This disclosure generally relates to food processing methods and systems, and, more particularly, to methods and systems for breading or otherwise coating food.
Breaded food products are highly demanded by today's consumers. Fast food restaurants, traditional dining establishments and grocery stores each contain a variety of breaded foods. Exemplary breaded food products include chicken wings, chicken strips, chicken nuggets, chicken breasts, fish sticks, fish patties and a variety of vegetables. A breading preparation can be flour-based and can include a variety of spices depending upon the food to be breaded.
The breading process typically requires an individual to apply the breading preparation to the food in a bowl, dish or basin that contains the breading preparation. In order to adhere the breading preparation to the food, the food is typically moist. Over time, moisture can cause the breading preparation to clump together. Such clumped breading preparation is unsuitable for further use. Accordingly, from time to time, the clumps must be removed from the breading preparation.
One way to remove clumps is to discard all of the breading preparation when too many clumps occur. While this method has the advantage of removing all unusable breading preparation, it is inefficient and costly because usable breading preparation is discarded as well. Particularly for a high-volume breading operation, such as a restaurant or food processing plant, the cost of such lost materials can be excessive and prohibitive,
In order to make efficient use of usable breading preparation, systems for separating clumped breading preparation from usable breading preparation have been devised. Such systems include a perforated rotating drum, such as the one described in U.S. Pat. No. 5,265,525 to Stewart, and a brush for sweeping breading preparation, such as the one described in U.S. Pat. No. 4,952,309 to King, the disclosure of each of which is incorporated herein by reference in its entirety. However, problems exist with such devices. For example, such devices are typically too noisy to use in a place of business where customers are present, such as a restaurant. Other devices, such as those described in U.S. Pat. No. 4,936,246 to Reece, U.S. Pat. No. 3,955,529 to Reed and U.S. Pat. No. 3,910,227, the disclosure of each of which is incorporated herein by reference, use basket or hopper mechanisms that are also noisy, and which require frequent cleaning and maintenance.
Accordingly, a need exists for a method and system for removing clumps from usable breading preparation that may be operated in a place of business frequented by customers.
A further need exists for a method and system for quickly and efficiently separating usable breading preparation from unusable breading preparation.
The present embodiments are directed towards satisfying one or more of these problems.
Before the present methods and systems are described, it is to be understood that this invention is not limited to the particular methodologies and systems described, as these may vary. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the invention which will be limited only by the appended claims. It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
In addition, the word “comprising” as used herein means “including but not limited to.” Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art.
In one embodiment described herein, a food coating system includes a first tub having a drain, as well as a vibratory feeder. The vibratory feeder includes a vibratory device and a trough. The feeder is positioned to receive material from the drain, and the vibratory device is used to vibrate the trough such that material received in the trough moves from an input area of the trough toward an output area of the trough. The trough also includes a sifting layer, which may include mesh, slots or holes. A second tub is positioned to receive, from the output area, material that does not sift through the sifting layer when the trough is vibrated. A third tub is positioned to receive material that is sifted from the trough through the sifting layer when the trough is vibrated.
Optionally, the first tub and second tub may be removably connected to a support frame, and wherein the first tub and third tub are interchangeable. The drain may be plugged during a food coating process and unplugged when material is to be removed from the first tub. Also optionally, the system may include a delivery device that delivers material from the frame to the vibratory feeder, and the support frame may include one or more noise-dampening walls, and the support frame may include a door so that a first tub location can receive the first tub when the door is ajar.
In another embodiment, a method for removing unusable breading preparation when breading food includes: (i) applying breading preparation to one or more food products in a first tub having a plug filling an opening; (ii) removing the plug from the opening; (iii) directing the breading preparation through the opening into a vibratory feeder; (iv) replacing the plug in the opening; (v) vibrating the vibratory feeder to separate usable breading preparation from unusable breading preparation through a sifting layer of the vibratory feeder; (vi) collecting the unusable breading preparation in a second tub; and (vii) discarding the unusable breading preparation. The method may also include collecting the usable breading preparation in the first tub and reusing the usable breading preparation. Alternatively, it may include collecting the usable breading preparation in a third tub and reusing the usable breading preparation.
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate various embodiments and together with the description, serve to explain the principles of the various embodiments.
As used herein, a “breading preparation” is representative of any breading or other coating to be applied to a food product to be breaded. For example, a “breading preparation” may include a flour-based staple ingredient, such as white flour, corn meal, wheat flour, corn flour, and/or the like. Optionally, but not necessarily, one or more spices may be added to the staple ingredient to impart flavor to the breading preparation. It is to be understood that the above recitation of staple ingredients and spices is not meant to be limiting but only illustrative of the basic components of the breading preparation.
As used herein, a “food product” or a “product to be breaded” is representative of any product to be breaded with the breading preparation. Such products may include meats, such as chicken, beef, fish or pork, or vegetables, such as mushrooms, squash, zucchini or okra. It is to be understood that the above recitation of food products is not meant to be limiting but only illustrative of the types of products that may be breaded.
The support frame 110 may provide support for the other components of the food breading apparatus 100. Be support frame 110 may include a first tub location 112, a second tub location 114 and a third tub location 116. The first tub location 112 may be on a top portion of the support frame 110. The second tub location 114 and the third tub location 116 may each be on or attached to a lower portion of support frame 110 and/or they may be internal to support frame 110. Each of the first tub location 112, the second tub location 114 and the third tub location 116 may support one or more tubs. A tub may be sized to fit within the dimensions of a corresponding tub location.
In an embodiment, the first tub location 112 may include a door 118. The door 118 may be opened so that first tub 130 may be more easily removed from the first tub location 112, as shown in
The first tub location 112 may be sized to receive a first tub 130. In an embodiment, the first tub 130 may comprise polypropylene. However, other materials, including metals or other plastics, may be used. In an embodiment, the first tub 130 may have a drain, such as an opening 210 in its base. The opening 210 may be round, square or other-shaped and it may be of any desired size. A larger opening 210 will allow for faster removal of material from the tub through the opening, while a smaller opening may provide for a more controlled release of material. In an embodiment when desired, the opening 210 may be covered, filled or otherwise stopped up using, for example, a plug (not shown) plate other item. Any plug known to one skilled in the art that provides a barrier to reduce or inhibit the passage of materials may be used. It is to be understood that the above recitation of a plug and its size is not meant to be limiting but merely illustrative of the types or sizes of devices used to fill an opening 210
In an embodiment, a funnel tube, chute or other guide or similar device may be positioned beneath the opening 210. In an embodiment, the funnel may substantially contact the first tub 130 at the position of the opening 210 when the first tub 130 is positioned in the first tub location 112. The opening 210 and/or the funnel may be positioned above the input end of the vibratory feeder 300. However, a funnel, chute, tube or other guide is optimal, and there may be embodiments where the opening 210 simply is positioned above the vibratory feeder 300.
In an embodiment, the second tub location 114 may be sized to receive the second tub 140. In an embodiment, the second tub 140 may comprise any suitable material, such as polypropylene, metal or other material. In an embodiment, the third tub location 116 may be sized to receive the first tub 130 and/or a third tub 170. In an embodiment, the third tub 170 may comprise any suitable material, such as polypropylene, metal or other material
The vibratory feeder is a device that moves material from one location to another through vibration. In an embodiment, the vibratory feeder 300 may include a vibratory device 310 and a trough 320. During operation, the vibratory device 310 may be used to vibrate the trough 320.
In an embodiment, the vibratory feeder 300 may sift breading preparation at a rate of approximately 15 to approximately 20 pounds per minute. Other feed rates, such as approximately 1 pound per minute, approximately 5 pounds per minute, approximately 10 pounds per minute, rates in between the rates listed above, or rates higher than 20 pounds per minute are possible in various embodiments, and depending on the weight of the product being sifted. In an embodiment, the vibratory feeder 300 may be a Syntron® Electromagnetic Feeder from FMC Technologies, Inc. of Homer City, Pa. with a modified trough 320. The trough may be modified to include a sifting layer 410 described above. It is to be understood that the above recitation of the vibratory feeder 300 is not meant to be limiting but only illustrative of the types of vibratory feeders that may be used.
In an embodiment, the sifting layer 410 may include a plurality of slots. In an alternate embodiment, the sifting layer 410 may include a mesh (not shown). In an embodiment, the mesh may have openings of 0.3 mm in diameter and the opening may be placed in a 2×2 mm grid arrangement. It is to be understood that the above recitation of the sifting layer 410 is not meant to be limiting but only illustrative of sifting layer embodiments. Other mesh sizes are possible
The collection layer 420 may be located underneath the sifting layer 410. In an embodiment, the length of the collection layer 420, in the direction from the input end 423 to the output end 427, may be less than the length of the sifting layer 410. Accordingly, the end of the collection layer 420 may permit sifted material to be transferred to a tub at the third tub location 116, while non-sifted material may be transferred to the second tub 140 at the second tub location 114.
Now referring to
The vibratory motor portion 500 may further comprise a motor housing 550. The motor housing 550 totally or partially encloses an electromagnetic motor (not shown). The electromagnetic motor causes the vibratory feeder 800 to vibrate, resulting in separation of used breading from unused breading. It is also recognized that any means that is know now or hereafter to cause the vibratory feeder 800 to vibrate are within the scope of the embodiments herein.
In
The breading trough 630 of the trough and upper base assembly 600 may include one or more external walls 640, a sifting layer 650 and a collection layer 660. The trough 630 may have an input end 670 and an output end 680. The external walls 640 may surround the sifting layer 650 and the collection layer 660 on at least one side. In an embodiment, the external walls may surround the sifting layer 650 and the collection layer 660 on three sides. In an embodiment, no external wall may be located at the output end 680 of the trough 630. Thus, the trough may be a simple conveyor, a bucket mechanism or any device capable of moving material along an axis, plane or path.
In an embodiment, the vibratory feeder 800 may sift breading preparation at a rate of approximately 15 to approximately 20 pounds per minute. Other feed rates, such as approximately 1 pound per minute, approximately 5 pounds per minute, approximately 10 pounds per minute, rates in between the rates listed above, or rates higher than 20 pounds per minute are possible in various embodiments, and depending on the weight of the product being sifted. In an embodiment, the vibratory feeder 800 may be a Syntron® Electromagnetic Feeder from FMC Technologies, Inc. of Homer City, Pa. with a modified trough 630. The trough may be modified to include a sifting layer 650. In an embodiment, the sifting layer 650 may include a plurality of slots. In an alternate embodiment, the sifting layer 650 may include a mesh. In an embodiment, the mesh may have openings of 0.3 mm in diameter and the opening may be placed in a 2×2 mm grid arrangement. It is to be understood that the above recitation of the sifting layer 650 is not meant to be limiting but only illustrative of sifting layer 650 embodiments. Other mesh sizes are possible.
It is to be understood that the above recitation of the vibratory feeder 800 is not meant to be limiting but only illustrative of the types of vibratory feeders that may be used.
As the breading preparation is applied, moisture may cause some or all of the remaining, non-applied breading preparation in the first tub 130 to clump together. Such clumps may be unusable as breading for additional food products. When it is desired to remove the unusable breading preparation, the plug may be removed (step 1010) from the first tub 130, and the breading preparation in the first tub 130 may be directed (step 1015) towards the opening 210 by scraping, sweeping or otherwise directing the breading preparation to the opening.
Referring together to
The input end of the trough 320 may receive some or all of the breading preparation from the opening 210 and/or the funnel. Once or as the breading preparation is received, the vibratory feeder 300 may be activated, and the trough 320 may vibrate (step 1030), The vibration may direct the breading preparation from the input end of the trough 320 towards the output area of the trough 320. As the trough 320 vibrates, the unusable breading preparation may move (step 1035) towards and, ultimately, into the second tub 140 at the second tub location 114. Moreover, referring to
It is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in this description or illustrated in the drawings. The disclosed method and system are capable of other embodiments and of being practiced and carried out in various ways. Hence, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the disclosed embodiments.
This application claims priority to pending U.S. Provisional Application Ser. No. 60/695,049, filed Jun. 9, 2005, which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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60695049 | Jun 2005 | US |