Patent Description:
The invention also relates to a small-scale, variable retention time (VRT) food storage system, which utilises a food product-carrying unit as hereinbefore defined.

VRT food storage systems are used as part of an automated food processing system and typically store food products for varying amounts of time before a packaging stage. The food product can be chilled or frozen while resident in the storage system. The storage system can also act as a buffer as the in-feed of product is decoupled from the out-feed.

<CIT> describes conveying and storage systems, which use a product-carrying tray with longitudinally slotted end members for sliding engagement on guide rails in a conveyer installation or storage unit. Transverse edges of the tray are provided with coupling members for inter-engagement with other like trays also accommodated on the guide rails. The tray is especially suited to accommodating food products within a storage or treatment chamber.

The Tray-Link system, manufactured by Power Food Technology of Site E1, Clane Business Park, Clane, Co. Kildare, Ireland, is an example of a large-scale VRT system, which uses the product-carrying tray as described in <CIT>. The system automatically chills and freezes various products simultaneously on a storage rack, while keeping them separated in layers on the rack. Multiple in-feed conveyers feed trays with various products into the system simultaneously. On the out-feed side, multiple conveyers convey automatically transfer trays with the required chilled/frozen products to the various packing stations on demand. <CIT> discloses a food product-carrying unit according to the preamble of claim <NUM>.

The product-carrying trays are automatically linked together on each layer of the storage rack, which permits any tray to be pushed or pulled from either end of a layer. The system storage capacity can be utilised for production buffering and accumulation. If the out-feed is stopped for any reason, the in-feed continues to accept product. Alternatively, if production is stopped, packing can continue uninterrupted.

The Tray-Link system is computer controlled and is engineered to a high level to ensure a trouble-free working life. However, since the longitudinally slotted end members on the product-carrying trays are suspended on guide rails in a conveyer installation or storage unit, heavy-duty motors are required to push or pull a row of trays through the storage rack. Lubrication of the guide rails is required for smooth running. Thus, the storage rack and trays must be cleaned on a regular basis.

Furthermore, the manufacture and installation of a Tray-Link system is a costly business and would be outside the budget of a small food manufacturing company.

It is an object of the present invention to overcome the disadvantages of the VRT food storage systems hereinbefore described.

Thus, the invention provides a food product-carrying unit for transferring food product from an in-feed section to an out-feed section of a small-scale, variable retention time (VRT) food storage system, the food product-carrying unit comprising a pair of opposing side portions joined by a pair of opposing end portions to form an open rectangular frame section, the side portions having formations thereon, which formations are adapted to reversibly link the food product-carrying unit to corresponding formations on neighbouring food product-carrying units in the food storage system, a wheel mounted at each end of the end portions, the and each wheel having an axle with a plastics wear part, with the wheels being aligned such that, in use, the food product-carrying unit is movable forwards and backwards on the wheels in a straight line through the food storage system, and a wear pad mounted on the and each end portion to the outside of the frame section.

In the context of the current invention the adjective "small-scale" has the meaning of small in scope. Thus, a small-scale, variable retention time (VRT) food storage system would be used by a small food manufacturing company, who is currently producing product manually.

An advantage of the food product-carrying unit in accordance with the invention is that, as it is mounted on a set wheels, it requires less energy to push or pull it, and any neighbouring units attached thereto, through the food storage system.

A further advantage of the set of wheels is that no lubrication is required between the unit and the storage system and therefore the cost of cleaning the storage system is reduced as compared to the prior-art system which uses lubricated rails on which the product-carrying units are suspended and along which the units are pushed and pulled.

A further advantage of the food product-carrying unit in accordance with the invention is that the combination of the set of wheels, with the and each wheel having an axle with plastics wear part, together with the plastics wear pads on the outside of the frame section, means that metal-on-metal contact is eliminated when moving the units in the storage system. This eliminates the danger of metal shaving contamination of the food product in the storage system.

A support member is located within the frame section and is attached thereto, which support member is adapted to receive an insert thereon.

An advantage of the addition of the member to the frame section is that it provides a firm support for the insert.

A further advantage of the frame section and support member combination is that it can accommodate a variety of inserts.

In one embodiment in accordance with the invention, the insert is a drip tray.

An advantage of a drip tray insert is that any food waste, such as juices from a meat product, will be retained in the drip tray, and the drip tray can be cleaned between uses of the food product-carrying unit.

Preferably, a rack for hanging food product above the drip tray is mounted on the frame section.

An advantage of the addition of a rack is that food product can be stored, without it resting on the food product-carrying unit.

Further, preferably, the food product is a pork belly, with the and each pork belly, in use, being laid horizontally on the drip tray or being hung by a hook from the rack.

An advantage of the food product-carrying unit in which the product can be stored both horizontally and then vertically is that it mimics the manual method of storing the pork bellies prior to slicing and packaging. In this method smoked pork bellies are laid horizontally for a day or so and are then hung for another day, before slicing and packaging.

Further, preferably, one or more retaining arms are mounted on the opposing side portions and are upstanding therefrom.

An advantage of the retaining arms is that the pork bellies, when laid horizontally on the drip tray will be retained on the tray, particularly when the food product-carrying unit is being moved within the food storage system.

In a further embodiment in accordance with the invention, the insert is a steel mesh grating.

An advantage of a steel mesh grating insert is that air is free to circulate through the grate and around any food product supported thereon. Efficient air circulation is important where a product is being cooled or heated while being stored.

In a further embodiment in accordance with the invention, the insert is a moulded plastics tray having depressions therein for receipt of individual product units.

An advantage of a moulded plastics tray having depressions therein is that the individual product units will be held in the insert in a stable manner.

Preferably, the individual product units are tubs of ice-cream or the like.

An advantage of holding tubs of ice-cream within depressions in the plastics tray is that it reduces the danger of any tubs falling off the food product-carrying unit.

In another aspect of the invention, there is provided a small-scale, variable retention time (VRT) food storage system, comprising a modular storage rack having a three-dimensional, lattice structure defining a plurality of bays, the and each bay being separated into a plurality of levels, a rail mounted to each side of the and each bay, at each level therein, such that, in use, one or more food product-carrying units, as claimed in Claims <NUM> to <NUM>, are receivable, at an in-feed section to one side of the modular storage rack, onto the rails on a level within a bay, for storage therein.

An advantage of the small-scale, variable retention time (VRT) food storage system in accordance with the invention is that, because of its modular form, the capacity thereof can be increased as the business, employing it, expands.

A further advantage of the storage system according to the invention is that the food product-carrying units sit on the rails in the bays and travel along the rails on the set of wheels, thus, eliminating the requirement for lubrication between the rails and the food product-carrying units.

Preferably, the one or more product-carrying units are removable from an out-feed section on the opposite side of the modular storage rack.

An advantage of having the in-feed section and the out-feed section at opposite sides of the modular storage rack is that food product-carrying units can be added and removed from the rack in an efficient manner.

In a further embodiment in accordance with the invention, the in-feed section and an out-feed section are on the same side of the modular storage rack, such that the and each product-carrying unit is receivable in and removable from the same side of the modular storage rack.

An advantage of this arrangement is that food product-carrying units can be added and removed from the rack by the same handling machinery.

Preferably, a crane is adapted to introduce the and each food product-carrying unit to an in-feed section and to remove the and each food product-carrying unit from the modular storage rack.

An advantage of this arrangement is that the initial cost of the system will be reduced and ongoing maintenance costs.

The invention will be further illustrated by the following description of embodiments thereof, given by way of example only with reference to the accompanying drawings in which:.

Referring to <FIG>, there is illustrated generally at <NUM>, a food product-carrying unit for transferring food product from an in-feed section to an out-feed section of a small-scale, variable retention time (VRT) food storage system in accordance with the invention. The food product-carrying unit <NUM> comprises a pair of opposing side portions <NUM>, <NUM> joined by a pair of opposing end portions <NUM>, <NUM> to form an open rectangular frame section <NUM>. The side portions <NUM>, <NUM> have formations <NUM>, <NUM>; <NUM>, <NUM>, respectively, thereon, which formations <NUM>, <NUM>; <NUM>, <NUM> are adapted to reversibly link the food product-carrying unit <NUM> to corresponding formations on neighbouring food product-carrying units (not shown) in the food storage system. A wheel <NUM>, <NUM> is mounted at ends <NUM>, <NUM>, respectively, of end portion <NUM>. Corresponding wheels <NUM> (only one wheel shown) are mounted at ends <NUM>, <NUM>, respectively, of end portion <NUM>. The and each wheel <NUM>, <NUM>, <NUM> has an axle (not shown) with a plastics wear part (not shown), and the wheels <NUM>, <NUM>, <NUM> are aligned such that, in use, the food product-carrying unit <NUM> is movable forwards and backwards on the wheels <NUM>, <NUM>, <NUM> in a straight line through the food storage system. The food product-carrying unit <NUM> also has a wear pad <NUM>, <NUM>; <NUM> and <NUM> (see <FIG>) mounted on the and each end portion <NUM>, <NUM>, respectively, to outside <NUM> of the frame section <NUM>.

Referring to <FIG>, the food product-carrying unit <NUM> is shown in a plan view. A member, shown generally at <NUM>, consists of two slotted shelves <NUM>, <NUM>, located within the frame section <NUM>, and abutting respective end portions <NUM>, <NUM>. The member <NUM> also includes two ledges <NUM>, <NUM>, which bridge the gap between the slotted shelves <NUM>, <NUM>, with the member <NUM> being adapted to receive an insert thereon. Wear pads <NUM>, <NUM>, <NUM>, <NUM> are all visible in <FIG>.

The formations <NUM>, <NUM> on the side portion <NUM> are offset relative to the formations <NUM>, <NUM> on the side portion <NUM>. This offsetting facilitates the coupling of the food product-carrying units <NUM> together.

Referring to <FIG>, an end elevation of the food product-carrying unit <NUM> is shown. The wheels <NUM>, <NUM> are mounted on the end portion <NUM> in wheel housings <NUM>, <NUM> respectively. The wheels <NUM>, <NUM> are mounted for rotation on axles <NUM>, <NUM>, respectively, and the wheels <NUM>, <NUM> extend below lower surface <NUM> of the food product-carrying unit <NUM>. The wear pads <NUM>, <NUM> are mounted on outside surfaces <NUM>, <NUM>, respectively, of wheel housings <NUM>, <NUM>.

Referring to <FIG>, a side elevation of the food product-carrying unit <NUM> is shown. The wheel <NUM> is mounted within the wheel housing <NUM> and the wheel <NUM> is mounted in a wheel housing <NUM>.

Referring to <FIG>, a second embodiment of the food product-carrying unit <NUM> is shown in perspective. The food product-carrying unit <NUM> of <FIG> has been modified by the addition of an insert in the form of a drip tray <NUM>, which drip tray <NUM> is located within the frame section <NUM>.

A rack for hanging food product above the drip tray <NUM>, shown generally at <NUM>, is mounted on the frame section <NUM>. The rack <NUM> consists of a folded plate section <NUM> defining a plurality of holes <NUM> therein, in which, in use, hooks for hanging food product food product are locatable. Tubular box section supports <NUM>, <NUM> are mounted on the end portion <NUM> and support end <NUM> of the folded plate section <NUM> above the drip tray <NUM>. Similar box section supports <NUM>, <NUM> are mounted on the end portion <NUM> and support end <NUM> of the folded plate section <NUM> above the drip tray <NUM>.

A pair of retaining arms <NUM>, <NUM> is mounted on the side portion <NUM> and a corresponding pair of retaining arms <NUM>, <NUM> is mounted on the side portion <NUM>.

In use pork bellies are laid horizontally on the drip tray for part of their stay in the storage system and are hung from the folded plate section <NUM> for the remainder of their stay in the storage system.

Referring to <FIG>, a third embodiment of the food product-carrying unit <NUM> is shown in perspective. The food product-carrying unit <NUM> of <FIG> has been modified by the addition of an insert in the form of a steel mesh grating <NUM>, which grating <NUM> is located within the frame section <NUM> and rests on the member <NUM>. In use, the steel mesh grating <NUM> facilitates the flow of air around any product supported thereon.

Referring to <FIG>, a fourth embodiment of the food product-carrying unit <NUM> is shown in perspective. The food product-carrying unit <NUM> of <FIG> has been modified by the addition of an insert in the form of a moulded plastics tray <NUM>, which moulded plastics tray <NUM> is located within the frame section <NUM> and rests on the member <NUM> (not shown). Three depressions <NUM>, for receipt of individual product units, such as ice-cream tubs, are formed in the moulded plastics tray <NUM>.

Referring to <FIG>, there is illustrated generally at <NUM>, a small-scale, variable retention time (VRT) food storage system in accordance with the invention. The storage system <NUM> comprises a modular storage rack <NUM> having a three-dimensional, lattice structure defining a plurality of bays <NUM>, the and each bay <NUM> being separated into a plurality of levels <NUM>. A rail <NUM> mounted to each side of the and each bay <NUM>, at each level <NUM> therein, such that, in use, one or more food product-carrying units (not shown) in accordance with the invention, are receivable, at an in-feed section <NUM> to one side <NUM> of the modular storage rack <NUM>, onto the rails <NUM> on a level <NUM> within a bay <NUM>, for storage therein.

Referring to <FIG>, a detailed view of a section of the food storage system of <FIG> is illustrated. The modular storage rack <NUM> has a lattice structure defined by vertical supports <NUM> and horizontal supports <NUM> and diagonal bracing supports <NUM>. Each vertical support <NUM> is mounted on an adjustable foot <NUM> for levelling the modular storage rack <NUM>.

Claim 1:
A food product-carrying unit (<NUM>) for transferring food product from an in-feed section to an out-feed section of a small-scale, variable retention time (VRT) food storage system, the food product-carrying unit (<NUM>) comprising a pair of opposing side portions (<NUM>, <NUM>) joined by a pair of opposing end portions (<NUM>, <NUM>) to form an open rectangular frame section (<NUM>), the side portions (<NUM>, <NUM>) having formations (<NUM>, <NUM>; <NUM>, <NUM>) thereon, which formations (<NUM>, <NUM>; <NUM>, <NUM>) are adapted to reversibly link the food product-carrying unit (<NUM>) to corresponding formations on neighbouring food product-carrying units in the food storage system, a wheel (<NUM>, <NUM>, <NUM>) mounted at each end (<NUM>, <NUM>; <NUM>, <NUM>) of the end portions (<NUM>, <NUM>), the and each wheel (<NUM>, <NUM>, <NUM>) having an axle (<NUM>, <NUM>) with a plastics wear part, with the wheels (<NUM>, <NUM>, <NUM>) being aligned such that, in use, the food product-carrying unit (<NUM>) is movable forwards and backwards on the wheels (<NUM>, <NUM>, <NUM>) in a straight line through the food storage system, a wear pad (<NUM>, <NUM>; <NUM>, <NUM>) mounted on the and each end portion (<NUM>, <NUM>) to the outside of the frame section (<NUM>), and a member (<NUM>) located within the frame section (<NUM>) and attached thereto, which member (<NUM>) is adapted to receive an insert thereon
characterized in that
the insert is in the form of a drip tray (<NUM>), a moulded plastics tray (<NUM>) having depressions (<NUM>) therein for receipt of individual product units or a steel mesh grating.