WO1998000034A2

WO1998000034A2 - Process for producing chip food product and system therefor

Info

Publication number: WO1998000034A2
Application number: PCT/CA1997/000449
Authority: WO
Inventors: William Stewart Wilson
Original assignee: Wabfi Holdings Ltd.
Priority date: 1996-07-01
Filing date: 1997-06-26
Publication date: 1998-01-08
Also published as: CA2185485A1; WO1998000034A3; AU3162897A

Abstract

A process for producing a food chip product comprising the steps of: (i) extruding a liquid batter composition to form a sheet thereof; (ii) conveying the sheet to a radiative heating station; (iii) radiating the sheet to remove moisture from the liquid batter composition to produce a non-liquid sheet; (iv) conveying the non-liquid sheet to a cutting station; (v) cutting the non-liquid sheet into a plurality of pieces; (vi) conveying the plurality of pieces to a frying station filled with a frying medium; (vii) frying the plurality of pieces to effect cooking thereof to produce the food chip product; and (viii) removing the food chip product from the station. A system for producing a food chip product, the system comprising: an extruder having an orifice for discharging extrudate; first conveyor means in communication with the orifice; heater means in communication with the first conveyor means and located downstream from the extruder; cutter means in communication with the first conveyor means and located downstream from the heater means; fryer means located downstream from the first conveyor means; and second conveyor means in communication with and downstream from the fryer means.

Description

-l-

PROCESS FOR PRODUCING CHIP FOOD PRODUCT AND SYSTEM THEREFOR

TECHNICAL FIELD The present invention relates to a process for producing a food chip product and a system therefor. An aspect of the present invention also relates to a frying apparatus particularly suited for use in the present process and system.

BACKGROUND ART

Processes and systems for producing food chip products are known.

Generally, such known processes and systems fall into two categories.

The first category relates to a process and system for producing a food chip product from a solid sliceable food. This would include the production of potato chips, sliced vegetable chips and the like. The second category relates to a process and system for the production of a food chip product from a liquid composition. Generally, this category relates to the production of corn chips and the like and involves the use of a liquid composition containing large particles of solid (e.g. cornmeal) which is then dolloped in a frying medium to cook the composition thereby rendering it solid.

To the applicant's knowledge, there does not exist a process and system for producing a food chip product from a smooth batter composition which contains no discernable particles of food.

Another problem with prior art processes and systems relates to the known fryers for use in producing food chip products. Specifically, to the applicant's knowledge, conventional fryers comprise an integral tank for holding a frying medium and heater for heating the frying medium. The design of this arrangement necessitates the use of a high temperature heating element since, when the heating element is disposed directly in the frying medium, for safety reasons, extreme care must be exercised to avoid significant agitation of the frying medium (ordinarily, this would assist in distributing the heat from the heating element throughout the frying medium thereby lowering the required temperature of the heating element). Thus, it is not unusual for a conventional fryer to have a heating element which is operated at a temperature of approximately 650 "C. In contrast, the decomposition temperature of most frying media (e.g. canola and other vegetable oils) is less than 260 ^°C. Accordingly, significant and rapid breakdown of the frying medium is inevitable and, in the case of vegetable oils, this leads to the production of harmful free fatty acids. For these reasons, the conventional fryer design of heating the frying medium where it is cooking the food product is disadvantageous. It would be desirable to have a process and system for producing a food chip product which could be utilized with a milled or refined batter composition free of discernable particles of food. It would also be desirable to have an improved fryer to cook a food product which obviates or mitigates the disadvantages of conventional fryers discussed hereinabove.

DISCLOSURE OF THE INVENTION

It is an object of the present invention to provide a novel process for producing a food chip product.

It is another objection of the present invention to provide a novel system for producing a food chip product.

It is yet another object of the present invention to provide a novel fryer for frying, inter alia, a food chip product.

Accordingly, in one of its aspects, the present invention provides a process for producing a food chip product comprising the steps of (i) extruding a liquid batter composition to form a sheet thereof;

(ii) conveying the sheet to a radiative heating station;

(iii) radiating the sheet to remove moisture from the liquid batter composition to produce a non-liquid sheet;

(iv) conveying the non-liquid sheet to a cutting station; (v) cutting the non-liquid sheet into a plurality of pieces;

(vi) conveying the plurality of pieces to a frying station filled with a frying medium; (vii) frying the plurality of pieces to effect cooking thereof to produce the food chip product; and

(viii) removing the food chip product from the station.

In another of its aspects, the present invention provides a system for producing a food chip product, the system comprising: an extruder having an orifice for discharging extrudate; first conveyor means in communication with the orifice; heater means in communication with the first conveyor means and located downstream from the extruder; cutter means in communication with the first conveyor means and located downstream from the heater means; fryer means located downstream from the first conveyor means; and second conveyor means in communication with and downstream from the fryer means. In yet another of its aspects, the present invention provides a fryer comprising a tank for receiving a frying medium in communication with a heat exchanger for heating the frying medium.

BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the present invention will be described with reference to the accompanying drawings, in which:

Figure 1 illustrates a perspective, schematic view of an embodiment of the process and system for producing a food chip product;

Figure 2 illustrates a side elevation of a portion of the schematic illustrated in Figure 1 ;

Figure 3 illustrates an enlarged, side elevation of the upstream end of the schematic illustrated in Figure 1;

Figure 4 illustrates an enlarged, side elevation of a mid-stream portion of the schematic illustrated in Figure 1 ; Figure 5 illustrates an enlarged top view of a mid-stream portion of the schematic illustrates in Figure 1 ; Figure 6 illustrates an enlarged, side elevation of the downstream portion of the schematic illustrated in Figure 1 ;

Figure 7 illustrates a perspective view of an embodiment of the food chip product prior to cooking thereof; and Figure 8 illustrates a perspective, schematic of the present fryer.

BEST MODE FOR CARRYING OUT THE INVENTION

With reference to Figures 1 and 2, there is illustrated a system 10 for producing a food chip product. System 10 comprises a mixture 15 which is connected to a holding tank

25 via a line 20. Holding tank 25 comprises an inlet 30 and an outlet 40.

Outlet 40 comprises a valve 35 which is operable to open or close outlet 40.

Below holding tank 25 there is disposed a table 45. T ble 45 comprises a conveyor belt 50. Conveyor belt 50 is conventional in the food industry. Preferably, conveyor belt 50 is constructed of a non-stick material (e.g. Teflon™) and is capable of withstanding temperatures of up to 260° C or even more. Conveyor belt 50 is driven by a suitable motor (not shown) of conventional design.

Disposed above conveyor belt 50 are a pair of heaters 55,60. Heaters 55,60 are preferably radiative heaters, more preferably infrared radiative heaters. These heaters are conventional in the art and preferably comprise an array of radiation emitting rods 65 which are able to emit infrared radiation, preferably having a wave length of greater than about 750nm. Preferably, rods 65 are coated with gold. While rods 65 are illustrated as being disposed longitudinally with respect to conveyor belt 50, it will be clear to those of skill in the art that rods 65 quickly displaced transverse to conveyor belt 50. Heaters 55,60 are connected via a wiring harness 70 to a suitable electrical supply (not shown). Upstream of heaters 55,60 is disposed to an extruder 75. Extruder 75 comprises an open top 80 capable of receiving discharge from outlet 40 of holding tank 45. Extruder 75 also has an orifice 85 which is oriented for discharging extrudate directly onto conveyor belt 50. The height of orifice 85 will depend on the consistency of the batter composition (described hereinbelow). Generally, it is preferred that the orifice have a height of less than about 100 thousandths of an inch. More preferably, the orifice defines an opening having a height in the range of from about 10 to about 60, most preferably from about 10 to about 40, thousandths of an inch. Located downstream of heaters 55,60 is a cutting station 95. Cutting station 95 comprises a feed roller 100 and a cutter roller 105. Feed roller 100 serves to lift a dough sheet 1 10 off conveyor belt 50 and feeds dough sheet 1 10 to cutter roller 105. Cutter roller 105 in cooperation with feed roller 100 serves to cut dough sheet 1 10 into a number of pieces 1 15. Cutter roller 105 is rotated by a suitable motor (not shown) in the direction of arrows 120.

Preferably, table 45 is equipped with a heater (not shown) which is capable of heating conveyor belt 50 to facilitate heating of the batter composition. More preferably, the heater is capable of heating conveyor belt 50 to a temperature in the range of from about 25 ° to about 50 ' C.

Disposed downstream of table 45 is a fryer 120. Fryer 120 comprises a tank 125 for containing a frying medium 130. Fryer 120 further comprises a heat exchanger 135. Heat exchanger 135 comprises a container 140, an intake manifold 145 and an output manifold 150. Container 140 is sealed and comprises a plurality of cylindrical tubes 155. Cylindrical tubes 155 pass through and are sealed with respect to the interior of container 140. Disposed within each cylindrical tube 155 is a heater element (not shown).

Each heater element (not shown) disposed in cylindrical tubes 155 is connected via wiring 160 to a power supply 165. Preferably, power supply 165 includes a thermostatic control (not shown) for controlling the temperature of the heating elements (not shown) disposed in cylindrical tubes 155.

Emanating from tank 125 is a pipe 170 which is connected to a pump 175. Pump 175 is connected to a first filter 185 and a second filter 190 via a pipe 180. First filter 185 and second filter 190 are connected to intake manifold 145 via a pipe 195. Pipe 180 is equipped with bypass valves 200 and 205, and pipe 195 is equipped with bypass valves 210 and 215. Bypass valves 200,205,210,215 enables selective bypass of first filter 185 and second filter 190 to permit cleaning thereof without the need to cease operation of fryer 120. The operation of bypass valves 200,205,210,215 is within the purview of a person skilled in the art.

Output manifold is connected to tank 125 via a pipe 200. A pair of sensors (not shown) are disposed in pipe 220 and container 140, respectively, and are connected to power supply 165 via wiring 225. The purpose of this arrangement is to allow for thermostatic control of the operation of heat exchanger 135. Preferably, this may be achieved using a solid relay control in power supply 165. The choice and operation of such a control is within the purview of a person skilled in the art.

Fryer 120 further comprises a pair of paddle wheels 230,235 which are disposed in tank 125 in a manner such that a portion of paddle wheels 230,235 is immersed in frying medium 130. Paddle wheels 230,235 are rotated by any suitable means (not shown) and serve to convey pieces 1 15 through frying medium 130.

Partially immersed in frying medium 130 in tank 125 is a conveyor belt 240 comprising a conveyor belt 245. Preferably, conveyor belt 245 is constructed of a suitable material which can withstand immersion in hot frying medium 130. This can be achieved by the use of a food quality, metal mesh conveyor belt of conventional design in the art. Conveyor 240 is operated such that conveyor belt 245 removes cooked food chip product 250 from frying medium 130. As illustrated in Figure 6, conveyor 240 discharges cooked food chip product onto a supplementary conveyor 255. Supplementary conveyor 255 transports cooked food chip product 250 to a packaging station (not shown) or optionally, to a seasoning station (not shown) which may include a vibratory seasoner for applying seasoning to cooked food chip product 25 prior to packaging thereof.

The operation of system 10 will now be described with reference to Figures 1-8. Initially, a batter composition 12 is produced in mixer 15. The composition of batter composition 12 is not particularly restricted. For example, batter composition may contain 18 kilograms starch flour, 2 kilograms protein, 1 kilogram fibre and sufficient water to achieve a viscous or syrupy consistency. The general characteristic of batter composition 12 is that it is a milled composition which is substantially free of discernable particulate material (compare with the conventional composition used to produce corn chips which is a thick, abrasive, relatively unmilled composition which cannot be extruded). Batter composition 12 is discharged from mixer 15 into holding tank 25 via line 20 and inlet 30.

Preferably, batter composition 12 has a moisture content of at least about 30 percent by weight. More preferably, batter composition 12 has a moisture content in the range of from about 30 to about 70, even more preferably from about 35 to about 60, most preferably from about 40 to about 60, percent by weight.

When it is desired to operate system 10, conveyor belt 50 is turned on such d at it travels in the direction of arrow 260 (Figure 3 and 4). Valve 35 is opened to allow batter composition 12 to enter open top 80 of extruder 75. The opening of valve 35 is controlled to maintain extruder 75 substantially full of batter composition 12.

Batter composition 12 is discharged from extruder 75 as a sheet 265. At this point, sheet 265 is still in substantially liquid form. Preferably, conveyor belt 50 is heated to a temperature in the range of from about 25 ° to about 50 °C. Also preferably, conveyor belt 50 is operated at a speed in the range of from about 2 to about 10, more preferably 2 to about 8, most preferably from about 2 to about 6, feet per minute. Of course, those of skill in the art will recognize that the speed at which the conveyor belt 50 is operated depends on factors such at the temperature of the downstream heaters, the number of heaters, the desired throughput of production and the like. Accordingly, the speed of conveyor belt is not particularly restricted.

Sheet 265 is passed under heater 255 wherein it is subjected to sufficient heat to remove moisture therefrom. As discussed above, this is preferably achieved using an array of infrared emitting heaters. Preferably, the heaters emit a radiation having a wavelength of at least about 750nm and result in heating the sheet to a temperature of less than about 265 'C, more preferably in the range of from about 175 ^" to about 235 ^° C. It is important, at this point, to avoid thorough cooking of sheet 265. Rather, the intent is to apply sufficient heat to remove moisture from sheet 265 to transform sheet 265 to a non-liquid sheet. The term "non-liquid sheet" is intended to mean a sheet which will not flow and includes pliable, handleable sheets of dough. Ideally, sufficient moisture is removed from sheet 265 such that the moisture content thereof is reduced to less than abut 20 percent by weight. Preferably, after heating, sheet 265 has a moisture content in the range of from about 5 to about 20, more preferably from about 5 to about 15, most preferably from about 10 to about 15 percent by weight. At this point, sheet 265 is equivalent to dough sheet 110 referred to above which is fed to fryer 120. Specifically, pieces 1 15 are discharged from conveyor belt 50 into fryer medium 130 in tank 125. Preferably, the frying medium is oil, more preferably vegetable. Those of skill in the art will recognize that the frying medium is generally liquid and that the nature thereof is not particularly restricted.

Preferably, fryer 120 is operated to maintain frying medium 130 at a temperature of less than about 235 ' C. More preferably the temperature of frying medium is maintained in the range of from about 175 ^° to about 235 ' C, even more preferably in the range of from about 190^° to about 215 ° C, most preferably in the range of from about 190° to about 210^°C. The key feature is that fryer 120 is of a unique design which enables maintaining the temperature of the frying medium below the decomposition temperature thereof. Paddle wheels 230,235 are operated to move pieces 115 through frying medium 130 to conveyor 250. Conveyor 250 serves to remove cooked food chip product from frying medium 130. Conveyor 250 discharges cooked food chip product to supplementary conveyor 255 for further handling as discussed hereinabove. The operation of fryer 120 will now be discussed in more detail with reference to Figure 8. An important feature of fryer 120 is that, in normal operation, it continually circulates and heats frying medium 130. This is believed to be unique in that heating of frying medium 130 is conducted externally to tank 125 where cooking takes places. This design feature allows for more efficient, low temperature heating of frying medium 30 to avoid breakdown thereof. Thus, frying medium 130 is continuously discharged from tank 125 by pump 175 via line 170. Frying medium 130 then passes through pipe 180 into one or both of first filter 185 and second filter 190. First filter 185 and second filter 190 are of conventional design and preferably comprise a stainless steel or other filter which serves to remove particulates of greater than 40 microns from fryer medium 130. Filtered frying medium 130 is then discharged from first filter 185 and second filter 190 and fed to intake manifold 145 via pipe 195.

Frying medium 130 enters container 140 and passes, in a tortuous manner, around cylindrical tubes 155 disposed within container 140. The number and size of cylindrical tubes 155 is such that there is presented to frying medium 130 a large heating surface area in container 140. This allows enhanced control of temperature and reduces the temperature needed to heat the frying medium. Frying medium 130 then passes to output manifold 150 and is recirculated to tank 125 via a pipe 220.

Thus, in fryer 120, there is no direct contact between a high temperature heating element and the oil in the fryer. Rather, oil is circulated through an independent heat exchanger below the fryer which is tightly controlled to ensure the heating temperature does not significantly exceed the breakdown temperature of the frying medium.

The operation of paddle wheels 230,235 is conventional and can be adjusted to adjust the residence time of pieces 115 in frying medium 130 - this will depend on the nature of batter composition 112, the desired colour of the product and the like, all of which are within the purview of a person skilled in the art. Preferably, paddle wheels 230,235 are designed to force pieces 115 beneath the surface of frying medium 130, more preferably resulting in turnover thereof. Thus, the present process and system provide a means to produce a food chip product from a finely milled relatively smooth batter composition. Generally, the process involves removing moisture from the batter composition to render it into a pliable, easily handled sheet of dough which may then be cut and fried. Thus, the present process and system are readily adapted for use with any food sheet material. Non-limiting examples of food products which may be produced in this manner include nachos, tachos, pita, sheeted pasta, egg roll covers and the like. An important advantage of the present process and system is that the equipment necessary to produce the food chip product is relatively simple and large scale, commercial operation may be effected at minimal capital expense.

While the invention has been described with reference to particular illustrated embodiments, those of skill in the art will immediately recognize that various modifications to the illustrated embodiments are possible without departing from the scope and spirit of the present invention. It is of course the applicant's intent that such modifications are included in the present application.

Claims

What is claimed is:

1. A process for producing a food chip product comprising the steps of (i) extruding a liquid batter composition to form a sheet thereof; (ii) conveying the sheet to a radiative heating station;

(iv) conveying the non-liquid sheet to a cutting station; (v) cutting the non-liquid sheet into a plurality of pieces; (vi) conveying the plurality of pieces to a frying station filled with a frying medium;

(vii) frying the plurality of pieces to effect cooking thereof to produce the food chip product; and

(viii) removing the food chip product from the station.

2. The process defined in claim 1 , wherein the batter composition has a moisture content in the range of from about 30 to about 70 percent by weight.

3. The process defined in claim 1 , wherein during Step (ii), the sheet is heated to a temperature in the range of from about 25 ^° to about 50 °C.

4. The process defined in claim 1 , wherein during Step (iv), the sheet is heated to a temperature in the range of from about 25 ° to about 50 °C.

5. The process defined in claim 1, wherein Step (iii) comprises radiating the sheet with infrared radiation.

6. The process defined in claim 1 , wherein Step (iii) comprises heating the sheet to a temperature of less than about 265 ° C.

7. The process defined in claim 1 , wherein Step (iii) comprises radiating the sheet for a sufficient period of time such that the moisture content thereof is in the range of from about 10 to about 15 percent by weight.

8. The process defined in claim 1 , wherein Steps (ii), (iv) and (vi) are conducted on a single conveyor belt.

9. The process defined in claim 1 , wherein the conveyor belt is operated at a speed in the range of about 2 to about 10 feet per minute.

10. The process defined in claim 1 , wherein Step (iv) comprises passing the sheet to a rotary cutter.

11. The process defined in claim 1 , wherein Step (vii) comprises maintaining the frying medium at a temperature less than about 235 °C.

12. The process defined in claim 1 , wherein Step (vii) comprises maintaining the frying medium at a temperature in the range of from about 190° to about 210°C.

13. The process defined in claim 1 , wherein Step (vii) comprises rotating at least one paddle wheel partially immersed in the frying medium to translate to plurality of pieces through the frying medium.

14. The process defined in claim 1 , wherein Step (viii) comprises removing the food chip product with a conveyor partially immersed in the frying medium.

15. A system for producing a food chip product, the system comprising: an extruder having an orifice for discharging extrudate; first conveyor means in communication with the orifice; heater means in communication with the first conveyor means and located downstream from the extruder; cutter means in communication with the first conveyor means and located downstream from the heater means; fryer means located downstream from the first conveyor means; and second conveyor means in communication with and downstream from the fryer means.

16. The system defined in claim 15, wherein the extruder comprises an inlet to receive a liquid batter composition, the inlet being disposed above the orifice such that the exudate is discharged by gravity.

17. The system defined in claim 15, wherein the orifice defines an opening of substantially the same width as the first conveyer means.

18. The system defined in claim 15, wherein the orifice defines an opening having a height of less than about 100 thousandths of an inch.

19. The system defined in claim 15, wherein the first conveyor means comprises a conveyor belt.

20. The system defined in claim 19, wherein the first conveyor means comprises means to heat the conveyor belt to a temperature in the range of from about 25 ° to about 50 ° C.

21. The system defined in claim 15, wherein the heater means comprises at least one radiative heater.

22. The system defined in claim 21 , wherein the infrared radiative heater comprises an array of radiation emitting rods disposed above to the first conveyor means.

23. The system defined in claim 15, wherein the cutter means comprises a rotary cutter in combination with feed means to pass a dough sheet to the rotary cutter.

24. The system defined in claim 15, wherein the cutter means comprises a feed roller means to lift a dough sheet off the first conveyor means and rotary cutter roller means the cut the dough sheet.

25. The system defined in claim 24, wherein the feed roller means and the rotary cutter roller means comprise, in combination, a pair of rollers disposed substantially transverse to the first conveyor means in tangential abutment with one another.

26. The system defined in claim 15, wherein the first conveyor means comprises a conveyor belt and a motor to is operate the conveyor belt at a speed in the range of about 2 to about 10 feet per minute.

27. The system defined in claim 15, wherein the fryer means comprises a tank for receiving a frying medium in communication with a heat exchanger for heating the frying medium.

28. The system defined in claim 27, wherein the heat exchanger comprises a container having a plurality of tubes extending therethrough, the tubes containing at least one heating element.

29. The system defined in claim 28, wherein the container is sealed and further comprises a container inlet and a container outlet.

30. The system defined in claim 27, wherein the fryer means further comprises means to circulate the frying medium from a tank outlet to the container inlet and from the container outlet to a tank inlet.

31. The system defined in claim 27, wherein the fryer means further comprises translation means for conveying frying medium toward the second conveyor means.

32. The system defined in claim 31, wherein the translation means comprises at least one rotary paddle wheel disposed on the fryer means such that a portion of the paddle wheel is immersible in frying medium in the tank.

33. A fryer comprising a tank for receiving a frying medium in communication with a heat exchanger for heating the frying medium.

34. The fryer defined in claim 33, wherein the heat exchanger comprises a container having a plurality of tubes extending therethrough, the tubes containing at least one heating element.

35. The fryer defined in claim 34, wherein the container is sealed and further comprises a container inlet and a container outlet.

36. The fryer defined in claim 33, wherein the fryer means further comprises means to circulate the frying medium from a tank outlet to the container inlet and from the container outlet to a tank inlet.

37. The fryer defined in claim 33, wherein the fryer means further comprises filter means disposed between the tank and the heat exchanger.

38. The fryer defined in claim 33, wherein the fryer means further comprises filter means disposed between the tank outlet and the container inlet.

39. The fryer defined in claim 33, wherein the fryer means further comprises filter means disposed between the container outlet and the tank inlet.

40. The fryer defined in claim 33, wherein the fryer means further comprises translation means for conveying frying medium toward the second conveyor means.

41. The fryer defined in claim 40, wherein the translation means comprises at least one rotary paddle wheel disposed on the fryer means such that a portion of the paddle wheel is immersible in frying medium in the tank.

42. The fryer defined in claim 41, wherein the at least one rotary paddle wheel spans a distance substantially the same as a width of the tank.