Abstract:
A fully automated apparatus and system for processing shellfish such as shrimp and crawfish including the cooking, drying and peeling thereof. The present invention utilizes excessive heat generated by boilers to heat the dryers. The product is cooked in a brine mix that once used is transferred to a broth processing system to make a seafood flavored broth and is also injected as a fine mist into a furnace where it crystallizes into a solid product to be used as a seafood flavored salt.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to shrimp processing and, more specifically, to a method and apparatus for boiling, drying, peeling and size grading shellfish products such as shrimp and crawfish while simultaneously utilizing the by-products to process broth and salt. The present invention includes a fully automated means for processing shrimp, broth, salt, food additives, animal feed and fertilizer and moving the product from the loading dock to a finished product storage area without the need of human contact with the product thereby greatly reducing the risk of contamination and the cost of labor. 
     The procedures currently being used for processing shrimp require having personnel and employees manually dump the product into a conk tank and transfer it from one processing system into the next thereby exposing the food product to sweat, saliva, respiratory germs and the like. Furthermore, airborne contaminants also come in contact with the food product during processing, increasing the risk of causing sickness and disease to the consumer. 
     Furthermore, airborne contaminants also come in contact with the personnel during processing thereby increasing the risk of respiratory disease associated with the inhalation of sodium bisulphate and other harmful airborne contaminants. 
     The present invention seeks to alleviate these inherent dangers by eliminating the need for workers to come in contact with the product and providing a plurality of vacuums and cleaning systems to ensure a clean environment during processing. Automated conveyors serve to move the product from one system to the next from the loading dock to the storage tank. Each system involved in the processing is independent from the others and the conveyors are not attached thereby allowing a facility to upgrade current equipment to the completely automated system in steps. 
     2. Description of the Prior Art 
     There are other shellfish processing means known in the art. While these shrimp processors may be suitable for the purposes for which they were designed, they would not be as suitable for the purposes of the present invention, as hereinafter described. 
     SUMMARY OF THE PRESENT INVENTION 
     A primary object of the present invention is to provide a method and apparatus for processing shellfish that will add automation to the current process. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that greatly reduces heat within the work area. 
     Yet another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates the contamination of product during the current drying system due to condensation which accumulates on ceiling and then drops onto product. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates the exposure to excessive perspiration from employees, which currently falls directly onto product while loading, raking (rotating) and unloading. 
     Yet another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates air contamination within the work area due to shrimp dust and possible preservatives such as sodium bisulphate that fishermen apply to raw product and that become airborne during the process. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates the hands-on labor of loading and unloading raw product into the boiling system. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates the hands-on labor of loading and unloading boiled seafood into dryers. 
     Yet another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates the hands-on labor of loading and unloading of dried product into the peeling device. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates the hands-on labor of rotating the product every thirty minutes during the drying process. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates the contamination transfer of shrimp dust from previous batches of product to subsequent batches of product. 
     Yet another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates the over-drying of smaller product and the under-drying of larger product while offering a perfectly dried product based on size. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates the hands-on labor of hand picking debris from the finished product up to 66% above the present means. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that adds an additional smaller size of product, which is normally lost in the peeling process, thereby increasing the yield. 
     Yet another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates the breaking of the tips of the tails of the product, thereby having a great impact on the yield increase. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that offers a cleaner product without damaging the finished product thereby removing the legs, heads and shells while leaving the tails intact. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that adds an easy means of sanitizing between batches of product whereas the prior art has no sanitizing means whatsoever. 
     Yet another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates the hands-on labor of sweeping up peelings and shrimp dust for shipment by packing the peelings and dust in 50-gallon drums. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that offers a more cost-effective and energy-efficient process of drying by utilizing residual heat from the boilers and broth system to heat the dryers. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that will reduce the cost of the product on the consumer end thereby making it a more desirable product. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that eliminates human contact therewith, thereby reducing the risk of contamination and the cost of labor. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish wherein crates of iced shrimp are placed on a conveyor belt on the loading dock and transported to a tilt-dumping cage at the end thereof into which they are dropped so that the shrimp and ice fall into a conk tank and the crate is subsequently tossed aside by a removal bar to make room for the following crate thereby negating the need of manually dumping the product into the conk tank. 
     Yet another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish including a conk tank filled with water wherein jetted water is used to separate conk shells and other heavy items which become trapped in the bottom of the tank while the lighter items which respond to the agitated water are moved to the transport system. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish wherein the conk tank includes a conveyor system to transport the product to a primary seafood boiler. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish wherein the primary seafood boiler cooks the product at a predetermined temperature for a selected amount of time while jetted air serves to stir it during the boiling process. 
     Yet another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish wherein the primary seafood boiler is supplied and replenished with brine or salt water (water with salt added) that is mixed in a brine mixing tank and stored in auxiliary boilers to maintain the fresh brine at a specific temperature until such time that it is to be introduced into the primary seafood boiler. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish including a spray drying system wherein brine is extracted from the primary seafood boiler and injected into a heated furnace or hopper as a fine mist where it is almost immediately dehydrated thereby creating a solid product to be used as a seafood flavored salt or additive. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish wherein the product is transferred from the primary seafood boiler via a seafood dryer conveyor system where it is spread out and stirred by a plurality of spreader bars and rakes as it is cooled by high speed fans to terminate the cooking process in a thorough, uniform manner. 
     Yet another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish wherein the product is transferred to dryers from the primary seafood boiler by a conveyor system rather than manually as is the current method used in the industry. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish wherein the product is dried in stacked dryers and rotated periodically at a predetermined rate to ensure even drying. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish wherein the product is dried in spiral dryers that move the product in a spiral rotation to the top of the dryer where it is dumped through a chute back to the bottom and reloaded as the process is repeated. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that will vacuum dried product from the traditional box dryers into the peeling device described in this process. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that is to vacuum dried product from the traditional tumbler peelers previously being used. Which is one step for upgrading the old method to this new system. 
     Yet another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish wherein the dryers may be piggybacked with the product being transferred from one dryer to the next. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish wherein the product is transferred from the dryers to a peeling device that will de-shell the product while keeping the tails intact. 
     Another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish wherein the peeling device includes a spinning blade that causes the cleaned product to ride along the sides of an inner compartment which is smooth and allow the unclean product which is heavier and bulky to remain on the screen area. 
     Still another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that is simple and easy to use. 
     Still yet another object of the present invention is to provide a fully automated method and apparatus for processing shrimp and crawfish that is inexpensive to manufacture and operate. 
     Additional objects of the present invention will appear as the description proceeds. 
     The foregoing and other objects and advantages will appear from the description to follow. In the description reference is made to the accompanying drawings, which forms a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawings, like reference characters designate the same or similar parts throughout the several views. 
     The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       In order that the invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawings in which: 
         FIG. 1  is a schematic diagram of the present invention; 
         FIG. 2  is a diagrammatic view of the product from the loading dock to the primary seafood boiler; 
         FIG. 3  is a block diagram of the boiler system; 
         FIG. 4  is a block diagram of the heat exchange system; 
         FIG. 5  is a block diagram of the present invention; 
         FIG. 6  is a block diagram of the dryer and its related components; 
         FIG. 7  is a front view of the peeling device and associated options; 
         FIG. 8A–8C  is a block diagram showing the components and relationship for the seafood processing system; 
         FIG. 9  is a block diagram of the brine broth processing system; 
         FIG. 10A–10B  is a block diagram of the heat recovery system; and 
         FIG. 11  is a block diagram for processing the seafood byproducts. 
     
    
    
     DESCRIPTION OF THE REFERENCED NUMERALS 
     Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the figures illustrate the Apparatus and System for Cooking, Drying and Peeling Shellfish Products of the present invention. With regard to the reference numerals used, the following numbering is used throughout the various drawing figures. 
       10  Shellfish Processing System 
       12  refrigerated loading dock 
       14  conk tank 
       16  jetted water 
       18  product 
       20  conveyor of  14   
       21  boiler system 
       22  primary seafood boiler 
       24  brine 
       26  brine mixing tank 
       28  auxiliary tanks 
       30  dryer 
       32  air return system 
       34  broth processing system 
       36  peeler 
       38  product transfer system 
       40  broth 
       42  broth storage tank 
       44  broth packaging 
       46  raw product testing 
       48  packaging room 
       50  loading dock conveyor 
       52  crate 
       54  ice 
       56  dumping cage conveyor 
       58  dumping cage 
       60  paddle wheel 
       62  ice guard 
       64  hot air manifold 
       66  conduit 
       68  random test of raw product 
       70  foreign substance/chemical detection sensors 
       72  gross weight monitoring 
       74  salinity monitoring sensors 
       76  high speed fans 
       78  spreader bars 
       80  rakes 
       82  spray drying system 
       84  product tracking 
       86  rheostats 
       88  timers 
       90  aerated conveyor belt 
       92  seafood dryer conveyor 
       94  humidity/moisture sensors 
       96  conveyor sensors 
       98  timer of  50   
       100  sanitizing system 
       102  collection system 
       104  vacuum system 
       106  air flow controls 
       108  air contaminate sensors 
       110  video monitoring 
       112  hopper of  36   
       114  screen of  36   
       116  motor-power source of  36   
       118  tilting unit 
       120  stationary stand 
       121  legs of  120   
       122  loading device 
       124  unloading device 
       126  screen sweeper 
       128  blade 
       130  opening of  112   
       132  control panel of  118   
       134  jets of  124   
       135  conventional tumbler (peeling device) 
       136  enhanced peeling device 
       138  peeler hinged access port 
       139  conventional leading means 
       140  sensors 
       141  conventional dust collection system 
       142  conventional boiler with screen baskets 
       143  product lifting unit 
       144  conventional boiler with conveyor 
       146  conventional dryers 
       148  stacked conveyor dryer (manual load and unload) 
       150  enhanced stacked conveyor dryer 
       152  spiral conveyor dryer 
       154  enhanced spiral conveyor dryer 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The following discussion describes in detail one embodiment of the invention. This discussion should not be construed, however, as limiting the invention to those particular embodiments, practitioners skilled in the art will recognize numerous other embodiments as well. For definition of the complete scope of the invention, the reader is directed to appended claims. 
       FIG. 1  is a schematic diagram of the present invention  10 . Raw product  18  is crated in ice and introduced to the present invention  10  at a refrigerated loading dock  12  where raw product testing  46  is randomly performed to check for contaminants prior to being transferred to a conk tank  14  that serves to separate heavier items such as conk shells that become trapped in the lower section thereof. Jetted water  16  is injected into the conk tank  14  to agitate the contents therein, thereby moving the product  18  to a conk tank conveyer  20  for transferal to a primary seafood boiler  22  filled with a brine  24  mix of salt and water that is prepared in brine mixing tanks  26  and stored in auxiliary boilers  28  to maintain the brine  24  at a specific temperature until ready for distribution to the primary seafood boiler  22 . Once the product  18  is fully cooked, it is transferred to at least one dryer  30 , with all dryers  30  supplied with hot air by an air return system  32  that transfers residual heat from all related heat generating equipment such as the boilers  22 , 28 , the broth processing system  34  and the like. The product  18  is subsequently delivered to the peelers  36  for deshelling once adequately dried by means of a product transfer system  38  that initially vacuums the smaller product  18  from the dryers  30  and continues to separate the product  18  by size as the suction of the vacuum gradually increases, thereby enabling the transfer system  38  to lift increasingly larger product  18  to the peeler  36 . The transfer system  38  is filtered to remove harmful contaminates such as bisodium sulfate. 
     Used brine  24  is removed from the primary seafood boiler  22  and transported to a broth processing system  34  for the development of a seafood flavored broth  40  that is then stored in broth storage tanks  42  prior to broth packaging  44 . 
       FIG. 2  is a diagrammatic view of the movement of the product  18  from the refrigerated loading dock  12  to the primary seafood boiler  22  of the present invention  10 . The product  18  is delivered to the loading dock conveyor  50  packed in crates  52  with ice  54  and transported to the inclined dumping cage conveyor  56  and tumbles into the dumping cage  58  thereby allowing the ice  54  and product  18  to fall into the conk tank  14 . The dumping cage  58  then rejects the empty crate  52  and tosses it aside to allow the following crate  52  to drop therein. A plate-like vertical ice guard  62  traverses the width of the conk tank  14  and extends above and below the water surface to prevent the floating ice  54  from contacting the conk tank conveyor  20 . The product  18  travels along on the conk tank conveyor  20  and is then delivered into the primary seafood boiler  22  where it is cooked at a predetermined temperature for a specific amount of time. At least one agitation means, such as the paddle wheel  60  shown, is provided to stir the product  18  to allow for the uniform cooking thereof. 
       FIG. 3  is a block diagram of the boiler system  21  demonstrating the fluid connections through conduit  66  from the brine mixing tank  26  to the auxiliary tanks  28  and the primary seafood boiler  22  and then to the broth processing system  34 . 
       FIG. 4  is a block diagram depicting the heat exchange system of the present invention  10  wherein heat is scavenged from heat-generating machinery such as the auxiliary tanks  28 , the primary seafood boiler  22  and the broth processing system  34  and transferred to the dryers  30  by means of a warm air manifold  64 . An air return system  32  returns the air from the dryers  30  and returns it to the heat generating machinery. 
       FIG. 5  is a block diagram of the present invention  10  wherein the primary seafood boiler includes paddle wheels  60  and jetted water  16  to agitate the liquid and product  18  therein. Random product testing  68  is performed prior to introduction to the system and foreign substance/chemical testing  70  is performed within the conk tank  14  to assure greater safety of the food product. Quality control in the cooking process includes a plurality of automated tests and overseer devices such as gross weight monitoring  72 , salinity monitoring sensors  74 , product tracking means  84 , timers  88 , rheostats  86  and the like. The shellfish product  18  is moved from the primary seafood boiler  22  via the primary seafood boiler conveyor  92  which has a mesh like belt to move the product  18  to the dryer  30  while letting air pass through. High speed fans  76  above the primary seafood conveyor  92  blow air over the food as it travels therealong to blow away the steam from the shellfish product  18  and cool it off to terminate the cooking process. A plurality of spreader bars  78  and rakes  80  serve to ensure that the seafood product  18  is evenly distributed over the conveyor  92 . Heat is transferred from the primary seafood boiler  22  to the dryer  30  by a hot air manifold  64  and returned thereto for reheating by a hot air recovery &amp; air circulation system  32 . 
       FIG. 6  is a block diagram of the dryer  30  and its related components including conveyor sensors  96  for monitoring how much product  18  is being transferred from the boiler  22  to the dryer  30 . Thermostats and regulators  112  are provided for temperature control and humidity and moisture sensors  94  activate the conveyor rakes  80  to stir the product  18  during drying. Other such options to monitor and regulate the dryer  30  functions include video monitoring  110 , rheostats  86 , air contaminate sensors  108 , air flow controls  106 , and a timer  98  to determine product  18  rotation which activates conveyor causing product  18  to be dumped from the upper level of the chute to the lower level. Further options include a sanitizing system  100 , a collection system  102 , a built-in vacuum system  104 , and video monitoring  110 . 
       FIG. 7  is a front view of the peeler  36  and additional options associated therewith. The stainless steel outer container  112  has an opening  130  at the top for manual unloading by dumping or vacuuming cleaned product  18  therethrough. The opening  130  is also used for the auto-loading device  122 . The spinning blade  128  may be fabricated of a wide variety of materials including stainless steel, aluminum, polymeric composites etc. The motor and power source  116  may be electrical, pneumatic or hydraulic. The screen  114  is constructed of a plain weave, single or double square screen or meshed material. The unloading device is a sectional piece of the screen which opens and allows the screen sweeper  126  to sweep cleaned product into the opening  130  which jets air for extraction of product  18 . The hopper  112  may be mounted on a mobile tilting unit  118  with a control panel  132  for manual dumping or on a stationary stand  120  with legs  121  for use with air induced loading  122  and unloading  124  devices. 
       FIGS. 8A–8C  is a block diagram of the seafood processing system of the present invention comprised of delivery to the conk tank, cleaning the shrimp in a conk tank, boiling the shrimp, drying the shrimp and peeling the shrimp. Anyone of these function can accomplished in whole or in part by the system of the present invention. Delivery of the shrimp to the conk tank  14  can be either manual or automated. In the automated method the shrimp is placed on either a conveyor belt  50  or product lifting unit  143  that either may have a dumping cage  58  forming an integral part therewith. The conk tank  14  is used to clean the seafood product and remove any foreign matter therefrom which may include sensor(s) for determining chemical contaminants. The conk tank  14  may also include apparatus to enhance processing of the seafood, such as water jets  16 , raw product testing  46  dumping cage  58 , paddle wheel  60 , ice guard  62 , random testing of product  68 , and salinity monitoring sensor(s)  74 . Once the seafood product is cleaned, it is moved either manually or mechanically to a boiler. The boiler may be a conventional boiler with lift baskets  142  or conveyor  144  or the boiler system  22  of the present invention. Each of these may incorporate additional apparatus, such as auxiliary tanks  28  and/or hot air manifold  64  providing additional functions. In addition, other processes may extend from the boiling of the seafood product, such as processing the brine solution into a broth  34  or food flavoring  82 . Once boiled the seafood product is moved either manually or mechanically to a drying process. The drying process may include conventional dryer box with screened deck  146 , spiral conveyor dryer  152 ,  154  or stacked conveyor dryer  148 ,  150  with each of these devices having additional apparatus, such as air return system  32 , spreader bars  78 , rakes  80 , product tracking  84 , aerated conveyor belt  90 , conveyor sensors  96 , sanitizing system  100 , collection system  102 , vacuum system  104 , air flow control  106 , air contaminate sensors  108  and video monitoring  110  for enhancing the functionality of the drying system. Once dried the product is transferred either manually or mechanically to a peeling process. The peeling process may include conventional tumbler peeler  135 , peeler  136 , and peeler  36  where each of these may include additional apparatus, such as loading device  122 , screen sweeper  126 , blade  128 , tilting unit  118 , stationary stand  120 , unloading device  124 , hopper  112  and screen access panel  138 . 
       FIG. 9  shows a block diagram of an additional element of the present invention comprising a brine broth processing system  34  wherein brine  24  from the brine mixing tank  26 , auxiliary tanks  28  or salt is added to water and introduced into the aforementioned boilers and under predetermined conditions the broth  40  is moved to storage tank(s)  42  where it is packaged  48  as either a brine broth  34  or spray dried  82  and packaged  48  as a food additive. 
       FIGS. 10A and 10B  is a block diagram showing another element of the present invention comprising a heat recovery system. The system recovers heat from the aforementioned boiler systems and broth system and recycles the heat to the aforementioned boiler systems and/or dryer systems  148 ,  150 ,  152  and  154  and/or peeling devices  36 ,  136 . 
       FIG. 11  is a block diagram showing another element of the present invention comprising processing of the byproduct shells and heads of the seafood process. As previously stated the seafood passes from the conk tank  14  to the boiler system  21  to the dryer  30  and peeler  36 . The byproduct shells and heads are transferred to a product transfer system  38  and packaged for resale. 
     It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above. 
     While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention. 
     Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.