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Pro Load Overview & Specification

The Pro-Load live bird handling system is based around a standard galvanised steel transport frame (module) which carries plastic drawers to contain the birds. Modules are manufactured in either 3, 4 or 5 tier variations dependent on birds to be handled.
The modules are either hand or machine loaded on the farms and transported to the processing plant on the back of trucks. The modules are then unloaded onto the Pro-Load system, which is an automated system for unloading the drawers from the modules and presenting each drawer to the hang-on operators. Each drawer and module is washed, drawers are loaded back into the modules and each filled module then loaded back onto the truck.

The Pro-Load system accommodates 3, 4 or 5 tier modules. Modules are constructed from Galvanised Mild Steel and weigh approximately 650lbs per unit.

Note; 4 tier module shown.

pro load live bird handling system Wrightfield

MODULE CIRCUIT

Module in-feed

  • Stainless steel pressed sided conveyor, fitted with heavy duty modular section plastic chain, plastic chain section has been used as it has shown to have superior wear properties and allows for more efficient cleaning and easier maintenance.
  • The conveyor will be fitted with a hopper section at the loading point to aid the positioning of the module and to minimise the chance of possible damage, hydraulic scissor lift and single hydraulic drive.
  • Guarding will consist of a perimeter steel mesh fence attached to the main conveyor body and will incorporate quick action emergency stop buttons and or cords.
  • The hydraulic scissor lift is designed to be low maintenance but easy to work on for all essential works and routine greasing etc. the lift is fitted with a fast action safety curtain around its perimeter and non-return valves to support the lift in the event of pressure failure.

Module shuttle; (low capacity)

  • Stainless steel pressed sided conveyor uses dual plastic chains to transfer the module from the system infeed of the system across to the infeed of the module washer.
  • The chain used is common to the rest of the module circuit to keep spares inventory and costs to a minimum.
pro load

Module shuttle; (high capacity)

  • The general construction is the same as the above unit however for systems processing upwards of 50 modules per hour the modules are shuttled across using a transfer chain, this can either be powered by hydraulic or electric motors depending the customer preferences.

Module wash

  • The module wash enclosure and frame is completely constructed from stainless steel, and will contain a reciprocating conveyor section, this will allow for multiple passes of the module through the jet banks (this can be either pre-programmed or time dependant).
  • The conveyor will use plastic chain to allow for easy care and maintenance, it will be complete with its own hydraulic drive unit.
  • The module washer frame will incorporate 3 sets of stainless steel jet banks; each bank specifically designed and positioned to sweep debris from
    the module frame, all the banks will be installed using a quick release system to allow for quick effective cleaning away from the washer.
  • The module washer base will be fitted with a drain door for easy wash down and all the connections the module washer system. Pneumatically controlled doors will be fitted at the infeed and the outfeed to minimise overspray and water loss.

Water Filtration system

  • The module wash is connected to a water re-circulation system, capable of removing debris down to 1mm in diameter.
  • Filtration will be in the form of a rotary screen, complete with header tank and adjustable weir.
  • Filtered water will accumulate in a reservoir mounted under the screen where a series of pumps will deliver it through to the jet banks via stainless steel pipework, a recirculation pump will remove debris laden water from the base of the washer, and the water will then be pumped through UPVC pipework to the screen header tank.
  • Please note that pump size will be determined by the throughput required by the system.
  • The rotary screen will be driven by a shaft mounted motor so there will be no need for chains or adjustments, the screen will be self-cleaning using a back purge system that can either be pre-programmed to work at a fixed time or can be done manually to fit in with breaks etc.

Module Takeaway conveyor and roller outfeed

  • Stainless steel pressed sided conveyor, fitted with heavy duty modular section plastic chain, plastic chain section has been used as it has shown to have superior wear properties and allows for more efficient cleaning and easier maintenance.
  • This section again has its own dedicated hydraulic drive, this section is where the drawers are either manually reloaded or there is the option of an automatic drawer re-loader, this additional unit will stack the drawers into either 3, 4 or 5 high and then reload them into the cleaned module.
  • The reloaded modules are then fed out onto a roller section where they can be retrieved with the fork lift.

Infeed/outfeed buffers

  • To reduce the potential damage that a forklift could cause while loading and unloading modules from the system a heavy duty buffer section is used.
  • These frames will protect the system from potential abuse and accidental damage, these structure are securely fixed to the concrete by using a core cutter and sinking steel anchor points for the buffers to be bolted to, this allows for removal but does not compromise the protection it provides.
  • Buffers are constructed from mild steel and galvanised for long lasting protection.
  • The buffers will be tailored to suit the type of vehicle used whether it be a Moffatt or standard forklift.

Drawer push out tower

  • The drawer push out tower consists of a stainless steel frame, this is anchored to the floor and also the module lift frame to guarantee that the unit is secure and constantly pushes the drawers out square to the module.
  • The tower uses a hydraulic cylinder which drives the push out forks through the module, pushing the drawers through and out on to the drawer transfer conveyor.
  • The push out tower has been engineered for constant reliable service, but has also been designed for easy maintenance and features many unique design elements for easy servicing and reliable operation.

Drawer Transfer Conveyor

  • The transfer conveyors use twin uni-flex side flexing plastic chain, it is used due to its strength, durability and reliability, it has excellent wear characteristics and is virtually maintenance free.
  • The main conveyor frame and support legs are constructed from galvanised mild steel.
  • All the lids on the transfer conveyors are fixed from the top to minimise damage that could be caused to the poultry and the drawers, all lids are constructed from Stainless steel and are hinged to allow for easy access and maintenance, the lids are secured in such a way as allow access for only engineering staff.
  • To make cleaning and maintenance easier a GRP walkway complete with safety handrail is fitted to the top of the conveyors.

Drawer Turn Unit

  • The turn unit is of a pressed stainless steel construction.
  • To minimise damage to the drawers they will be driven through 90 degrees by being driven from the underside, this guarantees that the drawers are being pushed/driven on their strongest point and not the more flimsy top edge.
  • The drawers are driven on an acetal modular belt with drive bars to ensure a smooth transfer through the 90° turn unit.
pro load

Drawer Accumulation

  • The accumulation conveyors use twin uni-flex side flexing plastic chain, it is used due to its strength, durability and reliability, it has excellent wear characteristics and is virtually maintenance free.
  • The main conveyor frame and support legs are constructed from galvanised mild steel.
  • All the lids on the transfer conveyors are fixed from the top to minimise damage that could be caused to the poultry and the drawers, all lids are constructed from Stainless steel and are hinged to allow for easy access and maintenance, the lids are secured in such a way as allow access for only engineering staff.
  • To make cleaning and maintenance easier a GRP walkway complete with safety handrail is fitted to the top of the conveyors.
  • The length of the accumulation conveyor is tailored to the speed requirements of the live bird system, the faster the system the easier it becomes if there is a reasonable amount of accumulation.

Hang-on Conveyor, Hang-on personnel stand;

  • The basic construction and chain specifications are the same as the transfer conveyors, however where the personnel work is left open to allow for the staff to retrieve the birds and hang on the overhead line.
  • The conveyor is traditionally driven in the opposite direction of the line to allow for easier hanging and bird placement.
  • The foot stand is designed to allow a minimum 800mm per person and is 800mm deep it is accessed via steps with an interlocking gate at the top to reduce trips and hazards, the stand construction is galvanised mild steel with a GRP non slip grating platform, this is easier to clean and creates less stress on the feet and legs of the operators.
  • The end operator uses a knee switch to “call” for another drawer, as he is the last operator he ultimately hangs the last bird in the drawer.
pro load

Drawer inverter

  • The drawer inverter is used to invert the drawers into a base up orientation, this initial inversion helps by shaking all the loose dirt from the drawer.
  • The inverter is constructed from a stainless steel frame with stainless steel access doors,
  • The inverter is constructed in such away so as backed up drawers cannot force the next drawer up and cause a jam.
pro load

Drawer washer infeed

  • The drawer washer infeed is the conveyor between the inverter and the drawer washer, this conveyor elevates the drawers to the correct level to infeed into the drawer washer, and this is variable and tailored to suit each customer’s site.
  • The drawers are taken up via a plastic modular chain fitted with “lugs” to positively drive the drawers uphill, however in the unlikely event of a jam up the drive motor is fitted with and electronic shear pin, this will cut the motor before any damage can be done to the drawers or the conveyor.

High level drawer wash

  • Constructed from stainless steel the draw wash which is approximately 3 metres long, the washer is fitted with gullwing doors to allow for easy access to the entire internals of the washer.
  • There are multiple spray nozzles fitted to easily removable jet banks, the nozzles are fitted in such a way so that they cannot be remounted in the incorrect orientation, this also allows for easy cleaning with little or no disruption to production.
  • The water for the drawer washer is handled by the water filtration system as listed in the module circuit.

Control;

  • Control for the system will be through a touch screen HMI mounted in the main electrical panel.
  • The panel will house all the electrical control equipment for the module circuit, along with the safety circuit monitoring system and control for the hydraulic lift.
  • A secondary satellite cabinet will be provided to house the drawer control and remaining pumps and filtration unit.
  • Whether motors chosen are hydraulic or electric they will all be fitted with variable speed control, providing optimum efficiency and speed for the system.
  • The control system can be networked view real time and historic data such as drawers per minute, downtime etc.
pro load

Pro Load Extras;

Module De-stacker & Re-stacker;

  • Modules are loaded onto the Pro-Load system in singles where speed and fork truck movements are not an issue, however, to reduce the number of fork lift movements we can install a module de- stacker.
  • The de-stacker enables the fork truck to load the Pro-Load system two at a time, one on top of the other, as they are transported.
  • The double stack module is transported along the infeed conveyor to the de-stacker, which lifts the top module off and allows the lower module to move further into the system.
  • The top module is then lowered onto the infeed conveyor to continue along behind.
  • The re-stacker works in reverse, once the module has been reloaded with drawers, where the fork lift can reload the truck two at a time.

Drawer Dip Tank;

  • Fabricated from stainless steel sheet the dip tank can be built to suit space available, the tank is fitted with multiple drain doors and associated pipework for filling and level control.
  • The dip tank outfeed can also accommodate a pre-wash unit that can house either high pressure jets or a flood type system again this can be made to suit environmental and customer needs.
  • The tank can be fitted with air agitation units, motorised brushes as well as chemical dosing.

Drawer Re-loader;

  • On faster systems an automatic drawer re-loader is often desirable.
  • This automatically accumulates the drawers after the drawer washer and reloads them into the washed modules.
  • This unit takes the drawers stacks them in the desired amount and pushes them back into the module using a hydraulic or pneumatic cylinder depending on system specification.
  • On systems using 4 and 5-tier modules and auxiliary sensor is fitted prior to the drawer re-loader so that it can stack the required amount of drawers.

Further Information

For information on Conveyor Systems designed for the Food processing sector  click here

For information on other Stainless Steel products manufactured by Wrightfield Click Here

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