SUPPORT ELEMENT FOR STORING CRATES, SUPPORT SYSTEM FOR STORING CRATES, STORAGE SYSTEM FOR STORING CRATES AND REARING UNIT FOR REARING OF INSECTS OR INSECT LARVAE OR WORMS

A support element for storing crates, wherein the support element is an elongate element having a cross section that is substantially formed in an U-shape, comprising a bottom section and two opposite side walls extending from the bottom section. The side walls each comprise a top portion, forming two elongate supporting areas, whereby the elongate supporting areas are configured to support a crate or a column of stacked crates, The inner side sections of the side walls each comprise a step symmetrically protruding to the inside of the U-shape forming two elongate running surfaces, whereby the elongate running surfaces are configured to support a conveyor system for transporting the crate. The invention further refers to a support system, a storage system and to a rearing unit.

The present disclosure relates to a support element for storing crates according to claim1, to a support system for storing crates according to claim6and to a storage system for storing crates according to claim9and to a rearing unit for rearing of insects or insect larvae or worms according to claim15.

In the field of insect or worm rearing, crates are utilised which are specifically designed to house the insects or worms and a nutrient medium for the insect larvae or worms. In order to save space, the crates are stacked on each other to a certain height, and stored in a room having a condition climate adapted to the requirements of the insects or worms in order to provide suitable conditions for growth of the insects or worms. In general, multiple lanes of stacked crates are stored next to each other. The stacks of crates in the rearing room have to be supported by support elements, e.g. in form of pallets or rack systems as shown by U.S. Pat. No. 10,405,528 B2. The stacked crates have to be stacked in such a way that they may be automatically picked up or moved, e. g., for control or further processing purposes such as checking growth and vital parameters or further processing of the insects or worms. This is usually done using a conveyor system, e. g., on rails.

It may occur that larvae or worms exit the crates which may lead to a cross-contamination of different lanes. Also, debris from the storage rooms may contaminate the floor. Currently, free standing rails are used which are difficult to clean because the washing fluid e.g. water spreads over the entire floor since the water is not effectively channelled.

The object of the present invention is therefore to avoid at least partly the disadvantages of the prior art and especially to provide a support element for storing crates which prevents cross-contamination and may be easily cleaned. Furthermore, the support elements shall be long-lasting and configured to allow storage and transport of the crates. Further objects of the present invention are also to provide a support system for storing crates, a storage system for storing crates and a rearing unit for rearing of insects or insect larvae or worms.

Furthermore, contamination of adjacent lanes of stacked crates should be prevented and larvae which escaped from the crates or any fluid used in cleaning should not move across the lanes. It is also desirable that the lanes may be easily cleaned when there are no crates placed upon them.

These objects are achieved by a support element, a support system and/or a storage system and/or a rearing unit as disclosed herein.

In particular, a support element according to the present disclosure comprising an elongate element having a cross section that is substantially formed in an U-shape, comprising a bottom section and two opposite side walls extending from the bottom section, wherein the side walls each comprise a top portion, forming two elongate supporting areas, whereby the elongate supporting areas are configured to support a crate or a column of stacked crates, wherein inner side sections of the side walls each comprise a step preferably symmetrically protruding to the inside of the U-shape forming two elongate running surfaces, whereby the elongate running surfaces are configured to support a conveyor system for moving the crate or stacked crates.

Such a support element provides a stable support for the crates, also for stacked crates and at the same time are easily cleanable. The side walls extend from the same side of the bottom section for forming the U-shape together with the bottom section.

Alternatively, the support element is substantially formed from two L-shaped elements, each comprising a bottom section and a side walls extending from this bottom section. The two L-shaped elements form together a support element that is substantially formed in a U-shape, but comprising a discontinuous (not continuous) bottom section. The contact surface of the bottom sections between the two L-shaped elements is preferably sealed, at least partly.

Preferred the support element is formed of concrete and therefore easily producible. Preferably the concrete is cast on metal rails that the support element is more stable and resistant also against tension.

Preferred the running surfaces of the support element are covered with a steel coating to provide a perfect surface for the conveyor system. Preferably, the running surfaces of the support element are covered with a stainless steel coating, so that the steel coating does not rust, also in a potentially aggressive environment. E. g., the coating comprising a band material which preferably is cast-in during fabrication of the support element. Such running surfaces are advantageously, especially if the conveyor system comprising wheels or other rotational means, because they create guides and long-lasting surfaces.

Alternatively, the support element is formed of steel which allows to provide plane or even surfaces. Preferably the support element is formed of stainless steel, so that the support element does not rust, also in a potentially aggressive environment.

Preferred the support element is monolithic that an easy handling of the support member is guaranteed.

Alternatively the support element is as multi-piece element. Thereby, especially the width between the support element pieces can be adjusted according on a respective size of the crate.

The invention refers also to a support system for storing crates comprising at least one support element as aforementioned and a conveyor system, wherein the conveyor system extends in size for being moveable underneath the crates supported by the supporting element without interfering with the crates.

This support system provides the advantages of the support element as well as a compact and a space-saving solution. A correct handling of the crates and the columns of stacked crates is given.

The measurements at the height of the conveyor system are chosen so that—in an arranged state of the conveyor system—the upper edge of the conveyor system is lower than the top portion of the side walls

Preferably, the conveyor system is configured for being supported by the elongate running surfaces formed by the steps of the support element. More preferably, the conveyor system comprising wheels or other rotational means configured for being supported by the elongate running surfaces formed by the steps of the support element. Thereby, a reliable support system is provided.

Alternatively, the conveyor system is configured to be arranged on the floor or on the bottom section of the support element. This alternative solution is preferably used when the conveyor system comprising automated guided vehicles (AGV).

Preferred the conveyor system includes means for lifting the crates in order to move the crates or columns of stacked crates along the support element. Thereby, an easy handling of the crates is ensured.

Preferred the conveyor system is movable by a drive that the conveyor system can be moved inside of the support system.

Alternatively the conveyor system comprising a drive for moving the conveyor system along the elongation of the support element what facilitates the handling of the crates or of the columns of stacked crates.

Preferably, the conveyor system is, at least partly, autonomous moveable, whereby a respective control for controlling the conveyor system is provided.

The invention refers also to a storage system for storing crates comprising a plurality of support element as aforementioned and a plurality of crates arranged on the top portions of the side walls of the support elements, wherein the crates have a substantially rectangular perimeter defined by upstanding front and rear walls and opposing side walls, wherein preferably the length of the crates between the front and rear walls substantially corresponds to the distance of the side walls of the support element. Alternatively the width of the crates between the both side walls substantially corresponds to the distance of the side walls of the support element. Preferably, at least one dimension of the crate fits with the respective dimension of the support element.

Alternatively or additionally the invention refers also to a storage system for storing crates comprising at least one support system as aforementioned and a plurality of crates arranged on the top portions of the side walls of the support element, wherein the crates have a substantially rectangular perimeter defined by upstanding front and rear walls and opposing side walls, wherein preferably the length of the crates between the front and rear walls substantially corresponds to the distance of the side walls of the support element. Alternatively the width of the crates between the both side walls substantially corresponds to the distance of the side walls of the support element. Preferably, at least one dimension of the crate fits with the respective dimension of the support element.

Such storage systems are easy to handle with the advantages as mentioned before.

Preferred the storage system the support elements are arranged consecutively in a longitudinal direction along the elongation of the support elements for a space-saving arrangement. The support elements are preferably sealed on their contact surfaces or between each other, respectively.

Preferably, the distance between at least two longitudinal spaced support elements is chosen so that provided air can circulate or pass between the crates for providing optimal conditions for the rearing. At least partly the distance between two support elements is chosen so that an operator can pass between the stacked crates, e.g., for a visual inspection.

Preferred the crates are stacked in at least one column of stacked crates what results in a space-saving arrangement.

Alternatively or additionally, the crates or columns of stacked crates are arranged adjacently on the at least one support element.

Preferred the storage system comprises a conveyor system for transportation of the crates, whereby the conveyor system is configured for being supported by the elongate running surfaces formed by the steps of the support element for moving the conveyor system along the elongation of the support element underneath the crates supported by the supporting element without interfering with the crates. The conveyor system preferably comprises wheels or other rotational means.

Preferred the conveyor system is positioned by an observation system, wherein the observation system comprising at least one laser or at least one camera. By the observation system the correct position of the conveyor system can be determined and/or controlled. This positioning of the conveyor system can be laser-based. If a camera as observation system is used, the position of the conveyor system is defined based on an analysis of the pictures made by the camera.

Preferred the crates are adapted to allow rearing of insects or insect larvae or worms. Preferably Black Soldier Flies (BSF) larvae are reared.

The invention refers also to a rearing unit for rearing of insects or insect larvae or worms comprising a rearing room and a storage system as aforementioned, whereby an easy handling of the crates especially during the rearing process of the insects or insect larvae or worms and the respective process steps is guaranteed.

With the present invention, a support element1according toFIG.1is proposed. The support element1is formed of concrete and is monolithic. The support element1is an elongate element having a cross-section substantially formed in a U-shape. I. e., the support element1essentially forms a vertically aligned U and is extended in a horizontal direction. When viewed in a cross-section, the support element1comprises a preferably continuous bottom section13and two opposite side walls14extending from the bottom section13. Preferably they are formed in a symmetrical manner.

The side walls14each comprise a top portion11which form two elongate supporting areas. The sidewalls each comprise a step12which symmetrically protrudes to the inside of the U-shape. Said steps12form two elongate running surfaces. Said running surfaces are aligned in the same direction as the supporting areas11. The running surfaces of the support element1are covered with a steel coating15which is cast-in and preferably is a stainless steel coating.

Running surfaces are configured to support a conveyor system2for moving the crates3. The conveyor system2may be a so-called satellite which is an autonomous robot having wheels21or other rotational means adapted to the width of the running surfaces and having lifting means23for carrying and transporting the crates3. A drive25is provided for moving the conveyor system2along the supporting elements1. This drive25is preferably designed for driving the conveyor system2and also for driving the lifting means23.

The conveyor system2may thus drive below a single crate3or column39of stacked crates which are stored on the supporting elements1and lift them using the lifting means23until the crates3lose contact with top portion11of the supporting elements1. The conveyor system2might lift several columns of stacked crates at the same time.

The conveyor system2may then move the crates3to another place in the rearing unit (rearing facility). The lifting means23may be designed as hydraulic, electrical or mechanical means or any other means suitable for lifting and carrying crate3, e. g. as a scissor lift. The conveyor system2may additionally comprise side wheels to avoid direct contact of the conveyor system2with the inner side of the side walls14of the support elements1, and thus avoid friction.

The support elements1may be connected to form a line or lane. They may be mounted on the ground or floor and may be sealed in respect to each other such that no fluid and larvae can enter a lane or a space under the lanes.

Shims may be used to achieve a desired height of the support elements1, e. g. in case the floor is not level. In order to be cleanable the space between the support element1and the floor may be sealed.

Multiple lanes may be positioned adjacent to each other in a rearing (storage) room. The width between the lanes may be provided in such a manner that air can circulate between the crates or columns of staked crates. Preferably the width between the lanes is chosen that the staff may pass between the lanes and perform maintenance or inspection operations. The width may be between 200 and 1000 mm, preferably between 300 and 400 mm and more preferably 360 mm. The space between two spaced support elements or lanes of support elements is preferably chosen that escaping larvae or liquids are collected and cannot escape from the space between two lanes. The aforementioned space corresponds preferably to 20% up to 200% of the larvae stored in the crates of one lane. By this measures, cleaning is facilitated and spreading of larvae or matured insects throughout the whole system is avoid.

By the U-shape as described above fluid and larvae may be prevented from cross-contaminating different lanes in the rearing room. In order to provide good cleanability of the insides of the U-shaped support elements1, the surfaces preferably not comprise holes or grooves. I. e., the surface of the support elements1should be smooth. When viewed in a cross-section, each support element1thus has a closed circumference. This also allows that the support elements1may be easily cleaned by effective channelling of water.

The support elements1may preferably be formed from concrete. It may also be advantageous to cast concrete on metal rails, in which case, however, concrete still forms the surface of the support elements1. In addition to any of the materials, the running surfaces may comprise a coating made of steel. This may reduce the point load on the concrete and provide a perfect surface for the wheels21of the conveyor system2. In another preferred embodiment the support elements1may be formed from stainless steel.

In order to prevent crates3from toppling and to provide easy access a transport means, the support elements1should meet certain tolerances to ensure that the lanes and tracks are straight and homogenous. The materials preferably used according to the present invention also avoid the problem of rust which occurs in the currently used systems. Due to the often humid, ammonia rich and warm climate inside a rearing room and the use of metal rails, rust may significantly decrease the lifetime of such a storage system51.

In the case the support elements1are formed of concrete, they may be cast at the respective location. This saves costs for the reinforcement of concrete because the support elements1do not need to be transported. It has to be considered though, that the tolerances may be harder to meet when the support elements1are cast on location. Furthermore, the floor has to be prepared more thoroughly.

The functions and requirements of the support elements1are now described using an example. However, other parameters such as width, height, force, weight etc. may act or be required. The support elements1ofFIG.1andFIG.2substantially correspond. The description of similar or the same parts may thus be omitted.

According to an exemplary configuration as shown byFIG.3, the support elements1have to support stacks of up to twelve crates3. Each crate3may have a weight of 40 kg. The crates3may be rectangular having a shorter side and a longer side. The longer side (width) w may be between 400 and 1000 mm, preferably 800 mm long. The shorter side (length) may be between 200 and 800 mm, preferably 600 mm long.

Each support element1may have height H of 100 to 600 mm, in the present exemplary embodiment 490 mm. The height is also defined by the required space between two lanes of support element for receiving at least 50% up to 100% of the reared larvae in one lane. The lower the crates3are stacked or the smaller the crates are the lower the height H of the support elements1can be chosen.

The width W of the support elements1may substantially correspond to the width w of the crates3.

For the sake of stability, the support elements1may be formed wider than the crates3. When viewed in a cross-section, the U-shaped support elements1may be divided in at least two sections. In the present example as shown inFIG.2, the support element1may be described in three sections. The three sections may roughly be of the same height and thus substantially divide the U-shape in thirds. In the present example, the bottom section A between the floor of the storage room and the bottom part13of the U-shape is 150 mm high. On the bottom section A, potential escaped larvae, debris, residuals and fluid may be collected. The middle section B is formed between the bottom section13of the U-shape and the step12which is symmetrically formed on the side walls14of the U-shape. The step12thereby forms the running surface. Preferably, the side walls14of the middle section B connecting the bottom section13and the step12are not exactly vertical. Preferably the side walls14of the middle section B are inclined in at least one segment. This allows for effectively collecting residuals, larvae and fluids and facilitates cleaning. In the present example, both side walls14are formed at an angle of 20° with respect to each other and are 169 mm high. The top section C is formed between the step12or running surface, respectively, and the supporting area, i. e. the top portion11. In the present example, the top section C is 171 mm high. The top portion11preferably is bevelled downwards on at least one side. The inner side of the side walls14of the top section C forming the top portion11are preferably inclined in at least one section, i. e. not exactly vertical over the entire length.

The supporting areas (top portion11) may be between 50 and 100 mm wide each. In the present example, both supporting areas are around 70 mm wide each, leading to a distance of the inner side of the side walls14of the top section of 655 mm, less the bevelled portion. The running surface supporting the conveyor system2in the present example is 70 mm wide on both sides.

The conveyor system2extends in size for being moveable underneath the crates3supported by the supporting elements1without interfering with the crates3. The conveyor system2or satellite, respectively, may carry up to 4 columns of stacked crates3at the same time. The weight of the conveyor system2itself of ca. 400 kg must also be taken into account.

An observation system56(seeFIG.3) is provided for positioning of the conveyor system2inside of the Support element1. The observation system56comprises one or more laser or one or more cameras.

In order to be cleanable, larvae or any fluid should not be able to move across the lanes of support elements1. At least during production or rearing, there may be at least one empty lane which may be cleaned before new crates3are placed on it. During cleaning, the cleaning water carrying larvae, fluid or residuals should not contaminate the adjacent lane or under the lanes. This is achieved by the structure of the support elements1as presented above.

In summary, the present disclosure provides a support element1which may be used in an insect rearing unit (facility). Said support element1may be provided in multiple and connected to form lanes or lines. Thus, a modular and expandable system may be formed. Due to the simplified and robust construction it may have a lifetime of 20 years and more without deformation or impact of shear stress. Also, rust may be prevented since materials such as concrete and stainless steel are utilised. Furthermore, a conveyor system2for conveying the crates3may be supported by and fit into the support elements1. By having a closed structure substantially without holes and grooves, cleaning of the rearing room is facilitated and cross-contamination between different lanes may be prevented. Cleaning water may be effectively channelled along the lanes.

FIG.3shows a rearing unit81for rearing of insects or insect larvae or worms comprising a rearing room83(schematically shown) and a storage system71.

The storage system71for storing crates3comprises support elements1or support systems51, respectively, and a plurality of crates3arranged on the top portions11of the side walls14of the support elements1.

The crates3are stacked in columns39of stacked crates3and are arranged adjacently on the support elements1. The crates3have a substantially rectangular perimeter defined by upstanding front and rear walls and opposing side walls, wherein preferably the length of the crates3between the front and rear walls substantially corresponds to the distance between the side walls14of the support elements1.

The support elements1are arranged in rows, consecutively in a longitudinal direction along the elongation of the support elements1. The space16between multiple support elements1arranged in line to form lanes are preferably sealed.

In reference toFIG.4ashowing the storage system71, the support system51for storing crates3comprises a plurality of support elements1and30which are arranged parallel to each other. Furthermore, the support system51comprises a conveyor system2. Preferably each lane of support elements1or30is provided with one conveyor system2. Alternatively, the conveyor system2can switch from one lane to another lane.

The bottom of the space between two support elements1may be provided with a sealing. E. g., the sealing41comprises concrete, preferably flow mortar or sealants. Alternatively or additionally, the sealing43comprising a foil or cover, e. g., made of plastic, which is glued on.

The U-shaped support elements30(see example inFIG.4a) described above may also be implemented by connecting two mirrored L-shaped elements36and37comprising the step32, i. e. running surface, as well as the top portion31as supporting area as set forth above. The contact area34of the two L-shaped elements36and37is sealed.

In the storage system76according toFIG.4btwo support elements1are arranged directly to each other in longitudinal direction and another support element1is arranged spaced from the support element1nearby in a width D. The width D between the two support elements1which are spaced from each other in longitudinal direction may be between 200 and 1000 mm, preferably between 300 and 400 mm and more preferably 360 mm. The space46between the two spaced support elements1or lanes of support elements1is preferably chosen that escaping larvae or liquids are collected and cannot escape from the space between two lanes. The aforementioned space corresponds preferably to 20% up to 200% of the larvae stored in the crates of one lane. By this measure, cleaning is facilitated and spreading of larvae or matured insects throughout the whole system is avoided.

FIGS.5ato5eshow each different alternative embodiments of the inventive support element. For levelling the existing floor91an insulation foam layer92may be provided which may be covered by a concrete layer93. Alternatively, for levelling the existing floor91the concrete layer93may also be provided directly on the existing floor91.

The support element101(seeFIG.5a) comprising two L-shaped elements102and106made from concrete. The L-shaped elements102and106are arranged in a respective distance to each other depending on the size of the crates3arranged thereon.

The L-shaped element102comprising a bottom section103and a side wall104. The running surface105is formed by the upper surface of the bottom section103. The L-shaped element106comprising a bottom section107and a side wall108. The other running surface105is formed by the upper surface of the bottom section107.

For arrangement of the support element101openings94are provided in the concrete layer93for receiving anchorage elements96extending from the bottom section103or106of the elements112and116(FIG.6a). The anchorage elements96are made of metal and may be casted-in when the elements112and116are casted. The anchorage elements96may have a longitudinal shape (then the openings94are preferably formed as slits) or are bar-shaped (then the openings94are preferably formed as holes).

The openings94are filled with a gluing compound, e. g. a synthetic glue or flow mortar, before the elements112and116are mounted (FIG.6b). For supporting the elements112and116against shearing forces formwork elements97are provided on both sides of the elements112and116which run in longitudinal direction.

The space between the formwork elements97and the respective elements112or116is then filled with a gluing compound, e. g. a synthetic glue or flow mortar (FIG.6c).

The support element111(seeFIG.5b) comprising two Z-shaped elements112and116made from metal, preferably made from stainless steel. The Z-shaped elements112and116are arranged in a respective distance to each other depending on the size of the crates3arranged thereon.

The Z-shaped element112comprising a box-shaped bottom section113and a side wall114. The running surface115is formed by the upper surface of the bottom section113. A horizontal section119extending from the upper end of the side wall114for forming a top portion by which the crates3are supported. The Z-shaped element116comprising a box-shaped bottom section117and a side wall118. The other running surface115is formed by the upper surface of the bottom section117. A horizontal section119extending from the upper end of the side wall118for forming a top portion by which the crates3are supported.

The support element121(seeFIG.5c) comprising two elements122and126made from concrete. The elements122and126are arranged in a respective distance to each other depending on the size of the crates3arranged thereon.

The element122comprising a stepped section which forms the running surface125. The element126comprising a stepped section which forms the other running surface125.

The support element131(seeFIG.5d) comprising two elements132and136made from concrete. The elements132and136are arranged in a respective distance to each other depending on the size of the crates3arranged thereon.

The element132comprising a flat extension133which forms the running surface135. The element136comprising a flat extension137which forms the other running surface135. The extensions133and137are made of metal, preferably made of stainless steel.

The support element141(seeFIG.5e) comprising two elements142and146made from concrete. The elements142and146are arranged in a respective distance to each other depending on the size of the crates3arranged thereon.

The element142comprising a console143which forms the running surface145. The element146comprising a console147which forms the other running surface145. The consoles143and147may be made of metal, preferably made of stainless steel, or may be made of concrete, preferably formed when the element142or146is casted.

Other aspects, features, and advantages will be apparent from the summary above, as well as from the description that follows, including the figures and the claims.

Furthermore, in the claims the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. A single unit may fulfil the functions of several features recited in the claims. The terms “essentially”, “about”, “approximately” and the like in connection with an attribute or a value particularly also define exactly the attribute or exactly the value, respectively. Any reference signs in the claims should not be construed as limiting the scope.

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