Innovative Biological SolutionsInnovative Biological Solutions

Oklahoma State UniversityOklahoma State UniversityBAE 4012BAE 4012

Dec. 4, 2003Dec. 4, 2003

Steven FowlerSteven FowlerDerek Storm Derek Storm Travis GuyTravis Guy

Project IntroductionProject IntroductionScott Pet ProductsScott Pet Products

One of the nations leaders in the pet food and One of the nations leaders in the pet food and treat industrytreat industry

Final destination of 20% of the nations pig earsFinal destination of 20% of the nations pig ears

Would like to increase the production and Would like to increase the production and efficiency of this product lineefficiency of this product line

IBS has been contacted to develop a system to IBS has been contacted to develop a system to sort, count, and meter pig earssort, count, and meter pig ears

Project IntroductionProject Introduction

Pig earsPig earsFavorite treat of many dogsFavorite treat of many dogs

Thawed, baked, flavoredThawed, baked, flavoredSome ears are cut in halfSome ears are cut in half

Counted, packaged, sealed, shippedCounted, packaged, sealed, shipped

Project IntroductionProject Introduction

PackagingPackagingEars sold by amount not weightEars sold by amount not weight

Ears have to be countedEars have to be countedCurrently counted by handCurrently counted by hand

Ears stick togetherEars stick togetherHave to be separated to be countedHave to be separated to be counted

Customer RequirementsCustomer Requirements

Ears need to be sorted, counted, and Ears need to be sorted, counted, and meteredmetered800 bags of 25 pieces per hour800 bags of 25 pieces per hourEconomicalEconomical

Minimize labor requiredMinimize labor requiredMaximize production capacityMaximize production capacity

HACCP compliantHACCP compliant

Engineering SpecificationsEngineering SpecificationsMachine must not exceed 12 feet in height and Machine must not exceed 12 feet in height and no longer than 20 feet.no longer than 20 feet.

The machine must have the correct number of The machine must have the correct number of both size ears in 99 out of 100 bags.both size ears in 99 out of 100 bags.

Patent ResearchPatent ResearchUnited States Patent Office United States Patent Office search search

Results that came up applied Results that came up applied to construction of individual to construction of individual pieces of equipment.pieces of equipment.

Processes patents were not Processes patents were not found found

We plan on buying We plan on buying different pieces and different pieces and applying them towards our applying them towards our system.system.

Process ResearchProcess Research

No research has been done on pig ear No research has been done on pig ear singulation, sorting, or metering.singulation, sorting, or metering.

The closest product that would react and The closest product that would react and have similar irregularities to pig ears is beef have similar irregularities to pig ears is beef jerky.jerky.

All of the information needed to complete All of the information needed to complete the project will come from our testing.the project will come from our testing.

Breaking Down The ProblemBreaking Down The Problem

This problem can be This problem can be broken down into broken down into three main objectives three main objectives

Singulation and Singulation and SeparationSeparation

CountingCounting

MeteringMetering

Separation ConceptsSeparation Concepts

Different Speed ConveyorsDifferent Speed Conveyors

Elevated conveyorsElevated conveyors

Air CurtainAir Curtain

““Air Hockey Table”Air Hockey Table”Fluidized BedFluidized Bed

Counting ConceptsCounting ConceptsLane separatorLane separator

two diverging lanestwo diverging lanes

Electronic eyeElectronic eye

Gravity separatorGravity separatorlimited flow controllimited flow control

Metering ConceptsMetering Concepts

Using a pneumatic Using a pneumatic diverter arm to divert diverter arm to divert two lanes of ears into two lanes of ears into four lanesfour lanes

Have a trap door to Have a trap door to stop flow of ears, stop flow of ears, allowing the conveyor allowing the conveyor to continue to runto continue to run

Ear Dimension TestingEar Dimension Testing

These ears were taken from retail bags.These ears were taken from retail bags.

This data allows us to have a lane width for our design.This data allows us to have a lane width for our design.

Whole Ears (n=40) Half Ears (n=10)

Weight (oz)

Length (in)

Width (in)

Weight (oz)

Length (in)

Width (in)

Max 2.09 7.50 5.00 1.20 7.00 4.50

Average 1.56 5.86 4.17 .90 5.09 3.80

Standard Deviation

0.32 0.91 0.61 .20 1.00 0.40

Conveyer Speed TestConveyer Speed Test

Test is set up with two conveyers in series, Test is set up with two conveyers in series, with the first conveyer set at (slowest with the first conveyer set at (slowest speed) and the second conveyer set at 6.6 speed) and the second conveyer set at 6.6 ft/s.ft/s.

Shearing force from the faster conveyer Shearing force from the faster conveyer singulates the ears.singulates the ears.

The lower the mass flow rate and higher The lower the mass flow rate and higher speed difference, allows for greater speed difference, allows for greater singulation.singulation.

Elevation TestElevation Test

Setup same as previous Setup same as previous test except slower test except slower conveyer is elevated.conveyer is elevated.

Provided greater Provided greater singulation than even singulation than even conveyers.conveyers.

The height change allows The height change allows for more force to be for more force to be applied to ear mass.applied to ear mass.

Air Curtain TestAir Curtain TestSetup the same as elevated test but at Setup the same as elevated test but at junction of conveyers a high velocity, high junction of conveyers a high velocity, high volume air nozzle was placed.volume air nozzle was placed.

The pressure delivered to the nozzle is 60 The pressure delivered to the nozzle is 60 psi.psi.

Fast Conveyer

Slow Conveyer

Air Curtain

Lane TestLane Test

After the ears are After the ears are singulated they singulated they need to be placed need to be placed into lanes.into lanes.

The lane system is The lane system is placed over the placed over the second conveyer second conveyer after the air curtainafter the air curtain

Diverging Arm TestDiverging Arm Test

The arm was held over The arm was held over the high speed conveyer the high speed conveyer to guide the ears to to guide the ears to separate lanes.separate lanes.The first conveyors are The first conveyors are slower than the large slower than the large single conveyer.single conveyer.If the four lanes ever fill If the four lanes ever fill up with ears the feeding up with ears the feeding conveyers will stop.conveyers will stop.

Trap Door TestTrap Door TestThis test is to determine the This test is to determine the feasibility of holding counted feasibility of holding counted ears in a lane until the operator ears in a lane until the operator calls for them.calls for them.

Proposed DesignProposed Design

Design will include elevated conveyer Design will include elevated conveyer separation, air curtain, and lane separation.separation, air curtain, and lane separation.

A cleated conveyer will load the system and A cleated conveyer will load the system and be the limiting factor on bags per hour.be the limiting factor on bags per hour.

To unload the machine 2 operators will hold To unload the machine 2 operators will hold bags under chutes.bags under chutes.

Photo Eye ArrayStart Stop

Conveyer

Diverter ArmLane SeparatorAir Curtain

Cleated Conveyer inclined at 30°

Hopper

Helix Slide

Half Ears

RecognitionsRecognitions

Scott Pet ProductsScott Pet ProductsMark OsteenMark OsteenMike ZimmermanMike Zimmerman

OSU ExtensionOSU ExtensionDoug EnnsDoug Enns

BAE Faculty and StaffBAE Faculty and StaffBAE Lab PersonnelBAE Lab Personnel

Wayne KinerWayne Kiner

Innovative BiologicalInnovative Biological SolutionsSolutions111 Agricultural Hall 111 Agricultural Hall Oklahoma State University Oklahoma State University Stillwater, OK 74078 Stillwater, OK 74078 Telephone: 405-744-7577Telephone: 405-744-7577

Fax: 405-744-6059Fax: 405-744-6059

http://biosystems.okstate.edu/http://biosystems.okstate.edu/SeniorDesign/2003/PetFoodSorter/SeniorDesign/2003/PetFoodSorter/