Patent Description:
The current state of animal nutrition, especially in relation to sectors as important as aquaculture or poultry farming, presents serious problems related to obtaining the proteins necessary to provide a good diet for animals. In this field, an alternative to achieving healthy nutrition is to use insects as a base and/or food supplement. In addition, the use of insects as food brings with it a significant number of environmental, health, social and life benefits, which also makes insect-based nutrition an appropriate solution to solve problems related to human nutrition.

The metamorphosis process of insects is an essential phase in their life cycle. In this phase, insects go from the larval stage to the pupal stage, where the larva is covered with a protective shell and remains in a dormant state, to reach the adult stage after metamorphosis.

During the breeding process, the larvae about to enter the pupal stage are separated from the rest of the larvae and placed in a new container where they complete their transition to the pupal stage and undergo metamorphosis. In some cases, the newly emerged adults attack the other larvae that have not completed metamorphosis, so the number of larvae that transform into adults may be reduced. To avoid this problem, the larvae are separated manually and placed in individual containers to undergo metamorphosis, so adult insects are isolated in their respective container, preventing them from harming the rest of the larvae. This manual process is not productive, so it is generally only applied in aggressive insect species where the decrease in the insect population can be considerably affected by cannibalism, while, in other less aggressive species, the loss of population due to cannibalism is considered acceptable, and all the larvae are treated together in the same container without separation.

Document <CIT> relates to a device for filling sales packages with pharmaceutical products in a solid form, said device comprising a storage container for the pharmaceutical products, a filling station for the targeted filling of sales packages with the pharmaceutical products, transport devices for guiding the sales packages to the filling station and transporting them away from the same, and a rotating transfer drum for separating and transferring the pharmaceutical products in an ordered manner from the storage container to the filling station. Said transfer drum is provided, on the periphery thereof, with a number of cups for respectively receiving a pharmaceutical product, said cups being actively connected to a vacuum chamber located inside the transfer drum, along the path of the cups from the container to the filling station, and to a pressurised chamber located inside the transfer drum, in the region of the filling station. The pressurised chamber is embodied in such a way that it can be deactivated as required or transformed into another vacuum chamber.

The object of the invention is to provide a process and a machine for filling a container with insect larvae, as defined in the claims.

One aspect of the invention relates to a process for filling a container with insect larvae, wherein the container has a plurality of compartments distributed in rows for receiving a larva in each compartment, the process comprising:.

Another aspect of the invention relates to a machine for filling a container with insect larvae, wherein the container has a plurality of compartments distributed in rows for receiving a larva in each compartment, the machine comprising a hopper for receiving the larvae, a roller which is arranged adjacent to the hopper and has lines of openings on its outer surface for adhering a larva at each opening, a vacuum pump for applying a vacuum inside the roller and adhering the larvae to the openings, a conveyor belt for moving the container according to a forward movement direction towards the roller, the container being moved through an area below the roller and the roller being arranged in a transverse position with respect to the forward movement direction of the container, and rotation means for rotating the roller in a manner that is synchronized with the forward movement of the container from a loading position in which the larvae from the hopper are adhered to the openings of the roller to an unloading position in which one of the lines of openings of the roller faces the compartments of one of the rows of the container, such that when the vacuum is removed from the line of openings in the unloading position, the larvae are released, with one larva being arranged in each compartment of the row of the container.

In this way, the larvae are automatically arranged in the compartments of the container, where they undergo metamorphosis individually, thus leaving the newly emerged adults isolated from the rest of the larvae. Cannibalism is thereby avoided and the percentage of larvae that reach the adult stage is efficiently increased.

These and other advantages and features of the invention will become evident in view of the figures and the detailed description of the invention.

The invention relates to a process and a machine for filling a container <NUM> with insect larvae <NUM>, more particularly larvae of Tenebrio molitor (commonly called mealworm).

As observed in detail in <FIG> and <FIG>, the container <NUM> has a plurality of compartments <NUM> distributed in rows <NUM> for receiving a larva <NUM> in each compartment <NUM>.

As shown in the example of <FIG> and <FIG>, the machine comprises a hopper <NUM> for receiving the larvae <NUM>, a roller <NUM> which is arranged adjacent to the hopper <NUM> and has lines <NUM> of openings <NUM> on its outer surface for adhering a larva <NUM> at each opening <NUM>, a vacuum pump (not depicted) for applying a vacuum inside the roller <NUM> and adhering the larvae <NUM> to the openings <NUM>, a conveyor belt <NUM> for moving the container <NUM> according to a forward movement direction A towards the roller <NUM>, the container <NUM> being moved through an area below the roller <NUM> and the roller <NUM> being arranged in a transverse position with respect to the forward movement direction A of the container <NUM>, and rotation means (not depicted) for rotating the roller <NUM> in a manner that is synchronized with the forward movement of the container <NUM> from a loading position in which the larvae <NUM> from the hopper <NUM> are adhered to the openings <NUM> of the roller <NUM> to an unloading position in which one of the lines <NUM> of openings <NUM> of the roller <NUM> faces the compartments <NUM> of one of the rows <NUM> of the container <NUM>, such that when the vacuum is removed from the line <NUM> of openings <NUM> in the unloading position, the larvae <NUM> are released, with one larva <NUM> being arranged in each compartment <NUM> of the row <NUM> of the container <NUM>.

Preferably, the number of compartments <NUM> of a row <NUM> of the container <NUM> coincides with the number of openings <NUM> of a line <NUM> of the roller <NUM>. Depending on production needs, containers <NUM> with a different number of compartments <NUM> can be used.

The roller <NUM> has channels <NUM> inside, each channel <NUM> is in fluid communication with one of the lines <NUM> of openings <NUM>, and one of the ends of the roller <NUM> is rotatably attached to a fixed collector <NUM> having a first sector <NUM> that is in fluid communication with the vacuum pump, such that during the rotation of the roller <NUM> a vacuum is applied to the openings <NUM> of the channels <NUM> that are connected to the first sector <NUM>, with the vacuum being absent in the rest of the openings <NUM>.

The channels <NUM> are arranged on the radial periphery of the roller <NUM> and extend parallel to the axial shaft <NUM> of the roller <NUM>. The channels <NUM> are aligned with the lines <NUM> of openings <NUM> and are equally spaced from one another. Preferably, the roller <NUM> has the same number of lines <NUM> as channels <NUM>, and preferably the number of openings <NUM> in each line <NUM> of the roller <NUM> corresponds to the number of compartments <NUM> in each row <NUM> of the container <NUM>.

The first sector <NUM> has an angular distribution and extends between the loading position, in which the larvae <NUM> are loaded into the hopper <NUM>, and a position immediately preceding the unloading position, in which the larvae <NUM> are released. During the rotation of the roller <NUM>, a vacuum is thereby applied to the openings <NUM> of the roller <NUM> between the loading position and the position immediately preceding the unloading position, and the vacuum is no longer applied to the openings <NUM> in the unloading position.

Preferably, as seen in the example of <FIG>, the fixed collector <NUM> has a second sector <NUM> arranged in the unloading position that is in fluid communication with air injection means (not depicted), such that during the rotation of the roller <NUM>, air is injected into the openings <NUM> of the channel <NUM> that are connected to the second sector <NUM>. An air stream thereby forces the larvae <NUM> to detach from the roller <NUM>, which is preferable, since the larvae <NUM> tend to be adhered to the surface of the roller <NUM>.

Alternatively, the second sector <NUM> is not connected to air injection means, so that during the rotation of the roller <NUM>, a vacuum is not applied to the second sector <NUM>, and the larvae <NUM> are no longer adhered to the openings <NUM> of the roller <NUM>, with the larvae <NUM> being discharged by gravity.

As shown in <FIG>, a first hose <NUM> connects the first sector <NUM> of the fixed collector <NUM> to the vacuum pump, and a second hose <NUM> connects the second sector <NUM> to the air injection means, preferably with a compressed air intake.

The openings <NUM> of the roller have a diameter of between <NUM> and <NUM> and the vacuum pump is configured to apply a vacuum through the openings <NUM> of between <NUM> Pa and700. The larvae <NUM> are thereby adhered to the openings <NUM> but are not sucked through the openings <NUM>.

The conveyor belt <NUM> is arranged in a position below the roller <NUM>, and the roller <NUM> is attached to the frame <NUM> of the machine, the roller <NUM> being arranged in a position above the conveyor belt <NUM>. The roller <NUM> is cantilevered over the conveyor belt <NUM>.

The axial shaft <NUM> of the roller <NUM> is rotatably driven by the rotation means, which are a motor that rotatably drives the axial shaft <NUM>. The conveyor belt <NUM> is driven by another motor, and by means of a control unit the forward movement speed of the conveyor belt <NUM> and the rotation of the roller <NUM> are regulated to sequentially align the lines <NUM> of openings <NUM> of the roller <NUM> with the rows <NUM> of compartments <NUM> of container <NUM> and depositing a larva <NUM> in each compartment <NUM>.

The machine further comprises a first collection tray <NUM> which is arranged adjacent to the roller <NUM> in a position that is between the loading position and a position immediately preceding the unloading position, according to the rotation of the roller <NUM>, to collect by gravity larvae <NUM> that are adhered to the outer surface of the roller <NUM> without being adhered to the openings <NUM>.

The machine further comprises a second collection tray <NUM> which is arranged adjacent to the roller <NUM> in a position below the hopper <NUM> and vertically aligned with the hopper <NUM>, to collect larvae <NUM> that slip through a space between the hopper <NUM> and the roller <NUM>.

The hopper <NUM> and the collection trays <NUM> and <NUM> are arranged adjacent to the roller <NUM> and separated by a distance, said distance being approximately the thickness of a larva to allow rotation of the roller with respect to the hopper <NUM> and the trays <NUM> and <NUM> without damaging the larvae <NUM>.

The hopper <NUM> is arranged on a moving shaft <NUM> to move the hopper <NUM> with respect to the roller <NUM> according to a back-and-forth movement in a transverse direction T with respect to the forward movement direction A (see <FIG> and <FIG>) and distribute the larvae <NUM> on the roller <NUM>. The hopper <NUM> thus oscillates with respect to the roller <NUM>, allowing the larvae <NUM> from the hopper <NUM> to be distributed along the outer surface of the roller <NUM>. The moving shaft <NUM> is attached to the frame <NUM> and supports the hopper <NUM> while allowing back-and-forth movement. The hopper <NUM> is cantilevered over a part of the outer surface of the roller <NUM>.

The first collection tray <NUM> is supported on a first beam <NUM> which is attached to the frame <NUM>. The first collection tray <NUM> is arranged cantilevered over the conveyor belt <NUM> and in a position below a part of the roller <NUM>. The second collection tray <NUM> is supported on a second beam <NUM> which is attached to the frame <NUM>. The second collection tray <NUM> is cantilevered over the conveyor belt <NUM> and in a position below a part of the roller <NUM> and in a position below the hopper <NUM> and vertically aligned with the hopper <NUM>.

The machine further comprises a sensor <NUM> arranged downstream of the roller <NUM> according to the forward movement direction A of the container <NUM>, the rotation of the roller <NUM> being maintained while the sensor <NUM> is active. Preferably, the sensor <NUM> is a limit switch which is arranged on one side of the conveyor belt <NUM> and is configured to contact the container <NUM>.

The conveyor belt <NUM> has guides <NUM> on both sides that guide the containers <NUM> in the forward movement direction A. The sensor <NUM> is arranged on one guide <NUM>, or both guides <NUM>, and downstream of the roller <NUM>.

The machine further comprises a collection drawer <NUM> which is arranged upstream of the roller <NUM> at one end of the machine and in a position below the conveyor belt <NUM>. The drawer <NUM> allows the recovery of larvae <NUM> that may have fallen out of the container <NUM> onto the conveyor belt <NUM>. See <FIG> and <FIG>.

The larvae <NUM> are supplied to the hopper <NUM> automatically through a conveyor belt <NUM> which is arranged in a position above the hopper <NUM>.

Therefore, as shown in <FIG>, the process for filling a container <NUM> with insect larvae <NUM> comprises the following phases:.

Preferably, the vacuum is removed from the line <NUM> of openings <NUM> in the unloading position and an air stream is applied through those openings <NUM> in the unloading position, expelling the larvae <NUM> towards the compartments <NUM> of the container <NUM>.

As shown in <FIG>, the larvae <NUM> from the hopper <NUM> are adhered to the openings <NUM> of the lines <NUM> during the rotation of the roller <NUM> from the loading position to a position immediately before the unloading position. During this travel of the roller <NUM>, from the loading position to the unloading position, some of the channels <NUM> are in fluid communication with the first sector <NUM> of the fixed collector <NUM>, so that all the openings <NUM> associated with said channels <NUM> have a larva <NUM> adhered thereto. When a channel <NUM> reaches the unloading position, it is no longer subjected to a vacuum and enters into fluid communication with the second sector <NUM> of the fixed collector <NUM>, applying an air stream through said channel <NUM> to expel the larvae <NUM> adhered to the openings <NUM> of said channel <NUM> which is in the unloading position, as shown in <FIG>.

Claim 1:
A process for filling a container with insect larvae, wherein the container (<NUM>) has a plurality of compartments (<NUM>) distributed in rows (<NUM>) for receiving a larva (<NUM>) in each compartment (<NUM>), the process comprising:
- supplying the larvae (<NUM>) to a hopper (<NUM>) which is arranged adjacent to a roller (<NUM>) having lines (<NUM>) of openings (<NUM>) on the outer surface thereof for adhering a larva (<NUM>) at each opening (<NUM>),
- applying a vacuum inside the roller (<NUM>) for adhering the larvae (<NUM>) to the openings (<NUM>),
- moving the container (<NUM>) in a forward movement direction (A) towards the roller (<NUM>), the container (<NUM>) being moved through an area below the roller (<NUM>) and the roller (<NUM>) being arranged in a transverse position with respect to the forward movement direction (A),
- rotating the roller (<NUM>) in a manner that is synchronized with the forward movement of the container (<NUM>) from a loading position in which the larvae (<NUM>) from the hopper (<NUM>) are adhered to the openings (<NUM>) of the roller (<NUM>) to an unloading position in which one of the lines (<NUM>) of openings (<NUM>) of the roller (<NUM>) faces the compartments (<NUM>) of one of the rows (<NUM>) of the container (<NUM>), and
- removing the vacuum from the line (<NUM>) of openings (<NUM>) in the unloading position in order to release the larvae (<NUM>), with one larva (<NUM>) being arranged in each compartment (<NUM>) of the row (<NUM>) of the container (<NUM>).