IE20080911U1 - A process and apparatus for analysing and separating grain - Google Patents

Abstract

ABSTRACT A process and apparatus for analysing quantities of grain in-line and separating the grain into batches on the basis of one or more grain parameter values is disclosed. The grain is separated in—line on the basis of the grain parameter value thus allowing the grain to be separated into homogeneous batches.

Description

The present invention relates to a process and apparatusfor analysing quantities oi grain in-line and separating the grain into batches on the basis of one or more grain parameter values In the specification the term "in-line” refers to a procedure which can be carried out while an apparatus is running and does not require the apparatus to be shut down during the procedure.

The quality of the grain used is an important aspect of all types of grain processing.

For example, in malting, barley quality has a significant effect on the resultant malt quality. Two of the most critical factors which determine barley quality are grain moisture and protein content and these factors therefore require special attention prior to storage and processing.

The moisture content of the grain has an important role in its health and viability during storage. Harvested barley, for example, with a moisture content of greater that 14% by weight of the barley, needs to be dried to reduce the moisture level to between 12% and 13% prior to storage. The exact level depends on expected duration of storage until processing and storage temperature. The drying process must be rather gentle and thus air temperatures not exceeding 65°C to 70°C are utilised depending on the initial grain moisture content. The final grain temperature should not exceed 40°C, othen/vise irreversible damage of the embryo and other living tissue in the barley will hamper the downstream melting process.

The protein levels in barley determine the resultant protein levels in the malt and thus the malt quality. It has been found that barley which has a protein content in the range of between 9.5% to 12% dry matter would yield malt having a protein level in the region of between 9.2% and 11.7% dry matter. The protein content has an impact on the water uptake during steeping and the degree and quality of endosperm would result in uneven germination of the batch. This will affect the colour, aroma and flavour of the malt, as well as downstream processing of the malt.

Many methods are presently available for measuring the protein and moisture content of grain. Moisture content can be measured by weighing batches of grain before and after drying, however the main drawback of this process is that it is very time- consuming, with each batch analysis taking between 2 and 3 hours. Rapid methods based on this principle such as the Sartorious method have been developed and this method for example only requires 20 to 30 minutes of analysis time including preparation but has been found to be less accurate. Another rapid method for measuring moisture content is the “HOH-Express” (Heckmann company, Germany).

This method only takes three to five minutes and has good accuracy but requires time consuming automatic or manual sampling beforehand. Previous methods of measuring protein content include the Kjeldahl method, which involves nitrogen analysis. This method is also very time consuming and requires sampling.

In the case of all of the above methods, a few samples from a batch are taken, these quantities are analysed in accordance with these methods and an average result is calculated for the particular grain parameter value being measured, i.e. protein content, moisture content. The average value for the grain parameter value measured however is dependent on the type of grain in each sample and generally may not be representative of the overall batch of grain.

An improved apparatus for measuring grain parameters is that disclosed in US Patent No. 5,406,084. Thisdocument discloses an NIH measuring process and apparatus for measuring constituents of pourable foodstuffs in-line. After the measurements are obtained, however they are averaged to provide an average value for a particular constituent for a batch of grain. apparatus would lead to inhomogeneity within grain batches.

It is envisaged therefore that this process and Accordingly, there is a need for a more effective process and apparatus for analysing and for separating grain to provide more homogeneous batches of grain on the basis of a particular grain parameter.

IIOBOQH Statements of Invention According to the invention, there is provided a process for analysing quantities of grain in-line and separating the grain into batches on the basis of one or more grain parameter values, the process comprising: delivering an optically dense grain layer continuously past an in-line measurement area; analysing a quantity of the grain by emitting light onto the grain layer, the light being reflected from the quantity of grain passing the in-line measurement area and detecting the light reflected from the quantity of grain to provide a spectrum of the quantity of grain; converting the spectrum into the or each grain parameter value; and separating the grain into batches by sorting the grain quantity on the basis of the or each grain parameter value; characterised in that: the grain is separated in-line on the basis of the or each grain parameter value.

The advantage of this process is that more accurate separation of the grain on the basis of a specified grain parameter value can be achieved. Thus, after separation, grain quantities with similar values for a specific grain parameter can be stored together as homogeneous batches. This obviates any of the drawbacks associated with inhomogeneity of grain. For example, in the case of han/ested barley, batches of barley with similar moisture contents can be stored accordingly in order to optimise the drying performance as well as ensuring the required viability of the grain after the drying process. Additionally, barley with homogenous protein contents, can be stored and processed resulting in more even modification. iloeosti '31‘: isoaoait ugeufiifi quantities or sub-lots of grain can be traced. Thus documentation for each specific process can be made available to clients, which is important in terms of the Hazard Analysis Critical Control Point (HACCP) (an internationally recognized system for ensuring that food products are safe and wholesome to eat) and food safety policies.

In one embodiment of the invention, separating the grain in-line comprises the steps of: storing one or more grain threshold values; comparing the or each grain parameter value to the corresponding stored grain threshold value; generating a signal based on the comparison between the or each grain parameter value and the corresponding grain threshold value; using the signal to effect automatic delivery of the grain quantity to a predetermined location on the basis of the grain parameter value. in another embodiment of the invention, the optically dense grain layer is delivered at a speed of between 0.5 and 2.5 m/s. in a further embodiment of the invention, the optically dense grain layer is delivered at a speed of between 1 and 2 m/s. The advantage of these speeds is that they allow rapid analysis and separation of the grain. The process is therefore less time consuming and more cost effective.

’ Preferably, the light is emitted continuously onto the optically dense grain layer. in one embodiment of the invention, the light is emitted at a wavelength of between 200 and 2000nm in another embodiment of the invention, the light is emitted at a Near infrared (NIR) spectral region of between 780nm and 2000nm and an NIH spectrum is provided.

In a further embodiment of the invention, the light is emitted at a wavelength of L...L...-_,_ nan- - '21: iE0809t1 ltoaoctt in one embodiment of the invention, the light is detected from the quantity of grain in a time of between 15 and 70 milliseconds.

In another embodiment of the invention, the light detected from the quantity of grain in a time of between 30 and 50 milliseconds. Thus as the light is rapidly detected, this also accelerates the process for analysing and separating the grain.

According to the invention, there is also provided an apparatus for analysing quantities of grain in-line and separating the grain into batches on the basis of one or more grain parameter values, the apparatus comprising: means for continuously delivering an optically dense grain layer past an in- line measurement area; a light source for emitting light onto the grain layer, the light being reflected from the quantity of grain passing the in-line measurement area; a sensor unit for detecting the light reflected from the quantity of grain to provide a spectrum of the quantity of grain; means for converting the spectrum into the or each grain parameter value; and means for separating the grain into batches by sorting the grain quantity on the basis of the or each grain parameter value; characterised in that: the apparatus further comprises in-line means for separating the grain on the basis of the or each grain parameter value.

In one embodiment of the invention, the in-line grain separating means comprises: i;oeo9H 3. itoacotl a controller comprising one or more stored grain threshold values; a transmitter for transmitting the or each grain parameter value to the controller; wherein the controller compares the or each grain parameter value to the corresponding stored grain threshold value; the controller generates a signal based on the comparison between the or each grain parameter value and the corresponding grain threshold value; and the controller transmits the signal to at least one exit means such that the signal is used to affect automatic delivery of the quantity of the grain via the exit means to a predetermined location on the basis of the grain parameter value.

In another embodiment of the invention, the exit means comprises: a controlled slide having an open position and a closed position and connected to a first silo; and an end slide connected to a second silo; wherein the controller communicates with the controlled slide and controls the position of the controlled slide to allow or prevent the quantity of grain exiting via that slide; such that when the controlled slide is in the closed position the quantity of grain will exit the apparatus via the end slide.

In a further embodiment of the invention, the controlled slide is pivotally movable between the open position and the closed position. ,, .5... L. LI... an...‘ E! 080911 J- tioaoeti position during detection of grain parameter values which are consistently lower or higher than the grain threshold value. in another embodiment of the invention, the controller transmits a signal to the controlled slide to prepare to change position and triggers a pre-determined lag time t.ag to begin upon detection of a sufficient change in the grain parameter value such that the grain parameter value crosses over the grain threshold value,.

In a further embodiment of the invention, the controller transmits the signal to the controlled slide to change position after detection of a series of sufficiently changed grain parameter values during the lag time hag. in this embodiment of the invention, the position of the controlled slide changes at a time equal to t|ag + t,,; wherein t,. is equal to the period of time allowed for the final grain quantity analysed during the lag time tjag to travel from the sensor unit to the controlled slide. The advantage of these particular embodiments is that they allow rapid separation of the grain in-line while overcoming possible limitations which could be envisaged due to the mechanical nature of the apparatus. Thus as the slide only changes position after detection of a series of sufficiently changes grain parameter values this prevents constant oscillation of the slide or other suitable opening means.

In one embodimentqof the invention, the controller is a programmable logic controller V in another embodiment of the invention, the delivery means delivers the optically dense grain layer at a speed of between 0.5 and 2.5 m/s. in a further embodiment of the invention, the delivery means delivers the optically dense grain layer at a speed of between 1 and 2 m/s. in one embodiment of the invention, the delivery means comprises a dosing slide which is slideably adjustable within the delivery means to provide the optically dense grain layer. The advantage of the dosing slide is that it controls the flow and Qnnfld fl‘ Han nun?»-n Mn..- —|l—— ' IEOOOO11 lloaoolti appropriately dense grain layer as it passes by the in-line measurementarea.

In another embodiment of the invention, the delivery means comprises one or more of a grain in-feed chute and a conveyor.

In this embodiment of the invention, the grain in-feed chute is positioned at an angle of between 45° and 90° relative to the conveyor.

In another embodiment of the invention, the grain in-feed chute further comprises a grain quantity divider having a plurality of chutes providing channels for flow of individual grain quantities. in one embodiment of the invention, the light source emits light continuously onto the optically dense grain layer.

In another embodiment of the invention, the light source emits light at a wavelength range of between 200 and 2000nm.

In a further embodiment of the invention, the light source emits light at a Near Infrared (NIH) spectral region of between 780nm and 2000nm and an NIH spectrum is provided.

In a still further embodiment of the invention, the light source emits light at a wavelength range of between 900 and 1500 nm.

In one embodiment of the invention, the sensor unit is mounted at an angle in the region of 90° to the delivery means.

In one embodiment of. the invention, the grain parameters are selected from the group comprising one or more of grain protein content, grain moisture content, starch extract content, B-glucan content, beta-amylase content and mycotoxine content. lloeoctt .9. Miami‘! Detailed Description of Invention The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which: - Fig. 1 is a schematic of the apparatus of the invention; Fig. 2 is a view of the grain in-feed hopper and grain in-feed chute of one embodiment of the invention; Fig. 3 is a view of the grain in-feed chute of another embodiment of the invention; Fig. 4 is a view of one embodiment of the downstream apparatus of the invention; Fig. 5 is a view of another embodiment of the downstream apparatus of the invention; Fig. 6 is a view of a further embodiment of the downstream apparatus of the invention; Fig. 7 is a view of another embodiment of the downstream apparatus of the invention; Fig. 8 is a view of a further embodiment of the downstream apparatus of the invention; Fig. 9 is a view of a still further embodiment of the downstream apparatus of the invention; Fig. 10 is a view of a lab scale grain in-feed hopper and grain in-feed chute with a measuring head applied; ’ Fig. 11 is another schematic of the apparatus of the invention; and Fig. 12 is a further schematic of the apparatus with each of the parameters required to programme the controller of the apparatus.

E0809” .. lE@@©911 indicated generally by reference numeral 1. The apparatus comprises a grain in-feed hopper 2 and a grain in-feed chute 3 for continuous delivery of grain into the apparatus 1. The apparatus 1 also comprises a conveyor 4 for continuous delivery of grain through the apparatus 1. A dosing slide 5 which provides consistent and even grain flow through the apparatus 1 is provided either within the grain in-feed chute 3 as shown or at any suitable position within the conveyor 4. The closing slide 5 can be adjusted manually to control the flow of grain through the apparatus 1 and thus provide a consistent grain flow at a fixed speed and an optically dense grain layer for analysis. in the specification the term “optically dense grain layer’ refers to a dense grain layer of at least 10mm without any gaps between the grain.

The apparatus 1 further comprises a light source 6 for emitting light onto the grain layer and a sensor unit 7 for detecting light reflected from a quantity of the grain layer and providing a spectrum from the quantity of grain. The light source 6 can optionally be positioned within the sensor unit 7. The sensor unit 7 can also comprise a measuring head (not shown) and a black/white referencing system (not shown). A spectrometer 8 is further provided for converting the spectrum into an electrical signal which is subsequently converted into the respective grain parameter value for that quantity using specifically designed software. The grain parameter values generated by the spectrometer 8 are transmitted to a controller 9 generally by means of a transmitter (not shown).

The apparatus 1 further comprises one or more slides 10a, 10b through which the quantities of grain can exit the apparatus 1. The controlled slide 10a is controlled by thecontroller 9 and is either opened or shut depending on the grain parameter value for that particular quantity. When the controlled slide 10a is open, the quantity of grain passing over the controlled slide we at that time will exit via the controlled slide 10a to a storage silo (not shown).

The controller 9 will also control when the controlled slide 10a is to open and for how long the controlled slide 10a is to stay open and further details of this are discussed in relation to Fig. 12. Any quantities of grain which are not within the specified parameter range are delivered via the conveyor 4 to the and slide 10b, where they will exit the apparatus via the end slide 10b to another storage silo (not nl.-—.......\ LL--— —— " .11.

Fig. 2 shows a more detailed view of the grain being fed into the grain in-feed chute 3 by the grain in-feed hopper 2. The light source 6 is housed within the sensor unit 7. The sensor unit 7 is positioned exterior of the grain in-feed chute so as to emit light onto an area of the grain in-feed chute referred to as the measurement area.

The sensor unit 7 should also be positioned at an angle to the flow of the grain in such a manner that the emitted light will be accurately reflected from the grain layer passing by. A grain in-feed chute angle of between 45° and 90° has been found to be most suitable. The closing slide 5 is positioned downstream of the sensor unit 7 and is slideably adjustable within the grain in-feed chute to ensure that an optically dense grain layer is provided for measurement by the sensor unit 7.

Fig. 3 shows an alternative embodiment of the grain in-feed chute 3. in this embodiment a grain quantity divider 20 is provided within the grain in-feed chute 3.

The grain quantity divider 20 comprises a plurality of chutes 21, through which a quantity of grain can flow prior to being mixed homogeneously before passing the sensor unit 7. The grain quantity divider 20 ensures that the grain quality within the grain mass differential passing by the sensor unit 7 will be homogenous across the diameter of the respective chute 21. The quantity divider 20 is particularly suitable for higher grain flows and in particular grain flows of greater than approximately 400t/h. A dosing slide 5 can also be provided to control grain flow.

Referring now to Figs. 4 to 9 there is provided a view of different embodiments of the downstream apparatus 1. As shown in Fig. 4 the grain in-feed chute 3 is positioned at approximately a 45° angle to the conveyor 4. The sensor unit 7 is positioned exterior the grain in-feed chute 3 such that it is mounted at an angle of 90° to the grain flow. A Fig. 4 also shows controlled slide 10a and end slide 10b leading to separate storage silos 30a and 30b respectively.

Fig. 5 shows an alternative embodiment of the apparatus 1. In this embodiment the sensor unit 7 is positioned exterior of the conveyor 4 downstream of the grain in- feed chute 3. In this embodiment of the invention, the dosing slide 5 can be either positioned within the grain in-feed chute 3 upstream of the sensor unit 7 or within the conveyor 4 downstream of the sensor unit 7 so as to provide an optically dense JEO809ll lE@e@9yi Fig. 6 shows a further alternative embodiment of the apparatus 1. in this embodiment, the sensor unit 7 is also positioned exterior of the conveyor 4 however on the opposite side of the conveyor 4 and thus not shown.

Figs. 7, 8 and 9 correspond to Figs. 4, 5 and 6, with the exception that the grain in- feed chute 3 is positioned at a 90° angle to the conveyor 4. In this embodiment of the invention, the use of a grain quantity divider 20 is also preferable and a dosing slide will be provided within the grain in—feed chute 3 as above. Thus the apparatus can be applied to any industrial application where the grain in-feed chute angle may vary from between 90° (vertical) to 45°. The angle of the grain in-feed chute 3 depends on certain typical flow criteria. Such criteria include the type of grain being analysed and separated, the material of the in-feed chute, friction indices, available space for installation within silo facilities and other relevant factors.

Referring to Fig. 10, there is shown a lab scale grain in-feed hopper 2 and grain in- feed chute 3 with measuring head 40 applied for calibration purposes. The measuring head 40 comprises a light source and optics and is identical to that of the measuring head housed within the sensor unit 7 of the apparatus 1. Thus identical physical optical conditions to the industrial conditions of the apparatus 1 are provided. Prior to use of the apparatus 1 validation and referencing of the apparatus 1 must be carried out for the specific type of grain and grain parameter value to be measured. A sample of the type of grain to be measured is delivered into the lab scale model and a spectrum of the grain is obtained using the measuring head 40. A spectrometer is linked to the measuring head 40 via fibre- optics (not shown) and the spectrometer is connected to a PC (not shown) with the required software to convert the received spectres into corresponding analysis values. The grain sample is then analysed using other analysis methods such as chemical analysis and a calibration curve can be derived on the basis of the analysis values for the parameter and the spectrum obtained. The calibration curve and corresponding validated calibration data will be used to convert the spectres into analysis values within the industrial scale application.

Referring to Fig. 11, in use, grain is delivered into the grain in-feed chute 3 of the A __..--.. ..._!L W ___-!L!_.__,I _,,;,,.,_. _.......

Claims (2)

1. A process for analysing quantities of grain in-line and separating the grain into batches on the basis of one or more grain parameter values, the process comprising: delivering an optically dense grain layer continuously past an in-line measurement area; analysing a quantity of the grain by emitting light onto the grain layer, the light being reflected from the quantity of grain passing the in-line measurement area and detecting the light reflected from the quantity of grain to provide a spectrum of the quantity of grain; converting the spectrum into the or each grain parameter value; and separating the grain into batches by sorting the grain quantity on the basis of the or each grain parameter value; characterised in that: the grain is separated in-line on the basis of the or each grain parameter value.

2. A process as claimed in claim 1, wherein separating the grain in-line comprises the steps of: - A : storing one or more grain threshold values; comparing the or each grain parameter value to the corresponding stored grain threshold value; generating a signal based on the comparison between the or each grain parameter value and the corresponding grain threshold value; using the signal to effect automatic delivery of the grain quantity to a predetermined location on the basis of the grain parameter value. A process substantially hereinbefore described with reference to the accompanying drawings. An apparatus (1) for analysing quantities of grain in-line and separating the grain into batches on the basis of one or more grain parameter values, the apparatus (1) comprising: means for continuously delivering an optically dense grain layer past an in-line measurement area; a light source (6) for emitting light onto the grain layer, the light being reflected from the quantity of grain passing the in-line measurement area; a sensor unit (7) for detecting the light reflected from the quantity of grain to provide a spectrum of the quantity of grain; means for converting the spectrum into the or each grain parameter value; and means for separating the grain into batches by sorting the grain quantity on the basis of the or each grain parameter value; characterised in that: the apparatus further comprises in-line means for separating the grain on the basis of the or each grain parameter value. An apparatus substantially hereinbefore described with reference to the accompanying drawings