NL1020185C2 - Rotating drum system for covering French fries with batter. - Google Patents

Description

Rotating drum system for covering fries with batter.

DESCRIPTION

This invention generally relates to systems and methods for applying a viscous batter in a food processing line for dosing batter-covered food products, such as batter-covered fries and the like. More particularly, this invention relates to an improved device and method for batter coating for substantially complete and uniform coating of the food products with the batter composition while at least substantially eliminating excessive batter use and the associated problems and disadvantages. associated with the recovery and recycling of herds.

Batter-covered food products are well known in the art and have enjoyed increasing popularity among consumers in recent years. For example, in a conventional form, a selected food product, such as french fries, is subjected to a batter-covered step by dipping or spraying to cover the food product or. to enclose with a liquid, although relatively viscous batter, which comprises a desired mixture of ingredients, such as flavorings and spices and the like. The batter-covered food products are then usually transported on a porous wire conveyor to a cooking vessel, such as a deep-frying pan for at least partially cooking the products prior to further processing steps, such as freezing and final packaging. Particularly in the case of a deep-frying pan for partially pre-frying batter-covered potatoes, the cooking step hardens and hardens the batter adhering to the external surfaces of the food products. The batter cover therefore remains on the products at the time of heating and / or finishing cooking immediately prior to consumption.

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During the production of batter-covered food products, as described above, substantial excess amounts of the liquid-based batter are usually delivered to the product bars in order to obtain a substantially thorough coverage of the external bar surfaces. The porous wire conveyor is designed with a sufficient length to allow the excess batter portion to drip or fall off from the bar products prior to delivery of the batter-covered bars to the frying pan. In this regard, it is particularly desirable to separate this excess batter from the food products to reduce adherence or clod formation of bars prior to or within the frying pan and to minimize further contamination of frying oil and / or excessive oil consumption. to minimize the production of baked batter crumbs.

A drip tray is normally disposed under the porous mesh conveyor for collecting or reclaiming this excess batter and thereby allowing recycling thereof to the batter cover station. However, such recovery and recycling of batter may undesirably contribute to characteristics of aged batter, such as leaf thinning or leaf thickening of the batter composition depending on the specific ingredients of the batter. It may also allow for loss of batter influence due to exposure to elevated temperatures. Recycle recycling also reduces product control regarding the freshness of batter since specific batter portions can be recycled many times. In a conventional recycled batter system, as a result, the overall quality and characteristics of the batter tends to deteriorate over time, whereby it is periodically necessary to discard the batter in favor of a fresh batter load. The inclusion of the elongated porous drip-mesh conveyor moreover gives a batter covering system that has a length that is generally incompatible with relatively simple and economically novel adaptation of a conventional production line of fries without batter for producing of batter-covered products.

The present invention provides an improved device and method for applying liquid-based batter to food products, such as french fries, in which the batter is applied to the potato bars as a relatively thin and substantially uniform surface covering, substantially without delivery of require excess batter on the bars. In addition, the present invention is suitable for relatively inexpensive and economically novel adaptation of a conventional fries-free production line.

In accordance with the invention, there is provided an improved system and method for applying a liquid-based batter cover to the external surfaces of a food product in a food processing line, in particular with regard to applying a batter cover to the external surfaces of French fries. The system and method comprises an elongated end-open rotating drum for the tumbling flow-through of pre-cut and blanched potato strips in combination with a batter delivery piece arranged inside the drum to transfer the liquid-based batter on the potato bars. The potato strips are covered on the surface with a relatively thin and substantially uniform batter film prior to emergence from the rotary drum for transport to a subsequent processing station, such as a hot oil-frying pan. The delivery flow value of mash is accurately controlled in relation to the mass flow value of the potato bars through the rotating drum to substantially eliminate excess mash use and associated problems associated with recovering and recycling mash.

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In the preferred form, the elongated rotatable drum is generally horizontally oriented with an axis thereof extending with a selected and usually relatively small angle of inclination from an upstream to a downstream end thereof. The upstream end of the drum is aligned with input means for delivering the food product, such as pre-sliced and blanched potato bars into the hollow interior of the drum. A downstream end of the rotary drum is similarly aligned with discharge means, such as a suitable conveyor, for transferring the potato bars to subsequent processing equipment, such as a hot oil deep fryer for pre-frying the batter-covered potato bars prior to freezing and packaging steps. The rotary drum is suitably arranged and supported for rotation about the center line and a drive motor is arranged for rotating the drum. The interior of the rotating drum is covered with a number of elongated radially inwardly extending blades or baffles, which are formed to allow the potato strips transferred into the drum to tumble and to ensure that these potato strips are generally placed on a first-in first move from base from the input end to the discharge end for transfer to the discharge conveyor.

The fitting for transferring fittings comprises an elongated support rod which is arranged inside the interior of the rotary drum and which extends generally parallel to the axis of the drum in the longitudinal direction. A plurality of nozzles are provided along the length of the manifold conduit for delivery of the fluid-based batter by dripping or spraying to the interior of the drum at a plurality of longitudinally spaced locations therein. The drum is rotated so that the blades sweep up the potato strips and then allow the strips to fall back freely from the blades to the underside of the interior of the drum. The carrier bar and the nozzles mounted thereon are arranged within the interior of the drum to transfer batter directly to the potato bars, preferably while these bars are in a free fall position. The cut strips are thus directly covered with the batter by each of the plurality of nozzles, followed by gentle tumbling to achieve the desired relatively thin, substantially uniform batter film cover, substantially without excessive batter use.

Other features and advantages of the invention will become more apparent from the detailed description below, taken in conjunction with the accompanying drawings, which illustrate the principles of the invention by way of example.

The accompanying drawings illustrate the invention, in which: Figure 1 is a schematic flow chart showing a production line system and method for preparing batter-covered food products, such as French fries, provided with a batter-covered system with a rotating drum in accordance with the rotating drum present invention.

Figure 2 is a somewhat schematic side view of the system with rotating drum for covering with fittings;

Figure 3 is an enlarged sectional view of the rotating drum, generally taken on the line 3-3 of Figure 2; and

Figure 4 is an enlarged sectional view, similar to Figure 2, but showing an alternative form of the invention.

As shown in the explanatory drawings, an improved system and associated method, generally indicated by reference numeral 10, is provided for applying a liquid-based batter coating to the external surfaces of a food product, such as potato used in the production of fries. bars. The system and method 10 of the present invention generally includes a rotary drum 12 for tumbling flow-through passage of the potato bars in combination with a batter delivery piece 14 disposed within the rotating drum 12 to hold the batter on apply the tumbling bars with a controlled current value.

In the preferred product environment, the rotating drum system and method are used in a production line of a potato processing plant for applying a substantially uniform and relatively thin film-like batter coating to the external surfaces of pre-cut and blanched potato bars prior to steps of pre-frying the bars, freezing and packaging. While the specific formulation and composition of the batter may vary, the rotating drum system and method of the present invention are particularly suitable for applying thin film-like, so-called clear coating fittings to the potato bars, such as the batter compositions, which are disclosed in U.S. Patent Nos. 5,059,435; 5,141,759; 5,648,110; 5,750,168, 6,132,785 and copending U.S. Patent Application No. 09 / 441,112, all of which are incorporated herein by reference.

Figure 1 is a schematic flow chart showing a conventional sequence in a production line process for producing pre-baked and frozen French fries, modified for incorporating the rotating drum system and method of the present invention. More specifically, Figure 1 shows the supply of raw potatoes, such as Russet Burbank or other suitable potato variety to an initial washing step 16, followed by an optional peeling step 18 and a cutting step 20, through which the raw potatoes in elongated patat bars of selected cross-section size and shape are cut. Thereafter, the sliced fries bars are usually subjected to a blanching step 22, in which the bars are partially cooked such as by water or steam blanching, and furthermore, this blanching step 22 usually involves the presence of additives such as dextrose and / or 1 7 sodium pyrophosphate (SAPP) in small amounts for improving tanning and color control during subsequent processing. The blanched potato strips are then usually stripped of excess water and may be subjected to a drying step 24, which may include exposure to ambient or heated air for a sufficient time to obtain a target bar weight loss such as in the order of 15 %. In some processing methods, a hydrocolloid surface coating may also be applied to the potato bars prior to batter coating, as described in US Patents 5,885,639 and 6,033,697 which are incorporated herein by reference.

In general terms, the rotating drum batter system and method 10 is installed along the production line at a downstream end of the blanching and drying steps 22, 24 and at an upstream end of subsequent processing steps including a pre-baking step 26, a freezing step 28 and a packaging step 30. Pre-cut, blanched and partially dried potato strips are transported to an input end 32 of the rotating drum 12 for delivery of the liquid-based batter via the manifold 14 for delivering the batter. The potato strips are tumbled around and transported through the drum 12, preferably in a continuous flow-through mode and discharged through a discharge end 34 of the drum for transport to subsequent pre-frying steps and further processing.

Figures 2 and 3 show in more detail the construction and operation of the rotating drum 12. As shown, the rotatable drum comprises an elongated hollow and end-open structure, which is supported by suitable bearings 36 (Figure 2) or the like for rotation. a center line 38. The rotatable drum 12 is supported such that its center line 38 is oriented at a selected angle of inclination with respect to a horizontal plane, the input end 32 of the drum being at least a little higher than the discharge end 34 of the drum prepared. This angle of inclination can be made adjustable for controlling the throughput speed of the product and so as to variably select the residence time of the product within the drum. A motor 40 is provided for rotatingly driving the drum 12 about its axis 38. The drum 12 can be made of a material such as stainless steel suitable for use in food processing facilities and has a size and shape, which is sufficient to receive a considerable through-flow capacity of the product. In a preferred configuration for use in batter covering french fries, the drum 12 has a length of about 1.8-2.4 m and a diameter dimension of 0.9-1.2 m. The motor 40 drives the drum 12 turning at a relatively moderate rotational speed of the order of about 6 revolutions per minute. With these parameters, the drum 12 has a considerable throughput of potato bars of approximately 1800-9000 kg per hour.

The potato bars are delivered to the input end 32 of the rotatable drum 12 by a suitable conveying means, such as the input trough 42 shown for illustration, in figure 2. The hollow interior of the drum 12 is covered with a number of radially inwardly extending vanes or baffles 44 (Figure 3), which extend longitudinally over substantially the entire length of the interior of the drum. These internal vanes 44 include leading end facets 45 that protrude radially inwardly from the adjacent inner drum surfaces 46 over a sufficient distance and at an appropriate angle to collect potato strips 48 and sweep up from a lower region of the drum and to carry the bars substantially up to and preferably a short distance above a horizontal axis 49 of the drum before allowing the bars 48 to slide from the leading end facets 45 and free through the hollow interior of the drum fall back to a lower area of the drum. In the preferred geometry of the drum, the leading end facets 45 of the vanes 44 protrude about 1-2 inches radially inwards from the adjacent drum surfaces 46 and are oriented at an obtuse angle relative to the adjacent drum surface. , preferably in the order of magnitude of about 135 °. This blade shape produces substantially free fall of the bars 48, as seen in Figure 3, followed by substantial tumble of the bars as the bars are collected and swept up by another of the blades 44, again followed by free fall back to the lower area of the drum.

The batter delivery piece 14 comprises an elongated support bar 50, which is arranged directly inside the interior of the hollow rotatable drum 12 and extends therein in the longitudinal direction 15. Figure 2 shows the manifold conduit 50, which has an input end coupled to a supply conduit 51, which in turn is connected to a suitable and conventionally cooled batter supply 52. The manifold 50 extends from the input end 32 of the drum to extend therein in the longitudinal direction. A pump 54 may be provided along the supply line 51 for delivering the batter from the source 52 to the manifold line 50 and this with a selected flow rate and pressure. A plurality of nozzles 58 are disposed along the length of the support bar 50 within the interior of the drum for dispensing the batter at a number of selected spaced apart locations. Figure 3 shows the specific and preferred mounting location of the carrier bar 50 within the drum 12 at a location generally disposed on the horizontal axis 49 and laterally over a short distance to a side of a vertical axis 58 through the drum 12.

In a preferred embodiment of the invention, the liquid-based batter is attached to the support bar 50.

10 and further delivered to the plurality of nozzles 56 for dripping the batter directly onto the potato bars 48 if these bars 48 fall free from the vanes 44 in the course of the above-described circular motion. That is, the drum 12 is pivotally driven in a direction indicated by arrows 60 in Figures 2-3 to carry the potato strips 48 up from a central lower region of the interior of the drum to a position generally at or slightly above the horizontal axis 49, after which the bars 48 fall freely through the hollow interior of the drum into the path of fittings dripping from the nozzles 56. With this construction, the batter is dripped directly onto the underlying bars, which are then tumbled substantially continuously along the length of the drum 12. This direct attachment to the free-falling bars in combination with the tumbling action results in a substantially through-and-through covering of the potato bars with the batter material of uniform thickness and relatively thin film.

Figure 4 shows an alternative embodiment of the invention, in which the position of the support bar 50 is adjusted for adapting to pressure spraying of the batter in the interior of the drum. In this configuration, compared to the configuration shown in Figure 3, the carrier bar 50 and the nozzles 56 mounted thereon are shifted to the left as seen in Figure 4 and the batter is discharged under pressure from the nozzles 56 as a rain for direct application to the free-falling bars. 48.

In accordance with an important aspect of the invention, the flow value of the liquid-based batter delivered to the interior of the rotary drum 12 is closely controlled with respect to the mass flow value of the potato bars moving through the drum. More specifically, a control member 62 (Figure 2) is provided for adjusting the flow value of delivery of batter in accordance with the mass flow value of the 11 potato bars 48, so that the supply of excess batter is avoided. The controller 62 can be manually adjusted in accordance with the product mass flow value or it can be provided with a computer-containing and automated station for controlling flow value 5 of fittings in accordance with mass flow as measured, for example, by weighing equipment (not shown), which along the upstream conveyor 42 for delivery of the potato bars to the rotating drum 12. With this arrangement, the batter supplied to the interior of the drum is almost completely absorbed by the potato bars, eliminating recovery and recycling considerations.

The batter-covered potato strips exit from the rotary drum 12 onto a discharge conveyor 64 or the like (Figure 2) near the discharge end 34 of the drum. The drain conveyor 64 transports the covered strips 48 to the subsequent processing equipment, such as pre-frying station 26 (Figure 1), in which the covered strips are pre-fried in hot oil. It is important that by substantially eliminating excess batter escaping from the rotating drum 12, problems associated with bonding of the strips to the discharge conveyor 64 and / or during pre-frying are considerably reduced. The covered and pre-baked potato strips are transferred from the pre-frying station 26 for subsequent processing, such as freezing, packaging followed by suitable transport or storage.

The system of battered with a rotating drum and method of the present invention advantageously substantially reduce and eliminate the use of excess batter in the production line of fries since all of the batter delivered to the rotary drum is used to cover the potato bars. The circular effect of the rotatable drum ensures that the strips 30 are at least almost completely covered on the surface with the desired uniform and relatively thin batter film. Since no part of the batter is recovered or recycled, there is no need for precise monitoring of the characteristics and quality of the batter as in known systems using components of recycled batter. The overall size of the rotating drum system is moreover relatively compact and can therefore be suitably and economically incorporated or renewed in an existing production line for fries bars compared to known fitting systems that require porous mesh drop conveyors of large lengths. for collecting and recycling excess batter.

A number of modifications and improvements to the batter-covered covering system with a rotating drum as well as to the method of the present invention will be apparent to those skilled in the art. For example, the batter delivery nozzles 46 may be electrically charged and the structure of the rotating drum 12 may be charged oppositely to provide electrostatic precipitation of the batter on the tumble potato bars 48. Accordingly, it is not intended that the above description and accompanying drawings will limit the invention in any way except as set forth in the appended claims.

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Claims (17)

Claims 1. A system for covering a food product with batter comprising: an elongated rotating drum defining an input end and a discharge end, said drum being supported with a center line thereof at a desired angle of inclination with respect to a horizontal plane; a plurality of elongated blades covering the interior of the drum, generally protruding radially inwardly thereof, the blades engaging the food product upon rotation of the drum to tumble the food product and to sweep up the food product within the drum, the blades are formed to allow the swept-up food product thereof to fall freely within the drum; means for rotating the drum about its center line at a controlled rotational speed; and batter dispensing member within the drum which batter dispensing member is provided with a manifold conduit which generally extends longitudinally within the drum and has a plurality of nozzles disposed along its length for delivering batter to the interior of the drum about contacting the food product during free fall thereof, wherein the combined tumbling and free fall action of the food product within the drum 25 results in a substantially uniform and thoroughly occurring coating with batter of the food product. 2. System as claimed in claim 1, characterized in that the system is further provided with means for delivering a flow of the food product into the drum via the input end thereof and means for transporting the food product from the discharge end of the drum to a subsequent food processing station. J System according to claim 1 or 2, characterized in that the food product consists of potato bars. 4. System as claimed in any of the foregoing claims, characterized in that the selected angle of inclination is adjustable for variable selection of the mass flow value by and residence time of the food product in the rotary drum. A system according to any one of the preceding claims, characterized in that each of the blades extends substantially along the length of the drum in the longitudinal direction within the drum. A system according to any one of the preceding claims, characterized in that each of the blades determines a leading end facet rotation relative to the direction of rotation of the drum to sweep up the food product within the drum to a position at least slightly above a horizontal axis of the drum before allowing the food product 15 to fall free thereof. The system of claim 6, characterized in that the leading end facet of each of the vanes is oriented at an obtuse angle of about 135 ° with respect to an adjacent inner surface of the drum. 8. System as claimed in any of the foregoing claims, characterized in that the system is provided with a pumping member for pumping fittings through the manifold conduit to the nozzles. 9. System as claimed in claim 8, characterized in that the pump member delivers the batter through the manifold conduit for substantially trickle flow passage through the nozzles. A system according to claim 8, characterized in that the pump member delivers the batter through the manifold conduit for spray flow passage through the nozzles. 11. System as claimed in any of the foregoing claims, characterized in that a control member is arranged for controlling the magnitude of the batter flow through the distribution piece to the mouth; '· -; ü / :. . Pieces in proportion to the mass flow value of the food product through the drum to substantially eliminate at least an out of batter from the drum. 12. System as claimed in any of the foregoing claims, characterized in that the system is provided with a control member for controlling the value of batter flow through the distributor piece! feeding to the nozzles in proportion to the mass flow value of the food product through the drum to at least substantially eliminate excess batter from the drum. A method of applying a batter cover to a food product, the method comprising the steps of: passing the food product through an elongated rotatable drum, which is supported such that a center line thereof is at a selected angle of inclination with respect to a horizontal plane 15 and having a plurality of elongated blades covering the interior of the drum, generally protruding radially inwardly therein for engaging the food product upon rotation of the drum to tumble the food product within the drum and sweep up the food product within the drum drum wherein the blades are shaped to allow the swept-up food product thereof to fall freely within the drum; rotatingly rotating the drum about its axis with a controlled rotation speed; and delivering batter through a plurality of nozzles disposed longitudinally of each other within the drum in longitudinal direction of the drum such that the batter comes into contact with the free-falling food product wherein the combined tumbling and free-fall action of the food product enters the drum results in a substantially uniform and thorough coverage of the food product with the batter. A method according to claim 13, characterized in that the food product is formed by potato bars. A method according to claim 13 or 14, characterized in that the method comprises the further step of variably adjustable the angle of inclination chosen for variably selecting the mass flow value by a residence time of the food product in the rotary drum. A method according to any one of claims 13-15, characterized in that the method further comprises the step of pumping the batter to the nozzles. 17. Method as claimed in any of the claims 13-16, characterized in that the method comprises the further step of controlling the value of batter flow to the nozzles in relation to the mass flow value of the food product through the drum for the substantially eliminating excess out of the drum.