Apparatus for manufacturing biodegradable food service article and method

Abstract

An apparatus and method manufactures biodegradable food dishes and the like using a slurry of food starch and limestone which is formed and heated in a press into a shape of a food dish or food container or the like. The formed dishes or containers are removed from the press and trimmed in a trimming station, after which a lamination station laminates a biodegradable film onto food contacting surfaces of the food dish or the like. An optional step of applying a wax coating to a rear surface of the food dish or the like is provided. The now completed food dish or food container is provided to a packaging apparatus for stacking and packaging.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to an apparatus and method for manufacturing biodegradable food service products, and in particular to an apparatus for forming, shaping, coating, and packaging of biodegradable food dishes, food containers and the like.

2. Description of the Related Art

Disposable food dishes and food service containers are increasingly being used in today's society. The food dishes and food containers are generally used once and then disposed of by the user. Such disposable food service products represent a high volume of waste to be disposed of, filling waste disposal sites at an ever increasing pace. The disposable food service dishes and containers are typically formed of plastic polymer materials, such as polystyrene or other plastic, which does not biodegrade significantly in the environment and which is formed of petroleum products. Petroleum products are a non-renewable resource that also increase dependence on imports of foreign oil.

Food service products may also be formed of paper. However, such paper is frequently coated with a plastic coating, making it resistant to biodegrading.

It would be a benefit if disposable food dishes were formed of a biodegradable material, especially if such material is a renewal resource.

The manufacture of such food service items should be as efficient as possible in order to provide reliable, low cost production at competitive pricing.

SUMMARY OF THE INVENTION

The present invention provides a method and apparatus for manufacture of biodegradable food dishes and food containers. In particular, the present apparatus and method utilize a slurry of simple, abundant and renewable materials, such as food starch and limestone, from which foam-like food dishes and food service containers are formed using high temperature and high pressure presses. The slurry is molded into shape and once molded, the raw molded dishes and containers are forwarded to a further station for trimming. After being trimmed, the dishes, containers or other products are transferred to yet another station for coating the food contacting surfaces with a biodegradable film. An optional further step provides a wax coating to the surface of the plate, dish or food container opposite the film. Lastly, a module stacks and packages the food containers or dishes for distribution to a user. The resulting food service product is strong, light, attractive and biodegradable.

The present food service product forming apparatus is a modular system that permits independent operation of the modules. Each module has a molding, trimming and coating apparatus. The outputs of a plurality of the module are fed to a single conveyor where the products are provided with a wax coating, inspected, stacked and packaged. The modules can all be operated simultaneously or one or more of the modules can be shut down for service, for example, while the other modules remain in operation feeding product to the conveyor. Life of the manufacturing apparatus is increased over earlier devices, product quality is improved, servicing and maintenance is reduced, and machine operation is more precise.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an apparatus for manufacture of biodegradable food dishes and packages;

FIG. 2 is a schematic diagram of the apparatus according to the present invention;

FIG. 3 is perspective view of the press portion of the present apparatus;

FIG. 4 is a perspective view into the mold set plates of the press;

FIG. 5 is a front elevational view of an air supply for the present press;

FIG. 6 is a perspective view of an air supply inlet and control;

FIG. 7 is a perspective view of further air supply controls for the press;

FIG. 8 is a front view of air supply accumulators for the press;

FIG. 9 is front view of a cavity pump and slurry unit for the press;

FIG. 10 is a front view of a lower transfer unit for transferring the molded dishes;

FIG. 11 is an end perspective view of a dollop dolly;

FIG. 12 is a perspective view of an arrangement of suction cups for removing the molded dishes from the molds;

FIG. 13 is an enlarged view of one set of the suction cups of FIG. 12;

FIG. 14 is a top perspective view of the upper transfer assembly of the present apparatus;

FIG. 15 is schematic plan view of a mold for the present apparatus showing a removal sequence;

FIG. 16 is a bottom perspective view of the upper transfer assembly of FIG. 14;

FIG. 17 is a top perspective view into a lamination chamber of the present apparatus;

FIG. 18 is a flow chart of the method carried out according to the present invention;

FIG. 19 is a side view of one embodiment of a stacker apparatus at an end of the conveyor for stacking the food service articles;

FIGS. 20a and 20b are a top plan view and an end view, respectively, of a three way stacker for stacking the food service articles;

FIG. 21 is a floor plan of a factory layout according to the present invention;

FIG. 22 is top plan view of a depositor and lower transfer assembly of a preferred embodiment;

FIG. 23 is a front elevational view of the depositor and lower transfer assembly of FIG. 22;

FIG. 24 is a side elevational view of the depositor and lower transfer assembly of FIG. 22;

FIG. 25 is a side elevational view of a deceleration valve of a preferred embodiment;

FIG. 26 is a top plan view of the deceleration valve of FIG. 25;

FIG. 27 is a top plan view of the lower transfer assembly including the deposition of FIG. 22 and a rail system;

FIG. 28 is a side elevational view of the lower transfer assembly and rail system of FIG. 27;

FIG. 29 is a side elevational view of the press and hose routing rollers with a portion of a support frame for the transfer assemblies;

FIG. 30 is a top plan view of the press, rollers and frame of FIG. 29;

FIG. 31 is a side view of a visual inspection station;

FIG. 32 is an end view of the visual inspection station of FIG. 31;

FIG. 33 is a top view of the visual inspection station of FIG. 31;

FIG. 34 is an end view of the transfer apparatus;

FIG. 35 is a side elevational view of the transfer apparatus of FIG. 34;

FIG. 36 is a top view of the transfer apparatus of FIG. 34;

FIG. 37 is an enlarged fragmentary view of the paddle gears of the transfer apparatus from the circled area of FIG. 35;

FIG. 38 is an end view of the opposite end of the transfer apparatus from that shown in FIG. 34;

FIG. 39 is an end view of the dust collector of a preferred embodiment;

FIG. 40 is a side elevational view of the dust collection apparatus of FIG. 39;

FIG. 41 is a top view of the dust collection apparatus of FIG. 39;

FIG. 42 is a side elevational view of a film dispensing apparatus;

FIG. 43 is an end view of the film dispensing apparatus of FIG. 42;

FIG. 44 is a perspective view of the press, generally from the front;

FIG. 45 is a perspective view of the press of FIG. 44, generally from the back;

FIG. 46 is a side elevational view of the press of FIG. 44;

FIG. 47 is a plan view of the upper transfer assembly;

FIG. 48 is a side elevational view of the upper transfer assembly of FIG. 47;

FIG. 49 is an end elevational view of the upper transfer assembly of FIG. 47;

FIG. 50 is a top plan view of the press and transfer rail assembly including the trimming and laminating stations;

FIG. 51 is a side elevational view of the press and transfer rail assembly of FIG. 50;

FIG. 52 is a top plan view of the trimming apparatus;

FIG. 53 is a side elevational view of the trimming apparatus of FIG. 52;

FIG. 54 is an end elevational view of the trimming apparatus of FIG. 52;

FIG. 55 is a side view of a trimming saw of an end of the trimming apparatus of FIG. 52;

FIG. 56 is a top plan view of the trimming saw of FIG. 55;

FIG. 57 is a side view of a trimming saw of a middle of the trimming apparatus of FIG. 52;

FIG. 58 is a top view of the trimming saw of FIG. 57;

FIG. 59 is a top plan view of a lamination station;

FIG. 60 is a side elevational view of the lamination station, or laminator, of FIG. 59;

FIG. 61 is an end elevational view of the laminator film roller;

FIG. 62 is a side view of the laminator film roller;

FIG. 63 is a top view of the film roller of FIG. 62;

FIG. 64 is an enlarged side view of the film roller of FIG. 62;

FIG. 65 is an end elevational view of the film supply and a vacuum pump on the frame of a preferred embodiment;

FIG. 66 is a side elevational view of the film supply and vacuum pump of FIG. 65; and

FIG. 67 is a top view of the film supply.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention provides an automated production apparatus that utilizes a process for converting natural ingredients into biodegradable food service products. The preferred apparatus as four primary forming modules, as shown in FIG. 1, that feed to a single processing and packaging system, and is installed in a factory that supplies, for example, a compressed air supply, a chilled water supply, and a dust collection system. The four modules are independently operable so if one or more is inoperative, the others can continue in operation. Thus, product production delays are avoided. The four forming modules are all full production mechanisms for the product. The four modules are connected to a common output conveyor to feed the manufactured products to a single packaging apparatus. Each of the four modules in the group may operate independently and so the product can be produced by one, two, three or all four of the modules working simultaneously. Modules can be shut down for repair without effecting the other modules.

In particular, the present apparatus is in the form of a production line that includes the following equipment for making the biodegradable food service products: mixing equipment for mixing the slurry. The slurry such as a slurry made according to a recipe of Earthshell Corporation is made by combining limestone, starches such as potatoes and a small amount of fiber, which may include recycled fibers, along with water, in a mixer. A slurry prepared by other recipes or according to other technologies is also contemplated for use with the present apparatus. The prepared slurry is transported such as by being carried in slurry delivery carts to slurry hoppers. Of course, the slurry may be transported via another slurry transport means, such as via pipes. The slurry hoppers supply the slurry to the present manufacturing apparatus. The slurry delivery carts, or transport carts, of a preferred embodiment have a pump by which the slurry is pumped to the hopper. The delivery cart pump of one embodiment has an enlarged line size of the diaphragm pump of, for example, three inches in diameter so as to reduce shear on the slurry as it is being pumped from the transport cart to the hopper.

Slurry pumps in the hopper or hoppers force the slurry through slurry piping to the depositors which place a quantity of the slurry into each mold of a mold set that comprises a plurality of molds. The mold set is closed by a press in a high pressure, high temperature baking press. In a preferred embodiment, the high pressure press is a 120 ton press, although this is dependent on the product design and matrix of molds.

The press has product specific mold sets that form the product with pressure and heat. The heat is controlled by a heat control system specifically designed for the present press. The heat causes steam to be emitted from the press during molding and so a steam collection apparatus is provided at each press to pull steam away from the mold area Once the product is formed in the mold, the mold is opened. The molded products are removed from the molds by a takeout and transfer unit. The takeout and transfer unit preferably also has sensors to check for stuck or partial product in the molds. The takeout or transfer also deposits slurry into molds on the way out of the press The takeout and transfer unit or rotation of the products to invert the products top for bottom. The inverted products are engaged, in the preferred embodiment, two rows at a time by a further transfer unit and then are trimmed by sawing and sanding units for removing flashing from the molded products. A dust collection system is preferred for vacuuming the flash and dust away from the sawing and sanding area. The waste collected by the dust collecting system may be recycled. The waste collected by the dust collecting system may be recycled. After trimming of the product, the further transfer unit moves the product to a film laminator to provide a coating of film on the food contacting surface of the product. The further transfer unit then deposits the product into a drop-off unit feeds the product to the common conveyor. The foregoing functions are provided by each module.

The common conveyor connects to a plurality of the modules, four modules in the present embodiment. The common conveyor transfers the products produced by all of the modules connected to that conveyor to a waxing unit to have the side of the product opposite the film coated, to a visual inspection and defective product removal station, then to counter/stacker station and finally to either manual or automatic bagging units. The conveyor is a belt conveyor that utilizes food grade material for handling the product.

The sequence of operation for a preferred apparatus according to the invention includes the following steps, as set forth in FIG. 18. First, bulk raw material is batched, weighed, measured and sent to mixing equipment for mixing and making the slurry, as show at step 20. At step 22, an operator moves the slurry with dump carts to hoppers that feed slurry pumps. Alternatively, the slurry may be transported in pipes or by other transport means, or the slurry may be mixed at the hopper to avoid transport. It is noted that pumping of the slurry over the distances required between a central mixing station and the modules located throughout the factory may result in problems, so this is not recommend, although for some pumping systems and slurry mixtures acceptable performance may be achieved The slurry is pumped by a slurry pump from the hoppers to press depositors for automatic placement of dollops of the slurry into lower half (female) mold sets inside a 120 ton baking press. A press holding the mold sets closes and the molds are heated, at 26. During the baking cycle, steam generated from the baking process is collected at each press and pulled away from the mold area and vented to the atmosphere above the press, at 28 or to a common steam collection header. The press opens and takeout/transfer units enter the press, check the mold array to ensure product is present in the female cavity, at 30, and removes the baked product from the mold, at 32. A check is made for stuck or partial product in the mold, at 34. Thereafter, the depositors start to deposit more slurry into each mold set for a further set of the product.

The baked and formed products are rotated by 180° and transferred outside the press area and picked up by another transfer unit (using vacuum manifolds) to be moved into a sawing/sanding station, at 36 for removal of flashing from the rim of the product, at 38. Dust collection units are used to vacuum the flashing away from the saw/sander area and from a brush station. The trimmed products are transferred to the lamination station, at 40, for laminating a film coating to the inside of the product. Heat is applied to the film while simultaneously pulling a vacuum through the substrate and trimming the film from the product to laminate the food contacting surface, at 42. After laminating, the product is placed onto a belt conveyor for transport to the waxing area, at 44. The conveyor system transports the products single file to the waxing station for waxing of the backside of the product, at 46. After waxing, the products are inspected, automatically counted, automatically stacked, and manually or automatically bagged at 48.

In further detail, FIG. 1 shows a factory floor arrangement 50 of four manufacturing lines or modules for manufacturing biodegradable articles, such as dishes and food service items. Each of the four food service product production machines include the following operating units:

A metering and depositing unit 52 is provided for transferring as well as metering and depositing of the slurry. The slurry is carried to the metering unit from a hopper 54. Transportation of the biodegradable material in slurry form between the hopper and the metering/depositing unit is accomplished via low shear pumping systems through hoses 56 or through stainless steel headers. A metering and depositing device places precise dollops of slurry into each mold cavity in a press 58. The accuracy and consistency of the slurry depositing is essential for effective execution of the forming process.

In a forming step, material that has been deposited in the mold is heated in closed cavity molds. Water contained in the material is converted to steam, which induces material movement and results in the forming of a plate, bowl, or other food service article in each of the molds. Steam is vented from the mold cavity to the atmosphere. The molded products are transported out of the molds by a transport apparatus 60.

The trimming step is performed in a trimming apparatus 62 after the products are removed from the molds. In particular, excess material that escapes the mold cavity remains attached to the plate, bowl or other food service article. This excess material must be trimmed away. The trimming processes remove this excess material and results in the molded product having the desired final shape.

In a film laminating step in the laminator 64, a biopolymer film is applied by clamping the film to the material surface, heating of the film and by application of vacuum energy. The application of heat is controlled by a heat control system. The film is trimmed around the plate, bowl or food service article perimeter to free the product from the sheet of film.

The coating step provides an exterior wax coating selected from among different coating blends. The coating is applied to the side opposite the film of the plate or food service article in a coating station 66. Thereafter, the finished products are transported on a conveyor system 68 to a packaging apparatus. An electrical enclosure 70 is seen in the FIG. 1 as well. For the sake of safety, the apparatus may be enclosed in protective screening to keep plant personnel from the moving machinery.

In FIG. 2, the food service production apparatus 50 has a depositor and lower transfer assembly 72 at one end. The depositor 72 is connected by the hoses 56 to the hopper 54 (see FIG. 1). The depositor 72 moves over the molds 74 in the press 58. Transport of the molded products from the molds 74 is performed by a lower transfer assembly as the transport apparatus 60. The molded products are passed to the upper shuttle and then transferred to the trimming apparatus 62, show here indicated as saws. Also shown is a debris collection apparatus 76 which vacuums up the dust and debris from the saws 62. A rotating brush assembly 78 is preferably also provided to remove dust and trimmed particles from the product. The laminator 64 follows the trimming apparatus 62. In the embodiment shown in FIG. 2, the laminator is followed by an off-load station 80 that provide the products to the conveyor 68.

In one embodiment, air jets, or so-called air knives, are provided to direct streams of air toward the food service articles while they are being held by the lower transfer assembly. This removes debris, specs and other foreign matter from the product prior to laminating and waxing and improves product quality. It also prevents debris from clogging the vacuum intakes of the transfer assemblies. The air jets are positioned to direct the air stream to the lower transfer assembly as it enters the press.

FIG. 3 illustrates additional detail of the press and mold assembly 58. The press has a lower portion with a press block 90. On the press block is a lower mold set and insulation 92. Above the lower mold set is an upper mold set and insulation 94, above which is an upper press bolster 96. A main press cylinder 98 causes the two mold halves to be pressed together to form the product.

Also shown in FIG. 3 is a press electrical enclosure 100 for the electrical controls of the press. Assists 102 are provided adjacent the main press cylinder 98. As noted above, steam is driven off during the pressing operation, and so a pair of steam vents 104 is provided on the press to capture the steam and direct it away from the product.

FIG. 4 shows the upper and lower mold sets 92 and 94 in further detail. The lower mold set has a number of female mold portions 110 shaped to form the underside of a food service product. The bottom half of the mold set is the female half of the mold. The mold portions 110 are arranged in a regular arrangement of rows and columns. In one embodiment, the molds are set in a six by six array for a total of 36 individual plate molds per set. The upper mold set 94 has male mold portions 112 in the same arrangement as the lower mold set. The upper mold set 94 has the shape of the inside or upper surface of the food service product. The upper set is the male half of the mold.

The operating temperatures for the mold are defined. The molds 92 and 94 are heated from above and below with a plurality of heaters in the form of heater rods distributed between the top and the bottom. The heaters are set in a series of holes that run the length (from front to back) of the top and bottom of the mold set. The preferred heaters are heating rods that are mounted in holes in the press. Heat sinks are provided on exposed ends of the heating rods, which increases the life expectancy of the heating rods and increases the time between servicing of the press. Easier servicing of the device is provided if the holes for the heating rods are of a greater diameter than the heating rods themselves. This enables the heater rods to be replaced as needed quite easily, even after long term use.

For one embodiment of the preferred device, the molds are pre-heated to an operating temperature of 242 degrees Celsius for the top mold half and to 240 degrees Celsius for the bottom mold half. The temperature control preferably regulates the temperature to ±1 degree Celsius, particularly during heating. In one embodiment, the mold surface is heated to 200° Celsius.

In an advantageous embodiment, the press is provided with insulation at the press plates to insulate against heat loss from the press and thereby keep the press plates at the desired temperature while consuming less energy. The insulation helps to maintain a constant heat control CF the mold surfaces. The insulating material provides a long life and improved heat control for the press.

According to one aspect of the invention, the molds are kept at an intermediate temperature during down time of the press. During periods of extended shut down, the mold temperatures are reduced to 150 degrees Celsius to retain internal heat and therefore decrease the amount of time required to bring the molds back up to the normal operating temperature. If the molds are allowed to cool to room temperature, it will take approximately 24 to 26 hours at 150 Celsius to bring the molds back up to operating temperature.

A predetermined quantity of the slurry is put into the mold cavities using the depositor 72 shown at the back of the mold sets 92 and 94. The depositor 72 moves on lower transfer rails 114 to reach each of the mold cavities. The predetermined quantity of slurry deposited into each mold cavity for each of the food service articles is referred to as a dollop. A dollop is dropped in the mold to form the plate After the quantity of slurry has been put into the mold cavities, the press is closed and the forming process begins. When the press closes, the dollops are baked for 45 seconds.

FIG. 5 shows the depositor 72 in further detail, including six slurry deposit nozzles 116 are mounted. The six nozzle arrangement is provided for the molding of plates while an eight nozzle arrangement is provided for molding bowls. The nozzles 116 are connected to supply lines 118 through which the measured quantities of the slurry are provided. The connections 120 for carrying away the steam generated during pressing are also shown.

Referring now to FIG. 6, the air supply to the present apparatus plays an important roll in the operation of the forming machinery due to the use of compressed air to operate much of the mechanisms of the present device. Air pressure is fed to a main air inlet 128 is set at line pressure (in a preferred embodiment, at 125 PSI) with no restriction. A main air supply inlet and control 130 is provided. The main air supply, which is filtered in a filter 132, feeds the entire machine with compressed air. The primary air supply lockout/tag-out valve latch 134 is located on a shut off valve 130. The valve must be in the locked out position and locked anytime personnel are inside any working area of the machine as a safety measure to prevent accidental operation of the machine.

In FIG. 7, from the main air supply valve, a main air supply line 128 tees off to an accumulator line 136 that feeds the two accumulators or assists 102 (see FIG. 3) located on the top of the press 58. A shut off valve 138 for the air supply to the accumulators 102 is provided, as is a manual air supply blade shutoff 140.

Referring now to FIG. 8, the accumulators 102 for the air supply are provided along side the main air cylinder 98 on the top of the press 58. The main cylinder 98 is assisted by the two smaller lift cylinders 102. Air supply lines 140 are provided to the accumulators 102.

The operating stroke of the press is divided into three stages: an air-operated approach stroke; a pneumo-hydraulic power stroke; and an air-operated return stroke. The air supply provides the air pressure for the press movement and a hydraulic system provides the power stroke for the press, which must be equal to or greater than the pressure generated by the molds.

As shown in FIG. 9, the hopper 54 and supply lines 56 provide slurry to the lower transport assembly. The preferred embodiment uses a progressing cavity pump 142 to transport the slurry. An example of such a progressing cavity pump is provided by Moyno Inc. In a best mode, the pressure by the pump has been reduced from 100 psi to 60 psi to reduce shear forces on the slurry. The pump is driven by a motor 144 to form a cavity pump and slurry unit, which is located downstream of the press (relative to the product flow direction) in the middle left side apart from the module. The cavity pump 142 is a progressive (or progressing) cavity pump, which can be used to carry highly viscous liquids. In the progressing cavity pump, a single helical rotor rolls eccentrically in the double helix of the stator to create the pumping action. The rotor in conjunction with the stator forms a series of sealed cavities that are 180 degrees apart. As the rotor turns, the cavities progress from the input end or suction end to the discharge. The result is a pulsation-free positive displacement flow.

The slurry hopper 54 may be provided for each module of the present apparatus, but it is preferred that a single slurry hopper 54 be provided for each four press modules. A single pump, in one example a Moyna pump, is provided for the single slurry hopper. The pump, of course, must be of sufficient capacity to supply all four modules with the slurry. This saves floor space and cost, as well as making supplying the slurry to the hopper a simpler matter for the factory personnel monitoring the levels in each hopper. An alternate embodiment provides a slurry pump of a capacity to supply two press modules, but the cost savings for the pump is not offset by the savings from other factors.

Another component in the present device is the lower transfer assembly 72 as shown in FIGS. 10 and 11. This component is located at a home position directly behind the press bed 74. The lower transfer assembly 72 has three primary functions, namely for slurry dollop dropping, for product removal, and for positioning of the upper transfer assembly 60 to pickup the product and move it to the next station. In particular, the dollop drop provides that the predetermined portions of slurry, or dollops, are fed from slurry pump system 142 up and over the top of the press 58 and then back down to the lower transfer assembly 72 where the material is pushed under pressure thru a material delivery system. On a press cycle start, the press is in the up position. The lower transfer assembly 72 includes a metering system with depositor nozzles that correspond in number to the number of molds in a row and which are connected to slurry accumulators 148 to deliver predetermined, or metered, amounts of the slurry to each row of the molds, starting with the front most set of molds 110. On command, the metering system and accumulator 148 drops the product material (the slurry) into the bottom 110 of the first row of the molds through the nozzles. As the lower transfer assembly 72 retracts toward the home position, the metering system 148 deposits the product material into the next set, or row, of molds 110. This process is repeated until the rows of molds 110 are full (dolloped) and the lower transfer assembly 72 has been moved back to the home position out from between the press plates. The press 58 is operated to the closed position to mold and heat the products in the respective molds. If this is the initial product material drop, the lower transfer assembly 72 will rest in the home position until the press 58 has cycled. After the press 58 has completed the “bake cycle”, the press opens to the full upward position. The lower transfer assembly 72 does not make any movement until the press 58 has cleared the proximity sensors that are mounted to detect the press position and a predetermined amount of time has passed.

The retraction of the depositor to the home position during depositing of the slurry results in wear on the slurry carrying hoses. The preferred embodiment of the present apparatus includes various hose handling features that reduce the wear on the hose from drag over other components so that the life of the hose is increased.

With the press 58 in the full upward open position, the lower transfer assembly 72 rotates suction cup units 150, as shown in FIG. 12, to the down position to remove any left over product material. The suction cups 150, as shown in greater detail in FIG. 13, then rotate back to the up position. The lower transfer assembly 72 then starts movement toward the press. As the lower transfer assembly 72 clears the upper transfer assembly 60, the lower transfer assembly 72 moves to the up position and rotates the suction cups 150 to the down position for product. When the lower transfer assembly 72 reaches the end of the travel, the lower transfer assembly is lowered to the mold. The front two suction cups 150 draw vacuum over the product and grab the product. The rear suction cup 152 does not draw vacuum. The rear suction cup 152 acts as a stabilizer for the front two suction cups. With the suction cups 150 holding the product, the lower transfer assembly 72 moves to the up position and the product is rotated to the up position. With the product in the up position, the lower transfer assembly 72 lowers and then travels back to its home position. As the lower transfer assembly 72 is moving back to its home position, the depositor is dropping product material (dollops) into the molds. When the lower transfer assembly stops, it will be in the home position waiting on the next cycle.

The upper transfer assembly 60 as shown in FIG. 14 is located at a home position that is directly behind the press 58 and above the lower assembly 72. FIG. 14 shows the top of the upper transfer assembly 60, including various vacuum connections for generating the low pressure to engage the food service product. The upper transfer assembly 60 is movable along rails 162 to move the product as needed. The movement is facilitated by a rolling wire and tubing cage 164, also referred to as a cat track, that encloses wires and tubes connected to the movable transfer assembly 60 to prevent the wires and tubes from being caught in the machinery and being damaged or interfering with the operation of the machinery. The lower transfer assembly 72 is also visible in FIG. 14, including the metering devices and the slurry delivery tube.

The upper transfer assembly 60 has several primary functions, namely, to pick-up product from the lower transfer assembly 72, to transfer and process product across the saws 62, to place the product in the lamination chambers 64, remove the product from lamination chambers and deliver product to an offload station 80. In particular, the product pickup function is performed as follows: when the lower transfer assembly 72 has completed the process of moving the product from the inside of the press 58 and stops in its home position, the upper transfer assembly 60 is in position to receive product from the first pickup (in rows 1 and 4 of the mold set).

The layout of the mold set 74 is shown in FIG. 15, which is in a 6 by 6 matrix having six rows 170 and six columns 172 for plates. An eight by eight matrix is provided for molding bowls. The product pickup sequence is indicated in the drawing. Specifically, the first pickup picks up the first and fourth rows, the second pickup picks up the second the fifth rows, and the third pickup picks up the third and sixth rows. After processing the products from rows 1 and 4, the second pickup stops directly over rows 2 and 5. After processing rows 2 and 5, the third pickup stops directly over rows 3 and 6. With the upper transfer assembly 60 in the pickup position, product manifolds 180 as shown in FIG. 16 are lowered to the product being held by the lower transfer assembly suction cup assemblies 150. The vacuum on the lower transfer assembly suction cups 150 is discontinued to release the products and the manifold vacuum begins. With the product held by the manifold cups 180, the upper transfer assembly 60 retracts.

The manifolds 180 of a preferred embodiment are shaped to flex the food service article in such a way as to present the edge thereof for trimming by the trimming saws. The flexing is provided by a contour geometry that differs from the shape of the mold for the product. The contour flexes the outer edges of the product downward. For example, a manifold having a more concave shape than the molded article will direct the flashing at the rim for better presentation to the saw blades. The food service article should not be flexed so much as to crack or break the product, however. The food service article is held in this flexed position by the manifold during transport, trimming, lamination and drop off.

In a further embodiment, the manifolds are provided with a ceramic coating at least on the surface contacting the molded food service product. This provides improved abrasion and wear resistance, particularly in embodiments using contour shaped manifolds that flex the products for trimming, since this results in sliding movement of the product over the product surface. Although ceramic is preferred, any hardening of the manifold surface is envisioned for improving the service life of the present device.

With the plates or other food service product firmly grasped in the suction manifolds as shown in FIG. 16, the upper transfer assembly 60 travels away from the press 58 to the saws 62. As the product encounters a saw 62, the flashing (extra material around the product) is sawed or cut away. The saw station 62 of a preferred embodiment has ten individual diamond coated saw blades staggered in an array that encompasses the entire width of the platens for trimming plates, while eight saws are provided for trimming bowls. The saw blade assemblies 62 are belt driven. In the event that a belt must be removed from this assembly, a maintenance manual is provided for instructing the user in belt positioning and instructions. The saw blades are turning between 5000 and 7500 rpm in one embodiment and are preferrably cooled to maintain a constant temperature. The speed of the saws 62 may be varied by the user depending on the product being formed. A gap setting is also provided between the manifold cups and the saw blades which in one embodiment should be set by the user at a nominal dimension of approximately 0.087″. Again, refer to the CPS to determine the exact gap requirements of this machine. The saws are contained inside a low pressure chamber of the dust collection apparatus 76 that removes the trimmed flashing and dust from the saw blades. The flashing and dust are carried away from the saws and deposited in the collection system that is located at the end of the line.

The product lamination station 64 is located after the upper transfer assembly has passed the product over the saws, so that the upper transfer assembly 60 may deliver the product to the lamination station 64. With the first upper transfer assembly station positioned directly over the lamination station 64, the laminating process begins. Film that is roll fed through the lamination station 64 is heated to the point of plasticity. With the film heated, air is pushed into the lamination chamber, which may cause a bubble to form. The upper transfer assembly 60 is then lowered to the lamination chamber, forcing contact with the product. The same vacuum that is retaining the product is also used to draw the film to the product's surface. The film is preferably applied to the food contacting surfaces of the food service product.

A high performance vacuum pump is preferably utilized for creating the vacuum on the manifolds of the upper transfer assembly. The high performance pump speeds the lamination process to enable a lamination cycle time of less than 60 seconds. The high performance pump still has enough capacity to pick up the product as required.

As the upper transfer assembly 60 continues downward, the product is pushed down further to trim the product. The final motion generated by the upper transfer assembly trims the excess film from the product using, for example, a hot air trimmer or air knife. The trimming is accomplished by a high pressure blast of air directed at the edges of the plate or bowl. The upper transfer assembly 60 then moves in the upward position back to its extreme “up” position. As the upper transfer assembly 60 is traveling up the film plate opens, the remaining film (waste) that was not used in the laminating process is pulled between the film plates of the laminator and rolled up on a scrap roller. As the scrap is being pulled thru the laminator, a new stretch of film is being pulled right behind it, and the film is readied for the next batch of product.

As shown in FIG. 17, a lamination chamber 190 uses a heater 192 in the bottom of the chamber to heat the film prior to attachment of the film to the product. As the film is heating, a low pressure blast of air is blown into the mold to inflate the film. The lamination of the film to the plate or bowl is accomplished as a result of a controlled combination of heat, air flow, vacuum pressure and timing. The lamination system operation and timing is controlled by a PID (promotional-integral-derivative) heat loop control.

The product is forwarded to an offload station 80 where the food service products are loaded onto a conveyor 68.

The conveyor 68 feeds the product to a waxing station which applies a wax coating to the bottom of the food service products, allows the products to cool, and then forwards the products to a counting and packaging station.

FIG. 19 shows the conveyor system 218 with a belt drive motor 200 and pulleys 201 moving belts 202 over belt rollers 203 to carry the food service articles in a conveying direction. The conveyor 218 is supported on a conveyor frame 204 and extends from the modules that form the food service articles. The conveyor 218 transfers the food service articles one at a time to a stacker 220. The stacker 220 collects the food service articles in an aligned stack until a predetermined number of the food service articles has been stacked together. Optical sensors in the stacker determine when the desired number of food service articles are in the stack. Sensors and controllers connected to the sensors are provided throughout the present apparatus to automate the operation thereof and provide for effective operation, as will be understood by those of skill in this art.

The stacked food service articles are then transferred along a second conveyor 205 to a packaging platform 206. The second conveyor 205 has a belt 207 and a small motor 208 and is provided on a frame 209 to carry the stacks to the packaging platform 206. Workers in the factory gather the stacks and put them into packages, in this embodiment. For example, the stacks may be placed into a plastic bag for retail sale. It is also foreseen that the stacks may be a packaged in an automated packaging machine.

In the stacker, transfer paddles 210 and 211 are provided at two staggered locations to effect a transfer of the food service articles from the conveyor onto a stack. The transfer paddles 210 and 211 are mounted in an alignment frame 212. A ramp 213 is provided between the second conveyor 205 and the platform 206.

Referring now to FIGS. 20a and 20b, an embodiment of the stacker is provided with three stacking stations 214. The conveyor 218 shown in FIG. 19 is branched into three conveyor branches by adding two branching conveyors 215 each leading to a stacker apparatus 216. In each of the stackers 216, the food service articles are received one at a time and transferred to the stack until the predetermined number of food service articles has been received in the stack. Three secondary conveyors 217 carry the stacks to three packaging platforms 219 for packaging by workers. The three way stacking operation enables a high product output to be accomplished, matching the rate of product production by the four modules, in the preferred embodiment, to the stacking and packaging abilities of the stackers and packaging workers.

The illustrated stacker is but one embodiment of stacker possible for use with the present system. Other stackers and packaging options are encompassed within the scope of this invention.

FIG. 21 shows a typical factory layout 210 of the present food service product machines 50. In the factory is provided a mixing room 212 for mixing the slurry. A materials storage area 214 is adjacent the mixing room 212. The present food service product machines 50 are grouped together in groups of four so that four machines 50 are working to form the products and feed the products to a single conveyor that carries the products to a packaging apparatus. The four machines work in parallel. An input 216 supplies the machines with the slurry for forming the products, the products are made by the four machines simultaneously and feed to the conveyor 68, waxed by a waxer 218, and then are packaged by a single packaging device 220 at the output of the conveyor 68.

The packaging device 220 includes a stacker that stacks the food service articles it receives from the conveyor 68. The stacker counts the articles and stacks them into stacks of a predetermined number for insertion into a plastic bag, for example. In the preferred apparatus, the stacker is made to strict specifications and performance requirements to optimize the stacking process. The stacker of one embodiment is provided with mechanical design improvements to accommodate eight plate modules. The packaged products are then provided to a further conveyor 222 for transport to a pack-out area 224 for storage and loading into transport means, such as trucks or shipping containers.

The conveyor 68 of the preferred system is provided in at least two parts. A first part of the conveyor that connects to the modules and is in each of the modules is separate from a second part of the conveyor outside of the modules. The assembly of the present system, such as at a new factory location, is thereby simplified. In particular, the portion of the conveyor inside each module need not be removed when breaking down the module for shipment to the factory. The manufacture of the present apparatus includes set up and testing of each module at the manufacturing site, followed by disassembly and transport of the modules to the food service article factory where they will be used. The present apparatus had many of the components left in an assembled state during transport to facilitate easy re-assembly at the factory.

In the example shown in FIG. 21, the machines are grouped according the product being produced. One side 226 of the factory is configured to produce plates (having five groups of four machines, or modules, producing plates) and the other side 228 of the factory is configured to produce bowls (having three groups of four machines, or modules, producing bowls). Any number of modules or groups of modules may be provided in a factory or other facility as needed.

In FIG. 22, the depositor and lower transfer assembly 72 is shown in further detail. The supply pipe 56 through which the slurry is fed is provided coming from the right of FIG. 22. It is supported by pipe clamps 240. At the end of the pipe 56 is a pressure gage 242 branching from the pipe 56 are branching pipes 244 that lead to a depositor 246, six such branching pipes 244 and depositors 246 are provided. The depositors 246 feed the predetermined quantity of slurry as dollops to the molds through nozzles 248. The nozzles and depositors 246 and 248 are supported on a beam 250 held by beam brackets 252. Various further fittings and controls provide for the operation of the dollop feed.

The dollop feed of FIG. 22, is also shown in FIG. 23. Two accumulators 260 are mounted in housings 262 on the upper part of the depositor 72. The accumulators 260 receive quantities of the slurry and store the slurry in the accumulators while the depositors are not operating. When the depositors are operating, such a quantity of slurry is required at such a rate that the supply line is not able to keep up, so the slurry stored in the accumulators 260 is fed to the depositors during the depositing operation. The slurry is receive through and returned through a branch 264 from the slurry feed line 56. The accumulators 260 are also shown in another embodiment in the FIG. 10 in one example of the apparatus, mounted atop the lower transfer assembly.

In the preferred embodiment, the accumulators 260 are located very close to the depositors for greater efficiency during the depositing operation. The accumulators reach a pressure to pump the slurry to the depositor nozzles during the depositing operation. The pressure generated in the accumulators may be as high as 100 psi, although a preferred embodiment with the accumulators located close to the nozzles is set to generate an accumulator pressure of 45 psi, thereby reducing the shear on the slurry.

The frame of the lower transfer assembly should be of a shape and construction to ensure accurate retrieval and transfer of the molded food service articles. To ensure that this is true, the frame is provided with a construction and materials to ensure parallelism of the frame elements and squareness of the overall frame. The carriage of the lower transfer assembly is also constructed so at the ensure squareness. Accuracy and reliability of the operation of the apparatus is thereby improved.

The dollop feed 72 is shown in side view in FIG. 24. The pump housing 262 sets atop the dollop feed and serves as a accumulator. An additional support bracket 266 is provided below the middle two nozzles 248. Each of the nozzles 248 is fed by a slurry metering apparatus 268.

The nozzles for the depositor are, in one embodiment, form of a heat resistant, high temperature tubing, particularly in view of the depositor's proximity to the heated molds. Little or nor deforming or thermal change results to that the desired amount of the slurry is consistently released into the mold regardless of whether the apparatus has just be started up or has been running for an extended period of time.

The nozzles and other tubing in the slurry supply are provided with a push lock design for ready removal for servicing. Air pressure tubing and other connections are also preferably provided with easy release connections to facilitate servicing.

Turning to FIG. 25, a deceleration valve assembly 270 is shown. The deceleration valve assembly 270 controls the speed of the ram on the press as it lowers. The assembly 270 includes a cam lever arm 272 held in a cam mounting bracket 274 by a screw 276. At the upper end of the cam lever arm 272 is a cam surface 278 which is in contact with a roller 280. A second roller 282 engages the side of the cam lever arm 272 on the side opposite the cam surface 278. The rollers 280 and 282 are mounted in a slide block 294. A port block 286 is mounted on the side block 284. A spring 288 acts to press against a piston 290 that slides within a valve body 292 depending on the motion of the roller 280 on the cam surface 278. A bearing 294 permits the motion of the roller and piston assembly.

The deceleration valve 270 enables bolster shocks that are ordinarily present on a press of this type to be removed. The deceleration valve provides a simplified control of the press closure motion.

Turning to FIG. 26, the side block 284 is shown in further detail including the piston roller 280 riding on the cam surface 278 and rotatable on a bearing 296 and a piston rod 298 which slides through the bearing 294. The piston rod 298 is engaged into the piston 290 which moves within the valve body 292 to which is attached the port blocks 286. The spring 288 that presses on the bearing 290 is held in an end cap 300. A mounting angle 302 is fastened to the slide block 284. The cam lever arm 272 can be seen within the slide block 284 engaged by the roller 282. A bearing 304 supports the roller 282 for rotation.

The piston of the preferred deceleration valve is preferably formed of a very hard, durable material to provide a longer life for the piston, and thus the deceleration valve.

The lower transfer assembly is shown in FIG. 27 in detail. In particular a servo and gear box 306, a driveshaft 308 which is supported by bearings 310. The driveshaft 308 drives linear modules 312 that include a gear mount and coupling to enable movement of the transfer assembly along the rails 162. The transfer assembly includes vacuum pickups 314, 36 of which are provided in the illustrated embodiment. The vacuum pickup is supported in a carriage assembly 316. A vacuum tube 318 extends between the vacuum pickups 314. The vacuum tubes 318 are supported by support blocks 320 and a rotating joint 322 is provided at the end of each vacuum tube 318. The transfer assembly moves along the rails 162 under the control of a servo motor and is stopped at its farthest extent by bumpers 324. A brace 326 extends between the rails 162 to ensure proper spacing.

The suction cups of the lower transfer assembly are provided with means for vertical adjustment of their position to enable alignment with the molds and the upper transfer assembly. The preferred vertical adjustment apparatus allows the vertical adjustment to be made while still maintaining an air tight connection to the vacuum pump at the connections.

The rails 162 of FIG. 27 are provided on a frame as shown in FIGS. 29 and 30. It is preferred that a clearance be provided between the press corner posts and the rails 162 to avoid interference therebetween.

A rotary actuator 328 is mounted on the rail 162 to enable rotation of the vacuum pickups 314. The rotary actuator 328 turns the suction cup assemblies and the food service article held therein over top for bottom so that the upper transfer assembly can engage the product for trimming and lamination. The rotary actuator must permit the suction cups to be rotated while maintaining the vacuum. A relatively large diameter rotary actuator is provided to provide smooth motion during rotation and to ensure reliable holding of the product without dropping. The food service article is thereby removed from the mold and turned over reliably.

Operation of the present vacuum pickups utilize counter weights 330 for proper balancing. A quick release 332 is provided to release the upper transfer assembly for servicing. The lower transfer assembly 72 as shown in FIGS. 22, 23 and 24 is also shown in FIG. 27.

FIG. 28 shows the transfer assembly from a side view with a servo motor 306. The rail 162 is held by a clamp 340 and includes brackets 342, a carriage guard 344 is provided at the end of the carriage 316, a rack 346 and rack keeper 348. The rack 346 has teeth that engage a spur gear 350 connected to the rotary actuator 328. The rack 346 in turn engages further spur gears 352 at each of the six vacuum tubes 318 to enable rotation of the vacuum pickups. Various guides for the rack 346 are provided along the length thereof. A trantorque 354 is also provided. An end tray 356 is provided mounted on a bracket, 358 supported on legs 360 below the dollop dispenser 72. An air nozzle 362 is provided below the dollop dispenser mounted on a bracket. A guide 364, a shock absorber 366 cushions movement of the upper transfer assembly. A thruster 368 provides lift for the transfer assembly.

The vacuum pickup assemblies 314 are shown in their down position in FIG. 28 engaging plates P with the suction cups 150.

In FIG. 29 is shown the press and apparatus for supporting the slurry supply hose. In particular the press 74 has the main press cylinder 98 connected to an upper press bolster 96 which supports the insulation and the upper mold set 94. The upper mold set 94 fits into the lower mold set and insulation 92 on the press block 90. The press is supported by legs 370.

The slurry supply hose 56 must be able to accommodate the movement of the lower transfer assembly while dollops of slurry are placed into the press 74. To accomplish this, a spool 372 having an outer wheel 374 and an inner wheel 376 is mounted on a bracket 378 of an arm 380. The arm 380 is mounted on a ball bearing pivot 382 of a spool stand 384. A counterweight 386 which is adjustable as needed is mounted at the other end of the arm 380. A stop block 388 receives the end of the arm 380 at the spools' highest position.

A support frame 390 for the transfer assemblies is provided outside of the press 74. A pair of hose rollers 392 are mounted on a roller flange 394 which in turn is mounted on a roller stand 396 on the frame 390. Thus, air hoses and other supply lines are kept free of the press during press operation by being suspended over the spool and hose rollers.

A robust support frame for the transfer assemblies is preferably provided. The present frame is in two parts or sections to facilitate fabrication and set up. Dowel pins are added to the to the frame to help in the alignment of the frame sections with one another during the initial setup of the apparatus for testing and during re-assembly at the factory. Locate pins are provided for assistance in locating and positioning of the rails for the upper and lower transfer assemblies during initial setup and later in situ re-assembly.

In a preferred embodiment, the slurry supply hose is of a construction and material to resist expansion or swelling during pumping of the slurry so that the slurry is pumped more efficiently. In addition, this reduces wear on the hose and wear on components in contact with the hose. Less frequent servicing and better performance of the slurry pump and the system results.

In FIG. 30, the press 74 is shown from above with the hose rollers 392 and the spool 372 disposed above one another. The spool 372 is supported on the arm 380 that is mounted on the bracket 384 on top of the press 74. The counterweight 386 and stop block 388 are also provided.

In FIG. 31, is disclosed a quality checking apparatus which verifies the integrity of the product produced by the present invention. As noted previously, a waxer 218 is included in the manufacturing process to coat the bottoms of the food serve items. The waxer is shown in FIG. 31 to the right. The waxer includes a wax spraying nozzle to apply a coating to the surfaces of the food service articles opposite the surface with the laminated film. The food service articles are carried through the waxer on a conveyer belt 400. The conveyor belt 400 has a first portion 402 leaving the waxer 218 and riding over rollers 404 so as to move the food service articles P through the waxer 218. A second section of the conveyor belt 406 rides over rollers including the roller 408 through a product inspection station. It is noted that the conveyor 402 has a catch tray 410 to catch debris which may be on the conveyor belt. Belt cleaners are provided to clean any wax from the belts. The catch tray 410 catches the wax that has gotten on the belts.

The waxer operates according to predetermined specifications. These specifications define the structure and operation of the waxer and the wax to achieve a desired performance.

In a preferred embodiment, a visual inspection station is provided prior to the waxing station. As the food service products P move in the direction of the arrow 412 along the conveyor 406 they are inspected by a camera system 414 mounted below the conveyor belt 406. The camera 414 is a block box to control light that has a transparent cover 416 which looks up to the food service articles to look for incomplete faulty product. The camera system 414 is mounted on a frame 418 which has horizontal support bars 420, bottom support bars 422 and vertical support bars 424. A camera 428 is mounted on a bracket 428 next to a controller 430. The transparent panel 416 may become obscured by dust and debris and so an air nozzle 432 is provided to direct a stream of air to the panel 416 to keep the panel clear of debris.

As air nozzle 434 is provided downstream of the camera 426 and below the conveyor surface on which the products P are being carried. When the camera 426 detects an irregular or misformed food service product P, the air nozzle 434 directs a stream of air upward against the food service product directly thereabove to blow the product from the conveyor so as to keep it from being packaged with the other completed products. Thus, an optical vision and rejection function is performed by the apparatus of FIG. 31.

In FIG. 32, the conveyor belt 406 can be seen as two side-by-side cylindrical or rope-like belts which provide a clear view of the food service product P riding on the belt for inspection by the camera 426. Pulleys 408 over which the belt 406 rides are provided, driven by a belt drive motor 440.

A housing 442 in which is provided the transparent window 416. The nozzle 432 for cleaning the window 416 is provided as a card shaped structure to direct a sheet of air to the window.

The products P travel through a guideway having a top panel 444 and sides 446. The guideway keeps the food services products P from moving about during the visual inspection by the camera 426.

In FIG. 33, the visual inspection station has the sides 446 between which the food service products pass for inspection while traveling on the conveyor belts 406 for inspection by the camera 426. The belts 402 from the waxer are each doubled so that four belts carry the food service products P through the waxer and then hand the products over to the two belts 406 in the visual inspection station. The supports 424 and 420 which hold the camera 426 and controller 430 are seen below the conveyor belts 406. The nozzle 434 is positioned to the side of the conveyor to blow the plates off the conveyor path when it is desired to remove the product from the conveyor.

FIG. 34 shows the product transfer apparatus 448, also referred to as a drop station, by which the food service product P is placed on the conveyor. In the illustration of FIG. 34, three belts 450 are provided on a conveyor support 452. Over the conveyor is a transfer housing 454 on supports 456 and 458. On the sides of the housing are spur gears 460 and 462 which engage a rack 464 which moves within a rack support 466. Bearings 468 are provided. A catch tray 470 lies below the food service product P to catch any product P that is dropped.

In side view, as shown in FIG. 35 the food service products P are transferred through the housing 454 between dividers 472. An upper paddle plate 474 formed of Teflon material is provided on a paddle shaft 470. Below the upper paddle plate 474 is provided a lower paddle plate 476, also of Teflon. A shield hanger 478 has a shield support 480 mounted thereto a roller 482 is provided. The area within the circle 484 is described in further detail in conjunction with FIG. 37. The food service product P is transferred by being deposited by the upper transfer assembly to the transfer apparatus 448 on the upper paddle plates 474. The upper paddle plate rotates to transfer the product to the lower paddle plates 476, which then rotates to transfer the product to the conveyor.

A laminated roller is provided in the drop station to improve the performance of the food service article transfer from the upper transfer assembly to the conveyor belts.

Turning now to FIG. 36, a shield 486 extends below the six transfer stations of the transfer apparatus. A hinged cover 488 is shown supported by hinges 490. A locator finger 492 is provided for each of the coating stations have the Teflon paddle plates 476 and 474. A cover stop 494 is provided at three locations along the hinged cover 488.

Operation of the present apparatus has revealed that occasionally food service articles are produced that have the film delaminated from the foam body of the molded article. In such cases, this delaminated portion of film can become caught in the equipment, resulting in blockage of the process flow. The present drop station becomes a critical area for such blockage. A lowering of the leading edge of the drop station structure as seen by the inflowing product results in reduced blockage and better product pass through.

The enlargement of the area 484 in FIG. 35 is shown in FIG. 37. A shaft 500 is held in a shaft collar 502. A rotary actuator 504 is mounted on an end plate 506 and drives a gear assembly 508 that in turn rotates a shaft 510 held in a shaft collar 512. Operation of the actuator 504 rotates shafts 500 and 510 and moves the rack 464 of FIG. 34. The transfer apparatus 448 is shown from the opposite direction in FIG. 38, including a rack 514 which engages spur gears 516 and 518. The rack 514 is held in a rack guide 520. The roller mount 478 in which the roller 482 is mounted is shown on an extension bracket 522.

FIG. 39 shows an end view of the dust collector 76 which includes a number of brushes for collecting dust and debris from the trimmed molded food service articles. A motor 530 drives a belt 532 that in turn drives a pair of rotary brushes 534. A brush bracket 536 holds a brush support 538 which is one of several brush supports positioned on either side of the brushes 534. Additional brushes 536 are provided in a brush holder 538 supported on a bracket 540. The dust collector 76 is supported on legs 542 and has a dust collection hood 544.

Brushes have been provided for the dust collector 76 to brush against the food service articles. These brushes clean any remaining debris from the product that may remain after the sawing operation at the sawing station. For instance, so-called “angel hair” debris, fine wisps of the trimmed or partially trimmed foam material, may remain on the food service product after the trimming operation and the brushes are provided in such number and position to ensure removal of this undesirable excess, thereby preventing it from remaining on the food service product during the lamination step.

In FIG. 40, the motor 530 is mounted at the end of the dust collector 76 adjacent one of the legs 542. The dust collection hood 544 has two openings 546 through which a partial vacuum draws the air to remove the dust caused by trimming the food service product. The brushes 534 are cylindrical conveyor brushes which extend the width of the dust collector 76. The brushes are mounted in a flange bearing 548. A guard 550 is mounted around the ends of the brushes. The motor 530 drives the brushes through gear belt pulleys 552 so that the brushes rotate in the opposite direction of the product flow. Leg brackets and foot brackets 554 and 556, respectively, are mounted on the frame. A bearing spacer 558 is provided for ends of the rollers. The opposite end of the roller brushes are mounted in pillow block bearings 560.

A high volume vacuum pump is preferred for the dust collection system to increase the air flow and thereby collect a greater percentage of the dust and debris on the food service articles and on the equipment. This reduces the debris that would otherwise become trapped on the finished product during the lamination process. A high quality food service product is thus ensured.

FIG. 41, has the dust collector from a top view with a motor mounting plate 562 mounting the motor 530, a stationary brush mount 564 extends the width of the dust collector 76, which the rotary brushes 534 extend only partway and the balance of the distance is made up by a second rotary brush 534. A center mounting bar 566 supports the bearing spacers 558. The shafts 568 of the roller brushes extend from the pillow block 560.

The dust collector includes an air filter to remove the dust and debris collected by the apparatus from the air. In a preferred embodiment, this air filter is a self cleaning air filter. The self cleaning filter system is integrated with a debris transport system to remove the debris from the apparatus. The debris transport system provides automatic operation to thereby reduce maintenance costs and the chance of a scheduled cleaning being missed.

In the preferred arrangement, a single dust collection filter and debris transport is provided for each group of four manufacturing modules, in other words for each four press arrangement. This reduces the floor space required in the factory and reduces the cost of equipment.

Turning now to FIG. 42, the biodegradable film which is applied to the food contacting surfaces of the food service product is supplied to the coating apparatus from a roll, the filled portions of the film applied to the food service product are cut from the roll and the waste film is rerolled as scrap film with holes cut in it corresponding to the locations where the film was applied to the food service product. In FIG. 42, the apparatus for rerolling the waste film includes a frame 570 on which is mounted a reroll shaft 572 that is driven by a motor 574 through a pair of spur gears 576. The shaft is mounted in bearings 578 that are supported in a shaft retainer 580. A second take-up shaft 582 is mounted on the frame 570 in a second set of shaft retainer 584 for ready replacement of the take-up roller once it is filled. This second take-up shaft 582 means quicker change over from a filled take-up roll to a new take-up roll, reducing down time of the apparatus during an operating run.

In the side view of FIG. 43, the lower take-up roller 572 is driven by the motor 574 through the spur gears 576 via an ironman 588 which is supported on a bracket 590 on the frame 570. As can be seen in this side view, the shaft retainer 580 is hook shaped and holds the take-up roller 572 by gravity. Similarly, the shaft retainer 584 for the upper spare take-up roller 582 is also hook shaped. Thus, maintenance personnel may easily exchange the two take-up rollers by merely lifting from the hook-shaped retainers.

The press is shown in FIG. 44 with the support legs 370 holding up the press block 90. A lower mold set 92 having 36 lower mold portions mounted therein is setting on the press block 90. Support columns 600 support the upper press bolster 96 on which the upper mold set 94 is mounted. Guides 602 ensure alignment of the upper and lower mold sets 94 and 92 when pressed together. Additional bolts and dowels are provided in the press bolsters to improve the alignment of the press plates to the frame. The press corner posts are provided with dowel pins at the corner posts, which improves the alignment of the upper press ram to the lower press bolster.

The main press cylinder 98 is accompanied by two lift assist cylinders 102. Brackets 604 are mounted on the side of the press bed 90. A frame 606 extends from the top of the press at the upper press housing 608.

The press includes a lift fixture so that the press can be transported with minimal disassembly.

The press is assembled with fasteners, such a screws and bolts. The fasteners are preferably provided with an anti-seize compound that is optimized for this application.

In the back view of the press shown in FIG. 45, the lower mold set 92 includes a number of steam pipes 610 of a steam collection system that carry the steam away from the molds as the product is being formed. Similarly, steam collection pipes 612 are provided on the upper mold set 94. The steam collection system is designed to provide improved robustness. Foam insulation is provided for the steam collection system for insulation. The preferred steam collection system keeps the foam insulation contained. The steam pipes of a preferred embodiment are of stainless steel tubing, thereby providing an improvement over sheet metal and stove pipe steam collection systems. The steam collection system also includes drains to allow condensed moisture to escape from the system. Clean out doors are also provided on the steam collection system to permit cleaning of any slurry debris that may become trapped in the steam system.

A mounting bracket 614 is provided on the top of the press housing 608. While a further mounting bracket 616 extends upwardly from the press housing 608.

The press bolster and the press ram are provided with holes to provide clearance for bolts on the press plates. As the press plates are heated to operating temperature, they expand and so the bolts are subject to movement. The preferred system includes increased diameter holes in the press ram and bolster to accommodate the thermal expansion of the press plates and molds without binding.

In FIG. 46, the press has the steam conduits 610 and 612 directed downwardly and upwardly, respectively, so as not to interfere with one another during the pressing operation. Also apparent in FIG. 46, is the presence of wires 620 and 622 that extend from the upper and lower mold sets. These wires connect into small conduits and to temperature sensors for monitoring and maintaining temperature during the press operation.

The press plates for the mold sets 92 and 94 are provided with mounting holes for mounting the molds in the press. In a preferred embodiment, the mounting holes are in a symmetrical arrangement so that the assembly of the press does not depend on the worker positioning the mold in only one correct orientation. Eliminating the need for orientation of the press plates enables quicker and more error free assembly and servicing of the press, particularly during change over to mold other food service articles. Machining errors are also reduced by this symmetrical arrangement of mounting holes.

Further, geometric tolerances are incorporated into the press components and details so that the assembly will function properly.

The upper or second transfer assembly is shown in FIG. 47. As described above, the upper transfer assembly 60 engages two of the six rows of the food service product at a time. To accomplish this, two transverse members 640 extend between to the two transport rails 642 along which the transverse members 640 move. The transport rails 642 extend parallel to the direction of transport 644 of the food service product and permit the travel of the two transverse members 640 of the transfer assembly 60. The transverse members 640 each include, in the illustrated embodiment, six vacuum pickups or mandrels 646 that are shaped to hold the food service product. The vacuum pickups 646 are spaced and arranged to correspond to the spacing and arrangement of the food service products as formed in the molds. The vacuum pickups 646 are provided with air openings and air hoses to vacuum pumps so as to selectively apply a vacuum to the lower face of each of the pickups 646. The vacuum pickups are shaped to match the shape of the molded product. Vacuum switches 647 are provided on the transverse members 640.

The two transverse members 640 are connected to one another by crossbars 648 and the crossbars 648 are mounted to transverse frame members 650 so that the two transverse members 640 move as a unit along the rails 642. The movable component is also referred to as a shuttle. On the transverse members 642 are cylinder mounts 652. Vertical movement mechanisms 654 are provided on each end of each transverse member 640 to permit vertical movement of the transverse member 640 relative to the rails 642.

The movement of the transverse members 640 along the rails 642 is accomplished by a drive acting along the rails, the drive being operated through a transmission 656 at the end of each rail 642 that is driven through a drive shaft 658. The drive shaft 658 is rotated by a belt acting on a pulley 660. The drive shaft 658 is held in bearing blocks 662 for support.

The preferred embodiment of the upper or second transfer assembly has a strengthened shuttle frame, that is also preferably flattened. The shuttle of one embodiment has a frame formed of a rigid tooling plate and used doweled bearings to accomplish stable motion of the shuttle and product held thereon, thereby improving the quality of the lamination and trimming steps.

FIG. 48 shows the assembly 60 in side view, including six of the vacuum manifolds or mandrels 646, which are mounted on a pickup mounting plate 670. The mounting plate 670 has air channels 672 to the openings of the vacuum mandrels 646, the air channels 672 being connected to air lines through the vacuum switches 647. The vacuum switches are supported on a frame 649.

The upper transfer assembly moves in a vertical direction during operation. The vertical motion of the transverse members are enabled by the vertical guides 674. Vertical motion is provided by a pneumatic actuator. Stops 678 are provided to limit the vertical motion of the transverse member 640. A linear motion detector bracket 680 is mounted to the side of a slider 682 that rides on the rail 642. A standoff 684 holds a trough 686. A hose coupling 688 is also provided. A trough 690 is also provided on the opposite end of the transverse member 640. The troughs 686 and 690 provide support for cables and the like.

As a further improvement, the vertical guide shafts of the upper transfer assembly include bar straps to ensure that the guide shafts remain parallel. Error free operation results. Shocks are provided in the frame of the upper transfer assembly to smooth the vertical retraction motion.

In FIG. 49, the two transverse members 640 with the vacuum pickups 646 are spaced apart from one another by a distance sufficient to permit them to engage and carry the food service products from rows of product taken from the moldset spaced, in this case, three rows apart.

Rubber bumpers 692 are provided for contact with the stops 678 during vertical movement of the transverse member 640. A rubber bumper 694 is also provided adjacent the vacuum pickups 646, also for cushioning impact during the vertical movement.

A rail mount plate 696 is provided for each transverse member 640. In the center of the crossbars 648 is a manipulator 698.

FIG. 50 provides and overview of the manufacturing line of a module without the upper and lower transfer assemblies. In particular, the press 58 with the main cylinder 98 and the lift assists 102 are shown. A drive motor bracket 699 is provided on the press 58. The press 58 is connected to the frame 390 (see for example FIG. 30) that includes supports the rails from the upper and lower transfer assemblies (not shown in this view). The frame 390 is connected to the press 58 by extensions 700 connected at connectors 702 at the press. Brackets 703 for connection to the lower transfer assembly 72 is mounted on the frame 390. The rails 642 on which the upper transfer assembly 60 moves is mounted within the frame 390 by brackets 705 and 707. After the lower transfer assembly 72 transfers the food service product to the upper transfer assembly 60, the excess flashing is removed by the sawing and sanding station 62. The sanding and sawing station 62 has a plurality of saws 704 over which the food service product is passed for removal of the flashing before being transferred to the lamination station 64. The lamination station 64 has a film feed 706 adjacent thereto that provides the film web which is applied to the product at the lamination station 64. The film feed 706 includes a roller system, as will be explained in further detail hereinafter. A bracket 710 for mounting the lamination station components to the frame 390 is provided downstream of the laminator 64. The lamination station 64 includes heaters 712 mounted in recesses. A hose connection 714 is provided.

At the end of the rail 642 is the drive shaft 658 with the pulley 660. A motor, such as a servo motor, 716 with a gear box 718 drives the pulley 660. The motor 716 is mounted on a mounting bracket 720.

Turning to FIG. 51, the press 58 with the frame 390 attached by the connector 700 includes the rails 642 for the upper transfer assembly 60, which is shown in this view. The upper transfer assembly corresponds to the construction shown in FIGS. 47-49. Below the sawing and sanding station 62 is the dust collection station 76 which corresponds to the construction of FIGS. 39-41, and below that is the take up roller arrangement for pulling the film through the laminator 64. A supply roller for the film is provided as well, for example of the type shown in FIGS. 42 and 43, although that supply roller is not shown in FIG. 51. Instead, an alternative supply roller 724 is shown.

The upper transfer assembly is moved by the motor 716 acting through a belt 726 to the drive shaft pulley 660. An electrical cabinet 728 is provided on an elevated part 730 of the frame 390. The electrical cabinet 728 encloses the electrical controls for the present device and is connected by wiring that extends throughout the system. It is also possible that different portions of the present system may have separate electrical cabinets. Also mounted on the elevated part 730 is an upper transfer vacuum pump 732. The vacuum pump 732 is connected via appropriate hoses (not shown for the sake of simplicity) to the upper transfer assembly 60. A cable track support 734 extends from the elevated part 730. A hose coupling 736 is provided on this part.

The sawing and sanding station 62 is shown in FIG. 52. The sawing station includes a number of cylindrical saws 704 arranged in a as determined by the product being formed. The saws 704 are driven by belts 740 that interconnect various ones of the saws 704 with one another and with a pair of drives 742. Each drive 742 drives the saws 704 of one half the sawing station 62. The saws are mounted on a saw base 744, which is in turn supported on a saw frame 746. The saw frame is connected to the frame 390 shown in FIGS. 50 and 51. Idler rollers 748 maintain tension on the belts 740 to ensure proper running by all saws 704 and are mounted on the saw base 744. The saws 704 remove flashing and other excess material from the edges of the food service products, and the removed material is collected below the saws 704 and removed through a debris opening 750.

In the embodiment of the saw station 62 for trimming excess material from bowls or like food service article, the preferred arrangement includes only eight saw blades. This reduces the number of saw blades that are in contact with the food service product that must be aligned, adjusted and maintained. In general, it is desirable to reduce the number of saw blades for any product, while still having enough for the necessary trimming.

FIG. 53 is a side view of the sawing and sanding station 62, with the drives 742 including two electric motors 752 having drive pulleys 754 mounted on their output shafts. The drive pulleys 754 have the first ones of the belts 740 extending therearound and connected to a lower part of the first saw 704 in the row. The idler pulley 748 provides the tension on the first belt 740. The first saw has a second pulley section engaging the second belt 740 which extends to the other saws 704 in that half of the sawing station 62. A like arrangement is provided for the electric motor 752, drive pulley 754, belts 740 and saws 704 of the other side as well.

Each of the saws 704 has the pulley portion 758 that is driven by the belts 740 and an upper portion 760 on which is mounted a saw blade 762. The saw blades 762 define a cutting plane 764. The upper transfer assembly 60 (FIGS. 47-49) engage the food service product with the desired molded part secured in the vacuum pickup and any excess material, flashing or attached waste extending downward from the desired molded part. Movement of the upper transfer assembly 60 over the saws 704 with the excess material extending across the cutting plane 764 results in the excess being trimmed from the product.

To ensure that the product is not damaged during this trimming operation, the saw blades are provided with recessed arbors 766 below the cutting plane 764. By staggering the saws 704, it is ensured that no material passes the cutting station without being removed from the product. In the preferred embodiment, the saw blades are diamond abrasive wheels having direct plated diamond grit to provide both cutting and sanding operation simultaneously without the need for frequent sharpening or replacement.

A guard 780 is provided over each of the drive pulleys 754 to keep personal safe from the moving machinery. In the preferred embodiment, safety shields, covers and guards are provided throughout the present system, many of which are not shown for the sake of clarity in the illustrations.

The frame in which the saws are mounted is manufactured to a high tolerance, as are the saw spindles. This ensures that the saws do not deviate from a desired sawing plane, which results in a higher quality product. Specific flatness and parallelism requirements are provided for the saw spindles and the saw frame.

FIG. 54 provides a better view of the saws 704 mounted in the staggered, or zig-zag, arrangement and the saw blades 762 with the recessed arbors 766. A debris guard 784 is connected to a housing 786 in front of the saw blades 762. The debris guard 784 improves the removal of the debris that has been trimmed from the molded food service articles. A deflector 788 is mounted on a bracket 790 below the saw blades 762. In the preferred embodiment, the saw station includes one or more air jets directed toward the saws 762 to blow debris away from the saws during operation so is does not accumulate around the saws. The continued operation of the present apparatus is improved when dust, debris, and any excess material is kept clear of the operating machinery, so blower jets and vacuum debris collectors are provided as needed.

The end most saw 704 of the row is shown in FIG. 55, having the double wide pulley 758 for the belt from the drive 742 and the belt to the other saws. A long spindle 792 is mounted in bearings 794 in a mount housing 796 having a mounting flange 798. The upper end of the long spindle 792 is threaded and has a mounting collar 800 on which the saw blade 762 is mounted, such as by a threaded nut as shown in the preceding figure.

FIG. 56 shows the arrangement of mounting bores 802 in the mounting flange 798. By inserting bolts through the bores 802 in the mounting flange 798 and into the saw base 744, the saws 704 are securely mounted in the sawing station 62.

FIG. 57 is an inside saw 704 of the sawing station. The inside saw 704 has a single width pulley 758 mounted on the spindle 792. It is possible that the spindle 792 may be shorter than for the outside saws as shown in FIG. 55, or as show that the spindle 792 merely extends from the single width pulley 758. A lock washer and lock nut 804 hold the spindle 792 in the bearing 794. The mounting flange 798, which is also shown in FIG. 58, is configured like the saw of FIG. 55. A bearing cover 806 is provided on the upper end of the housing 796. The collar 800 is also referred to as a grind spacer. The threaded end 808 of the spindle 792 extends above collar 800.

The saw spindle assembly of the preferred embodiment include a modification to provide longer bearing life and prevent early bearing failure.

Turning to FIG. 59, the laminating station has an arrangement of six heating recesses or heat cans 712. The heat cans 712 are arranged in a heating assembly 814 that is mounted in a lamination frame 816. The product flow is indicated by arrow 818 indicating the direction from which the upper transfer assembly with the products held in the vacuum pickups moves into the lamination station 64 for application of the film over the food contacting surface. The lamination station heats the film over the heat cans 712 as the vacuum is applied to the vacuum pickups on the upper transfer assembly so as to draw the warm film against the surface of the plate or bowl. A hot air ring 820 at the edge of the heat cans 712 melts the film so as to cut out the portion applied to the plate or bowl and free it from the film web. The film web now has holes where the circular pieces where cut, but is otherwise in tact. A pair of rollers 824 and 826 are provided for advancing new film and take up of the used film.

Bumpers 822 are provided against which the upper transfer assembly contacts the film plate during the laminating process as to insure correct positions of the lamination steps.

The laminator is again shown in FIG. 60. The heat cans 712 each have heaters 830 deep within the laminator structure. Temperature sensing in the heat cans 712 is provided by stainless steel thermocouples that are mounted within the heat cans. These thermocouples provide a highly accurate and reliable sensing of the heat being applied to the film during lamination. Better heat control means more reliable lamination and better product flow through. A heat blanket 831 provides insulation and prevents cooling of the heaters and warming of the film where not desired, as well as saving energy in the operation of the device. Cooling bars 832 over which the hot film passes after being bonded to and cut from the plates or bowls is provided in the film path to ensure that the film is cool when rolled up on the waste roller. A thruster 834 is mounted to the frame 816. A plate stiffener 836 extends across the top of the lamination station 64. A cover, such as of Lexan, extends over the heater unit and thermal blanket 831.

The operating parameters, such as the temperature, time and airflow, used in the lamination process are important to the successful application of a quality lamination coating on the food service article. These parameters are controlled by a controller for optimized performance. The controller for this and other operating stations may be found in the electrical box shown in another portion of this specification.

The film plates and the mounting frame of the laminator are provided with holes and matching dowels to ensure alignment of the components during assembly.

FIG. 61 shows the heater 830 below the heat can 712. A bottom lower plate 840, top lower plate 842 and upper plate 844, which then has a covering of Teflon tape provides the film/plate/bowl contacting surface.

The heat cans 712 have an improved construction for easier fabrication and assembly, including the fabrication and assembly of both the inner heat cans and outer heat cans.

To the side of the frame 816 is the film mounting plate 850 on which is mounted the roller spacer 852 and a bearing block 854 for the film roller 856. A rod is held in a rod clamp 858.

The film for the laminator may be moved over the laminator heat cans via various means. In one embodiment, a driven pinch roller assembly 860 as shown in FIG. 62 engages the film between rollers 862 and 864 which are driven by a roller motor 866. The rollers 862 and 864 are mounted in bearing blocks 868 on mounting plates 870. The motor 866 drives the rollers via gears 872.

In the preferred embodiment, the frame for the pinch roller assembly 860 is provided with dowel holes and the pinch rollers 862 and 864 are provided with dowels to fit into the dowel holes to provide alignment of the pinch rollers on the frame. Faster and more reliable set up is provided.

FIG. 63 shows the arrangement of staggered bearing blocks 868 that provide for close spacing to ensure engagement of the film web. A cover 874 over the gears 872 prevents jamming of the gears with foreign matter or injury to workers. The mounting plates 870 are mounted on spacers 876 that are connected to a frame 878.

In FIG. 64, the gears 872 include a larger drive gear 880 for the drive motor and smaller gears 882 and 884 for the pinch rollers. A spacer block 886 ensures that the gears are aligned with one another. The pinch rollers of the preferred embodiment have the drive gears at only one end, rather than at both ends. This results in a reduced chance of binding by the rollers, and thus reduced maintenance and more independent operation of the system. Also, the use of gears at both ends of the pinch rollers could cause uneven rolling of the film. By careful alignment of the rollers and by providing the gears at only one end, uneven rolling is prevented.

The supply of film may be provided according to FIG. 65. The frame 888 has the vacuum pump 732 and electrical cabinet 728 as mentioned above on the upper part, while a supply spool 890 of the film is provided on the lower part. The film rolls off the supply roll 890 to a roller 892 on a bracket 894, then to a roller 896 on a dancer arm 898. The dancer arm 898 is mounted to pivot on a bearing 900 and is counterweighted by a weight 902. Sensors 904 sense the position of the dancer arm and control release of more film. A pusher and cylinder 906 are provided to insure proper film tension.

The unspooling of the film is powered by a gear assembly 910 driven by a motor 912, which is under control of the sensors 904. A toggle clamp 914 holds the supply roll in place and permits change out by service personnel.

FIG. 66 shows the film supply from the front view. The frame 888 supports both the film spool 890 and the vacuum pump 732. The electronics cabinet 728 is mounted atop the frame 888. Eyebolts 920 are connected to the top of the electrical cabinet 728 to which is connected supports, such as support cables, to provide stability to the present frame 888 and electrical cabinet 728. The pump 732 and the electrical cabinet 728 sit on a platform 922 that is supported not only by the outer frame members 924 but also by an intermediate frame member 926 connected to a cross bar 928.

In the lower part of the frame 888, the spool 890 is supported on a shaft 930 that extends to a gear 932 of the gear assembly 910, the gear 932 being driven by the motor 912 through a drive gear 934. As mentioned above, the motor 912 is controlled by the operation of a dancer arm 898.

FIG. 67, the film supply is illustrated in top view, including the dancer arm 898 by which the advancing operation of the spool 890 is controlled. The release apparatus 914 that permits the spool 890 to be released from the apparatus is operable to exchange an exhausted spool with a full spool of the film.

The film used in a preferred embodiment of the present apparatus has been produced by a process that eliminated so-called gel spots in the film. These uncured areas of the film react unfavorably during the lamination process so as to result in poorly covered areas on the final product. Ensuring that such areas do not occur provides a higher quality food service product.

A chiller is provided in the present food service article manufacturing apparatus. The chiller cools the laminating film that has been heated in the laminator, for example, to permit re-rolling on the take-up spool. For example, the cooling bars 832 may be connected to the chiller. In addition, the saw blades and saw units are preferably cooled by the chiller to maintain a constant temperature. It is also possible to utilize the chiller in cooling the product following the lamination station. Although it is possible to provide a chiller for each module, it is preferred to provide a single chiller for each group of four modules, so as to reduce equipment costs and floor space.

The present apparatus and method is disclosed for producing biodegradable food service articles; however, the present machinery may also be used to produce non-biodegradable articles as well. Further, the present machinery and method is not limited to food service articles but also could be used for producing products outside the food service industry.

A system for a manufacturing plant having four plate modules and the four bowl modules is provided. Each module is constructed to mold a plurality of the plates or bowls at the same time. For instance, the foregoing illustrations provide for molding 36 plates in a six by six arrangement of molds. The transfer assemblies are similarly configured. A bowl forming module of the preferred embodiment molds 64 bowls in an eight by eight arrangement of molds, with a similar change to the transfer assemblies to accommodate the eight by eight arrangement.

Thus, the present invention provides the a number of improvements over prior food service article forming systems.

Although other modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art.

Claims

1. An apparatus for manufacture of biodegradable food service articles and the like, comprising:

a press having upper and lower press plates operable to press the press plates together, said press plates defining cavities having a shape for molding a plurality of food service articles, said press being operable to form the food service articles in a matrix arrangement;

a heater in said press to heat said cavities;

a supply of biodegradable slurry;

a depositer mounted to move between said upper and lower press plates, said depositor being connected to said supply of biodegradable slurry and operable to deposit predetermined quantities of the slurry into said cavities in said press plates, said depositer including an accumulator to receive a quantity of the slurry from said supply and provide the slurry during depositing, said depositor including a plurality of depositor nozzles connected to said accumulator and being operable to deposit the slurry row by row in said matrix arrangement;

a first transfer assembly including a plurality of vacuum pickups in a matrix arrangement corresponding to said matrix arrangement of said press, said first transfer assembly being mounted and operable to move between said upper and lower press plates, said vacuum pickups being operable to engage molded food service articles substantially simultaneously in substantially all of said cavities of said matrix arrangement of said press and to remove the molded food service articles from said cavities, said first transfer assembly having a turn over apparatus constructed and operable to invert the food service articles held by said vacuum pickups, said first transfer assembly being movable along a first transfer path;

a second transfer assembly having a plurality of article vacuum holding elements, said second transfer assembly being operable to receive the molded food service articles from said vacuum pickups of said first transfer assembly at a transfer position and hold the food service articles in said article vacuum holding elements, said second transfer assembly receiving the food service articles from said first transfer assembly, said second transfer assembly constructed to receive rows of said food service products from said first transfer assembly, said second transfer assembly being movable along a second transfer path, said second transfer path overlapping said first transfer path at said transfer position;

a trimmer having trimming blades, said trimmer being positioned along said second transfer position and being constructed and operable to trim excess material from the molded food service articles held in said article vacuum holding elements of said second transfer assembly, said trimmer being constructed and operable to trim said food service articles on a row by row basis;

a dust collector operable to collect debris from said trimmer;

a laminator in said second transfer path, said laminator being operable to apply a film to a surface of the food service articles after said trimmer has trimmed the food service articles, said laminator constructed and operable to apply the film to the food service articles row by row;

an off loading station in said second transfer path and constructed and operable to receive the food service articles row by row from the second transfer apparatus;

a conveyor receiving the food service articles from said off loading station, said conveyor being constructed and operable to transport the food service articles along a conveying path in single file;

a coating station constructed and operable to apply a coating to the food service articles, said coating station being disposed along said conveying path;

an inspection station in said conveying path, said inspection station including an optical inspection device constructed and operable to visually inspect the food service articles on the conveyor, said inspection station including a food service article removing apparatus to selectively remove ones of the food service articles from the conveyor; and

a packaging station along said conveyor path.

2. An apparatus as claimed in claim 1, wherein said heater in said press includes heater rods and heat sinks in thermal contact with ends of said heater rods.

3. An apparatus as claimed in claim 1, wherein said press includes a lift fixture.

4. An apparatus as claimed in claim 1, further comprising: a deceleration valve on said press and connected to affect closure motion of said press.

5. An apparatus as claimed in claim 1, further comprising: insulation on said press at said press plates disposed to reduce heat loss from said press plates.

6. An apparatus as claimed in claim 1, wherein said supply of slurry is a hopper, and further comprising:

a transport cart for transport of mixed slurry to said hopper, said transport cart including a pump and a hose connected from said pump, said hose having a diameter of greater than 2 inches.

7. An apparatus as claimed in claim 1, wherein said slurry supply includes a low expansion hose.

8. An apparatus as claimed in claim 1, further comprising: air jets directed toward the food service articles held by said first transfer assembly.

9. An apparatus as claimed in claim 1, wherein said second transfer assembly includes manifolds shaped to hold the food service article, said manifolds being shaped to flex the food service article to present an edge of the food service article for trimming by said trimmer.

10. An apparatus as claimed in claim 9, further comprising: a ceramic coating on a surface of said manifolds.

11. An apparatus as claimed in claim 1, further comprising: a high performance vacuum pump connected to said second transfer assembly to generate a vacuum to hold the food service articles.

12. An apparatus as claimed in claim 1, wherein said second transfer assembly includes a shuttle mounted for movement along a frame, said shuttle having a frame formed of a rigid plate.

13. An apparatus as claimed in claim 1, further comprising: bar straps connected so vertical guide shafts of said second transfer assembly to maintain said guide shafts in parallel.

14. An apparatus as claimed in claim 1, further comprising: shocks on said second transfer assembly to cushion vertical motion of a shuttle of said second transfer assembly.

15. An apparatus as claimed in claim 1, wherein said apparatus is configured for forming bowls, and said trimmer includes eight trimming blades.

16. An apparatus as claimed in claim 1, further comprising: air jets directed toward said trimming blades of said trimmer.

17. An apparatus as claimed in claim 1, further comprising: debris guards at said trimmer mounted to deflect debris from said trimming blades.

18. An apparatus as claimed in claim 1, wherein said dust collector includes brushes contacting said food service articles to remove debris.

19. An apparatus as claimed in claim 1, wherein said laminator includes heaters to heat the film, said heaters including stainless steel thermocouples.

20. An apparatus as claimed in claim 1, wherein said off load station includes a lamination roller.

21. An apparatus as claimed in claim 1, wherein said laminator includes a film supply, said film supply including pinch rollers for moving the film of the film supply, said pinch rollers including drive gears at only one end of said pinch rollers.

22. An apparatus as claimed in claim 1, wherein said laminator includes a film take-up for used portions of the film, said film take-up including a second take-up roller station for supporting a second take-up roller.

23. An apparatus as claimed in claim 1, wherein said dust collector includes a self cleaning filter.

24. An apparatus as claimed in claim 1, wherein said apparatus includes a plurality of modules, each of said modules including: a press, a depositor, first and second transfer assemblies, a trimmer, a laminator and an off loading station, said plurality of modules being connected to a single one of said conveyor.

25. An apparatus as claimed in claim 24, wherein said dust collector includes a single vacuum apparatus for said plurality of modules.

26. An apparatus as claimed in claim 24, further comprising: a chiller connected to each of said plurality of modules.

27. An apparatus as claimed in claim 24, wherein said slurry supply is connected to supply slurry to each of said plurality of modules.

28. An apparatus as claimed in claim 24, wherein said conveyor includes a plurality of first conveyor portions connected to each of said plurality of modules at said off loading stations, said conveyor includes a single second portion extending from said first portions to said coating station and said inspection station and said packaging station.

29. An apparatus as claimed in claim 1, further comprising: a steam collection system connected to said press, said steam collection system including drains and clean out traps.

30. An apparatus as claimed in claim 1, wherein said depositor includes push lock connectors.

31. An apparatus as claimed in claim 1, wherein said first and second transfer assemblies are mounted to a frame, said frame including two frame portions capable of separate transport, said two frame portions being joined to one another to form said frame.

32. An apparatus as claimed in claim 1, further comprising: rotary actuators in said first transfer assembly connected to said vacuum pickups and operable to invert said vacuum pickups.

33. An apparatus as claimed in claim 1, wherein said press includes press plates for said molds, said press plates defining holes, said press having dowels mounted to extend into said holes in said press plates, said holes and dowels being sized to accommodate thermal expansion of said press plates.

34. An apparatus as claimed in claim 1, wherein said heater in said press includes a plurality of heater rods disposed in a corresponding plurality of holes in said press, said heater rods and said holes being sized to provide a loose fit of said heater rods in said holes.

35. An apparatus as claimed in claim 34, further comprising: thermocouples connected to ends of said plurality of heater rods.

36. An apparatus as claimed in claim 1, further comprising: alignment dowels and alignment openings between components of said apparatus.

37. A method for manufacturing biodegradable food service products, comprising the steps of:

mixing a slurry of biodegradable materials;

depositing said slurry as dollops of a predetermined quantity into molds for a plurality of food service articles;

pressing and heating said dollops to form an plurality of the food service articles;

removing the plurality of food service articles from said molds using a first vacuum pickup;

inverting the plurality of food service articles using said first vacuum pickup;

transferring ones of said plurality of food service articles to a second vacuum pickup;

flexing the food service articles in said second vacuum pickup;

trimming excess material from the food service articles while in said flexed condition in said second vacuum pickup;

coating at least one surface of the food service articles with a film; and

collecting and packaging the food service articles.

38. A method as claimed in claim 37, wherein said step of transferring including a first transferring step transferring less than all of the food service articles held by said first vacuum pickup to said second vacuum pickup and a second transferring step transferring further of the food service articles from said first vacuum pickup to said second vacuum pickup.

39. A method as claimed in claim 37, wherein said steps of depositing, pressing, removing, inverting, transferring, flexing, trimming and coating are performed simultaneously in a plurality of modules, and said step of collecting is performed for said plurality of modules in a single collecting apparatus.