Multi-layer frankfurter loading method

Abstract

A method of loading a plurality of food items in multiple layers comprises collecting food items in a staging area in a first plurality of groups, each group having a plurality of food items. The first plurality of groups is displaced substantially simultaneously downwardly into an accumulating and storage area and thereby forming a plurality of first layer group. A second plurality of groups of food items is collected, each of the second plurality of groups having a plurality of food items. The second plurality of groups is displaced substantially simultaneously downwardly into the accumulating and storage area such that the second plurality of groups forms a plurality of second layer groups of food items superposed to the first layer groups, and thereby forming a plurality of two layer-groups. The plurality of two-layer groups of food items are displaced downwardly into a receptacle in a packing area.

What is claimed is: 
     
         1 - 7 . (canceled) 
     
     
         8 . A system for loading food items in multiple layers comprising: a staging device for sequentially collecting food items into a plurality of groups, each of said groups having a plurality of food items, and for displacing said plurality of groups substantially downwardly; an accumulating and storage device for receiving said groups substantially simultaneously from said staging device, thereby sequentially forming successive layers of groups of said food items in an accumulating and storage area, and for displacing a predetermined number of received layers of said groups downward substantially simultaneously; and a packing device for receiving said predetermined number of received layers of said groups from said accumulating and storage device in a packing area. 
     
     
         9 . The system of  claim 8  wherein said staging device allows said plurality of groups to fall by gravity into said accumulating and storage area. 
     
     
         10 . The system of  claim 8  wherein said accumulating and storage device allows said predetermined number of received layers of said groups to fall by gravity into said packing area. 
     
     
         11 . The system of  claim 8  wherein said staging device includes a lug chain drive having lugs spaced to form said groups therebetween. 
     
     
         12 . The system of  claim 8  wherein said staging device includes a pair of laterally reciprocating rods, whereby said rods support said groups thereon and displace sidewardly to allow said groups to fall downwardly by gravity to said accumulating and storage area. 
     
     
         13 . The system of  claim 8  wherein said accumulating and storage device includes a pair of laterally reciprocating rods, whereby said rods support said groups thereon and displace sidewardly to allow said groups to fall downwardly by gravity to said packing area. 
     
     
         14 . The system of  claim 8  wherein said accumulating and storage area includes a plurality of dividers positioned to direct said groups and maintain said groups intact and aligned as said groups fall from said staging area. 
     
     
         15 . The system of  claim 14  wherein said packing device includes a receptacle having a plurality of separators dividing said receptacle into cavities shaped to receive said predetermined number of received layers of said groups from said accumulating and storage area, and said dividers are shaped and positioned to correspond to said separators such that separation between said plurality of groups is maintained. 
     
     
         16 . The system of  claim 8  further comprising a controller for controlling said staging device, said accumulating and storage device and said packing device such that said staging device receives groups of said food items and positions said groups substantially above said accumulating and storage device as said accumulating and storage device allows said predetermined number of received layers of said groups to fall by gravity to said packing device. 
     
     
         17 . The system of  claim 15  further comprising a pair of rotatable tucking flaps positioned between said accumulating and storage area and said packing area, said tucking flaps being shaped to rotate downwardly into said packing area to ensure that said predetermined number of received layers of said groups fall into said cavities in proper alignment. 
     
     
         18 . The system of  claim 17  wherein said tucking flaps include notches shaped to provide clearance for said separators, thereby allowing said flaps to rotate below horizontal into said cavities. 
     
     
         19 - 20 . (canceled) 
     
     
         21 . A system for loading food items in multiple layers comprising: a staging device for sequentially collecting food items into a plurality of groups, each of said groups having a plurality of food items, said staging device including a lug chain drive having lugs spaced to form said groups therebetween, and for allowing said plurality of groups to fall substantially downwardly by gravity; an accumulating and storage device for receiving said groups substantially simultaneously from said staging device, thereby sequentially forming successive layers of groups of said food items in an accumulating and storage area, and for allowing a predetermined number of said received layers of said groups to fall downwardly substantially simultaneously by gravity; and a packing device for receiving in receptacles said predetermined number of received layers of said groups from said accumulating and storage device in a packing area. 
     
     
         22 . The system of  claim 21  further comprising a pair of rotatable tucking flaps positioned between said accumulating and storage area and said packing area, said tucking flaps being shaped to rotate downwardly into said packing area to ensure that said predetermined number of received layers of said groups fall into said cavities in proper alignment. 
     
     
         23 . A system for loading food items in multiple layers comprising: a staging device for sequentially collecting food items into a plurality of groups, each of said groups having a plurality of food items, said staging device including a lug chain drive having lugs spaced to form said groups therebetween, and for allowing said plurality of groups to fall substantially downwardly by gravity; an accumulating and storage device for receiving said groups substantially simultaneously from said staging device, thereby sequentially forming successive layers of groups of said food items in an accumulating and storage area, and for allowing a predetermined number of said received layers of said groups to fall downwardly substantially simultaneously by gravity, said accumulating and storage area including a plurality of dividers positioned to direct said groups and maintain said groups intact and aligned as said groups fall from said staging area; and a packing device for receiving in receptacles said predetermined number of received layers of said groups from said accumulating and storage device in a packing area. 
     
     
         24 . A system for loading food items in multiple layers comprising: a staging device for sequentially collecting food items into a plurality of groups, each of said groups having a plurality of food items, said staging device including a lug chain drive having lugs spaced to form said groups therebetween, and for allowing said plurality of groups to fall substantially downwardly by gravity; an accumulating and storage device for receiving said groups substantially simultaneously from said staging device, thereby sequentially forming successive layers of groups of said food items in an accumulating and storage area, and for allowing a predetermined number of said received layers of said groups to fall downwardly substantially simultaneously by gravity, said accumulating and storage area including a plurality of dividers positioned to direct said groups and maintain said groups intact and aligned as said groups fall from said staging area, said accumulating and storage device including a pair of laterally reciprocating rods, whereby said rods support said groups thereon and displace sidewardly to allow said groups to fall downwardly by gravity; and a packing device for receiving in receptacles said predetermined number of received layers of said groups from said accumulating and storage device in a packing area. 
     
     
         25 . A system for loading food items in multiple layers comprising: a staging device for sequentially collecting food items into a plurality of groups, each of said groups having a plurality of food items, said staging device including a lug chain drive having lugs spaced to form said groups therebetween, and for allowing said plurality of groups to fall substantially downwardly by gravity, said staging device including a pair of laterally reciprocating rods, whereby said rods support said groups thereon and displace sidewardly to allow said groups to fall downwardly by gravity to said accumulating and storage area; an accumulating and storage device for receiving said groups substantially simultaneously from said staging device, thereby sequentially forming successive layers of groups of said food items in an accumulating and storage area, and for allowing a predetermined number of said received layers of said groups to fall downwardly substantially simultaneously by gravity, said accumulating and storage area including a plurality of dividers positioned to direct said groups and maintain said groups intact and aligned as said groups fall from said staging area; and a packing device for receiving in receptacles said predetermined number of received layers of said groups from said accumulating and storage device in a packing area. 
     
     
         26 . A system for loading food items in multiple layers comprising: a staging device for sequentially collecting food items into a plurality of groups, each of said groups having a plurality of food items, said staging device including a lug chain drive having lugs spaced to form said groups therebetween, and for allowing said plurality of groups to fall substantially downwardly by gravity; an accumulating and storage device for receiving said groups substantially simultaneously from said staging device, thereby sequentially forming successive layers of groups of said food items in an accumulating and storage area, and for allowing a predetermined number of said received layers of said groups to fall downwardly substantially simultaneously by gravity; and a packing device for receiving in receptacles said predetermined number of received layers of said groups from said accumulating and storage device in a packing area, said packing device including a pair of rotatable tucking flaps positioned between said accumulating and storage area and said packing area, said tucking flaps being shaped to rotate downwardly into said packing area to ensure that said predetermined number of received layers of said groups fall into said cavities in proper alignment. 
     
     
         27 . The system of  claim 26  wherein said packing device includes a receptacle having a plurality of separators dividing said receptacle into cavities shaped to receive said predetermined number of received layers of said groups from said accumulating and storage area, and wherein said tucking flaps include notches shaped to provide clearance for said separators, thereby allowing said flaps to rotate below horizontal into said cavities.