Claims:We Claim:

1) An apparatus (100) for making payasam granules, comprising:
a vessel (11) configured to hold one or more ingredients used for making the payasam granules as a product;
a stirrer assembly (2) configured to rotate and scrap the one or more ingredients held in the vessel for homogenous mixing and prevent charring;
a central shaft (5) configured to transfer rotary motion to the stirrer assembly (2) from a first gear box assembly (17); and
a second gear box assembly (24) configured to tilt the vessel (11) automatically to empty the product after each batch completion.

2) The apparatus (100), as claimed in claim 1, further comprising teflon wiping blades (3) to wipe the one or more ingredients from bottom of the vessel to prevent charring.

3) The apparatus (100), as claimed in claim 1, further comprising a nylon brush (4) configured to avoid metal to metal contact between the stirrer (2) and the central shaft (5) while rotating the stirrer (2).

4) The apparatus (100), as claimed in claim 1, wherein the central shaft (5) is of approximately 50 dia.

5) The apparatus (100), as claimed in claim 1, further comprising one or more ball bearings (7, 18) for carrying load and reducing friction while rotating the stirrer (2).

6) The apparatus (100), as claimed in claim 1, further comprising induction coils (15) to provide high voltage to heat the product at required temperature.

7) The apparatus (100), as claimed in claim 1, wherein the first gear box assembly (17) is of approximately 5HP and comprises of almost a 6mm plate holder to hold the first gear box assembly (17) by utilizing a flange (20).

8) The apparatus (100), as claimed in claim 1, further comprising a square tube front & back (22, 23) configured to provide a support for motor and the first gear box assembly (17) to mount in the apparatus (100).

9) The apparatus (100), as claimed in claim 1, further comprising a shaft (25) configured to rotate and transmit power from a driving device to tilt the vessel (11) automatically.

10) The apparatus (100), as claimed in claim 1, further comprising a connecting rod (26) provided between the second gear box assembly (24) and the shaft (25).

11) The apparatus (100), as claimed in claim 1, further comprising a square block bearing (27) for tilting the vessel (11) smoothly, and one or more pillow blocks (29) for tilting the apparatus (100) to discharge the product after each batch completion.

12) The apparatus (100), as claimed in claim 1, further comprising a titling motor controller limit switch (31) to control the position of tilting mechanism.

13) The apparatus (100), as claimed in claim 1, further comprising a first variable frequency drive (39) of around 5HP for controlling speed of an AC motor used in the stirrer assembly (2) and prevent a heavy load from straining the motor on start-up of the apparatus (100).

14) The apparatus (100) as claimed in claim 1, further comprising a second variable frequency drive (40) of around 2 HP for controlling the speed of an AC motor in the tilting mechanism of the apparatus (100).
, Description:FIELD OF INVENTION

[0001] The present invention is directed to a food making apparatus, more particularly to an improved apparatus for making sadhya payasam granules.

BACKGROUND OF INVENTION

[0002] Making sadhya payasam granules is a traditionally known art for many years. Today, attempts have been made to modernize this technique with introduction of sophisticated devices and apparatuses to automate the entire process steps. However, the devices known in art for forming payasam granules have suffered from several disadvantages, including the necessity of concentrating the liquid and converting in the form of granules. Major trouble has always persisted in maintaining the uniform size of granules so that the finished product possesses the required consistency. Typically, prior art devices for forming payasam granules involve use of machine stirrer, which is not strong enough to take the load during the solidification stage of the substance, causing the frequent breakage of stirrer.
[0003] Further, material distribution in the payasam kettle is usually not uniform due to the various stirrer angles, which cause the uneven stirring of material and during the solidification stage of substance can cause the breakage of stirrer. Furthermore, gear motor mounding bed and tie rod forming the payasam granule making devices gets damaged, while switching the direction of motor from forward to reverse and vice versa. Also, while the ingredient is getting concentrated, the substance becomes stickier and hard in nature, due to which the stirrer motor gets tripped frequently. All this needs to be addressed and readily rectified to ensure complete mechanization of this process with optimum ease.
[0004] In one other limitation, with completion of each batch, the material sticks to the stirrer blade affecting the product quality, which inadvertently increases the machine cleaning time. In some of the known payasam kettles, the bottom portion has a right-angle corner, due to which more residue of the material settles in corners, adversely affecting the product quality. In one of many other limitations, when the substance gets transformed into a semi- solid stage, it gets stick to the bottom surface of the kettle due to the improper angle of stirrer wiping scraper, which makes the concentration process difficult.
[0005] Additionally, huge amount of manpower is invested in traditional delicacy manufacturing machines.. In the background of foregoing limitation, there exists a need to provide improved payasam granule making apparatus which can essentially overcome above mentioned and other disadvantages effectively.
OBJECT OF THE INVENTION

[0006] The primary objective of the present disclosure is to provide an improved, easy to use and cost effective payasam granule making apparatus that can effectively automate entire process of granule making.
[0007] In one other objective of the present disclosure, the payasam making apparatus is easily adaptable to be used for making other similar sweets and delicacies.
[0008] Another objective of the present disclosure is to provide a payasam granule making apparatus capable of making end product with uniform size of granules and consistency.
[0009] Another objective of this disclosure is to provide an apparatus equipped with additional stirrer making the apparatus strong enough to handle load of solidified product.
[0010] Yet another objective of the disclosure is to provide payasam making apparatus that facilitates uniform distribution of product inside the apparatus for uniform consistency.
[0011] Still other objective of the present disclosure is to provide easy to maintain and sturdy apparatus for payasam granule making that can withstand gearbox tie rod associated failures.
[0012]Still other objective of the present disclosure is to provide payasam granule making apparatus that can assure of a quality product making by obviating deposition of residual material inside the apparatus.
[0013] One other objective of the present disclosure is to provide a payasam granule making apparatus that is energy efficient and requires less energy due to usage of induction base system.
[0014] In one another objective of the present disclosure, the payasam granule making apparatus is less manpower intensive compared to traditional methods.

[0015] These and other objects will become apparent from the ensuing description of the present invention.

SUMMARY OF THE INVENTION

[0016] The present invention is directed to an apparatus for making payasam granules. The apparatus primarily comprising: a vessel configured to hold one or more ingredients used for making the payasam granules as a product; a stirrer assembly configured to rotate and scrap the one or more ingredients held in the vessel for homogenous mixing and prevent charring; a central shaft configured to transfer rotary motion to the stirrer assembly from a first gear box assembly; and a second gear box assembly configured to tilt the vessel automatically to empty the product after each batch completion.

[0017] These and other aspects, features and advantages of the present invention will be described or become apparent from the following detailed description of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Fig. 1 shows an exploded view of payasam granule making apparatus, in accordance with one embodiment of present disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0019] Before the present machine for forming payasam granules is described in detail, it is to be understood that this disclosure is not limited to the particular apparatus, design or machine for achieving so, as described, since it may vary within the specification indicated. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present invention, which will be limited only by the appended claims. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. The disclosed embodiments are merely exemplary methods of the invention, which may be embodied in various forms. Terms such as “payasam granule machine”, “payasam granule manufacturing apparatus”, “granule making device” and the like have been interchangeably used in present disclosure, and shall be treated accordingly.
[0020] In one general embodiment of present disclosure, an improved machine for forming payasam granules, as for example, converting milk into a milk pada by concentrating the milk with a controlled heating, is proposed. It is ideally suited for the manufacture of sweets and similar food products. In one exemplary embodiment, the present invention is used for preparing the instant sadhyapaysam granules; a base mix of south Indian concentrated sweet called "Palada Payasam". The recipe of the payasam mix contains liquid and solid substances. By using the induction-based heater, the substance is concentrated and converted into granules. While it is getting concentrated, the substance becomes more stick and hard in nature, a problem which needs to be overcome by the design changes made in existing machine.
[0021] An additional stirrer is provided for the stirrer arm, which successively overcomes the frequent failure of stirrer. In another significant aspect, the present disclosure is provided with 120 degree angle to ensure equal distribution of product in the side the kettle to cause even stirring in the kettle and avoid breakage. In one further advantageous disclosure, the motor mounting bed is modified by adding more stiffeners on all four sides of the motor bed, which results in prevention of gearbox tie rod failure.
[0022] Moreover, in order to overcome problem of stirrer motor getting tripped due to increased concentration of ingredients, an inclination of approximately 25 degree Celsius is provided in kettle during operation, which gravitates the flow of material inside the kettle. This makes the load acting on the stirrer to come down. Also, a pharma grade teflon coating is provided for the stirrer and inside portion of the kettle, which prevents the charring issue of material and reduces the cleaning time. In one other preferred embodiment, the right-angled corner design in the conventional kettles has been replaced with fillet type corner, which reduce the material residual product deposit in the corner. Furthermore, the wiping scraper is re-oriented from inclined position (30˚) to vertical position to prevent the charring of material and sticking of it at bottom surface of the kettle due to otherwise improper angle of stirrer wiping scraper.
[0023] In one general embodiment, for illustration purposes, the present disclosure is used for preparing the instant sadhyapaysam granules. As known, the recipe of the payasam mix contains liquid and solid substances. By using the induction-based heater, the substance is concentrated and converted into granules. While it is getting concentrated, the substance becomes more sticky and hard in nature. Due to the sticky hard nature of product, three major issues are generally witnessed: motor tripping, stirrer breakage and gear motor tie rod breakage. Further, huge amount of manpower is invested and wasted in managing product discharge as discussed in background section of present disclosure. To overcome these issues, design changes are made to existing machines.
[0024] Referring now to Fig. 1, an illustrative embodiment of payasam granule making apparatus 100 is depicted. Each component of the machine 100 is discussed herein detail. As shown, top threaded stirrer cap (1) is provided to arrest the total stirrer assembly and it will tight the stirrer from top. The stirrer arm assembly (2) is provided to mix the product during process time of the apparatus (100). It rotates and wipes the bottom surface of the vessel to prevent the product charring and to enable homogenous mixing of product ingredients. Next, Teflon wiping blades (3) are provided to wipe the product from the bottom heated surface to prevent the product from charring. Nylon bush (4) is provided to avoid the metal to metal contact of the stirrer and the shaft while rotating the stirrer (2). The center pole inner shaft (5) of approx 50 dia transfers the rotary motion from main geared motor to stirrer assembly (2) of the apparatus (100).
[0025] The Teflon cover (6) provided in the apparatus (100) protects the bearings from foreign particles or from dust. The ball bearing (7) carries loads and reduces friction while rotating the machine wiping stirrer. Further, bearing holders (8) are provided to hold the bearing assembly of the stirrer and ensure the smooth rotation of the stirrer. The Circlips (9) are provided to restrict the main shaft up down motion from the gear box assembly. Furthermore, tower lamps (10) are provided to visual and audible indicators of a machine's status to machine operators, technicians during start up. Product heating process and mixing will be carried out in this drum or vessel (11) and drum (11) can be tilted after the process completion. In one example embodiment, it is made up of SS-304 grade steel. The center pole pipe assembly (12) is provided as a cover for the main shaft connecting to the stirrer and gear box assembly.
[0026] Next, temperature sensor cover (13) is provided to protect the sensor from direct hitting. Now, bottom temperature sensor (14) is used to measure the temperature of the heating pan & the product temperature. Induction coils (15) are used to provide high voltage to heat the product at required temperature. Fan cover (16) is the protection for the cooling fan provided in the induction coil (15). A gear box (17) of approximately 5HP and almost 6mm plate holder is provided that holds the stirrer main gear box assembly. Now, ball bearing (18) carries loads and reduces friction while rotating the machine wiping stirrer. Teflon cover (19) prevents the bearings from foreign particles or from dust.
[0027] A Flange (20) of approximately 50mm thickness is provided to mount the gear box in the plate assembly. The Gear box and motor (21) is provided to give a rotation to the stirrer with lesser rpm. A square tube front & back (22, 23) serves a support given for the motor and gear box assembly to mount in the machine. Now, a Gear box (24) (of 1.5KW titling gear box) and motor is provided to tilt the total machine drum automatically to empty the product after the each batch completion. Also, a shaft (25) of circular cross section is provided that rotates and transmits power from a driving device, such as motor to tilt the machine manually. Shafts (25) can carry gears and sprockets to transmit rotary motion. Tilting mechanism connecting rod (26) is provided between shaft (25) and gear box (24). Further, a square block bearing (27) for tilting shaft is provided as a bearing assembly to tilt the drum smoothly. Wheels (28) are also provided to tilt the machine manually for discharging the final product. Pillow blocks (29) are provided for tilting the machine assembly to discharge the product after each batch completion. Doors (30) are provided to protect the machine internal parts from dust and other.
[0028] Now, a titling motor controller limit switch (31) is a safety interlock to control the position of tilting mechanism. Limit switch (32) can be used for controlling machinery as part of a control system, as a safety interlock. Shaft (33) of a circular cross section is provided that rotates and transmits power from a driving device, such as motor to tilt the machine. Shafts (33) can carry gears and sprockets to transmit rotary motion. Human Machine Interface (HMIs) (34) allow operators to start and stop machine process, adjust set points, and perform other functions required to adjust and interact with a control process.
[0029] Now, a heater display (35) is provided for monitoring the level of heater position from 0-9 stage. Heater control knob (36) is provided for controlling the induction heater switch ON/OFF process. The Emergency stop buttons (37) are wired in series with the control circuit of machinery. When pushing the mushroom head of emergency stop button it will break the circuit of machine and removes power supply. A black box (38) serves as the control unit for the induction coil. 5HP VFD /Variable Frequency Drive (39) is used for controlling the speed of an AC motor used in the stirrer mechanism of the machine assembly. It will prevent a heavy load from straining the motor on start-up.
[0030] A 2HP VFD /Variable Frequency Drive (40) is used for controlling the speed of an AC motor in the tilting mechanism of the machine assembly. It will prevent a heavy load from straining the motor on start-up. Then, PLC (Programmable Logic Controller) (41) is used as industrial computers used to control different electro-mechanical processes in the machine to work in the automatic mode. SMPS or switch-mode power supply (42) is deployed that converts wall-voltage AC power to lower voltage DC power. A miniature Circuit Breaker or MCB (43) automatically switches OFF electrical circuit during any abnormal condition in the electrical network mainly in the SMPS board, such as overload & short circuit conditions. Also, a Miniature Circuit Breaker or MCB (44) automatically switches OFF electrical circuit during any abnormal condition in the electrical network mainly in the machine main motor, such as overload & short circuit conditions.
[0031] A fuse (45) is provided, which commonly consists of a current-conducting strip or wire of easily fusible metal that melts, and thus interrupts the circuit of which it is a part, whenever the fan circuit is made to carry a current larger than that for which it is intended. Further, pneumatic parts such as 8 WAY CONNECTOR (46) may be provided that connects sections of pipe, tube, and hose in pneumatic (pressurized gas) systems. Multiple hoses (Upto-8nos) can be connected in this connector and it allows the user to easily change the connections in a system. Finally, a DIN rail (47), a metal rail of a standard type is provided that is widely used for mounting circuit breakers and industrial control equipment inside equipment racks.

[0032] The foregoing description is a specific embodiment of the present disclosure. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.