SORTING AND PACKING FRESH EGGS
The fresh eggs are graded with an MOBA grading machine, type FT 170. Production takes place in 2 shifts of 5 people each.
First, the fresh eggs are delivered on pallets. Upon arrival, the eggs are still ungraded, i.e. the eggs are not yet sorted to size (XL, L, M, S). The ungraded eggs are stored in a storage area with separate compartments for each type of eggs: an enriched cage compartment, an organic compartment, a free-range compartment and a scharrel compartment.
How do you sort the eggs?
First, the eggs are taken to the loader. At the loader, the eggs are placed on the conveyor belt using the easy-lift. The trays are initially taken from the stack 1 by 1. These trays are put on a belt and continue to the second part of the loader. In the second part, there are 30 suction cups in a tray layout that take 30 eggs and put them on a yellow rolling conveyor belt. The empty trays go to an end tray where they are stacked.
When the eggs are on the yellow belt, they undergo several checks. First the egg goes through the egg inspector, where it is checked for blood or dirt, then the eggs go through the crack detection process. In this process, each egg is tapped 16 times on different sides, and each time the machine listens to the resonance of the metal on the egg shell. The machine calculates the average of the results and after 16 taps, can know if the egg is broken or not. Then the eggs go over the weighbridge. Here the machine weighs each egg to see if it is S, M, L, XL or XL. That way the machine knows to which belt to route each egg to.
Next, the eggs are transferred by clamps, each handling 1 egg. The clamps know what kind of egg they are holding and which belt it should be on. Once they are above the right belt they drop the egg.
Then the eggs fall into the receiver. Each belt has 2, where the eggs fall when they are above the right belt. Then the receiver passes the eggs to the buffers. And the buffers pass the eggs to the drop set. The drop set puts the eggs in boxes. The drop set can be set for boxes of 12, 6, 4 and 10.
The boxes in the drop set are provided by a de-nester, which will automatically place a box when a full box rolls off the conveyor belt. The de-nester has to be set by hand and can be used for empty boxes of 10 eggs, 2x4 eggs, 12 eggs and 2x6 eggs.
When the boxes are full, the belt pushes another box forward. The full box is then moved on to the hatch that closes the boxes. There is a large hatch on each belt and sensors tell it when there is a box that needs to be closed. When the box is closed, it is sent to the end of the belt and another label is placed on the box. After that, the box is pushed onto a rolling belt that rotates constantly.
There are four belts that rotate constantly and there are also four belts with sensors. The four sensor belts can be used as normal belts (manual box filling by operators) or route them to contiflow, connected to the case packer (automatic packing). The contiflow is a belt where the boxes are placed in front of the case packer. If an open box is detected, it is pushed aside by a hatch on the back-up case packer belt. Just before the boxes enter the case packer, a printer prints the date on the box. Next, the case packer collects 4 boxes and puts them in corrugated cardboard transport boxes with a robot arm. The case packer can fill boxes of all different sizes.
The last step in the production process: the full boxes end up on a roller conveyor. This takes the boxes to the tape machine. The machine consists of 2 parts. First, the boxes are folded from above and then the boxes are taped at the bottom and top. The boxes are then put onto a pallet and are ready to go to the customer.