CA1150095A - Efficient high humidity food processing system with sanitizing improvements - Google Patents
Efficient high humidity food processing system with sanitizing improvementsInfo
- Publication number
- CA1150095A CA1150095A CA000356856A CA356856A CA1150095A CA 1150095 A CA1150095 A CA 1150095A CA 000356856 A CA000356856 A CA 000356856A CA 356856 A CA356856 A CA 356856A CA 1150095 A CA1150095 A CA 1150095A
- Authority
- CA
- Canada
- Prior art keywords
- heating
- water
- spray
- food
- belt
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 235000013305 food Nutrition 0.000 title claims abstract description 96
- 238000012545 processing Methods 0.000 title claims abstract description 51
- 238000011012 sanitization Methods 0.000 title claims abstract description 34
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 75
- 239000007921 spray Substances 0.000 claims abstract description 59
- 238000010438 heat treatment Methods 0.000 claims abstract description 48
- 238000000034 method Methods 0.000 claims abstract description 47
- 238000004140 cleaning Methods 0.000 claims abstract description 38
- 239000003599 detergent Substances 0.000 claims abstract description 32
- 230000008569 process Effects 0.000 claims abstract description 30
- 238000011109 contamination Methods 0.000 claims abstract description 11
- 235000013372 meat Nutrition 0.000 claims abstract description 9
- 244000144977 poultry Species 0.000 claims abstract description 8
- 241000251468 Actinopterygii Species 0.000 claims abstract description 7
- 239000007788 liquid Substances 0.000 claims abstract description 7
- 230000037361 pathway Effects 0.000 claims abstract description 6
- 238000010411 cooking Methods 0.000 claims description 40
- 238000001816 cooling Methods 0.000 claims description 31
- 238000005086 pumping Methods 0.000 claims description 10
- 241000894006 Bacteria Species 0.000 claims description 7
- 230000018044 dehydration Effects 0.000 claims description 6
- 238000006297 dehydration reaction Methods 0.000 claims description 6
- 238000009825 accumulation Methods 0.000 claims description 5
- 230000009471 action Effects 0.000 claims description 5
- 239000000686 essence Substances 0.000 claims description 5
- 238000012163 sequencing technique Methods 0.000 claims description 4
- 239000003595 mist Substances 0.000 claims description 2
- 230000035515 penetration Effects 0.000 claims description 2
- 238000005507 spraying Methods 0.000 claims description 2
- 238000005406 washing Methods 0.000 claims description 2
- 238000010025 steaming Methods 0.000 claims 2
- 125000004122 cyclic group Chemical group 0.000 claims 1
- 238000007599 discharging Methods 0.000 claims 1
- 238000007781 pre-processing Methods 0.000 claims 1
- 238000004321 preservation Methods 0.000 claims 1
- 238000009736 wetting Methods 0.000 claims 1
- 230000000737 periodic effect Effects 0.000 abstract description 3
- 239000010794 food waste Substances 0.000 abstract description 2
- 108090000623 proteins and genes Proteins 0.000 abstract description 2
- 102000004169 proteins and genes Human genes 0.000 abstract description 2
- 238000005201 scrubbing Methods 0.000 abstract description 2
- 239000000047 product Substances 0.000 description 51
- 239000000796 flavoring agent Substances 0.000 description 10
- 235000019634 flavors Nutrition 0.000 description 10
- 230000007812 deficiency Effects 0.000 description 7
- 235000013594 poultry meat Nutrition 0.000 description 6
- 235000019587 texture Nutrition 0.000 description 5
- 208000005156 Dehydration Diseases 0.000 description 4
- 238000007710 freezing Methods 0.000 description 4
- 230000008014 freezing Effects 0.000 description 4
- 238000003860 storage Methods 0.000 description 4
- 238000007791 dehumidification Methods 0.000 description 3
- 235000019688 fish Nutrition 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 241000287828 Gallus gallus Species 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 235000011389 fruit/vegetable juice Nutrition 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 235000015255 meat loaf Nutrition 0.000 description 2
- 235000013622 meat product Nutrition 0.000 description 2
- 238000003672 processing method Methods 0.000 description 2
- 230000005855 radiation Effects 0.000 description 2
- 238000005057 refrigeration Methods 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- NSMXQKNUPPXBRG-SECBINFHSA-N (R)-lisofylline Chemical group O=C1N(CCCC[C@H](O)C)C(=O)N(C)C2=C1N(C)C=N2 NSMXQKNUPPXBRG-SECBINFHSA-N 0.000 description 1
- 101100506443 Danio rerio helt gene Proteins 0.000 description 1
- 101100506445 Mus musculus Helt gene Proteins 0.000 description 1
- 241001674048 Phthiraptera Species 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 102100028079 Uncharacterized protein C20orf144 Human genes 0.000 description 1
- 101710189798 Uncharacterized protein C20orf144 Proteins 0.000 description 1
- 235000014787 Vitis vinifera Nutrition 0.000 description 1
- 240000006365 Vitis vinifera Species 0.000 description 1
- 238000010420 art technique Methods 0.000 description 1
- 210000000988 bone and bone Anatomy 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 230000001143 conditioned effect Effects 0.000 description 1
- 230000001351 cycling effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 235000013332 fish product Nutrition 0.000 description 1
- 235000019601 food appearance Nutrition 0.000 description 1
- 235000011194 food seasoning agent Nutrition 0.000 description 1
- 230000036571 hydration Effects 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- 235000015250 liver sausages Nutrition 0.000 description 1
- 229920000136 polysorbate Polymers 0.000 description 1
- 235000013613 poultry product Nutrition 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- WQGWDDDVZFFDIG-UHFFFAOYSA-N pyrogallol Chemical compound OC1=CC=CC(O)=C1O WQGWDDDVZFFDIG-UHFFFAOYSA-N 0.000 description 1
- 235000021067 refined food Nutrition 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000013049 sediment Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000001954 sterilising effect Effects 0.000 description 1
- 238000004659 sterilization and disinfection Methods 0.000 description 1
- 239000013589 supplement Substances 0.000 description 1
- 230000001502 supplementing effect Effects 0.000 description 1
- 235000019640 taste Nutrition 0.000 description 1
- 235000013311 vegetables Nutrition 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23B—PRESERVATION OF FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES; CHEMICAL RIPENING OF FRUIT OR VEGETABLES
- A23B2/00—Preservation of foods or foodstuffs, in general
- A23B2/40—Preservation of foods or foodstuffs, in general by heating loose unpacked materials
- A23B2/42—Preservation of foods or foodstuffs, in general by heating loose unpacked materials while they are progressively transported through the apparatus
- A23B2/425—Preservation of foods or foodstuffs, in general by heating loose unpacked materials while they are progressively transported through the apparatus in solid state
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23B—PRESERVATION OF FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES; CHEMICAL RIPENING OF FRUIT OR VEGETABLES
- A23B4/00—Preservation of meat, sausages, fish or fish products
- A23B4/005—Preserving by heating
- A23B4/0053—Preserving by heating with gas or liquids, with or without shaping, e.g. in form of powder, granules or flakes
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47J—KITCHEN EQUIPMENT; COFFEE MILLS; SPICE MILLS; APPARATUS FOR MAKING BEVERAGES
- A47J37/00—Baking; Roasting; Grilling; Frying
- A47J37/04—Roasting apparatus with movably-mounted food supports or with movable heating implements; Spits
- A47J37/045—Roasting apparatus with movably-mounted food supports or with movable heating implements; Spits with endless conveyors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
- B08B3/02—Cleaning by the force of jets or sprays
- B08B3/022—Cleaning travelling work
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P60/00—Technologies relating to agriculture, livestock or agroalimentary industries
- Y02P60/80—Food processing, e.g. use of renewable energies or variable speed drives in handling, conveying or stacking
- Y02P60/85—Food storage or conservation, e.g. cooling or drying
Landscapes
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Food Science & Technology (AREA)
- Wood Science & Technology (AREA)
- Zoology (AREA)
- Chemical & Material Sciences (AREA)
- Polymers & Plastics (AREA)
- Commercial Cooking Devices (AREA)
- Meat, Egg Or Seafood Products (AREA)
- Baking, Grill, Roasting (AREA)
Abstract
ABSTRACT
Food products such as produce, fish, meat and poultry are rapidly cooked and chilled in separate units through which a continuously running conveyor belt passes in a spiral pathway to conserve cabinet space and produce energy efficient operation. Water is used as the heating and chilling medium in 100% humidity steam and cold humid air atmospheres respectively preferably at a pressure above atmospheric. This keeps all equipment surfaces moist and not readily contaminated by dried, accumulated, burnt on drippings, fat, proteins or other food residues. Thus, the sanitization process is simplified. The system operates with the conveyor belt continuously running in both food processing and mechanical sanitizing modes. The latter mode includes continuous cleaning of the belt and a periodic sanitation cycle with the food processing system shut down. The sanitization is achieved by jet spray scrubbing with warm water and detergent solution and circulation through the system.
Spiral belt paths of both chiller and cooker units are scanned by a rotary jet spray within the spiral.
Sanitization of the entire system simultaneously prevents any re-contamination of one section by residue from another and saves time, cleaning liquids and energy.
Food products such as produce, fish, meat and poultry are rapidly cooked and chilled in separate units through which a continuously running conveyor belt passes in a spiral pathway to conserve cabinet space and produce energy efficient operation. Water is used as the heating and chilling medium in 100% humidity steam and cold humid air atmospheres respectively preferably at a pressure above atmospheric. This keeps all equipment surfaces moist and not readily contaminated by dried, accumulated, burnt on drippings, fat, proteins or other food residues. Thus, the sanitization process is simplified. The system operates with the conveyor belt continuously running in both food processing and mechanical sanitizing modes. The latter mode includes continuous cleaning of the belt and a periodic sanitation cycle with the food processing system shut down. The sanitization is achieved by jet spray scrubbing with warm water and detergent solution and circulation through the system.
Spiral belt paths of both chiller and cooker units are scanned by a rotary jet spray within the spiral.
Sanitization of the entire system simultaneously prevents any re-contamination of one section by residue from another and saves time, cleaning liquids and energy.
Description
~l~5~ 5 EFFICIENT HIGH H~MIDITY FOOD PR~CESSING
SYS M WITH SANITIZING IMPROVEMENTS _ Technical Field This invention relates to industrial food processing systems for cooking and chilling food products carried on continuously running conveyor belts and more particularly it relates to such systems which include sanitizing means operable to clean said units and belts~
Back~round Art Industriai cookers and chillers are known in the art which pass food products therethrough on a continuously running conveyor belt. Also sanitizing equipment and features are commonly used whenever food is processed.
Cooking techniques which help preserve product charac-teristics are also known.
Examples of typical prior art techniques are as ~ollows:
Conveyor type freezing and broiling apparatus in stainless steel cabinets with access doors permitting internal manual cleaning has been marketed by Certified Manufacturing, Inc. of Lynwood, Caliornia 90262.
Spiral type conveyor paths in a freezing unit cix-culating cold dry air about a product and having associated belt sanitation equipment is disclosed in U.S. Patent 3 412 476 - S. Astrom - Nov. 26, 1968.
Certain techniques resolving deficiències in cooking and cooling food products are known in batch type fooa processing equipme~t where batches are placed in an oven or freezer as long as necessary for processing. Thus, U.S. Patent 3 597 228 - M. R. Jeppson - Aug. 3, 1971 introduces steam into a microwave oven to reduce loss of water from the product and cooks in a hot oil bath to brown the produc~.
Similarly, U.S. Patent 2 846 318 - E~ J. ~elley et al.
- Aug. 5, 1958 introduces humidity in a low pressure freezing gas atmosphere to reduce dehumidification.
However, many unresolved problems remain in the prior art food processing systems, particularly where large ~ ~
.. v ~
.
volumes of food are rapidly processed on a continuously running conveyor passing through cooking and chilling units.
One order of problems relates to energy efficiency.
In many cooking systems hot gases escape, radiation losses - are large, particularly where large heated surface areas exist. In both cooking and heating systems there is generally~an inefficiency in heat interface surfaces be-tween the heating medium and the food product, requiring a significant expenditure of energy without achieving the end result intended. Particularly there is a lack of acceptable solutions available to the energy losses generally caused by the entrance and exit of the conveyor belt from the cooking and chilling units.
Another order of problems relates to food appearance, taste and texture. It is difficult to avoid losses of moisture and food essences in the drying atmosphere of heating ovens and chillers, which both by nature tend to dehy`drate a product. Thus, a meat, fish or poultry product in particular will tend to change shape and appearance as well as to lose flavor and moisture in both cooking and cooling processes. Complete uni~orm cooking throughout without unwanted c~ange to the food texture has been difficult to attain particularly when rapid processing is required in ind~strial type food processors.
Yet another set o~ problems comes with the requirement to process food in a sanitary and sanitizable environment.
In most systems a disproportionate time span ana inef~iciency of energy is spent in tearing down a prod~ction line for sanitization. Cooking in particular tends to burn on, dry out and accumulate`drippings, proteins and other food contamination resulting in unsightly and unsanitary equip-ment. Also complex equipment has surfaces and interfaces difficult to reach and in warm or protected places where bacteria can breed.
Accordingly, it is an object of this invention to provide improved food processing equipment resolving the foregoing deficiencies of the prior art.
. . .
Ci95 Various techniques are known for the processing of food products such as fish, meat, poultry or produce through cook;ng and cooling cycles. For example, the continuous flow of products on conveyors with elongated paths in the form of spirals or the like through cookers or coolers is represented by the following prior art:
U.S. Patent 3 412 476 ~ S. Astrom - Nov.. 26, 1968 prcvides a spiral conveyor through a reezer compartment which employs refrigerated dry air.
Cert;fied Manufacturing, Inc. of Lynwood~ California has commercially supplied contin~ous flow conveying systems for gas heated cooking and freezing of food products passed along a flow path~
U.S. Patent 3 982 481 - E. T. Console et al. -Sept. 28, 1976 shows a continuous conveyor type steam heat-ng line'for blanchi'ng produce.
Also various cooking techniques are-known in the art for treating the food products for texture, color, sanita-tion and flavor, as well as speed of cookLng and efficiency of t~e treatment process. Representative art is:
U.S. Pa~ent 3 597 228 - M~ ~ Jeppson et al. - Aug. 3, 1~71 whlch supplements steam cooking with'special micro-waves and hot oil treatment to color bones and skin in poultry and to prepare a precoo]kins step in a chicken product with'the objective of improved flavor, coloration and sterilization resulting in a packaged product.
U.S. Patent 2 846 318 -'E. J. Kelly et al~ - Aug. 5, 1958 provides low pressure water vapor in ~ freezer to reduce d~hydration of a chilling process.
U.S. Patent 4 058 635 - W. Durth - Nov. 15, 1977 treats foodstuffs in an oven with steam or water spray after cooking begins to prevent dehydration during cooXing.
U.S. Patent 998 236 - L. Detoy et al. - July 18, 1911 which has a spiral conveyor withi'n a processing chamber for processing raisins with controls for passing air or steam under controlled atmospheric conditions within the chamber.
~ 5~395 In all these and other known prior art systems there are several deficiencies which need be corrected in an improved system.
One deficiency is the coo~ing-cooling-product through-put efficiency. Various losses in the continuous typesystems are encountered not only by inefficient use of energy in various steps but also by combining in a flow process incompatible techniques which'require significant losses of energy or time at interfaces and thus significant-ly increase the'processing cost per element of product,which'for example'may be a vegetable, a piece of meat, fish chicken, prepared meatloaf, or the like.
Another de~iciency is sanitation, since ease of clean-ing, lack of'accumulated product or processing ingredient waste'and supervisory agency approval of food processes is critical to any processing of food products.. The accumulation of dirt, bacteria,. or down time'for cleaning is critical. . . .
A critical deficiency is t'he 'flavor, texture and appearance'of'the''processed product. Not only is dehydra-tion critical' in almost any product,'but flavor, tenderness, color with'uniformity under all conditions must be critically .
controlled.. For ex'ample the: herei'n~efore described systems and techniques all 'fail to produce a system t~at produces uniformly sterile products of pleasing appearance because of specific deficiencies such'as uneven cooking at various depths particularly when products such as poultry may have a fatty insulating outside skin. Many processes produce blemishes ~ecause of drippings-or non-uniform product be-cause of complex controls of many variables during theprocess.
Another deficiency is the lack of simplicity of heat-chi'll methods. Where additional steps and complexities are added more difficulties are'encountered in maintaining product uniformity and sanitation as well as energy efficien`cy~
Thus it is an objective of this invention to provide improved food processing methods correcting the aforesaid deficiencies and producing an efficient and rapid cooking-cooling process that produces uniform high quality and sterile processed food products.
,Brief Disclos~re''o'f' the Invention This invention improves the state of the prior art by both cooking and chilling food products such as fish, meat, poultry and produce in an atmosphere'approaching 100%
humidity by use of water carried`in gaseous form about the product as it is carried on a continuously moving conveyor belt. The water is ;n the`'form of steam for cooking and - co.ld moist air for chilling to a product temperature approachi'ng 0C. Because'of thi's moist environment con-' taminating residue 'does not tend to dry, harden or burn onto equipment surfaces there~y`maki'ng ~ea'sible simple mechanical sanitization techn'iques. Also loss of moisture juices and essences from the''product is prevented resulting in be~ter' flavor. In particular the 'heat'interchange between ~he'water processing medium and the'food product is efficient and reduces processing energy.
The ~ot cooked food product is immedlately introduced on.a common conveyor bel't'into a chi'lling unit to prevent - any chance'to come.'into contact with'contamination or to . be 'in a warm environment-long enough'to breed bacteria, as is thb'case 'in ~atch processing reguiring transfer of the product from a cooker'to a chi'ller.
Sanitary.features include'a continuously sanitized moving,conveyor bel`t and..an automatically cycling detergent bath'system for periodic'cleaning of the entire food pro-cessing equipment at one time~
Thus, the 'system is operated in two modes, namely a food processing mode and a sanitation mode with the conveyor belt running'continuously in ~oth'modes. There is no carry '35 over contamination from one'unit to the other as in the manual or sequential cleaning of a food processing system.
9~
To obtain proper product dwell time in relatively small processing unit cabinets for cooking and chilling the conveyor belt îs in a spiral path giving other operational advantages such as efficient energy transfer in both cook-ing and chilling. Thi's permits small insulated coo~ing and ,chilling cabinets with fax less energy loss from radiationand attrition. The-spiral path is cleaned in the sanitizing mode by rotary jet spray nozzles rotated within the spirals as the belt moves.
lO' This invention further provides for the cooking and cooling in a consecutive 'sequence 'along a single product flow line'of food products such'as meats, produce, etc., and . is particularly adapted for the'cooking of spareribs, short ribs, unskinned chi'cken, poul1:ry pieces, etc. The coo~ing 15 ' is solely by steam in a cooker with'pressure maintained ..
, . above atmospheric pressure at near 100% humidity and 99C~
.~ ~ ` The'cooling is ~olely by circulation of cold humid air in a cooler at a pressure. above `~tmospheric at near lO0~
humidity at a temperature'less than 5C. The products are : 20 continùously pas'sed along.a conveyor flow line through the steamer and chiller in a completely sanitary process to be'fully cooked (if desired) and chi'Iled for cold storage ; without de~dration at hi~h energy efficiency, speed and ., volumQ. .
: .
Thus broadly, the invention contemplates a food processing system for heating and chilling unpackaged food products, such as fish, meat, poultry and produce, passing in sequence on a common.conveyor belt through heating and chilling stations which comprises, in combination, a continuously running single conveyor belt passing commonly through food loading, cooking, chilling and unloading stations, a heating chamber having a heating spiral conveyor belt path therethrough for carrying the unpackaged food products loaded at the loading station, a chilling chamber separately disposed from the heating chamber having a cooling spiral conveyor belt path therethrough for carrying the unpackaged food products on the belt heated in the heating chamber to present chilled food products at the unloading station, steam heat means for heating the products on the heating spiral with water carried solely in gaseous form in a steam bath at a temperature approaching 100C, and a humidity approaching lO0~ without loss of moisture and food essences in the unpackaged food products and, a mechanically operable sanitizing system for the heating and chilling chambers including means for pumping and spraying detergent solutions inside the chambers over the spiral pathway of the conveyor belt therethrough.
The invention also includes the above system wherein the mechanically operable sanitizing system incluaes rotatable spray nozzle means extending within the spiral belt paths respectively inside the heating and chilling chambers to rotate and scan the spray about the insides of the chambers, and means operating both the rotatable spray means in a cleaning mode simultaneously.
--8~
In a further embodiment, the invention can include a system wherein the chilling chamber has chilling means circulating cold water through spray atomi~er means and a fan circulating cold humid air from the spray region to contact food products on the spiral conveyor belt path, and the mechanical sanitizing system is operated together with the chilling chamber means for circulating water and air, thereby to pass sanitizing solution through the chilling means for the chilling chamber.
The invention also contemplates a method of sanitizing a food processing s~vstem which changes food temperature in at least one food processing unit b~ carrying food products through the unit on a conveyor belt having grating aperture structure therethrough and the-method comprises the steps of pumping a warm cleaning liquid at a pressure in the order of at least 100 psi (690k Pa) to a spray nozzle set positioned adjacent the conveyor belt, moving the belt past the spray nozzle set, and directing the spray nozzle set to release the detergent in a jet cleaning action against the moving belt.
~0 Flavor and texture is protec'ted and heating-chilling efficiency is~ increase~ by the' humid atmosphere, wh'ich is stripped of water droplets to preve'n~ contamination or bad appearance.'' Other features, advantages and objects of the invention ~:S will be found t~roughout the fo'llowing. text and the accom-panying drawings.
9~
BrieE DescriF~tion of the Drclwillgs Figure 1 is a schemati.c system diagram of the coo~er-chiller-sanitization system afforded by this invention;
Figure 2 is an opera-ti.onal` mode chart showing the sanitation and food processing mode control cycles operations in the system of Figure l; and Figures 3 to 6 are diagrammatic views of the various parts of the system of Figure 1 shown in respective sequential order from i.llpUt of a raw pl c ~ ct to o ~ItpUt lQ of a cooked and chilled product through the cooker unit of Figure 4 and the chiller unit of Figure 5.
~.~s~ass Detailed Descri tion of the Preferred Embodiment P
As may be seen in the system view of Figure 1, a continuously running conveyor belt 12 feeds raw food products 12 loaded on the belt at an input station 20 through the cooker 40 and the chiller 50 to the output station 70 at which the cooked food products 12' are unloaded. The belt passes the products at a belt speed controlled by variable speed drive means 14 so that the dwell time in cooker 40 cn belt spiral 16 permits thorough cooking throughout to a temperature approaching 100C if desired and similarly a chill dwell time on spiral belt path 18 thro~gh the chiller 50 permits the hot cooked product to ~e chilled immediately without chance for contamination or bacteria growth to a t`emperature approach-1~ ing 0C, if desired.
The atmospheire in ~oth cooker and'chiller is kept near100% humidity there~y to assure efficient thermal exchange con~act bet'ween respectively hot water in the form of steam and cold water carried by cold humid air about thP
products on the spiral belts. This prevents any dehumidi-fication of the product as weLl and keeps all equipment humid'so tha'~ any drippings or food residues do not burn, dry out or accumulate, thereby facilitating sanitation.' The heater 40 has two 60urces of steam, namel'y an internal pool of water 41 heated by a heat-er 42 and an external steam generator 43. The products are spiraled upwardly so that if they are fatty, such as with spare ribs, fewer drippings will drop on the cooked food products as they spiral upwardly to leave the cooker unit 40. The simplè cooker unit has insulated walls and plain int'erior stainless steel surfaces for ready sanitization and'little tenden'cy to form accumulated deposits of cooking res;dues.
.. .. .. . .. . . . . . . . . ... . .
~5~B95 The chiller 50 has refrigerated , water from refrigerator 51 passed by pipe 52 into atomizer sprays 53 so that the fan 54 can direct cold moist air upwardly through tne spiral 18 in an efficient heat ex- :
chan~e wnere cooler products on the lower part of t~.e ' spiral 18 encounter the cooler air exiting the fan 54 r' thus permitting efficient heat exchange a~ the upper part :
of ~he spiral 18 where the hot cooked products enter. The ,~
pump 55 recirculates the ~old water through refrigerator 51 ?;
t~ replace the energy lost in cooling the products.
By using spiral conveyor paths and the water as a heat :~' exchange medium in the,cooker 40 and chiller 50, small r~
cabinets are used for a large'~hroughput of,food products.
This significantly red~ces energy losses in heating up or cooling down a larger cabinet structure with attendan~ ' radiation and condensation losses over greater surface areas, and thus provides Lmproved operating econom~.
' In the bel't return path toutside the chiller and cooker) at least two sanitizing spray bath stations 60 and 30 are posi~ioned for respectively washing the'belt with a detergent spray and rinsing with water. The belt, which is preferably a stainless,steel grating type belt is scrubbed by the spray nozzles 61, 31 with a jet scrubbing action on and through the moving ~,eltO The liquid is received in basins 62, 32 and circulated by pumps 63, 33 continuously whenever thb belt moves. The water and detergent solution is warm in the order of 70C and is pumped at a pressure ~n the order of at least 100 p~i ~69OkPa~.
Because of the high humidi~y in the cooker and chiller un;ts 40, 50, residue does not collect on the belt and dry on or bake'on and thus any residue from the food processing or any introduction of bacteria at unloading station 70 is easily removed by this continuous belt cleaning and sanitizlng process~
. ., i95 Belt tension.i.ng meanC; 48 is located in thc'returll path, and as i.s shown in ~'igure 4 r a further spray jet cleaner 46 station may also be located at an intermed.iate belt return path position for detergent wash if a water pre-rinse is preferred at cleaning sta~ion 60.
The foregoing-description of the food processing mode . of operation with the periodic'portion of the cleaninq cycles inactive is summarized in the control. flow ch.~rt of Fi~ure 2 in the ~ood Processing Mode Sec.tion, whère ~he various units are placed in o~f or on condition by appropriate valves, switches r servo units r etc.
Periodically the system is shut down for the mechanical mode cleaning and sanitizing opera-tion. This cleaning and sanitizing mode is also set forth in sl~nmary control flow chart form in Figure 2 together with two au~iliary cycles namely the pre-clean mode and the cleaning sub-cycles.
Thus mode control means'80 contains for exalllple a set of'switches, valves or servo controls manually or auto-matically sel'ectable to place the requixed ite[ns into on-off position. For the.auxiliary cycles namely the pre-cleaning mode'and the cleaning sub-cycles, timers may be used to control the sequencing, or manual controls may select each'condition .in a sequence manually timed. It is to be'recognized the clearli'rlg mode m~y b~ made completely automatic, if desired by use of an ~ppropriate control system.
Water, such as from supply tank 81, is used for rinse cycles and detergent may be drawn from supply tank 82. The ' fluia water and detergent solution are heated to supply the ,. 30 water at a~out 66C and the`detergent at about 70C. Then pump 83 tllrough piping 84 supplies the s~ored water or detergent as selected by valve 85 through two rotary joints 86 to the''vicinity of the respective cooker helt ;~piral 16 ' and chiller belt spiral by way of spray nozzle rods 87, 88 respectively'positioned along the spiral axis. These - rotate with''a jet scrub~ing'action by means of motor 89 to ) -13-scan all sectors of the sp;.ral in sequence with a hiyh pressurc jet spray. ~he belt is moviny so that t~le j~ets effectively scrub the ent;.re belt surfaces and the clcall-ing of the interior surfaces of both c~ooking and cllil].ing units is done simultaneously to prevent carrying residue or contamir~ation from one to the other as might happen if sequentially cleaned.
The heater water pool 41 is drained by way of valves 9Q, ~1 and warm water if clean and sanitary and without fat or residue in heater pool 41 may be stored in -tank 81 for the cleaning cycle Otherwise pure water is inscrtcd by inlet 92 and heated beEore use in the cle.~nillg cycle.
With the valve 90 open and T-valve 91 discha-giny water as indicated ~y -the flow schematic notation 93, the cleansing bath from rotating spray noz~le pipe 87 can clean the entire inner surfaces of the cooker 40 and be discharged in an appropriate sewer line, or the like. P~Jre water may then be introduced into cooker 40 at 94 and heated for a further cooking cycle.
Similarly in cooler 50,. residue water 95 being circulated throu~h rcfrigcrator 51 is ~iscl~ar~ea~e ~y T-valve 96, for the pre-clean rnode only. For both clean and'cook modes the water is punlped through refrigerator 51 and spray nozzles 53.. New pure water may ~c ell~.ered at 97 25 for a new cook-chill mode of operation after clcaning alld discharge'oE cleaning fluids. Also T-valve 96 may send some of the rinse water back into storage tank 81 after any initial portion of the rinse water containing residues is discharged, thereby to save wa-ter and thus also energy.
For sanitary purposes, any water salvage is initiated only after the initial.detergent sediment and residue is drained off. Similarly T-valve 91.will permit rinse wat~r to be saved from cooker 40.. The dual line pipe notation such as at link 97 is shown for water-detergent flow paths and control'mode linkage's' are shown by the single line notation of control lines 99, '100.
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It is seen, by reference to the conditions of E`ig~lre
SYS M WITH SANITIZING IMPROVEMENTS _ Technical Field This invention relates to industrial food processing systems for cooking and chilling food products carried on continuously running conveyor belts and more particularly it relates to such systems which include sanitizing means operable to clean said units and belts~
Back~round Art Industriai cookers and chillers are known in the art which pass food products therethrough on a continuously running conveyor belt. Also sanitizing equipment and features are commonly used whenever food is processed.
Cooking techniques which help preserve product charac-teristics are also known.
Examples of typical prior art techniques are as ~ollows:
Conveyor type freezing and broiling apparatus in stainless steel cabinets with access doors permitting internal manual cleaning has been marketed by Certified Manufacturing, Inc. of Lynwood, Caliornia 90262.
Spiral type conveyor paths in a freezing unit cix-culating cold dry air about a product and having associated belt sanitation equipment is disclosed in U.S. Patent 3 412 476 - S. Astrom - Nov. 26, 1968.
Certain techniques resolving deficiències in cooking and cooling food products are known in batch type fooa processing equipme~t where batches are placed in an oven or freezer as long as necessary for processing. Thus, U.S. Patent 3 597 228 - M. R. Jeppson - Aug. 3, 1971 introduces steam into a microwave oven to reduce loss of water from the product and cooks in a hot oil bath to brown the produc~.
Similarly, U.S. Patent 2 846 318 - E~ J. ~elley et al.
- Aug. 5, 1958 introduces humidity in a low pressure freezing gas atmosphere to reduce dehumidification.
However, many unresolved problems remain in the prior art food processing systems, particularly where large ~ ~
.. v ~
.
volumes of food are rapidly processed on a continuously running conveyor passing through cooking and chilling units.
One order of problems relates to energy efficiency.
In many cooking systems hot gases escape, radiation losses - are large, particularly where large heated surface areas exist. In both cooking and heating systems there is generally~an inefficiency in heat interface surfaces be-tween the heating medium and the food product, requiring a significant expenditure of energy without achieving the end result intended. Particularly there is a lack of acceptable solutions available to the energy losses generally caused by the entrance and exit of the conveyor belt from the cooking and chilling units.
Another order of problems relates to food appearance, taste and texture. It is difficult to avoid losses of moisture and food essences in the drying atmosphere of heating ovens and chillers, which both by nature tend to dehy`drate a product. Thus, a meat, fish or poultry product in particular will tend to change shape and appearance as well as to lose flavor and moisture in both cooking and cooling processes. Complete uni~orm cooking throughout without unwanted c~ange to the food texture has been difficult to attain particularly when rapid processing is required in ind~strial type food processors.
Yet another set o~ problems comes with the requirement to process food in a sanitary and sanitizable environment.
In most systems a disproportionate time span ana inef~iciency of energy is spent in tearing down a prod~ction line for sanitization. Cooking in particular tends to burn on, dry out and accumulate`drippings, proteins and other food contamination resulting in unsightly and unsanitary equip-ment. Also complex equipment has surfaces and interfaces difficult to reach and in warm or protected places where bacteria can breed.
Accordingly, it is an object of this invention to provide improved food processing equipment resolving the foregoing deficiencies of the prior art.
. . .
Ci95 Various techniques are known for the processing of food products such as fish, meat, poultry or produce through cook;ng and cooling cycles. For example, the continuous flow of products on conveyors with elongated paths in the form of spirals or the like through cookers or coolers is represented by the following prior art:
U.S. Patent 3 412 476 ~ S. Astrom - Nov.. 26, 1968 prcvides a spiral conveyor through a reezer compartment which employs refrigerated dry air.
Cert;fied Manufacturing, Inc. of Lynwood~ California has commercially supplied contin~ous flow conveying systems for gas heated cooking and freezing of food products passed along a flow path~
U.S. Patent 3 982 481 - E. T. Console et al. -Sept. 28, 1976 shows a continuous conveyor type steam heat-ng line'for blanchi'ng produce.
Also various cooking techniques are-known in the art for treating the food products for texture, color, sanita-tion and flavor, as well as speed of cookLng and efficiency of t~e treatment process. Representative art is:
U.S. Pa~ent 3 597 228 - M~ ~ Jeppson et al. - Aug. 3, 1~71 whlch supplements steam cooking with'special micro-waves and hot oil treatment to color bones and skin in poultry and to prepare a precoo]kins step in a chicken product with'the objective of improved flavor, coloration and sterilization resulting in a packaged product.
U.S. Patent 2 846 318 -'E. J. Kelly et al~ - Aug. 5, 1958 provides low pressure water vapor in ~ freezer to reduce d~hydration of a chilling process.
U.S. Patent 4 058 635 - W. Durth - Nov. 15, 1977 treats foodstuffs in an oven with steam or water spray after cooking begins to prevent dehydration during cooXing.
U.S. Patent 998 236 - L. Detoy et al. - July 18, 1911 which has a spiral conveyor withi'n a processing chamber for processing raisins with controls for passing air or steam under controlled atmospheric conditions within the chamber.
~ 5~395 In all these and other known prior art systems there are several deficiencies which need be corrected in an improved system.
One deficiency is the coo~ing-cooling-product through-put efficiency. Various losses in the continuous typesystems are encountered not only by inefficient use of energy in various steps but also by combining in a flow process incompatible techniques which'require significant losses of energy or time at interfaces and thus significant-ly increase the'processing cost per element of product,which'for example'may be a vegetable, a piece of meat, fish chicken, prepared meatloaf, or the like.
Another de~iciency is sanitation, since ease of clean-ing, lack of'accumulated product or processing ingredient waste'and supervisory agency approval of food processes is critical to any processing of food products.. The accumulation of dirt, bacteria,. or down time'for cleaning is critical. . . .
A critical deficiency is t'he 'flavor, texture and appearance'of'the''processed product. Not only is dehydra-tion critical' in almost any product,'but flavor, tenderness, color with'uniformity under all conditions must be critically .
controlled.. For ex'ample the: herei'n~efore described systems and techniques all 'fail to produce a system t~at produces uniformly sterile products of pleasing appearance because of specific deficiencies such'as uneven cooking at various depths particularly when products such as poultry may have a fatty insulating outside skin. Many processes produce blemishes ~ecause of drippings-or non-uniform product be-cause of complex controls of many variables during theprocess.
Another deficiency is the lack of simplicity of heat-chi'll methods. Where additional steps and complexities are added more difficulties are'encountered in maintaining product uniformity and sanitation as well as energy efficien`cy~
Thus it is an objective of this invention to provide improved food processing methods correcting the aforesaid deficiencies and producing an efficient and rapid cooking-cooling process that produces uniform high quality and sterile processed food products.
,Brief Disclos~re''o'f' the Invention This invention improves the state of the prior art by both cooking and chilling food products such as fish, meat, poultry and produce in an atmosphere'approaching 100%
humidity by use of water carried`in gaseous form about the product as it is carried on a continuously moving conveyor belt. The water is ;n the`'form of steam for cooking and - co.ld moist air for chilling to a product temperature approachi'ng 0C. Because'of thi's moist environment con-' taminating residue 'does not tend to dry, harden or burn onto equipment surfaces there~y`maki'ng ~ea'sible simple mechanical sanitization techn'iques. Also loss of moisture juices and essences from the''product is prevented resulting in be~ter' flavor. In particular the 'heat'interchange between ~he'water processing medium and the'food product is efficient and reduces processing energy.
The ~ot cooked food product is immedlately introduced on.a common conveyor bel't'into a chi'lling unit to prevent - any chance'to come.'into contact with'contamination or to . be 'in a warm environment-long enough'to breed bacteria, as is thb'case 'in ~atch processing reguiring transfer of the product from a cooker'to a chi'ller.
Sanitary.features include'a continuously sanitized moving,conveyor bel`t and..an automatically cycling detergent bath'system for periodic'cleaning of the entire food pro-cessing equipment at one time~
Thus, the 'system is operated in two modes, namely a food processing mode and a sanitation mode with the conveyor belt running'continuously in ~oth'modes. There is no carry '35 over contamination from one'unit to the other as in the manual or sequential cleaning of a food processing system.
9~
To obtain proper product dwell time in relatively small processing unit cabinets for cooking and chilling the conveyor belt îs in a spiral path giving other operational advantages such as efficient energy transfer in both cook-ing and chilling. Thi's permits small insulated coo~ing and ,chilling cabinets with fax less energy loss from radiationand attrition. The-spiral path is cleaned in the sanitizing mode by rotary jet spray nozzles rotated within the spirals as the belt moves.
lO' This invention further provides for the cooking and cooling in a consecutive 'sequence 'along a single product flow line'of food products such'as meats, produce, etc., and . is particularly adapted for the'cooking of spareribs, short ribs, unskinned chi'cken, poul1:ry pieces, etc. The coo~ing 15 ' is solely by steam in a cooker with'pressure maintained ..
, . above atmospheric pressure at near 100% humidity and 99C~
.~ ~ ` The'cooling is ~olely by circulation of cold humid air in a cooler at a pressure. above `~tmospheric at near lO0~
humidity at a temperature'less than 5C. The products are : 20 continùously pas'sed along.a conveyor flow line through the steamer and chiller in a completely sanitary process to be'fully cooked (if desired) and chi'Iled for cold storage ; without de~dration at hi~h energy efficiency, speed and ., volumQ. .
: .
Thus broadly, the invention contemplates a food processing system for heating and chilling unpackaged food products, such as fish, meat, poultry and produce, passing in sequence on a common.conveyor belt through heating and chilling stations which comprises, in combination, a continuously running single conveyor belt passing commonly through food loading, cooking, chilling and unloading stations, a heating chamber having a heating spiral conveyor belt path therethrough for carrying the unpackaged food products loaded at the loading station, a chilling chamber separately disposed from the heating chamber having a cooling spiral conveyor belt path therethrough for carrying the unpackaged food products on the belt heated in the heating chamber to present chilled food products at the unloading station, steam heat means for heating the products on the heating spiral with water carried solely in gaseous form in a steam bath at a temperature approaching 100C, and a humidity approaching lO0~ without loss of moisture and food essences in the unpackaged food products and, a mechanically operable sanitizing system for the heating and chilling chambers including means for pumping and spraying detergent solutions inside the chambers over the spiral pathway of the conveyor belt therethrough.
The invention also includes the above system wherein the mechanically operable sanitizing system incluaes rotatable spray nozzle means extending within the spiral belt paths respectively inside the heating and chilling chambers to rotate and scan the spray about the insides of the chambers, and means operating both the rotatable spray means in a cleaning mode simultaneously.
--8~
In a further embodiment, the invention can include a system wherein the chilling chamber has chilling means circulating cold water through spray atomi~er means and a fan circulating cold humid air from the spray region to contact food products on the spiral conveyor belt path, and the mechanical sanitizing system is operated together with the chilling chamber means for circulating water and air, thereby to pass sanitizing solution through the chilling means for the chilling chamber.
The invention also contemplates a method of sanitizing a food processing s~vstem which changes food temperature in at least one food processing unit b~ carrying food products through the unit on a conveyor belt having grating aperture structure therethrough and the-method comprises the steps of pumping a warm cleaning liquid at a pressure in the order of at least 100 psi (690k Pa) to a spray nozzle set positioned adjacent the conveyor belt, moving the belt past the spray nozzle set, and directing the spray nozzle set to release the detergent in a jet cleaning action against the moving belt.
~0 Flavor and texture is protec'ted and heating-chilling efficiency is~ increase~ by the' humid atmosphere, wh'ich is stripped of water droplets to preve'n~ contamination or bad appearance.'' Other features, advantages and objects of the invention ~:S will be found t~roughout the fo'llowing. text and the accom-panying drawings.
9~
BrieE DescriF~tion of the Drclwillgs Figure 1 is a schemati.c system diagram of the coo~er-chiller-sanitization system afforded by this invention;
Figure 2 is an opera-ti.onal` mode chart showing the sanitation and food processing mode control cycles operations in the system of Figure l; and Figures 3 to 6 are diagrammatic views of the various parts of the system of Figure 1 shown in respective sequential order from i.llpUt of a raw pl c ~ ct to o ~ItpUt lQ of a cooked and chilled product through the cooker unit of Figure 4 and the chiller unit of Figure 5.
~.~s~ass Detailed Descri tion of the Preferred Embodiment P
As may be seen in the system view of Figure 1, a continuously running conveyor belt 12 feeds raw food products 12 loaded on the belt at an input station 20 through the cooker 40 and the chiller 50 to the output station 70 at which the cooked food products 12' are unloaded. The belt passes the products at a belt speed controlled by variable speed drive means 14 so that the dwell time in cooker 40 cn belt spiral 16 permits thorough cooking throughout to a temperature approaching 100C if desired and similarly a chill dwell time on spiral belt path 18 thro~gh the chiller 50 permits the hot cooked product to ~e chilled immediately without chance for contamination or bacteria growth to a t`emperature approach-1~ ing 0C, if desired.
The atmospheire in ~oth cooker and'chiller is kept near100% humidity there~y to assure efficient thermal exchange con~act bet'ween respectively hot water in the form of steam and cold water carried by cold humid air about thP
products on the spiral belts. This prevents any dehumidi-fication of the product as weLl and keeps all equipment humid'so tha'~ any drippings or food residues do not burn, dry out or accumulate, thereby facilitating sanitation.' The heater 40 has two 60urces of steam, namel'y an internal pool of water 41 heated by a heat-er 42 and an external steam generator 43. The products are spiraled upwardly so that if they are fatty, such as with spare ribs, fewer drippings will drop on the cooked food products as they spiral upwardly to leave the cooker unit 40. The simplè cooker unit has insulated walls and plain int'erior stainless steel surfaces for ready sanitization and'little tenden'cy to form accumulated deposits of cooking res;dues.
.. .. .. . .. . . . . . . . . ... . .
~5~B95 The chiller 50 has refrigerated , water from refrigerator 51 passed by pipe 52 into atomizer sprays 53 so that the fan 54 can direct cold moist air upwardly through tne spiral 18 in an efficient heat ex- :
chan~e wnere cooler products on the lower part of t~.e ' spiral 18 encounter the cooler air exiting the fan 54 r' thus permitting efficient heat exchange a~ the upper part :
of ~he spiral 18 where the hot cooked products enter. The ,~
pump 55 recirculates the ~old water through refrigerator 51 ?;
t~ replace the energy lost in cooling the products.
By using spiral conveyor paths and the water as a heat :~' exchange medium in the,cooker 40 and chiller 50, small r~
cabinets are used for a large'~hroughput of,food products.
This significantly red~ces energy losses in heating up or cooling down a larger cabinet structure with attendan~ ' radiation and condensation losses over greater surface areas, and thus provides Lmproved operating econom~.
' In the bel't return path toutside the chiller and cooker) at least two sanitizing spray bath stations 60 and 30 are posi~ioned for respectively washing the'belt with a detergent spray and rinsing with water. The belt, which is preferably a stainless,steel grating type belt is scrubbed by the spray nozzles 61, 31 with a jet scrubbing action on and through the moving ~,eltO The liquid is received in basins 62, 32 and circulated by pumps 63, 33 continuously whenever thb belt moves. The water and detergent solution is warm in the order of 70C and is pumped at a pressure ~n the order of at least 100 p~i ~69OkPa~.
Because of the high humidi~y in the cooker and chiller un;ts 40, 50, residue does not collect on the belt and dry on or bake'on and thus any residue from the food processing or any introduction of bacteria at unloading station 70 is easily removed by this continuous belt cleaning and sanitizlng process~
. ., i95 Belt tension.i.ng meanC; 48 is located in thc'returll path, and as i.s shown in ~'igure 4 r a further spray jet cleaner 46 station may also be located at an intermed.iate belt return path position for detergent wash if a water pre-rinse is preferred at cleaning sta~ion 60.
The foregoing-description of the food processing mode . of operation with the periodic'portion of the cleaninq cycles inactive is summarized in the control. flow ch.~rt of Fi~ure 2 in the ~ood Processing Mode Sec.tion, whère ~he various units are placed in o~f or on condition by appropriate valves, switches r servo units r etc.
Periodically the system is shut down for the mechanical mode cleaning and sanitizing opera-tion. This cleaning and sanitizing mode is also set forth in sl~nmary control flow chart form in Figure 2 together with two au~iliary cycles namely the pre-clean mode and the cleaning sub-cycles.
Thus mode control means'80 contains for exalllple a set of'switches, valves or servo controls manually or auto-matically sel'ectable to place the requixed ite[ns into on-off position. For the.auxiliary cycles namely the pre-cleaning mode'and the cleaning sub-cycles, timers may be used to control the sequencing, or manual controls may select each'condition .in a sequence manually timed. It is to be'recognized the clearli'rlg mode m~y b~ made completely automatic, if desired by use of an ~ppropriate control system.
Water, such as from supply tank 81, is used for rinse cycles and detergent may be drawn from supply tank 82. The ' fluia water and detergent solution are heated to supply the ,. 30 water at a~out 66C and the`detergent at about 70C. Then pump 83 tllrough piping 84 supplies the s~ored water or detergent as selected by valve 85 through two rotary joints 86 to the''vicinity of the respective cooker helt ;~piral 16 ' and chiller belt spiral by way of spray nozzle rods 87, 88 respectively'positioned along the spiral axis. These - rotate with''a jet scrub~ing'action by means of motor 89 to ) -13-scan all sectors of the sp;.ral in sequence with a hiyh pressurc jet spray. ~he belt is moviny so that t~le j~ets effectively scrub the ent;.re belt surfaces and the clcall-ing of the interior surfaces of both c~ooking and cllil].ing units is done simultaneously to prevent carrying residue or contamir~ation from one to the other as might happen if sequentially cleaned.
The heater water pool 41 is drained by way of valves 9Q, ~1 and warm water if clean and sanitary and without fat or residue in heater pool 41 may be stored in -tank 81 for the cleaning cycle Otherwise pure water is inscrtcd by inlet 92 and heated beEore use in the cle.~nillg cycle.
With the valve 90 open and T-valve 91 discha-giny water as indicated ~y -the flow schematic notation 93, the cleansing bath from rotating spray noz~le pipe 87 can clean the entire inner surfaces of the cooker 40 and be discharged in an appropriate sewer line, or the like. P~Jre water may then be introduced into cooker 40 at 94 and heated for a further cooking cycle.
Similarly in cooler 50,. residue water 95 being circulated throu~h rcfrigcrator 51 is ~iscl~ar~ea~e ~y T-valve 96, for the pre-clean rnode only. For both clean and'cook modes the water is punlped through refrigerator 51 and spray nozzles 53.. New pure water may ~c ell~.ered at 97 25 for a new cook-chill mode of operation after clcaning alld discharge'oE cleaning fluids. Also T-valve 96 may send some of the rinse water back into storage tank 81 after any initial portion of the rinse water containing residues is discharged, thereby to save wa-ter and thus also energy.
For sanitary purposes, any water salvage is initiated only after the initial.detergent sediment and residue is drained off. Similarly T-valve 91.will permit rinse wat~r to be saved from cooker 40.. The dual line pipe notation such as at link 97 is shown for water-detergent flow paths and control'mode linkage's' are shown by the single line notation of control lines 99, '100.
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It is seen, by reference to the conditions of E`ig~lre
2, that eac-h of the valves, pum2s, motors.~nd heclt e~ci~ e units can be controli.ed for on-off oper~t;on or d;s-connected by means of controls designated al.onc3 t}le lines 99, 100. Thus, heater 42 may be turned on or of~ and valves 90, 91 operated along control ~ine 99. An auxiliary pump (not shown) of course could be used to pllmp out the heater water pool 41 and also is controlled by this line 99 .
Similarly line 100 can turn the refrigeration of unit 51 on or off, operate T-valve 96 to any of three disch~rye paths, turn on or off pump 55 for circul.atin(3 wat~r throl1yh the refrigerati.on~atomizer cooker circuit, choose water 81 or detergent 82 by operation of T-valve 85, operate clean-ing pump 83, control belt drive at 14 if dcsired, rotate sprays 87,. 88 by means of motor 89, turn on or off the steam su~ply from generator 43, and operate fan 54.
Thus when in the cleaninq mode detergent solution or water rinse spray from nozzles 88 in cooler 50 is accumulatea in pool ~5 and circulated through the refriger-a-tor and nozzles 53~ Thus atolni~.cd nloi.st:ure i5 ca~:r;e~
through fan filter 54 to effect;vely~clean the entire chiller 50 and also its auxiliary refrigeration system.
Preferably the cleaning .is donc cycl.ically ;ll tll~ee steps, namely pre-rinse with watcr, wash wi.th dcte~c3ent, and rinse with water sub-cycles, wllere about the last half of the rinse water is stored in tank 81 for reuse. The necessary operations are shown in the cleaning sub-cycles - mode por-tion of Figure 2 Manual sequencing or automati-cally timed steppers can be used for control of these cycles while the processor is in the main cleanirlg mode condition.
The sequencing controls utilize pump 83, T-valv~ R~ .~nd storage T-valves 91, 96 for selection of the del:er-3ent solution and water and.storage of rinse water.
Preferably duri~g the food processing mode, cooking . and chilling operations,.the cooXer 40 and chiller 50 are ""' '! -15- ) maintained at a prcssure above atmospheric to re~uce cooking and cooling time and improve energy efficiellcy~
One means~for supplementing -the pressure is to install the cooker and cooler 40, 50 within a pressurized room signified by walls 21, 71. This leads also-to a receptive-ness of the food product loaded under atmos~hcLic ~ressure at station 20 to penetration of heat in cooker 40 and -' further retards losses of mois-ture and food essences from the product.
Various system features contribute in unison and cooperatively to save eneryy, includ;ng such Eeatllres as recirculation of belt wash water, the direction of bclt travel and the spiral pathway throug~ the he2t e~change ' units, the use of water as a heat excll~llqe meclillln in a near 100% humidity atmosphere, the saving of cleaning fluid, the'short cleaning cycle and reduced system down time, the'small cabinet structure with attendant reduced losses, the short conveyor belt paths, etc. Other such features are also to be recognized from considera-tion of Figures 3 to 6.
Thus in Figure 3, the belt 12 is retained in pro-tective ducts 35 in which control means ~uch as baEfles and fans are introduce(1 for prevellting olltry or t~xiL o~
air carriea by the belt from one UJlit to anoth~r.~uch a '25 trap unit is shown at 65 ;n Figure 6, where the ducts 35 go through the u~tloading stat;on wall 71. Thus, a fan at ' 73 may prevent entry of cool outside air, which can diss;pate the'solution spray heat at cleaning sta-tion 60, carried b~ belt 12 by creating a counter 1Ow of air opposite'the belt tra~el and ba~fles may be placed in duct portion 74 ~or reducing and reL.lrdirlg ;nt~ar~ ~low o~ .~ir.
Similar traps may be placed in the duct systelll at: ellt:ral~ce-ways and exitways into the coo~er 40 and cooler 50 to reduce heat losses~from flow of atmosphere with the belt.
Note that a water pre-rinse may be effected at spray cleaning station 60 ih Figure 6, a detergert bath at inter-9~ ~
med;ate spray cleaning station ~6 in Fi(Jure 4 and a fi.nal rinse at the typical cleaning station 30 in Figure 3 àll in the conveyor belt return path between unloadiJlg station 70 and the loading station 30, thereby assuring a sanitized belt for loading the products at station 20 under sanitary belt condit;ons.
In the spray station 30 the sump basin 32 is arranged in the ductway about belt 12 to permit the spray no~zle arms 36 to pass the cleaning jets of warm water at a pressure produced by pump 33 in the order of 100 psi t690k Pa~. Thus warm water passes through and scrubs -the grid-work of the moving belt for effective rinsing. The squeeze or cleaning brush 37 cleans liquid from roller 38 to prevent carrying of excess moisture alollc3 thc belt patll into tl loading station.
It has been found that products 12 preferably of common size and shape positioned across a wide conveyor belt can pass through the system in about 20 minutes and achieve a consistent cooking temperature througho~lt greater 20. than 90C in the cooker and a s;.m:ila.r consist:ent temperature approaching 0C in the chiller, typically 5C.
As seen in the drawing Figure 1 food product:s 12' preferably of substantia].ly the same size ancl we;gllt are passed through a contînuous flow path from load.;ng station 20 to unload;ng station 70 by means of continuously rurllling conveyor belt 12 for cooking as it passes through steam cooker 40 and chilling as it passes through cooker 50. The product could be produce meat products such as spareribs prepared meat cuts, poultry parts ana the like which may be pre-cleaned and conditioned by seasoning etc. at station 20. The processing method ;s parl.icllla~ly advanl:cl-geous for cooking food products 12 which have been cleaned cut and sized a-t station 20 and loaded on the conveyor bel.t 12, generally with several parts 12' being positioned across the width of the conveyor belt 12.
-~7-~5~ 95 In cooking and chilling almost any food product it is essential to get uniform cooking throughout with ~3Ood efficiency and without dehydration while preserving good appearance and flavor with a consistent product under all conditions, and various features of this invclltioll are provided to assure that.
For attaining high'efficiency of input energy and permitting a large throughput of products 12' in a small space,' several features contr;bute to the system. Thus, consider 'the cooking is solely by s-team at a pressure above atmospheric ma;ntained in part for the coo~iny arld other steps of the entire process by having a module such as a building with walls 71 kept above atmocs~-heric ~ ssllre.
Also the steam cooker 40 is in a scparate housing compart-~ent into which the'steam'from generator 43 is entered atd pressure 'above atmospheric. This g;ves a sort of pressure cooker efficiency to the 'cooking process and enables the steam to penetrate and cook the food product for example 'since it is basically at atmospheric pressure from processing at loading station 20 ou~:s;de the incre~sed pressure compartments. -To assure a good heat exchan~e interr~ce, ~ t;culclrlywith Eatty food products where the fat servcs as an insulator, a fine spray mist we~tens the surface for intima-te and efficient interface thermal contact with the steam in cooker 40 to decrease cooXing time Sanitation is important throughout as is pr~servation of flavor. Thus, pure water is provided for steam generator 43 and valves provide 'for a flow of steam through cooker 40 to exhaust at a controlled flow rate and pressllre. The rate of steam flow thl-o-lt3h the cooker lO is as low cls fe.lsible to maintain minimum energy losses while retaining the close to 100C a~bient temperature within the cooker 40 thereby to improve'energy efficiency. Also, the steam produces a 35 humiditymaintained as close as possible to 100~ within the ` cooker to avoid any dehydration of the product and with the pressure to avoid loss of juices from the product.
For proper coo~lng o.f various products, the conveyor 12 speed ~hrough the systeTn may be changed and the tor~ious route 16 of the conveyor within the cooker 40 produces a dwell time proper for cookinc3 the produlcts to the extent desired. The system could be use~ for blanci~ y pcas, for cooking spareribs, meat slices or meatloafs, or processing ' other food products, preferably unpackaged, through a heat-chill cycle.' Because a quick chill immediately after cooking is a lQ. most sanitary condition reducing possibility of in-tro-duction and growth'of bacteria, the product is passed from the steclm cooker 40 directly into the cooler 50 along the flow path defined by continuous conveyor belt 12. ln the interest of energy e~ficiency in the cooler 50 a heat stripper is provided to entrap and confine within -the cooker 40 the hot air flowing with the product 12' and eonveyor 12 out of cooker 40 before the eonveyor enters eooler 50 with'the hea'-ted products 12'. Thus, baffles and fans can be used, for example,' in a conveyor duct between eooker 90 and cooler 50 to retain hot steam in cooker 40 and prevent flow.of all but a residual inerelncnt in~o c,ooler 50 with the produet 12'.
Also in the eooler 50 it is eritieal to maintain a pressure higher than atmospher;e and near 100% humidity to keep the product from dehydrating and losing j~lices or flavor as it is passed along-tortious path 16 providing a dwell time long enoug~ to bring the product temperature at eooking heat near ~9C, for example, down to near 0C.
This is aehieved by cireulating saturated 100~ humidity 3Q air without droplets through the cooler 50 by means of fan 54 ~hich kceps the cooler intelllal prcss~lrc aho~e .ltmOS~)h~ i.C.
The air leaving the cooler is kept cold and humid by a cold ~ater spray 53 which uses uncontaminated water. A filter 54 strips water droplets before circulation into cooler 50 so there can be no dripp;ng.to assure best appearance and sanitation conditions. Thus, the belt 12 and products 12' Ji95 thereon rerllain subs-tantialLy free of residual dr;p~il)ys or accumulation o~ product or water drop contamination anc~ the belt 12 is readily sanitized at stations 60 and 30 beEore re-entry into a repeat cycle thro~lyl~ e heat-cl~ill plo-e~s.
The conveyor is returned outside the cooking and cooling chambers to prevent any baked on contamination or the like.
The high humidity contributes to the easy removability of any drippings or product residue in the conveyor sanitizer station which might simply be a spray detergent bath.
It is therefore evident that various novel features including a mechanically operated sanitizing system and efficient cooking and chilling means are provided by this invention. Those novel features believecl deSCI ipt.ive of the spirit and nature of the invention are defined with particularity in the claims ~ J
Industrial Application . . .
An industrial Eood processing system rapidly cooks and chills food products carried between a Ioacling s-~ation and unloading station by a corctinuously~moving conveyor belt. The system operates in both food processing and automatic sanitization modes. It processes food through both heating and chilling cycles with high energy efficiency and without dehumidification in a sanitary environment.
~..
Similarly line 100 can turn the refrigeration of unit 51 on or off, operate T-valve 96 to any of three disch~rye paths, turn on or off pump 55 for circul.atin(3 wat~r throl1yh the refrigerati.on~atomizer cooker circuit, choose water 81 or detergent 82 by operation of T-valve 85, operate clean-ing pump 83, control belt drive at 14 if dcsired, rotate sprays 87,. 88 by means of motor 89, turn on or off the steam su~ply from generator 43, and operate fan 54.
Thus when in the cleaninq mode detergent solution or water rinse spray from nozzles 88 in cooler 50 is accumulatea in pool ~5 and circulated through the refriger-a-tor and nozzles 53~ Thus atolni~.cd nloi.st:ure i5 ca~:r;e~
through fan filter 54 to effect;vely~clean the entire chiller 50 and also its auxiliary refrigeration system.
Preferably the cleaning .is donc cycl.ically ;ll tll~ee steps, namely pre-rinse with watcr, wash wi.th dcte~c3ent, and rinse with water sub-cycles, wllere about the last half of the rinse water is stored in tank 81 for reuse. The necessary operations are shown in the cleaning sub-cycles - mode por-tion of Figure 2 Manual sequencing or automati-cally timed steppers can be used for control of these cycles while the processor is in the main cleanirlg mode condition.
The sequencing controls utilize pump 83, T-valv~ R~ .~nd storage T-valves 91, 96 for selection of the del:er-3ent solution and water and.storage of rinse water.
Preferably duri~g the food processing mode, cooking . and chilling operations,.the cooXer 40 and chiller 50 are ""' '! -15- ) maintained at a prcssure above atmospheric to re~uce cooking and cooling time and improve energy efficiellcy~
One means~for supplementing -the pressure is to install the cooker and cooler 40, 50 within a pressurized room signified by walls 21, 71. This leads also-to a receptive-ness of the food product loaded under atmos~hcLic ~ressure at station 20 to penetration of heat in cooker 40 and -' further retards losses of mois-ture and food essences from the product.
Various system features contribute in unison and cooperatively to save eneryy, includ;ng such Eeatllres as recirculation of belt wash water, the direction of bclt travel and the spiral pathway throug~ the he2t e~change ' units, the use of water as a heat excll~llqe meclillln in a near 100% humidity atmosphere, the saving of cleaning fluid, the'short cleaning cycle and reduced system down time, the'small cabinet structure with attendant reduced losses, the short conveyor belt paths, etc. Other such features are also to be recognized from considera-tion of Figures 3 to 6.
Thus in Figure 3, the belt 12 is retained in pro-tective ducts 35 in which control means ~uch as baEfles and fans are introduce(1 for prevellting olltry or t~xiL o~
air carriea by the belt from one UJlit to anoth~r.~uch a '25 trap unit is shown at 65 ;n Figure 6, where the ducts 35 go through the u~tloading stat;on wall 71. Thus, a fan at ' 73 may prevent entry of cool outside air, which can diss;pate the'solution spray heat at cleaning sta-tion 60, carried b~ belt 12 by creating a counter 1Ow of air opposite'the belt tra~el and ba~fles may be placed in duct portion 74 ~or reducing and reL.lrdirlg ;nt~ar~ ~low o~ .~ir.
Similar traps may be placed in the duct systelll at: ellt:ral~ce-ways and exitways into the coo~er 40 and cooler 50 to reduce heat losses~from flow of atmosphere with the belt.
Note that a water pre-rinse may be effected at spray cleaning station 60 ih Figure 6, a detergert bath at inter-9~ ~
med;ate spray cleaning station ~6 in Fi(Jure 4 and a fi.nal rinse at the typical cleaning station 30 in Figure 3 àll in the conveyor belt return path between unloadiJlg station 70 and the loading station 30, thereby assuring a sanitized belt for loading the products at station 20 under sanitary belt condit;ons.
In the spray station 30 the sump basin 32 is arranged in the ductway about belt 12 to permit the spray no~zle arms 36 to pass the cleaning jets of warm water at a pressure produced by pump 33 in the order of 100 psi t690k Pa~. Thus warm water passes through and scrubs -the grid-work of the moving belt for effective rinsing. The squeeze or cleaning brush 37 cleans liquid from roller 38 to prevent carrying of excess moisture alollc3 thc belt patll into tl loading station.
It has been found that products 12 preferably of common size and shape positioned across a wide conveyor belt can pass through the system in about 20 minutes and achieve a consistent cooking temperature througho~lt greater 20. than 90C in the cooker and a s;.m:ila.r consist:ent temperature approaching 0C in the chiller, typically 5C.
As seen in the drawing Figure 1 food product:s 12' preferably of substantia].ly the same size ancl we;gllt are passed through a contînuous flow path from load.;ng station 20 to unload;ng station 70 by means of continuously rurllling conveyor belt 12 for cooking as it passes through steam cooker 40 and chilling as it passes through cooker 50. The product could be produce meat products such as spareribs prepared meat cuts, poultry parts ana the like which may be pre-cleaned and conditioned by seasoning etc. at station 20. The processing method ;s parl.icllla~ly advanl:cl-geous for cooking food products 12 which have been cleaned cut and sized a-t station 20 and loaded on the conveyor bel.t 12, generally with several parts 12' being positioned across the width of the conveyor belt 12.
-~7-~5~ 95 In cooking and chilling almost any food product it is essential to get uniform cooking throughout with ~3Ood efficiency and without dehydration while preserving good appearance and flavor with a consistent product under all conditions, and various features of this invclltioll are provided to assure that.
For attaining high'efficiency of input energy and permitting a large throughput of products 12' in a small space,' several features contr;bute to the system. Thus, consider 'the cooking is solely by s-team at a pressure above atmospheric ma;ntained in part for the coo~iny arld other steps of the entire process by having a module such as a building with walls 71 kept above atmocs~-heric ~ ssllre.
Also the steam cooker 40 is in a scparate housing compart-~ent into which the'steam'from generator 43 is entered atd pressure 'above atmospheric. This g;ves a sort of pressure cooker efficiency to the 'cooking process and enables the steam to penetrate and cook the food product for example 'since it is basically at atmospheric pressure from processing at loading station 20 ou~:s;de the incre~sed pressure compartments. -To assure a good heat exchan~e interr~ce, ~ t;culclrlywith Eatty food products where the fat servcs as an insulator, a fine spray mist we~tens the surface for intima-te and efficient interface thermal contact with the steam in cooker 40 to decrease cooXing time Sanitation is important throughout as is pr~servation of flavor. Thus, pure water is provided for steam generator 43 and valves provide 'for a flow of steam through cooker 40 to exhaust at a controlled flow rate and pressllre. The rate of steam flow thl-o-lt3h the cooker lO is as low cls fe.lsible to maintain minimum energy losses while retaining the close to 100C a~bient temperature within the cooker 40 thereby to improve'energy efficiency. Also, the steam produces a 35 humiditymaintained as close as possible to 100~ within the ` cooker to avoid any dehydration of the product and with the pressure to avoid loss of juices from the product.
For proper coo~lng o.f various products, the conveyor 12 speed ~hrough the systeTn may be changed and the tor~ious route 16 of the conveyor within the cooker 40 produces a dwell time proper for cookinc3 the produlcts to the extent desired. The system could be use~ for blanci~ y pcas, for cooking spareribs, meat slices or meatloafs, or processing ' other food products, preferably unpackaged, through a heat-chill cycle.' Because a quick chill immediately after cooking is a lQ. most sanitary condition reducing possibility of in-tro-duction and growth'of bacteria, the product is passed from the steclm cooker 40 directly into the cooler 50 along the flow path defined by continuous conveyor belt 12. ln the interest of energy e~ficiency in the cooler 50 a heat stripper is provided to entrap and confine within -the cooker 40 the hot air flowing with the product 12' and eonveyor 12 out of cooker 40 before the eonveyor enters eooler 50 with'the hea'-ted products 12'. Thus, baffles and fans can be used, for example,' in a conveyor duct between eooker 90 and cooler 50 to retain hot steam in cooker 40 and prevent flow.of all but a residual inerelncnt in~o c,ooler 50 with the produet 12'.
Also in the eooler 50 it is eritieal to maintain a pressure higher than atmospher;e and near 100% humidity to keep the product from dehydrating and losing j~lices or flavor as it is passed along-tortious path 16 providing a dwell time long enoug~ to bring the product temperature at eooking heat near ~9C, for example, down to near 0C.
This is aehieved by cireulating saturated 100~ humidity 3Q air without droplets through the cooler 50 by means of fan 54 ~hich kceps the cooler intelllal prcss~lrc aho~e .ltmOS~)h~ i.C.
The air leaving the cooler is kept cold and humid by a cold ~ater spray 53 which uses uncontaminated water. A filter 54 strips water droplets before circulation into cooler 50 so there can be no dripp;ng.to assure best appearance and sanitation conditions. Thus, the belt 12 and products 12' Ji95 thereon rerllain subs-tantialLy free of residual dr;p~il)ys or accumulation o~ product or water drop contamination anc~ the belt 12 is readily sanitized at stations 60 and 30 beEore re-entry into a repeat cycle thro~lyl~ e heat-cl~ill plo-e~s.
The conveyor is returned outside the cooking and cooling chambers to prevent any baked on contamination or the like.
The high humidity contributes to the easy removability of any drippings or product residue in the conveyor sanitizer station which might simply be a spray detergent bath.
It is therefore evident that various novel features including a mechanically operated sanitizing system and efficient cooking and chilling means are provided by this invention. Those novel features believecl deSCI ipt.ive of the spirit and nature of the invention are defined with particularity in the claims ~ J
Industrial Application . . .
An industrial Eood processing system rapidly cooks and chills food products carried between a Ioacling s-~ation and unloading station by a corctinuously~moving conveyor belt. The system operates in both food processing and automatic sanitization modes. It processes food through both heating and chilling cycles with high energy efficiency and without dehumidification in a sanitary environment.
~..
Claims (38)
1. A food processing system for heating and chilling unpackaged food products such as fish, meat, poultry and produce passing in sequence on a common conveyor belt through heating and chilling stations, comprising in combination, a continuously running single conveyor belt passing commonly through food loading, cooking, chilling and unloading stations, a heating chamber having a heating spiral conveyor belt path therethrough for carrying said unpackaged food products loaded at said loading station, a chilling chamber separately disposed from said heating chamber having a cooling spiral conveyor belt path therethrough for carrying said unpackaged food products on said belt heated in said heating chamber to present chilled food products at said unloading station, steam heat means for heating said products on said heating spiral with water carried solely in gaseous form in a steam bath at a temperature approaching 100°C, and a humidity approaching 100% without loss of moisture and food essences in said unpackaged food products and, a mechanically operable sanitizing system for said heating and chilling chambers including means for pumping and spraying detergent solutions inside the chambers over the spiral pathway of the conveyor belt therethrough.
2. A system as defined in claim 1 wherein the mechanically operable sanitizing system includes rotatable spray nozzle means extending within the spiral belt paths respectively inside the heating and chilling chambers to rotate and scan the spray about the insides of the chambers, and means operating both the rotatable spray means in a cleaning mode simultaneously.
3. A system as defined in claim 1 or claim 2 including means operating the mechanical sanitizing system while the conveyor belt is continuously running.
4. A system as defined in claim 1 wherein the chilling chamber has chilling means circulating cold water through spray atomizer means and a fan circulating cold humid air from the spray region to contact food products on said spiral conveyor belt path, and the mechanical sanitizing system is operated together with the chilling chamber means for circulating water and air, thereby to pass sanitizing solution through the chilling means for the chilling chamber.
5. A food processing system as defined in claim 2 having two said food processing units, one for heating food and the other for chilling foods with the conveyor belt passing in sequence through spiral paths in each unit, wherein said rotary spray means is located in each unit, and including means pumping the detergent through both rotating spray means simultaneously.
6. A food processing system as defined in claim 4 having two said food processing units, one for heating food and the other for chilling foods with the conveyor belt passing in sequence through spiral paths in each unit, wherein said rotary spray means is located in each unit, and including means pumping the detergent through both rotating spray means simultaneously.
7. A food processing system as defined in claim 2 or claim 4 including means operable with said heating unit establishing a water pool therein for steaming products passing through the heating unit on said belt, means removing said water from the heating unit, and means thereafter processing detergent from said spray over the entire inner surface of the heating unit.
8. A food processing system as defined in claim 5 or claim 6 including means operable with said heating unit establishing a water pool therein for steaming products passing through the heating unit on said belt, means removing said water from the heating unit, and means thereafter processing detergent from said spray over the entire inner surface of the heating unit.
9. A food processing system as defined in claim 2 or claim 4 including cooling means with a pump operable with said chilling unit for circulating refrigerated water through atomizing sprays and circulating air by fan means through the atomizing sprays, including means removing water from said cooling means and passing detergent therethrough when detergent is pumped through the rotating spray means in said chiller unit to thereby clean the entire interior surfaces of the chiller unit and those in the cooling means.
10. A food processing system as defined in claim 5 or claim 6 including cooling means with a pump operable with said chilling unit for circulating refrigerated water through atomizing sprays and circulating air by fan means through the atomizing sprays, including means removing water from said cooling means and passing detergent therethrough when detergent is pumped through the rotating spray means in said chiller unit to thereby clean the entire interior surfaces of -the chiller unit and those in the cooling means.
11. A system as defined in claim 2 or claim 4 wherein said sanitation means includes control means for sequencing a water rinse cycle, a detergent wash cycle and a water rinse cycle through said rotating spray.
12. A system as defined in claim 2 or claim 4 wherein said sanitation means includes means creating a spray jet discharging solution at a pressure in the order of 150 psi (1033.5k Pa).
13. A system as defined in claim 2 or claim 4 wherein said detergent cleaning solution is heated to a temperature in the order of 70°C.
14. A system as defined in claim 2 or claim 4 including sanitizing means continuously cleaning the running conveyor belt with a detergent spray solution at a pressure in the order of at least 100 psi (690k Pa) flowing from spray nozzles against said belt.
15. A system as defined in Claim 2 or claim 4 wherein the food processing unit is a heater in a housing, and spiral conveyor path passes upwardly therethrough to reduce drippings downwardly through said spiral path as fatty products are heated.
16. A system as defined in claim 2 or claim 4 wherein the food processing unit is a chiller in a housing, a spiral conveyor path goes downwardly through said housing and a fan passes cooling air upwardly through said spiral path to thereby effectuate an efficient cooling at all product temperature gradients along the spiral path.
17. The method of sanitizing a food processing system changing food temperature in at least one food processing unit by carrying food products through the unit on a conveyor belt having grating aperture structure there-through, comprising the steps of, pumping a warm cleaning liquid at a pressure in the order of at least 100 psi (690k Pa) to a spray nozzle set positioned adjacent said conveyor belt, moving the belt past said spray nozzle set, and directing said spray nozzle set to release said detergent in a jet cleaning action against the moving belt.
18. The method defined in claim 17 with the additional steps of moving the belt continuously, and pumping the detergent continuously through said spray nozzle set to pass through said belt.
19. The method defined in claim 17 wherein the belt is directed along a spiral pathway through the food processing unit, including the steps of rotating the spray nozzle set within the spiral pathway to scan the jet clean-ing action in a cyclic rotary path contacting the belt throughout its spiral path.
20. The method defined in claim 17 wherein the pumped cleaning liquid is water.
21. The method defined in claim 20 including the step of saving, storing and reusing a portion of the water spray-ed through said nozzle set.
22. The method defined in claim 17 wherein the pumping step includes the sequential pumping of a water pre-rinse, a detergent washing solution and a water rinse through said pumping step.
23. The method defined in claim 17 wherein the pumped cleaning liquid is a detergent solution
24. The method defined in claim 17 wherein the sanitizing-steps are periodically undertaken while the food processing unit is shut down.
25. The process of preparing food products by passing in a continuous flow path between an input and output station the food products, to heat and quick cool the product for preservation with low bacteria count, compris-ing the following ordered steps, (a) heating the products in the flow path solely by steam in an atmosphere of the order of 100% humidity, and (b) cooling the heated products in the flow path to a temperature in the order of less than 5°C in an atmosphere of chilled moist air of the order of 100%
humidity.
humidity.
26. The process defined in claim 25 wherein said food products are unpackaged with a preprocessing step before the steam heating step comprising the surface wetting of the unpackaged product with a fine spray mist so that the surface becomes wet without dripping, thereby to effectuate an efficient heat transfer interface between the steam and the product in the cooling step.
27. The process defined in claim 25 including the con-current step of flowing steam in contact with the products during the heating step and cold moist air into contact with the products during the cooling step while controlling humidity of the respective heating and cooling steam and moist air atmospheres to keep out water drops and thereby to prevent accumulation of water drops on the product and dripping along the flow path, thereby to assure product quality, good heating-cooling efficiency and to prevent unsanitary accumulation of deposits.
28. The process as defined in claim 27 wherein the control of humidity comprises respectively the steps of, flowing steam through the atmosphere of step (a) at a controlled rate, and flowing the controlled humidity moist air atmosphere at said temperature to establish the atmosphere of step (b) at a controlled rate to cool the products to substantially the cold air temperature without dehydration.
29. The process as defined in claim 25 including in step (b) the control of the cooling atmosphere by circulation flow of humid sanitary water stripped air about the product at a pressure above atmospheric thereby to cool the products efficiently in a short time without dehydration while avoiding contamination.
30. The process as defined in claim 25 including in step (a) the control of the heating atmosphere by the flow of live high humidity steam about the product and the discharge of the steam at a low rate reducing heat energy loss.
31. The process as defined in claim 25 including the step inserted between step (a) and step (b) of retaining atmospheric heat from the flow path from exiting the heating step before entry into the cooling step, thereby improving energy efficiency.
32. The process as defined in claim 25 with the steam heating temperature in the order of 99°C and the pressure greater than atmospheric to improve cooking efficiency in a short time period.
33. The process as defined in claim 25 with the cooling atmosphere provided by circulating air through a water spray chamber and stripping the air flow of any water droplets remaining before flowing about the product, thereby to reduce dripping or accumulation of contamination from the product.
34. The process as defined in claim 25 of preparing steam for the steam heating step and chilled moist air for the cooling step from sanitary water thereby to avoid carrying external contamination into the process.
35. The process as defined in claim 25 including the step of increasing pressure of the heating and cooling steps above atmospheric, thereby to reduce losses of moisture from the product and to improve penetration of steam and cooling air residual temperatures into the product.
36. The process as defined in claim 35 including a step of partially controlling the pressure of the entire process by maintaining a pressure above atmospheric in a housing containing the flow path.
37. The process as defined in claim 25 wherein the flow path of the product is attained by passing a continuously running conveyor belt in sequence through the cooker and chiller and a sanitizing detergent bath.
38. The process defined in claim 25 wherein the heat-ing and chilling are accomplished in separate compartments and the flow path of the product is attained by passing a continuously running conveyor belt through the heating and chiller compartments in sequence and back to the cooker in a path outside the heating and chilling compartments.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US6098479A | 1979-07-26 | 1979-07-26 | |
| US060,988 | 1979-07-26 | ||
| US060,984 | 1979-07-26 | ||
| US06/060,988 US4363263A (en) | 1979-07-26 | 1979-07-26 | Efficient high humidity food processing system with sanitizing improvements |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1150095A true CA1150095A (en) | 1983-07-19 |
Family
ID=26740607
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000356856A Expired CA1150095A (en) | 1979-07-26 | 1980-07-23 | Efficient high humidity food processing system with sanitizing improvements |
Country Status (4)
| Country | Link |
|---|---|
| CA (1) | CA1150095A (en) |
| DE (1) | DE3028278C2 (en) |
| GB (2) | GB2056842B (en) |
| NL (1) | NL8004261A (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB9019506D0 (en) * | 1990-09-06 | 1990-10-24 | Leek Brian | Cleaning apparatus and method |
| DE19507578A1 (en) * | 1995-03-04 | 1996-09-05 | Kemper Gmbh & Co H | Method and device for ripening food batches |
| DE19857481A1 (en) * | 1998-12-14 | 2000-06-15 | Christoph Stolle | Continuous roasting of poultry as they pass on a conveyor through long ovens |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US998236A (en) * | 1910-07-11 | 1911-07-18 | Louis Detoy | Steaming, drying, and cooling apparatus. |
| US2846318A (en) * | 1954-08-30 | 1958-08-05 | E J Kelly & Associates Inc | Method of rapid cooling with minimal dehydration |
| DE1131497B (en) * | 1958-11-21 | 1962-06-14 | Fmc Corp | Device for cooking and cooling food in closed containers |
| FR1516498A (en) * | 1966-03-15 | 1968-03-08 | Frigoscandia Ab | Air conditioning installation for products |
| US3597228A (en) * | 1967-06-30 | 1971-08-03 | Cryodry Corp | Method of preparing precooked poultry pieces |
| DE2037079A1 (en) * | 1970-07-27 | 1972-02-03 | Braun Ag, 6000 Frankfurt | Circuit arrangement for generating a high-voltage pulse |
| GB1297917A (en) * | 1968-12-19 | 1972-11-29 | ||
| US4058635A (en) * | 1972-07-12 | 1977-11-15 | Buderus'sche Eisenwerke Aktiengesellschaft | Method of treating a foodstuff in an oven with moisture |
| US3982481A (en) * | 1972-08-18 | 1976-09-28 | Console Edward T | Food processing apparatus |
-
1980
- 1980-07-23 CA CA000356856A patent/CA1150095A/en not_active Expired
- 1980-07-24 NL NL8004261A patent/NL8004261A/en not_active Application Discontinuation
- 1980-07-24 GB GB8024216A patent/GB2056842B/en not_active Expired
- 1980-07-25 DE DE3028278A patent/DE3028278C2/en not_active Expired
-
1983
- 1983-03-01 GB GB08305588A patent/GB2122474B/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| DE3028278C2 (en) | 1983-01-27 |
| DE3028278A1 (en) | 1981-02-19 |
| GB8305588D0 (en) | 1983-03-30 |
| GB2056842A (en) | 1981-03-25 |
| GB2122474B (en) | 1984-06-13 |
| GB2122474A (en) | 1984-01-18 |
| GB2056842B (en) | 1983-10-05 |
| NL8004261A (en) | 1981-01-28 |
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