TR2023008908A2 - COMPACT GRAMING, FILLING AND IRONING MACHINE FOR DOUGHY FOOD PRODUCTS - Google Patents

Abstract

The invention is related to the gramming, filling and ironing machine that grammages kashar cheese and similar doughy food products and fills them into molds in the food industry.

Description

DESCRIPTION COMPACT SIZING, FILLING, AND IRONING MACHINE FOR DOUGH-LIKE FOOD PRODUCTS Technical Field The invention relates to a machine that weighs cheddar cheese and similar doughy food products in the food industry and fills them into molds. The invention specifically relates to a machine that increases process efficiency for portion and weight types of cheddar cheese and similar doughy food products, ensures hygienic production conditions, prevents product losses and food waste, reduces related equipment investments, and saves space in the production line. State of the Art In cheddar cheese production, curd with certain technical properties is transformed into cheese dough by fermentation and acidity development, which is then given the desired structural properties during the boiling process. The structural characteristic in question is a product property defined as "texture" in food science and will be referred to as "structure" in the following descriptions. Cheese dough, at the end of the boiling process, is fluid at a temperature around 7°C. During this stage, the cheese is molded and cooled to a structure suitable for weighting and shaping. After ripening, depending on the type, it is packaged and marketed. During the cooling phase, kashar cheese develops its characteristic semi-hard structure, and different extraction techniques are used to remove it from the mold before packaging. Ensuring food safety in the market is the responsibility of the food producer. The deterioration of foods with high protein and nutritional value, such as cheese, within their intended shelf life, leading to spoilage reactions, rendering them inedible, leads to serious food waste and/or health problems. Kashar cheeses have improved their resistance to microbiological spoilage compared to other cheeses due to the heat treatment applied during the boiling process and the product's physicochemical structure, particularly its low water activity. The most common spoilage in kashar cheeses is the formation of yeast and mold on the surface. Hygienic conditions during post-boiling processing are a determining factor in this problem. However, facilities established in the food sector are subject to unplanned growth and infrastructure development, driven by the supply-demand balance within the sector. The global economy develops in a similar cycle, with small businesses gradually expanding into medium- and large-scale investments. The formation of customs unions and the periodic removal of customs barriers, coupled with changing global dynamics, significantly accelerate the development cycle of these investments. Therefore, the adaptability of manufactured machinery to different scales and types of fields is crucial. The need for universal machines, both in terms of capacity and functionality, is increasing. Current technology results in slow filling of weighing tubes due to pressure fluctuations caused by product flow within the product exit throat where weighing is initiated. Therefore, prematurely filled tubes are exposed to longer pressure while waiting for other tubes, creating deformations in the cheese dough known as burring. This creates permanent deformations, even though guides are provided during the dropping process. Furthermore, the surfaces of the weighing tubes that come into contact with the product are coated with a special material to prevent sticking, and the coating process must be repeated. Furthermore, operators must feed multiple cheese cassettes into the machines during operation, and operating ergonomics are inadequate in systems with multiple lines. Document number TR2018/16922 can be cited as an example of the state of the art. In this document, the technique involves guiding the product, which exits the cheese mold via a lowering table and discharge tube located in the exit throat group, into the cheese mold. Depending on the distance, non-standard-shaped products are formed in the molds. In this case, non-standard-shaped food products, once placed in the molds, cause process efficiency losses and quality defects throughout the production line. Furthermore, the ironing process is positioned on the conveyor that transports the product after weighing and molding. This ironing technique involves pressing and flattening the soft product within the mold and will hereafter be referred to as "ironing." The transition from molding to the ironing process necessitates a conveyor, requiring additional space and machinery investments. Consequently, the existence of the aforementioned problems and the inadequacy of existing solutions necessitated development in the relevant technical field. Purpose of the Invention: The present invention relates to a weighing, filling, and ironing machine that eliminates the aforementioned disadvantages and introduces new advantages to the relevant technical field. The main purpose of the invention is to develop a machine that increases process efficiency for kashar cheese and similar pasty food products, prevents product losses and food waste by improving hygienic infrastructure conditions, reduces equipment investments, and saves space in the production line. The purpose of the invention is to develop a machine that allows the same filling tube to be used within the profile mold sheet, using dividing devices, and with low investment costs, allowing for other weight types to be produced without the use of different tubes. This eliminates the need for racks, carts, and other transportation/storage equipment for these molds. The surfaces of the weighing tubes that come into contact with the product are coated with a special material to prevent sticking, and the coating process must be repeated. Due to the reduced equipment investment in the weighing tubes, the inventory and maintenance costs associated with backing up during this surface renewal process will also be significantly reduced. Another purpose of the invention is to create a machine that simultaneously injects product into the weighing tubes by rotating the product exit throat, where the weighting is initiated, 90°, ensuring even filling. It also prevents deformations by bringing the mold closer to the filling table. Another purpose of the invention is to create a compact machine that incorporates the ironing process thanks to innovations in the weighting and filling technique. Another purpose of the invention is to create a machine that saves space in the area transferred to the mold after weighting, incorporating the ironing process into this stage, eliminating the need for product advancement on the conveyor, and providing both space savings and efficiency in the process solution. Cassette input and output are made in the same area, and the advancement mechanism is positioned at the bottom. Another purpose of the invention is to create a machine that adapts the operator's manual cassette feeding position to the cassette feeding group by changing the direction of the product outlet throat, thus improving workspace ergonomics. Another purpose of the invention is to create a machine that allows multiple machines to be installed side by side in high-capacity production lines, enabling each machine operator to work side by side, thanks to improved workspace ergonomics. Another purpose of the invention is to create a machine that reduces equipment investment and storage space requirements for weighing tubes by using a partitioning method in the filling table group where weighing takes place, and also reduces labor time associated with mold changes during line operation. Another purpose of the invention is to produce a machine that significantly reduces stock and maintenance costs related to surface renewal and spare parts during the processing process by reducing equipment investment in weighing tubes. In order to fulfill all the objectives stated above and that can be derived from the detailed description, the invention; In the food industry, a weighing, filling and ironing machine that weighs kashar cheese and similar pasty food products and fills them into molds - cheese dough feeding group with a product exit throat, - filling table flange located on the product exit throat and closing the product exit throat by opening, filling table group with a weighing tube that ensures the filling and weighing of the cheese dough conveyed from the product exit throat, - profile mold guide positioned inside the weighing tube and enabling the preparation of products of different weights from the pasty food mass in flexible grams, - first intermediate partition and second intermediate partition separating the weighing tube, - height-adjustable adjustment group located inside the weighing tube to enable weight adjustment during product filling, - teflon bottom slide moving by means of movement pistons on a lower table and product - Filling table bed with a cutting mouth connected to the teflon lower slide that enables the cutting of the cheese dough conveyed to the exit throat in different sizes of elastic structure, - Cheese ironing group having spring-moving pressure wedges connected to the ironing sheet in order to create pressure on the surface of the cheese dough in the mold by moving downward by means of a cylinder on the lower surface of the ironing upper sheet on the ironing binding sheet, - Pilot pin that moves within the piston sliding bed located on the ironing upper sheet and transfers the movement provided by the cylinder connected to the ironing upper sheet to the ironing sheet, - Servo group chassis with the servo group that moves the movement pistons, - Weight adjustment and control unit that transmits downward movement to the profile mold guides and ensures that the weighted product exits the weighting tube and is transferred to the filling cassette with a free-falling movement. The structural and characteristic features and all advantages of the invention, including a reducing group, will be understood more clearly thanks to the figures given below and the detailed explanation written by making references to these figures. Therefore, the evaluation should be made by taking these figures and the detailed explanation into consideration. Figures Revealing the Details of the Invention Figure 1: Disassembled view of the gramming, filling and ironing machine which is the subject of the invention. Figure 2: Disassembled view of the cheese filling cassette advancement group of the gramming, filling and ironing machine which is the subject of the invention. Figure 3: Disassembled view of the filling table bed of the gramming, filling and ironing machine which is the subject of the invention. Figure 4: Disassembled view of the cheese ironing group of the gramming, filling and ironing machine which is the subject of the invention. Figure 5: View of the spring-moving pressure wedges of the weighing, filling and ironing machine which is the subject of the invention. Figure 6: View of the filling table of the weighing, filling and ironing machine which is the subject of the invention in disassembled state. Explanation of Part References 1.1. Product outlet throat 2. Cheese filling cassette advancing group 2.1. Advancement group chassis 2.2. Slide support bracket 2.3. AlpoIen slide 2.4. Teflon slide 2.5. Filling cassette advancing group 2.6. Multi-position cylinder 3. Filling table bearing 3.1. Lower table 3.2. Teflon lower slide 3.3. Bearing group 3.3.1. Slide gap adjustment shoe 3.4. Piston 3.5. Cutting edge 4. Cheese ironing group 4.1. Ironing upper sheet 4.2. Ironing sheet 4.3. Ironing connecting sheet 4.4. Pilot pin 4.5. Shaft protection 4.6. Spring moving pressure wedge 4.7. Piston connecting piece 4.8. Piston sliding bearing 4.9. Quick coupling socket 4.10. Cylinder. Servo group chassis 6. Filling table 6.1. Filling table flange 6.2. Weighting tube 6.3. Profile mold filling guide 6.4. First intermediate partition 6.5. Second intermediate partition 6.6. Adjustment group 6.7. Fixing bolt 6.8. Piston connecting component 7. Cage housing 8. Weight adjustment and reduction group Detailed Description of the Invention In this detailed description, the preferred alternatives of the weighing, filling, and ironing machine which is the subject of the invention are explained only for the purpose of a better understanding of the subject and in a way that does not create any limiting effects. Figure 1 shows a disassembled view of the weighing, filling, and ironing machine which is the subject of the invention. Accordingly, the weighing, filling, and ironing machine in its most basic form includes the cheese dough feeding group (1), cheese filling cassette advancement group (2), filling table bed (3), cheese ironing group (4), servo group chassis (5), filling table (6), cage housing (7), and weight adjustment and reduction group (8). In the cheese dough feeding group (1), the cheese dough is conveyed to the product exit throat (1.1) via augers and weighed using the system in the filling tray group (6). The product exit throat (1.1) extends vertically upward. According to the operating principle of the weighting, filling, and ironing machine in question, the cheese dough coming from the cheese dough feeding group (1) passes through the filling tray (6) and the filling tray bed (3) before being filled into the weighing tube (6.2). The product, weighted horizontally and vertically, is discharged into the filling cassette within the cheese filling cassette advancement group (2). The surface is smoothed and prepared for the next stage with the activation of the cheese ironing group (4). The weighting process in question is the preparation of a specific mass of cheese by portioning it for sale and packaging. In the following descriptions, it will be referred to as the weighting process. In the weighting process, the cheese dough, conveyed to the product exit throat (1.1) via augers in the cheese dough feeding group (1), passes through cutting nozzles (3.5) at different weights and is filled into the weighting tube (6.2) by the injection of profile mold filling guides (6.3). During this process, the weight of the cheese mass filled into the mold is controlled by the function of the profile mold filling guides (6.3). A height-adjustable adjustment group (6.6) has been designed using the bolt principle for precise weight adjustments of standard quality when filling standard volumes of product into the weighting tubes (6.2). The filling table group (6) is fixed to the pistons (3.4) on the filling table bed (3) using piston mounting components (6.8). In this fixed structure, the movement transmitted by the pistons (3.4) to the filling table (6) completes the weighting phase by cutting the elastic cheese dough at the end of the weighting process. The Teflon lower slide (3.2) prevents adhesion to the weighting cutting surface, and the filling process is completed with the ongoing movement. The slide gap adjustment shoe (3.3.1), located under the bed group (3.3), adjusts the pressure on the Teflon lower slide (3.2), thus minimizing part replacement and extending the life of the filling table bed (3). Profile mold filling guides (6.3) are positioned inside the weighing tube (6.2) to prepare products of various weights from pasty food masses and are separated by first and second partitions (6.4) and second partitions (6.5), selected according to product type. The first and second partitions (6.4) and (6.5) are separate. The first and second partitions (6.4) and (6.5) are fixed with a fixing bolt (6.7) to prevent flow resistance due to dough rheology during weighing and filling. The movement transmitted from the reducer and piston in the weight adjustment and reduction group (8) causes the profile mold filling guides (6.3) of different weights, located within the profile mold sheet mounted on the filling table flange (6.1), to oscillate up and down, thus achieving weight adjustment and mold filling. The screws in the cheese dough feeding group (1) convey the cheese dough to the product exit throat (1.1) and ensure that it is filled into the weighing tube (6.2) located at the product exit throat (1.1). The profile mold filling guides (6.3), which move upwards during filling, are stopped by the weight adjustment and reduction group (8) when the filling volume is complete. Upon completion of filling, the stop signal from the servo group (5) in the servo group chassis is transmitted to the pistons (3.4), which, upon activating the pistons (3.4), allow the Teflon lower slide (3.2) to move horizontally. This movement allows the elastic cheese dough to be cut by the cutting aperture (3.5) of varying sizes, mounted on the Teflon lower slide (3.2) on the filling table bed (3). The product, cut and weighted from the cheese dough at the product exit throat (1.1), is then transported to the filling chamber as the Teflon lower slide (3.2) continues its horizontal movement. The activation of the piston in the weight adjustment and reduction group (8) causes a downward movement of the profile mold filling guides (6.3), allowing the weighted product to exit the weighting tube (6.2) and be transferred to the filling cassette with a free-falling movement. The distance between the two eyelets/openings on the lower table (3.1) with the bearing group (3.3), where weighting and filling are performed, is preferably 113 mm. After the weighting tube (6.2) falls into the filling chamber, the multi-position cylinder (2.6) is activated and initiates its first movement, advancing the filling cassette 113 mm. Meanwhile, the newly weighted product is discharged from the filling table group (6). Similarly, the filling tray (6) moves in a synchronous back-and-forth motion, parallel to the movement of the filling tray (6), ensuring regular filling in the filling cassette. The filling tray (6), which moves vertically and horizontally during weighing and filling, is positioned by mounting the weighing tube (6.2) on the filling tray flange (6.1). The filling tray flange (6.1) is connected to the pistons (3.4) via piston mounting components (6.8), forming the mechanism that provides horizontal movement. The horizontal sliding motion transmitted by the pistons (3.4) to the filling tray operates via the slide system (2) in the cheese filling tray advancement group. On the cheese filling cassette advancement group (2), there is a roller guide (2.3) that supports the filling cassette advancement group (2.5) for the advancement of the filling cassettes. The cheese filling cassette advancement group (2) is mounted on the advancement group chassis (2.1) to ensure synchronous operation with the filling table bearing (3). The roller guides (2.3) are mounted on the advancement group chassis (2.1) by welding the slide support bracket (2.2). The surface of the cheese dough, placed on the filling cassette from the filling table bearing (3), is smoothed by the cheese ironing group (4) and prepared for removal from the mold after cooling. The cheese ironing group (4) is mounted on the upper ironing plate (4.1) to form the operating mechanism. This complete mechanism is connected to the lower table (3.1) via the ironing connecting plate (4.3). The cylinder (4.10) mounted on the upper ironing plate (4.1) transfers the motion transmitted by compressed air in the pneumatic system to the ironing plate (4.2) via the pilot pin (4.4) moving within the piston guide bearing (4.8) on the upper ironing plate (4.1). Spring-loaded pressure wedges (4.6) in various weights are mounted on the ironing plate (4.2) using the quick coupling socket (4.9). The downward movement of the ironing plate (4.2) creates pressure on the surface of the cheese dough in the mold. The piston guide bearings (4.8) are protected against the adverse effects of environmental conditions by being enclosed in a shaft guard (4.5) mounted on the ironing top plate (4.1), ensuring continuity of operation. The cylinder (4.10) on the ironing top plate (4.1) connects the piston connecting piece (4.7) mounted on the ironing top plate (4.2) to the ironing top plate (4.1). The movement transmitted by compressed air from the cylinder (4.10) to the cheese ironing group (4) from the point where the piston connecting piece (4.7) is located, initiates the movement of the pilot pins (4.4) within the piston guide bearings (4.8), and the spring-loaded pressure wedges (4.6) apply pressure to the cheese surfaces. The surface of the soft, malleable cheese dough is smoothed, and after it hardens, it is ready for vacuum removal from the mold. Spring-action pressure wedges (4.6) contain spring-action pressure wedge elements that provide precise adaptation for different weight steps within the same mold. For different weights, the spring-action pressure wedges (4.6) are mounted to the ironing plate (4.2) using a quick-coupling socket (4.9). For the movement of the spring-action pressure wedges (4.6) for different weights, the cylinder (4.10), connected to the piston connecting piece (4.7), opens and closes the piston, providing movement via the pilot pin (4.4). The ironing plate (4.2), piston connecting piece (4.7), pilot pin (4.4), and quick coupling socket (4.9) form a complete system for the ironing of different weights of fabric, which is connected to the ironing plate (4.2) via a quick coupling socket (4.9). The piston moves within the guide bearing (4.8) to perform the ironing. The parts of the machine where weighing, filling, and ironing take place are enclosed within a cage enclosure (7), preventing access to moving parts to ensure machine safety. In the single filling technique applied to the weighing, filling, and ironing machine in question, the weighing tube (6.2) is advanced and emptied after filling. Meanwhile, the product outlet throat (1.1) is closed by the filling table flange (6.1) and the product accumulates inside. As the weighing tube (6.2) returns to its position at the product outlet throat (1.1), the accumulated product is filled into the weighing tube (6.2).

Claims (1)

STEMS 1. It is a gramming, filling and ironing machine that weighs kashar cheese and similar doughy food products and fills them into molds in the food industry. Its features are; Cheese dough feeding group (1) with product outlet throat (1.1), filling tray flange (6.1) located on the product outlet throat (1.1) and closing the product outlet neck (1.1) by opening it, from the product outlet throat (1.1). 1 .1) filling table group (6), which has a gramming tube (6.2) that allows the cheese dough to be filled and weighed, a profile mold filling guide (6.3) positioned inside the gramming tube (6.2) and enabling the preparation of products in flexible weights in different amounts from the doughy food mass, The first intermediate partition (6.4) and the second intermediate partition (6.5), which separate the gramming tube (6.2) and are different from each other, are the adjustment group (6-6) located within the gramming tube (6.2) and whose height can be adjusted to enable weight adjustment during product filling. Filling with a teflon bottom slide (3.2) moving by pistons (3.4) on a bottom plate (3.1) and a cutting nozzle (3.5) of different sizes connected to the teflon bottom slide (3.2) which enables the cheese dough transmitted to the product outlet throat (1.1) to be cut in different sizes. The tray bed (3) is connected to the lower tray (3.1) with the ironing binding sheet (4.3) and the ironing upper sheet (4.1) on the ironing binding sheet (4.3) moves downwards by means of the cylinder (4.10) on its lower surface and presses on the surface of the cheese dough in the mold. cheese ironing with spring-moving pressure wedges (4.6) connected to the ironing sheet (4.2) to form The pilot pin (4.4) transfers the movement to the ironing sheet (4.2), the servo group with the servo group that activates the pistons (3.4), transmits downward movement to the profile mold filling guides (6.3) and allows the weighted product to come out of the weighting tube (6.2) and fall freely into the filling cassette. It contains a grammage adjustment and reduction group (8) that enables it to be transferred by movement. It is a gramming, filling and ironing machine in accordance with claim 1, and its feature is; It contains a fixing bolt (6.7) that ensures the fixing of the first intermediate partitions (6.4) and the second intermediate partitions (6.5). It is a gramming, filling and ironing machine in accordance with claim 1, and its feature is; It contains a piston fastening component (6.8) that enables the said filling tray group (6) to be fixed to the pistons (3.4) on the filling tray bed (3). It is a gramming, filling and ironing machine in accordance with claim 1, and its feature is; It contains a slide gap adjustment shoe (3.3.1) located under the mentioned bearing group (3.3) and allowing pressure adjustment for the teflon bottom slide (3.2). It is a gramming, filling and ironing machine in accordance with claim 1, and its feature is; It contains a quick coupling socket (4.9) that enables the said spring-moving pressure wedges (4.6) to be grasped by connecting them to the ironing plate (4.2). It is a gramming, filling and ironing machine in accordance with claim 1, and its feature is; It contains spring-action pressure wedges (4.6) that provide adaptability for different weight steps within the same mould. It is a gramming, filling and ironing machine in accordance with claim 1, and its feature is; It contains a piston connecting piece (4.7) that is connected to the said ironing sheet (4.2) and forms the connection between the cylinder (4.10) on the ironing top sheet (4.1) and the ironing top sheet (4.1).