Apparatus for processing and grading food articles and related methods

Abstract

This disclosure concerns methods for processing and grading food articles including x-raying the food articles a first time and taking a 3D image of the food articles.

1 . A method for grading a food article, the method comprising:
 utilizing a grading device to move a portion of the food article from a position on a surface of a grading conveyor,   wherein the portion is one of a plurality of portions of the food article that each have an alignment and orientation with respect to the surface of the grading conveyor and are positioned parallel to each other on the surface of the grading conveyor,   wherein none of the remaining portions of the plurality of portions that are positioned parallel to each other on the surface of the grading conveyor are substantially moved during the movement of the portion of the food article from the position on the surface of the grading conveyor, and   wherein the alignments and orientations of the remaining portions of the plurality of portions that are positioned parallel to each other on the surface of the grading conveyor are substantially maintained during the movement of the portion of the food article from the position on the surface of the grading conveyor.   
     
     
         2 . The method of  claim 1 , wherein the portion is adjoined on every side by another portion. 
     
     
         3 . The method of  claim 1 , wherein the grading device is selected from the group consisting of:
 a robot comprising a horizontally movable support member, a vertically movable support member slidably coupled to the horizontally movable support member, a first actuator attached to the horizontally movable support member, a second actuator attached to the vertically movable support member, and a means for moving at least one portion of the food article attached to the vertically movable support member,   a three degrees of freedom robot, and   a four degrees of freedom robot.   
     
     
         4 . (canceled) 
     
     
         5 . The method according to  claim 1 , wherein the surface is a surface of a grading conveyor having a direction of movement that is perpendicular to the parallel orientation of the plurality of portions. 
     
     
         6 . The method according to  claim 1 , wherein the portion that is moved is closely adjoined on opposing sides in an orientation substantially perpendicular to the parallel orientation of the plurality of portions by other portions. 
     
     
         7 . The method according to  claim 1 , wherein the plurality of portions of the food article are provided by cutting the food article into the plurality of portions. 
     
     
         8 . The method according to  claim 1 , wherein moving the portion comprises moving the portion from one area of the surface to another area of the surface, or removing the portion from the surface. 
     
     
         9 . The method according to  claim 1 , wherein moving the portion comprises moving the portion from the surface to a processing conveyor. 
     
     
         10 . The method according to  claim 1 , wherein the grading device is a needle grading device or a gripper grading device. 
     
     
         11 . The method according to  claim 1 , further comprising selecting the portion of the plurality of portions to be moved based on at least one criteria selected from the group consisting of size, weight, quality, and type. 
     
     
         12 . The method according to  claim 1 , wherein the grading device is a needle grading device, and wherein moving the portion comprises:
 orienting at least one needle of the needle grading device over the center of the portion;   penetrating the portion with the at least one needle; and   moving the needle,   such that the penetrated portion moves with the needle from its position on the surface.   
     
     
         13 . The method according to  claim 12 , wherein the portion is penetrated on its top surface without contacting another surface of the portion. 
     
     
         14 . The method according to  claim 1 , wherein the grading device is a gripper grading device, and wherein moving the portion comprises:
 contacting a gripper of the gripper grading device with the portion; and   lifting the portion with the gripper,   such that the portion is lifted from its position on the surface.   
     
     
         15 .- 47 . (canceled) 
     
     
         48 . A food processing apparatus comprising:
 at least one conveyor;   at least one x-ray machine;   a first imaging system;   at least one cutting machine;   at least one quality check station;   at least one additional imaging system;   a food grading device comprising:
 a horizontally movable support member; 
 a vertically movable support member slidably coupled to the horizontally movable support member; 
 a first actuator attached to the horizontally movable support member; 
 a second actuator attached to the vertically movable support member; and 
 a means for moving at least one portion of a food article attached to the vertically movable support member; 
   at least one realigning apparatus; and   at least one computer programmed to utilize information from the at least one additional imaging system to determine a feature selected from the group consisting of:   the location of a bone or bone fragment in a portion of a food article,   the location of fat in a portion of a food article,   the color of a portion of a food article,   the location of a gap in a portion of a food article,   the location of a visual defect in a portion of a food article, and   the location of parasites in a portion of a food article,   wherein the computer is programmed to utilize information about the movement of the at least one conveyor and any determined feature to adjust the position of the means for moving at least one portion of a food article of the grading device.   
     
     
         49 . The food processing apparatus of  claim 48 , wherein the at least one cutting machine comprises:
 a delta cutting device, a four degrees of freedom cutting device, or a six degrees of freedom cutting device; and   a robotic arm.   
     
     
         50 . (canceled) 
     
     
         51 . The food processing apparatus of  claim 48  containing in sequential order on the at least one conveyor a first x-ray machine, the least one cutting machine, and a second x-ray machine, wherein:
 the at least one computer is programmed to utilize information from the first x-ray machine to determine the location of a bone or bone fragment in a portion of a food article; 
 the at least one computer is adapted to adjust the operation of the at least one cutting machine according to the location of a bone or bone fragment in a portion of a food article, so as to maximize the size of the one or more portions of the food article containing flesh that remain(s) after cutting; 
 the at least one cutting machine is adapted to cut out a portion of a food article containing a bone or bone fragment from one or more portions of the food article containing flesh; and 
 the at least one computer is programmed to utilize information from the second x-ray machine to determine the location of a remaining bone or bone fragment in a portion of a food article. 
 
     
     
         52 . The food processing apparatus of  claim 51 , further comprising a manual or automated quality check station following the second x-ray machine. 
     
     
         53 . The food processing apparatus of  claim 51 , further comprising at least one food grading device located sequentially after the at least one cutting machine and before the second x-ray machine on the at least one conveyor, wherein the food grading device is adapted to move at least one portion of a food article containing a bone or bone fragment. 
     
     
         54 . The food processing apparatus of  claim 53 , wherein all or substantially all of the portion(s) containing a bone or bone fragment are moved by the at least one food grading device. 
     
     
         55 . The food processing apparatus of  claim 51 , further comprising at least one food grading device located sequentially after the second x-ray machine on the at least one conveyor, wherein the food grading device located sequentially after the second x-ray machine is adapted to move a portion of a food article containing a bone or bone fragment. 
     
     
         56 . The food processing apparatus of  claim 55 , further comprising a computer adapted to adjust the operation of the food grading device located sequentially after the second x-ray machine according to the location of a remaining bone or bone fragment in a portion of a food article, so as to move a portion of the food article containing a remaining bone or bone fragment. 
     
     
         57 . The food processing apparatus of  claim 55 , wherein the food grading device located sequentially after the second x-ray machine is capable of moving a parallel portion of the food article containing a bone or bone fragment from a first position on the at least one conveyor to a second position on the at least one conveyor while substantially maintaining the alignment and orientation of other parallel portions of the food article. 
     
     
         58 . A mountable needle gripper device comprising a plurality of needle sets, wherein each needle set may be activated, independently of other needle set(s), to grip a food article disposed beneath the gripper device by piercing the flesh of the food article. 
     
     
         59 . The needle gripper device of  claim 58 , wherein the needle set pierces the flesh at the top surface of the food article without contacting any other surface of the food article. 
     
     
         60 . The needle gripper of  claim 58 , wherein more than one of the needle sets are activated to grip a single food article, thereby substantially maintaining the alignment of the food article during a movement of the needle gripper. 
     
     
         61 . The needle gripper of  claim 58 , wherein at least a first needle set is activated to grip a first food article disposed beneath the gripper device, and wherein at least a second needle set is activated to grip a second food article disposed beneath the gripper device while the first needle set(s) is activated.