IE20060142A1 - A method for deboning carcasses - Google Patents

Abstract

A method for deboning carcasses comprises the steps of (a) transporting a carcass suspended by a first support on a transporting rail to a deboning station; (b) attaching a second support to portions of the carcass at the deboning station; and (c) applying a substantially constant force to move the supports apart to apply a pre-set separating force as a skeletal part is being removed from the carcass. <Figure 12>

Description

The invention relates to systems for deboning of carcasses.

Various carcass deboning systems are known, however, there is a need to provide a deboning system which can assist an operator during de-boning whilst maximising the yield of meat from carcasses.

Statements of Invention.

According to the invention there is provided a method for deboning carcasses 15 comprising the steps ofttransporting a carcass suspended by a first support on a transporting rail to a deboning station; attaching a second support to portions of the carcass at the deboning station; and applying a substantially constant force to move the supports apart to apply a preset separating force as a skeletal part is being removed from the carcass.

In one embodiment the substantially constant force is applied by a pneumatic ram which has an operational pressure.

In the invention the method comprises modulating the flow of air through the pneumatic ram so that a substantially constant separating force is applied. - 2 if 060 14a Air flow to and from the pneumatic ram may be controlled by a control valve and the flow of air from the ram is modulated by a pressure regulating valve.

In one embodiment the ram has at least two pre-set operational pressures and the method comprises the step of selecting the appropriate operational pressure to achieve the separating force appropriate to the skeletal part of the carcass to be removed.

Preferably, there is an initial skeletal part removal phase which has an associated initial phase operational pressure and a second phase skeletal part removal phase which has an associated second phase operational pressure, the pre-set second phase operational pressure being less than the pre-set initial phase operational pressure.

In one embodiment the difference between the initial phase operational pressure and the second phase operational pressure is greater than 5 psi, typically greater than 15 psi, greater than 25 psi, and possibly greater than 35 psi.

In one embodiment the initial phase is a first bone part deboning and the second phase is a second bone part deboning.

In one case the carcass is a hindquarter and the first bone part is an aitch bone and the second part is a chine bone. The pre-set operational pressure during aitch bone removal may be approximately 50 psi and the pre-set operational pressure during chine bone removal may be approximately 12 psi.

The carcass may be a hindquarter from which the aitch bone and chine bone have been removed and a second stage deboning is carried out comprising first phase deboning of one part of a shin bone and second phase deboning of another part of the shin bone. The first phase deboning of one part of the shin bone may be carried IE 0 60 1 42 - 3 out at an operational pressure of approximately 15 psi and a second phase deboning of a second part of the shin bone may be carried out at an operational pressure of approximately 10 psi.

In another case the carcass is a forequarter and the first bone part is a ribcage and the second bone part is a neck bone. The pre-set operational pressure during ribcage removal may be approximately 45 psi and the pre-set operational pressure during neck bone removal may be approximately 20 psi.

The carcass may be a forequarter from which the ribcage and neck bone have been removed and a second stage deboning is carried out comprising first phase deboning of one part of a blade bone and second phase deboning of another part of a blade bone. First phase deboning of one part of a blade bone may be carried out at an operational pressure of approximately 30 psi and a second phase deboning of a second part of a blade bone may be carried out at an operational pressure of approximately 20 psi.

In one embodiment the operating pressure of the pressure regulating valve is set by one of two adjustable pre-set regulators. A selection between the two pre-set regulators may be made by operation of a selector valve.

In one embodiment the piston of the pneumatic ram travels from an initial location at the beginning of the first phase deboning to a final location at the end of the second phase deboning, and the method comprises delaying the return of the piston from the final location to the start location. The delay may be approximately 2 seconds.

In one case the first support comprises a transport hook.

In one embodiment the method comprises pushing a drop arm carrying the second support downwardly and supporting the drop arm in a lowered position relative to *£ 060 1 42 - 4 the transport rail, at least during first phase deboning. The method may comprise the step of raising the drop rail after first phase deboning.

In one embodiment the pre-set operational pressure is changed from the first phase 5 operation pressure to the second phase operational pressure on raising of the drop rail.

In one embodiment the second support comprises a hook for engagement with part of the carcass, a link means being interposed between the hook and the drop arm.

The method may comprise moving the drop arm upwardly as a skeletal part is separated from a carcass.

In one embodiment the method comprises the steps of:15 preparing a carcass for deboning by placing the carcass on a cradle; moving the cradle so that the carcass is supported in a desired working position; and working on the carcass supported on the cradle.

A carcass may be transported to a first deboning station where part of the skeletal parts of the carcass are removed and the carcass with some of the skeletal parts removed is then transported to a second deboning station where further skeletal parts are removed.

In one embodiment, after deboning, the carcass is directed to one of a number of cutting or trimming stations for cutting and/or trimming the carcass. 142 The invention also provides carcasses or parts thereof whenever deboned, cut or trimmed by a method of the invention.

Brief Description of the Drawings The invention will be more clearly understood from the following description thereof given by way of example only, in which:l o Fig. 1 is an overhead schematic plan view of portion of a carcass dressing system; Fig. 2 is a side view of portion of the carcass dressing system of Fig. 1; Fig. 3 is a side view of an apparatus for deboning carcasses; Fig. 4 is a perspective view of portion of a carcass; Fig. 5 is a perspective view of a skeletal part of the carcass; Fig. 6 is a perspective view of a transport hook engaging means of the apparatus; Fig. 7 is an end view of the apparatus of Fig. 6; Fig. 8 is a side view of the apparatus of Fig. 6; Fig. 9 is a perspective view of another apparatus for deboning carcasses; Fig. 10 is a perspective view of a carcass preparation station; Fig. 11 is an end view of the preparation station of Fig. 10; and ιε0βο14ί Fig. 12 is a circuit diagram of a control system used in the method of the invention.

Referring to the drawings and initially to Figs. 1 and 2 thereof, there is illustrated a carcass dressing rail system including a transport rail 1 along which carcasses to be dressed are led. The dressing rail system comprises a first carcass dressing station 2, a second carcass dressing station 3, a first carcass deboning station 5, and a second carcass deboning station 6. The direction of travel of the carcasses along the rail system 1 is illustrated by the arrows in Fig. 1.

Referring to Figs. 6 to 8, the overhead rail 1 is shown in more detail and in this case comprises a pair of spaced-apart rail sections 9, 10 supported on an overhead support (not shown). A carcass transport hook 12 incorporation rollers 13 is suspended on the rail sections 9, 10. The hook 12 in turn supports a carcass such as a hindquarter 20. A rib part of the hindquarter 20 may be cut off at the preparation stations 2, 3. The operation of the apparatus will be described below with reference to the separation of skeletal parts from a hindquarter, however, it will be appreciated that the apparatus and method of the invention may be applied to any meat part including a forequarter.

Referring particularly to Fig. 3, there is illustrated a carcass deboning apparatus including engagement means in this case provided by a drop arm 30 which in this case is mounted adjacent to but to one side of the transport rail 1. The drop arm 30 is pivotally mounted at 31 to a fixed bracket 32. Means for pushing the drop arm 30 downwardly and for supporting the drop arm 30 in a lowered position relative to the transport rail 1 is in this case provided by a pneumatic ram 33. The ram 33 is pivotally mounted to the drop arm 30 at a point 34 which is spaced upwardly from the end of the drop arm 30 and is mounted at its upper end to a support bracket (not shown). The drop arm 30 may be angled inwardly towards the transport rail 1 to optimise the cutting operation. A support hook 35 is attached to the free end of the drop arm 30 by a link means, in this case formed by a chain 36. θθΟ 1 42 Transport hook engaging means for engaging the rollers 13 of a transport hook 13 is in this case provided by a hook engaging finger 40 which is hingedly mounted at 41 to a support 42 and a stop 43 is provided so that the finger 40 engages the rollers 13 o the transport hook 12 in only one direction of travel X (see Fig. 6), in this case the forward direction of travel of the transport hook 12. The support 42 for the transport hook engaging finger 40 and the stop 43 is carried by a transport hook ram means which in this case is provided by a double acting rodless ram 45. The ram is typically of the type sold under the Trademark ORIGA or the Trademark UNIVER.

In use, a transport hook 12 with a carcass 20 supported thereon is moved along the transport rail 1 until it passes beyond the drop arm 30 to the position illustrated in full line to the right in Fig. 3. In this position, the ram 33 is not extended and the drop arm 30 is in a position illustrated by the interrupted lines 30 (a) extending substantially parallel to the transport rail 1. When the carcass 20 is in position, the support hook 35 carried by the chain 30 of the drop arm 30 is engaged with part of the carcass, in this case a skeletal part which in this case is a recess 49 of an aitch or hip bone 50 in the carcass 20. An aitch bone 50 removed from the carcass is illustrated in Fig. 5. In this position, the hook 35 loosely engages the skeletal part and no force is applied. The rollers 13 of the transport hook 12 are engaged by the transport hook engaging finger 40 carried by the ram 45. An operative then activates the ram 33 to push the drop arm downwardly so that a separating force is applied to the skeletal part 50 of the carcass 20 through the hook 35. The ram 45 is actuated to pull the transport hook engaging finger 40 forwardly along the transport rail 1 moving the support hook 35 carried by the drop rail 30 and the transport hook 12 apart relative to one another.

The drop rail ram 33 applies a downward pushing force at the point of attachment of the hook 35 to the skeletal part 50 while the ram 45 applies a pulling force to the carcass 20. In this way, a separating force is applied, the drop arm 30 pulling the skeletal part 50 away from the carcass 20 as an operative cuts away the skeletal part from the carcass. The drop arm 30 moves upwardly to the position illustrated by £ 0 6ο 142 - 8 interrupted lines 30 (b) in fig. 3 as the operative continues the cutting away of the skeletal part from the carcass.

When the skeletal part 50 has been removed, it is unhooked from the support hook 35 carried by the drop arm 30 and the carcass 20 with the skeletal part 50 remover travels on to the next deboning station described below. Thus, a continuous separative pressure is applied to assist an operative to cleanly remove the bones from the carcass while avoiding damage to the meat. The operation which may be readily supervised is carried out in a comfortable standing position without a requirement for elevated io platforms. Not only is the operation considerably faster than conventional deboning operations, but also it is generally more efficient in that bones are cleanly remover without damaging the meat.

Referring particularly to Fig. 9, there is illustrated a second deboning station 6 incorporating a deboning apparatus also according to the invention. In the case of a hindquarter, the drop arm hook is attached to the Achilles tendon and the shin bone is removed at the second deboning station 6. The apparatus is similar to the apparatus described above with reference particularly to Figs. 3 to 7 and like parts are assigned the same reference numerals. In this case, a further transport rail 60 is provided and the drop arm 30 includes guide means 61 for engaging with corresponding guide means 62 of the transport rail 60 allowing the transport hook to travel on the rail 60 to direct a carcass to cutting or trimming stations for further processing, if desired.

Referring to Figs. 10 and 11, a typical preparation station 2, 3 is illustrated in more detail. The station 2 includes a support cradle or brace 70 of open framework construction pivotally suspended at 71 and movable in the direction of the arrow Y as illustrated in Fig. 11 by a pneumatic ram 72. As illustrated, the cradle 70 may be used to support a carcass 20 in a desired working position allowing an operative to readily work on the carcass as required. The cradle 70 allows the carcass to be presented to the operative in the optimum position for working. At the preparation station the •Ε 060 1 42 - 9 carcass may be scribed to indicate the position of cuts to be made later and/or part of the carcass may be removed.

It will be appreciated that the deboning apparatus of the present invention may be utilised with any type of transport rail including a round bar rail or a flat bar rail. In each case, the transport hook engaging means may be of different configuration to that described above, however, the principle of operation will be the same.

It will also be appreciated that the drop arm may be a rail and/or may be formed by part of the main transport rail and/or of another transport rail.

Referring to Fig. 12 there is illustrated a control system used in the method of the invention. A drop rail pneumatic ram 80 has an associated control valve 82 to which air is delivered from an air inlet 81. A separating pneumatic ram 85 provides a separating force during the deboning operation. The ram 85 has an associated control valve 86. The ram 85 has an operating pressure and the flow of air through the ram is modulated by a pressure regulating valve 87. The ram 85 has at least two pre-set operational pressures. The operational pressure of the pressure regulating valve 87 is set by one of two adjustable pre-set regulators 88, 89 connected to the pressure regulating valve 87 through a selector valve 90. The regulators 88, 89 are set to the appropriate operational pressure to achieve the separating force appropriate to the skeletal part of the carcass to be removed. We have found that by setting the operational pressure in this way the ease of carcass deboning is greatly increased for the operator with the additional benefits of increased yield of meat.

In more detail, to debone a hindquarter there are two deboning stages. In a first stage the aitch bone and chine bone are removed and in the second stage the shin bone is removed.

The first stage deboning of the hindquarter comprises two phases. In the initial phase the drop rail 30 is down and with the inlet air pressure at 80 psi the return air pressure IE 060 1 42 - 10 is set at 30 psi using the regulator 88 giving a net 50 psi constant applied pressure. During this phase the operator separates the aitch bone, to which the hook 35 is attached, from the meat. The drop rail 30 is then raised and in a second phase the return air pressure is set at 65 psi using the regulator 89 giving a net 15 psi. In this phase the operator removes the meat from the chine bone which is connected to the aitch bone. Thus, in the first phase the operating pressure is 50 psi which applies a substantially constant force to move the hooks apart so that a pre-set separating force is applied as the aitch bone is being removed. The operating pressure is then changed as the drop rail is raised so that in the second phase the operating pressure is 15 psi which applies a substantially constant but lower force. We have found that this optimises meat yield removal from the aitch bone and the chine bone.

On completion of the second phase deboning the piston of the separating ram 85 has moved to the end of its stroke. A timer delays the return of the piston to its start or rest position by about 2 seconds to ensure that the operator has sufficient time to finish aitch and shin bone removal.

In the second stage of hindquarter deboning the shin bone is first partially separated and a support in the form of a chain is attached to the shin bone. The drop rail 30 is lowered and in a first phase deboning the return air pressure is set at 65 psi giving a net 15 psi. After partial deboning of the shin bone the drop rail 30 is raised and in a second phase the return air pressure is set at 70 psi giving a net 10 psi. In this phase the operator removes remaining meat from the shin bone. Thus, a substantially constant force is applied during the first phase and a substantially constant but lower force is applied during the second phase deboning of the shin bone. Again, the process is optimised for the operator and meat yield is maximised.

In the case of a forequarter, the hook 35 is inserted into the ribcage for first stage deboning during which the ribcage and the neck bone which is connected to the ribcage is removed. In a second stage the shin bone and blade bone are removed.

IE 060 1 42 - 11 The first stage deboning of the forequarter comprises two phases, ln the initial phase the drop rail 30 is down and the return air pressure is set at 35 psi giving a net 45 psi constant applied pressure. During this phase the operator separates the ribcage from the meat. The drop rail 30 is then raised and in a second phase the return air pressure is set at 50 psi giving a net 20 psi. In this phase the operator removes the neck bone which is attached to the rib cage.

In the second stage of forequarter deboning the hook is inserted at the top of the briscuit, the drop rail is lowered and in a first phase deboning the return air pressure is set at 50 psi giving a net 30 psi. After deboning of the shin bone, the drop rail 30 is raised and in a second phase the return air pressure is set at 60 psi giving a net 20 psi. In this phase the operator removes the blade bone which is attached to the shin bone.

The method of deboning carcasses according to the invention minimises the work required by operators whilst also improving the yield and reducing trim loss of the product. A substantially constant preset separating force is applied as a skeletal part is being removed from the carcass. The pressure applied is optimised so that a relatively high pressure can be applied when removing more difficult bones such as the aitch bone but, on raising of the drop rail, the system automatically changes over to an appropriate lower per-set pressure for more delicate deboning, for example of the strip loin. Thus, yield is optimised and scarring of primal cuts is minimised with reduced operator input.

The invention is not limited to the embodiments hereinbefore described which may be varied in detail.

Claims (25)

1. A method for deboning carcasses comprising the steps of:5 transporting a carcass suspended by a first support on a transporting rail to a deboning station; attaching a second support to portions of the carcass at the de-boning station; and applying a substantially constant force to move the supports apart to apply a preset separating force as a skeletal part is being removed from the carcass. 15

2. A method as claimed in claim 1 wherein the substantially constant force is applied by a pneumatic ram which has an operational pressure.

3. A method as claimed in claim 2 comprising modulating the flow of air through the pneumatic ram so that a substantially constant separating force is applied.

4. A method as claimed in claim 3 wherein air flow to and from the pneumatic ram is controlled by a control valve and the flow of air from the ram is modulated by a pressure regulating valve. 25 5. A method as claimed in any of claims 2 to 4 wherein the ram has at least two pre-set operational pressures and the method comprises the step of selecting the appropriate operational pressure to achieve the separating force appropriate to the skeletal part of the carcass to be removed. 6. A method as claimed in claim 5 wherein there is an initial skeletal part removal phase which has an associated initial phase operational pressure and a second - 13 phase skeletal part removal phase which has an associated second phase operational pressure, the pre-set second phase operational pressure being less than the pre-set initial phase operational pressure.

5. 7. A method as claimed in claim 6 wherein the difference between the initial phase operational pressure and the second phase operational pressure is greater than 5 psi.

6. 8. A method as claimed in claim 7 wherein the operational pressure difference is 10 greater than 15 psi.

7. 9. A method as claimed in claim 7 or 8 wherein the operational pressure difference is greater than 25 psi. 15 10. A method as claimed in any of claims 7 to 9 wherein the operational pressure difference is greater than 35 psi. 11. A method as claimed in any of claims 6 to 10 wherein the initial phase is a first bone part deboning and the second phase is a second bone part deboning. 12. A method as claimed in claim 11 wherein the carcass is the hindquarter and the first bone part is an aitch bone and the second part is a chine bone. 13. A method as claimed in claim 12 wherein the pre-set operational pressure 25 during aitch bone removal is approximately 50 psi and the pre-set operational pressure during chine bone removal is approximately 12 psi. 14. A method as claimed in any of claims 11 to 13 wherein the carcass is a hindquarter from which the aitch bone and chine bone have been removed and 30 a second stage deboning is carried out comprising first phase deboning of one part of a shin bone and second phase deboning of another part of the shin bone. ΙΕ 06ο 142 - 14 15. A method as claimed in claim 14 wherein the first phase deboning of one part of a shin bone is carried out at an operational pressure of approximately 15 psi and a second phase deboning of a second part of the shin bone is carried out at 5 an operational pressure of approximately 10 psi. 16. A method as claimed in claim 11 wherein the carcass is a forequarter and the first bone part is a ribcage and the second bone part is a neck bone.

8. 10 17. A method as claimed in claim 16 wherein the pre-set operational pressure during ribcage removal is approximately 45 psi and the pre-set operational pressure during neck bone removal is approximately 20 psi. 18. A method as claimed in claim 16 or 17 wherein the carcass is a forequarter

9. 15 from which the ribcage and neck bone have been removed and a second stage deboning is carried out comprising first phase deboning of one part of a blade bone and second phase deboning of another part of a blade bone.

10. 19. A method as claimed in claim 18 wherein first phase deboning of one part of a

11. 20 blade bone is carried out at an operational pressure of approximately 30 psi and a second phase deboning of a second part of a blade bone is carried out at an operational pressure of approximately 20 psi. 20. A method as claimed in any of claims 4 to 19 wherein the operating pressure of 25 the pressure regulating valve is set by one of two adjustable pre-set regulators.

12. 21. A method as claimed in claim 20 wherein a selection between the two pre-set regulators is made by operation of a selector valve.

13. 22. A method as claimed in any of claims 2 to 21 wherein the piston of the pneumatic ram travels from an initial location at the beginning of the first 66ο 142 - 15 phase deboning to a final location at the end of the second phase deboning, and the method comprises delaying the return of the piston from the final location to the start location. 5

14. 23. A method as claimed in claim 22 wherein the delay is approximately 2 seconds.

15. 24. A method as claimed in any of claims l to 23 wherein the first support comprises a transport hook. io

16. 25. A method as claimed in any of claims 1 to 24 comprising pushing a drop arm carrying the second support downwardly and supporting the drop arm in a lowered position relative to the transport rail, at least during first phase deboning.

17. 26. A method as claimed in claim 25 comprising the step of raising the drop rail after first phase deboning.

18. 27. A method as claimed in claim 26 wherein the pre-set operational pressure is 20 changed from the first phase operation pressure to the second phase operational pressure on raising of the drop rail.

19. 28. A method as claimed in any of claims 25 to 27 wherein the second support comprises a hook for engagement with part of the carcass, a link means being 25 interposed between the hook and the drop arm.

20. 29. A method as claimed in claim 28 comprising moving the drop arm upwardly as a skeletal part is separated from a carcass.

21. 30. A method as claimed in any of claims 1 to 29 comprising the steps of: Ιε °6θ ΐ42 - 16 preparing a carcass for deboning by placing the carcass on a cradle; moving the cradle so that the carcass is supported in a desired working position; and working on the carcass supported on the cradle.

22. 31. A method as claimed in any of claims 1 to 30 wherein a carcass is transported to a first deboning station where part of the skeletal parts of the carcass are 10 removed and the carcass with some of the skeletal parts removed is transported to a second deboning station where further skeletal parts are removed.

23. 32. A method as claimed in any of claims 1 to 31 wherein after deboning, the carcass is directed to one of a number of cutting or trimming stations for 15 cutting and/or trimming the carcass.

24. 33. A method of deboning carcasses substantially as hereinbefore described with reference to the accompanying drawings.

25. 34. Carcasses or parts thereof whenever deboned, cut or trimmed by a method as claimed in any preceding claim.