This invention relates generally to an improved and modified cutting or processing machine, and related production process, for producing relatively small and substantially random sized potato pieces suitable for use in preparing potato hash browns and the like. More specifically, this invention relates to an improved processing machine and related production process for shattering potatoes into small random sized pieces.
Potato products such as hash browns and potato patties and the like are well known in the art, wherein these products comprise an aggregation of relatively small potato pieces. Such potato pieces are typically combined into a serving size of a few ounces, and then finish prepared as by frying, grilling, oven baking, etc. In some products, the small potato pieces are consolidated as by pressing into a unitized patty which is then finish prepared for consumption.
In one common form, a variety of cutting machines and related production processes are known for cutting potatoes into small potato pieces such as diced cubes or thin shreds. Alternative processing machines and methods utilize extrusion technology such as ricing equipment wherein cooked or partially cooked potatoes are forced through small openings in an extrusion-type die. Still other communication-type machines and processes are designed to produce small potato pieces by means of a shearing or tearing action. However, in general terms, such known processes and related production equipment typically produces an array of small potato pieces having a generally uniform overall size and shape which is readily apparent in the finish prepared food product. In addition, depending upon the processing parameters, some of these machines and processes will disrupt the cellular potato structure to cause release of a sufficient quantity of potato starch to result in a product that has an undesirably sticky or gummy character.
The improved processing machine and related production process of the present invention are specifically designed for quickly and easily reducing potatoes to smaller pieces having a substantially irregular or random overall size and shape, thereby providing a finish prepared food product having a unique, distinctive, and highly attractive appearance.
In accordance with the invention, an improved processing machine and related production process are provided for forming small, substantially random sized potato pieces suitable for use in preparing potato hash browns and the like. Blanched potatoes are chilled and then swept against a blunt edge resulting in shattering of each potato into the desired plurality of relatively small, random-sized pieces, substantially without cutting or extrusion of the potato. If desired, each blunt shatter-edge can be provided in a knife unit including one or more cross-cut knives to subdivide larger already-shattered pieces into a smaller size. The produced potato pieces are chilled as by freezing for shipment and/or storage to await finish preparation.
In the preferred form, potatoes such as whole potatoes in a raw and peeled or unpeeled state are initially cooked at least partially, as by blanching the potatoes in hot water or steam. More particularly, the potatoes are blanched as by heating hot water at a temperature of from about 180 F. to about 195 F., for a period of from about 20 to about 40 minutes. At the conclusion of the blanch step, the potatoes are partially cooked to exhibit a core pulp temperature of from about 165 F. to about 185 F.
The blanched potatoes are then chilled to reduce the core pulp temperature to near freezing, but substantially without freezing the blanched potatoes. In one preferred process, the chilling step comprises a two-step sequence including water quenching in cool water followed by air chilling to reduce the core pulp temperature to about 35 F.
The blanched and chilled potatoes are then processed in a modified cutting machine including at least one and preferably multiple knife units each having a relatively blunt edge for shattering the chilled potatoes into random sized pieces. In the preferred form, the modified cutting machine comprises a modified Model CC cutter available from Urschel Laboratories, Valparaiso, Ind., wherein conventional sharp-edged knife blades at the perimeter of a stationary frame have been replaced by the blunt edge, such as a blunt blade having a leading edge with a dull or blunt thickness on the order of about ¼ inch. Chilled potatoes supplied into the machine are swept by an internally mounted rotary impeller so that the potatoes impact and shatter against the blunt-edged blade on the stationary frame. The shattered potato pieces have a substantially random overall size and shape, while exhibiting a disrupted potato cell structure which is significantly different than that achieved by traditional extrusion-type or communition-type equipment and processes.
If desired, each blunt-edged blade on the stationary frame comprises a portion of a knife unit, wherein each knife unit may additionally include one or more cross-cut and relatively sharp-edged knife blades for subdividing relatively large-sized shattered pieces into smaller pieces. Importantly, when the cross-cut knives are used, each large-sized piece is cut on one or two surfaces thereof, whereby at least two surfaces remain uncut to retain the overall random size and shape appearance of the produced potato pieces.
The produced potato pieces are then chilled or frozen for storage and/or shipment, pending finish preparation as by frying, microwaving, grilling or oven heating or the like. In this regard, the produced potato pieces can be finished prepared in an unassembled hash brown configuration, or in an assembled patty-like shape. Regardless, the random-sized potato pieces provide the finish prepared comestible with a unique and distinct overall appearance, in combination with a pleasing taste and texture.
Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
The accompanying drawings illustrate the invention. In such drawings:
As shown in the exemplary drawings, an improved and modified cutting or processing machine referred to generally in
The processing machine 10 and related production process are designed for producing small potato pieces suitable for use in preparing so-called hash brown potato or potato patty products having a unique and distinct overall appearance, in combination with a pleasing taste and texture. In this regard, potato hash browns are typically prepared from an unconnected or loose aggregation of small potato pieces which are finished prepared for eating as by means of frying, grilling or oven heating or the like. By contrast, potato patty products generally comprise a similar aggregation of small potato pieces but wherein the potato pieces are pressed into a typically flattened and substantially unitized patty shape for finish preparation as by means of frying, grilling or oven heating or the like. The processing machine 10 and related production process of the present invention produces small potato pieces of random size and shape, thereby presenting a unique and distinct overall appearance. The potato pieces are produced with relatively minimal disruption of the potato cell structure, and correspondingly minimal release of starch with the above mentioned process, to avoid an undesirably sticky or gummy potato product.
The processing machine 10 generally comprises, in one preferred form, a modified cutting machine such as a modified Model CC cutting machine available from Urschel Laboratories, Valparaiso, Ind. See also U.S. Pat. Nos. 3,139,128 and 5,694,824, which are incorporated by reference herein.
In general terms, the modified processing machine 10 generally comprises an upper hopper or chute 18 (
More particularly, the stationary frame 26 has a generally cylindrical configuration defined by a circular outer wall 34 (
In accordance with the invention, each knife unit 28 includes the blunt-edged blade 14 mounted securely at one side of the associated perimeter wall opening 36 for impact engagement by potatoes carried by the internally mounted rotary impeller 30. In the illustrative drawings, with the impeller 30 designed for clockwise rotation (as viewed from above, per
As shown best in
In accordance with one further aspect of the invention, each knife unit 28 may further include at least one and preferably multiple cross-cut knives 46 positioned to subdivide larger shattered potato pieces 12 into small-sized pieces, if desired. As shown in
More particularly, in accordance with a preferred process aspect of the invention, raw potatoes in a large or whole state, peeled or unpeeled, are initially subjecting to a partial cooking step 58 as by blanching in hot water at a temperature of from about 175 F. to about 195 F., and more preferably at about 180 F., for a period of from about 20 to about 40 minutes, and more preferably about 30 minutes. At the conclusion of the blanch step, the potatoes are partially cooked to exhibit a core pulp temperature of from about 165 F. to about 185 F., and more preferably about 175 F.
The blanched potatoes are then subjecting to a chilling step 60 to reduce the core pulp temperature to near freezing, but substantially without freezing the blanched potatoes. In a preferred process, the chilling step comprises a two-step sequence including water quenching in cool water followed by air chilling to reduce the core pulp temperature to from about 33 F. to about 40 F. More particularly, this two-step sequence comprises, in the preferred form, initial temperature reduction by water quenching the blanched potatoes in cool water having a temperature of from about 35 F. to about 60 F., and more preferably about 40 F., for a time period of about 20 to about 45 minutes, sufficient to reduce the core pulp temperature to about 50 F. Thereafter, the partially chilled potatoes are subjected to refrigerated air for a time sufficient to reduce the core pulp temperature to less than about 50 F., more preferably to less than about 45 F., and most preferably to a temperature close to but slightly above freezing such as about 33 F. In this regard, lower core pulp temperatures approaching freezing are preferred since this is believed to enhance production of small shattered pieces with controlled or minimal release of free potato starch, whereas higher core pulp temperatures are believed to result in pastier cut product associated with higher quantities of free starch.
The blanched and chilled potatoes are then delivered to the processing machine 10 as previously shown and described herein for shattering against the blunt-edged blades 14 of the knife units 28. The produced potato pieces 12 exhibit a broad range of small sizes and random shapes. If desired, the cross-cut knives 26 are provided to reduce larger shattered pieces into smaller sizes, with such cross-cut pieces having at least two uncut surfaces to preserve the overall random size and shape appearance of the potato pieces 12.
The produced potato pieces 12 are then typically subjected to a freezing or chilling step 62 followed by suitable packaging for shipment and/or storage awaiting a finish preparation step 64, as by frying, grilling or oven heating as previously described herein.
Although an embodiment of the processing machine 10 and related production process have been described in detail for purposes of illustration, various modifications may be made without departing from the scope and spirit of the invention. Accordingly, no limitation on the invention is intended by way of the foregoing description and accompanying drawings, except as set forth in the appended claims.
Number | Date | Country | |
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60869252 | Dec 2006 | US |