PROCESS FOR PRODUCING MUSHROOMS IN A CLOSED CHAMBER ".
The present Patent of Invention refers to a process for producing mushrooms in a closed chamber, by the control of variables essential to the perfect development of mushroom cultivation, such as the compost temperature, room temperature and humidity, and the carbon dioxide content in the compost, by using temperature and humidity sensors during incubation and "graffiatura , and, additionally, carbon dioxide sensors and controllers during temperature lowering, induction to fructification, and harvesting, allowing greater productivity, better product quality, reducing production labor, allowing a greater flexibility by better adaptation to the several types of composts, greater profits, greater reliability, better contamination control, and easier production process management.
As it is well known by the technical means linked to the production of mushrooms in a closed chamber, nowadays, for producing mushrooms, are used thermally isolated chambers with refrigeration and heating control, with optional circulation of filtered cooled air, such air obtained by a refrigeration system, or circulation of filtered warm air, such air obtained by passage through an electrical resistor, being the air circulation made by fan with frequency rate manually controlled. There still is an entrance of secondary air through a dumper, directly from the atmosphere, besides room temperature sensors inside the chamber. Inside the chamber, hods are installed for direct placement of the sowed compost or shelves are installed for placement of the bags with the sowed compost. The addition of water in the compost is made manually through pails or helped by a hose. Opening inferior dumpers manually controls the exit of the carbon dioxide. These resources pose a limit to the current production processes, concerning
productivity, quality, reliability, profitability and contamination control, because there is not a control of important variables in the perfect development of the mushroom cultivation, such as the temperature of the compost, room temperature and humidit)', and carbon dioxide content in the compost, bringing inconveniences the production of mushrooms.
PROCESS FOR PRODUCING MUSHROOMS TN A CLOSED CHAMBER ", the object of the present patent, was developed to overcome the limitations and inconveniences of the current processes, because it has the domain and control of important variables in the perfect development of the mushroom cultivation, such as the temperature of the compost, room temperature and humidity, and carbon dioxide content in the compost, because it uses controllers and sensors for temperature and humidity, during incubation and "graffiatura''' and, additionally, sensors and controllers for carbon dioxide during the lowering of temperature, induction to fructification, and harvesting, what provides larger productivity, better quality of the product, decrease of labor in the production, flexibility represented by a better adaptation to the several types of composts, larger profitability, larger reliability, better contamination control and easier management of the production process.
For a better understanding of the present process the following drawings are enclosed:
FIGURE 1., that shows the block diagram of Phase A - Compost incubation;
FIGURE 2., that shows the block diagram of phase B - incubation and "' graffiatura " of the compost, Phase C - temperature lowering. Phase D - induction to the fructification and Phase E - harvesting;
FIGURE 3., that shows the diagram of the
process control.
According to the referred drawings the production process occurs in the following sequence:
I. Phase A - Compost Incubation;
1.1. Conventional previous chamber ( C ) sterilization by pulverizing a formaldehyde solution through a pump and hose and with internal air recycling;
1.2. conventional loading of the compost in the chamber ( C ) , manually or through a fray, directly in the hods or in bags ( S ) under shelves ( P ) , and with admission of filtrated air by fan ( VE ) with 100% of the flow rate and with external dumper ( DPE ) closed, being created a positive air flow in the chamber ( C ) ;
1.3. cleaning and conventional external sterilization of the compost bags, in case bags are used in the shelves;
1.4. Compost incubation for 15 to 20 days, through control of the compost temperature between 24 and 26 Celsius degrees, by placing a temperature sensor ( TCS ) directly in the compost, in a position which represents the average of the temperature of the compost obtained after determination of several temperatures and through turning on the electric resistor ( RE ) or the refrigeration system ( SR ) , through the control of relative humidity of the air inside the chamber in 85 to 95%, by placing a relative humidity sensor ( URS ) and room temperature sensor ( TAS ) inside the chamber ( C ) and placing an external dew point sensor ( TOS ) that controls the heating of the air through the electric resistors ( RE ) or cooling of the air through the refrigeration system ( SR ) and through the frequency rate controller ( VF ) that controls frequency rate of the motor ( M ) of the fan ( VE ) for air circulation in the chamber from 80 to 100% of the
frequency rate, all managed by Programmable Logical Controller ( PLC ) , that works the frequency rate controller ( VF ) , them servo-motors ( SM ) of the dumpers, the electrical contacts ( CT ) of the electric resistors and the solenoid valve ( VS ) of the refrigerating gas of refrigeration system;
1.5. conventional opening of the mouths of the bags ( S ) , in the case of using bags ( S ) on the shelves ( P ) ;
1.6. Sieving of covering earth through manual or mechanical sieve, separating only fine earth for use;
1.7. conventional correction of the pH of the covering earth, by adding vermiculite and gypsum or calcite with aid of a shovel and a pH meter or pH paper;
1.8. conventional sterilization of the covering earth with a 3 to 10 % aqueous solution of formaldehyde at 3 to 10% being used manually operated watering can and shovel and making the control by microscopy; Alternatively, sterilization of the covering earth through ultraviolet rays, by continuously passing it through a tray with a thin layer of earth on an ultraviolet ray generator;
1.9. conventional spreading of the sterilized covering earth upon the incubated compost, manually, and maintaining the chamber ( C ) with fan ( VE ) recycling between 80 and 100% of the air and with external dumper ( DPE ) closed, in so creating a positive air flow in the chamber ( C )
1.10. washing of the chamber ( C ) for withdrawal of the excess of covering earth, manually with aid of hose and water, at the same time keeping the chamber ( C ) closed with fan ( VE ) recycling between 80 and 100% of air, being temperature of the compost controlled between 24 and 26 Celsius degrees and relative humidity of the air in 88 to 95%, through the
sensors ( TCS ) , ( TAS ) , ( TOS ) and ( URS ) , controller ( PLC ) , fan ( VE ) , electric resistor ( RE ) , refrigeration system ( SR ) and motors ( SM ) of the dumpers ( DPE ) and ( DPI ) ;
1.1 1. addition of a 1 % formaldehyde aqueous solution on the covering earth by means of hose and pump, at the same time keeping closed the chamber ( C ) with fan ( VE ) recycling between 80 and 100% of air, compost temperature controlled in 24 to 26 ° C and relative humidity of the air in 88 to 95%, through the sensors ( TCS ) , ( TAS ) , ( TOS ) and ( URS ) , controller ( PLC ) , fan ( VE ) , electric resistor ( RE ) , refrigeration system ( SR ) and motors ( SM ) of the dumpers ( DPE ) and ( DPI ) ;
1.12. addition of an aqueous solution of insecticide on the covering earth by means of hose and pump, at the same time keeping closed the chamber ( C ) with fan ( VE ) recycling between 80 and 100% of the air, compost temperature controlled in 24 to 26 ° C and relative humidity of the air in 88 to 95%, through the sensors ( TCS ) , ( TAS ) , ( TOS ) and ( URS ) , controller ( PLC ) , fan ( VE ) , electric resistor ( RE ) , refrigeration system ( SR ) and motors ( SM ) of the dumpers ( DPE ) and ( DPI ) ; and
1.13. incubation of the covering earth during 10 to 13 days, keeping closed the chamber ( C ) with fan ( VE ) recycling between 60 and 80% of the air, compost temperature in 24 to 26 ° C and relative humidity of the air in 88 to 95%, through the sensors ( TCS ) , ( TAS ) , ( TOS ) and ( URS ) , controller ( PLC ) , fan ( VE ) , electric resistor ( RE ) , refrigeration system ( SR ) and motors ( SM ) of the dumpers ( DPE ) and ( DPI ) ;
II. Phase B - Incubation and " Graffiatura "' ILL Revolving of the covering earth manually, at the same time keeping closed the chamber ( C ) with fan ( VE ) recycling between 60 and 80% of the air, compost temperature controlled in 24 to 26 ° C and
relative humidity of the air in 88 to 95%, tlirough the sensors ( TCS ) , ( TAS ) , ( TOS ) and ( URS ) , controller ( PLC ) , fan ( VE ) , electric resistor ( RE ) , refrigeration system ( SR ) and motors ( SM ) of the dumpers ( DPE ) and ( DPI ) ; and
II.2. Keeping the chamber ( C ) closed by 48 hours with fan ( VE ) recycling between 60 and 80% of the air, compost temperature controlled in 24 to 26 ° C and relative humidity of the air in 88 to 95%, through the sensors ( TCS ) , ( TAS ) , ( TOS ) and ( URS ) , controller ( PLC ) , fan ( VE ) , electric resistor ( RE ) , refrigeration system ( SR ) and motors ( SM ) of the dumpers ( DPE ) and ( DPI ) ;
III. Phase C - Lowering of Temperature;
III.1. Lowering of the compost temperature to 16 to 19 °C, keeping of the relative humidity of the air in 88 to 95% and carbon dioxide content in 600 to 1200 ppm ( parts per million ) in the compost, during 1 to 2 days, with chamber ( C ) closed, with fan ( VE ) having a frequency rate variable in function of the reading of carbon dioxide content, managed by the Programmable Logical Controller ( PLC ) , according to the data of the compost temperature sensor ( TCS ) , of the carbon dioxide sensor ( C02S ) , of the room temperature sensor ( TAS ) , of the dew temperature sensor ( TOS ) and of the relative humidity sensor ( URS ) and by acting frequency rate controller ( VF ) of the motor ( M ) of the fan ( VE ) , of the electrical contacts ( CT ) of the electric resistors ( RE ) , of the solenoid valve ( VS ) of the refrigeration system ( SR ) and of the servo motors ( SM ) of the internal dumper ( DPI ) and external dumper ( DPE ) ;
IV. Phase D - Induction to Fructification; and
IV.1. Lowering of the room humidity to 84 to 88%, variation of the frequency rate of the fan ( VE ) in function of the carbon
dioxide content, keeping of the compost temperature in 16 to 19 ° C and keeping of the carbon dioxide content between 600 and 1200 ppm, through the management by the confroller ( PLC ) , according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ) , the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ;
V. Fase E - Harvesting
V. l . Conventional adding of an aqueous solution of Sodium or Calcium Hypochlorite on the covering earth by means of pump and hose, with the chamber ( C ) closed and keeping room humidity in 84 to 88%, frequency rate of the fan ( VE ) in 100% until drying of the mushroom. Soon after the frequency rate will vary with the carbon dioxide content, the compost temperature will vary between 16 and 19 ° C and carbon dioxide content between 600 and 1200 ppm, through the management by the controller ( PLC ) , according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ) , the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ;
V.2. growth for 5 days, with the chamber ( C ) closed and keeping room humidity in 84 to 88%, frequency rate of circulation of the fan ( VE ) variable with the carbon dioxide content, compost temperature in 16 ° C to 19 ° C and carbon dioxide content in 600 to 1200 ppm, through the management by the controller ( PLC ) , according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ) , the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ;
V.3. conventional harvesting of the 1st Harvest for 5 days using knife and pail, with the chamber ( C ) closed and keeping room
humidity in 84 to 88%, frequency rate of the fan ( VE ) variable with the carbon dioxide content, compost temperature in 16 to 19 ° C and carbon dioxide content between 600 and 1200 ppm, through the management by the controller ( PLC ) , according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ) , the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ;
V.4. Conventional adding of an aqueous solution of Sodium or Calcium Hypochlorite on the covering earth by means of pump and hose, with the chamber ( C ) closed and keeping room humidity in 84 to 88%, frequency rate of the fan ( VE ) in 100% until drying of the mushroom. Soon after the frequency rate will vary with the carbon dioxide content, the compost temperature will be kept between 19 and 21 ° C and carbon dioxide content between 750 and 950 ppm, through the management by the confroller ( PLC ) , according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ) , the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ;
V.5. growth for 3 days, with the chamber ( C ) closed and keeping room humidity in 84 to 88%, frequency rate of the fan ( VE ) variable with the carbon dioxide content, compost temperature between 19 ° and 21 °C and carbon dioxide content between 750 and 950 ppm, through the management by the controller ( PLC ) , according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ) , the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ;
V.6. conventional harvesting of the 2nd Harvest for 5 days by means of knife and pail, with the chamber ( C ) closed and keeping room humidity in 84 to 88%, frequency rate of the fan ( VE ) variable according to
the carbon dioxide content, compost temperature between 19 ° C and 21 ° C and carbon dioxide content between 750 and 950 ppm, through the management by the controller ( PLC ) , according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ) , the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ;
V.7. Conventional adding of an aqueous solution of Sodium or Calcium Hypochlorite on the covering earth by means of pump and hose, with the chamber ( C ) closed and keeping room humidity in 84 to 88%, frequency rate of the fan ( VE ) in 100% until drying of the mushroom. Soon after the frequency rate will vary with the carbon dioxide content, the compost temperature will be kept between 19 and 21 ° C and carbon dioxide content between 950 and 1200 ppm, through the management by the controller ( PLC ) , according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ) , the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ;
V.8. growth for 3 days, with the chamber ( C ) closed and keeping room humidity in 86%, frequency rate of the fan ( VE ) variable with the carbon dioxide content, compost temperature between 19 ° and 21 ° C and carbon dioxide content between 950 and 1200 ppm, through the management by the controller ( PLC ) , according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ) , the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ;
V.9. conventional harvesting of the 3rd Harvest for 5 days by means of knife and pail, with the chamber ( C ) closed and keeping room humidity in 84 to 88%, frequency rate of the fan ( VE ) variable with the carbon dioxide content, compost temperature between 19 ° and 21 ° C and
carbon dioxide content between 950 and 1200 ppm, through the management by the controller ( PLC ), according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ) , the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ;
V.10. Conventional adding of an aqueous solution of Sodium or Calcium Hypochlorite on the covering earth by means of pump and hose, with the chamber ( C ) closed and keeping room humidity in 84 to 88%, frequency rate of the fan ( VE ) in 100% until drying of the mushroom. Soon after the frequency rate will vary with the carbon dioxide content, compost temperature will be kept between 18 and 22 ° C and carbon dioxide content above 1200 ppm, through the management by the controller ( PLC ), according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ) , the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ;
V.l 1. growth for 3 days, with the chamber ( C ) closed and keeping room humidity in 84 to 88%, frequency rate of the fan ( VE ) variable in function of the carbon dioxide content, compost temperature 18 ° C and 22 ° C and carbon dioxide content above 1200 ppm, through the management by the controller ( PLC ) , according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ), the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) ; and
V.l 2. conventional Harvesting of the 4th Harvest for 5 days by means of knife and pail, with the chamber ( C ) closed and keeping room humidity in 84 to 88%, frequency rate of the fan ( VE ) variable with the carbon dioxide content, compost temperature between 18 ° C and 22 ° C and carbon dioxide content above 1200 ppm, through the management by the
controller ( PLC ), according to the data of the sensors ( TCS ) , ( TOS ) , ( TAS ) , ( C02S ) and ( URS ) and by acting the fan ( VE ), the resistors ( RE ), the refrigeration system ( SR ) and the dumpers ( DPI ) and ( DPE ) .
The openings of the dumpers ( DPI ) and ( DPE ) are directly interlinked to the carbon dioxide content, having manual or automatic control, the operator being able to choose an option more adapted to each situation, that is to say: to change only the frequency rate of the fan ( VE ) , to change only the dumpers and to change both simultaneously ( automatic system ) .
The control of the dew temperature allows to adapt the room relative humidity through the refrigeration system ( SR ) or the heating resistors ( RE ) , using the parameters of a psycrometric chart.
The enthalpy is used when the external temperature and relative humidity are close to the values internally adjusted in the chamber. If this happens the external air dumper is opened and the internal recycling dumper is closed for use of the variables available in the external environment. Its use aims to reduce costs with electrical energy and to provide a natural environment more adapted to the mushroom growth.