Abstract:
A mushroom compost compacting system and method includes a roller assembly mounted to a compost receptacle to form a nip, and a web or conveyor to convey mushroom compost to the nip. Mushroom compost is compacted at the nip from an initial compost height to a final compost height. The roller assembly has a roller, a shaft, and fixtures coupled to each end of the shaft. The fixtures are adjustable to define the roller nip height. In one embodiment, the fixtures are mounted to sleeves that engage the sidewalls of the compost receptacle. In another embodiment, the ends of the fixtures are mounted to a support, which may be a joist or a separate channel extending under the floor portion of the compost receptacle, or which may be a post that forms support structure for the compost receptacle.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional of U.S. Ser. No. 12/902,523, filed Oct. 12, 2010, now U.S. Pat. No. 8,069,608. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The field of the invention is mushroom compost compacting systems, and particularly those systems for composting Phase II or Phase III mushroom composts. 
     2. Background 
     Mushroom farming comprises generally six steps: (1) Phase I composting; (2) Phase II composting; (3) spawning; or (2a/3a) Phase III composting; (4) casing; (5) pinning; and (6) cropping. The most used and least expensive mushroom compost is straw-bedded horse manure to which nitrogen supplements and a conditioning agent, such as gypsum, are added. After the compost ingredients have been mixed, watered and aerated in Phase I for a requisite number of days, the compost is pasteurized in Phase II. Pasteurization kills insects, unwanted fungi or other pests that may be present in the compost. 
     Preparing Phase II mushroom compost can be difficult. One reason for the apparent difficulty with this phase is that pasteurization can last up to two weeks, depending upon the production system used. The time required, as well as other difficulties in maintaining temperature control and eliminating pests during this phase have led many mushroom farmers to purchase pre-pasteurized compost. In many cases, the Phase II compost is pre-mixed with mushroom spawn. Alternatively, Phase III compost is pasteurized, pre-mixed with mushroom spawn and spawn run. 
     When commercial mushroom farmers purchase pre-pasteurized Phase II or Phase III composts, proper compaction of mushroom beds is still necessary to spawn and grow mushrooms. Moreover, regardless the type of receptacle in which the compost is stored during processing, uniform compaction and density of the compost is beneficial for mushroom cultivation. For maximum yield, mushroom beds should have Phase II and Phase III compost density and compaction that fosters gas exchange, keeps compost temperatures sufficiently low, and prevents spawn kill in the next phase of processing. 
     Presently, commercial mushroom farmers who purchase pre-pasteurized compost introduce the Phase II or Phase III compost into beds by conveyor and attempt to use spawning machines to compact the compost. These machines, however, are not designed to compact to the degree desired for mushroom cultivation. Furthermore, these machines are less than desirable for commercial mushroom farmers because during operation they also chop up the spawn incorporated into the compost, potentially interfering with the next step in mushroom farming. 
     Other known compacting systems and methods are impractical for commercial use. One such system uses an assembly with rollers and smoothing plates. In this system, mushroom compost is partially compacted after placement into the mushroom bed. The assembly is then horizontally positioned over the bed and manually guided by two operators located on each side of the bed. This system tends to compact only a surface layer portion of the bed. Compaction to some degree has also been performed by hand after placement of compost in the bed. These time-consuming manual systems and methods make clear the need for improved mushroom compaction systems. 
     While certain aspects of prior art mushroom compacting systems have been discussed, aspects of these systems are in no way disclaimed and it is contemplated that the claimed invention may encompass one or more aspects of the prior art devices discussed herein. 
     SUMMARY OF THE INVENTION 
     The present invention is directed toward a mushroom compost compacting system and method. In one embodiment, the system comprises a roller assembly mounted to a compost receptacle, and a web, all of which are configured to compact mushroom compost from an initial compost height to a final compost height. The compost receptacle is configured to receive mushroom compost from any source. 
     The roller assembly includes a roller, a shaft, and two fixtures to removably mount or affix the roller and shaft to the compost receptacle. The roller is mounted for rotation on the shaft, such as by a through-hole for receiving the shaft. The fixtures are coupled to the shaft for height adjustment of the roller and the shaft in relation to the floor portion of the compost receptacle. Each fixture has (a) a first end that is coupled to one respective end of the shaft, (b) a mid-section that is coupled to a sleeve that seats over a sidewall of the compost receptacle, and (c) a second end that is adapted to mount to a support onto the compost receptacle. The sleeve that is coupled to the mid-section of the fixture is adapted to removably mount onto the sidewalls of the compost receptacle. 
     The web or liner or conveyor included in the mushroom compacting system is adapted to move under the roller to convey compost to the nip. As the web or liner or conveyor moves under the roller, the mushroom compost is compacted from an initial compost height to a final desired compost height. 
     Accordingly, a mushroom compacting system and method are disclosed. Advantages of the system and method will appear from the drawings and following description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention described above will be explained in greater detail below on the basis of embodiments and with reference to the accompanying drawings in which: 
         FIG. 1  is a top perspective view of a mushroom compost bed with a mushroom composting system; 
         FIG. 2  is a cross-sectional view of the mushroom composting system shown in  FIG. 1  taken along line  2 - 2  in  FIG. 1 ; 
         FIG. 3  is a left side partial perspective view of a roller assembly; 
         FIG. 4  is a right side partial perspective view of the roller assembly of  FIG. 3 ; 
         FIG. 5  is a right side view of the roller assembly; 
         FIG. 6  is a broken front elevation view of the roller assembly; 
         FIG. 7  is a right side view of two roller assemblies operably attached to two mushroom compost beds; and 
         FIG. 8  is a right side view of an alternative fixture for a roller assembly. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Turning in detail to the drawings,  FIG. 1 . illustrates a mushroom compost bed  10  that includes a series of trays or shelves, herein compost receptacles  12 , into each of which mushroom compost  8  is deposited or laid. The mushroom compost  8  may be Phase I, Phase II or Phase III compost. Phase II compost may be pre-spawned, and Phase III compost may be spawn run. The compost receptacle  12  may be any geometric configuration suitable to house mushroom compost  8 . In one configuration as shown in  FIG. 1 , the compost receptacle  12  is an elongated bin, tray, or shelf that has two endwalls  18  (not shown), two sidewalls  20 , and a bottom  22 . The bottom may be a series of slats or decking running generally lengthwise. Each compost receptacle  12  is supported by vertical posts or members  24  positioned at each corner of the compost receptacle  12  and optionally at intervals along the length of the compost receptacle  12 . The vertical posts or members  24  may act as supporting legs for one or more compost receptacles  12 . As shown in  FIG. 1 , the vertical posts or members  24  extend vertically to support other compost receptacles (three tiers shown in  FIG. 1 ). These types of multi-tiered compost receptacles are typical in commercial mushroom farming. For additional support, some compost receptacles also have horizontal members or joists  26  that may be mounted to or connected to the vertical members  24  and extend under the floor portion of the compost receptacle  12 . Typically, the compost receptacles  12  are wooden, although any suitable material may be used, including, but not limited to plastic, metal, and composite materials. 
     The mushroom compost  8  is initially placed into the compost receptacle  12  from any suitable source. Preferably, the mushroom compost  8  is distributed inside the compost receptacle  12  along the length of the compost receptacle using a conveyor system (not shown) that acts on the web or conveyor or liner  28 . In one type of conveyor system, at one end of the compost receptacle  12 , compost is placed on top of the flexible web or conveyor or liner  28  in the bottom  22  of the compost receptacle  12  at a proximal end thereof. The liner  28  is then pulled from the opposite distal end of the compost receptacle  12 , such that the compost  8  is distributed or spread along the length of the compost receptacle  12 . Examples of suitable materials for the liner include woven fabrics with a plastic or Teflon coating, or may be polyester. 
     A mushroom compost compacting system  11  includes a roller assembly  14  that is removably affixed to the compost receptacle  12 . Each roller assembly  14  comprises a roller  32 , a shaft  34 , and two fixtures  36 ,  36 ′. The shaft  34  and roller  32  extend laterally over the tray portion of the compost receptacle  12 . The roller  32  may be made from a lightweight material such as plastic or aluminum, or may be made of another metal lined on its outer surface with a nylon or Teflon or other sheeting. The roller surface is smooth such that the mushroom compost to be compacted by the roller may move easily under the roller  32 . In one embodiment, the diameter of roller  32  is from about 8 to 20 inches. The shaft  34  may be formed of steel; however, any material suitable to support the weight of the roller  32  may be used. 
     As shown in  FIGS. 3 ,  5  and  6 , the first fixture  36  includes a first end  40 , a mid-section  42  coupled to a sleeve  44 , and a second end  46 . The first fixture  36  is coupled at one end  40  to one shaft end  38  at pillow block bearing  50  and is coupled at the opposite end  62  to a support  58 , such as a channel member. The pillow block bearing  50  is then mounted onto a mounting bracket or plate  52 , using bolts  53  or other suitable fasteners. The mounting bracket or plate  52  is then welded to a first mounting element  54  which is threaded to the mid-section  42 . Disposed within the first mounting element  54  is a pin  56  which may be rotated for adjustment of the first end  40 , such that height adjustment of the roller  32  and shaft  34  is possible for compaction of the mushroom compost. As an example, the nip height between the outer circumferential surface of the roller and the floor of the compost receptacle may be from about 2 to about 8 inches. The nip height is set at a distance that is less than the desired compacted height of the mushroom compost. 
     The mid-section  42  of first fixture  36  may be joined by a spacer  48  or may bewelded to a sleeve  44  that is removably mounted or seated or engaged onto a first sidewall  20  of the compost receptacle  12 . The second end  42  of the first fixture  36  is threaded to engage the mid-section  42  and to mount onto the compost receptacle  12 . Preferably, the second end or opposite end of the first fixture  36  is joined to or mounted to a support, such as channel member  58 , that abuts joist or horizontal member  26 . In one embodiment, the channel member  58  is a square hollow pipe with a length sufficient to extend under the compost receptacle, and the dimensions of such square may be from 2 inches to 6 inches. In another embodiment, the support may also comprise a solid pipe of suitable cross-sectional shape as desired. The second end  46  is further coupled to a handle element  60  to allow for adjustment of the second end  46 . For additional adjustment of the second end  42 , washer(s)  63  may be placed between the channel member  58  and the handle element  60 . 
     Referring next to  FIGS. 4 and 6 , the second fixture  36 ′ may be joined by spacer  48 ′ or may be welded to a sleeve  44 ′. The second fixture  36 ′ is coupled at one end  40 ′ to one shaft end  38  at pillow block bearing  50 ′ and is coupled at the opposite end  62 ′ to a support  58 , such as a channel member. The pillow block bearing  50 ′ is then mounted onto a mounting bracket or plate  52 ′, using bolts  53  or other suitable fasteners. The plate  52 ′ is then welded to a first mounting element  54 ′ which is threaded to the mid-section  42 ′. Disposed within the first mounting element  54 ′ is a pin  56 ′ which may be rotated for adjustment of the first end  40 ′. 
     In an alternative embodiment, however, the second end of the first fixture  36  and the second end of the second fixture  36 ′ are mounted directly to the compost receptacle  12 , such as to post  24  or to joist  26  (not shown). 
     The roller shaft may be turned by hand. Preferably, the first end of the shaft  34  is coupled to a motor  64  for rotation of the roller  32 . As shown in  FIG. 3 , the motor  64  is mounted to a vertical post  24  of the compost receptacle  12  using a mounting plate  66 . Adjustment of the mounting plate  66  is achieved through use of a pin  68  that is threaded to the mounting plate  66 . Suitable motors include electric and hydraulic motors rated at 1 to 5 HP, or higher HP, although any motor with sufficient capacity to rotate shaft  34  may be used. 
     The first and second fixtures  36 ,  36 ′ may be formed from shaped metal, such as steel; however, other materials with sufficient strength to support the roller  32  and shaft  34  may be used. 
     Once installed, the mushroom compacting system  11  compacts mushroom compost from a first height A to a compacted height B as illustrated in  FIG. 2 . Gauge boards (not shown) can be inserted adjacent to the side walls of the compost receptacle  12  to help workers place a quantity of mushroom compost onto the conveyor, web or liner  28  at a desired height at one end of the compost receptacle. The roller  32  is rotated in the direction of arrow  9  and the conveyor, web or liner  28  conveys mushroom compost laid thereon to the nip between the roller  32  and the floor portion of the compost receptacle  12 . The mushroom compost compacting system  11  can be used with pre-spawned Phase II compost or spawn run Phase III compost without adversely impacting the mushroom crop. As one example, the height A may be about 15 to 16 inches and the height B may be about 6 to 9 inches. A successful degree of compaction is determined at the mushroom grower&#39;s discretion. The mushroom compacting system  11  provides means to obtain a more uniform compaction of the mushroom compost at the top, middle and bottom portions of the compacted compost bed. 
     Upon completing compaction of compost to a desired thickness within a first bin or tray of a mushroom compost bed  10 , the mushroom compacting system  11  may be detached from the sidewalls  20  of the compost receptacle  12  and attached to another bin or tray. 
     As shown in  FIG. 7 , the mushroom compacting system  11  can include multiple roller assemblies  14  operating concurrently on separate trays or shelves or compost receptacles  12  of one or more compost beds  10 ,  10 ′. Each roller assembly  14  is portable, and may be easily disassembled and re-installed to other areas along the length of a compost receptacle  12  or to other trays positioned above or below a first compost receptacle  12  of a compost bed  10 . Compost beds may include six or seven compost receptacles  12  mounted in stacked relation. After a lower compost receptacle is prepared and compacted, the next highest compost receptacle may be installed and prepared and compacted for growing mushrooms. 
     An alternative construction of a fixture  76  is shown in  FIG. 8 . The fixture  76  is welded at weld seam  78  to the sleeve  44 . The fixture  76  may be formed with thicker sidewalls than the fixtures  36 ,  36 ′ in  FIGS. 1-7 , and has a generally square configuration in cross-section. 
     A properly compacted mushroom compost bed using the mushroom compacting system according to the invention can shorten the mushroom grow time cycle by one or two days. The system not only expedites mushroom bed preparation with Phase II or Phase III compost, but also produces a more consistent compost compaction that can lead to enhanced yield in a shorter grow time cycle. 
     While embodiments of this invention have been shown and described, it will be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the following claims.