, and more preferably about 70° as shown. With reference toFIG. 3E, it is appreciated that the cap of the egg to be cut extends upwardly from the reference opening58for cutting. Each of the two reference plates60have 18 reference openings58arranged in three rows corresponding to the rows shown inFIG. 3A, i.e., one reference plate60for de-cap unit56ahas the reference openings arranged to cut the eggs in three rows—R2, R4and R6of tray36a(FIG. 3A); the other reference plate for de-cap unit52bhas the openings arranged to cut in rows R1, R3and R5of tray36b. Thus, in the present embodiment, half of the eggs of a tray are cut at one de-cap unit, the other half at the other de-cap unit.

The upper face60aof the reference plate60includes linearly extending channels62on either side of the reference openings58(seeFIGS. 3C and 3D). With specific reference toFIGS. 3C,3D and3E, the reference plate60further includes debris removal openings64. For each reference plate60, there are 18 circular debris removal openings64, one such opening64positioned adjacent to each of the 18 reference openings58as shown. The debris removal openings64open to an angled channel66extending between the reference opening58and the debris removal opening64associated therewith. It is seen that each angled channel66slopes downward towards the debris removal opening64to facilitate removal of the debris created by the egg de-capping. Finally, it is appreciated that the reference plate60can be made of any suitable material for pharmaceutical use, such as stainless steel.

The de-cap plate70forms a cutting member positioned directly above the reference plate60for cutting the eggs21(seeFIGS. 3B,3C and3I, the de-cap plate70being part of the upper portion102positioned above the reference plate60as shown inFIG. 3C). With further reference toFIG. 3H, the de-cap plate70includes 18 cutting members68which, in the preferred embodiment, are provided in the form of cutting blades68, one for each reference opening58. The blades68are attached to the underside of the de-cap plate70via blade retainers72which have registration protrusions74for mating with blade notches76to properly align the blades with the reference openings58of reference plate60(FIG. 3E). With reference toFIG. 3H, the blades68preferably have a thickness in the range from about 0.5 to about 2.5 mm, and more preferably about 1 mm in thickness, and made from a stainless steel material suitable for pharmaceutical use. The cutting edge of the blade is preferably formed of two sharp edges69extending back at about a 20° angle from the front center point of the blade, although other angles, such those within the range from about 0° to about 60° may be acceptable. Other suitable blade configurations and angles are possible, as are blades with one, two, and three or more edges positioned at various angles from the center or another point on the blade. In still other embodiments, blades are provided having concave, convex, and/or serrated edges. The blade retainers72are held to the underside of the de-cap plate70with screws77and screw holes79(FIG. 3C).

Eighteen generally rectangular openings78are formed in the de-cap plate70, each opening78being configured to align above and cooperate with the one of the reference openings58and the debris removal opening64associated therewith of the reference plate60as further described below. It will further be seen that the openings78are sized and configured to permit a wiper cap92of the wiper plate88to move back and forth therein as further described below. Put another way, during the egg cutting process, the de-cap plate70moves back and forth relative to the reference plate60to cut the eggs. This motion carries the blades68across the reference opening58and then back again (seeFIGS. 3E,3F, and3G illustrating the movement of the blades68over a reference opening58to cut the eggs21). Since the openings78of the de-cap plate moves with the blades68, the openings78of the de-cap plate must be sized for the relative movements of the wiper cap92therein as is further described below. Preferably, with reference toFIG. 3C, the rows of blades68are offset by about 0, 3, and 6 mm from one another so that the three rows of blades, e.g. rows R2, R4, R6, do not contact the eggs at the same time. Other suitable offset dimensions can be used e.g., offsets from about 0 to about 9 mm.

With further reference toFIGS. 3B,3C and3D, to ensure proper alignment, the blade retainers72of the de-cap plate70extend into and are slidable within the channels62of the reference plate60. Rod guides80, attached to the de-cap plate70, engageably slide over stationary rods82(FIG. 3C). The rods82are held stationary by rod holders83(FIG. 3). An actuator coupling86, attached by screws to the de-cap plate70, which attaches to an actuating arm as described below, moves the de-cap plate70back and forth between the precut and post cut positions. The motion and stroke of the de-cap plate70is controlled by the actuator108as described below. The clearance between the de-cap plate70and the reference plate60is preferably from about 0 to about 5 mm, with about 1.5 mm being more preferred, and the clearance between the blades68and the reference plate is preferably about 0.5 mm. The blade stroke over the reference opening58is preferably from about 25 mm to about 60 mm, and more preferably at least about 40 mm. While preferred for the present embodiment, other suitable dimensions and tolerances may be used.

With reference toFIG. 3C, the debris wiper plate88is positioned above the de-cap plate70and includes rod guides90slidable on the rods82as controlled by the actuators108and110. Cleaning members92for removing the debris created by the cutting process, in the form of debris removal caps92as shown in the preferred embodiment, are supported on the wiper plate top face88aby cap top92a. The caps92are mounted in and extend through openings94in the wiper plate88and extend downward through the openings78of the de-cap plate70to be positionable over an associated reference opening58. The clearance between the blades68and the debris removal caps is preferably less than about 0.25 mm, and more preferably about 0.127 mm or less.

With further reference toFIG. 3L, the bottom end of the debris removal caps92has a partially spherically shaped face92bconfigured for receiving the top cap of the egg21, and which ends in a semi-circular edge92c. An air outlet opening92d, receiving air from air inlet92e, is positioned to blow air into the concave area formed by the spherically shaped face92b. Air channels96are formed in the debris wiper plate88(FIG. 3C) for delivering air from an air source to the debris removal caps92. As an alternative, air may be delivered to the opening92dfrom an opening in the back side of the cap92opposite of the opening92d, such as from an air conduit as shown inFIG. 3I. A cover plate98, cover screws98a, handles98b, and actuator coupling100complete the upper portions102of the de-cap units56aand56b, which sit above the reference plates60. SeeFIGS. 3B and 3C. The blade set up plates104shown inFIG. 3Bare used for set up purposes and do not form part of the working embodiment. The motion and stroke of the debris removal plate88is controlled by the actuator110.

The movements of the de-cap and debris wiper plates70,88relative to the reference plate60for de-capping the eggs21are now described with reference toFIGS. 3,3B,3C, and3D, and particularly toFIGS. 3E,3F,3G,3H,3I,3J and3K.FIGS. 3E,3F, and3G are cross sectional views of the reference plate60illustrating the movements of the de-cap blades68and the wiper caps92and showing eggs in the reference openings58.FIGS. 3H,3I, and3J are similar toFIGS. 3E,3F, and3G, but showing more structure and details, and are cross sectional views of the reference plate60, de-capping plate70and debris wiper plate88showing three eggs lifted into the reference plate openings58. As seen, lifting arms122(which are further described below) have lifted the eggs21from the tray36into the openings58of the reference plate60. With specific reference toFIGS. 3E and 3I, which shows the plates and eggs in the pre-cut position, it is seen that the de-cap plate70is positioned such that the blades68are adjacent to the reference openings58of the reference plate60, i.e., the blades68are to the left of the eggs21as oriented inFIGS. 3E and 3I. It is further seen that in the precut position the wiper plate88is also to the left positioned so that the removal caps92sit over the reference openings58such that the eggs21are within the spherically shaped cap faces92b. For purposes of orientation, this view is consistent with the de-cap station56ainFIGS. 3 and 3B, i.e., the de-cap and wiper plates70and88are in the left most position relative to the reference plate60. The direction of the movements for the second de-cap station56bis reversed from that being now described. The reference plate60remains stationary while the de-cap plate70and wiper plate88move to carry out the de-cap process in various steps as now described.

In a first movement, with further reference toFIGS. 3F and 3J, and with the reference plate60and wiper plate88remaining stationary, the actuator108pulls the de-cap plate70in the direction of the arrow106(rightwardly for de-cap station56aas illustrated inFIG. 3B), pulling the blades68through the eggs21to a post cut position where the blades68now cover the reference openings58and are positioned between the reference openings58and the removal caps92of the wiper plate88, the cut egg sections21abeing shown detached from the eggs and above the blades68.

In a second movement, with further reference toFIGS. 3G and 3Kanother actuator110then pushes the debris wiper plate88in the direction of the arrows106, moving the debris removal caps92over the debris removal openings64in the reference plate60below it, thereby pushing the shell debris21adown the angled channels66into the removal openings64. At the completion of this second movement, both the de-cap plate70and the debris wiper plate88are in the post cut position, both plates70,88have moved to the right relative to the reference plate60as oriented inFIG. 3J.

In a third movement, the actuator110pulls the wiper plate88back to the precut position, opposite direction of arrow106inFIGS. 3G and 3Kand going back to the position shown inFIGS. 3F and 3J.

In a fourth and final movement, the actuator108that pulled the de-cap plate70in the first movement now pushes the de-cap plate70back to the precut position (opposite direction of arrow106and going back to the position shown inFIGS. 3E and 3I) for cutting the next group of eggs21. It is appreciated that the openings78of the de-cap plate78must be sized to accommodate the relative movements of the wiper caps92back and forth within the openings78as the de-cap plate70moves relative to the reference plate and wiper plate to cut the egg in the first step (the cap92moving to an opposite side of the opening) and then as the cap92of the wiper plate88moves relative to the reference plate and wiper plate to wipe away the cap debris in the second step (the cap92moving back to the side of the opening78that it started in prior to the first step).

Put another way, and again with specific reference toFIGS. 3E,3F,3G,3I,3J, and3K, in the first movement, the de-cap plate70with blades68of the de-cap unit56aon the right side ofFIG. 3Bis pulled to the right (arrow106) by actuator108acting on coupling86to de-cap the eggs. In the second movement, the debris wiper plate88with wiper caps92is pushed to the right (arrow106) by actuator110acting on coupling100to push the debris into the debris removal openings64of the reference plate60. In the third movement, the debris wiper plate88is pulled to the left (opposite arrow106) by the actuator110to return it to its precut position. In the fourth and final movement, the de-cap plate70is pushed back to the left (opposite arrow106) by actuator108, acting on coupling86, moving back to the precut position over the stationary reference plate60. While the present embodiment has the above described sequence of movements, it is understood that this sequence may be modified or altered as suitable for other embodiments of the invention. For example, the de-cap plate70and wiper plate88could be returned to there pre-cut positions together by one of the actuators in a single step rather than separate steps, e.g., the de-cap plate could be configured to pull the wiper plate with it when moving back to its pre-cut position.

The actuators108and110can be of any suitable type mechanism. For example, in the preferred embodiment, with reference toFIGS. 3 and 3N, the actuator108of the present embodiment is formed from a longitudinally cylindrical fluidic muscle250which, when pressurized with a gas, such as air, expands diametrically and thereby contracts longitudinally against the force of a spring252to pull the joint254and thereby pull coupling86. When the air pressure is released from the fluidic muscle250, the spring252returns the muscle to its original configuration and length, thereby pushing the coupling86. The fluidic muscle and spring are contained within a stainless steel housing256and supplied with a compressed gas as is known in the art. A suitable supplier of fluidic muscles is Festo AG & Co. KG. Nevertheless, any suitable actuating mechanism may be used in place of or in addition to a fluidic muscle. The actuator110can be an air cylinder type actuator, among others.

With further reference toFIG. 3and particularlyFIG. 3B, the reference plate60is mounted on support members112with clamps112a. Debris removal channels114have openings114apositioned below the debris removal openings64to collect the debris. Timed blasts of compressed gas, such as air, can be used for dry removal of the debris through the channels114to waste collection conduits116(seeFIG. 1A).FIG. 3M, taken along line3M-3M ofFIG. 3k, shows the relationship of the reference plate60, de-cap plate70and wiper plate88from another angle.

The process by which the eggs21are lifted out of the tray36and up against the reference plate60is now described with reference toFIGS. 1A,3A,4, and4A.FIG. 3Ais a top view looking down on the egg trays36from beneath the de-cap units.FIG. 4is an isometric view of the egg lifting assembly andFIG. 4Ais a side view of the egg lifting assembly with the side of the table removed to show the inner elements. For orientation purposes, positioned within a processing table118(FIG. 1A) below the de-cap units56a,56bis an enclosure120housing the equipment used to lift the eggs21from the trays36up into the reference plate60(FIG. 4). The housing has a top120aand a bottom120bthat rests on the floor. Each de-cap unit56a,56bcooperates with one of the sets of 18 cylindrical egg lifter arms122to lift eggs21up from the tray36to the reference plate60. The lifter arms122are sized to fit within the openings40of the tray36. As can best be seen inFIG. 4A, all 36 lifter arms122(18 arms for de-cap unit56a, and18arms for de-cap unit56b) move up and down in unison with a servo plate124controlled by servo motor124avia shaft124b. The servo plate124moves two nest blocks126via connector rods128, each nest block126moving 18 of the arms122. A drive shaft130for each of the arms122is connected to one of the nest blocks126through a compression spring132(FIG. 4B) that compensates for the variability in egg sizes, i.e., a larger egg may contact the reference plate60before a smaller egg and thus the spring132would take up the additional distance that the servo plate124would move to bring the smaller egg up against the reference plate60. The drive shafts130extend through the enclosure top120aand preferably include a vibration isolation mount130a.

In the illustrated embodiment, the drive shafts130are not physically connected to the lifter arms122, but are magnetically coupled to one another to move in unison therewith. As seen inFIGS. 4A and 4C, each drive shaft130moves up and down within a stationary or static cylindrical coupler tube138that is threadingly fixed to the enclosure top120avia a threaded coupling120cand which has a cap138ato seal closed the top of the coupler tube138. The lifter arm122, coaxial with the drive shaft130and coupler tube138, moves slidably up and down over the coupler tube138in unison with the drive shaft132to which it is magnetically coupled.

With further reference toFIGS. 4A,4B,4C,4D,4E, and4F, drive shaft130extends through the enclosure top120athrough the circular threaded collar120cattached to the enclosure120a, and includes a cylindrical coupler piston134moveable up and down above the enclosure top120awithin the coupler tube138(seeFIGS. 4B and 4C). The coupler piston134has an alignment cap136screwed thereto which is slightly larger in diameter than the diameter of the coupler piston134. Four columns (eight rows) of magnets MC-1through MC-16are attached to the coupler piston134a shown.

The lifter arm122includes a cylindrical hollow sleeve portion140, a cylindrical drip shield142, a cylindrical extension sleeve140a, and an egg cup144(FIG. 4C,4F). The egg cup144preferably has four arms144aas shown inFIG. 4Fconfigured to receive and hold the egg21, although other suitable configurations, e.g., more or less arms, may be used. The egg cup144is preferably made of a polymer material within the range of about 30 to about 90 Shore A durometer polyurethane, and more preferably 65 Shore A durometer polyurethane, and is sized to fit through the openings40of the egg trays36. Attached to the inside of the cylindrical hollow sleeve140is a coupler magnet cartridge146which contains four columns (eight rows) of magnets ML-1through ML-16which align with complementary magnets MC-1through MC-16of the coupler piston134. The upper row of magnets may be thinner than those of the other rows to allow for the screw136.

The magnetic forces between the magnets (MC-1through MC-16) of the coupler piston134and those (ML-1through ML-16) of the lifter arm122couples the two together such that the lifter arm122moves with the coupler piston134. This configuration advantageously provides a sealed connection between the lifter arm122in the coupler piston134to prevent debris or contamination from passing between the two, and makes it easier to clean. Other configurations and designs are contemplated, such as direct connections from the actuator to the lifting arms.

In operation, the eggs are lifted preferably from the tray36in a manner to adjust the alignment of any of the eggs that may be out of alignment. As noted previously, it is desirable to cut the top section of the egg21in the air space. The handling of the eggs and the trays may cause some of the eggs to move out of alignment. In the preferred embodiment, to align the eggs prior to cutting, the lifter arms122first lifts the eggs21a short distance above the tray36and then quickly reverses direction to unweight the eggs21sufficiently such that the eggs realign under the action of gravity. The lifter arms122then carry the eggs21all the way to the reference plate60where the eggs are referenced and de-capped. An egg lift brake is provided to lock the lifting arms in place so that they cannot move during the cutting process. This stops the eggs from lowering as the blades make the cut, and can be provided in any suitable manner, such as by braking the nest blocks128. Although the above described method of lifting eggs is preferred for the present embodiment, other suitable means for bringing the eggs into contact with the reference plate may be used. For example, to re-align the eggs, sequences of motion other than the two movements (up and then quickly down) are contemplated.

In summary, and with reference toFIG. 1A, a tray36containing thirty-six eggs21is supported on and conveyed forward towards the de-capping station by the rollers52. The tray stop54releases the tray36which is then conveyed by rollers52into the first the de-capping unit56awhere another tray stop54stops further movement of the tray. Stationary tray hold down bars (not shown) are positioned just above the tray36in the de-capping units to prevent upward movement of the tray. The lifting arms122then lift eighteen eggs from the tray and quickly reverse direction to better align any misaligned eggs. The lifting arms122then lift the eighteen eggs all the way up to the referencing plate60and, while the eggs are held against the reference plate60with the lifting arms122locked in position, the de-cap plate70is pulled to the right (arrow106) as oriented inFIG. 3to remove the egg caps. Next the debris wiper plate88is pushed to the right to move that the debris into the debris removal openings64. Next, the debris wipe plate88is pulled back to the left (opposite of arrow106) to the precut position, followed by the de-cap plate70pushed back to the left (opposite of arrow106) to the precut position. The lifter arms122return the de-capped eggs to the tray36, which tray is then released by the tray stops54to be conveyed by the rollers52to the intermediate position55between the two de-capping units56a,56b(seeFIG. 3A) where the tray is held by another tray stop54while a second de-capping process is carried out in the two de-capping units56a,56bon the trays immediately behind and immediately in front of the present tray. Upon completion of this second de-capping process, the tray is again released and stopped at the second de-capping unit56bby another tray stop54. A third de-capping process is carried out to de-cap the remaining 18 eggs in de-cap unit56b, the tray36immediately behind the present tray now being held at the intermediate position55. The eggs cut in the first de-capping unit56aremain covered under the reference plate while in the second de-capping unit56bto prevent debris from falling in. This process is carried out in a continuous manner with a tray36moving to the de-capping unit56a, then the intermediate position55, and then the second de-capping unit56b.

With all eggs in the tray36now de-capped, the tray is released and conveyed on the rollers52towards the inspection station26. With reference toFIGS. 5 and 1A, once outside the de-capping station24, an indexing tray pusher150, using two indexing arms152having tray pusher fingers154that move linearly back and forth and rotate upward to engage the tray posts44a, pushes the tray on two slide rails156one index position (the length of a tray), repeating this process for each tray coming from the de-cap station, and thereby moving all trays in contact therewith forward in unison through the inspection station26. The rails156can include a ledge to keep the trays thereon. The rollers52do not extend into this area and thus no longer convey the trays from this point forward.

With reference toFIGS. 1 and 1A, at the inspection station26the de-capped eggs are manually inspected. In the illustrated embodiment, the inspection station provides for two operators, one on either side of the apparatus20, to manually inspect each egg, and reach the eggs through oval gloveless ports as shown, although glove or sleeve ports can be used. Each operator has room within the enclosure for an empty tray36to store unde-capped eggs for reprocessing once the tray is filled. Rejected eggs can be discarded into a waste port148at each inspection station. The egg trays continue through the inspection station26to the end of the rails156at the infeed pan and invert station28(FIGS. 1,1A,1B,6,6A and6B). It is preferable to provide an atmospheric pressure in the area of the invert station28and downstream thereof that is higher than the pressure in the inspection and preceding areas. In this way, as is known in the art, the air flows from the higher pressure zone to the lower, preventing any dust and other debris from reaching the higher pressure areas where the allantoic fluid is exposed.

At the infeed pan and invert station28, the tray36is mated with a drain pan162and inverted (turned upside down) to drain the allantoic fluid. SeeFIGS. 6,6A and6B. With reference toFIG. 6B, showing one pan in a non-inverted position (on the right) and another in an inverted position (on the left), the drain pan162is rectangular in shape and configured to fit over the tray36. It has a pan top162ahaving a flared central drain spout162b, and pan sides162c. The drain spout162bis preferably not positioned to be directly below the opening of an egg when mated with a tray36so that the allantoic fluid does not fall from the egg directly into the drain spout as the added distance of the fall could cause the allantoic fluid to foam. One of the pan sides includes two pan bumpers162dto space the adjacent pans from one another on the rails and pan screws162eto hold an embryo retainer164to the pan and allow removal for cleaning. Registration slots160attached to and extending from the underside of the top of the pan receive the registration projections44of the tray36for proper alignment of the pan on the tray.

The retainer164, attached to the sides of the pan, forms retainer members164b. In the preferred embodiment, the retainer members164btake the form of retainer fingers164bwhere two interwoven retainer forming wire loops165intersect, the wires having a preferred diameter from about 2 mm to about 6 mm, and more preferably about 3.5 mm, and the height of the outer wire is preferably from about 30 mm to about 50 mm and more preferably about 38.18 mm from the outer diameters of the wires. The fingers164bare configured to extend into the openings of the de-capped eggs21to hold the contents of the egg (e.g., the embryo) within while the allantoic fluid drains when the tray is inverted. It is believed that the upper wire of the finger164bruptures the allantoic membrane to release the fluid while the two wire loops of a finger164bof the fingers provide sufficient surface area to hold the embryo in place without perforating the embryonic membrane, although one wire loop may also be suitable. It is appreciated that the egg shell rests on the wires at the end of the loops, i.e., the flat portion of the wire, and thus the width of the base of the loops must be smaller than the cut diameter of the egg shell. Thirty-six such fingers are provided, positioned to fit into the opening of each egg21in the tray. Other finger configurations may be suitable, including those that do not use wire.

The drain pans162are provided from the tray rinse unit33(FIGS. 1 and 1B) where the pans are rinsed and delivered to the infeed pan and invert station28on slide rails in any know manner. Rinsed drain pans162are delivered to the pan pick up station166(FIG. 6) by any suitable conveyor means and with a final movement by the arm168which swings to engage the drain spout162band push the pan against a stop to accurately position the pan for pick up. A pick and place servo170having servo fingers170agrabs the pan162by its flared drain spout162b(FIG. 6B), lifts the pan up, rotates the pan over a tray36, lowers the pan onto the tray, and then opens the fingers to release the pan. The servo170is configured to have a high velocity when the pan is not in contact with the eggs, and to decrease velocity for a more gentle and smooth motion when in contact with the eggs. The fingers170ahave grip pads to avoid damaging the pans. The pick and place servo170preferably has two sets of servo fingers170aon opposite sides from one another (the front side shown inFIG. 6), and rotates in both directions, e.g., with reference toFIG. 6, the pick and place servo170first moves clockwise using a first set of fingers170aand is lowered to deliver a pan162to a tray while at the same time the fingers170aon the opposite side picks up the next pan at the pick up station166to be delivered to a tray by counterclockwise direction. This switching of directions is continued.

The trays are moved into the exact position (pan place position174) for receiving the drain pan162by an index servo172(FIG. 6B) having an arm172aand posts172battached to the arm that pulls the tray32(via tray posts44a) along the rails from the end of the inspection station to the pan place position174. Hold down members176attached to the top of the rails above the trays restrict movement of the egg tray when loading a pan onto a tray. Sensors179(FIG. 6), e.g. laser sensors connected to a controller, monitor the exact position of the tray, the left sensor controls the position of the tray when the pan is placed, the right sensor is not for pan placement, but to ensure that the tray/pan combination178has been moved to the next position and to allow the next pan to be lowered onto the next tray. Once the tray is properly positioned, a drain pan162is placed thereon by the pick and place servo170, with the bumper pads162dorientated so as to contact the adjacent pan as the pan moves through the process.

Next the combined tray/pan unit36/162(also referenced as numeral178) is moved to an invert unit180by a post172coff of the same arm172aof the same index servo172that moved the tray into the pan place position174. It is seen that the index server172moves 2 trays at the same time, one into the pan place position174, the second (tray/pan) to the inverter member180. Guide rails182support the trays and tray/pan in this area. With further reference toFIGS. 6A and 6Cthe inverter member180receives the tray/pan178via the index servo172on rails182. The inverter member180has a pair of static rails for holding the tray/pan178in place between them during the inversion process; lower static rails184made of stainless steel and upper static rails186formed of a polymer material such as UHMW. Two sets of static rails pairs184,186are provided on opposite sides of a central shaft189that is connected to a rotary servo motor for rotating the invert unit180. A rod (not shown) in between the two rails184positioned to be on the underside of the tray/pan178can be provided connected to the rotary servo motor to help hold the tray/pan178in place during the inversion process. It is further seen that the rails182extend past and in between the front end of static rails184of the invert unit180so that the tray/pan178can slide into the invert unit180and allow the invert unit to rotate without interference from the rails182. Once within the inverter static rails184,186, the tray/pan178is inverted, moving clockwise as oriented inFIG. 6(or counter clockwise as inFIG. 6C) to a lower elevation, positioning the tray/pan178in an inverted position for draining with the pan drain162bfacing downward, while placing the second set of static rails184,186in position for receiving the next tray/pan assembly178to be inverted.

The inversion places the tray/pan assemblies178in the drainage station30where the allantoic fluid drains from the eggs. Here, the tray/pans178are moved over a collection trough188from left to right in the drainage station30(FIGS. 1 and 1B) during the collection process. With the embryos held within the eggs by retainer fingers164b(FIG. 6B), and the tray36held in the pan162by gravity, the allantoic fluid drains from the openings in the eggs into the pans and out of the pan drain spout162binto the collection trough188. The tray/pans178move slidably above the trough188on guide rails190.

With further reference toFIGS. 1B,7, and7A, the trough is “V” shaped in cross section as shown, is sloped from both ends192a,192btowards a central trough drain port194where there is a funnel, and rests on a trough base196. The trough is made of suitable material such as stainless steel and can be optionally cooled by glycol-chilled tubes198running underneath the trough base to cool the allantoic fluid if desired. The drain port194connects to a fluid connection vessel195stored in the access area200(FIG. 1B) from which the fluid can be pumped for further processing. The trough188is sufficiently long to obtain as much of the allantoic fluid as reasonably possible. Although a range of time from about 40 to about 90 seconds for an egg to drain over the trough is believed to be a good time, a more preferable range is from about 60 to about 65 seconds which is believed to be a good balance to collect as much fluids as possible without collecting too much unwanted materials (e.g., yolk, blood, albumen, etc.)

The guide rails190extend over the entire trough and are made of a suitable material to allow the metal pan surface to slide over it, such as UHMW (SeeFIG. 7Bshowing the rails removed from the trough). The inverted tray pans178are moved onto the guide rails190directly from the invert unit180, thus one end192aof the rails is adjacent the invert unit180and positioned to receive the inverted tray/pan assemblies178directly therefrom. With reference toFIG. 7C, tray/pan indexer202is positioned underneath the load invert unit and has pusher arms202aand pusher fingers202bthat rotate upward to engage the tray posts44awhile the tray/pan is still within the static rails184and186of the inverter unit, and then push the tray/pan178from the static arms of the invert unit onto the guide rails190over the drain trough. As the tray/pans contact each other, the continuous action of the tray/pan indexer202moves the tray/pans over the entire length of the trough towards the outfeed pan and invert station32. With reference toFIGS. 6,6A, and7C, it is seen that the indexer202is located under the infeed pan and invert station28and supports the rails182on which the trays36and tray/pan assemblies178slide up until the invert of the tray/pan178.

It is believed that some amount of jarring, vibration or other such movement of the eggs may help release additional allantoic fluid that might not normally drain out, or at least help speed up the draining process. One possibility is an optional tray tilter240capable of tilting three tray/pans178at the same time. With reference toFIGS. 1,1B,7D and7E, the tray tilter240is has a servo motor242driving a shaft244connected to tilt rails246which are adjacent to and align with the guide rails190of the collection trough188to receive tray/pans178therefrom. The collection trough is extended under the tilter to collect any fluid from the tray/drain pans178. The tilter240further includes tray hold down members248to help keep the trays in place on the rails during the tilt action, one being a bar248apositioned over the back side of the tray36between a row of eggs. In use, three tray/pans178can be moved into the tray tilter on the rails246(only one being shown in the center position inFIG. 7D) and once in proper position, the servo motor tilts the tray/pan178and then immediately returns it to its starting position so that any additional fluid can drain. In the preferred embodiment, the tilter240can tilt the pans to an angle from about 0° to about 85° and more preferably to at least about 82 degrees from the horizontal, at a tilt servo speed preferably of at least about 250°/s, and with a pant tilt servo acceleration preferably of less than about 505°/s2although other specifications are believed suitable depending on the particular design. A stop245can help control the movement of the shaft244with stop plate247. Here, the direction of tilt is perpendicular to the direction of the pan motion. The tilter can be turned off allowing the tray/pans178to pass through to the next station. Any suitable indexer may be used to move the tray/pans178into and out of the tilter, including relying on the index servo moving the tray/pans over the collection trough. Any other suitable means of obtaining additional fluids can be used, one such means might include inducing vibrations into the eggs.

At the outfeed pan and invert station32, and with reference toFIGS. 1,1B and8the tray/pan178is re-inverted so that the drain pan162can be removed and sent to the rinse unit33. Near the end of the drainage trough188, the trays are moved into a second inverter unit204on guide rails205by another index servo206which is similar to the index servo172discussed above with reference toFIGS. 6,6A and6C. The inverter unit204is similar in construction to the inverter unit180discussed previously, re-inverting the tray/pan178so that the pan162is again on top (semicircle29ainFIG. 1indicating the inversion motion).

Once inverted, the tray/pan178is indexed forward by an index servo208having a walking beam208awith 4 arms208b(seeFIGS. 1 and 1B) and posts208cthereon for moving 4 trays simultaneously downstream of the inverter204(by engaging the tray posts44a). Thus, with one index movement, it moves a re-inverted tray from the inverter204onto rails210and into the pan pick up position212, an adjacent tray (not shown) from the pan pick up station212one index movement forward on the rails210, and also moves the next two adjacent trays one index movement forward on the rails210into and then out of the tray dump system220.

At pick up position212, a second pick and place unit214, similar in construction, components and operation as the pick and place unit170described previously, picks the drain pan162up off the tray36and rotates in the direction215to place the drain pan on an infeed conveyor216that moves the pans into the rinse unit33where the pans are rinsed and conveyed to the infeed pan and invert station28for re-use. Mechanical stops218engage the pan to prevent the pan/tray178from traveling past the pick up position212, the stop218being positioned to stop only the pan as once the pan is lifted the tray can move to the next position without interference from the stop.

With further reference toFIGS. 8 and 8A, after removal of the drain pan from the tray36, the tray is indexed forward to a tray dump system220by the servo index unit208. The tray dumping system includes two tray clamp rails222into which the tray36is slidably moved by the index servo208. The tray clamp rails222have hold down members223positioned to be just above the registration projections44of the tray to hold the tray in place during inverting. A dump servo226, connected to clamp rails222by arm224, rotates to invert the tray over a waste dump228where the remaining debris (eggs) is disposed. Any suitable combination of characteristics of the dump system, such as velocity, acceleration and angle of the tray, can be chosen to remove the eggs from the tray. The dump servo then reverses rotation to return the emptied tray36for a final index movement by the index servo208from the tray dump system onto slide rails228, and then the tray is finally pushed by the trays behind it into the tray outfeed station34where the trays are conveyed through any known means, such as by moving conveyor belts230as shown, from the apparatus20for collection and cleaning as may be desired for reuse.

Sensors, controllers, and other electronics as known in the art can be used to control the movements and processes of the apparatus20.

It is understood that the foregoing description is intended to describe a preferred embodiment of the present invention, and is not intended to limit the invention in any way. For example, it is appreciated that use of a differently configured egg tray, or one having a different number of eggs, might require modifications and alterations from the preferred embodiment described above. It is further appreciated that the term tray can mean any device for holding multiple eggs. Similarly, the number and configuration of the de-cap units could be changed, the construction of the egg lifting components (e.g., directly coupled lifting arms rather than magnetically coupled arms), and alternative means of moving and conveying the trays could be employed. Suitable servo motors, actuators, and other mechanical and/or fluidic powered drive mechanisms may be substituted without affecting the operation of particular parts of apparatus20based on routine experimentation. It is further appreciated that the various devices and methods of transporting the eggs through the apparatus20comprises an egg transport system that can be formed of any suitable device or combination of devices and systems as known in the art.