Patent Application
20200390129
The background description provided herein is for the purpose of generally presenting the context of the disclosure. Unless otherwise indicated herein, the materials described in this section are not prior art to the claims in this application and are not admitted to be prior art or suggestions of the prior art, by inclusion in this section.
Materials, such as food products, may be desirous to be processed to a particular end temperature, have particular end product characteristics, processed within a certain time frame, exhibit positive taste, exhibit positive shelf-life, and/or the like. In commercial environments, consistent process reproducibility and/or higher yield may also be design considerations. An example food process may comprise heating or cooking a food product to a particular end temperature. While an overall or average desired end temperature may be achieved, the resulting food product may be lacking in other ways. For example, the temperature in different portions of the resulting food product may differ from each other, which may result in the resulting food product undercooked in some portions and overcooked in other portions. This and other characteristics associated with processing of food products (as well as materials, in general) may be desirous to be better controlled and/or achieved.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter.
In some embodiments, a method includes positioning a load at a first temperature to electrically couple with a radio frequency (RF) processing system; applying, for a first time period, a RF signal to the load to change a temperature of the load from a first temperature to a second temperature; positioning the load at the second temperature within an impingement processing system; and circulating a heated gaseous medium to the load to change the temperature of the load from the second temperature to a third temperature. The first and second time periods together is less than or equal to a time period for the load to change from the first temperature to the third temperature from only impingement processing.
In some embodiments, a system includes a first unit configured to generate and apply radio frequency (RF) energy to a load positioned in the first unit during a first time period, wherein the load is at a first temperature at a start of the first time period and at a second temperature different from the first temperature at an end of the first time period; and a second unit configured to receive the load at the second temperature and to cause heat transfer by impingement to the load during a second time period different from the first time period, wherein the load is at a third temperature at an end of the second time period. A processing yield associated with the load is higher than if the load undergoes impingement processing to change from the first temperature to the third temperature.
In some embodiments, a system includes a first device that includes first radio frequency (RF) signal generation components and first gaseous medium circulation generation components, the first device configured to simultaneously provide first RF processing and first gaseous medium circulatory processing to a material of interest for a first time period; and a second device that includes second impingement generation components, the second device configured to provide second impingement processing to the material of interest for a second time period after the first time period. The material of interest changes from a first temperature to a second temperature during the first time period and from the second temperature to a third temperature during the second time period.
In some embodiments, a system includes a first device that includes first radio frequency (RF) signal generation components, the first device configured to provide first RF processing to a material of interest for a first time period; and a second device that includes second RF generation components and second impingement generation components, the second device configured to simultaneously provide second RF processing and second impingement processing to the material of interest for a second time period after the first time period. The material of interest changes from a first temperature to a second temperature during the first time period and from the second temperature to a third temperature during the second time period.
In some embodiments, a system includes a first unit configured to generate and apply radio frequency (RF) energy and air circulation to a load positioned in the first unit during a first time period, wherein the load is at a first temperature at a start of the first time period and at a second temperature different from the first temperature at an end of the first time period; and a second unit configured to receive the load at the second temperature and to cause heat transfer by impingement to the load during a second time period different from the first time period, wherein the load is at a third temperature different from the second temperature at an end of the second time period. At least one of the second or third temperatures is at or near a temperature of a solid-to-liquid phase transition latent zone associated with the load.
The foregoing aspects and many of the attendant advantages of the present disclosure will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings.
Embodiments of a system, apparatus, and method for radio frequency (RF) and impingement thermal processing are described herein. In the following description numerous specific details are set forth to provide a thorough understanding of the embodiments. One skilled in the relevant art will recognize, however, that the techniques described herein can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring certain aspects
While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described herein in detail. It should be understood, however, that there is no intent to limit the concepts of the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives consistent with the present disclosure and the appended claims.
References in the specification to “one embodiment,” “an embodiment,” “an illustrative embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may or may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. Additionally, it should be appreciated that items included in a list in the form of “at least one A, B, and C” can mean (A); (B); (C); (A and B); (B and C); (A and C); or (A, B, and C). Similarly, items listed in the form of “at least one of A, B, or C” can mean (A); (B); (C); (A and B); (B and C); (A and C); or (A, B, and C).
The disclosed embodiments may be implemented, in some cases, in hardware, firmware, software, or any combination thereof. The disclosed embodiments may also be implemented as instructions carried by or stored on one or more transitory or non-transitory machine-readable (e.g., computer-readable) storage medium, which may be read and executed by one or more processors. A machine-readable storage medium may be embodied as any storage device, mechanism, or other physical structure for storing or transmitting information in a form readable by a machine (e.g., a volatile or non-volatile memory, a media disc, or other media device).
In the drawings, some structural or method features may be shown in specific arrangements and/or orderings. However, it should be appreciated that such specific arrangements and/or orderings may not be required. Rather, in some embodiments, such features may be arranged in a different manner and/or order than shown in the illustrative figures. Additionally, the inclusion of a structural or method feature in a particular figure is not meant to imply that such feature is required in all embodiments and, in some embodiments, it may not be included or may be combined with other features.
In some embodiments, system 1 may be configured to process the material of interest 2 using more than one processing technique. The material of interest 2, also referred to as a load, material, or product, may be processed by the RF processing system 3 sequentially followed by the impingement processing system 4. Material of interest 2 may be located on a transport mechanism 5. Transport mechanism 5 may be configured to move or transport the material of interest 2 in a direction 6 to one or more particular locations within the system 1 (e.g., to align with particular electrodes or gaseous medium circulation pathways) and/or at one or more particular speeds through the system 1 for processing by RF and impingement processing systems 3 and 4. Transport mechanism 5 may be configured to operate in continuous motion (e.g., the material of interest 2 continuously moves through system 1 at one or more speeds) and/or in non-continuous motion (e.g., the material of interest 2 moves for a period of time, is stationary for a period of time, moves again for a period of time, and the like). Transport mechanism 5 may comprise, without limitation, conveyor belts, rollers, plates, or the like.
RF processing system 3 may be configured to apply RF energy having particular characteristics to the material of interest 2, to cause the material of interest 2 to change from a first temperature to a second temperature. As an example, without limitation, the first temperature can be −40° C. to −10° C. The second temperature comprises a temperature higher than the first temperature. As another example, without limitation, the second temperature can be within a few degrees (e.g., ±1, 2, or 3° C.) below or at a latent zone temperature associated with a state phase transition from solid (e.g., frozen) to liquid of the material of interest 2. If the second temperature is a latent zone temperature associated with the material of interest 2, in which change in the energy content or enthalpy of the material of interest 2 occurs but the temperature change in the material of interest 2 may be negligible or none, the second temperature may be the same or approximately the same as the first temperature even though energy is applied to the material of interest 2.
In some embodiments, RF processing system 3 may comprise a system 100 or system 1300 as described in Appendix A attached herewith. RF processing system 3 may also comprise one or more cells, zones, or stages. For example, RF processing system 3 may comprise N cells, as in the embodiment of system 1300 in Appendix A, in which each cell of the N cells may be configured to process the material of interest 2 within a particular temperature sub-range of the overall temperature range associated with the RF processing system 3. As another example, RF processing system 3 may comprise a single cell, as in the embodiment of system 100 in Appendix A, configured to cause the temperature associated with the material of interest 2 to be changed to the second temperature from the first temperature.
Processing of the material of interest 2 from the first temperature to the second temperature is also referred to as a first processing, RF dominant processing, or the like. The corresponding processing time period is referred to as the first processing time period, first time period, RF dominant processing time period, or the like.
In some embodiments, the frequency of the RF energy applied to the material of interest 2 by RF processing system 3 is controlled using voltage controlled oscillation (VCO). An oscillator module included in RF processing system 3 includes an electronic oscillator configured for dynamic operating frequency setting. A particular input voltage value applied to such an electronic oscillator determines a particular RF operating frequency of the system. As the input voltage value changes, so does the operating frequency value. Thus, the system is capable of operating at any of a variety of frequencies. While the RF frequency is held constant during processing of the material of interest 2, the frequency can change prior to or after the processing time period. Frequency can be changed/set during system configuration, at the factory to meet particular customer requirements, depending on the characteristics of the material of interest to be processed, and/or the like. As an example, without limitation, the frequency may change within ±1 MHz or ±3% of the previous frequency value (e.g., 27 MHz, 27.1 MHz, 12 Hz, approximately 12 Hz, 10-100 MHz, etc.).
Impingement processing system 4 may be configured to continuously, periodically, sporadically, or repetitiously circulate a heated gaseous medium (with optional steam) both above and beneath (impinge upon) the material of interest 2, to cause the material of interest 2 to change from the second temperature to a third temperature. The heated gaseous medium may be circulated or distributed around the material of interest 2 (from any direction or be non-directional) using one or more fans, forced (high) velocity ducts or nozzles, and/or the like selectively distributed within the impingement processing system 4. Impingement processing system 4 may comprise one or more cells, zones, or stages, in which each cell may be associated with a particular temperature sub-range of the overall temperature range associated with system 4 and/or a particular circulation pattern/pathway. For example, each cell may include a particular set of forced (high) velocity ducts/nozzles and/or other circulation mechanism configured to output heated gaseous medium having a temperature, pattern, or characteristic different from heated gaseous medium associated with another cell. Alternatively, one, more than one, or all cells may be configured to provide the heated gaseous medium at the same (or approximately the same) characteristics as each other.
The impingement processing system 4 may also include one or more steam generating mechanisms so as to provide steam or moisture and/or additional heat to the material of interest 2 during impingement processing. Transport mechanism 5 may comprise a porous structure to facilitate heated gaseous medium and/or steam circulation, in some embodiments. At least the chamber associated with the impingement processing system 4, in which the material of interest 2 is to be located during impingement, may comprise a closed or partially enclosed space, in some embodiments. For instance, the impingement processing system 4 may include inlet and/or outlet doors (not shown).
In some embodiments, impingement processing system 4 may comprise any of impingement systems described in Appendix B attached herewith. Moreover, certain components included in system 1 may be configured in accordance with similar components set forth in Appendix B. For instance, transport mechanism 5 need not be linear and/or horizontal as shown in
Processing of the material of interest 2 from the second temperature to the third temperature (or to undergo a chemical or composition change) is also referred to as a second processing, impingement dominant processing, or the like. The corresponding processing time period is referred to as the second processing time period, second time period, impingement dominant processing time period, or the like. In some embodiments, second and third temperatures are the same, second and third temperatures are approximately the same, third temperature is higher than the second temperature, one or both of the second and third temperatures are within a few degrees of the solid-to-liquid latent zone temperatures associated with the material of interest 2, the second temperature is a temperature near a first end of the solid-to-liquid latent zone associated with the material of interest 2 and the third temperature is a temperature near a second end, opposite the first end, of the solid-to-liquid latent zone, and/or the like.
Continuing the example of the second temperature being within a few degrees below or at a latent zone temperature associated with a state phase transition from solid (e.g., frozen) to liquid of the material of interest 2, the third temperature can be a temperature (just) above the solid-to-liquid latent zone temperature(s) associated with the material of interest 2. The second processing thus takes the material of interest 2 through its solid-to-liquid latent zone, thereby completing thawing. Alternatively, the second and third temperatures are the same or approximately the same to each other when the material of interest 2 undergoes a chemical or composition change in the second processing, for example.
In some embodiments, material of interest 2 may comprise, without limitation, one or more of the following: food; biologic material; dough; protein; meats; poultry (e.g., chicken, turkey, quail, duck); beef; pork; red meat; lamb; goat meat; rabbit; seafood; foods encased in one or more bags, plastic, film, liner, cardboard, can, packaging, enclosure, box, and/or container (collectively referred to as packaging) (e.g., raw poultry, beef, pork, or seafood products inside a vacuum sealed bag and which may, in turn, be packed in cardboard boxes); various cuts of beef (e.g., sirloin, shoulder, trimmings, chuck, brisket, round, ribs, cheek, organs, flank, skirt, bone-in cuts of beef); various cuts of pork (e.g., butt, shoulder, loin, ribs, ham, trimmings, cheek, bacon, bone-in cuts of pork); various cuts of poultry (e.g., strips, breasts, wings, legs, thighs, bone-in cuts of poultry); whole or portions of seafood (e.g., fish, salmon, tilapia, tuna, cod, halibut, haddock, octopus, shellfish (with shell on or off), crab, lobster, clams, mussels, crawfish, shrimp (shell on or off)); bone-in meat, protein, or seafood; carbohydrates; fruits; vegetables; raw or uncooked bakery goods; bakery goods; pastries; dairy; cheese; butter; cream; milks; eggs; juices; broths; liquids; soups; stews; grains; foods that are combinations of one or more of the above (e.g., pizza, lasagna, curry); non-food materials; plastics; polymers; rubbers; metals; ceramics; wood; soil; adhesives; and/or the like.
One or more materials of interest may be simultaneously processed within system 1 at a given time. As an example, a first material of interest may undergo RF processing within the RF processing system 3 while a second material of interest may simultaneously undergo convection processing within the convection processing system 4. As another example, a first plurality of materials of interest may undergo RF processing (e.g., each material of interest of the first plurality of materials of interest located at a respective cell of the plurality of RF processing cells) while a second plurality of materials of interest may simultaneously undergo convection processing within the convection processing system 4. The transport mechanism 5 associated with the RF system may be configured to operate in an incrementally advancing mode, in which the transport mechanism 5 advances/increments one cell for each time interval; thereby advancing the first plurality of materials of interest to respective next RF electrodes/antennas within a RF tunnel system, for example. This is an example of batch processing. Another example of batch processing may comprise each material of interest of the first plurality of materials of interest located at respective RF electrode/antenna locations within the RF tunnel system, and then processing all of the materials of interest to the end RF processing-related temperature without moving them within the RF tunnel system.
RF and convection processing systems 3, 4 may be configured to be separate systems from each other, according to alternative embodiments. In such a configuration, the two systems may connect to each other via the transport mechanism 5.
At block 202, transport mechanism 5 may be configured to position the material of interest 2 relative to the RF processing system 3 to initiate RF dominant processing (also referred to as the first processing). In some embodiments, system 1 may include one or more controllers (not shown) configured to generate and communicate appropriate command signals to the transport mechanism 5 to position or align the material of interest 2 with particular electrode(s) of the RF processing system 3.
With the material of interest 2 in position, RF processing system 3 may be configured to generate and apply (continuous) RF energy or signal to the material of interest 2, at block 204. RF energy or signal is continuously applied to the material of interest 2 for the first processing time period and accordingly may also be referred as continuous RF processing. As the RF energy or signal is applied to the material of interest 2, RF processing system 3 may be configured to monitor one or more parameters, such as the reflected power level, associated with the RF processing system 3, at block 206. Details regarding reflected power level monitoring and usage are provided in Appendix A.
Next, at block 208, a determination may be made as to whether an endpoint has been reached. The endpoint may be based on a pre-defined RF processing time, particular value of the monitored reflected power level, particular temperature of the material of interest 2, per RF processing cell, and/or the like. In embodiments in which a plurality of RF processing cells may be used to process the material of interest 2, the endpoint detection may comprise determining whether processing using the current RF processing cell has been completed and to advance the material of interest 2 to the next
RF processing cell. In embodiments in which a single RF processing cell may be used to process the material of interest 2 or if the current RF processing cell comprises the last RF processing cell of the plurality of RF processing cells, the endpoint detection may comprise determining whether RF processing has been completed and to advance the material of interest 2 for impingement processing (e.g., the second processing).
Alternatively, endpoint may be based on pre-testing of various materials of interest, in which each of the materials of interest is tested through the system to determine which settings, how long to process, etc. for each of the different system operating modes (such as the two batch processing modes discussed above) produces desired treatment of the particular material of interest. Such empirical observations/testing may be the basis for the endpoint.
If endpoint has been reached in embodiments using a plurality of RF processing cells (“yes, if RF cells” branch of block 208), then process 200 returns to block 202 to advance the material of interest 2 to the next RF processing cell. If endpoint has been reached in embodiments using a single RF processing cell or the material of interest 2 is located at the last cell of the plurality of RF processing cells (“yes, if single RF cell or last cell” branch of block 208), then process 200 may proceed to block 213. If endpoint has not been reached (no branch of block 208), then process 200 may proceed to block 210.
In some embodiments, while RF processing may be in progress, an impedance matching module included in the RF processing system 3 can be adjusted in accordance with change in impedance associated with the material of interest 2 as it is changing temperature due to application of RF energy. Additional details are provided in Appendix A. If the match impedance in the impedance matching module does not need to be adjusted (no branch of block 210), then process 200 may return to block 204 to continue providing RF energy to the material of interest 2. Match impedance adjustment may be omitted if the match impedance circuitry is configured in a fixed or static configuration, the reflected power level is at or below a pre-set threshold level, endpoint is determined based on a pre-set time duration of applied continuous RF energy, system 3 is configured to operate without match impedance adjustment, and/or the like. If the match impedance is determined to be adjusted (yes branch of block 210), then process 200 may proceed to block 212 to perform the adjustment. After match impedance adjustment has been performed, process 200 may return to block 204.
As an example, the material of interest 2 may comprise bone-in poultry and the applied RF energy or signal may be at approximately 4.5 kiloWatt (kW). The start temperature of the material of interest 2 at the beginning of RF processing (e.g., the first temperature) may be 5 degree Celsius (° C.) and the end temperature or end state of the material of interest 2 at the end of RF processing (e.g., the second temperature) may be 30 to 35° C. The second temperature may be uniform throughout the material of interest within 1° C. The total RF processing time may be approximately 6 minutes.
At the end of RF processing, the surface of bone-in poultry may be dry, with skin intact, and/or no hot spots. Uncooked bone marrow (also referred to as red bone) may be absent or eliminated (or significantly reduced) in the bone-in poultry upon completion of the RF process.
In alternative embodiments, one or both of blocks 208 and 220 may be optional where endpoint detection associated with RF or impingement processes, respectively, may not be implemented.
In some embodiments, impingement processing may start sequentially, consecutively, and/or immediately after completion of RF processing. In some embodiments, if material of interest 2 includes packaging but removal of packaging did not occur at block 201, then removal of packaging can take place a block 213. Alternatively, block 213 may be optional if material of interest 2 is already devoid of packaging (e.g., due to performance of block 201) and/or impingement processing is to occur with the packaging intact.
At block 214, transport mechanism 5 may be configured to position the material of interest 2 relative to the impingement processing system 4 to initiate impingement processing. Positioning of the material of interest 2 can include moving the material of interest 2 at the second temperature into the appropriate impingement processing start location within the impingement processing system 4. Positioning the material of interest 2 can also or in the alternative include, without limitation, manual, automatic, and/or mechanical distribution/arrangement of the material of interest 2 comprising a plurality of sub-parts to the impingement surface. For example, material of interest 2 may comprise a case of six 2.2 kilogram (kg) poultry portions (e.g., wings), and each of the six 2.2 kg poultry portions may be distributed or arranged relative to each other. System 1 may include one or more controllers (not shown) configured to generate and communicate appropriate command signals to the transport mechanism 5 to position or align the material of interest 2 at a particular location within the impingement processing system 4.
Alternatively, block 214 may be optional if positioning of material of interest 2 is not required. For example, if both first and second processing occurs within the same device (e.g., RF processing system 3 includes impingement components of impingement processing system 4), then moving the material of interest 2 upon completion of first processing to a different device may not be required. Or if material of interest 2 is sufficiently exposed to receive heat transfer by impingement, then distribution or other positioning to facilitate desired impingement may not be required.
With the material of interest 2 in position, impingement processing system 4 may be configured to generate and apply a circulating heated gaseous medium to impinge upon the material of interest 2, at block 216. In some embodiments, steam may also be provided in block 216. The steam may comprise unsaturated, saturated, or super saturated steam. The circulating heated gaseous medium may be configured to be at a particular temperature, flow velocity, and/or volumetric flow rate. Continuing the above example of bone-in poultry, the circulating heated gaseous medium may be provided at approximately 235° C. and/or at a flow velocity in the range of approximately 10 m/s.
In some embodiments, blocks 214 and 216 may be performed simultaneously, in which the material of interest 2 may be moving within the impingement processing system 4 while surrounded by the circulating heated gaseous medium and, optionally, steam.
As impingement is in progress, one or more operating conditions associated with the impingement environment may be monitored, at block 218. For example, temperature sensor(s), moisture sensor(s), gaseous velocity sensor(s), gaseous flow direction sensor(s), and/or the like may be used to determine whether the circulating heated gaseous medium and/or steam are at desired characteristics (e.g., whether the circulating heated gaseous medium impinges on the material of interest at 235° C.).
At block 220, endpoint detection may be performed. As with block 208, the endpoint may be based on a pre-defined impingement time, an end temperature detection, location of the material of interest 2 on the transport mechanism 5, and/or the like. If endpoint is detected (yes branch of block 220), then transport mechanism 5 may be actuated to position the material of interest 2 outside of the impingement processing system 4 or otherwise stop impingement processing of the material of interest 2, at block 224. If endpoint is not detected (no branch of block 220), then one or more of the operating conditions monitored in block 218 may be adjusted, as needed, in block 222. Then process 200 may return to block 216 to continue impingement processing of material of interest 2. Additional details pertaining to impingement processing are provided in Appendix B.
One or more post-impingement processing operations can be performed at block 224. For instance, without limitation, the material of interest 2 (as a whole or in parts) can be packaged (e.g., pack each of the 2.2 kg poultry portions into reusable totes for local distribution to a spiral outfeed), maintain the material of interest 2 at the third temperature, transport the material of interest 2 to another processing device (e.g., fryer, flash freezer), prepare the material of interest 2 for shipment or storage, and/or the like.
In this manner, material of interest 2 may be at a first temperature at the start of first processing, a second temperature at the end of first processing and start of second processing, and at a third temperature by the end of second processing. In some embodiments, the first and second processing times together is less than or equal to (or does not exceed) the time to process the material of interest 2 from the first to the third temperature without RF processing and with impingement processing alone.
In alternative embodiments, one or both of blocks 208 and 220 may be optional where endpoint detection associated with RF or impingement processes, respectively, may not be implemented.
Continuing the above example of bone-in poultry, bone-in poultry that has been RF “pre-treated” or “pre-processed” by undergoing blocks 202-210 to 30-35° C. may be consecutively processed in the impingement processing system 4 operating at 235° C. with steam for 18 minutes. The bone-in poultry may have a core temperature of 85° C. ±1° C. (e.g., the third temperature) upon completion of impingement. Bone-in poultry may thus undergo dual processing totaling approximately 24 minutes, and have a processing yield greater than 75%. Processing yield, also referred to process yield, comprises a measure (e.g., percentage, ratio, etc.) of products from a process or operation that pass quality control or compliance check.
By contrast, bone-in poultry processed using just the impingement processing system 4 may have a lower processing yield than using the dual processes described above, and even if the bone-in poultry reaches a core temperature of 85° C. ±1° C. at completion of impingement process, uncooked bone marrow may be present (or more present) in the bone-in poultry than when processed using RF energy followed by impingement.
In alternative embodiments, the RF processing system 3 may operate at powers less than or greater than 4.5 kW, at approximately 3 kW, up to approximately 4.5 kW, or the like. As another example, the RF energy or signals applied to the material of interest 2 may be at 6 kW. The first, second, and/or third temperatures may be different from those discussed above. The time duration of each of the RF and impingement processes may be different from those discussed above. A time delay or gap may exist between end of RF processing and the start of impingement processing.
The convection generated and provided by the first processing system 502 comprises a circulating heated gaseous medium (e.g., air) configured to cool potential local hot/warm spots which may exist in the material of interest 2 caused by application of RF energy. In some embodiments, the air circulation or movement associated with the provided convection may of lower intensity or level than that associated with impingement provided in the second processing or than that associated with conventional convection processes. In other embodiments, air movement or circulation other than convection may be generated and provided in conjunction with RF energy/signals. The convection occurring during the first processing time period is also referred to as “light” convection, packaging-related convection, or the like.
In alternative embodiments, first processing system 502 may include air circulation components (e.g., fans) instead of convective providing components, convective providing components operated to approximate air circulation characteristics as would be generated by fans, impingement providing components operated to approximate air circulation characteristics as would be generated by fans, or the like. It is understood that reference to performance of convective processing during the first processing time period encompasses any of a variety of types or intensities/levels of air (or other gaseous medium) circulatory treatment to the material of interest 2
Second processing system 504 is configured to perform the impingement dominant processing (e.g., second processing) during the second processing time period. Second processing system 504 comprises the impingement processing system 4 or impingement processing system 4 with RF energy generating components (also referred to as a combined RF and impingement processing system). If second processing system 504 is configured as a combined RF and impingement processing system, such system includes RF and impingement processing components as discussed herein for RF and impingement processing systems 3, 4. The combined system is configured to provide intermittent or non-continuous RF energy simultaneous with impingement to the material of interest 2 during the second processing time period, as will be described below. The RF application in the second processing time period may be similar to or different from RF parameters associated with the first processing time period. The RF application during the second processing time period is also referred to as intermittent RF, non-continuous RF, or the like.
Alternatively, first and second processing systems 502, 504 together may comprise a single device or module for use during both the first and second processing time periods. In the single device configuration and if dual RF and convective processes are to be performed for the first processing, the single device/module includes both RF and impingement associated components. The impingement components may be configured to operate at a low intensity/level or in a limited capacity to approximate convective parameters during the first processing time period. Impingement may be considered to be convection at a significantly higher convective heat transfer coefficient. Alternatively, the single device may be configured to include RF, impingement, and convection generation components.
The single device/module is configured to provide RF only, impingement only, combined continuous RF and “light” convection, intermittent RF and impingement, and/or the like as will be described below. Various of the RF and impingement (and optionally convection) components may be selectively powered on/off, reduced in intensity, or not used if only one process is to be performed on the material of interest 2 during a given time period. In other words, one or more devices is configured to operate in RF processing mode, (intense) RF and (less intense) convective processing mode, impingement processing mode, or (less intense or intermittent) RF and (intense) impingement processing mode at particular time periods associated with the particular first and second processing to be performed.
Accordingly, system 1 or system 500 is configured to perform one or more of the following processing schemes or techniques.
Process 200 of
In some embodiments, blocks 601-624 are similar to respective blocks 201-224 of
Certain types of packaging included in the material of interest 2 have high dielectric constants. Examples of high dielectric constant packaging include, without limitation, plastic bags, film, or liners encasing or surrounding the actual material to be processed from the first temperature to the third temperature. The dielectric constant of plastic bags, film, or liners is higher or significantly higher than the dielectric constant of the actual material to be processed (e.g., food, meat, dough, etc.). Such plastic bags, film, or liners, in turn, may itself be provided inside a cardboard box or otherwise used in conjunction with a box or other container. In some cases, the high dielectric constant of the plastic bag, film, or liner is further increased in areas where the plastic bag, film, or liner is wadded or bunched, such as at the corners or at the top of the box/container. Wadding or bunching at the top of the plastic bag, film, or liner, for example, causes the top portion of the material being processed to be at a higher temperature relative to other portions of the material (e.g., local hot spot) in the presence of RF energy (e.g., when RF energy is applied at block 604). Non-uniform temperatures among different portions of the material of interest 2 are undesirable. Other non-uniformity in treatment can also be possible in the presence of packaging or other high dielectric constant materials.
Non-uniformity associated with packaging (and/or other high dielectric constant materials adjacent the material to be processed) present during RF energy application in the first processing time period, can be reduced or eliminated by providing air movement to the material of interest 2 and/or the space in which the material of interest 2 is located for the first processing time period (e.g., thaw tunnel). Air movement improves uniformity of RF processing to the material of interest 2 by reducing potential warm/hot spots within the material of interest 2 (material actually to be processed as well as surrounding packaging). Moving air past the warm/hot spots facilitates cooling those spots to a certain extent, thereby improving uniformity of the impact of RF energy application on different portions of the material of interest 2. Air movement can comprise a convective process.
Packaging referred to herein may encompass one or more structures surrounding the actual material to be processed such as, but not limited to, a plastic, a bag, a film, a liner, a box, a case, cardboard, a container, a fluid retaining enclosure, a high dielectric constant enclosure, an enclosure having a higher dielectric constant than the actual material to be processed, and/or the like.
Sources or conditions other than and/or in addition to packaging within the RF processing system can also contribute to undesirable treatment of the material of interest 2. In some embodiments, unintended local hot/warm spots in the material of interest 2, within the processing space (e.g., a tunnel) of the RF processing system in which the material of interest 2 is located, and/or of component(s) exposed to the processing space may be reduced, eliminated, or addressed by moving or circulating air (or other gaseous medium) to and around those areas (or through the processing space overall).
The circulating air (or other gaseous medium) may be configured to be at a particular temperature or at room/ambient temperature.
According, for the first processing time period, material of interest 2 may benefit from simultaneous application of RF and air circulation processes (e.g., convection). In some embodiments, a material of interest 2 that is void of packaging (e.g., just the product, such as meat or dough, directly processed in the first processing system 502) as well as a material of interest 2 that includes packaging (e.g., the same product, such as meat or dough, encased in packaging and processed together in the first processing system 502) may both benefit from the combination RF and convective processes performed for the first processing time period (e.g., block 601 can be performed or be optional). The combined RF and convective processes may also be referred to as simultaneous or dual RF and convective processes, continuous RF and convective processes, continuous RF and “light” convective processes, RF dominant process, RF and air circulation processes, or the like.
Returning to
For this reason, convection occurring in the first processing time period may be referred to as “light” convection at least in comparison to RF energy application at block 604 or impingement occurring in the second processing time period, and the first processing may be overall referred to as a RF dominant processing. Convective parameters associated with the circulating heated gaseous medium of block 630 are configured to facilitate cooling of potential localized warm/hot spots of the material of interest 2 (such as due to packaging) so that the material of interest 2 uniformly changes from a first temperature to a second temperature.
In some embodiments, the second processing time period benefits from application of both impingement and RF processes to the material of interest 2, instead of just impingement. One or both of material of interest 2 including packaging and material of interest 2 that does not include packaging may see improvement in treatment, uniformity, and/or processing time by simultaneous application of RF and impingement in the second processing time period. If packaging has not been removed at block 601, packaging can be removed at block 613. In alternative embodiments, block 601 and/or block 613 may be optional.
As shown in
In some embodiments, RF processing associated with block 604 is at a higher intensity or level than RF processing associated with block 640. Impingement processing associated with block 616 is at a higher intensity or level than convective processing associate with block 630. Alternatively, the intensity or level may be similar to each other, reversed, or otherwise configured depending on the desired second and third temperatures and/or material characteristics.
As an example, process 600 may be implemented to thaw a material of interest (e.g., chicken wings) quickly, automatically, and without loss of flavor, texture, etc. A major quick service restaurant may have cases or boxes of frozen chicken wings (at the first temperature) that are desirous of being thawed to a particular endpoint temperature above the chicken wings' solid-to-liquid latent zone. The chicken wings are first processed using RF and convection processes (e.g., blocks 604-612 and 630-634) to raise the product temperature to a second temperature that is just below its associated latent zone temperature. The RF and convection processes may occur as the chicken wings pass through a processing tunnel. Next, the chicken wings are secondly processed using impingement only (e.g., blocks 316-322 of
It is beneficial to configure a device or process by which a material of interest 2 can transition from solid to liquid state (also referred to as moving through the solid-to-liquid latent zone) without incurring damage, overheating, inconsistency, overly long processing time, or the like. Accordingly, for example, for a material of interest 2 to be processed through (and above) its latent zone, air is moved or circulated in a thaw tunnel (to push out stray heat from various forms of inefficiencies or undesirable impact) while RF energy is applied to change the temperature of the material of interest 2 from =18° F. to 28° F. in the first time period, then impingement is applied (either alone or with RF) to move around significant amount of air for thermal processing in the second time period, to change the temperature of the material of interest 2 from 28° F. to 34° F. In both processing time periods and within both systems 502, 504, air circulation of various characteristics occurs.
For example, as shown in
Continuing the above example of chicken wings, cases/boxes of chicken wings may be unpacked (if not already unpacked for the first processing) and 2.2 kg smaller bags of chicken wings may be distributed on the transport mechanism 702 to move through combined system 700. System 700 can be configured to take the chicken wings through its latent zone to an end temperature just above the latent zone temperature without overheating few or portions of chicken wings. Removal of chicken wings from the case/box aids in heat transfer, since boxes, cases, containers, or other enclosures around the product may act as a significant (or sufficiently significant) insulator against convective heat transfer.
As another example, RF and convective processes followed by RF and impingement processes can be implemented at respective first and second processing time periods in continuous flow operations, such as at a product processing line implemented in a warehouse. A plurality of cases of a product to be thawed is received at the warehouse. Each case may be 33 to 80 pounds, frozen at a first temperature of approximately −18 degree Fahrenheit (° F.), and include packaging having a high dielectric constant. These cases traverse a tunnel for first processing comprising simultaneous (intense) RF and (light) convective processing (e.g., blocks 604-612 and 630-634). Temperature is increased from approximately −18 degree ° F. to near the latent zone temperature associated with the product to be thawed (e.g., the second temperature).
Next, the cases are opened and a plurality of portions of the product within is distributed onto a conveyor of a device configured for second processing, such as a spiral RF and impingement device (e.g., blocks 613-614). For instance, each case may include six 2.2 kg bags of poultry. Distribution may be accomplished using mechanical, manual, and/or automatic mechanisms. The 2.2 kg bags of poultry are treated with intermittent RF in conjunction with impingement (e.g., blocks 616-622 and 640-642) to transition them through their associated latent zone. The intermittent RF aids in thawing ice while preventing overheating or product damage during the second processing time period. Lastly, the 2.2 kg bags of poultry, which are now at the third temperature just above the latent zone temperature, may be packed into reusable totes for local distribution at a spiral outfeed (e.g., block 624).
In still another example, RF and convective processes followed by RF and impingement processes can be implemented at respective first and second processing time periods in a small batch RF and impingement processing unit, such as may be implemented in a quick service restaurant. A case of a product to be thawed is placed in the processing unit configured for simultaneous intense RF and light convection processing mode (e.g., the first processing). The case of the product to be thawed may be 33 to 80 pounds, frozen at a first temperature of approximately −18° F., and include packaging having a high dielectric constant. Temperature is increased from approximately −18 degree ° F. to near the latent zone temperature associated with the product to be thawed (e.g., the second temperature).
Next, the case is opened and a plurality of portions of the product within is distributed within the processing unit (e.g., the same small footprint unit as used for first processing operations). The plurality of portions of the product may include size 2.2 kg bags of poultry, for example. The plurality of portions of the product is distributed within the processing unit to facilitate impingement. Distribution may be accomplished using mechanical, manual, and/or automatic mechanisms.
The 2.2 kg bags of poultry are treated with intermittent RF in conjunction with constant impingement (e.g., blocks 616-622 and 640-642) to transition them through their associated latent zone. The intermittent RF aids in thawing ice while preventing overheating or product damage during the second processing time period. Lastly, the 2.2 kg bags of poultry, which are now at the third temperature just above the latent zone temperature, may be held at the third temperature (e.g., the end or target temperature) until needed. When needed, one or more of the thawed 2.2 kg bags of poultry is provided to the appropriate device for further processing, such as being moved to a restaurant fryer for deep frying.
In some embodiments, blocks 801-824 and 830-834 are similar to respective blocks 601-624 and 630-634 of
As an example, if the material of interest 2 will not be transitioning through its latent zone as it is processed from the start temperature to the desired end temperature, then process 800 or 300 may be appropriate for processing such material of interest 2.
In some embodiments, blocks 901-924 and 940-942 are similar to respective blocks 601-624 and 640-642 of
As an example, without limitation, material of interest 2 with no packaging (e.g., removed at block 901) or having packaging at a lower dielectric constant (at least low enough not to incur hot/warm spots associated with undesirable temperature non-uniformity) may not require air movement (e.g., convection) during RF application in the first processing time period. Hence, RF only processing of blocks 904-912 may be sufficient to achieve the desired second temperature and without adverse impact on the material of interest 2. Then if it is desirous for such material of interest 2 to transition through its latent zone to reach the third/end temperature, then the RF and impingement combined processes of the rest of process 900 can be performed.
It is understood that RF energy applied for second processing may alternatively be continuous, of similar intensity as the RF energy applied for the first processing, of higher intensity than the RF energy applied for the first processing, and/or the like for processes 600 and/or 900. It is also understood that air movement provided in the first processing in processes 600 and/or 800 is not limited to convection and may be achieved by a variety of other air circulation mechanisms, such as using impingement units or the like.
Illustrative examples of the apparatuses, systems, and methods of various embodiments disclosed herein are provided below. An embodiment of the apparatus or system may include any one or more, and any combination of, the examples described below.
1. A method comprising:
positioning a load at a first temperature to electrically couple with a radio frequency (RF) processing system;
applying, for a first time period, a RF signal to the load to change a temperature of the load from a first temperature to a second temperature;
positioning the load at the second temperature within an impingement processing system; and
circulating a heated gaseous medium to the load to change the temperature of the load from the second temperature to a third temperature,
wherein the first and second time periods together is less than or equal to a time period for the load to change from the first temperature to the third temperature from only impingement processing.
2. The method of clause 1, further comprising:
determining whether an endpoint with respect to RF processing is detected; and
if the determination is affirmative, positioning the load within the impingement processing system.
3. The method of any of clauses 1-2, wherein determining whether the endpoint is detected comprises determining whether the endpoint is detected based on a reflected power level.
4. The method of any of clauses 1-3, wherein determining whether the endpoint is detect comprises determining whether the RF signal has been applied to the load for a particular amount of time.
5. The method of any of clauses 1-4, wherein circulating the heated gaseous medium around the load comprises transitioning the load through a solid-to-liquid phase transition latent zone associated with the load.
6. The method of any of clauses 1-5, further comprising circulating steam around the load simultaneous with circulating the heated gaseous medium around the load.
7. The method of any of clauses 1-6, wherein the RF signal is at 4.5 kiloWatt (kW).
8. The method of any of clauses 1-7, wherein the second temperature is higher than the first temperature and the third temperature is higher than the second temperature.
9. The method of any of clauses 1-8, wherein the first temperature is 5 degree Celsius (° C.), the second temperature is 30-35° C., and the third temperature is 85° C.
10. The method of any of clauses 1-9, wherein applying the RF signal to the load comprises applying the RF signal to the load consecutively to circulating the heated gaseous medium to the load.
11. The method of any of clauses 1-10, wherein circulating the heated gaseous medium to the load comprises circulating the heated gaseous medium to the load after a time delay after the load is at the second temperature.
12. The method of any of clauses 1-11, wherein the load comprises food, bone-in meat, or bone-in poultry.
13. The method of any of clauses 1-12, wherein applying the RF signal to the load comprises changing an energy content of the load, and wherein the first and second temperatures are the same.
14. The method of any of clauses 1-13, wherein positioning the load at the first temperature comprises continuously moving the load through the RF processing system and positioning the load at the second temperature comprises continuously moving the load through the impingement processing system.
15. The method of any of clauses 1-14, wherein the second temperature is within a few degrees below or a temperature of a latent zone associated with the load, one or both of the second and third temperatures are within a few degrees of the latent zone associated with the load, or the second temperature is a temperature near a first end of the latent zone associated with the load and the third temperature is a temperature near a second end, opposite the first end, of the latent zone associated with the load.
16. A system comprising:
a first unit configured to generate and apply radio frequency (RF) energy to a load positioned in the first unit during a first time period, wherein the load is at a first temperature at a start of the first time period and at a second temperature different from the first temperature at an end of the first time period; and
a second unit configured to receive the load at the second temperature and to cause heat transfer by impingement to the load during a second time period different from the first time period, wherein the load is at a third temperature at an end of the second time period,
wherein a processing yield associated with the load is higher than if the load undergoes impingement processing to change from the first temperature to the third temperature.
17. The system of clause 16, wherein the second temperature is higher than the first temperature, the third temperature is higher than the second temperature, the second and third temperatures are the same, the second and third temperatures are approximately the same, one or both of the second or third temperatures is at or near a temperature of a solid-to-liquid phase transition latent zone associated with the load, or the second temperature is a temperature near a first end of the solid-to-liquid phase transition latent zone and the third temperature is a temperature near a second end, opposite the first end, of the solid-to-liquid phase transition latent zone.
18. The system of any of clauses 16-17, wherein the second unit is configured to transition the material through a solid-to-liquid phase transition latent zone associated with the load.
19. The system of any of clauses 16-18, wherein the first unit is further configured to generate and provide air circulation to the load during the first time period.
20. The system of any of clauses 16-19, wherein the air circulation comprises convection.
21. The system of any of clauses 16-20, wherein the second unit is further configured to generate and apply a second RF energy different from the RF energy to the load during the second time period.
22. A system comprising:
a first device that includes first radio frequency (RF) signal generation components and first gaseous medium circulation generation components, the first device configured to simultaneously provide first RF processing and first gaseous medium circulatory processing to a material of interest for a first time period; and
a second device that includes second impingement generation components, the second device configured to provide second impingement processing to the material of interest for a second time period after the first time period,
wherein the material of interest changes from a first temperature to a second temperature during the first time period and from the second temperature to a third temperature during the second time period.
23. The system of clause 22, wherein the first gaseous medium circulation generation components are the same as the second impingement generation components and the gaseous medium circulation generation components are operated at a lower intensity or level than the second impingement generation components, or the first gaseous medium circulatory processing comprises air circulation.
24. The system of any of clauses 22-23, wherein the second device further includes second RF signal generation components, the second device further configured to simultaneously provide second RF processing and the second impingement processing to the material of interest for the second time period.
25. The system of any of clauses 22-24, wherein the second RF processing comprises intermittent RF processing.
26. The system of any of clauses 22-25, wherein the second RF processing is of a lower intensity or level than the first RF processing.
27. The system of any of clauses 22-26, wherein the first and second devices are the same device.
28. The system of any of clauses 22-27, wherein the first and second devices are different devices and the material of interest is moved from the first device to the second device to receive the simultaneous second RF processing and the second impingement processing.
29. The system of any of clauses 22-28, wherein the second temperature is higher than the first temperature, the third temperature is higher than the second temperature, the second and third temperatures are the same, the second and third temperatures are approximately the same, one or both of the second or third temperatures is at or near a temperature of a solid-to-liquid phase transition latent zone associated with the material of interest, or the second temperature is a temperature near a first end of the solid-to-liquid phase transition latent zone and the third temperature is a temperature near a second end, opposite the first end, of the solid-to-liquid phase transition latent zone.
30. The system of any of clauses 22-29, wherein the material of interest comprises a material, to be changed from the first temperature to the third temperature, and packaging surrounding the material, and wherein the packaging surrounding the material comprises one or more of a plastic, a bag, a film, a liner, a box, a case, cardboard, a container, a fluid retaining enclosure, or a high dielectric constant enclosure.
31. A system comprising:
a first device that includes first radio frequency (RF) signal generation components, the first device configured to provide first RF processing to a material of interest for a first time period; and
a second device that includes second RF generation components and second impingement generation components, the second device configured to simultaneously provide second RF processing and second impingement processing to the material of interest for a second time period after the first time period,
wherein the material of interest changes from a first temperature to a second temperature during the first time period and from the second temperature to a third temperature during the second time period.
32. The system of clause 31, wherein the second RF processing is of a lower intensity or level than the first RF processing.
33. The system of any of clauses 31-32, wherein the second RF processing comprises intermittent RF processing.
34. The system of any of clauses 31-33, wherein the first device further includes first gaseous medium circulatory processing, the first device further configured to simultaneously provide first gaseous medium circulatory processing and the first RF processing to the material of interest for the first time period.
35. The system of any of clauses 31-34, wherein the first and second devices are the same device.
36. The system of any of clauses 31-35, wherein the first and second devices are different devices and the material of interest is moved from the first device to the second device to receive the simultaneous second RF processing and the second impingement processing.
37. The system of any of clauses 31-36, wherein the first gaseous medium circulatory processing is of a lower intensity or level than the second impingement processing, the first gaseous medium circulatory processing comprises convective processing, or the first gaseous medium circulatory processing comprises air circulation.
38. The system of any of clauses 31-37, wherein the second device is configured to transition the material of interest through a solid-to-liquid phase transition latent zone associated with the material of interest.
39. The system of any of clauses 31-38, wherein the second temperature is higher than the first temperature, the third temperature is higher than the second temperature, the second and third temperatures are the same, the second and third temperatures are approximately the same, one or both of the second or third temperatures is at or near a temperature of a solid-to-liquid phase transition latent zone associated with the material of interest, or the second temperature is a temperature near a first end of the solid-to-liquid phase transition latent zone and the third temperature is a temperature near a second end, opposite the first end, of the solid-to-liquid phase transition latent zone.
40. The system of any of clauses 31-39, wherein the material of interest comprises a material, to be changed from the first temperature to the third temperature, and packaging surrounding the material, and wherein the packaging has a higher dielectric constant than the material.
41. A system comprising:
a first unit configured to generate and apply radio frequency (RF) energy and air circulation to a load positioned in the first unit during a first time period, wherein the load is at a first temperature at a start of the first time period and at a second temperature different from the first temperature at an end of the first time period; and
a second unit configured to receive the load at the second temperature and to cause heat transfer by impingement to the load during a second time period different from the first time period, wherein the load is at a third temperature different from the second temperature at an end of the second time period,
wherein at least one of the second or third temperatures is at or near a temperature of a solid-to-liquid phase transition latent zone associated with the load.
42. The system of clause 41, wherein the second unit is configured to transition the material through the solid-to-liquid phase transition latent zone associated with the material.
43. The system of any of clauses 41-42, wherein the air circulation comprises convection.
The above description of illustrated embodiments of the claimed subject matter, including what is described in the Abstract, is not intended to be exhaustive or to limit the claimed subject matter to the precise forms disclosed. While specific embodiments of, and examples for, the claimed subject matter are described herein for illustrative purposes, various modifications are possible within the scope of the claimed subject matter, as those skilled in the relevant art will recognize.
These modifications can be made to the claimed subject matter in light of the above detailed description. The terms used in the following claims should not be construed to limit the claimed subject matter to the specific embodiments disclosed in the specification. Rather, the scope of the claimed subject matter is to be determined entirely by the following claims, which are to be construed in accordance with established doctrines of claim interpretation.
This application claims the benefit of U.S. Provisional Patent Application No. 62/566,183 filed Sep. 29, 2017, the disclosure of which is incorporated herein by reference in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2018/053802 | 10/1/2018 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62566183 | Sep 2017 | US |
