Abstract:
An automated process for cleaning fruit bins, and particularly grape bins, deploys a conveyer system in which bins are simultaneously rinsed on the inside and outside in an inverted position. Two rinse cycles are rapidly completed with the conveyance of the inverted bins through a wash station. The wash station deploys a pivoting U-shaped spray rod inside the bin, below the conveyor track, while the outside is rinsed by a second surrounding inverted U-shaped spray bar that moves transverse to conveyor direction will the bin is stationary inside the wash station. A pivoting L-shaped arm with an integrated conveyor track move the bins on or off the central conveyor, while flipping them 90 degrees. Two such conveyors return the bins to an upright position for use and stacking. The water from a first rinse is optionally screens to remove solids and collected water is then locally treated before using it to rinse subsequent bins. The water used in a second or final rinse is ozonated to kill any bacteria and wild yeast. The accumulated rinse water is optionally ozonated before final discharge from the cleaning system. The system and method improves the quality and efficiency of cleaning fruit bins while minimizing water use.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims the benefit of priority to the US Provisional patent application of the same title, which was filed on Aug. 31, 2010, and having application Ser. No. 61/378,768, which is incorporated herein by reference. 
         [0002]    The present application also claims the benefit of priority to the US Provisional patent application of the same title, which was filed on Mar. 4, 2011, and having application Ser. No. 61/449,251, which is incorporated herein by reference 
     
    
     BACKGROUND OF INVENTION 
       [0003]    The present invention relates to a method and apparatus for cleaning large fruit and grape picking bins with high efficiency. 
         [0004]    Wineries receive grapes in generally square or rectangular half ton or ton capacity picking bins. While only grapes and the juice that inherently leaks from these grapes, should enter the bins, some grapes and juice as well as field debris (leaves, twig and material other than grapes) tends to remain in the bins after dumping to remove bulk of the harvested grapes, at least in part because grape juice is inherently sticky from the high sugar content, and becomes even stickier as water evaporates. Hence, grape and other fruit picking bins will become more contaminated over time if not thoroughly sanitized, as residual grape juice just below the rim readily evaporates leaving a sticky concentrated residue that will attracts insects, that are can be vectors for undesirable spoilage bacteria, and can also harbor wild yeasts. While such yeast and bacteria are not a problem in small quantities from the field, they can rapidly multiply to levels that are more difficult to control if they have the opportunity to do so if the grape bins are not promptly cleaned. 
         [0005]    Thus, it is good harvest practice to clean the bins before refilling with freshly picked grapes. Hence, bins are preferably returned to the field, that is the same or different vineyard for repeated use in a clean condition, as well as cleaned before an initial use at the beginning of the harvest season. 
         [0006]    As the bins may be hauled a long distance from the field to the winery on trucks, it is desirable to also replace the clean and empty bins as quickly as they are emptied, so that the delivery truck can return the same bins to the vineyard for re-filling without delay. 
         [0007]    Accordingly, there is a need to rapidly clean fruit bins, and particularly grape bins, after they are emptied. 
         [0008]    There is a further need that the cleaning be complete and thorough, as well as kill any residual yeast and bacteria on the surface of the bins. 
         [0009]    As water is the primary cleaning agent, it is highly desirable to be as efficient as possible in the use of such water, as it is a major expense for wineries, in particular in the Western United States and in regions with “Mediterranean” climates that do not receive significant summer precipitation to replenish aquifers and water reservoirs. When grape and other fruit juice partially evaporates it can only be removed by scrubbing as well as the mechanical action of high velocity water jets. Scrubbing is difficult to automate, and also consumes rinse water. As high velocity jets consume large quantities of water there is a great need to reduce this use to a minimum. 
         [0010]    Prior methods of automated grape bin cleaning methods are known, but do not keep up with the rate a truck can empty grape bins at an efficient crush pad. 
         [0011]    It is therefore a first object of the present invention to provide a means to rapidly clean grape bins, that is highly effective and hygienic, yet does not waste significant quantities of water, and to do so rapidly with a high level of automation. 
         [0012]    It is therefore a first object of the present invention to provide a means to clean grape bins that is highly effective and hygienic. 
         [0013]    It is another object of the present invention to provide a means to rapidly clean grape bins according to the first object that does not waste significant quantities of water. 
         [0014]    It is a still further object of the present invention to provide a means to rapidly clean grape bins, that is highly effective and hygienic, does not waste significant quantities of water, and to do so rapidly with a high level of automation. 
       SUMMARY OF INVENTION 
       [0015]    In the present invention, the above and other object is achieved by process for washing grape bins comprising the steps of providing a first upright dirty grape bin, providing a washing station having a means to spray water and a means to collect and filter particle form the collected water, inverting the grape bin, disposing the inverting the grape bin in the washing station, providing a first spray of water to at least one of the inside and outside of the inverted grape bin, collecting the water after it drains off of the inverted grape bin and passes through the particle filter, providing a second spray of the water to at least one of the inside and outside of the inverted grape bin after said step of providing a first spray, wherein the water used in the first spray is from the collected water and the water used in the second spray is from a purer source of water than the collected water. 
         [0016]    A second aspect of the invention is characterized by an apparatus and process for washing fruit bins that simultaneously rinses the 4 inside walls and the top and opposing sides while an inverted bin is stationary, wherein the front and back sides are rinsed as the bin is transported in and out of the stationary position used to wash the inside and top. 
         [0017]    A third aspect of the invention is characterized by an apparatus and process for washing fruit bins wherein each fruit bin is inverted to the inverted position by two sequential rotations of about 90 degrees, each 90 degree rotation occurring in an L-shaped pivoting arm. 
         [0018]    A fourth aspect of the invention is characterized by an apparatus and process for washing fruit bins wherein the fruit bin is transported from the first L-shaped pivoting arm to the second L-shaped pivoting upon being rotated 90 degrees by the first L-shaped pivot arm. 
         [0019]    The above and other objects, effects, features, and advantages of the present invention will become more apparent from the following description of the embodiments thereof taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]      FIG. 1  is a schematic diagram illustrating the primary components of the inventive system, with the wash station shown in a side elevation view along the bin transport direction. 
           [0021]      FIG. 2  is a schematic diagram illustrating the primary components of the inventive system, with the wash station shown in a front elevation view transverse to the bin transport direction. 
           [0022]      FIG. 3A  is a plan view of a washing station and conveyor system. 
           [0023]      FIG. 3B  is a side elevation of the washing station and conveyor system of  FIG. 3A . 
           [0024]      FIG. 3C  is a front elevation of the washing station and conveyor system of  FIGS. 3A and 3B . 
           [0025]      FIG. 4  is a perspective view of a wash station portion of the system omitting the bin to show the interior spray pattern. 
           [0026]      FIG. 5  is a plan view of washing station and conveyor system having additional entrance and exit conveys including means for rotating the fruit bins. 
           [0027]      FIG. 6A  is a side elevation of a first and second L-shaped pivoting arm optionally deployed at the exit to the conveyor. 
           [0028]      FIG. 6B  is a plan view of  FIG. 6A . 
           [0029]      FIGS. 7A and 7B  are plan and side elevations views respectively of a first embodiment of an L-shaped pivoting arm deployed in  FIG. 5 ,  6 A and  6 B. 
           [0030]      FIGS. 8A and 8B  are plan and side elevation views respectively the second embodiment of an L-shaped pivoting arm deployed in  FIG. 5 ,  6 A and  6 B. 
           [0031]      FIG. 9A  is a perspective view of a portion of the conveyor system of  FIG. 5  showing the cooperative operation of the first and second embodiments of the L-shaped pivoting arm, whereas  FIG. 9B  is a schematic elevation view at a smaller scale showing the orientation of the bin as received in the first L-shaped pivoting arm from the washing station. 
           [0032]      FIG. 10A  is a perspective view showing the subsequent stage in the movement of the L-shaped pivoting arm for rotating the bin 90 degrees from the inverted orientation in  FIG. 9B , whereas  FIG. 10B  is a schematic elevation view at a smaller scale showing the orientation of the bin during this stage. 
           [0033]      FIG. 11A  is a perspective view showing resulting of completing the prior stage in the movement of the L-shaped pivoting arm for rotating the bin 90 degrees from the inverted orientation in  FIG. 9B , whereas  FIG. 10B  is a schematic elevation view at a smaller scale showing the orientation of the bin upon completing this stage. 
           [0034]      FIG. 12A  is a perspective view showing the subsequent stage in the movement of the L-shaped pivoting arm for rotating the bin 90 degrees from the inverted orientation in  FIG. 9B , whereas  FIG. 10B  is a schematic elevation view at a smaller scale showing the orientation of the bin during this stage. 
           [0035]      FIG. 13  is a perspective view showing resulting of completing the prior stage in the movement of the L-shaped pivoting arm for rotating the bin 90 degrees from the inverted orientation in  FIG. 9B , whereas  FIG. 10B  is a schematic elevation view at a smaller scale showing the orientation of the bin upon completing this stage. 
           [0036]      FIG. 14  is a perspective view showing the subsequent stage in the movement of the L-shaped pivoting arm for rotating the bin 90 degrees from the inverted orientation in  FIG. 9B , whereas  FIG. 10B  is a schematic elevation view at a smaller scale showing the orientation of the bin during this stage. 
           [0037]      FIG. 15A  is a side elevation of a first and second L-shaped pivoting arm optionally deployed at the exit to the conveyor. 
           [0038]      FIG. 15B  is a plan view of  FIG. 6A . 
       
    
    
     DETAILED DESCRIPTION 
       [0039]    Referring to  FIGS. 1 through 15 , wherein like reference numerals refer to like components in the various views, there is illustrated therein a new and improved Fruit and Grape Bin Cleaning Method and Apparatus, generally denominated  100  herein. 
         [0040]    In accordance with the present invention the system includes a wash station  110  having a funnel  112  disposed at the bottom for collecting water that drains off bins  10  as they are washed in an inverted state. Preferably, the bins or tanks  10  disposed in an inverted orientation in the wash station  110  are supported by a rack or a conveyor system  180  or frame on its rim  11 . The funnel  112  has an upper rim  112   a  and terminates at the bottom end with orifice  112   b . It should be appreciated that a wash station  110  will generally have at least one of an integrated side wall to catch overspray and spatter, or a separate external screen. Hence it is desirable, but not essential, that such integrated wall or separate external screen also drain to rim  112   a  of funnel  112 . As grape picking bins, and other fruit picking bins, to which the invention is also applicable to, usually have a 4×4 ft. base, and are usually 2 or 4 ft in height, the dimension of the funnel rim  112   a  should be larger than 4×4 ft. 
         [0041]    A screen  114  is disposed between the upper rim  112   a  and the orifice  112   b  of the funnel  112 . A water storage tank  120  is in fluid communication to receive effluent from funnel orifice  112   b . A pump  130  is configured to remove water from the storage tank  120  and transfer it under pressure via internal manifold  174  and exterior manifolds  172  and  176  to spray nozzles  116  where it emerges as a high velocity jet of water to clean bins  10 . Further, an ozone source or generator  140  provides ozone gas to at least one portal  141  of a water source that is in fluid communication with the nozzles  116 . 
         [0042]    Generally, water from storage tank  120  is pumped to one or more spray nozzles  116  that surround or traverse the inside or outside of the inverted tank or bin  10 . These preferably high velocity water jets or sprays first wash grosser debris and grape residue off of tank  10  which flows downward to drain to funnel  112 . The screen  114  disposed in funnel  112  to capture solid matter so that generally particulate free rinse water flows back to tank  120 . Thus, this first rinse step, as it uses drain water that accumulates in tank  120 , is intended primarily to remove the solid and dried or syrupy grape juice residues. 
         [0043]    In the next step, clean water, such as from source  141  is used in a final rinse. In order to insure that the final rinse also kills if not totally removes yeast and bacteria, the final rinse water is optionally ozonated either in-line from ozone source  140  via conduit or line  143 . The system  100  may deploy a single pump, or multiple pumps depending on the inherent pressure of the water used in the rinse stage, or the need to achieve very high pressure in the initial knock down or debris removal stage. 
         [0044]    Optionally, the water storage tank  120  is also ozonated to insure it does not harbor yeast and bacteria. The quantity of water from the repeated first and final rinses of bins will eventually fill tank  120 , which is periodically drained. Usually such water, even if ozonated is considered waste, so it must be disposed of in a treatment pond  190 . Deploying either the continuous ozonation in tank  120  or subsequent ozonation before emptying to the pond  190  reduces the biological oxygen demand (BOD) in the pond. Any subsequent ozonation optionally takes place in drain line that leads from tank  120  to wastewater pond  190   
         [0045]    More preferably, the tank or bin  10  is rinsed on the outside via the spray nozzles  116  connected to an exterior manifold  172  and internally with spray nozzles connected to an interior manifold  174 . Both the exterior manifold  172  and the interior manifold  174 , are optionally connected to receive water at valve  230  via a common line or pipe  170 . 
         [0046]    The interior manifold  172 , as shown in  FIG. 2 , is preferably an inverted U-shaped bar or pipe, of which the 3 sides of the U define a primary reference plane thereof. Rinse or spray water preferably enters the manifold  172  from the terminal arms that extend from the middle portion of the U-shape to minimize a potential difference in water pressure and flow rate between the spray nozzles  116  distributed on the interior manifold  172 . The spray nozzles  116  are preferably selected and oriented such that the water spray there from fans outward substantially in this primary reference plane so that the collection of spray nozzles provides a substantially planar spray pattern that extends outward from the perimeter of the U-shape. Alternatively the interior manifold  172  can also be in the shape of a “D” rotated 90 degrees counter clockwise, but with the spray nozzles  116  disposed on the rounded upward facing part of the “D”. In this configuration, water can be feed to the curved part of the D from either the center of the flat side, or the opposing terminals of the curved part of the “D”, or just one side of the downward disposed flat portion to provide for a uniformity of water pressure and flow rate from the spray nozzles  116 . 
         [0047]    This resulting water spray pattern  117  ( FIG. 4 ) is not only effective in reaching all portion of the interior tank surface, but by sweeping over the surface in oscillatory fashion, is very efficient at providing an energetic stream that dislodges partially adhered particulate water and concentrated sticky grape juices, yet is highly efficient at doing so with a relatively small quantity of water per bin that is washed. The interior manifold  172 , as shown in  FIG. 2 , is also configured to be disposed between 2 tracks  181  and  182  that together form a conveyor system  180  for transporting the bins  10  into the wash station  110 . Since the width of the interior manifold, W (defined by the length of the bottom portion of the U shape) is less than the separation distance, S, between tracks  181  and  182 , the interior manifold  172  can rotate downward below the common plane of these tracks so that bins  10  can be transported in and out of the wash station  110  by the conveyor system  180 . 
         [0048]    In a more preferred embodiment, As shown in  FIG. 3B , the exterior manifold  174  is also preferably an inverted U-shape, but has nozzles  116  that are inward facing from the side, and downward facing from the top. The Inverted U profile of manifold  174  is dimensioned to straddle over bins  10  after they are transported into the washing station  110 . Such an exterior manifold  174  can be engaged and transported by an overhead track or rail system  160  to be driven over the bin  10  in the transverse direction with respect to the transport direction of the bins  10  on conveyor  180 . Thus, the front and back of the bins are washed by the water emitted from the side facing nozzles, while the top of the bin is rinsed by the downward facing nozzles on manifold  174 . Preferably, water is feed from the terminal end of the side arms of the “U” to provide a more uniform flow rate and water pressure at each of the nozzles  116 . 
         [0049]    Furthermore, it is also preferable that the system  100  also provide 2 pairs of vertically oriented spray bars  176  and  176 ′, each having a vertical sequence of nozzle  116  just inside the entrance and exit portal of the wash station  110  so as to wash the exterior sides of bin  10  that are disposed in a plane that is aligned with the transport direction on conveyor  180 . The first set of spray bar pairs  176  provide a knock down spray as the bin is being transported into the wash station  110 , while the second pair  176 ′ provide a final clean up rinse as the bin  10  is being transported into the wash station  110  by conveyor  180 . 
         [0050]    In contrast, preferably the interior and exterior manifolds sequentially provide both the first or knock down spray, the water from which is directed to tank  120 , and then the final rinse while the bin  10  is stationary in the wash station  110 . The ozonated water from tank  120  can be used for the initial rise of bins  10  on the sides via spray bar pair  176 . 
         [0051]    It should be appreciated that the ozonation of the collected knock down spray and/or rinse water from funnel  112  can occur in tank  120 , as well as when or after tank  120  drains to the treatment pond  190 . 
         [0052]    It should be appreciated that additional screening filters than screen  140  may be placed anywhere in the flow of water from drain  112   b  to nozzles  116  to remove debris that would clog the nozzles or otherwise interfere with efficient operation. The preferred placement and screening capacity of such additional screening filters is likely to depend on the throughput and the nozzle apertures, as well as the rate at which debris settle in tank  120 , as rinse water is preferably drawn from the top of tank  120 . Accordingly, screen  140  may in fact be a series or collection of screens. 
         [0053]    In a more preferred aspect of the present invention, the bins  10  are rotated to and from the inverted position in the washing station by a plurality of L-shaped pivoting arms  500 . A non-limiting example of the use of such pivoting arms  500  with a conveyor system is illustrated in the plan view of  FIG. 5 , in which the central portion  180  provides the washing station  110  described above. However, bins  10  are delivered to conveyor  180  by an entry conveyor  180 ′ and removed from conveyor  180  after washing on the exit conveyor  5180 ′. While this embodiment shows the combination of conveyers  18 ′,  180  and  5180 ′ deployed in a U-shape, the L-shaped pivoting arms, which are described in further detail below, can be used with the central conveyor portion  180  only, provided the bins  10  are at least turned on their side when delivered thereto for washing. 
         [0054]    Each L shaped pivoting arm  500  (also designated as  510 ,  520  and  530  in the alternative embodiments that follow) has a vertical support section  501  and a horizontal support section  502  attached thereto substantially at a right or 90 degree angle, with an axle  503  or similar rotary means provided at the junction of these supports sections. It should be appreciated that the terms horizontal and vertical are relative, as they refer to the orientation of the orthogonally disposed arms in a nominal reference rotation angle of axle  503 . Thus, as the pivot arm rotates about axle  503  to rotate the bin  10  by 90 degrees each arm will alternate between the vertical to horizontal orientations. 
         [0055]    A shown in  FIG. 5 , the bins  10  while optionally received in the upright position, are first flipped 90 degrees (bin  10 ′) on loading to the entrance conveyor  180 ′, and then to an inverted position (bin  10 ″) before entry to the washing station  110  in the process of being transferred from the entry conveyer  180 ′ to the central conveyor  180 . Likewise, after washing, the inverted bins  10 ″ are flipped 180 degrees to the upright position (bin  10 ′″) on removal from the washing station on the central conveyor portion  180  as they are transported to the exit conveyor  5180 ″. Alternatively, the bins  10  may be flipped  180  directly on the central conveyor  180  housing the washing station  110 . It should be appreciated that an accumulating track can be deployed on placed of conveyor  5180 ′, in which the track has free spinning rollers to support the bins, and the entrance of a new clean bin on the track then urges the other bins forward. 
         [0056]    It is particularly preferable that the 180 degree flip of each bin  10  before and after washing is provided by the cooperative action of pair of L-shaped pivoting arms  510  and  520 , each of which rotates the bins  10  by 90 degrees. 
         [0057]    A particularly preferred aspect of such conveyance is illustrated in FIGS.  6  and  9 - 15 . It should first be noted in  FIG. 6  that the first L-shaped  510  is position to receive the bin  10  via the conveyor tracks  181  and  182 . Hence, the vertical support section  501  or horizontal support section  502 , while optionally solid or an open, is preferably pronged in a fork like manner to fit within the conveyer  180 , between tracks  181  and  182 . Further, on rotation of L-shaped pivoting arm  510  counter clockwise 90 degrees about axle  503 , the present vertical support section  501  is configured to fit in nested engagement within the horizontal support section  522  of the second L-shaped pivoting arms  520 . This orientation of L-shaped pivoting arm  520  after rotation is illustrated in  FIGS. 8A and 8B . Thus, without further need for lateral conveyance of the bin, the further rotation of the second L-shaped pivoting arm  520  by 90 degrees in the counter clockwise direction (about axle  523 ) will complete the inversion of the bin  10 , disposing in the vertical support section  521 , which would then be substantially horizontally oriented. 
         [0058]    In more preferred embodiments illustrated in  FIG. 6-14 , the L-shaped pivot arm  520 , has a vertical or horizontal support portion that includes a means to convey the bin laterally after rotation of 90 degrees. Thus, as shown in  FIG. 7A and 7B , vertical support section  521  includes a pair of right  582  and left  581  roller tracks, which are support by a frame  523 . In the particular embodiment of  FIG. 8-13 , the conveyance is accomplished by a pneumatically actuated push rod  526  with initiates the rolling movement of the bin over a series of free spinning rollers  581  and  582 . A frame  524  also supports an actuator rod  525  that propels a push bar  526  that is coupled thereto. The actuator rod  525  drives the push bar  526  in the direction of arrow  527 , so that when it is finally disposed at the phantom position  526 ′ it will urge the bin  10  to roll on the roller tracks  581 / 582 . As the vertical support section  521  preferably has as a support portion  522  consisting of the free spinning roller tracks,  581  and  582 , is preferably pointed slightly downward so that the movement is assisted by gravity. The stroke of the push rod is about the width of the bin  10 . 
         [0059]    Further lateral conveyance of the bin  10  after this 90 degree rotation can be either in the direction of the rotation axis associated with the L-shaped pivoting arm, or transverse. Conveyance in the direction of the rotation axis is appropriate where the central conveyor portion  180  and the entrance  180 ′ or exit conveyors  5180 ′ are disposed at right angle as shown in  FIG. 5 . The contrary of the L-shaped pivoting arm  530  using roller  580  to conveyor the bin transverse to the rotation axle  530  of the L-shaped pivoting arm is shown in  FIGS. 15A and 15B . 
         [0060]    The sequence of the collaborative movement of L-shaped pivoting arm  510  and L-shaped pivoting arm  520  is depicted in more detail in  FIG. 9A-14A , in which the bin is omitted for clarity. However, the bin orientation and position in illustrated in the inset labeled  FIG. 9B-14B  on the correspondingly numbered figure. Thus,  FIG. 9A  corresponds to the orientation of the L-shaped pivoting arms  510  and  520  shown in  FIG. 7 , but in a perspective view. 
         [0061]    In  FIG. 10 ,  510  is rotated 90 degrees counter clockwise to position bin  10  onto horizontal support section  521  of L-shaped pivoting arm  520 .  FIG. 11A  shows the process of L-shaped pivoting arm  520  rotating 90 degrees counter-clockwise, in which it has rotated about 45 degrees.  FIG. 12  the completion of the 90 degree rotation of L-shaped pivoting arm  520 .  FIG. 13  shows the process of L-shaped pivoting arm  520  returning to the position in FIG., in which it has rotated about 45 of 90 degrees clockwise.  FIG. 14  shows the process of L-shaped pivoting arm  510  returning to the position in FIG., in which it has rotated about 45 of 90 degrees clockwise. 
         [0062]      FIGS. 15A and 15B  illustrate an alternative embodiment in which either single or multiple roller tracks or conveyor  580  is disposed vertical support surface  531  on L-shaped pivoting arm  530  to urge bin  10  onto the accumulator track  5180 ′ that is oriented to convey sequential bins in the same direction as they are transported on conveyor system  180  having washing station  110 . 
         [0063]    It should be appreciated that alternative conveyance means to the push rod  526  and roller combination  581 / 582  of  FIG. 7-15  is powered belt, linked plates, chain drive(s) and the like. 
         [0064]    While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be within the spirit and scope of the invention as defined by the appended claims.