Patent Description:
The present invention generally relates to sanitization of food products, and more particularly relates to sanitization of food products using electrostatic dispensing.

Sanitization of food products is of critical importance in the food industry for the promotion of public health, the efficient processing of food products, and to comply with government regulations. Control of microbial pathogen growth, such as, e.g., Escherichia coli (i.e., E. coli), Salmonella, etc., is an important component of food product sanitization. Existing microbial pathogen control techniques involve coating antimicrobial agents onto the food product; however, the existing techniques suffer from inefficient utilization of the antimicrobial agents and/or are not well suited for high volume sanitization of food products.

Accordingly, there exists a need for improved microbial pathogen growth control in the food industry that more efficiently utilizes antimicrobial agents and that is adapted for high volume sanitization of food products.

<CIT> discloses a coating material dispensing system includes a peristaltic voltage block. <CIT> discloses a method for electrostatic spraying liquid and dry material onto foodstuffs by means of spray nozzles.

These needs are met, to a great extent, by an electrostatic dispense system according to claim <NUM>, i.e. comprising a material supply that contains a coating material, and a voltage block configured to be in fluid communication with the material supply such that the voltage block is configured to receive the coating material from the material supply. The electrostatic dispense system further comprises a power supply that is configured to electrostatically charge the coating material received by the voltage block to provide an electrostatically charged coating material. The electrostatic dispense system further comprises a dispense assembly comprising at least one liquid outlet and an internal fluid pathway that is configured to provide fluid communication between the voltage block and the liquid outlet. The dispense assembly being configured to receive the electrostatically charged coating material from the voltage block and to dispense the electrostatically charged coating material from the at least one liquid outlet. The electrostatic dispense system further comprises a conveyor through or by which a food product is configured to be conveyed, the conveyor comprising an electrically conductive material that is electrically grounded and that is electrically isolated from the internal fluid pathway, and a support that supports the at least one liquid outlet at a position adjacent to the conveyor such that the at least one liquid outlet is configured to dispense the electrostatically charged coating material onto the food product. The voltage block is interposed between the material supply and the dispense assembly and is configured to electrically isolate the material supply and the dispense assembly. The electrostatic dispense system further comprises a feeder that feeds the food product to the conveyor, wherein the feeder comprises a scale that is configured to determine a weight of the food product fed to the conveyor; a flow meter that is configured to determine a flowrate of the electrostatically charged coating material dispensed from the at least one liquid outlet; and a controller that is configured to: receive a weight output corresponding to a weight of the food product fed to the conveyor; and to control the flowrate of the electrostatically charged coating material to the at least one liquid outlet based on the weight output.

The coating material can be an antimicrobial material, such as peracetic acid. The voltage block further can include a pump that is configured to continuously pump the electrostatically charged coating material to the at least one liquid outlet at a pressure that atomizes the coating material sprayed from the at least one liquid outlet. The at least one liquid outlet can be at least one airless atomizing spray nozzle. The voltage block can include a reservoir that is configured to contain the coating material received from the material supply, and a shuttle that is configured to selectively electrically isolate the material supply and the dispense assembly.

The electrostatic dispense system can further include a container containing the power supply and the voltage block. The at least one liquid outlet can include a plurality of liquid outlets spaced apart along the support within or over the conveyor. The support can include a cantilever. The position adjacent to the conveyor, at which the support supports the at least one liquid outlet, can be at least <NUM> inches away from the conveyor.

The dispense assembly can further include a manifold that is mounted to the support. The at least one liquid outlet can be mounted to the manifold and can be in fluid communication with the manifold, and the internal fluid pathway can extend within the manifold. The manifold can include an electrically nonconductive material. The manifold can include at least one of a metal and a chemical-resistant polymer. The dispense assembly can further include an electrically nonconductive hose and the internal fluid pathway at least partially extends within the electrically nonconductive hose.

The electrostatic dispense system can further include a sensor that is configured to sense a presence of the food product in the conveyor. The sensor can further be configured to communicate the sensed presence of the food product to a controller that is configured to control dispensing of the electrostatically charged coating material from the at least one liquid outlet in response to the sensed presence of the food product.

The conveyor can be a barrel, a dispense booth, or a conveyor belt.

The support can be electrically nonconductive or electrically conductive and electrically isolated from the conveyor.

The electrostatic dispense system can further include a switch that is configured to selectively ground the support. The support can support a repulsion rod that is configured to be electrostatically charged to a polarity. The power supply can be configured to electrostatically charge the coating material received by the voltage block to provide the electrostatically charged coating material at a polarity. The polarity of the repulsion rod can be the same as the polarity of the electrostatically charged coating material such that the repulsion rod is configured to repel the electrostatically charged coating material.

A method of electrostatically dispensing coating material on a food product is also disclosed. The method includes supplying a coating material from a material supply, and electrically isolating the supplied coating material from the material supply to provide an isolated coating material. The method further includes forming an electrostatically charged coating material from the isolated coating material by electrostatically charging the isolated coating material, and dispensing the electrostatically charged coating material from at least one liquid outlet while the food product is conveyed through or by a conveyor. The method further includes determining a weight of the food product fed to the conveyor. The method further includes receiving a weight output corresponding to the determined weight of the food product fed to the conveyor and a flowrate output corresponding to a flowrate of the electrostatically charged coating material dispensed from the at least one liquid outlet. The method further includes controlling the flowrate of the electrostatically charged coating material dispensed from the at least one liquid outlet based upon the weight output.

Dispensing the electrostatically charged coating material from the at least one liquid outlet can include atomizing the electrostatically charged coating material to form a continuous atomized spray of electrostatically charged coating material.

The method can further include sensing a presence of the food product in the conveyor and controlling the dispensing of the food product based upon the sensed presence of the food product within the controller.

Various additional features and advantages of this invention will become apparent to those of ordinary skill in the art upon review of the following detailed description of the illustrative embodiments taken in conjunction with the accompanying drawings.

The following detailed description is better understood when read in conjunction with the appended drawings. For the purposes of illustration, examples are shown in the drawings; however, the subject matter is not limited to the specific elements and instrumentalities disclosed. In the drawings:.

<FIG> illustrates a schematic overview of an electrostatic dispense system <NUM> according to aspects of the present invention. The electrostatic dispense system <NUM> includes a material supply <NUM> that contains a coating material. The material supply <NUM> may be a container (not shown) and the electrostatic dispense system <NUM> may further include a material supply pump <NUM>, in fluid communication with the material supply <NUM>, that may pump the coating material from the material supply <NUM>. Fluid communication, as used herein, may mean that two or more structures are connected, directly or indirectly, in a manner (e.g., via hoses, valves, conduits, connectors, etc.) that permits fluid to move from one structure to the other structure(s). The coating material may be an antimicrobial agent that may control and/or eliminate microbial growth. The antimicrobial agent may comprise (alone or in combination), for example, chlorine dioxide, acidified sodium chlorite, hypobromous acid, lactic acid, peracetic acid, percarboxylic acid, etc..

The electrostatic dispense system <NUM> further includes a voltage block <NUM> configured to be in fluid communication with the material supply <NUM> and Z configured to receive the coating material from the material supply <NUM>. The electrostatic dispense system <NUM> also includes a power supply <NUM> configured to electrostatically charge the coating material received by the voltage block <NUM> to provide an electrostatically charged coating material. The power supply <NUM> may be adjustable such that the degree to which the coating material is electrostatically charged may be variably controlled.

The electrostatic dispense system <NUM> also includes a dispense assembly <NUM> comprising one or more liquid outlet <NUM> and an internal fluid pathway <NUM> that provides fluid communication between the voltage block <NUM> and the liquid outlet <NUM>. The power supply <NUM> may be operatively connected to the voltage block <NUM> and/or the dispense assembly <NUM> to electrostatically charge the coating material. The dispense assembly <NUM> is configured to receive the electrostatically charged coating material from the voltage block <NUM> and to dispense the electrostatically charged coating material from the liquid outlet <NUM>. The voltage block <NUM><NUM>. is interposed between the material supply <NUM> and the dispense assembly <NUM> and is configured to electrically isolate the material supply <NUM> and the dispense assembly <NUM>. Further, the voltage block <NUM> may include a pump <NUM> that may pump the electrostatically charged coating material to the liquid outlet <NUM>. In embodiments, the pump <NUM> may pump the electrostatically charged coating material at a pressure that atomizes the coating material dispensed or sprayed from the liquid outlet <NUM>. The electrostatically charged coating material are accordingly dispensed continuously from the liquid outlet.

The electrostatic dispense system <NUM> further includes a conveyor <NUM> that a food product may be conveyed by or through. The term "conveyor," as used herein, means any structure that the food product may be conveyed by or through. The conveyor <NUM> may have two ends 152a, 152b through or between which the food product FP may pass. The food product FP may be any food item having exposed surface areas at risk for microbial growth. For example, the food product FP may comprise (alone or in combination) produce such as vegetables, seafood such as fish, grains, and/or meat products such as whole or partial carcasses, and meat trimmings/other materials that may be subsequently ground or otherwise processed into, e.g., ground beef, ground turkey, ground chicken, sausage, ground pork, etc. The food products may also include by-products such as bred animal-derived by-products including carcasses, hides, hoofs, heads, feathers, manure, offal, viscera, bones, fat and meat trimmings, and blood; seafood-derived by-products including skins, bones, oils, and blood; dairy-derived by-products including whey, curd, and milk sludge; vegetable-derived by-products including peelings, stems, seeds, shells, bran, trimmings residues after extraction of oil, starch, juice, and sugars. The conveyor <NUM> may comprise an electrically conductive material that may be electrically grounded and that may be electrically isolated from the internal fluid pathway <NUM>.

The electrostatic dispense system <NUM> further includes a support <NUM> that supports the liquid outlet <NUM> at a position adjacent to the conveyor <NUM> such that the liquid outlet <NUM> is configured to dispense the electrostatically charged coating material onto the food product FP. The position adjacent to the conveyor <NUM>, at which the support <NUM> may support the liquid outlet <NUM>, may be a position above, below, to the side of, or within the conveyor <NUM>. The position adjacent to the conveyor <NUM>, at which the support <NUM> may support the liquid outlet <NUM>, may be a minimum distance from a surface of the conveyor <NUM>. The surface of the conveyor <NUM> may be any surface of the conveyor <NUM> that is nearest to the position adjacent to the conveyor <NUM>. The minimum distance may, for example, be at least <NUM> inches from away from the surface of the conveyor <NUM>. Maintaining the liquid outlet <NUM> the minimum distance away from the surface of the conveyor <NUM> reduces the chances that the electrostatically charged coating material may be prematurely discharged (i.e., discharged before contact with food product FP) by the surface of the conveyor <NUM>. The support <NUM> may include a cantilever that supports the liquid outlet <NUM> at the position adjacent to the conveyor <NUM>.

The liquid outlet <NUM> is configured to dispense the electrostatically charged coating material onto the food product FP. For example, the liquid outlet <NUM> may dispense the electrostatically charged coating material onto the food product FP as the food product FP passes between the two ends 152a, 152b of the conveyor <NUM>. The support <NUM> may be electrically isolated from ground, from the conveyor <NUM>, and/or from the dispense assembly <NUM>. For example, the support <NUM> may be electrically nonconductive. Additionally and/or alternatively, the support <NUM> may comprise conductive materials. For example, the support <NUM> may support a repulsion rod that is electrostatically charged (e.g., via the power supply <NUM>) at a polarity that is a same polarity as the electrostatically charged coating material. The repulsion rod may be electrically isolated from the support <NUM>. The repulsion bar, electrostatically charged at the same polarity as the electrostatically charged coating material, may repel the electrostatically charged coating material, which may direct the coating material away from the repulsion rod and towards the food product FP thereby improving the coating on the food product FP and reducing waste. Features of the repulsion rod and associated structures for implementing operation of the same in accordance with aspects of the invention may be found in <CIT>.

According to aspects of the invention, the electrostatically charged coating material may be dispensed onto the food product FP as the food product FP is conveyed by or through the conveyor <NUM>. By electrostatically charging the coating material, the coating material may be attracted to the food product FP, which is not electrostatically charged, as the food product FP is conveyed by or through the conveyor <NUM>. The attraction between the electrostatically charged coating material and the food product FP may improve the coverage of the coating material on the exterior surfaces of the food product FP, which may improve the efficacy of the antimicrobial control and may improve efficiency by reducing waste/overspray. In addition, in embodiments of the invention the electrostatically charged coating material may be attracted to and coat the electrically conductive material of the conveyor <NUM>, which is grounded. By coating the conveyor <NUM>, a secondary means for coating the food product FP may be provided as a result of incidental contact with the coated conveyor <NUM> as the food product FP is conveyed.

As shown schematically in <FIG>, the voltage block <NUM> may be any voltage block <NUM> capable of electrically isolating the material supply <NUM> and the dispense assembly <NUM>. Providing electrical isolation between the material supply <NUM> and the dispense assembly <NUM> enables electrostatic charging of the coating material dispensed from the dispense assembly <NUM> without necessitating electrical isolation of the entire material supply <NUM> from ground. The voltage block <NUM> may, for example, include a reservoir <NUM> that may contain the coating material received from the material supply <NUM> and a shuttle <NUM> that may selectively electrically isolate the material supply <NUM> and the dispense assembly <NUM>. The shuttle <NUM> may be interposed between the material supply <NUM> and the reservoir <NUM>. The shuttle <NUM> may include a shuttle coupling (e.g., a male or female coupling, not shown) that may connect to a complimentary material supply coupling (e.g., a female or male coupling, not shown) in fluid communication with the material supply <NUM>.

The shuttle <NUM> is movable (e.g., via a rod/piston arrangement, not shown) such that the shuttle coupling may be physically disconnected from the material supply coupling to provide electrical isolation between the material supply <NUM> and structures downstream from the shuttle <NUM>, such as the reservoir <NUM>, the dispense assembly <NUM>, etc. For example, in a first position at which the shuttle coupling is connected to the material supply coupling, coating material may be pumped from the material supply <NUM> via the material supply pump <NUM> to fill the reservoir <NUM> of the voltage block <NUM>. In a second position at which the shuttle <NUM> is moved from the first position to physically disconnect and electrically isolate the shuttle coupling and the material supply coupling, the coating material in the reservoir <NUM> may be electrically isolated from the material supply <NUM> (i.e., from ground) and an electrostatic charge may be applied to the coating material via the power supply <NUM>.

According to embodiments of the invention (not shown), the voltage block <NUM> may include a plurality of shuttles, couplings, reservoirs, pumps, etc. to provide at least one parallel flow arrangement. The parallel flow arrangement may allow for continuous electrical isolation between the material supply <NUM> and the dispense assembly <NUM> and may allow the voltage block <NUM> to be continuously supplied with coating material from one or more parallel supply paths such that the fluid may be dispensed from the liquid outlet <NUM> continuously. Additional and/or alternative features of the voltage block <NUM> in accordance with aspects of the invention are described in <CIT>.

The dispense assembly <NUM> may include a hose <NUM> that may be in fluid communication with the voltage block <NUM> such that the hose <NUM> may receive the coating material from the voltage block <NUM>. The dispense assembly <NUM> may further include a connector <NUM> (e.g., a nozzle block <NUM> or a manifold <NUM> as discussed in detail below) in fluid communication with the hose <NUM> and with the liquid outlet <NUM> and that connects the hose <NUM> and the liquid outlet <NUM>. The connector <NUM> may transfer the coating material from the hose <NUM> to the liquid outlet <NUM>. The liquid outlet <NUM> may be a separate structure, such as a nozzle, that is mounted to (e.g., screwed into) the connector <NUM>. Alternatively, the liquid outlet <NUM> may be formed directly in the connector <NUM>. The liquid outlet <NUM> may be an airless atomizing spray nozzle, such as the atomizing spray nozzle disclosed in <CIT>. Airless atomization of the electrostatically charged coating material via the liquid outlet <NUM> may reduce overspray to improve the transfer efficiency and utilization of the coating material and reduce operating costs.

The internal fluid pathway <NUM> of the dispense assembly <NUM> may extend within/may comprise hollow regions within, e.g., the hose <NUM>, the connector <NUM> (e.g., the manifold <NUM> described below), the liquid outlet <NUM>, and/or any other structures that may form the dispense assembly <NUM>. That is, the hose <NUM>, the connector <NUM>, the liquid outlet <NUM>, and/or any other structures that may form the dispense assembly <NUM> may include internal hollow regions that are fluidly connected and that together may define at least portions of the internal fluid pathway <NUM>. The internal fluid pathway <NUM> may be electrically isolated from ground, and accordingly may electrically isolate the electrostatically charged coating material from ground such that the coating material remains electrostatically charged as the coating material is dispensed from the liquid outlet <NUM>. Any of the structures that the internal fluid pathway <NUM> extends within may comprise nonconductive materials (e.g., plastic, a chemical-resistant polymer such as polyether ether ketone etc.) that may isolate the charged coating material from ground. For example, the hose <NUM>, the connector <NUM>, and/or the liquid outlet <NUM> may each comprise electrically nonconductive materials.

Any of the structures that the internal fluid pathway <NUM> extends within, e.g. the manifold <NUM>, may additionally or alternatively comprise conductive materials (e.g., metal such as stainless steel) and nonconductive materials may be arranged in a manner that electrically isolates the internal fluid pathway <NUM> from ground to maintain the electrostatic charge of the coating material. For example, the internal fluid pathway <NUM> (including the manifold <NUM>) that contacts the coating material may be formed of a corrosive-resistive material such as stainless steel, while remaining electrically isolated from a ground. In embodiments, the hose <NUM> may include a conductive reinforcement layer and may further include nonconductive inner and/or outer layers that provide the electrical isolation. In addition, the connector <NUM> (e.g., the manifold <NUM> described below) and/or the liquid outlet <NUM> may comprise a conductive material and may be supported by nonconductive materials (e.g., nonconductive fittings and/or the support <NUM> may comprise a nonconductive material) that isolate the connector <NUM> and/or the liquid outlet <NUM> from ground. According to aspects of the invention, structures (e.g., the connector <NUM> and/or the liquid outlet <NUM>) of the dispense assembly <NUM> that may comprise conductive materials may be electrostatically charged by the electrostatically charged coating material. The dispense assembly <NUM> may be arranged in a manner to ensure that arcing does not occur from any electrostatically charged structures that comprise the dispense assembly <NUM>. For example, electrostatically charged structures (e.g., the connector <NUM> and/or the liquid outlet <NUM>) may be spaced a predetermined safe distance from each other and from grounded structures to prevent arcing.

The electrostatic dispense system <NUM> further includes a controller <NUM>, e.g., a programmable controller, that may coordinate/automatically control aspects of the electrostatic dispense system <NUM>. The controller <NUM> may be a programmable logic controller (PLC), a microprocessor based controller, personal computer, or another conventional control device capable of carrying out the functions described herein as understood by a person having ordinary skill in the art. For example, the controller <NUM> may control the pumping of the coating material, selective electrostatic isolation of the material supply <NUM> and the voltage block <NUM>, etc. The controller <NUM> may be in electrical communication (e.g., via wired and/or wireless connections) with any of the structures of the electrostatic dispense system <NUM> that may be subject to automatic control, including but not limited to, the material supply pump <NUM>, the voltage block <NUM>, the pump <NUM>, etc. A human machine interface (HMI) device (not shown) may be operatively connected to the controller <NUM> in a known manner. The HMI device may include input devices and controls, such as a keypad, pushbuttons, control knobs, a touch screen, etc., and output devices, such as displays and other visual indicators, that may be used by an operator to control the operation of the controller <NUM> and, thereby, control the operation of the electrostatic dispense system <NUM>. The HMI device may further include an audio output device, such as a speaker, by which an audio alert may be communicated to an operator.

The electrostatic dispense system <NUM> may further include a sensor <NUM> (e.g., a beam sensor and/or encoder(s)), or series of sensors (not shown), that may sense the presence of the food product FP in the conveyor <NUM> and/or may sense a rate of operation of a feeder <NUM>, described below. The sensor <NUM> may communicate the sensed presence of the food product FP to the controller <NUM>, and the controller <NUM> may control dispensing of the electrostatically charged coating material from the liquid outlet <NUM> in response to the sensed presence of the food product FP, as described below. The electrostatic dispense system <NUM> also includes a flow meter <NUM>, which may be provided, for example, within the voltage block <NUM>. The flow meter <NUM> is configured to determine a flowrate of the electrostatically charged coating material pumped to the liquid outlet <NUM> and configured to communicate the determined flowrate to the controller <NUM>, e.g., for automatic feedback control. The electrostatic dispense system <NUM> may further include a valve <NUM> (e.g., a ball valve) that is electrically isolated from ground and that may manually or automatically initiate and/or terminate flow of the coating material to the liquid outlet <NUM>.

The electrostatic dispense system <NUM> further includes the feeder <NUM> that feeds the food product FP to the conveyor <NUM>. The feeder <NUM> may comprise, for example, a conveyor, a rail/trolley system, a chute, other aspects described in detail below, etc. Food product FP may additionally or alternatively be manually fed to the conveyor <NUM>. The feeder <NUM> includes a scale <NUM> that is configured to determine a weight of the food product FP fed to the open end 152a of the conveyor <NUM>. The scale <NUM> may include a load cell. The electrostatic dispense system <NUM> may additionally include other structures (not shown), such as a camera, that may be used to determine or estimate an amount of food product FP fed to the conveyor <NUM>.

The electrostatic dispense system <NUM> may include a container <NUM> that the power supply <NUM> and the voltage block <NUM> are each contained within. The voltage block <NUM> may receive the uncharged coating material from the material supply (not shown) via a material supply hose <NUM>. The container <NUM> may be sealed/wash-down rated to facilitate cleaning thereof and to protect the power supply <NUM> and the voltage block <NUM> from contaminants. The container <NUM> may be mounted on wheels <NUM> that facilitate movement of the voltage block <NUM> and the power supply <NUM>.

<FIG> shows aspects of an exemplary embodiment of the electrostatic dispense system <NUM> in which the connector <NUM> that connects the liquid outlet <NUM> and the hose <NUM> is a nozzle block <NUM>, in accordance with the invention. <FIG> shows a top view of the electrostatic dispense system <NUM>. <FIG> shows a side view of the electrostatic dispense system <NUM> including a partial cut-away view of a conveyor <NUM> of the exemplary embodiment. <FIG> shows a view of the liquid outlet <NUM> and the nozzle block <NUM> of the exemplary embodiment of the electrostatic dispense system <NUM>. <FIG> shows another view of the liquid outlet <NUM> and the nozzle block <NUM> of the exemplary embodiment of the electrostatic dispense system <NUM>. In addition to features of the electrostatic dispense system <NUM> shown in <FIG> and/or the features described below, the electrostatic dispense system <NUM> may also include any of the features of the electrostatic dispense system <NUM> of <FIG> (e.g., the material supply <NUM>, the controller <NUM>, the feeder <NUM>, etc.) that are not mutually exclusive with the features of the electrostatic dispense system <NUM>, and vice versa.

As shown in <FIG>, the conveyor <NUM> of the electrostatic dispense system <NUM> may have a barrel shape and two open ends 252a, 252b. As a result of the two open ends 252a, 252b, the conveyor <NUM> may have an at least partially open interior environment during the dispense operation, which may allow for continuous feeding of the food product FP and may improve the amount of food product FP that may be processed per unit time. The conveyor <NUM> may be mounted to a stand <NUM> that may support and may electrically ground the conveyor <NUM>. In embodiments not shown, the conveyor <NUM> may be mounted to the stand <NUM> at an incline to promote movement of the food product FP between the two open ends 252a, 252b of the conveyor <NUM>. The inclination of the conveyor <NUM> may be variable. For example, the stand <NUM> may include a mechanism (not shown) that permits at least one of the two open ends 252a, 252b to be raised and/or lowered relative to the other of the two open ends 252a, 252b.

The conveyor <NUM> may further be movable relative to the stand <NUM> to further promote movement/agitation of the food product FP through the conveyor <NUM>, which may improve the coverage of the coating material on the food product FP. For example, the electrostatic dispense system <NUM> may include a motor (not shown) and associated transmission mechanism (not shown) that may rotate, vibrate, and/or spin the conveyor <NUM> relative the stand <NUM>. The conveyor <NUM> may include an internal surface having a topography that agitates the food product FP as the food product FP passes between the two open ends 252a, 252b of the conveyor <NUM>. In embodiments not shown, the topography of the internal surface of the conveyor <NUM> may include, for example, baffles, slots, fins, paddles, stops, etc. The topography of the internal surface of the conveyor <NUM> may be automatically varied, for example, internal fins and/or baffles that comprise the topography may be movable within the conveyor <NUM> to vary the topography of the internal surface of the conveyor <NUM>.

The dispense assembly <NUM> of the electrostatic dispense system <NUM> may include a plurality of liquid outlets <NUM> and/or nozzle blocks <NUM> spaced apart along the support <NUM> at the position adjacent to the conveyor <NUM>. The plurality of liquid outlets <NUM> and/or nozzle blocks <NUM> may be spaced a predetermined distance apart from each other to prevent arcing and/or to enhance the distribution of liquid dispensed within the conveyor <NUM>.

<FIG> includes a magnified view of one of the plurality of liquid outlets <NUM> attached to one of the plurality of nozzle blocks <NUM>, and <FIG> shows a view of the liquid outlet <NUM> and nozzle block <NUM> isolated from the electrostatic dispense system <NUM>. The liquid outlet <NUM> may be fluidly connected (e.g., via a nozzle nut) to the nozzle block <NUM>. In embodiments not shown, a plurality of liquid outlets <NUM> may be fluidly connected to a single nozzle block. The nozzle block <NUM> may include, e.g., two openings 249a, 249b that may be in fluid communication with the hose <NUM> of the dispense assembly <NUM> to supply the nozzle block <NUM> and the liquid outlet <NUM> with the electrostatically charged coating material from the voltage block <NUM>. In embodiments not shown, the nozzle block <NUM> may include only one opening in fluid communication with the hose <NUM> such that the nozzle block <NUM> forms a dead head including a terminal liquid outlet <NUM>, at which the dispense assembly <NUM> terminates.

The nozzle block <NUM> may further include a fixture <NUM> that connects the nozzle block <NUM> to the support <NUM>. The fixture <NUM> may allow selective positional manipulation of the nozzle block <NUM> relative to the support <NUM>, which may accordingly permit manipulation of the dispense or spray direction of the liquid outlet <NUM>. The fixture <NUM> may include, for example, a through hole 214a extending through the nozzle block <NUM>. The support <NUM> may extend through the through hole 214a to mount the nozzle block <NUM> to the support <NUM>. The fixture <NUM> may also include a fastener 214b, such as a hex bolt, that may fasten the nozzle block <NUM> to the support <NUM> and may selectively lock the nozzle block <NUM> in one or more radial positions on the support <NUM> to control the dispense or spray direction of the liquid outlet <NUM>. In embodiments not shown, the fixture <NUM> may automatically be movable to vary the dispense or spray direction during operation of the electrostatic dispense system <NUM>.

The electrostatic dispense system <NUM> may further include a switch <NUM> or disconnect that may selectively electrically ground the support <NUM> when the electrostatic dispense system <NUM> is not in use. By selectively grounding the support <NUM>, any electrostatic charge that may have built during use of the electrostatic dispense system <NUM> may be safely discharged to prevent injury to a user that may contact the support <NUM>. In embodiments not shown, switches/disconnects may be provided to selectively discharge any structures of the electrostatic dispense system <NUM> that may build charge during operation of the electrostatic dispense system <NUM> to improve the safety of the electrostatic dispense system <NUM>.

<FIG> shows aspects of another exemplary embodiment of the electrostatic dispense system <NUM> in which the connector <NUM> that connects the liquid outlet <NUM> and the hose <NUM> is a manifold <NUM>, in accordance with the invention. <FIG> shows a top view of the electrostatic dispense system <NUM>. <FIG> shows a side view of the electrostatic dispense system <NUM> including a partial cut-away view of a conveyor <NUM> of the exemplary embodiment. <FIG> shows a view of the manifold <NUM> including a plurality of liquid outlets 142a-142j. In addition to features of the electrostatic dispense system <NUM> shown in <FIG> and/or the features described below, the electrostatic dispense system <NUM> may also include any of the features of the electrostatic dispense systems <NUM> (e.g., the material supply <NUM>, the controller <NUM>, the feeder <NUM>, etc.) and/or <NUM> (e.g., the switch <NUM>) that are not mutually exclusive with the features of the electrostatic dispense system <NUM>, and vice versa.

As shown in <FIG>, the conveyor <NUM> of the electrostatic dispense system <NUM> may have a barrel shape and two open ends 352a, 352b. As a result of the two open ends 352a, 352b, the conveyor <NUM> may have an at least partially open interior environment during the dispense operation, which may allow for continuous feeding of the food product FP and may improve the amount of food product FP that may be processed per unit time. The conveyor <NUM> may be mounted to a stand <NUM> that may support and may electrically ground the conveyor <NUM>. In embodiments not shown, the conveyor <NUM> may be mounted to the stand <NUM> at an incline to promote movement of the food product FP between the two open ends 352a, 352b of the conveyor <NUM>. The inclination of the conveyor <NUM> may be variable. For example, the stand <NUM> may include a mechanism (not shown) that permits at least one of the two open ends 352a, 352b to be raised and/or lowered relative to the other of the two open ends 352a, 352b.

The conveyor <NUM> may further be movable relative to the stand <NUM> to further promote movement/agitation of the food product FP through the conveyor <NUM>, which may improve the coverage of the coating material on the food product FP. For example, the electrostatic dispense system <NUM> may include a motor (not shown) and associated transmission mechanism (not shown) that may rotate, vibrate, and/or spin the conveyor <NUM> relative the stand <NUM>. The conveyor <NUM> may include an internal surface having a topography that agitates the food product FP as the food product FP passes between the two open ends 352a, 352b of the conveyor <NUM>. In embodiments not shown, the topography of the internal surface of the conveyor <NUM> may include, for example, baffles, slots, fins, paddles, stops, etc. The topography of the internal surface of the conveyor <NUM> may be automatically varied, for example, internal fins and/or baffles that comprise the topography may be movable within the conveyor <NUM> to vary the topography of the internal surface of the conveyor <NUM>.

The dispense assembly <NUM> of the electrostatic dispense system <NUM> may include the manifold <NUM> having the plurality of liquid outlets 142a-142j spaced apart along the manifold <NUM> at the position adjacent to the conveyor <NUM>. The plurality of liquid outlets 142a-142j may be spaced a predetermined distance apart from each other to prevent arcing and/or to enhance the distribution of liquid dispensed within the conveyor <NUM>. The plurality of liquid outlets 142a-142j may be airless atomizing spray nozzles. In addition, the support <NUM> may include a cantilever that supports the manifold <NUM>.

The plurality of liquid outlets 142a-142j may be fluidly connected to the manifold <NUM>. The manifold <NUM> may include, e.g., two conduits 348a, 348b that may be in fluid communication with the hose <NUM> of the dispense assembly <NUM> and with the plurality of liquid outlets 142a-142j. The two conduits 348a, 348b may be supplied with coating material by the same system (e.g., including the material supply <NUM>, the voltage block <NUM>, the hose <NUM>, etc.). Alternatively, the conduits 348a, 348b may be supplied with coating material by two separate systems, each including a material supply <NUM>, voltage block <NUM>, a hose <NUM>, etc. By supplying the two conduits 348a, 348b with coating material separately, the flow rate of coating material through each conduit 348a, 348b may be improved to enable, for example, atomization at the plurality of liquid outlets 142a-142j. The manifold <NUM> may include a hollow tube <NUM> that the conduits 348a, 348b extend within and the plurality of liquid outlets 142a-142j may be screwed into. The conduits 348a, 348b may supply the plurality of liquid outlets 142a-142j with the electrostatically charged coating material from the voltage block <NUM>. The conduits 348a, 348b may be a part of the internal fluid pathway <NUM> and may be electrically isolated from ground, and accordingly may electrically isolate the electrostatically charged coating material from ground such that the coating material remains electrostatically charged as the coating material is dispensed from the liquid outlet <NUM>. The manifold <NUM>, including the conduits 348a, 348b and/or the hollow tube <NUM>, may comprise nonconductive materials (e.g., plastic, a chemical-resistant polymer such as polyether ether ketone etc.) that may isolate the charged coating material from ground. In embodiments, the conduits 348a, 348b may be PVC pipes. The manifold <NUM>, conduits 348a, 348b and/or the hollow tube <NUM>, may additionally comprise conductive materials (e.g., metal) and nonconductive materials may be arranged in a manner that electrically isolates interior of the conduits 348a, 348b from ground to maintain the electrostatic charge of the coating material. For example, the conduits 348a, 348b may include a conductive reinforcement layer and may further include nonconductive inner and/or outer layers that provide the electrical isolation. For example, the conduits 348a, 348b may comprise a conductive material and may be supported by nonconductive materials (e.g., nonconductive fittings and/or the hollow tube <NUM> may comprise a nonconductive material) that isolate the conduits 348a, 348b and/or the liquid outlet <NUM> from ground.

<FIG> show aspects of another exemplary embodiment of the electrostatic dispense system <NUM> having a dispense booth in accordance with aspects of the invention. <FIG> shows a side view of the electrostatic dispense system <NUM> including a partial cut-away view of the conveyor <NUM>. <FIG> shows another side view of the electrostatic dispense system <NUM>. In addition to features of the electrostatic dispense system <NUM> shown in <FIG> and/or described below, the electrostatic dispense system <NUM> may also include any of the features of the electrostatic dispense systems <NUM> (e.g., the material supply <NUM>, the container <NUM>, the controller <NUM>, etc.), <NUM>, and <NUM> that are not mutually exclusive with the features of the electrostatic dispense system <NUM>, and vice versa.

As shown in <FIG>, the conveyor <NUM> of the electrostatic dispense system <NUM> may be a dispense booth with two open ends 452a, 452b. As a result of the two open ends 452a, 452b, the conveyor <NUM> may have an at least partially open interior environment during the dispense operation, which may allow for continuous feeding of the food product FP and may improve the amount of food product FP that may be processed per unit time. The conveyor <NUM> may include a sloped floor <NUM> such that excess coating material may be funneled to a drain (not shown) for collection and/or disposal. The dispense assembly <NUM> may include first and second manifolds 349a, 349b respectively mounted in a vertical orientation on first and second supports 160a, 160b. The first and second manifolds 349a, 349b may each include the features of the manifold <NUM>, discussed above. The first and second manifolds 349a, 349b may be respectively mounted on the first and second supports 160a, 160b on both sides of the conveyor <NUM> to dispense the fluid onto the food product FP from both sides. The first and second supports 160a, 160b may include a cantilever. Further, the first and second supports 160a, 160b may support a repulsion rod or bar, as described above. The repulsion rod or bar may be electrically isolated from the support <NUM>.

The electrostatic dispense system <NUM> may include the container <NUM>, having the voltage block <NUM> and the power supply <NUM> contained therein. The container <NUM> may be provided adjacent to the conveyor <NUM> and may supply the electrostatic coating material to the hose <NUM> of the dispense assembly <NUM>.

The electrostatic dispense system <NUM> may include a feeder <NUM> that extends through the two open ends 452a, 452b of the conveyor <NUM>. The feeder <NUM> may, for example, include a motor operatively connected to a drive system <NUM> (having any of, e.g., a rail, a belt, a chain, etc.). The feeder <NUM> may further include a carriage <NUM> having a hook <NUM> that extends from the carriage <NUM>. The carriage <NUM> may be slideably connected to the drive system <NUM> and may be conveyed along the drive system <NUM> through the two open ends 452a, 452b of the conveyor <NUM>. The hook <NUM> may hold the food product FP suspended from the drive system <NUM>. Accordingly, the food product FP may be conveyed and fed through the two opens ends 452a, 452b of the conveyor <NUM> as the electrostatic coating material is dispensed onto the food product FP via the dispense assembly <NUM>, which may enable the coating of larger food products such as whole or half carcasses. The sensor <NUM> may be mounted within the conveyor <NUM> on the support <NUM> and may detect that the food product FP is conveyed through the conveyor <NUM>. The controller <NUM> may control dispensing such that the electrostatically charged coating material is only dispensed upon a sensing (via the sensor <NUM>) of the food product FP within the conveyor <NUM>.

<FIG> shows aspects of another exemplary embodiment of the electrostatic dispense system <NUM> having a conveyor belt in accordance with aspects of the invention. In addition to features of the electrostatic dispense system <NUM> shown in <FIG> and/or described below, the electrostatic dispense system <NUM> may also include any of the features of the electrostatic dispense systems <NUM> (e.g., the material supply <NUM>, the container <NUM>, the controller <NUM>, etc.), <NUM>, <NUM>, and <NUM> that are not mutually exclusive with the features of the electrostatic dispense system <NUM>, and vice versa.

As shown in <FIG>, the conveyor <NUM> of the electrostatic dispense system <NUM> may be a flat conveyor belt that may receive a food product FP thereon and convey the food product forwards and/or backwards along a conveying direction of the conveyor <NUM>. The electrostatic dispense system <NUM> may include the manifold <NUM> mounted above the conveyor <NUM> and extending in a direction perpendicular to the conveying direction of the conveyor <NUM>. The manifold <NUM> may be mounted above the conveyor <NUM> via first and second supports 160a, 160b provided on both sides of the conveyor <NUM>. The first and second supports 160a, 160b may include a cantilever. The electrostatic dispense system <NUM> may include the container <NUM>, having the voltage block <NUM> and the power supply <NUM> contained therein. The container <NUM> may be provided adjacent to the conveyor <NUM> and may supply the electrostatic coating material to the hose <NUM> and from the hose <NUM> to the manifold <NUM> for dispensing on the food product
FP.

<FIG> shows aspects of another exemplary embodiment of the electrostatic dispense system <NUM> having an overhead conveyor <NUM> in accordance with aspects of the invention. In addition to features of the electrostatic dispense system <NUM> shown in <FIG> and/or described below, the electrostatic dispense system <NUM> may also include any of the features of the electrostatic dispense systems <NUM> (e.g., the material supply <NUM>, the container <NUM>, the controller <NUM>, etc.), <NUM>, <NUM>, <NUM>, and <NUM> that are not mutually exclusive with the features of the electrostatic dispense system <NUM>, and vice versa.

As shown in <FIG>, the conveyor <NUM> of the electrostatic dispense system <NUM> may be an overhead conveyor <NUM>. The electrostatic dispense system <NUM> may include the manifold <NUM> mounted below the conveyor <NUM> and extending in a direction parallel to a conveying direction of the conveyor <NUM>. The manifold <NUM> may be mounted below the conveyor <NUM> via first and second supports 160a, 160b that stand to the side of the conveyor <NUM>. The first and second supports 160a, 160b may include a cantilever. The electrostatic dispense system <NUM> may include the container <NUM>, having the voltage block <NUM> and the power supply <NUM> contained therein. The container <NUM> may be provided adjacent to the conveyor <NUM> and may supply the electrostatic coating material to the hose <NUM> and from the hose <NUM> to the manifold <NUM> for dispensing on the food product FP.

The overhead conveyor <NUM> may include a motor operatively connected to a drive system <NUM> (having any of, e.g., a rail, a belt, a chain, etc.). The overhead conveyor <NUM> may further include a plurality of carriages 694a-694e, each having a respective hook 696a-696e that extend therefrom and that may hold food product FP thereon. The plurality of carriages 694a-694e may be slideably connected to the drive system <NUM> and may be conveyed along the conveying direction and above the manifold <NUM> via the drive system <NUM>.

<FIG> shows aspects of another exemplary embodiment of the electrostatic dispense system <NUM> having a chain-on-edge conveyor <NUM> in accordance with aspects of the invention. In addition to features of the electrostatic dispense system <NUM> shown in <FIG> and/or described below, the electrostatic dispense system <NUM> may also include any of the features of the electrostatic dispense systems <NUM> (e.g., the material supply <NUM>, the container <NUM>, the controller <NUM>, etc.), <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> that are not mutually exclusive with the features of the electrostatic dispense system <NUM>, and vice versa.

As shown in <FIG>, the conveyor <NUM> of the electrostatic dispense system <NUM> may be a chain-on-edge conveyor <NUM>. The electrostatic dispense system <NUM> may include the manifold <NUM> mounted above the conveyor <NUM> and extending in a direction parallel to a conveying direction of the conveyor <NUM>. The manifold <NUM> may be mounted above the conveyor <NUM> via a support <NUM> that stands to the side of the conveyor <NUM>. The support <NUM> may include a cantilever. The electrostatic dispense system <NUM> may include the container <NUM>, having the voltage block <NUM> and the power supply <NUM> contained therein. The container <NUM> may be provided adjacent to the conveyor <NUM> and may supply the electrostatic coating material to the hose <NUM> and from the hose <NUM> to the manifold <NUM> for dispensing on the food product FP.

The chain-on-edge conveyor <NUM> may include a motor operatively connected to a drive system <NUM> (having any of, e.g., a rail, a belt, a chain, etc.). The chain-on-edge conveyor <NUM> may further include a plurality of stakes <NUM> that extend vertically from the drive system <NUM> and that may hold food product FP thereon. The plurality of stakes <NUM> may be slideably connected to the drive system <NUM> and may be conveyed along the conveying direction and below the manifold <NUM> via the drive system <NUM>.

<FIG> shows an exemplary process <NUM> of electrostatically dispensing onto a food product FP. The process <NUM> may be used with any of the embodiments of the electrostatic dispense system discussed above, and aspects of the process <NUM> may be automatically implemented by the controller <NUM>. At step <NUM> of the process <NUM>, the coating material is supplied from the material supply <NUM> to the voltage block <NUM>. For example, the coating material may be pumped from the material supply <NUM> via the material supply pump <NUM>.

At step <NUM>, the process <NUM> includes electrically isolating the supplied coting material from the material supply <NUM> to provide an isolated coating material. For example, the supplied coating material may be stored in the reservoir <NUM> of the voltage block <NUM> and may thereafter be electrically isolated from the material supply <NUM> via movement of the shuttle <NUM>. After forming the isolated coating material, step <NUM> includes forming an electrostatically charged coating material from the isolated coating material by electrostatically charging the isolated coating material. For example, the isolated coating material may be electrostatically charged by the power supply <NUM> in the reservoir <NUM> of the voltage block <NUM> and/or in the internal fluid pathway <NUM>.

At step <NUM>, food product FP may be conveyed through or by the conveyor (e.g., the conveyor <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>) and the electrostatically charged coating material may be pumped to at least one liquid outlet <NUM> to dispense the electrostatically charged coating material onto the food product FP. The electrostatically charged coating material may be dispensed continuously. In embodiments, the liquid outlet <NUM> may be a spray nozzle and the pump <NUM> may be controlled to form an atomized spray of the electrostatically charged coating material to coat the food product FP. The pumping of the electrostatically charged coating material may be initiated by a user manually, or automatically via the controller <NUM>. For example, the pumping of the electrostatically charged coating material may be initiated by the controller <NUM> in response to a sensed presence of the food product FP from the sensor <NUM>. In addition, the controller <NUM> automatically controls the flowrate of the coating material pumped to the liquid outlet The controller <NUM> receives a weight output (e.g., an electrical output from the feeder <NUM> representing weight of the food product FP as measured by the scale <NUM>) corresponding to the weight of the food product FP fed to the conveyor. The controller <NUM> may automatically control operation of the pump <NUM> (e.g., by varying power applied to the pump <NUM> to control the pump speed) in response to the received weight output. The controller <NUM> controls the flowrate of the electrostatically charged coating materials to the liquid outlet <NUM> based on the weight output. The controller <NUM> further receives a flowrate output (e.g., from the flow meter <NUM>) corresponding to the flowrate of the electrostatically charged coating material pumped to the liquid outlet <NUM> for feedback control. For example, the controller <NUM> may include stored target flowrates for the electrostatically charged coating material for various weights/quantities of food product FP, and may iteratively adjust the pump <NUM> until the flow meter <NUM> indicates that the target flowrate has been achieved.

Step <NUM> further includes dispensing the electrostatically charged coating material on the food product FP, while the food product FP is conveyed through or by the conveyor. In embodiments, an atomized spray of electrostatically charged coating material may be sprayed onto the food product FP. Accordingly, the electrostatically charged coating material may be dispensed onto the food product FP as the food product FP passes through or between the two ends of the conveyor. By electrostatically charging the coating material, the coating material may be attracted to the food product FP, which is not electrostatically charged, as the food product FP is conveyed through or by the conveyor. The attraction between the electrostatically charged coating material and the food product FP may improve the coverage of the coating material on the exterior surfaces of the food product FP, which may improve the efficacy of the antimicrobial control and may improve efficiency by reducing waste.

Claim 1:
An electrostatic dispense system (<NUM>), comprising:
a material supply (<NUM>) that contains a coating material;
a voltage block (<NUM>) configured to be in fluid communication with the material supply (<NUM>) such that the voltage block (<NUM>) is configured to receive the coating material from the material supply (<NUM>),
a power supply (<NUM>) that is configured to electrostatically charge the coating material received by the voltage block (<NUM>) to provide an electrostatically charged coating material;
a dispense assembly (<NUM>) comprising at least one liquid outlet (<NUM>) and an internal fluid pathway (<NUM>) that is configured to provide fluid communication between the voltage block (<NUM>) and the liquid outlet (<NUM>), the dispense assembly (<NUM>) being configured to receive the electrostatically charged coating material from the voltage block (<NUM>) and to dispense the electrostatically charged coating material from the at least one liquid outlet (<NUM>);
a conveyor (<NUM>) through or by which a food product is configured to be conveyed; and
a support (<NUM>) that supports the at least one liquid outlet (<NUM>) at a position adjacent to the conveyor (<NUM>) such that the at least one liquid outlet (<NUM>) is configured to dispense the electrostatically charged coating material onto the food product,
wherein the voltage block (<NUM>) is interposed between the material supply (<NUM>) and the dispense assembly (<NUM>) and is configured to electrically isolate, , the material supply and the dispense assembly (<NUM>);
wherein the electrostatic dispense system (<NUM>) comprises:
a feeder (<NUM>) that feeds the food product to the conveyor (<NUM>), wherein the feeder (<NUM>) comprises a scale (<NUM>) that is configured to determine a weight of the food product fed to the conveyor (<NUM>);
a flow meter (<NUM>) that is configured to determine a flowrate of the electrostatically charged coating material dispensed from the at least one liquid outlet (<NUM>); and
a controller (<NUM>) that is configured to:
receive a weight output corresponding to a weight of the food product fed to the conveyor (<NUM>); and
control the flowrate of the electrostatically charged coating material to the at least one liquid outlet (<NUM>) based on the weight output.