The invention relates to methods and apparatus for the deposition of powders and/or toppings onto moving objects, and particularly onto moving food items, e.g. on a conveyor belt. Particular features relate to the deposition of powdered flavourings, seasonings, colourings and/or other toppings onto moving food items.
Background and Prior Art
In the food industry, it is often required to apply a powdered ingredient, such as a flavouring or colouring to the top surface of a food item during processing.
This method of applying powdered ingredients has the disadvantage that quite a lot of the powdered material can end up on the conveyor itself, rather than on the food items. Not only can this lead to wastage, but could potentially require regular cleaning of the conveyor to prevent buildup of powder, and possible microbiological risks. In some applications, items to be coated are carried on cords so that unused seasoning passes through to a lower collection system for recycle—a typical recycle can be up to 300% of that which adheres to the food items. This recycle is often hygroscopic due to sugars and other ingredients in the seasoning which then leads to agglomeration, and undesirable spotting and poor adhesion. Additionally the recycle system must be cleaned causing lost production time. The use of a curtain of seasoning can also result in flyaway particles of dust that adhere to surfaces in the vicinity; this also requires additional cleaning and lost production. These issues are especially problematic when the food items are fast-moving.
It is among the object of the present invention to propose a solution to the problem.
Accordingly, the invention provides a production line for producing items having powder and/or a topping deposited on them, said production line comprising a conveyor arranged to convey items to be coated and a powder and/or topping depositor arranged to deposit powder and/or toppings in items on said conveyor; said powder and/or topping depositor comprising: (a) a powder and/or topping reservoir to hold powder and/or topping to be deposited; (b) a screen, positioned to receive powder and/or topping from said reservoir onto a face of said screen; (c) a vibratory actuator arranged to apply intermittent vibrations to said screen to cause powder and/or topping to pass through apertures in said screen; (d) a controller to control the interval between said intermittent vibrations such that powder and/or topping is deposited predominantly onto said items as they pass below said screen.
Preferably, said items are arranged in plural lanes on said conveyor, said line comprising a plurality of powder and/or topping depositors arranged to deposit powder and/or topping on items in a plurality of corresponding lanes.
Preferably also, a plurality of powder and/or topping depositors are arranged to deposit powder and/or toppings on items in a plurality of rows of items on said conveyor.
Also included in the scope of the invention is production line as described above comprising a powder and/or topping depositor in which said vibratory actuator is configured to also apply intermittent vibrations to said reservoir.
Preferably, said intermittent vibrations have a dominant frequency of between 1 and 200 kHz, preferably between 5 and 100 kHz, more preferably between 10 and 50 kHz, and most preferably between 10 and 30 kHz.
Preferably such a production line comprises a powder and/or topping depositor in which said screen is supported on a baseplate, and said vibratory actuator is functionally connected to said baseplate to enable vibration of said screen.
More preferably, such a production line comprises a powder and/or topping depositor in which said reservoir is also functionally connected to said baseplate such that said vibratory actuator can also enable vibration of said reservoir.
In any such production line it is preferred that said line comprises a powder and/or topping depositor in which said vibratory actuator comprises a piezo-electric actuator.
In any such production line it is preferred that said line comprises a powder and/or topping depositor in which said controller is configured to deliver said intermittent vibrations at a repeat rate of between 2 and 30 Hz, preferably between 6 and 15 Hz.
In any such production line it is preferred that said line comprises a powder and/or topping depositor in which said screen comprises a mesh. More preferably, said mesh comprises apertures of between 0.2 and 7 mm, for example between 1.0 and 6 mm.
Alternatively, it is preferred that said screen comprises a perforated plate.
In any such production line, it is preferred that said conveyor is configured to convey said items at a velocity of 0.1 to 3 m/s, preferably between 0.2 and 1.5 m/s, more preferably between 0.25 and 1.3 m/s, most preferably between 0.6 and 1.1 m/s. Such velocity can result in a production line that can deposit powder and/or toppings onto items at a rate of 10-12 items per second per lane. A typical production might run with 20-24 lanes giving production rates of 240-288 items per second.
In any such production line it is preferred that said line comprises a powder and/or topping depositor configured to deposit powder and/or topping only on a part of an item.
In any such production line it is preferred that said line further a sensor, arranged to sense the presence or absence of an item to be coated, and configured to send a signal to a controller to control deposition of powder and/or topping onto said item.
In any such production line it is preferred that said line comprises plural powder and/or topping depositors arranged along a lane and configured to deposit powder and/or topping onto different items.
In any such production line it is preferred that said line comprises plural powder and/or topping depositors and wherein the vibratory actuators in multiple powder and/or topping depositors are provided with a driving signal from a common signal generator. More preferably, said driving signal is independently controlled in each of said multiple powder and/or topping depositors to allow independent intermittent vibrations for each of said multiple powder and/or topping depositors.
In any such production line it is preferred that the line further comprises charging apparatus configured to impart an electrostatic charge to said powder.
Also falling within the scope of the invention is the use of a production line described above wherein said items are food pieces, for example, crackers or chips.
Also falling within the scope of the invention is a powder and/or topping depositor array for use in such a production line.
The invention will be described with reference to the accompanying drawings, in which:
The term “powder” as used herein means particles having a typical particle size distribution of 10-400 microns. The term “powder” is intended to include salt, seasonings and colourings. Examples of seasonings include bbq flavouring, dairy powder (e.g. sour cream), herbs, spices, and sugar. Seasonings may also be pre-blended mixtures.
The term “topping” as used herein means particulates which are physically discernible pieces. The topping may have a typical particle size distribution of greater than 1 mm, for example 1-10 mm or 1-7 mm. However, in some embodiments, the topping particulates may have a particle size distribution of less than 1 mm but are not a homogenous powder. Toppings that may be deposited using the powder and/or topping depositor according to the invention include nuts (e.g. pine nuts, chopped cashews etc), vegetable pieces (e.g. chilli flakes, crushed chilli, carrot pieces, olive pieces, herb pieces, peppercorns, etc), seeds (e.g. poppy seeds, chia seeds etc), edible spices (e.g. cumin seeds), confectionary pieces (e.g. “Nerds”, popping candy, etc.), large sugar crystals, rock salts, and/or processed food fragments (e.g. crushed potato chips, tortilla chips etc). Where larger toppings are used, the toppings may be pre-sieved to narrow the particle size distribution.
The introduction of powder and/or topping into the reservoir 3 may be achieved by e.g. the use of a vibratory feeder, a screw feeder, a conveyor belt, or other such means as will be apparent to the skilled addressee. The depositor also comprises a screen 8 that is arranged to receive powder and/or topping 4 from the reservoir 3. In this embodiment, the screen 8 is mounted across an aperture in a baseplate 9. The screen could comprise a wire mesh, e.g. a woven mesh, or other perforated structure as will be described below.
A vibratory actuator is also provided, in this embodiment in the form of piezo-electric actuators 10, driven by a suitably amplified signal source. Suitable arrangements will be described below.
In this embodiment, the reservoir 3 is coupled to the baseplate 9, such that vibrations applied to the baseplate 9 are transmitted to the walls of the reservoir 3 to assist with flow of powder and/or topping 4 towards the screen 8. In alternative embodiments, separate vibratory actuators could also be attached directly to the reservoir 3 itself.
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In some embodiments, the screen may have a gradient. For example, the gradient may be radial, linear or non-liner. A gradient screen can be used with a single particle type or multiple particle types.
In some embodiments, the screen may be bi-modal, for example, the screen may comprise a first part and a second part. The first and second parts may be of equal size or of unequal sizes. The first and second parts may have the same or different aperture sizes. The first and second parts may be of the same configuration (aperture shape, gradient, pattern etc) or may be of different configuration (aperture shape, gradient, pattern etc). The first part and the second part may be fed from the same reservoir or may be fed from different reservoirs.
In some embodiments, the screen may be multi-modal. For example, the screen may comprise three or more parts of equal or unequal sizes. Each of the parts may have the same or different aperture sizes. Each of the parts may be of the same configuration (aperture shape, gradient, pattern etc) or may be of different configuration (aperture shape, gradient, pattern etc). Each of the parts may be fed from the same reservoir or may be fed from different reservoirs.
In some embodiments, the screen may be planar. In other embodiments, the screen may be three-dimensional, for example, upright or inverted cone, hemispherical, pyramidal etc. Where there is more than one screen, there may be a mixture of planar and three-dimensional screens used. Three-dimensional screens may have advantages such as enabling the flow of otherwise layering materials (such as flakes) by enabling the aperture to be perpendicular in plane to the settled layer (much like posting a letter through a letter box). This can be beneficial as flake-like toppings can tend to settle in flat layers that can block two-dimensional planar apertures.
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In each embodiment, food items 1 are fed onto a conveyor 2 which transports them in a direction indicated by the arrows 15. Also in each embodiment, four lanes of food items are illustrated. In practice, for the production of snack foods, it is likely that many more lanes, e.g. six, eight or even ten might be typical.
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In some embodiments, the powder/topping reservoir may be divided into two or more zones (divided hopper). This enables the depositor to deposit multiple toppings in the same deposition.
The pulse train 21 is then fed though amplifiers 22 to producing an amplified driving pulse train 23 that may be used to drive the vibratory actuators of the powder and/or topping depositors 7. The amplification provided by the amplifiers 22 (i.e. the amplifier gain) may be controlled by the controller 16. It will be appreciated by the skilled addressee that the order of application of the amplification and gating steps may be interchanged.
A variety of powders and/or toppings have been tested for flowability using an embodiment of a powder and/or topping depositor of the invention. The results of these results are shown in the table below.
This table summarizes the flow characteristics of various toppings used. The Hausner ratio and Can index are both derived from measurements of changes in bulk density from an initial “as poured” or fluffy density to that in a “conditioned” state where the sample is consolidated in a controlled manner. These two ratios are then used to categorise the flowability of the materials using empirical guidelines. Similarly the angle of repose is a measure of internal friction and propensity the “jam” with lower angle of repose being less likely to jam than high angles. What can be seen in the table is that all of the toppings tested had either “good” or “excellent” flow characteristics. What can also be seen from the table is that all of the toppings had similar angles of repose and yet the toppings all behaved differently in real world testing with the depositor.
Number | Date | Country | Kind |
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2005814.5 | Apr 2020 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2021/060314 | 4/21/2021 | WO |