WO1988002999A1

WO1988002999A1 - Apparatus and method for preparing fried potato products

Info

Publication number: WO1988002999A1
Application number: PCT/US1987/002698
Authority: WO
Inventors: William Bartfield; Michael Segundo
Original assignee: Prize Frize, Inc.
Priority date: 1986-10-22
Filing date: 1987-10-22
Publication date: 1988-05-05
Also published as: EP0288522A1; FI882998A; FI882998A0; AU8155787A; BR8707512A; CA1330739C; EP0288522A4; JPH01500963A

Abstract

Apparatus and method for preparing hot food products in portions of predetermined size by rehydrating a dehydrated food product to provide a dough that can be shaped and heated. The apparatus includes means (18) for storing bags of dehydrated product and for opening individual bags as needed to maintain a desired level of dehydrated product in a hopper. Rehydration means (22) are provided, including a metering chamber (80) to meter a portion of the dehydrated food product, and a rehydration head (86) to uniformly wet the dehydrated food product to form a coherent dough. The dough is passed through a forming means to form it into predetermined pieces that are extruded from a forming chamber, and a wire knife (152) passes linearly across the forming chamber to separate the extruded product therefrom. A product transfer conveyor (208) is provided to convey the shaped dough pieces to a fryer vessel (222) in which heated frying oil is provided.

Description

APPARATUS AND METHOD FOR PREPARING FRIED POTATO PRODUCTS

Cross-Reference to Related Application

This application is a continuation-in-part of co-pending application Serial No. 728,208, filed April 29, 1985, and entitled, "APPARATUS AND METHOD FOR PREPARING FRIED POTATO PRODUCTS", which is a continuation-in-part of co-pending application Serial No. 593,584, filed March 26 , 1984, and entitled, "APPARATUS AND METHOD FOR DISPENSING INDIVIDUAL ORDERS OF A HOT FOOD PRODUCTS", which is a division of application Serial No. 352,579, filed February 26, 1982, now U.S. Patent 4,438,683.

Background of the Invention

The invention relates to apparatus and a method for preparing heated food products, and more particularly to a method and apparatus for preparing and dispensing individual portions of a fried potato product prepared from dehydrated potatoes that are rehydrated immediately prior to frying and dispensing, and to a method of frying such products. Various types of devices and methods have been disclosed for preparing hot food products from dehydrated food products that are reconstituted by adding water, formed, and then cooked or fried to provide the desired product. The co-pending application of which the present application is a continuation-in-part discloses an apparatus and a method for preparing a french fried potato product that is shaped from a dough prepared in the apparatus by rehydrating dehydrated potatoes. The dehydrated potatoes are reconstituted in situ to provide a dough that can be formed in the desired shape, and then fried and dispensed. The apparatus therein disclosed provides a product that closely resembles french fried potatoes that have been prepared by frying cut raw potatoes, the resemblance extending to the taste, the appearance, and the texture of the resulting product. The present invention is directed to improvements in the apparatus and method disclosed in the parent application.

It is an object of the present invention to provide an apparatus and method for preparing and dispensing a fried food product in which each individual portion is separately prepared. It is a further object of the present invention to provide am apparatus in the form of a vending machine for preparing a fried food product for immediate dispensing.

It is still a further object of the present invention to provide an apparatus and method for preparing a fried food product for dispensing in a dispensing machine and in which product residues that remain after a dispensing operation are minimized in order to maintain high sanitation levels.

Summary of the Invention

Briefly stated, in accordance with one aspect of the present invention, apparatus for preparing and dispensing a fried food product is described, the apparatus including means for storing individual bags of dehydrated product that can be opened as necessary depending upon the demand for the product, and in which the empty bags are retained for subsequent removal. A bag cutting device is provided to open the bag and to permit the product to fall into a product hopper. A product forming section is provided to reconstitute a measured portion of the dehydrated material to provide a dough that can be formed in the desired shape. The dough is formed into the shape of french fried potatoes and is thereafter fried in a fryer that contains hot frying oil and a plurality of open top, perforated baskets pivotally carried by the fryer for movement into and out of the frying oil, the product being sequentially transferred from one basket to another during the frying operation. The fried product is then removed from the fryer and passes to a dispensing station where the product is dispensed in cup-like containers. In accordance with another aspect of the present invention, a method is provided for preparing and dispensing a fried food product in which the product is formed from a dough prepared from dehydrated potatoes and water, the amount of the dough prepared being equal in volume to the volume of a single order of fried potatoes in order that no dough residue remains in the apparatus to eliminate sanitation problems. Any residue that does remain in the dough-forming portion of the apparatus is dried by means of heat in order to minimize the likelihood of biological contamination. Further, the method includes sequentially frying cut dough pieces in separate, pivotal perforated baskets carried in a frying vessel.

Brief Description of the Drawings

Figure 1 is a front elevational view of a machine for preparing and dispensing individual portions of heated food products in accordance with the present invention showing the several parts thereof in their operative relationship, and with the door of the machine open and partially broken away to illustrate the components that are carried on the inside of the door structure.

Figure 2 is a fragmentary perspective view of the top portion of the dispensing machine shown in Figure 1, and illustrating the raw material storage and transfer apparatus. Figure 3 is another fragmentary perspective view showing a portion of a raw material storage shelf upon which bags of the dehydrated material are stored, feeding means for feeding the bags to a hopper and cutting means for cutting the bags to permit the product to flow into the hopper.

Figure 4 is a fragmentary front view of the dough-making and rehydration section of the apparatus showing the positions of the parts at the beginning of an operating cycle.

Figure 5 is a fragmentary perspective view of a portion of the rehydration section of the apparatus looking upward and showing the structure for metering the dehydrated product and the piston that is employed to extrude the dough from a rehydration chamber.

Figure 6 is an exploded perspective view of a portion of the dough-making and rehydration section of the apparatus showing the relative positioning of the several parts thereof.

Figure 7 is a fragmentary cross-sectional view taken along the line 7-7 of Fig. 5 and showing the latching arrangement for causing joint movement of a support arm that carries a metering chamber and a support arm that carries a water distribution or rehydration head. Figure 8 is an exploded perspective view of the underside of the dough-making and rehydration section showing the structure for supporting and operating the dough cutoff knife.

Figure 9 is a fragmentary perspective view showing the several parts of the dough-making and rehydration section at the time the metering chamber is filled with the dehydrated product.

Figure 10 is a view similar to Figure 9, but showing the metering chamber and rehydration head after they have been moved into position over the rehydration chamber.

Figure 11 is a view similar to that of Figure 10 in which the rehydration head has been moved away from the metering chamber to permit the product to fall from the metering chamber into the rehydration chamber.

Figure 12 is a view similar to that of Figure 11, showing the rehydration head returned to the position illustrated in Figure 10 below the metering chamber and above the rehydration chamber.

Figure 13 is a view similar to that of Figure 12 showing the parts after the metering chamber and rehydration have returned to their original positions, and shows the extrusion piston beginning its descent. Figure 14 is a view similar to that of Figure 13 showing the extrusion piston descending into the rehydration chamber.

Figure 15 is a fragmentary cross-sectional view of the rehydration chamber showing the piston after it has descended into the rehydration chamber to extrude dough through the bottom of the rehydation chamber, and the cut dough pieces that have been cut by a cutoff wire.

Figure 16 is a view similar to that of Figure 15 showing the piston after it has further descended and a second group of cut dough pieces have been cut by the cutoff wire.

Figure 17 is a view similar to that of Figure 16 after the piston has descended an additional distance to the lowermost point of its travel, and the cutoff wire has made a third pass to cut a third group of dough pieces.

Figure 18 is a fragmentary perspective view showing the rehydration chamber and the product transfer conveyor that underlies it to carry the cut dough pieces to a fryer.

Figure 19 is a fragmentary view showing an alternative embodiment of the dough cutoff wire wherein the wire is provided in a supply reel to permit rapid repair of the cutoff knife in the event of a break in the wire. Figure 20 is a view similar to that of Figure 19 showing still another embodiment of the dough cutoff knife wherein the cutoff wire is spring-supported to cause it to be urged against the lower edge of the rehydration chamber.

Figure 21 is a fragmentary perspective view showing the product transfer conveyor in position above a fryer, and a product discharge chute.

Figure 22 is a longitudinal, cross-sectional elevational view through the fryer vessel showing the position of the product transfer conveyor and a pair of fryer baskets.

Figure 23 is an exploded perspective view of the fryer baskets and their associated carrying shafts.

Figure 24 is a fragmentary perspective view of a portion of the inside of the door of a dispensing machine showing the cup storage and transfer apparatus for cup-type containers into which the product is deposited for dispensing purposes.

Description of the Preferred Embodiments

Referring now to the drawings, and particularly to Figure 1 thereof, there is shown a food product dispensing machine 10 that includes a cabinet 12, and a door 14 supported on hinges 16 carried by the cabinet 12 The cabinet includes a dehydrated product bag s torage and t rans fer section 18 to receive bags of the dehydrated product and to transfer them to a bag cutter to permit the contents of a bag to be deposited into a hopper 20. A product forming section 22 is provided under hopper 20 and in which dehydrated potato product is metered into a suitable metering chamber, is rehydrated by adding a predetermined amount of water to the dehydrated potato product to form a dough, and is then formed into the desired product shape. Product forming section 22 includes drive apparatus that operates the various parts of the product forming section in a predetermined sequence. A power supply 24 provides the necessary electrical power for the various electrical components of the apparatus. A fryer section 26 is positioned below the product forming section and the formed product is fried to provide the desired heating and external appearance. The oil for the fryer is contained within a frying oil circulation system 28, and a frying oil supply 30 is provided to replace frying oil that remains on the product as it is dispensed and such frying oil that may vaporize during the frying operation. An air exhaust system 32 is provided to draw the oil fumes from the cabinet.

The door 14 tα cabinet 12 includes on the inner surface thereof a cup storage and dispensing section 34 for product containers in which the product is furnished to the purchaser. Additionally, a control cabinet 36 is provided to house the electronic circuitry, circuit boards, microprocessors, and the like that can be employed to control the operation of the various portions of the apparatus.

The raw material that is preferred for use in the apparatus and method of the present invention is a dehydrated potato product provided in agglomerated form and which is capable of reconstitution into a formable dough without the need for mechanical mixing of dehydrated potatoes and water. Products of that type are described in U.S. Patent 3,809,758, which issued May 7, 1984, to J.J. Matthias et al, and U.S. Patent 2,975,549, which

issued August 17, 1976, to M. A. Shatila et al. Those patents are merely illustrative of the type of dehydrated potatoes that are preferred, and the mention of those two patents should not be construed as limiting in any way the types of starting materials that can be used in the present apparatus and method.

The various sections of the apparatus, and their operation, will be separately described.

Dehydrated Product Bag Storage and Transfer Section

Referring now to Figures 2 and 3, there is shown in greater detail the dehydrated product bag storage and transfer section 18 that is provided in the upper portion of the cabinet 12 as illustrated in Figure 1. The denydrated potato product is provided in bags 36 that include a kraft paper outer liner and a substantially water-impervious inner liner, such as polyethylene or the like. A plurality of such bags are provided on a shelf 38 and are stacked in front-to-back relationship on their respective longitudinal edges, although only a single bag is shown in Fig. 2 so as not to obscure the bag transfer appartus. A bag pusher arm 40 is provided to urge the bags in the rightward direction toward hopper 20, so that the hopper always contains some amount of dehydrated potato that can be used to prepare an order on demand . The dehydrated potato product, which preferably is in the form of agglomerates, is released from a bag by the passage along the longitudinal edge of the rightmost bag of a rotating cutting wheel 42, best seen in Figure 3, which passes from one end of the bag to the other to slit it open and thereby permit the dehydrated potato product to fall into hopper 20. Cutting wheel 42 is a rotary cutter that is driven by a motor (not shown) and the cutter motor is moved along a linear slot 44 that extends transversely of the direction of movement of the bags of dehydrated potatoes. Limit switches 46, 48 are provided to sense the extreme positions of cutting wheel 42 and define the outer limits of its path of travel. The limit switches, the cutter drive motor, and the cutter transport motor are carried on or contained within a cutter support housing 50, in which slot 44 is formed.

Shelf 38 extends from cutter support housing 50 to the left end wall of cabinet 12, and a pair of spaced brackets 52, 54 are provided along the innermost edge of shelf 38 and secured to the back wail of cabinet 12. Brackets 52, 54 support s pair of spaced guide rods 56, 58 that extend across the back wail of cabinet 12 and slidably support a pusher support block 60 to which bag pusher arm 40 is secured. Bag pusher arm 40 acts against the endmost of the series of dehydrated potato bags that are carried on shelf 38 and urges them rightward toward the cutting wheel 42 as needed. The operation of bag pusher arm 40 is controlled through a lead screw 62 operated by a lead screw motor 64 that is caused to operate when a low level sensing switc 66h provided in the lower portion of hopper 20 senses a low dehydrated potato product level, whereupon lead screw motor 64 is energized to cause pusher support block 60 to push the bags in a rightward direction, as viewed in Figures 2 and 3, so that the rightmost bag overlies cutting wheel 42 so that the bag opening operation can be commenced.

On the inner surface of the right end wall of the cabinet 12, a pair of tines 68, 70 are positioned, the tines extending inwardly of cabinet 12 toward the bags and serving to penetrate the rightmost bag that is pushed into position over cutting wheel 42 in order to hold it stationary and prevent it. from moving along with the cutting wheel so that the latter can perform its bag cutting function. The empty bags are forced toward the right as viewed in Figure 2 by the full bags, and they are retained on the tines in flattened condition for removal during periodic machine servicing. Lead screw motor 64 is stopped when a full bag is in position over the cutter, either by sensing the position of a bag adjacent the cutter support housing by a suitable sensing switch (not shown), or, alternatively, by sensing an increase in the resistance to further motion of lead screw 62, which is indicative of the fact that a bag is in proper position over the cutting blade and adjacent the end wail of the cabinet.

Dough-Making Section

Referring now to Figure 4, hopper 20 includes a tubular outlet 72 at its Iowermost portion, and a flexible tubular extension 74 is attached thereto by means of a clamping ring 76. A movable hopper discharge blocking plate 78 is positioned immediately below the open end of flexible extension 74 to prevent the passage of dehydrated potato product therethrough when plate 78 covers the end of extension 74. As best seen, in Fig. 6, blocking plate 78 includes a metering chamber 80 in the form of a circular metering ring 82 that is open at the top and bottom, and that includes a plurality of substantially parallel partition members 84 to define separate compartments into which the dehydrated potato material is deposited.

Positioned immediately below metering ring 82 is a rehydration head 86 in the form of a circular disk 88, and includes an imperforate too plate 90 that underlies metering ring 82 to define metering chamber 80. Rehydration head 86 can be a hollow structure which is in communication with a source of water, and having a plurality of discharge apertures substantially uniformly distributed along its lower face. Alternatively, and preferably, the rehydration head is in the form of a sintered metal disk that includes an imperforate peripheral outer portion. The lowermost surface of the disk is provided with a plurality of small uniformly sized and spaced openings through which the water for rehydration can pass to uniformly wet the dehydrated potato product, as will hereinafter, be described.

Metering chamber 80 and hopper discharge blocking plate 78 are carried on a metering chamber support arm 92 that extends from and is loosely carried on a rehydration head pivot shaft 94. Pivot shaft 94 extends from and is supported in an upper shelf 96 and a lower shelf 98 for pivoting movement, and metering chamber support arm 92 is in non-driving relationship with pivot shaft 94. Metering chamber support arm 92 includes a latch 100 that is carried in a latch guide 102 for sliding movement in a plane that is parallel to the axis of rehydration head pivot shaft 94. Latch 100 includes a notch 104, the purpose of which will be hereinafter described. Rehydration head 86 is carried on a rehydration head support arm 106 that is secured to and pivots with the rehydration head pivot shaft 94. Latch 100 of metering chamber support arm 92 extends downwardly and bears against one side of rehydration support arm 106, as more clearly shown in Figure 7. As also therein shown, metering chamber support arm 92 also carries a downwardly depending guide plate 108, which bears against the opposite side of rehydration head support arm 106.

Product-Forming Section Referring now to Figures 4, 5, and 6, product- forming section 22 includes a rehydration chamber 110 that is carried on a rehydration chamber support plate 112 that is supported in spaced relationship between top shelf 96 and bottom shelf 98 of the dough-making section on three support rods 114, 116, and 118. Rehydration chamber support plate 112 includes a notch 120 at one end that is received by innermost support rod 118, and a pair of spaced apertures 122, 124 at its opposite end that are so sized that the plate is supported on ledges defined by shoulders formed in the support rods 114, 116, and 118. The uppermost ends of outer support rods 114, 116 include pivotahle retaining tabs 126, 128 to prevent separation of plate 112 from the support rods in a vertical direction. As clearly seen in Figure 6, rehydration chamber 110 includes a plurality of equally spaced, parallel wire dividers 130 at its lower edge, the position of which is more clearly seen in Figures 15 through 17. Wire dividers 130 are preferably thin wires having a thickness of from about 0.020 inches to about 0.040 inches and can be coated with Teflon or other non-stick coatings to minimize dough sticking thereto. Positioned immediately below rehydration chamber 110 is a dough dam 132 that is carried on a dam support arm 134 which , in turn , is secured to and pivots with a dam pivot shaft 136 that is rαtatahly carried in top and bottom shelves 96, 98. A dam pivot motor 138 is provided to pivot dam support arm 134 at appropriate intervals, and a rehydration head pivot motor ( not shown) is provided to separately pivot the rehydration head shaft at appropriate times.

Positioned above rehydration chamber 110 and spaced therefrom is a piston 140 that is secured to a piston support disk 142 which, in turn, is secured to a piston screw 144. A rotatable nut 146 is provided on screw 144 and rotatably carried in shelf 96. Nut 146 is driven by a piston: drive motor 148, to cause piston screw 144 to travel axially and move piston 140 toward and away from rehydration chamber 110. As best seen in Figures 5 and 15, the lowermost face of piston 140 includes a plurality of spaced, parallel, transverse slots 150 that have a width and depth that correspond with the diameter of wire dividers 13 in rehydration chamber 110 in order to force from rehydration chamber 110 all of the dough that is contained therein when the piston reaches the lowermost portion of its path of travel. Preferably, piston 140 is made from a plastic material that minimizes sticking thereto of the potato dough, and suitable materials for that purpose include Delrin and Teflon, which are registered trademarks of E.I. DuPont De Nemours Co.

Positioned below rehydration chamber support plate 112 is a cutoff knife in the form of a cutoff wire 152 that extends across and is adapted to contact the lower surface of rehydration chamber 110. Cutoff wire 152 is supported on a pair of spaced cutoff wire supports 152, 156, which, in turn, are carried on a U-shaped cutoff knife carrier 158, which is best seen in Figures 6 and 8. Knife carrier 158 is slidably supported against the lower surface of lower shelf 98 by means of a pair of spaced support plates 160, 162 that define slots along which knife carrier 158 slides. The slots can be provided either by bending support plates 160, 162, to the cross- sectional configuration illustrated in Figure 4, or, alternatively, by providing spacer plates 164, 166 that space the support plates from the lower surface of the bottom shelf, as illustrated in Figure 8. Preferably cutoff wire 152 is a wire having a diameter of about 0.041 inches.

Knife carrier 158 is driven linearly in a direction parallel to the direction of wire dividers 130 in rehydration chamber 110. The driving arrangement includes a pair of racks 168, 170 positioned on the lower surface of knife carrier 158, and which engage with a pair of spaced gears 172, 174, respectively, carried on a cutoff knife drive shaft 176 that is rotatably supported on a pair of spaced brackets 178, 180 secured tα the lower surface of bottom shelf 98. A cutoff knife drive motor 182 is provided to rotate knife drive shaft 176, and thereby rotate gears 172, 174 that engage racks 168, 170, respectively, on the knife carrier to move the latter rapidly in a linear direction parallel to wire dividers 130.

As best seen in Figure 6 , dam 132 is received on a disk-like dam carrier 184 that is or includes an electrical heating element. The heating element serves to maintain the dam at an elevated temperature, preferably about 180ºF, for purposes that will hereinafter be explained. Additionally, the upwardly facing surface of dam 132, which underlies rehydration chamber 110, preferably includes a low-friction coating such as, for example, Teflon, to minimize the friction between the dam and dough that is contained within the rehydration chamber when the dam is moved laterally away from the rehydration chamber.

Although the cutoff knife can be formed by securing a cutoff wire 152 to the respective cutoff wire supports 154, 156, as illustrated in Figures 4 and 8, cutoff wire 152 can also be provided on a supply reel 186 as illustrated in Figure 19, wherein one end of cutoff wire 152 is secured to an eyelet 188, or the like, that is carried on cutoff knife carrier 158, with the other end of the wire retained on supply reel 186. That arrangement facilitates the replacement of the cutoff wire in the even of breakage thereof.

An alternative arrangement for supporting cutoff wire 152 is illustrated in Figure 20, in which cutoff wire supports 190, 192 each include a lower, holiow wire support guide tube 194 carried by cutoff knife carrier 158, and a spring 196 positioned within each wire support guide tube and bearing against an upper, hollow wire support guide tube 198 that is positioned so as to be movable axially relative to lower guide tubes 194. Springs 196 urge cutoff wire 152 into close engagement with the lower surface of rehydration chamber 110 and with wire dividers 110, and thereby serve to minimize the amount of residual potato dough that remains on wire dividers 130. Operation of the Dough-Making and Product-Forming Sections The several elements of the device are initially in the position illustrated in Figures 4 and 9, wherein the metering chamber 80 and rehydration head 86 are adjacent each other in concentric relationship, and underlying the outlet of hopper 20. The product in hopper 20 thus passes through hopper outlet 72, and into metering chamber 80 that is defined by metering ring 82 and top plate 90 of rehydration head 86. The product fills the metering chamber, vhich is so sized as to provide the desired amount of dehydrated potato product. A motor or other suitable means (not shown) is then activated to pivot rehydration head pivot shaft 94 in a clockwise direction, looking downward, as in Figure 9, whereupon rehydration head support arm 106 bears against latch 100 to also carry metering chamber support arm 92 with it until metering chamber 80 and rehydration head 86 are in superposed relationship with rehydration chamber 110. As metering chamber 80 moves laterally away from hopper outlet 72, hopper discharge blocking plate 78 bears against flexible extension 76, and prevents further flow of potato product from hopper 20. Flexible extension 76 is provided in order to minimize the grinding action that would otherwise occur if a rigid extension were provided at and engagement with the blocker plate, which could rupture some of the potato cells and thereby result in a more sticky, and more difficult to handle reconstituted potato dough.

The pivoting of rehydration head 86 and metering chamber 80 terminates when they both overlie rehydration chamber 110 as illustrated in Figure 10. The arrangement of the particular parts is such that the lowermost surface of rehydration head 86 is in direct contact with the uppermost surface of rehydration chamber 110. Alεo as illustrated in Figure 10, dividers 84 in metering chamber 80 serve to retain the dehydrated potato material in a relatively uniform distribution across the metering chamber as the rapid pivoting operation is performed. If dividers 84 were not present, there is a possibility that by virtue of the rapid action, and the inertia of the originally stationary potato particles, that some of the potato granules may spill out of metering chamber 80 and that the main mass of potato particles would lie against one edge of the metering chamber, with the result that there would not be a uniform distribution of the particles, which could lead to nonuniform rehydration.

When rehydration head 86 and metering chamber 80 have reached the position illustrated in Figure 10, metering chamber 80 is unlatched from rehydration head 86 by means of a latch cam 200 that engages notch 104 in latch 100 and moves it in an upward direction so that the latch no longer is adjacent the εide of rehydration head support arm 106. As best seen in Figure 5, latch cam 200 is supported in position by a latch cam support 202, that is secured to the lower, surface of top shelf 96. As metering chamber support arm 92 pivots toward latch cam 200, the cam engages notch 104 and forces latch 100 upwardly so that arm 92 remains stationary relative to arm 106, so that the latter can be separately moved in a clockwise direction, when looking downward, while the former is stationary.

After metering chamber 80 and rehydration head 86 have reached the position shown in Figure 10, and the metering chamber support arm 92 has been unlatched from the rehydration head support arm 106, the rehydration head pivot shaft 92 is further pivoted in a clockwise direction so that rehydration head 86 moves laterally outwardly from each of metering chamber 80 and rehydration chamber 110, as illustrated in Figure 11. Consequently, the lower portion of metering chamber 80 is then open, by virtue of the removal of the blocking effect of top plate 90 of rehydration head 86 , and the dehydrated potato product contained in metering chamber 80 is permitted to fall into rehydration chamber 110. Thereupon, rehydration head support arm 106 is pivoted in a counterclockwise direction, to return it to a position in which it is underlying metering chamber 80 and overlying rehydration chamber 110, as illustrated in Figure 12. At that point, heated water (approximately 160ºF) is introduced into rehydration head 86, and by virtue of the plurality of small openings therein, the water is uniformly distributed over the dehydrated potato granules that are in rehydration chamber 110. Because of the nature of the preferred dehydrated potato particles, rapid and uniform rehydration occurs, and a formable dough is provided substantially immediately.

After the potato granules are rehydrated, metering chamber 80 and rehydration head 86 are then pivoted together in a counterclockwise direction to move them away from rehydration chamber 110 so that they again are in underlying relationship with hopper discharge outlet 72, as illustrated in Figure 13. The conjoint movement of the two support arms results from the presence of guide 108, illustrated in Figure 7, wherein rehydration support arm 106 bears against guide 108, which is rigidly connected to metering chamber support arm 92 to carry the latter along with it as it moves in the counterclockwise direction. As metering chamber 80 and rehydration head 86 move together away from rehydration chamber 110, piston 140 begins its descent, as illustrated in Figure 13. As it descends, the piston is caused to momentarily enter the rehydration chamber to provide a tamping action on the rehydrated potato granules, and thereby further ensure uniform rehydration of the potato granules. After a momentary retraction of the piston after the tamping step, the piston is advanced in a downward direction to cause the resulting reconstituted potato dough to extrude through the lower opening of rehydration chamber 110, whereupon cutoff wire 152 is rapidly moved linearly along the lower surface of rehydration chamber 110 to sever the extruded product from the dough mass that remains within rehydration chamber 110. Because of the presence of dividing wires 130, the cut pieces 202 are of generally rectangular cross section and very closely resemble the usual form of french fried potatoes as they are customarily provided.

The first extrusion step is carried out by moving piston 140 a predetermined first distance, and after the dough is severed, as illustrated in Figure 15, the piston advances another predetermined increment, as illustrated in Figure 16, whereupon the cutoff knife is passed along the lower surface of the rehydration chamber once again to sever a second group of dough pieces 204. Successive extrusion and cutting operations can be performed until the desired quantity of product is obtained, and the last extrusion step is illustrated in Figure 17, wherein the piston has reached the lower point in its path of travel to extrude the remaining portion of the dough through the lower opening of rehydration chamber 110 to define dough pieces 206, and so that respective divider wires 130 engage with and fit within corresponding slots 150 in piston 140 to cause all of the dough contained within rehydration chamber 110 to be expelled therefrom.

During the various extrusion operations illustrated in Figures 15 through 17, cam pivot motor 138 has pivoted dam pivot shaft 134 to carry the cam in a counterclockwise direction so that it no longer blocks the lower opening of rehydration chamber 110, as illustrated in Figure 14.

Product Transfer Section Referring now to Figure 18, after the extruded potato pieces 206 have been severed by means of cutting wire 152, they fall downwardly onto a product transfer conveyor 208, which carries them laterally, in the direction indicated by the arrow in Figure 18, for ultimate transfer to a fryer. The product transfer conveyor can be in the form of a wire conveyor as illustrated, which is driven by a suitable drive motor (not shown) and which is in the form of an endless belt that passes over a plurality of rollers 210 carried on parallel roller, shafts 212, 214, and 216 (see Fig. 21). Product transfer conveyor 208 preferably moves continuously during the dough-cutting operation so that each respective group of cut potato pieces is carried on a separate portion of the belt and is spaced from the previous and following groups of cut potato pieces in order that the cut pieces travel individually and are not in contact with each other. In that connection, it is highly desired that the dough be extruded in a vertical direction, so that the cut pieces fall vertically without bending. Bending could result if extrusion were accomplished in a horizontal direction, which would result in unnatural-looking potato pieces.

The size of the wires that form the dividers 130 in rehydration chamber 110 is preferably about 0.020 inches in diameter, although wires within the range of from about 0.020 inches to about 0.040 inches can also be used if desired. However, if the divider wires are too small in diameter, insufficient separation between adjacent potato pieces can result, which may cause the cut pieces to contact each other and perhaps stick to each other, which, again, is an undesirable condition. If the divider wires are too large in diameter, on the other hand, excessive buildup of potato dough residue can take place in the piston grooves and around the outer surfaces of the wires which, although tolerable, is not preferred. Further, dam 132 is maintained at an elevated temperature of approximately 180ºF, to provide sufficient heat to dry out any residual potato dough that may remain on rehydration chamber 110 or on divider wires 130, in order to improve sanitation by minimizing the likelihood of bacterial contamination due to the presence of moisture.

Although shown in Figure 18 as being a series of wires arranged transversely to the direction of movement of the conveyor, product transfer conveyor 208 can also be formed from a smooth, solid material, because no drainage apertures are required at this particular stage of the process. Suitable materials could also include synthetic rubber, or various base materials containing Teflon or other non-stick coatings. Additionally, it is also preferred that the diameter of the respective belt drive pulleys, or turning means, at the downstream end of the product transfer conveyor be as small as possible, preferably about 0.25 inches or less, in order to provide an abrupt edge and change of direction to facilitate separation between the cut potato piece and conveyor 208, and to minimize the possibility that a potato piece will stick to the belt while the belt passes around and beneath the respective guide rollers. Another alternative for facilitating separation is the positioning of a doctor blade (not shown) at the discharge end of the product transfer conveyor.

Frying and Dispensing Section

Referring now to Figures 21 and 22, product transfer conveyor 208 is supported in a frame 218, which overlies one end of a generally rectangular fryer vessel 220, within which hot frying oil is provided. Fryer vessel 220 includes a bottom portion 222, which is of generally rectangular configuration in both plan and elevation to define a frying oil container, and a top portion 224 that is also of generally rectangular configuration, and which overlies a part of bottom portion 222 to define a hood over approximately one-half of the surface of the frying oil in bottom portion 22. Top portion 224 and bottom 222 are connected by bolting together cooperating flanges 226 that extend around the vertical sides of each of the respective top and bottom portions of the fryer vessel.

Top portion 224 extends over roller shaft 212 and is open at the end adjacent to product transfer conveyor 208. Additionally, top portion 224 is also open at the opposite end, and a discharge chute 232 is connected thereto by means of bolts 234 to receive the fried product and to conduct it to a dispensing station, as will hereinafter be described. Top portion 224 also includes a fire extinguisher conduit 230, which can be connected to a suitable fire extinguisher (not shown), which, in turn, can be triggered by a sensor to activate the fire extinguisher in the event of a fire in fryer vessel 220.

Positioned within fryer vessel 220 are a pair of fryer baskets 236, 238 that extend transversely of the bottom portion 222 and are defined by a series of interconnected, perforated metal plates, or the like, that define an open top basket and in which a plurality of openings 240 are provided (see Fig. 23) to permit entry of hot frying oil into the interior of the baskets, and to also permit drainage of the frying oil from the baskets when the baskets are withdrawn from the frying oil that is contained in bottom portion 222. The baskets are carried on shafts 242, 244, respectively, that extend transversely through top portion 224 and are supported therein for pivotal movement.

As best seen in Figure 23, each of shafts 242, 244 is pivotally supported in a pair of bearings 246, 248, respectively, each of which is carried in the vertical walls of top portion 224 on opposite sides thereof, and the shafts each include a longitudinally extending flat portion 250, 252, respectively, and three spaced, threaded holes 254 to receive bolts (not shown). Each of the baskets 236, 238 includes a laterally extending lip, 310, 312, respectively, which, as shown, can be provided by an angle plate, the lip portions each having a plurality of holes 314 that correspond in number and spacing with the number and spacing of holes 254 in the flat portions of the respective shafts. The baskets are carried by the shafts by bolting the respective lips thereof to the flat portions of the shafts by means of bolts (not shown) that pass through the holes in the lip and threadedly engage with the threaded holes in the flat portions of the shafts.

Referring once again to Figure 21, each of shafts 242, 244 extends outwardly beyond one vertical wall of top portion 224 and includes a driven sprocket 316, 318, respectively, non-rotatably carried by the respective shafts. A pair of motors 320, 322 is provided, and can be carried on a mounting plate 324 as shown in Figure 21. Motors 320, 322 each drivingly support drive sprockets 326, 328, and respective drive chains 330, 332 that pass around respective ones of drive sprockets 326, 328 and driven sprockets 316, 318 to pivot the shafts through predetermined angles at predetermined times in the operating cycle. Pivotal movement of the shafts results in the respective baskets pivoting about the respective shaft axes so that products contained in first basket 236, which is closest to the center of the fryer vessel 220, are deposited in second basket 238, which is the basket closest to the end of the fryer vessel adjacent discharge chute 232. Pivotal movement of shaft 244 of the second basket causes the basket to carry the product therein contained into discharge chute 232, which carries the product to a dispensing station that includes cups for containing the product and which will be described in more detail hereinafter.

Bottom portion 222 of the fryer vessel preferably includes insulation 228 to cover the side, end, and bottom walls thereof and thereby minimize the heat loss therefrom. The source of heat to heat the frying oil is provided by a resistance heating element 330 positioned in bottom portion 222 of the fryer vessel, and extends through end wall 332 of the bottom portion to a connector 334, for connection to a suitable source of electrical power (not shown). The frying oil is introduced into fryer vessel 220 through oil inlet 336 from a frying oil reservoir (not shown).

Referring once again to Figure 22, the cut potato pieces that are deposited on product transfer conveyor 208 are carried in the direction indicated by arrow A, and fall from the end of conveyor 208 into first basket 236. Sufficient product to define a single serving is deposited into the basket, to fall into the hot frying oil that has passed through openings 240. After a frying time of approximately fifteen seconds, which is sufficient to provide a firm, fried outer surface skin or shell on the product, motor 320 associated with first basket 236 is activated to drive the chain and cause shaft 242 to pivot counterclockwise, as viewed in Figure 22, through an angle of approximately 180º, to deposit the partially fried product into second basket 238 for final frying. During the time motor 320 is activated, basket 326 is caused to vibrate by supe rimpos i ng a pulsed current on the steady state current supplied to the motor, tα cause the motor to execute a series of jerking movements as it rotates, the result being that basket 238, as well as the partially fried product therein contained, is vibrated in order to keep the pieces of partially fried product from sticking together.

After the partially fried product has been deposited into second basket 238, continued frying occurs for a period of approximately twenty seconds or so, during which time final frying of the product to the desired color and texture takes place. As final frying is taking place in second basket 238, an additional serving of cut potato pieces is provided to the f i rs t ba s ket in o rder to commence the f rying operat ion on a second portion to be dispensed. When the final frying time for the product in second basket 238 has elapsed, motor 322 associated with second basket 238 is activated to pivot shaft

244 and the connected basket 238 through an angle of approximately 180º to carry the final fried product from the frying oil and deposit it into discharge chute 232. As second shaft 244 and second basket 238 are pivoted in the counterclockwise direction as represented by arrow B from the position shown in solid lines to the position shown in phantom, as viewed in Figure 22, pulses of current are also supplied to motor 322, as was the case in connection with the operation of first motor 320, to shake basket 238 and the final product to minimize sticking together of the various pieces of the product, and simultaneously to shake excess frying oil from the surfaces of the fried product. Thereupon, the operating cycle can be repeated, depending upon the demand for the fried product as evidenced by the number of servings that have been ordered.

Cup Storage and Transfer Section

As shown in Figure 24, the inner surface of the housing door 14 includes a cup storage and dispensing section 34 that has a storage shelf 286 upon which a plurality of stacks 288 of cups (only one stack is shown in Figure 24) can be positioned. The dispensing section includes a pair of transversely arranged spaced helical feed coils 290, 292 that are adapted to engage the respective cup stacks. Upon a suitable signal generated by cup sensing switch. 294, a motor

(not shown) drives the drive chain 296 and the connecting chain

298 to cause helical feed coils 290, 292 to feed cup stacks 288 in the direction toward a dispensing opening. Positioned beneath the dispensing opening is a cup dispenser apparatus 300 and a pivotal cup platform 302. The structural details and the method of operation of a suitable cup dispensing apparatus is shown and described in U.S. Patent No. 4,618,073, entitled,

"Cup Dispensing Apparatus", the disclosure of which is hereby incorporated herein by reference.

The apparatus and method as hereinabove described and as illustrated in the appended drawings can be utilized either in an institutional setting in which french fried potatoes are one of the food items distributed, such as, for example, industrial cafeterias, fast food restaurants, and the like, or, alternatively, the machine can be utilized as a vending machine to provide individual servings αf french fried potatoes at places, where vending machines are normally found such as, for example, schools, industrial: plants, offices, and the like.

When used as a vending machine the device will, of course, require suitable coin equipment to control its operation, but such equipment is well known to those skilled in the art and is not further described herein.

In its operation, the apparatus and method hereinabove described can provide a ready-to-eat serving in about a minute. Further, the method and apparatus hereinabove described have been found to provide a product that very closely resembles french fried raw potatoes in appearance, texture, and a taste.

Although particular embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that changes and modifications can be made without departing from the spirit of the present invention, and it is intended to encompass in the appended claims all such changes and modifications that fall within the scope of the present invention.

Claims

What Is Claimed Is:

1. Apparatus for preparing hot food products in portions of predetermined size by rehydrating a dehydrated food product to provide a dough that can be shaped and heated, said apparatus comprising:

(a) dehydrated food product hopper means for storing a predetermined quantity of dehydrated food product, said hopper means having an inlet and an outlet;

(b) raw material storage and transfer means for storing a plurality of prepackaged quantities of a dehydrated food product and for transferring individual packages of the food product to said product hopper means as needed to maintain a part of the stored dehydrated food product ready for immediate use;

(c) rehydration means for receiving a measured quantity of dehydrated food product from said raw material storage and transfer means and for rehydrating the measured quantity of dehydrated food product without agitation of a mixture of the dehydrated food product and water to provide a coherent dough; (d) forming means for forming the dough into predetermined shaped dough pieces, said forming means including a dough-receiving chamber having an open top and an open bottom, said open bottom including a plurality of parallel, substantially equally spaced divider members, and piston means movable within said dough-receiving chamber to urge the contents thereof through said open bottom to cause said product to extrude vertically downwardly from said chamber into separate pieces defined by said divider members, said piston means including a slotted face having slots corresponding in size and orientation to the size and orientation of said divider members to prevent retention of dough between said divider members when said piston slots contact and engage with said divider members; and

(e) frying means to heat the formed dough pieces to provide a fried food product having a desirable texture, taste, and appearance, said frying means including a plurality of perforated baskets having open tops, said baskets being pivotally carried in said frying means for partial immersion in a frying oil, and for sequentially frying the formed dough pieces.

2. The apparatus of claim 1 wherein said frying means includes:

(a) a frying oil container for containing frying oil;

(b) first, perforated basket means pivotally carried by said frying oil container for pivotal movement into and out of the frying oil;

(c) second perforated basket means pivotally carried by said frying oil container for pivotal movement into and out of the frying oil, said second basket means positioned adjacent to said first basket means to receive a product dumped from said first basket means upon pivotal movement of said first basket means out of the frying oil;

(d) drive means for pivoting said first and second basket means; and

(e) means for providing heated frying oil to said frying oil container.

3. The apparatus of claim 2 wherein said means for providing heated frying oil includes heating element means positioned within said frying oil container.

4. The apparatus of claim 2 wherein said drive means includes separate drive motors far pivoting each of said first and second basket means.

5. The apparatus of claim 4 wherein said drive motors are operable to pivot said first and second basket means at a first, steady state pivoting speed.

6. The apparatus of claim 5 wherein said drive motors are operable to intermittently pivot said first and second basket means intermittently at a second pivoting speed greater than said first pivoting speed to cause the basket means to shake as they are pivoted to prevent sticking together of individual product pieces carried in said basket means.

7. A frying vessel comprising:

(a) a frying oil container for containing frying oil;

(b) first perforated basket means pivotally carried by said frying oil container for pivotal movement into and out of the frying oil;

(d) drive means far pivoting said first and second basket means; and

(e) means for providing heated frying oil to said frying oil container.

8. A frying vessel as claimed in claim 7 wherein said means for providing heated frying oil includes heating element means positioned within said frying oil container.

9. A frying vessel as claimed i n claim 7 wherein said drive means includes separate drive motors for pivoting each of said first and second basket means.

10. A frying vessel as claimed in claim 9 wherein said drive motors are operable to pivot said first and second basket means at a first, steady state pivoting speed.

11. A frying vessel as claimed in claim 10 wherein said drive motors are operable to intermittently pivot said first and second basket means at a second pivoting speed greater than said first pivoting speed to cause the basket means to shake as they are pivoted to prevent sticking together of individual product pieces carried in said basket means.

12. A method of frying shaped dough pieces, said method comprising:

(a) providing a plurality of shaped dough pieces;

(b) depositing the shaped dough pieces into a first perforated, open top basket;

(c) frying the dough pieces in a heated frying oil far a first frying time period to form a partially fried product having a firm surface skin;

(d) transferring the partially fried product from the first basket to a second perforated, open top basket; (e) frying the partially fried product in a heated frying oil for a second frying time period to provide a final fried product; and

(f) removing the final fried product from the second basket.

13. The method of claim 12 including the step of vibrating the first basket as the partially fried product is being transferred therefrom, to prevent sticking together of the pieces of partially fried products.

14. The method of claim 13 including the step of vibrating the second basket as the fried product is being removed therefrom, to prevent sticking together of the pieces of fried product and to shake excess frying oil therefrom.

15. The method of claim 12 wherein the baskets are pivotally carried on a frying vessel and are adjacent to each other, and said transferring step includes pivoting the first basket about a first basket pivot axis to dump the partially fried product into the second basket, and said removing step includes pivoting the second basket about a second basket pivot axis to dump the final fried product from the second basket to a product dispensing station.

16. A method for reconstituting a dehydrated food product and preparing shaped forms therefrom, said method comprising: (a) providing a chamber having an open top, a continuous side wall depending from said open top, and an open bottom, said open bottom including a plurality of spaced dividers to define the cross section of pieces of dough that pass therethrough;

( b) provi ding a movable bot tom wa l l movable f rom a position adjacent said open bottom to close the same to a position spaced from said bottom to open the same;

(c) supplying a predetermined quantity of dehydrated food product to said rehydration chamber while said bottom wall is against the open bottom;

(d) uniformly distributing sufficient water onto said dehydrated food product through said open top to wet the food product;

(e) momentarily tamping said dehydrated food product by pressing against the surface thereof to distribute the water therethrough and uniformly rehydrate the product to form a coherent dough;

(f) moving said bottom wall away from said chamber bottom;

(g) forcing said rehydrated product through the open bottom of said chamber to extrude a dough product;

(h) cutting the extruded product by passing a cutting knife across the open bottom of said chamber to provide a plurality of cut dough pieces of predetermined shape;

(i) depositing the cut dough pieces into a first perforated, open top basket;

(j) frying the dough pieces in a heated frying oil for a first frying time period to form a partially fried product having a firm surface skin;

(k) transferring the partially fried product from the first basket to a second perforated, open top basket;

(l) frying the partially fried product in a heated frying oil for a second frying time period to provide a final fluid product; and

(m) removing the final fluid product from the second basket.