US20170020172A1 - De-Oiling Method in the Manufacture of Low Oil Potato Chips - Google Patents
De-Oiling Method in the Manufacture of Low Oil Potato Chips Download PDFInfo
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- US20170020172A1 US20170020172A1 US15/285,860 US201615285860A US2017020172A1 US 20170020172 A1 US20170020172 A1 US 20170020172A1 US 201615285860 A US201615285860 A US 201615285860A US 2017020172 A1 US2017020172 A1 US 2017020172A1
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- conveyor
- oil
- potato slices
- potato
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- 238000000034 method Methods 0.000 title claims abstract description 41
- 235000013606 potato chips Nutrition 0.000 title description 13
- 238000004519 manufacturing process Methods 0.000 title description 4
- 244000061456 Solanum tuberosum Species 0.000 claims abstract description 114
- 235000002595 Solanum tuberosum Nutrition 0.000 claims abstract description 114
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 65
- 239000000203 mixture Substances 0.000 claims abstract description 6
- 238000005507 spraying Methods 0.000 claims abstract description 4
- 239000007921 spray Substances 0.000 claims description 26
- 239000003921 oil Substances 0.000 description 56
- 235000019198 oils Nutrition 0.000 description 55
- 235000013305 food Nutrition 0.000 description 12
- 235000011888 snacks Nutrition 0.000 description 12
- 238000010411 cooking Methods 0.000 description 7
- 239000000796 flavoring agent Substances 0.000 description 6
- 235000019634 flavors Nutrition 0.000 description 6
- 230000018044 dehydration Effects 0.000 description 5
- 238000006297 dehydration reaction Methods 0.000 description 5
- 238000001035 drying Methods 0.000 description 4
- 238000011144 upstream manufacturing Methods 0.000 description 4
- 239000002360 explosive Substances 0.000 description 3
- 230000000007 visual effect Effects 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 239000003570 air Substances 0.000 description 2
- 238000007664 blowing Methods 0.000 description 2
- 235000004213 low-fat Nutrition 0.000 description 2
- 239000003595 mist Substances 0.000 description 2
- 235000016709 nutrition Nutrition 0.000 description 2
- 230000035807 sensation Effects 0.000 description 2
- 235000019615 sensations Nutrition 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 235000015112 vegetable and seed oil Nutrition 0.000 description 2
- 239000008158 vegetable oil Substances 0.000 description 2
- 235000019486 Sunflower oil Nutrition 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 235000011194 food seasoning agent Nutrition 0.000 description 1
- 235000001497 healthy food Nutrition 0.000 description 1
- 150000002632 lipids Chemical class 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000002600 sunflower oil Substances 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L5/00—Preparation or treatment of foods or foodstuffs, in general; Food or foodstuffs obtained thereby; Materials therefor
- A23L5/20—Removal of unwanted matter, e.g. deodorisation or detoxification
- A23L5/23—Removal of unwanted matter, e.g. deodorisation or detoxification by extraction with solvents
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L5/00—Preparation or treatment of foods or foodstuffs, in general; Food or foodstuffs obtained thereby; Materials therefor
- A23L5/20—Removal of unwanted matter, e.g. deodorisation or detoxification
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
- A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L19/00—Products from fruits or vegetables; Preparation or treatment thereof
- A23L19/10—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
- A23L19/12—Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
- A23L19/18—Roasted or fried products, e.g. snacks or chips
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L33/00—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L33/00—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof
- A23L33/20—Reducing nutritive value; Dietetic products with reduced nutritive value
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
- A23V2002/00—Food compositions, function of food ingredients or processes for food or foodstuffs
Definitions
- This invention relates to an apparatus and method for de-oiling potato slices in the manufacture of low oil potato chips.
- potato chips It has been known for many years to produce potato chips from slices of potato which are fried in oil, usually vegetable oil. Typical conventional potato chips have an oil content of about 30 to 35 wt % oil, based on the total weight of the potato chip. Potato chips exhibit specific organoleptic properties, in combination with visual appearance, to the consumer. The consumer desirous of purchasing a potato chip has a clear expectation of these product attributes in the product.
- lower oil snack food products including potato chips and other products.
- Some of these processes are produced by modified frying processes using different frying temperatures than those conventionally employed, or cooking processes other than frying, such as baking.
- Some of these products produce snack foods with low oil, even as low as 5 wt %, but the snack food product is not regarded by the consumer to be an acceptable alternative to a potato chip, because the product cannot exhibit the organoleptic properties, in combination with the visual appearance, of a potato chip.
- WO-A-2008/011489 and WO-A-2009/091674 in the name of Frito-Lay Trading Company GmbH disclose processes for making a healthy snack food.
- a snack food is made so as to have an appearance and taste similar to conventional fried snack products, such as a potato chip.
- the potato slices are subjected to a sequence of steps which avoids frying of the slices in oil, and the result is a low fat potato chip.
- these specifications disclose the use of microwave cooking of potato slices which have been preconditioned, for example by being treated in oil.
- the potato slices Prior to the microwave cooking process, the potato slices are flexible, and have a typical thickness of 1 to 2.5 mm.
- the microwave cooking rapidly, or explosively, dehydrates the potato slices to achieve low moisture content in a drying step which simulates the conventional frying dehydration rate.
- the rapid microwave dehydration rigidifies the cooked potato slices, so that they have a crispness resembling that of typical fried potato chips. Additional final drying steps may be employed, for example using microwave drying.
- the oil preconditioning step comprises lipophilic preconditioning by placing the slices into a warm oil flume, a batch kettle or a continuous oil dip.
- a final slice temperature of about 60° C. to about 99.9° C. and a duration of about 30 to 600 seconds may be employed.
- the oil removal step is disclosed as being performed using a variety of different wet methods, which may, for example, use at least one of the following: a steam blancher; a perforated rotating drum; washing in a hot or cold water bath; pressurised water jets; water knives; air knives; air atomised water nozzles; a mist of fine droplets of water; superheated steam or nitrogen; or centrifugal oil removal. It is disclosed that the most preferred embodiment uses a water spray comprising a mist of fine droplets of water.
- the present invention accordingly provides an apparatus for de-oiling potato slices, the apparatus comprising an elongate longitudinal conveyor having an upstream end and a downstream end, the conveyor being permeable to oil, water and air and being adapted to convey potato slices on the conveyor, a water spray station located towards the upstream end and a plurality of air-blower stations located in succession downstream of the water spray station, the water spray station comprising upper and lower water spray units adapted to spray water downwardly and upwardly, respectively, towards the conveyor, and each air-blower station comprising upper and lower air knife units adapted to direct an air blade downwardly and upwardly, respectively, towards the conveyor.
- the present invention further provides a method of de-oiling potato slices which have been coated in oil, the method comprising the steps of:
- the present inventors have found that the provision of such a sequence of specific de-oiler elements and steps, and the avoidance of steam treatment during de-oiling, can provide a resultant potato chip, produced by the lipophilic preconditioning and microwave explosive dehydration steps discussed above, which not only has low oil but also has the combination of flavour, organoleptic properties and shelf life in a non-fried potato chip which is equal or superior in consumer acceptance to conventional fried potato chips.
- the invention uses water and air to de-oil the potato slices, whereas the known use of steam de-oiling was found to cause oxidation of potato lipids which reduced the achievement of both the desired flavour and long shelf life.
- FIG. 1 is a schematic side view of an apparatus for de-oiling potato slices, prior to microwave cooking, according to an embodiment of the present invention.
- FIG. 1 An embodiment of an apparatus for de-oiling potato slices, prior to microwave cooking of the potato slices to form potato chips, according to one aspect of the present invention is illustrated in FIG. 1 .
- a primary endless belt conveyor 2 having a substantially horizontal orientation is provided.
- An inlet end of the conveyor 2 communicates with an exit of an oil flume 4 (illustrated schematically) comprising a lipophilic preconditioning unit for the potato slices 6 .
- the conveyor 2 carries a succession of the potato slices 6 on its upper surface 8 .
- the potato slices 6 have been randomly delivered onto the conveyor 2 .
- the potato slices 6 are delivered onto the conveyor 2 in a slice distribution so as to have at least about 50% of the slices being single slices, i.e. not overlapping with an adjacent slice.
- at least 50% of the overlaps are no more than 50% of the area of each of the respective overlapping slices.
- no more than two slices 6 are stacked one upon the other on the conveyor 2 . This substantially provides a monolayer of potato slices 6 across the length and width of the conveyor 2 .
- the potato slices 6 typically have a thickness of 1 to 2.5 mm, more typically about 1.3 mm (51 thousandths of an inch).
- the potato slices 6 have been pre-treated in oil in the lipophilic preconditioning process and initially, prior to the de-oiling step, have about 30 to 45 wt % surface oil, typically about 40 wt % surface oil based on the dry weight of the final potato chip produced from the potato slice 6 .
- dry weight of the final potato chip assumes 2 wt % water content in the total weight of the final cooked and dried potato chip, prior to final seasoning of the potato chip.
- the oil typically comprises a vegetable oil such as sunflower oil, conventionally used for manufacturing potato chips.
- the oil is employed in the lipophilic preconditioning to provide the required organoleptic properties to the resultant potato chip, which has been cooked by the combination of the preliminary oil treating step and the subsequent microwave cooking step, and has not been fried, as for a conventional potato chip.
- the conveyor 2 has a translational speed of from 0.1 to 0.5 m/second, typically about 0.2 m/second.
- air is blown downwardly onto the potato slices 6 in a continuous manner at a primary air-blower station 18 .
- the velocity of the air is typically from 30 to 60 metres per second, more typically from 40 to 50 metres per second, optionally from 45 to 50 metres per second.
- the primary air-blower station 18 comprises a set of a plurality of primary air knives 10 , 12 which are mounted above the primary conveyor 2 . In the embodiment, two longitudinally spaced air knives 10 , 12 are provided.
- Each of the air knives 10 , 12 typically has an air exit aperture 14 extending along the length of the air knife 10 , 12 , which extends transversely across the conveyor 2 , for generating a downwardly-directed air blade 16 extending across the width of the conveyor 2 .
- the air exit aperture 14 may have a width of from 0.5 to 1.5 mm, optionally 0.75 to 1.25 mm, further optionally about 1 mm.
- Each air knife 10 , 12 is located so that a distance from the air exit aperture 14 to the upper surface 8 of the conveyor 2 carrying the potato slices 6 is from 20 to 40 mm, optionally 25 to 35 mm, further optionally about 30 mm.
- the air knives 10 , 12 generate downwardly directed parallel air blades 16 , spaced in the direction of movement of the potato slices 6 along the conveyor 2 , and act to blow excess surface oil on the potato slices 6 back into an oil supply for the lipophilic preconditioning apparatus.
- the air blades 16 most typically have an air velocity of 48 m/second.
- the excess oil removed by the air blades 16 is blown downwardly through the conveyor 2 , and is captured by an oil capture device 20 located thereunder.
- the conveyor 2 is permeable to the oil and typically comprises an open mesh structure, for example comprised of a stainless steel balanced spiral wire mesh belt.
- the air knives 10 , 12 are parallel and longitudinally separated by a distance of, for example, a distance of from 100 to 300 mm, typically about 150 mm, so that each potato slice 6 is sequentially impacted by plural air blades 16 during the passage of the potato slice 6 through the primary air-blower station 18 .
- the air knives 10 , 12 may be separated by a distance which is less than a typical dimension of a potato chip, for example a distance of less than 50 mm, such as 30 to 40 mm, so that each potato slice 6 is simultaneously impacted by plural air blades 16 during at least a portion of the passage of the potato slice 6 through the primary air-blower station 18 .
- the air knives 10 , 12 are inclined rearwardly so that the displaced oil is directed rearwardly into the oil capture device 20 , which enhances oil capture.
- the de-oiler unit 21 includes a second de-oiler belt conveyor 22 which, similar to conveyor 2 , is an endless belt mounted substantially horizontally and has a belt speed of from 0.1 to 0.5 m/second, typically about 0.2 m/second.
- the conveyor 22 is also permeable to oil and water, and comprises a similar open mesh structure as conveyor 2 , for example a stainless steel balanced spiral wire mesh belt.
- the de-oiler conveyor 22 conveys the potato slices 6 from an upstream end 24 to a downstream end 26 through a succession of de-oiling stations.
- a first de-oiling station 28 located relatively upstream along the conveyor 22 , comprises a water spray station 30 which sprays water onto the potato slices 6 which are carried on the upper surface 32 of the conveyor 22 .
- the water is sprayed both downwardly from an upper water spray device 38 , forming an upper spray 39 , and upwardly from a lower water spray device 40 , forming a lower spray 41 .
- a plurality of water pressure nozzles is provided across the width of the conveyor 22 .
- the water exits of the water spray devices 38 , 40 are located a distance of from 50 to 150 mm, optionally 75 to 125 mm, further optionally about 100 mm, from the conveyor upper surface 32 carrying the potato slices 6 .
- water is sprayed onto both upper and lower major surfaces 34 , 36 of each of the potato slices 6 .
- the water spray impacts on the upper and lower surfaces 34 , 36 of the potato slices 6 and acts to displace and lift surface oil from the surfaces of the slice 6 .
- a typical water feed rate from each of the upper and lower water devices 38 , 40 is from 3 to 5 kilograms of water per minute, optionally from 4 to 4.5 litres of water per minute, most typically 4.2 litres/minute, for a typical potato slice throughput of 250 kilograms per hour, i.e. from 0.72 to 1.2 litres of water per hour per kg of potato slices per hour, optionally from 0.96 to 1.08 litres of water per hour per kg of potato slices per hour.
- a succession of pairs of oppositely directed secondary air knives, and directed towards each other, is employed to remove the lifted oil, mixed together with the residual water, from the surfaces 34 . 36 of the potato slices 6 .
- three successive sets 42 , 44 , 46 of upper and lower air knives are employed, which sets 42 , 44 , 46 are located in a mutually spaced configuration extending along a portion of the length of the conveyor 22 downstream of the water spray station 30 .
- the conveyor 22 there are plural parallel sets 42 , 44 , 46 of upper and lower secondary air knives mounted above and below the conveyor 22 which are adapted to provide high velocity air, as a narrow blade-like flow extending across the width of the conveyor 22 , with the high velocity air blade blowing the water and oil mixture from the surfaces 34 , 36 of the potato slices 6 .
- the velocity of the air is typically from 30 to 60 metres per second.
- the water and oil mixture which has been blown off the slices falls downwardly into a base 60 of the de-oiler unit for removal and reuse or recycling.
- the air blades produced from the sets 42 , 44 , 46 of upper and lower air knives are parallel.
- a first air knife set 42 comprises upper and lower air knives 48 , 50 each of which is arranged to blow an air blade 52 , 54 at a high velocity onto the upper or lower surface 34 , 36 , respectively, of the potato slices 6 on the conveyor 6 .
- the air velocity may be from 30 to 40 metres per second, optionally from 32 to 37 metres per second.
- the upper air knife 48 has an air blade velocity of 34 m/second and the lower air knife 50 has an air blade velocity of 35 m/second.
- a second air knife set 44 comprises upper and lower air knives 56 , 58 each of which is arranged to blow an air blade 62 , 64 at a high velocity onto the upper or lower surface 34 , 36 , respectively, of the potato slices 6 .
- the air velocity may be from 40 to 50 metres per second, optionally from 45 to 50 metres per second.
- the upper air knife 56 has an air blade velocity of 47 m/second and the lower air knife 58 has an air blade velocity of 47 m/second.
- a third air knife set 46 comprises upper and lower air knives 66 , 68 each of which is arranged to blow an air blade 70 , 72 at a high velocity onto the upper or lower surface 34 , 36 , respectively, of the potato slices 6 .
- the air velocity may be from 40 to 50 metres per second, optionally from 45 to 50 metres per second.
- the upper air knife 66 has an air blade velocity of 46 m/second and the lower air knife 68 has a velocity of 47 m/second.
- a typical distance from the respective upper or lower air knife exit aperture 74 , 76 to the upper surface 32 of the conveyor 22 carrying the potato slices 6 is from 20 to 40 mm, optionally 25 to 35 mm, further optionally about 30 mm.
- Each of the air knives 48 , 50 , 56 , 58 , 66 , 68 has an exit aperture 74 , 76 extending along the length of the air knife 48 , 50 , 56 , 58 , 66 , 68 , which exit aperture 74 , 76 extends transversely across the conveyor 22 , for generating an air blade 52 , 54 , 62 , 64 , 70 , 72 extending across the width of the conveyor 22 .
- the air exit apertures 74 , 76 may have a width of from 0.5 to 1.5 mm, optionally 0.75 to 1.25 mm, further optionally about 1 mm.
- a longitudinally oriented hold-down belt 80 is located above the conveyor 22 in the vicinity of the air knife sets 42 , 44 , 46 .
- the potato slices 6 are conveyed between the lower conveyor 22 and the upper hold-down belt 80 and are held in position as they are conveyed successively past the air knife sets 42 , 44 , 46 .
- the hold-down belt 80 is typically undriven, but it may alternatively be driven so as to assist the conveyor 22 .
- a larger number of air knife pairs is provided, which can provide enhanced uniformity of oil content of the de-oiled potato slices.
- the air knives 10 , 12 blow air only downwardly, a hold-down belt is not required.
- the potato slices 6 are agitated by the downwardly blown air from the air knives 10 , 12 , which agitation assists removal of free surface oil, but the slices remain on the conveyor 2 .
- the final oil percent amount in the de-oiled potato slices 6 is achieved by balancing the amount of water and the amount of air supplied. It is possible to use more air and less water and vice versa to fine tune the de-oiling operation and the final oil content.
- the target final oil content for the potato slices using the de-oiler is 12.5 wt % oil+/ ⁇ 2 wt % based on the dry weight, having 2 wt % water content, of the final cooked and dried potato chip after microwave explosive dehydration and final drying.
- a single conveyor may be used instead of the combination of a primary conveyor and a de-oiler conveyor, and/or the number of air knives and/or water spray stations may be varied.
Abstract
A method of de-oiling potato slices, which have been coated in oil, the steps of the method including providing a plurality of potato slices that were pre-treated in oil; and randomly feeding the potato slices onto an elongate longitudinal conveyor which is permeable to oil, water and air. Further, the method includes spraying water downwardly and upwardly onto the plurality of potato slices on the conveyor to displace and lift surface oil from the potato slices. Then, directing air blades to blow a mixture of oil and water from the potato slices as these move along the conveyor.
Description
- This application is divisional of U.S. application Ser. No. 13/982,468 filed Oct. 9, 2013, which is a 371 National Stage Application claiming priority to PCT Application No. PCT/EP2012/051346 filed Jan. 27, 2012, which claims priority to Great Britain Application No. 1101607.8 filed Jan. 31, 2011, now GB Patent No. 2481469 issued Feb. 13, 2013, the technical disclosures of which are hereby incorporated by reference.
- This invention relates to an apparatus and method for de-oiling potato slices in the manufacture of low oil potato chips.
- It has been known for many years to produce potato chips from slices of potato which are fried in oil, usually vegetable oil. Typical conventional potato chips have an oil content of about 30 to 35 wt % oil, based on the total weight of the potato chip. Potato chips exhibit specific organoleptic properties, in combination with visual appearance, to the consumer. The consumer desirous of purchasing a potato chip has a clear expectation of these product attributes in the product.
- There is a general desire among snack food manufacturers, consumers and regulatory authorities for healthier food products. In the snack food industry, this has led to a desire for lower fat products. However, even though there may be a general consumer awareness of the benefits of eating lower fat versions of, or alternatives to, existing snack food products, the consumer generally requires the product to have desirable attributes such as texture and flavour. Even if a snack food product is produced which has high nutritional attributes, unless it also has the texture and flavour required by the consumer, the product would not successfully provide the consumer with an acceptable product to replace previous, less healthy snack food products. The challenge among snack food manufacturers is to produce nutritional or more healthy foods which provide the consumer with an improved taste and sensation experience, or at the very least do not compromise on taste and sensation as compared to the consumer's expectation for the particular product or class of products purchased.
- There are in the market so-called lower oil snack food products, including potato chips and other products. Some of these processes are produced by modified frying processes using different frying temperatures than those conventionally employed, or cooking processes other than frying, such as baking. Some of these products produce snack foods with low oil, even as low as 5 wt %, but the snack food product is not regarded by the consumer to be an acceptable alternative to a potato chip, because the product cannot exhibit the organoleptic properties, in combination with the visual appearance, of a potato chip.
- WO-A-2008/011489 and WO-A-2009/091674 in the name of Frito-Lay Trading Company GmbH disclose processes for making a healthy snack food. In those processes, a snack food is made so as to have an appearance and taste similar to conventional fried snack products, such as a potato chip. The potato slices are subjected to a sequence of steps which avoids frying of the slices in oil, and the result is a low fat potato chip.
- In particular, these specifications disclose the use of microwave cooking of potato slices which have been preconditioned, for example by being treated in oil. Prior to the microwave cooking process, the potato slices are flexible, and have a typical thickness of 1 to 2.5 mm. The microwave cooking rapidly, or explosively, dehydrates the potato slices to achieve low moisture content in a drying step which simulates the conventional frying dehydration rate. The rapid microwave dehydration rigidifies the cooked potato slices, so that they have a crispness resembling that of typical fried potato chips. Additional final drying steps may be employed, for example using microwave drying.
- It is disclosed that the oil preconditioning step comprises lipophilic preconditioning by placing the slices into a warm oil flume, a batch kettle or a continuous oil dip. During the lipophilic preconditioning step, a final slice temperature of about 60° C. to about 99.9° C. and a duration of about 30 to 600 seconds may be employed.
- Subsequent to the lipophilic preconditioning step an oil removal step is employed. The oil removal step is disclosed as being performed using a variety of different wet methods, which may, for example, use at least one of the following: a steam blancher; a perforated rotating drum; washing in a hot or cold water bath; pressurised water jets; water knives; air knives; air atomised water nozzles; a mist of fine droplets of water; superheated steam or nitrogen; or centrifugal oil removal. It is disclosed that the most preferred embodiment uses a water spray comprising a mist of fine droplets of water.
- Although a wide variety of such oil removal processes is disclosed in those prior specifications, there is still a need to provide a de-oiling process which provides a lower oil content potato slice that has a consumer acceptance on parity with conventional fried potato chips. It is necessary to accurately control the de-oiling process to achieve a desired oil content after the lipophilic preconditioning step so that the resultant flavour and organoleptic properties are achieved in the subsequent processing steps, which include microwave explosive dehydration.
- Furthermore, there is still a need to provide an oil content during the processing which ensures that the final non-fried potato chip has a lower oil content as compared to conventional fried potato chips yet has a consumer acceptance, provided by the resultant flavour and organoleptic properties, on parity with conventional fried potato chips.
- There is accordingly still a need for an apparatus and method for efficiently and reliably manufacturing, in a cost effective manner, a low fat potato chip which has not been fried but has organoleptic properties, in combination with the visual appearance, of a conventional fried potato chip.
- The present invention accordingly provides an apparatus for de-oiling potato slices, the apparatus comprising an elongate longitudinal conveyor having an upstream end and a downstream end, the conveyor being permeable to oil, water and air and being adapted to convey potato slices on the conveyor, a water spray station located towards the upstream end and a plurality of air-blower stations located in succession downstream of the water spray station, the water spray station comprising upper and lower water spray units adapted to spray water downwardly and upwardly, respectively, towards the conveyor, and each air-blower station comprising upper and lower air knife units adapted to direct an air blade downwardly and upwardly, respectively, towards the conveyor.
- The present invention further provides a method of de-oiling potato slices which have been coated in oil, the method comprising the steps of:
-
- (a) providing a plurality of potato slices, each slice having been pretreated in oil;
- (b) randomly feeding the potato slices onto an elongate longitudinal conveyor which is permeable to oil, water and air;
- (c) spraying water downwardly and upwardly from respective upper and lower water spray units onto the plurality of potato slices on the conveyor to cause the water to displace and lift surface oil on the potato slices; and
- (d) thereafter directing upper and lower air blades downwardly and upwardly, respectively, onto the plurality of potato slices on the conveyor to cause the air blades to blow a mixture of oil and water from the potato slices, wherein the air blades comprise a plurality of pairs of upper and lower air blades spaced along the conveyor.
- Preferred features are defined in the dependent claims.
- The present inventors have found that the provision of such a sequence of specific de-oiler elements and steps, and the avoidance of steam treatment during de-oiling, can provide a resultant potato chip, produced by the lipophilic preconditioning and microwave explosive dehydration steps discussed above, which not only has low oil but also has the combination of flavour, organoleptic properties and shelf life in a non-fried potato chip which is equal or superior in consumer acceptance to conventional fried potato chips. In particular, the invention uses water and air to de-oil the potato slices, whereas the known use of steam de-oiling was found to cause oxidation of potato lipids which reduced the achievement of both the desired flavour and long shelf life.
- An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:
-
FIG. 1 is a schematic side view of an apparatus for de-oiling potato slices, prior to microwave cooking, according to an embodiment of the present invention. - An embodiment of an apparatus for de-oiling potato slices, prior to microwave cooking of the potato slices to form potato chips, according to one aspect of the present invention is illustrated in
FIG. 1 . - A primary
endless belt conveyor 2 having a substantially horizontal orientation is provided. An inlet end of theconveyor 2 communicates with an exit of an oil flume 4 (illustrated schematically) comprising a lipophilic preconditioning unit for thepotato slices 6. Theconveyor 2 carries a succession of thepotato slices 6 on its upper surface 8. Thepotato slices 6 have been randomly delivered onto theconveyor 2. Thepotato slices 6 are delivered onto theconveyor 2 in a slice distribution so as to have at least about 50% of the slices being single slices, i.e. not overlapping with an adjacent slice. In addition, at least 50% of the overlaps are no more than 50% of the area of each of the respective overlapping slices. Also, for each overlap no more than twoslices 6 are stacked one upon the other on theconveyor 2. This substantially provides a monolayer ofpotato slices 6 across the length and width of theconveyor 2. - The
potato slices 6 typically have a thickness of 1 to 2.5 mm, more typically about 1.3 mm (51 thousandths of an inch). - The
potato slices 6 have been pre-treated in oil in the lipophilic preconditioning process and initially, prior to the de-oiling step, have about 30 to 45 wt % surface oil, typically about 40 wt % surface oil based on the dry weight of the final potato chip produced from thepotato slice 6. In this specification the “dry weight of the final potato chip” assumes 2 wt % water content in the total weight of the final cooked and dried potato chip, prior to final seasoning of the potato chip. The oil typically comprises a vegetable oil such as sunflower oil, conventionally used for manufacturing potato chips. The oil is employed in the lipophilic preconditioning to provide the required organoleptic properties to the resultant potato chip, which has been cooked by the combination of the preliminary oil treating step and the subsequent microwave cooking step, and has not been fried, as for a conventional potato chip. - The
conveyor 2 has a translational speed of from 0.1 to 0.5 m/second, typically about 0.2 m/second. As thepotato slices 6 are carried on the upper surface of theprimary conveyor 2, air is blown downwardly onto thepotato slices 6 in a continuous manner at a primary air-blower station 18. The velocity of the air is typically from 30 to 60 metres per second, more typically from 40 to 50 metres per second, optionally from 45 to 50 metres per second. The primary air-blower station 18 comprises a set of a plurality of primary air knives 10, 12 which are mounted above theprimary conveyor 2. In the embodiment, two longitudinally spaced air knives 10, 12 are provided. Each of the air knives 10, 12 typically has anair exit aperture 14 extending along the length of the air knife 10, 12, which extends transversely across theconveyor 2, for generating a downwardly-directedair blade 16 extending across the width of theconveyor 2. Theair exit aperture 14 may have a width of from 0.5 to 1.5 mm, optionally 0.75 to 1.25 mm, further optionally about 1 mm. Each air knife 10, 12 is located so that a distance from theair exit aperture 14 to the upper surface 8 of theconveyor 2 carrying the potato slices 6 is from 20 to 40 mm, optionally 25 to 35 mm, further optionally about 30 mm. - The air knives 10, 12 generate downwardly directed
parallel air blades 16, spaced in the direction of movement of the potato slices 6 along theconveyor 2, and act to blow excess surface oil on the potato slices 6 back into an oil supply for the lipophilic preconditioning apparatus. Theair blades 16 most typically have an air velocity of 48 m/second. - For example, the excess oil removed by the
air blades 16 is blown downwardly through theconveyor 2, and is captured by anoil capture device 20 located thereunder. Theconveyor 2 is permeable to the oil and typically comprises an open mesh structure, for example comprised of a stainless steel balanced spiral wire mesh belt. - The air knives 10, 12 are parallel and longitudinally separated by a distance of, for example, a distance of from 100 to 300 mm, typically about 150 mm, so that each
potato slice 6 is sequentially impacted byplural air blades 16 during the passage of thepotato slice 6 through the primary air-blower station 18. Alternatively, the air knives 10, 12 may be separated by a distance which is less than a typical dimension of a potato chip, for example a distance of less than 50 mm, such as 30 to 40 mm, so that eachpotato slice 6 is simultaneously impacted byplural air blades 16 during at least a portion of the passage of thepotato slice 6 through the primary air-blower station 18. Optionally, the air knives 10, 12 are inclined rearwardly so that the displaced oil is directed rearwardly into theoil capture device 20, which enhances oil capture. - After this preliminary step of blowing off excess surface oil with air blades, the
conveyor 2 feeds the potato slices 6 to ade-oiler unit 21. Thede-oiler unit 21 includes a secondde-oiler belt conveyor 22 which, similar toconveyor 2, is an endless belt mounted substantially horizontally and has a belt speed of from 0.1 to 0.5 m/second, typically about 0.2 m/second. Theconveyor 22 is also permeable to oil and water, and comprises a similar open mesh structure asconveyor 2, for example a stainless steel balanced spiral wire mesh belt. Thede-oiler conveyor 22 conveys the potato slices 6 from anupstream end 24 to adownstream end 26 through a succession of de-oiling stations. - A first
de-oiling station 28, located relatively upstream along theconveyor 22, comprises awater spray station 30 which sprays water onto the potato slices 6 which are carried on theupper surface 32 of theconveyor 22. The water is sprayed both downwardly from an upperwater spray device 38, forming anupper spray 39, and upwardly from a lowerwater spray device 40, forming alower spray 41. Typically, in each water-spray device 38, 40 a plurality of water pressure nozzles is provided across the width of theconveyor 22. Typically, the water exits of thewater spray devices upper surface 32 carrying the potato slices 6. - At the
water spray station 30, water is sprayed onto both upper and lowermajor surfaces lower surfaces slice 6. - A typical water feed rate from each of the upper and
lower water devices - After this initial surface oil lifting step using water, a succession of pairs of oppositely directed secondary air knives, and directed towards each other, is employed to remove the lifted oil, mixed together with the residual water, from the
surfaces 34. 36 of the potato slices 6. In the embodiment, threesuccessive sets conveyor 22 downstream of thewater spray station 30. - Accordingly, there are plural parallel sets 42, 44, 46 of upper and lower secondary air knives mounted above and below the
conveyor 22 which are adapted to provide high velocity air, as a narrow blade-like flow extending across the width of theconveyor 22, with the high velocity air blade blowing the water and oil mixture from thesurfaces sets - A first air knife set 42 comprises upper and
lower air knives 48, 50 each of which is arranged to blow anair blade lower surface conveyor 6. For theseair knives 48, 50 the air velocity may be from 30 to 40 metres per second, optionally from 32 to 37 metres per second. Typically, the upper air knife 48 has an air blade velocity of 34 m/second and thelower air knife 50 has an air blade velocity of 35 m/second. - A second air knife set 44 comprises upper and lower air knives 56, 58 each of which is arranged to blow an
air blade lower surface - A third air knife set 46 comprises upper and
lower air knives 66, 68 each of which is arranged to blow anair blade lower surface air knives 66, 68 the air velocity may be from 40 to 50 metres per second, optionally from 45 to 50 metres per second. Typically, theupper air knife 66 has an air blade velocity of 46 m/second and the lower air knife 68 has a velocity of 47 m/second. - The use of a plurality of sequential successive pairs of oppositely directed air knives mounted both above and below the
conveyor 22 in the de-oiler unit provides a greater degree of control in achieving a desired weight % of oil in thede-oiled potato slices 6 leaving thede-oiler unit 21. - For each of the air knife sets 42, 44, 46, a typical distance from the respective upper or lower air
knife exit aperture upper surface 32 of theconveyor 22 carrying the potato slices 6 is from 20 to 40 mm, optionally 25 to 35 mm, further optionally about 30 mm. Each of theair knives exit aperture air knife aperture conveyor 22, for generating anair blade conveyor 22. Theair exit apertures - Since the air knife sets 42, 44, 46 blow air upwardly as well as downwardly, in order to avoid the potato slices 6 being blown off the conveyor 22 a longitudinally oriented hold-down
belt 80 is located above theconveyor 22 in the vicinity of the air knife sets 42, 44, 46. The potato slices 6 are conveyed between thelower conveyor 22 and the upper hold-downbelt 80 and are held in position as they are conveyed successively past the air knife sets 42, 44, 46. The hold-downbelt 80 is typically undriven, but it may alternatively be driven so as to assist theconveyor 22. - In the illustrated embodiment, there are three sets of
air knives water spray station 30. In other embodiments a larger number of air knife pairs is provided, which can provide enhanced uniformity of oil content of the de-oiled potato slices. In contrast, since the air knives 10, 12 blow air only downwardly, a hold-down belt is not required. The potato slices 6 are agitated by the downwardly blown air from the air knives 10, 12, which agitation assists removal of free surface oil, but the slices remain on theconveyor 2. - The final oil percent amount in the de-oiled potato slices 6 is achieved by balancing the amount of water and the amount of air supplied. It is possible to use more air and less water and vice versa to fine tune the de-oiling operation and the final oil content. The target final oil content for the potato slices using the de-oiler is 12.5 wt % oil+/−2 wt % based on the dry weight, having 2 wt % water content, of the final cooked and dried potato chip after microwave explosive dehydration and final drying.
- In modifications to the illustrated embodiment, a single conveyor may be used instead of the combination of a primary conveyor and a de-oiler conveyor, and/or the number of air knives and/or water spray stations may be varied.
Claims (20)
1. A method of de-oiling potato slices which have been coated in oil, the method comprising the steps of:
(a) providing a plurality of potato slices, each slice having been pretreated in oil;
(b) randomly feeding the potato slices onto an elongate longitudinal conveyor which is permeable to oil, water and air;
(c) spraying water downwardly and upwardly from respective upper and lower water spray units onto the plurality of potato slices on the conveyor to cause the water to displace and lift surface oil on the potato slices; and
(d) thereafter directing upper and lower air blades downwardly and upwardly, respectively, onto the plurality of potato slices on the conveyor to cause the air blades to blow a mixture of oil and water from the potato slices, wherein the air blades comprise a plurality of pairs of upper and lower air blades spaced along the conveyor.
2. A method according to claim 1 wherein in step (b) the potato slices are fed onto the conveyor in a substantially non-overlapping configuration.
3. A method according to claim 1 , wherein the upper and lower water spray units are spaced a distance of from 50 to 150 mm, from the potato slices on the conveyor.
4. A method according to claim 1 , wherein the upper and lower water spray units are adapted each to spray from 0.72 to 1.2 litres of water per hour per kg of potato slices per hour, towards the conveyor.
5. A method according to claim 1 , wherein at least three pairs of parallel air blades are located in succession downstream of the water spray units.
6. A method according to claim 1 , wherein air blades are generated from respective air exit apertures having a width of from 0.5 to 1.5 mm.
7. A method according to claim 6 , wherein the air exit aperture is a distance from the conveyor of from 20 to 40 mm.
8. A method according to claim 1 , wherein the air blade has an air velocity of from 30 to 60 metres per second.
9. A method according to claim 8 , wherein the upper and lower air blades of a first pair of air blades located downstream of the water spray units have an air velocity of from 30 to 40 metres per second.
10. A method according to claim 9 , wherein the upper and lower air blades of a second pair of air blades located downstream of the first pair of air blades have an air velocity of from 40 to 50 metres per second.
11. A method according to claim 10 , wherein the upper and lower air blades of a third pair of air blades located downstream of the second pair of air blades have an air velocity of from 40 to 50 metres per second.
12. A method according to claim 1 , further comprising the step, between steps (b) and (c) of directing at least one primary air blade downwardly towards the potato slices on a primary conveyor.
13. A method according to claim 12 , wherein two primary air blades are provided which are longitudinally separated by a distance of from 100 to 300 mm.
14. A method according to claim 13 , wherein the primary air blades are each generated from a respective primary air exit aperture having a width of from 0.5 to 1.5 mm.
15. A method according to claim 14 , wherein the primary air exit aperture is a distance from the potato slices of from 20 to 40 mm.
16. A method according to claim 12 , wherein the primary air blade has an air velocity of from 30 to 60 metres per second.
17. A method according to claim 1 , wherein in step (a) the potato slices have an oil content of about 30 to 45 wt % oil, based on the dry weight of the final potato chip produced from the potato slice, and the potato slices after being de-oiled in step (d), have an oil content of about 10 to 15 wt % oil, based on the dry weight of the final potato chip produced from the potato slice.
18. A method according to claim 1 , further comprising holding the slices on the conveyor at least one of the air-blower station by an upper belt located above the conveyor, the slices being fed between the conveyor and the upper belt.
19. A method of de-oiling potato slices which have been coated in oil, the method comprising the steps of:
(a) lipophillically pretreating a plurality of potato slices in oil;
(b) randomly feeding the pretreated plurality of potato slices onto an elongate longitudinal conveyor which is permeable to oil, water and air;
(c) spraying water downwardly and upwardly onto the plurality of potato slices on the conveyor to cause the sprayed water to displace and lift surface oil off the potato slices; and
(d) directing upper and lower air blades onto the plurality of potato slices on the conveyor to cause the air blades to blow a mixture of oil and water from the potato slices, wherein the air blades comprise a plurality of pairs of upper and lower air blades spaced along the conveyor.
20. A method according to claim 19 , wherein after step (d) the plurality of potato slices have an oil content of about 10 to 15 wt % oil, based on the dry weight of a final potato chip product produced from the potato slice.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US15/285,860 US20170020172A1 (en) | 2011-01-31 | 2016-10-05 | De-Oiling Method in the Manufacture of Low Oil Potato Chips |
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GB1101607.8A GB2481469B (en) | 2011-01-31 | 2011-01-31 | De-oiling apparatus and method in the manufacture of low oil potato chips |
GB1101607.8 | 2011-01-31 | ||
PCT/EP2012/051346 WO2012104216A1 (en) | 2011-01-31 | 2012-01-27 | De-oiling apparatus and method in the manufacture of low oil potato chips |
US201313982468A | 2013-10-09 | 2013-10-09 | |
US15/285,860 US20170020172A1 (en) | 2011-01-31 | 2016-10-05 | De-Oiling Method in the Manufacture of Low Oil Potato Chips |
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US13/982,468 Division US9521857B2 (en) | 2011-01-31 | 2012-01-27 | De-oiling apparatus and method in manufacture of low oil potato chips |
PCT/EP2012/051346 Division WO2012104216A1 (en) | 2011-01-31 | 2012-01-27 | De-oiling apparatus and method in the manufacture of low oil potato chips |
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AU2013403970B2 (en) | 2013-11-01 | 2019-04-04 | General Mills, Inc. | Oil removal from food surface |
GB2536626B (en) * | 2015-03-18 | 2017-09-27 | Frito-Lay Trading Company (Europe) Gmbh | De-oiling method in the manufacture of low oil snack food |
GB2539540B (en) * | 2015-03-18 | 2019-09-04 | Frito Lay Trading Co Gmbh | Food slice de-watering method |
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- 2012-01-27 US US13/982,468 patent/US9521857B2/en active Active
- 2012-01-27 EP EP12701515.4A patent/EP2670258B1/en active Active
- 2012-01-27 ES ES12701515.4T patent/ES2546428T3/en active Active
- 2012-01-27 PL PL12701515T patent/PL2670258T3/en unknown
- 2012-01-27 CA CA2823650A patent/CA2823650C/en not_active Expired - Fee Related
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Also Published As
Publication number | Publication date |
---|---|
GB2481469B (en) | 2013-02-13 |
US9521857B2 (en) | 2016-12-20 |
CA2823650A1 (en) | 2012-08-09 |
EP2670258B1 (en) | 2015-07-01 |
EP2670258A1 (en) | 2013-12-11 |
US20140030407A1 (en) | 2014-01-30 |
CA2823650C (en) | 2015-03-31 |
GB201101607D0 (en) | 2011-03-16 |
GB2481469A (en) | 2011-12-28 |
PL2670258T3 (en) | 2015-12-31 |
AU2012213566A1 (en) | 2013-08-15 |
WO2012104216A1 (en) | 2012-08-09 |
ES2546428T3 (en) | 2015-09-23 |
AU2012213566B2 (en) | 2014-10-30 |
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AS | Assignment |
Owner name: FRITO-LAY TRADING COMPANY GMBH, SWITZERLAND Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SPURR, MICHAEL ALFRED JAMES;NEWBERRY, BRIAN RICHARD;REEL/FRAME:040233/0316 Effective date: 20131002 |
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Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |