The present disclosure relates to food processing apparatuses and methods, and more particularly, pertains to a breading machine and methods of use for uniformly applying different types of coating material, such as flour, bread crumbs and cracker meal to food products.
The following U.S. patents and U.S Published Patent application are incorporated by reference in entirety.
U.S. Pat. No. 3,547,075 discloses a machine for coating a food product with breading material having an elevated hopper for storing the breading material, and means for feeding the same in a smooth and controlled manner from the hopper through a free flowing down spout to be deposited on a belt beneath the food product. Further, it includes means for feeding the breading material in a smooth and controlled manner from the hopper to be deposited on top of the food product with a control valve at such outlet to control the rate of feed. A breading level plate is provided to maintain an even layer of breading material beneath the food product on the conveyor belt, and this plate is resiliently mounted to relieve pressure of breading material building up behind the plate. Edge control plates are provided for preventing spillage of breading material at the sides of the conveyor belt. A hooded portion of open mesh belt conveyor is provided near the discharge end of the machine with air spray pipes above the belt to remove excess material, and a hood is adapted to be raised without interrupting the operation of the machine. In a modification, a flip bar is provided across the conveyor belt towards the discharge end of the machine to flip over the product so as to shake off breading material lodging in cavities of the food product together with a novel arrangement for taking up excess length of the belt after it passes over the raised flip bar.
U.S. Pat. No. 5,052,330 discloses a coating machine which includes an endless pervious conveyor belt supported in an elongated frame which provides a food product conveyance path within the machine. A hopper is disposed above the food product conveyance path in which an amount of a coating material is provided to generate a falling curtain of bread crumbs or the like to cover the top and sides of food product pieces passing along the food product conveyance path. The machine also preferably includes a circular drum type conveyor which is rotatably supported along the elongated frame adjacent the hopper, and includes a plurality of pockets formed therein which open into the interior of the machine and the hopper. Conveyors are provided in both the elongated frame and hopper to distribute coating material from the frame enclosure to the circular conveyor which will, in turn, distribute coating material to the hopper to generate the upper layer of breading material. The machine also includes structure to distribute breading material within the frame enclosure so as to continuously and effectively generate a bottom layer of coating material on the food product conveyance path while avoiding congestion of the coating material. The distribution system of the machine is readily adaptable for different kinds of breading materials and allows utilization of the machine for fresh bread crumbs with handling thereof performed in a gentle manner while avoiding congestion or packing of such breading material.
U.S. Pat. No. 5,238,493 discloses a cost effective, simple and sanitary breading machine suitable for coating a variety of food products, such as poultry, with different types of breading materials. After coating of upper and lower surfaces of food products introduced into the breading machine, a significant dwell time within the breading machine is achieved in the construction to allow breading material to more effectively set up on the coated food products. The coating machine further includes structure to enable the food products introduced therein to be flipped a plurality of times, wherein additional coating material is continuously applied to alternate sides of the food products and desirable coating characteristics are achieved. The coating machine and process for coating food products as set forth herein provide a food processor with a means to more effectively and efficiently coat large volumes of food products with breading material without sacrificing desirable characteristics which yield a high quality and more appealing breaded food product.
U.S. Patent Application Publication No. 2006/0156931 discloses a breading machine, and improvements thereto, for use in high volume food production. An improved breading machine includes a side-mounted feed hopper, a low pressure auger assembly including an auger transfer box with an input port for accepting a cross-feed screw and paddle, and an output port for transferring coating material to a vertical screw. The improved breading machine also includes a substantially cylindrical, rod-based spreader assembly and a transport conveyor belt for feeding the spreader assembly within a top hopper of the breading machine. The improved breading machine further includes a vibrating filter assembly to filter out clumps of coating material while allowing un-clumped material to be re-used within the breading machine.
Through research and experimentation, the present inventors have determined that the prior art breading and coating machines and methods of use result in:
1) uneven homestyle breading coating texture across food product surfaces produced on drum style breading machines due to food products overlapping in the drum and during discharge from the drum onto a discharge conveyor;
2) downtime or change over time required to either remove the dedicated homestyle breading machine from the production line and install a conventional breading machine, or time required to remove the drum from and reconfigure a breading machine that is capable of running homestyle as well as conventional breading coatings;
3) restricting the breading machine to running only certain types of breaded products; and
4) unbalanced belt coverage across the discharge conveyor of the breading machine due to the inherent, inefficient action of the drum during infeeding and discharge of the food product therefrom.
Through research and experimentation, the present inventors have endeavored to improve upon prior art machines and processes for uniformly applying different types of breading and coating materials on various food products at a very high rate or volume as required in large institutional food processing facilities without the need for any drums or additional machines or removing any components from the machine, or the use of any tools in the food coating process.
In one example, the present disclosure relates to an apparatus for applying a coating material onto food products. The apparatus includes a machine provided with a food product input end and a food product output end, and having a machine framework configured with a conveyor framework for receiving a moving endless conveyor belt arranged to move food products thereon from the food product input end to the food product output end. The machine framework is further configured with a coating material transfer arrangement for coating the food products during movement thereof on the conveyor belt and through the conveyor framework. A shaker assembly is mounted to the machine framework, and is configured with a set of opposed fixtures arranged to oscillate back and forth and receive food products coated on the conveyor belt between the opposed fixtures and through the shaker assembly such that the coated food products are processed with a uniform coating material texture, and released from the shaker assembly to the output end of the machine.
In a further example, the present disclosure relates to a machine which transports food products through a process that creates a uniform homestyle breading coating on various food products by utilizing the force of gravity and two separately opposed horizontally oscillating fixtures in a shaker assembly with interchangeable infinitely designed riffle plates. In the shaker assembly, the distance of the two separately opposed horizontally oscillating fixtures can be adjusted to allow for various size food products along with breading to travel between and through the fixtures, while the two separately opposed horizontally oscillating fixtures cause the food products and breading to flip and bounce back and forth as the force of gravity pulls the food products down between the two fixtures creating the desired homestyle breading coating and discharging the food products evenly across the discharge conveyor. The machine is also capable of running conventional style breading products without the need to remove any components from the machine or the requirement for any tools.
In yet another example, the present disclosure relates to a method for applying a coating to food products comprising the steps of a) providing a machine provided with a food product input end and a food product output end, and a machine framework configured with a conveyor framework for receiving an endless conveyor belt arranged to move food products thereon from the food product input end to the food product output end, the machine framework being further configured with a coating material transfer arrangement for coating the food products during movement thereof on the conveyor belt and through the conveyor framework; b) providing a shaker assembly mounted on the machine framework and configured with a set of opposed fixtures arranged to oscillate back and forth relative to one another and receive food products coated on the conveyor belt; and c) aligning at least a portion of the conveyor framework with the shaker assembly such that the coated food products are introduced into one end of the shaker assembly and processed with a uniform coating texture by means of a flipping and bouncing motion as gravity pulls the coated food products downwardly through the shaker assembly causing the food products to exit from an opposite end of the shaker assembly onto a portion of the conveyor belt outside of the conveyor framework for transport to the output end of the machine.
The method also contemplates the step of d) moving the portion of the conveyor framework out of alignment with the shaker assembly such that the coated food products are delivered externally of the shaker assembly to the portion of the conveyor belt outside of the conveyor framework for transport to the output end of the machine.
Referring now to the drawings,
As viewed in
As seen in
The breading machine 10 also includes a shaker assembly 46 which is movably mounted for linear back and forth positioning on the machine framework 30. As seen in
As best seen in
Referring now to
The riffle plates 64, 66 are arranged in a staggered overlapping and offset formation such that the angled riffle plates 66 extend between adjacent pairs of the angled riffle plates 64. The distance between the opposed fixtures 60, 62 may be adjusted to allow for variously sized food products with the particular coating materials. The riffle plates 64, 66 may be designed to accommodate a variety of breading or coating textures. In addition, the riffle plates 64, 66 may each be removably mounted to their respective fixtures 60, 62, or the entire assembly of fixtures 60, 62 and riffle plates 64, 66 may be formed as a unit that can be easily removed and replaced with a different desired configuration.
As illustrated in
A method of use of the machine 10 is described as follows.
It should be understood that a coating material is metered in and onto the lower return portion 54 of the conveyor belt 34 from the side mounted feed hopper 26. The coating material deposited on the lower return portion 54 of the conveyor belt 34 is then transitioned into an auger arrangement such as shown at 73 (
When it is desired to apply a non-homestyle, conventional, more free flowing coating material, such as dried bread crumbs, to food products, the above described machine 10 can be easily modified without replacing/interchanging any components of the machine 10 or using any tools.
It should be appreciated that the swing arm assembly 40 may be selectively pivoted in an automatic manner between the positions shown in
In summary, an improved breading machine 10 is disclosed for uniformly applying different types of coating materials and textures to food products at a very high rate or volume without the need for any additional machines or drum components, without the necessity for removing any components from the machine, and without requiring any tools during the food coating process. The breading machine 10 improves upon prior art food coating machines by eliminating uneven coating material textures across food products, downtime to replace or reconfigure components of a machine or an entire machine, and drums or other cylindrical type rotating devices which restrict a machine to applying only particular coating materials. The breading machine 10 further improves over prior art designs in occupying a smaller footprint that previous coating and breading machines.
The breading machine 10 is capable of applying different textures of coating materials to food products in a highly efficient manner by simply adjusting the position of the swing arm assembly 40 and the shaker assembly 46. When applying heavier texture coating materials to food products, the oscillating nature of the fixtures 60, 62 and the particular configuration of the riffle plates 64, 66 in the shaker assembly 46 proves to be extremely effective in providing a consistent finished coating texture on the food products
In the present disclosure certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. The different configurations, systems, and method steps described herein may be used alone or in combination with other configurations, systems and method steps. It is to be expected that various equivalents, alternatives and modifications are possible within the scope of the appended claims.
The present utility application relates to and claims priority to U.S. Provisional Patent Application Ser. No. 62/100,705, filed Jan. 7, 2015, which is herein incorporated by reference in entirety.
Number | Date | Country | |
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62100705 | Jan 2015 | US |