SCUTCHING MACHINE AND METHOD

Technical field

This invention relates to the chemurgy sector, that is to say, the branch of industry and applied chemistry concerned with preparing products starting exclusively from raw materials of an agricultural and natural origin.

The invention relates to a machine and a method for scutching semi finished hemp-based products or the like.

In the following description, the term "scutching" is used to denote the operation designed to free the fibrous component from the woody component of the stem.

The expression “or the like" also refers to a plurality of textile plants which, although of different species, can be subjected to the same processing operations already used for processing hemp, with particular reference to scutching.

Background art

Hemp has been cultivated since ancient times in order to obtain various types of products, such as textiles and fabrics, rope making products, paper products and other commonly used products.

However, starting from the first half of the twentieth century, due to the availability of more competitive textile fibres on the market, such as, for example, jute and cotton, the adoption of synthetic fibres as well as commercial prohibition, the cultivation of hemp has gradually disappeared. In recent decades, the hemp production chain has undergone a renewed development.

In particular, the various components of hemp can be used to make a plurality of industrial products such as, for example, bio-building products, fuels, bio-plastics, fabrics, ropes and paper products. Moreover, hemp seeds are suitable, for example, for the production of flour for human and animal consumption as well as for phytocosmetics. Moreover, the industrial use of hemp offers numerous advantages, including its high environmental compatibility and the high capacity for reclaiming the soil in which it is cultivated.

Despite this, the hemp production chain has a number of interconnected problems which make the products not economically competitive, slowing down the development of the sector.

The cultivation of hemp is currently marginal and distributed non-uniformly over the territory, typically grown in small sites with a low volume of agricultural production.

The number of scutching plants is insufficient to serve these agricultural production sites which are also geographically located in the territory, typically far from these sites.

Lastly, the processing plants, that is to say, the plants for converting hemp into industrial products, are highly specialised and divided into independent, non-communicating facilities and production sites.

These factors result in the product not being very competitive on the market.

For this reason, the industrial sector seeks alternative and less costly products to be used in industrial production. The processing companies, due to the random request of the industrial sector, do investment in and/or renew the processing plants, nor do they purchase raw materials from the farmers. The latter, because of the impossibility of generating income, concentrate their efforts on other crops.

Moreover, the prior art scutching plants are obsolete, large in size, have high energy consumptions and are very expensive, contributing to making the transformation process even more onerous and providing a product of not very high quality.

Aim of the invention

In this context, the aim of the invention is therefore to meet the above- mentioned needs, and in particular an aim of the invention is to provide a machine and a method for scutching a hemp-based semi-finished product which is able to lower the costs for transformation and production of hemp- based products or the like, making them competitive on the market.

A further aim of the invention is to provide a machine for scutching hemp which operates in an efficient manner and which at the same time requires low investment costs.

A further aim of the invention is to provide a machine and a method for processing a hemp-based semi-finished product which guarantees a high quality product.

Brief description of the drawings

These and other aims which will become more apparent in the description below are substantially achieved by a scutching machine and method according to the invention, having the features illustrated in the accompanying claims and described below in a plurality of example, non limiting embodiments, as well as in the accompanying drawings, in which:

- Figure 1 shows a schematic representation of a preferred embodiment of a scutching machine according to the invention;

- Figure 2A shows a schematic representation of an embodiment of a first scutching module of the scutching machine of Figure 1 ;

- Figures 2B-2C show a schematic representation of an embodiment of a detail of the first scutching module of Figure 2A;

- Figures 2D-2E show a schematic representation of a further embodiment of a detail of the first scutching module of Figure 2A;

- Figures 3A-3B show a schematic representation of an embodiment of a second scutching module of the scutching machine of Figure 1.

Detailed description of preferred embodiments of the invention

With reference to the accompanying drawings, the numeral 1 indicates a machine for scutching a semi-finished product which is hemp-based or the like, designed for obtaining from the semi-finished product at least one fibrous-based component and one woody-based component.

Preferably, the machine 1 is a static frame machine, configured to be installed and operate in a stationary position and, therefore, not of the type operated by pulling by an agricultural vehicle.

Preferably, but not exclusively, the machine 1 is a machine designed to make, by scutching the semi-finished product, a fibrous component with long fibres, for example suitable for use in the textile sector, and/or a component with short fibres, for example suitable for use in the technical sector.

Moreover, the machine 1 is, preferably, but not exclusively, designed to make, by scutching the semi-finished product, a woody-based component or hemp.

The machine, as illustrated by way of example in Figure 1 , comprises a plurality of interconnected modules.

According to one aspect of the invention, the modules are designed to be removed and transported in such a way that the machine 1 can operate in an itinerant manner.

In other words, the machine 1 is designed to be disassembled, transported and reassembled at a processing location by means of transport suitable for the purpose.

The term "processing location" means a site for production and/or storage for the semi-finished product.

The term "module" means an operating unit of the machine, designed to be mounted and removed preferably quickly and combined with other modules of the machine in a flexible fashion, that is to say, in such a way as to define different sequences of operations depending on the requirements. The modules may therefore have suitable coupling means designed to allow the modules to be connected to each other and/or to be interchangeable with each other or reversed. For example, the modules may have same portions for coupling to a shared supporting frame and/or connecting interfaces which are compatible with each other for making a mutual coupling between the modules. Each module therefore comprises a supporting frame and an operating unit for performing at least one operation on the semi-finished product, as well as (where provided) electrical connecting means and/or a control unit.

Advantageously, by means of this feature, the machine 1 can serve a plurality of geographically adjacent processing locations in such a way as to considerably reduce, if not annul, the transport costs of the semi finished product.

As a result, the cost of the end product on the market is reduced and becomes competitive.

Moreover, since typically the transport of the semi-finished product is carried out over large distances using agricultural machines and/or trucks, the environmental impact is considerably reduced.

In the preferred embodiment of the machine 1 , illustrated by way of a non limiting example in Figure 1 , the plurality of modules comprises at least: one feeding module 10 configured to receive the semi-finished product in the form of bales and to obtain at outfeed the semi-finished product in broken up form; a scutching module 30 positioned downstream of the feeding module 10 and configured to receive at infeed the semi-finished product in a broken up form and to obtain from the semi-finished product a fibrous- based component and a woody-based component separated from the fibrous-based component; at least one movement module 60 configured to move the semi finished product and/or the fibrous and woody components between at least two modules of the plurality of modules.

Moreover, the machine 1 comprises a control unit "U", configured for managing the plurality of modules and for defining a feed path "L" of the semi-finished product passing through the plurality of modules.

In this description, the expression "in the form of a bales" means a variable quantity of semi-finished product, compressed and rigidly wound in sheeting or the like, or tied with a string/rope, defining a pack of semi finished product suitable for being transported and/or stored.

Moreover, the expression "in a broken up form" means a predetermined quantity of loose semi-finished product, without a rigid or semi-rigid structure which retains it.

With reference to the scutching module 30, it may comprise a first scutching module 40 (“compacting rollers” module), illustrated in Figures 2A-2E, in particular configured to obtain from the semi-finished product a fibrous-based component having long fibres, preferably intact, and a woody-based component separated from the fibrous-based component, and/or a second scutching module 50 (“hammer mill" module), illustrated in Figures 3A-3B, in particular configured to obtain from the semi-finished product a fibrous-based component having short and/or teased fibres and a woody-based component separated from the fibrous-based component. According to a preferred embodiment, the scutching module 30 may be made of both the first and second scutching module 40 and 50, which are operatively positioned in parallel, in such a way as to operate alternatively or simultaneously as a function of a predetermined processing.

In other words, according to the end product to be obtained (and therefore according to the long or short type of fibre), the control unit "U" defines a predetermined feed path "L" of the semi-finished product which is conveyed, by means of the at least one movement module 60, to the respective first or second scutching module 40, 50.

As is evident from the description, the feed path "L" of the semi-finished product is not a fixed path through the machine 1 but it is determined according to the predetermined processing.

Advantageously, in this way, it is possible to decide which type of fibrous component to produce as a function, for example, of the market demand. Flowever, according to further non-limiting example embodiments, the scutching module 30 comprises only one between the first and second scutching module 40 or 50.

This solution is, for example, effective when the investment costs are to be reduced by directing the transformation of the semi-finished product towards a limited family of products which can be obtained (and therefore towards a single, long or short, type of fibrous component).

At a structural level, as illustrated in Figures 2A-2E, the first scutching module 40 comprises a first containment body "C1" defining a first processing space and a plurality of penetrating rollers 41 operatively positioned inside the first processing space and configured to engage the semi-finished product in a broken up form.

More specifically, the penetrating rollers are positioned transversely along a first portion "L"' of the feed path "L" of the semi-finished product, inside the first processing space.

The penetrating rollers 41 are coupled in pairs 42 and are rotatable about respective axes of rotation, also transversal to the feed path "L".

The movement of the penetrating rollers 41 is accomplished by a respective movement apparatus (not illustrated in the accompanying drawings) with which the first scutching module 40 is equipped, operatively connected to the control unit "U". The first scutching module 40 comprises a number of pairs 42 of penetrating rollers 41 which is between 2 and 25, preferably between 4 and 20.

More specifically, the penetrating rollers 41 of a same pair 42 are counter rotating and located on opposite sides of the first portion "L"' of the feed path "L".

In other words, the first portion "L"' of the feed path "L" passes through the two penetrating rollers 41 of a same pair 42 and for each of the pairs 42 of penetrating rollers 41.

More specifically, the pairs 42 of penetrating rollers 41 are preferably translated in an alternating fashion in such a way that the first portion "L"' of the feed path "L" is at least partly curved. With reference to the structure of the penetrating rollers 41 , they have a toothed lateral surface configured to engage with the semi-finished product.

In other words, the penetrating rollers 41 have a plurality of teeth 41a alternated with grooves 41 b extending longitudinally to the lateral surface of the penetrating rollers 41 and, preferably, parallel to the respective axes of rotation.

However, according to alternative embodiments, teeth 41a and grooves 41b extend in a helical fashion on the lateral surface of the penetrating rollers 41.

The teeth 41a may have a triangular, parallelepiped, trapezoidal or circular shape.

According to one aspect of the invention, each pair 42 of penetrating rollers 41 may have penetrating rollers 41 of different sizes, as illustrated in Figures 2D-2E.

Moreover, the teeth of the pair 42 of penetrating rollers 41 are substantially shaped to match in such a way that the teeth 41a of one penetrating roller 41 are shaped to match the groove 41b of the other penetrating roller 41 and vice versa.

Preferably, the first scutching module 40 is made in such a way that the first portion "L"' of the feed path "L" does not have curves or angles of less than 150°.

It follows that the semi-finished product, passing along the first portion "L"' of the feed path "L", does not undergo deformations such as to cause the breakage of the fibrous component which is substantially intact at the outfeed of the first scutching module 40.

Moreover, the apparatus for moving the first scutching module 40 is configured in such a way as to allow the movement of the penetrating rollers 41 at least at three speeds as a function of the predetermined processing.

According to another aspect, the penetrating rollers 41 may be made at least partly of wood, preferably of particleboard, still more preferably made of particleboard with heartwood inserts.

The woody material is of any origin providing it guarantees compression, traction and surface abrasion resistance characteristics suitable for the processing to be performed according to the invention.

Advantageously, this construction material makes it possible to process the semi-finished product in an optimum and efficient manner.

In fact, the surface of the penetrating rollers 41 naturally has micro-crests, suitable for not stressing and ruining the fibrous-based component, guaranteeing a high quality of scutching.

Moreover, the micro-crests contribute automatically to a textile combing operation, that is to say, the elimination of impurities which have survived the previous processing and elimination of the fibrous-based component shorter than a predetermined length.

Moreover, advantageously, the use of wood allows a significant reduction in maintenance costs and times, as well as a considerable reduction in the weight of the first scutching module 40 (relative to prior art devices, which are typically made of metal).

Lastly, the use of the wood has a limited impact on the environment.

The apparatus for moving the first scutching module 40 may also comprise a plurality of vibrating tables (not illustrated in the accompanying drawings), operatively connected to the plurality of pairs 42 of penetrating rollers 41.

Preferably, each of the pairs 42 of penetrating rollers 41 is associated with a respective vibrating table of the plurality of vibrating tables in such a way that each pair 42 of penetrating rollers 41 can be moved independently by means of the respective vibrating table.

Advantageously, these vibrating tables facilitate the scutching operation performed by the penetrating rollers 41 thanks to the vibrations which allow a more effective separation of the fibrous and woody components. The machine 1 may comprise a module 70 for recovering the woody- based component made preferably, but without limiting the scope of the invention, in the form of screens, located downstream of the first scutching module 40, configured for retaining at least the woody-based component having a grain size greater than a predetermined value and sending it to the infeed to the first scutching module 40 with the aim of reducing the grain size and/or cleaning of possible fibrous-based residue.

At a structural level, the second scutching module 50 comprises a second box-shaped body "C2" defining a second processing space and, preferably, having a cross-section shaped in the form of a spiral.

The second scutching module 50 comprises at least one cutting roller 54, made of metal and/or wood, operatively positioned transversely along a second portion "L" of the feed path "L" of the semifinished product, inside the second processing space.

Each cutting roller 54 rotates about a respective axis of rotation and is moved by a respective movement apparatus of the second scutching module 50 (not illustrated in the accompanying drawings).

The control unit "U", operatively connected to the movement apparatus of the second scutching module 50, controlling the speed of rotation of the at least one cutting roller 54 can determine the grain size of the fibrous and woody-based components.

Structurally, each cutting roller 54 comprises a plurality of cutting elements 55 extending radially away from the respective axis of rotation and configured to engage and cut the semi-finished product in such a way as to obtain a fibrous component having short fibres and a woody component.

The cutting elements 55 are also configured to generate a radial pulling action of the semi-finished product in such a way as to move it inside the second processing space and, consequently, improve the cutting action. The cutting elements 55 may have a triangular, trapezoidal or, preferably, parallelepiped shape.

Preferably, each cutting element 55 is oriented in such a way as to have a base portion parallel to the axis of rotation.

Moreover, the cutting elements 55 are grouped in rows which extend preferably in a helical fashion along the lateral surface of the respective cutting roller 54.

The preferred embodiment of the cutting roller 54, illustrated in Figure 3B, comprises a single row of cutting elements 55 which extends in a helical fashion on the lateral surface of the cutting roller 54.

In more general terms, the second scutching module 50 comprises an infeed 51 , a primary outfeed 52 and a secondary outfeed 53.

The infeed 51 of the second scutching module 50 is configured for receiving the semi-finished product in a broken up form and channelling it in the second portion “L”” of the feed path "L" in the second processing space.

More specifically, the infeed 51 has a frustoconical structure in such a way that the semi-finished product is distributed uniformly to the at least one cutting roller 54.

The primary outfeed 52 is, on the other hand, equipped with a primary sieve configured for the passage of the fibrous-based component and for retaining the woody component. Preferably, the primary outfeed 52 is also equipped with a suction device configured to extract the fibrous-based component.

Advantageously, the cross section of the second processing space, shaped in the form of a spiral, allows a considerable fluid dynamic efficiency.

It follows that the suction device can be sized in an optimum manner, minimising the operating costs.

The secondary outfeed 53 is, on the other hand, configured for channelling at least the woody-based component.

The machine 1 may comprise a module 70 for recovering the woody- based component made in the form of screens, positioned downstream of the secondary outfeed 53, configured for retaining at least the woody- based component having a grain size greater than a predetermined value and sending it to the infeed 51 of the second scutching module 50 with the aim of reducing the grain size and/or cleaning of possible fibrous-based residue.

The machine 1 may also comprise a module 20 for retting the semi finished product, positioned upstream of the first and/or the second scutching module 40, 50 and comprising a retting tank.

The retting tank may be equipped with a plurality of sensors designed to generate an identification signal representing a respective plurality of operating parameters of the retting tank, such as, for example, humidity, pressure, temperature.

The retting module 20 is operatively connected to the control unit "U".

More specifically, the control unit "U" controls and optimises the operation of the retting module 20 by interpolating the identification signals generated by the plurality of sensors with a respective plurality of pre recorded operating data.

The retting module 20 may also comprise a sprayer.

Advantageously, the sprayer is configured for striking the semi-finished product with a jet of steam of predetermined temperature and pressure which facilitates the infiltration of the water particles inside the semi finished product structure guaranteeing in this way a reduction in the retting times of the semi-finished product as well as improving the retting process.

The machine 1 may comprise at least one extracting module 80 configured to obtain a powder-based component from the semi-finished product and/or from the fibrous and woody-based components.

In other words, the function of the extracting module 80 is to extract and eliminate impurities such as, for example, dust, soil and other waste components from the semi-finished product and/or from the fibrous and woody-based components.

The at least one extraction module 80 is preferably positioned downstream of the scutching module 30.

The machine 1 may comprise a woody-based component compacting module 100, configured for compacting said woody-based component in bales of various sizes, and/or a fibrous-based component compaction module 90, configured for compacting the fibrous-based component in bales of different sizes.

The modules 90 and 100 are operatively positioned downstream of the scutching module 30.

Advantageously, in this way, the woody-based component and/or the fibrous-based component are at the outfeed of the machine 1 (or at the infeed to further modules) in such a way as to be easily transportable and/or storable.

According to a further aspect of the invention, the machine 1 may comprise a plurality of mixing and processing modules (110) configured to mix and process the fibrous-based component and/or the woody-based component with a plurality of additives as a function of predetermined recipes in order to obtain a respective plurality of products of mixing, for example thermal insulation, acoustic insulation, geotextile, bioplastic, biofuel products, electricity storage biomaterials, blow-in insulation plasters and paints.

The mixing and processing modules 110 are positioned downstream of the scutching module 30 and can be positioned in parallel or in series, according to the type of processing to be performed.

Moreover, the mixing and processing modules 110 can be positioned downstream or in parallel to the compacting modules 90 and 100.

Advantageously, in this way, according to the product to be made, the control unit "U" defines the feed path "L" of the semi-finished product and which mixing and processing module is to be activated.

In other words, the control unit "U" determines the modules through which the feed path "L" (and, therefore, the semi-finished product) passes through. Advantageously, thanks to the possibility of performing with the same machine 1 a processing which starts directly from the raw material and arrives at the obtaining of an end product which can be sold, the cost of production of the product is greatly reduced.

In fact, the commercial intermediations between the farmer and the final consumer are greatly reduced.

Moreover, transport costs are greatly reduced, if not eliminated, because the semi-finished product need not be passed, during its many processing steps, through a plurality of specialised and specific plants.

In other words, there is a reduction in the cost of the end product which becomes competitive compared with other products.

A further advantage is the possibility, for the farmer, to generate income starting from substantially reduced production volumes.

Moreover, these products can be sold locally by the same farmers who in this way support and improve the artisan and manufacturing processes in the territory.

According to a further advantageous aspect of the invention, the modularity of the machine 1 translates into the possibility of varying the number, composition and overall layout of the modules in such a way as to:

- vary the type of operations performed (for example, processing the material using only hammer mills or using only compacting rollers;

- vary the production capacity of the individual operations (in particular, placing two or more modules of the same type alongside each other, for example “compacting rollers" 40 or “hammer mills” 50; in the case of compacting rollers, they would form rollers with larger axial dimensions, therefore a larger volume of material processed);

- vary the extent of the operations performed (in particular by having a greater number of modules, identical or different to each other, in series along the feed direction of the material).

This allows the installation of a machine layout which is optimised each time to the process to be performed and the quantity of material to be treated.

It follows that, in response to the requirements existing each time, it is possible that a machine which is initially operating in one location is, for example, subsequently divided into two smaller machines sent to two further different locations or, alternatively, that the machine is dismantled and transferred to another location, and then reassembled with the addition of further modules necessary for the new processing.

This invention also relates to a scutching method which can be performed using the machine 1 described above.

More specifically, the method comprises an initial step wherein the plurality of modules is transported close to a processing location.

Once the plurality of modules has been transported to the processing location, they are connected in such a way as to form the machine 1.

In other words, depending on the type of processing to be performed on the semi-finished product, the modules are connected to define a layout of the machine 1 suitable for the purpose.

Once the machine 1 is formed, a feed path "L" is defined using the control unit "U" as a function of the predetermined processing.

At this point, the semi-finished product, in the form of bales, is configured and the machine 1 is fed.

At this point, the semi-finished product is processed.

More specifically, the semi-finished product in the form of bales, preferably at the infeed to the feeding module 10, is processed mechanically in such a way as to obtain a semi-finished product in a broken up form.

Preferably, by means of the movement module 60, the semi-finished product is moved to the retting module 20 in which a retting of the semi finished product is executed in a broken up form.

The retting is managed by the control unit “U” as a function of operating parameters recorded by a plurality of sensors and of pre-recorded operating data. Still more preferably, there is a spraying sub-step which can be performed using the sprayer with which the retting module 20 is equipped.

At this point, according to the method, the semi-finished product, by means of a further movement module 60, is transferred to the scutching module 30, where a scutching step is performed which can be carried out at least using the first scutching module 40 and/or the second scutching module 50 as a function of the predetermined processing.

The method may also comprise a sub-step of recovering the woody-based component at the outfeed from the first and/or the second scutching module 40, 50 in such a way as to reintroduce into the first and/or second scutching module 40, 50 the woody-based component having predetermined grain size in order to recover possible residue of fibrous component.

These sub-steps may be performed using the recovery modules 70, operatively positioned at the outfeed to the first and/or from the second scutching module 40, 50.

After completing the scutching step, as a function of the predetermined processing, the method comprises further processing steps.

The method may comprise, for example, a step of extracting the semi finished product and/or the fibrous and woody-based components in such a way as to eliminate and retain a powder-based component. This step can preferably be performed using the at least one suction module 80.

In a first non-limiting example embodiment, following the scutching step, the method may comprise a step wherein the woody-based component is compacted by means of the woody-based component compacting module 100 and/or a step wherein the fibrous-based component is compacted using the fibrous-based component compactor module 90.

In a further non-limiting example embodiment, the method comprises that after or as an alternative to the steps of compacting the fibrous-based component and/or the woody-based component, these fibrous and/or woody-based components are subjected to steps of mixing and processing with additives as a function of predetermined recipes in order to obtain a respective plurality of products of mixing, for example thermal insulation, acoustic insulation, geotextiles, bioplastics, biofuel products, electricity storage biomaterials, blow-in insulation plasters and paints. The mixing and processing step can be performed using the plurality of mixing and processing modules 110.

Advantageously, the machine 1 and the method described overcome the drawbacks of the prior art as they are able to reduce the processing costs of semi-finished hemp-based products or the like. This result is achieved by the possibility of operating in an itinerant manner in such a way as to serve storage and/or adjacent production zones, reducing considerably, if not eliminating, the transport costs of the semifinished product.

Moreover, the lowering of the processing costs of the semi-finished product is achieved by incorporating in a single machine 1 a plurality of processing modules which are designed to transform the semi-finished product into a respective plurality of products, thereby reducing the chain of steps for production and commercial intermediations as well as reducing the transport costs of the semi-finished product (which is normally processed and transformed by a plurality of different, independent and geographically separate plants).

Lastly, this result is achieved by means of the low cost of the machine 1 which has small dimensions, low energy consumption, with a high performance and low environmental impact. Another aim achieved is to obtain high quality processing.

This result is achieved mainly by the constructional features of the first and second scutching modules, and in particular thanks to the respective penetrating and cutting rollers.