Patent Application
20120082775
This invention is directed to a method and apparatus for preparing dehydrated food products, especially potato chips and like products through application of a process vapor, and, more particularly, to a method and apparatus for impinging process gasses at high velocities and at predetermined temperatures and moisture contents against the surfaces of a food product until a preferred product moisture content is realized. This may occur in several steps or in product treatment zones until the desired finished moisture content and product cooking is achieved.
Conventionally, potato chips and like snack products have been prepared in hot oil baths with controlled cooking temperature profiles for obtaining the desired oil content and crispness which correlates with moisture content in the finished products. Although the vast majority of these products are produced in this manner, it is believed in some quarters that a non-oil fried chip is a more healthful food product for humans. Most desirably such a chip must have the appearance, taste and mouth feel of the conventional chip to be commercially viable.
A non-oil fried snack food is frequently cooked in a oven employing as the heating medium circulating hot air or microwave energy, or combinations thereof. In the case of cooking potato slices and similar products it is important that while cooking the individual products or slices do not overlap and thus tend to clump or mass together which would result in an unacceptable cooked product. Thus the placement, positioning and handling of such uncooked products during the cooking process is critical. Placing uncooked product pieces in a single layer upon an oven's horizontal conveyor belt for cooking may be satisfactory for some limited production purposes. However this configuration is economically unsatisfactory where high production quantities are specified thus suggesting an oven cooking apparatus with a prohibitively large cooking area occupying a vast plant floor space.
Air impingement ovens have been adopted in the process food and snack food fields for a wide variety of product applications. U.S. Pat. Nos. 5,934,178 and 6,146,678 granted to Andrew A. Caridis, et al. disclose apparatus and processes which have been widely adopted for cooking by impinging upon raw food products a cooking vapor at selected temperatures, velocities and moisture contents selected to suit cooking conditions. The food products are carried on a vapor permeable, wire mesh, horizontally moving conveyor during the cooking process while the process vapor is impinged upon the food products from above and below the conveyor belt. During the cooking process the products are substantially stationary in a horizontal position on the conveyor belt although some unintended movement of the products has been observed. Although air impingement cooking processes have received great success with many different products it is challenging to apply the principles of air impingement to high output production of potato chips and the like. European Patent EP 0370021, Bellas, Inc. applicant, International Publication WO 89/00393, 26 Jan. 1989, discloses an oven employing a product conveyor and jet tubes for impinging gases at predetermined humidity, temperature and velocity upon products on the conveyor. Alternate zones of impingement and non impingement establish a thermal pulsing heat application to the products.
From a commercial standpoint some of the most important characteristics of a potato chip are taste, over all appearance and color as well as the “crunch” feeling in the mouth when consumed. Industry standards have been adopted covering these characteristics. An “off” taste potato chip product must be avoided and a chip having a taste suggesting a “raw” or uncooked potato is not acceptable.
it has been determined that in a finished cooked chip the potato raw or uncooked taste can be tempered by insuring that the initial gelatinization of the starches on the potato slice surfaces is realized quite early in the cooking process. However, the gelatinized surfaces of the yet non-fully cooked potato slices have a glue-like stickiness that must be dealt with because the slices with their sticky surfaces will tend to adhere to one another and together form a clump of slices. This is an unacceptable result and such a product would be rejected in the marketplace. Thus there must be achieved in the non-oil fried chip, derived from root crops, an elimination of the raw or “green” taste as well as control of slices clumping together during the cooking step. Handling of the potato slices so as to eliminate clumping while they are in a gelatinized state is a critical step in the process of cooking a non-fried potato, or other root crop, chip.
an unintended constituent in many cooked snack food products, including potato chips, is acrylamide. Acrylamide was accidentally discovered in foods in April 2002 by scientists in Sweden when they found the chemical in starchy foods, such as potato chips. Production of acrylamide in the heating/cooking process was shown to be temperature-dependent and was not found in foods that had been boiled or in foods that were not heated. Acrylamide levels appear to rise as food is heated for longer periods of time. There is uncertainty still over the precise mechanisms by which acrylamide forms in foods, but many believe it is a byproduct of the Maillard reaction. In fried or baked goods, acrylamide may be produced by the reaction between asparagine and reducing sugars (fructose, glucose, etc.) at temperatures above 120° C. (248° F.). Governmental agencies have scrutinized the presence of acrylamide in food products and on 2005 Aug. 26, the California attorney general filed a lawsuit against prominent makers of French fries and potato chips to warn consumers of the potential risk from consuming acrylamide. The lawsuit was settled on 2008 Aug. 1 with the food producers agreeing to reduce acrylamide levels in half. The settlement required the producers to reduce acrylamide to 275 parts per billion (ppb) in three years. Presently there is a need for an efficient and reliable process to produce these food products, especially potato chips, within or below that level of acrylamide content.
In the study of producing potato chips in processes where the conventional cooking oil bath has been eliminated, it has been learned that it is highly beneficial to quite early in the process to set the initial chip structure. By this is meant that it is important quickly to develop the cell structure including blisters in the chip as well as chip color and integrity by rapidly removing moisture from the chip slice. This does not mean reaching the chip final moisture content but to achieve an intermediate moisture content, for example 30% moisture, wherefrom final moisture removal may be conducted as desired. Impingement of a process vapor in a cooking process can contribute significantly to dehydration or drying ‘of the product where the speed, impingement focus and moisture content of the vapor are controlled.
the present inventions in summary reside in a process and an apparatus, wherein food products, in particular snack food products, are oil-free prepared. A potato, an exemplary root crop, is prepared for cooking for instance by peeling, slicing, and washing the potato slices followed by drying off the slice surface moisture. The prepared food products are conveyed into rotatable, longitudinally extending cage-like drum with cylindrical, foraminous sidewall construction and disposed within at least one oven atmosphere. A process vapor within the impingement oven at a temperature substantially higher than that of the food products is impinged against a first sector of the cage sidewall where the food products are disposed. The process vapor is withdrawn at a temperature cooler than the initial temperature from a second sector of the cage while the cage is rotated and the food products are urged to traverse the cage longitudinally thereby reducing the moisture content of the food products to fall in the range of about 28% to 60% moisture, and then removing the food products from the cage-like drum for further treatment.
A general object of this invention is to provide a process and an associated apparatus that will afford the preparation of food products and in particular snack food products including a potato chip and the like in a non-oil cooking process and yet having the taste, appearance and “mouth feel” like that associated with food products, otherwise prepared.
Another object of this invention is to provide an apparatus in the form of a rotary impingement oven wherein various products may be prepared by the impingement of a temperature and moisture controlled process vapor upon the products as the same are urged through the oven.
Still another object of this invention is to provide a process wherein by control of the moisture content and temperature of a food product the generation of acrylamide is materially reduced.
Yet another object of this invention is to provide an air impingement process that permits rapid dehydration of potato slices while developing gelatinization of the slice surfaces and to set the initial chip structure including color and blistering of the slice thereby avoiding a “non-green” or raw taste in the finished product.
A further object of this invention is to provide a process including dehydration of a sliced root product in an atmosphere developed in one or more air impingent rotary ovens so as to reach a predetermined intermediate slice moisture content and then removing substantial residual moisture from the slice in the atmosphere of a dryer so as to obtain the final slice moisture content.
The foregoing and other objects an advantages of the invention will become apparent from the detailed description which follow taken in connection with the accompanying drawings and diagrams.
it should be noted that same reference signs throughout the accompanying drawings and diagrams refer to same of like components of the present invention.
Referring to
Referring now to
Referring specifically to
the chips finally dehydrated in the through circulation dryer are moved along in the production process to a seasoning stage where the appropriate final taste is established. Thereafter the seasoned chips are conveyed to a packaging station, all as indicated in
in the following, definitions and specifications relating to positions in space and relative positions in space should be understood in relationship to the weight force vector.
According to a preferred embodiment of the present invention, an air impingement oven 11, made in accordance with the principles of the present invention, is generally indicated in
Within the oven casing 12 internal partitions 21, 22 and 23 define a process vapor flow path to and from the fan 14 as indicated by the arrows 24. It will be understood that when the fan 14 is operating the partitions or baffles 21-23 divide the oven 11 into a high pressure compartment 26 in flow direction of the fan 14, for example on the left-hand side of
The fan is equipped to operate at a level to propel the process vapor at velocities in the range of 7,000 to 12,000 fpm (2,134 to 3,658 mpm). The cage-like drum 13 is disposed so that a sector portion of its sidewall is in the high pressure compartment 26 and another sector portion of its sidewall is in the lower pressure compartment 27, best shown in
the lower pressure compartment 27 and the high pressure compartment 26 are separated from each other by the internal partitions 21, 22 and 23. The internal partitions 21, 22 and 23 have two through passages, one of which is an inlet passage or duct, through which the process vapor passes from the lower pressure compartment 26 into the high pressure compartment 27. The cage-like drum 13 is disposed within the other through passage. The process vapor of the high pressure compartment 26 is impinged against the cage-like drum 13 and the food products therein and withdrawn from the cage-like drum 13 into the lower pressure compartment. The above described circulation of the process vapor is driven by the fan 14. It should be understood that in this context the fan 14, which is described to propel the process vapor, is only one embodiment of the present invention. In a more general embodiment, a circulation device comprising for instance at least one of a propeller (as illustrated), an air turbine, a ventilator and the like. The inlet passage or duct is arranged in relationship to the circulation device. The circulation device causes also the pressure difference between the pressure of the process vapor in the high pressure compartment 26 and the pressure of the process vapor in the lower pressure compartment 27 in that the process vapor is accelerated and compressed.
The drum or cage 13 is illustrated in
As shown in
the impingement process vapor is directed against the sidewalls of the cage from an array of Vee shaped discharge ports 34 spaced adjacent to the cage 13 as shown in
Referring to
The inlet sector portion of the sidewall of the cage-like drum 13, at which the process vapor is impinged from the high pressure compartment 26, and the sector portion of the sidewall of the cage-like drum 13, through which the process vapor is withdrawn from the cage-like drum 13 to the lower pressure compartment 27, have differing areas. As illustrated in cross section drawing shown in
The internal partition 22 provided below the cage-like drum 13 to separate the high pressure compartment 26 and the lower pressure compartment 27 is arranged substantially in alignment with the longitudinal axis of the cage-like drum 13 and adjoins the surface of the cage-like drum 13 without having contact therewith. Hence, the process vapor is impinged against the cage-like drum 13 substantially in horizontal and upwards direction, whereas the process vapor withdrawn from the cage-like drum 13 substantially in downwards direction (cf. arrows in
as further shown and best understood from
Although the present invention has been described at the beginning in the context of preparing root crops and in particular potato chips, it should be understood that the present invention is not limited thereto. Several food products, which are conventionally prepared by cooking or frying in oil, can be oil-free processed in the above described impingement oven. Such food products appropriate for oil-free preparation comprise in particular snack food products including inter alia the aforementioned root crops and chips thereof, vegetables and chips thereof, expansion of pallets, Direct extruded products, nuts, seeds or grains and meat containing food products. The conventional preparation of aforementioned food products, i.e. the preparation in a bath of hot oil, is subjected to the same drawbacks and problems set forth in the background description with respect to potato chips.
Pellets are produced in a similar way as noodles. A mixture of raw materials such as potatoes and different types of cereals with salt and water is pressed through an extrusion die. Conventionally, in an oil-bath based production process, the pellets get their crunchy bite by shortly frying them in vegetable oil and individual seasoning afterwards. The aforementioned air impingement oven 11 according to an embodiment of the present invention allows for expansion of such pallets in an oil-free preparation process.
direct extruded products or direct extrudates mean food products obtained by direct extruding or pressing dough of e.g. maize, rice, potatoes or wheat through an extrusion die under high pressure, wherein different extrusion dies make different forms out of the dough. Direct extrudates include, but not limited thereto, peanut flips, cheese flips, cheese rings, onion rings, etc. The aforementioned air impingement oven 11 according to an embodiment of the present invention allows for an oil-free preparation process of such direct extrudates.
Nuts and nut products should be understood in the context of the present invention as peanuts, coated peanuts and further products classified colloquially as nuts including, but not limited thereto, almonds, macadamia nuts, walnuts, cashew nuts, Brazil nuts and the like with or without coating. Such nuts and nut products are conventionally prepared in an oil bath. The aforementioned air impingement oven 11 according to an embodiment of the present invention allows for an oil-free preparation process of such nuts and nut products.
in analogy to nuts and nut products seeds or grains are conventionally prepared in an oil bath. The aforementioned air impingement oven 11 according to an embodiment of the present invention allows for an oil-free preparation process of such seeds or grains.
Batter wrapped meat containing food products should be understood as snack products containing meat wrapped in batter such as chicken pieces or wings wrapped in batter, meat wrapped with a breadcrumb coating and the like. Such batter wrapped meat containing food products are conventionally prepared in an oil bath. The aforementioned air impingement oven 11 according to an embodiment of the present invention allows for an oil-free preparation process of such batter wrapped meat containing food products.
it should be further noted that the pre- and post-production processes above described with reference to the slice cooking process 10 illustrated in the schematic block diagram of
The processing of the food products in the air impingement oven 11 is determined by several adjustable process parameters including inter alia the composition and properties of the process vapor such as moisture content and temperature; volume flow and velocity of the process vapor; area of the vapor inlet sector portion of the cage-like drum, area of the vapor outlet sector portion of the cage-like drum; distance between and size of the through holes, i.e. areal density, in the lateral area of the cage-like drum; and process time of the food products in the cage-like drum 13.
the slope or bias angle of baffle 32 for instance formed as a helix and the rotational speed of the cage-like drum 13 determine the resulting longitudinal conveyance speed of the food products from the food product inlet to the food product outlet of the cage-like drum 13. A longitudinal axis of the cage-like drum 13 may be designed to incline at least slightly downwards in direction of the product discharge end 38 of the cage-like drum 13 in order to support the conveyance of the food products through the cage-like drum 13. The length of the cage-like drum 13 and the speed of conveyance of the food products through the cage-like drum 13 determines the duration of stay of the food products within the cage-like drum 13.
The moisture content of the food products approaches the moisture content of the process vapor during duration of stay of the food products within the cage-like drum 13. The longer the food products stay within the cage-like drum 13 the closer the moisture content of the food products and the moisture content of the process vapor become.
Although some of the process parameters are described in the context of the exemplary potato chips and the processing thereof, those skilled in the art will appreciate that these process parameters including for instance number of impingement stages (number of oven environments), temperature ranges, air velocity ranges, cage hole sizes, processing time, moisture content of the process vapor and rotational speed of the cage-like drum also apply to the further food products and in particular snack food products described above.
it will be readily apparent that various modifications may be made to the structures and processes of this invention and still be within the scope of the present invention. In particular, in may be readily appreciated by those skilled in this art from the above description that the apparatus according to the invention provides for adjustability not only in the available rotational speeds of the cage-like drum as well as the fan speeds and the moisture content of the process vapor. The features of adjustability accord with better dehydration times and the resulting uniformity of the final product as to moisture content, quality and appearance. Accordingly, the scope of this invention shall only be limited within terms and spirit of the following claims.
