WO1991012756A1 - Apparatus for reheating french fries - Google Patents

Apparatus for reheating french fries Download PDF

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Publication number
WO1991012756A1
WO1991012756A1 PCT/US1990/000909 US9000909W WO9112756A1 WO 1991012756 A1 WO1991012756 A1 WO 1991012756A1 US 9000909 W US9000909 W US 9000909W WO 9112756 A1 WO9112756 A1 WO 9112756A1
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WO
WIPO (PCT)
Prior art keywords
potato strips
reheating
area
temperature
frozen
Prior art date
Application number
PCT/US1990/000909
Other languages
French (fr)
Inventor
Sudhakar P. Shanbhag
Marco A. Bonne
Gerald Milani
Original Assignee
Horizons International Foods, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Horizons International Foods, Inc. filed Critical Horizons International Foods, Inc.
Priority to PCT/US1990/000909 priority Critical patent/WO1991012756A1/en
Publication of WO1991012756A1 publication Critical patent/WO1991012756A1/en

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Classifications

    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47JKITCHEN EQUIPMENT; COFFEE MILLS; SPICE MILLS; APPARATUS FOR MAKING BEVERAGES
    • A47J27/00Cooking-vessels
    • A47J27/14Cooking-vessels for use in hotels, restaurants, or canteens
    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23LFOODS, 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
    • A23L19/00Products from fruits or vegetables; Preparation or treatment thereof
    • A23L19/10Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops
    • A23L19/12Products from fruits or vegetables; Preparation or treatment thereof of tuberous or like starch containing root crops of potatoes
    • A23L19/18Roasted or fried products, e.g. snacks or chips
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47JKITCHEN EQUIPMENT; COFFEE MILLS; SPICE MILLS; APPARATUS FOR MAKING BEVERAGES
    • A47J39/00Heat-insulated warming chambers; Cupboards with heating arrangements for warming kitchen utensils
    • A47J39/003Heat-insulated warming chambers; Cupboards with heating arrangements for warming kitchen utensils with forced air circulation

Definitions

  • the present invention relates to an apparatus and a method for reheating fully cooked and frozen potato strips and holding them at a palatable temperature for an extended period of time.
  • french fries The market for french fried potato strips, commonly referred to as french fries, is currently estimated at approximately 6.5 - 7 billion dollars annually.
  • the bulk of this market is the fast-food restaurant business, wherein parfried and frozen potato strips are commonly purchased in bulk from commercial suppliers and stored at freezer temperatures until shortly before serving.
  • the parfried and frozen potato strips are prepared for eating by deep fat frying in fat or oil, typically by finish frying in a medium consisting mainly of beef tallow at a temperature of 300-375°F for 1.5 - 3.5 minutes.
  • Fast food restaurants typically prepare french fries for consumption by the consumer by reconstituting frozen, parfried potato strips in a deep fryer.
  • McDonald'sTM french fries long considered the state-of-the art in the fast-food industry, apparently are processed according to the process disclosed in U.S. Patent No. 3,397,993 (Strong).
  • raw potato strips are blanched by steam or hot water until generally translucent throughout, dehydrated in hot air to cause a weight loss of at least 20 percent, parfried for 30-60 seconds at 375° and then frozen to about 0°F.
  • the frozen potato strips are shipped and/or stored until final frying is desired. They are finish fried by immersing in a deep fat or oil bath, usually containing a medium consisting mainly of beef tallow, at a temperature of about 300-375°F for 1.5 - 3.5 minutes.
  • Deep-fat fryers are not well suited to vendors who have limited amounts of space and help. Nor is reconstitution by deep fat fryers suited to impulse purchases by consumers who might be enticed to purchase french fries by seeing and smelling the final product in its ready-to-serve form.
  • U.S. 4,865,864 (Rijswijck) describes an air oven having a heating space into which materials such as french fries are introduced to be heated solely by swirling air heated by an electric heater.
  • Other air heating systems are described in U.S. Patent Nos. 4,817,509 (Erikson) ; U.S. 4,491,065 (Poulson) ; U.S. 3,870,193 (Schneider); U.S. 4,167,585 (Caridis) ; U.S. 4,374,318 (Gilliom) ; U.S.
  • One aspect of the present invention relates to a two-tiered apparatus for reconstituting frozen french fried potato strips for immediate consumption substantially without desiccating the potato strips, comprising a reconstituting area for reconstituting the potato strips to a condition suitable for consumption, and a holding area for holding the reheated potato strips at a suitable consumption temperature.
  • the apparatus further comprises transferring means for transferring reheated potato strips from the reconstitution area to the holding area when said potato strips attain said predetermined temperature.
  • Another aspect of the present invention relates to an apparatus for reconstituting frozen french fried potato strips in which the reheating area and holding area have substantially see-through walls so that the consumer can visualize and smell the potato strips as they are being reheated and maintained at a suitable consumption temperature.
  • Another aspect of the present invention relates to an apparatus for reconstituting frozen french fried potato strips which comprises a substantially transparent enclosure adapted to allow visual and olfactory inspection of the potato strips during reconstitution which includes reheating means for reconstituting the frozen french fried potato strips to a suitable consumption temperature comprising an air convection system, wherein the potato strips are reconstituted substantially without desiccation.
  • the frozen potato strips which are to be reconstituted have previously been fully cooked to a ready-to-eat condition and frozen.
  • the potato strips are substantially only reheated rather than cooked.
  • the resultant french fried potato product preferably has the flavor, aroma, texture, mouthfeel and total eating experience of fast food french fries which have been reconstituted by deep-fat frying.
  • FIGURE 1 is a perspective view of a representative apparatus according to the present invention.
  • FIGURE 2 is a cross-sectional view illustrating one embodiment of the upper portion of the present apparatus
  • FIGURE 3 is a cross-sectional view of one embodiment of an automated transferring means for transferring reheated potato strips from the reheating area to the holding area of the present apparatus.
  • the apparatus of the present invention provides a means for reconstituting frozen french fried potato strips which have previously been fully cooked and frozen such that the reheated potato strips have flavor, aroma, texture, mouthfeel and total eating experience closely resembling that of fast food french fries which are finally prepared for consumption by deep fat frying.
  • the present apparatus responds to the need for a device which caters to practically impulse purchasing and on- the-spot preparation without the need for a deep fat fryer and associated machinery.
  • the frozen potato strips which are to be reheated are finish fried to a cooked ready-to-eat condition and frozen, preferably in a manner which substantially avoids desiccation or structural damage of the potato strips.
  • the apparatus is a compact, integrated structure for reconstituting frozen fully cooked french fried potato strips and for holding the reconstituted french fries at a suitable consumption temperature while displaying the product to the ultimate consumer.
  • FIG. 1 such a compact integrated apparatus 1 having an enclosure comprising a top 1A, two side walls IB, a rear wall IC, a front wall ID, and a bottom IE is shown.
  • An upper portion 2 of the apparatus 1 comprises a reheating area 3, an enclosed area 4 comprising a reheating means 6 for reheating the frozen potato strips to a suitable consumption temperature and necessary circuitry (not shown) , and a control means 5.
  • the reheating means 6 is adapted to substantially evenly warm the frozen potato strips 7 to a palatable temperature substantially without structurally damaging or desiccating the potato strips.
  • a lower portion 8 of the apparatus 1 comprises a holding area 9 and means 10 for maintaining the temperature of the reheated french fries at a level suitable for consumption.
  • a transferring means separates the reheating area 3 from the holding area 9.
  • the upper surface 11A of the transferring means 11 forms the bottom of reheating area 3 while the bottom surface 11B of the transferring means 11 forms the top of holding area 9.
  • the transferring means 11 is adapted to transfer the reheated potato strips to the holding area 3.
  • the operator fills the reheating area by opening door 12 and dumping a premeasured amount of the frozen fully cooked potato strips 7 onto the upper surface of the transferring means.
  • the potato strips 7 are then reheated in the reheating area 3 via reheating means 6 until they attain an internal temperature that is suitable for consumption.
  • the potato strips 7 are reheated until they attain an internal temperature from about 140"F to about 215 ⁇ F, most preferably from about 160 ⁇ F to about 190'F.
  • the reheating means 6 is an air convection system which heats the air and circulates the heated air within the reheating area to a temperature from about 200'F to about 300 ⁇ F, and most preferably about 250"F.
  • the dimensions of the reheating area 3 may be, for example, about 8" high by about 18" wide by about 18" deep.
  • about 20-27 ounces (9-12 servings) of frozen potato strips which have previously been fully cooked to a ready-to-eat condition are placed onto the reheating area 3 at one time and attain an internal temperature of about 140-200"F in about 5-8 minutes.
  • the potato strips 7 are then transferred to the holding area 9.
  • This step may be performed manually by removing the reheated potato strips from the reheating area through door 12 and immediately thereafter loading the reheated potato strips into the holding area 9 through door 13. It is preferred that the reheated potato strips 7 be transferred to the holding area 9 via transferring means 11.
  • Transferring means may be manually operated, e.g., the transferring means may be rotatably mounted and the orientation of the transferring means.,is manually changed by a lever or tilting mechanism from substantially horizontal to an angle sufficient to dump the reheated potato strips from its upper surface 11A to the bottom of the holding area 9.
  • the transferring means 11 automatically transfers the potato strips 7 to the holding area 9 when the potato strips attain the desired predetermined internal temperature.
  • the holding area includes means 10 for maintaining the internal temperature of the reheated potato strips 7 at a suitable consumption temperature, which in the present example are infrared heating elements.
  • the infrared heating elements 10 in the present example maintain the temperature of the air within the holding area 9 from about 100°F to about 200 ⁇ F, which is sufficient to maintain the internal temperature of the potato strips 7 within the holding area 9 at a temperature of about 140 ⁇ F.
  • the infrared heating elements may be, for example, ceramic radiant 120 watts hairpin with a reflector (single-fixed) .
  • the dimensions of the holding area 9 in the present example may be, for example, about 12" high by about 18" wide by about 18" deep.
  • the reheated potato strips 7 may be maintained at a suitable consumption temperature in the holding area 9 for at least about one hour without substantial structural damage.
  • door 13 may be opened at any time and one or more servings removed.
  • the control means 5 is adapted to control the reheating and holding of the potato strips 7. It may include, for example, an on/off switch 17, a timer 18 for controlling the amount of time the potato strips 7 spend in the reheating area 3, and temperature controls 19 and 20 for displaying and adjusting the temperature within the reheating area 3 and the holding area 9, respectively. While the display may be digital or analog, it is preferred that each of the temperature ' controls 19 and 20 are digital displays.
  • the enclosed area 4 includes a plenum 30 which houses a heater 31 and a blower assembly 32.
  • the plenum is preferably composed of stainless steel. Air is circulated by the blower 33 into an air distribution plenum 34, which is a small compartment with a perforated plate 38 having holes which are smaller in the center of the plate and get increasingly larger toward its outer edges. This ensures substantially equal air distribution throughout the cavity.
  • blower Any blower known in the art may be used to circulate air.
  • the blower is a centrifugal blower which is designed to "scoop" ambient air and circulate the air to the heater 31.
  • a suitable commercially available blower is model numbers 50752D500 by Fasco.
  • the heater is preferably adapted to heat the circulated air to a temperature from about 260°F to about 270°F
  • heater 31 has a serpentine shape through which the air flows.
  • the air heater is 1300 W.
  • a suitable air heater is commercially available from Chromalox (1300W) .
  • the heated air which has circulated through heater 31 is then circulated into the reheating area 3 via a duct 35.
  • the air which has circulated through the reheating area 3 is removed from the reheating area 3 via return duct 37 and blower 33.
  • the blower 33 preferably operates at about 3000 revolutions per minute, and circulates the air within the apparatus of the present example at a rate from about 70 cubic feet per minute to about 130 cubic feet per minute, and most preferably at about 115 cubic feet per minute.
  • the transferring means may comprise trays 14A and 14B which are substantially oriented in a horizontal direction while the potato strips 7 in the reheating area 3 are being reheated.
  • the trays are adapted to change their orientation to a substantially vertical direction when the potato strips 7 attain the desired temperature, thereby dumping the potato strips 7 into the bottom of the holding area 9.
  • the orientation of the transferring means 11 may be controlled for example via a motorized system.
  • the movement of plates 14A and 14B is controlled via motors 41A and 4IB, respectively.
  • the motors may be, for example, 2 RPM reversible motors model number 3002-001 or 3002-002 commercially available from Hurst, or Grainger model number 6Z535 or 6Z536.
  • Trays 14A and 14B are connected to motors 41A and 4IB, respectively, via motor shaft 42 square shaft and hole 43, and plate holding pin 46.
  • the orientation of motorized trays 14A and 14B may be controlled by a switch or by a timer 18, which causes motors 41A and 4IB to activate when the potato strips within the reheating area 3 have attained the desired temperature.
  • motors 41A and 4IB cause plates 14A and 14B to move from a substantially horizontal orientation to a substantially vertical orientation, thereby dumping the potato strips resting upon the upper surface HA of plates 14A and 14B into the holding area 9.
  • the transferring means may also utilize a counterbalance system (not shown) . This may be accomplished for example, by making the centrally disposed edges of trays 14 and 14B lighter in weight than the opposite edges (which are connected to the enclosure) . When potato strips are loaded into the reheating area, they tend fall to the center, thereby making the centrally disposed edges relatively heavier than the opposite edges.
  • a solenoid having a tongue may be adapted to hold trays 14A and 14B horizontally such that when the warming cycle is over, the tongue disengages. The central portion of trays 14A and 14B are then forced downward by the weight differential, thereby unloading the reheated potato strips into the holding area 9.
  • the upper surface 11A of trays 14A ⁇ and 14B include means (not shown) for aiding in preventing the potato strips from sticking on its upper surface 11A.
  • Such means may comprise a plurality of strategically located raised areas or perforations on the upper surface 11A.
  • the upper surface 11A of the transferring means 11 includes a plurality of substantially evenly spaced, round perforations.
  • the plates have apertures measuring about 3/16 inch in diameter, the plates being about 51 percent perforated (open) area.
  • the transferring means preferably includes a trough 48 below the perforations to allow for the drainage and collection of any excess oil which may be released from the surface of the potato strips 7 during reheating. An adsorbent pad (not shown) may be placed in trough 48 for this purpose.
  • the trays 14A and 14B may be equipped with raised edges (not shown) to aid in preventing product from getting stuck between the walls of the enclosure and the trays.
  • the apparatus 1 has see-through walls in whole, or in part, and is adapted for placement on a countertop in food service outlets, other mass feeding environments such as convenience stores, sandwich shops, train stations, airport kiosks, newspaper stands, other outlets that have a limited amount of space and no ovens, or even in the home of the ultimate consumer.
  • the see-through walls may be made of any suitable material known in the art, such as tempered glass or plastic.
  • the see-through walls or portions thereof, are adapted to show the french fries sufficiently to promote impulse purchasing of the product.
  • the apparatus is preferably adapted to be able to utilize standard electrical outlets (120 volts, 15 amp).
  • the apparatus of the present invention advantageously provides a unique manner of reheating potato strips which enables the vendor/operator to sell potato strips substantially having the total eating experience of fast-food french fries which are reconstituted by deep-fat frying.
  • the see-through feature of preferred embodiments of the present apparatus allows the consumer to visualize the reheated potato strips and smell the well-recognized french fry aroma which permeates the surrounding environmental air, making impulse buying by consumers in potential mass- feeding environments more practical.
  • a potential vendor seeking to reconstitute french fries via a deep-fat fryer would require a facility having sufficient space for a deep-fat fryer and associated machinery such as a hood, etc.
  • the potential vendor would also need to employ an individual to operate the machinery and clean the area.
  • the present apparatus also minimizes employee/operator time needed to produce the ready-to- eat product, as well as the skill level of the operator. All the operator need do is dump a premeasured amount of potato strips into the reheating area and activate the timer.
  • the present apparatus is easily moved and easily cleaned as preferably all of the food-contact parts of the apparatus are easily removable.
  • the fully cooked and frozen potato strips may be prepared by blanching and otherwise pretreating potato strips obtained from whole potatoes; then optionally dust-coating the blanched potato strips with a coating (e.g. about 0.3 - 1.5 percent by weight of the potato strip) of fine potato granules; thereafter finish frying the potato strips to a cooked, ready-to-eat condition; and then freezing the potato strips.
  • the above- mentioned process preferably includes coating the finish fried potato strips with toasted potato granules containing from about 0.1 to about 4 percent, and more preferably about 1 to about 3 percent moisture by weight.
  • the coating of toasted potato granules is about 0.1 to about 0.4 percent, and most preferably 0.2 percent of the potato strips, by weight.
  • the potato strips are finish-fried to a moisture content from about 20 to about 46 percent, and a fat content from about 16 to about 30 percent, by weight.
  • the potato strips are of the "shoestring" variety and are finish fried to a moisture content from about 36 to about 42 percent and a fat content from about 15 to about 18 percent by weight.
  • the potato strips are preferably finish fried in a three-zone continuous fryer.
  • the potato strips are introduced via a conveyor belt into a first zone in first end of the fryer in which the frying medium is heated to a temperature from about 360°F to about 380°F.
  • the potato strips pass through the first zone and into a second zone of the fryer in which the frying medium is heated to a temperature from about 320°F to about 360°F.
  • the potato strips then pass into a third zone in an opposite end of said frying in which the frying medium is heated to a temperature from about 300°F to about 340 ⁇ F.
  • the potato strips pass through each zone preferably in about one minute.
  • the potato strips which exit said opposite end are in a fully cooked, ready-to-eat condition.
  • the finish-fried potato strips may also optionally be coated with fat-encapsulated salt prior to freezing.
  • the fat used to encapsulate the salt preferably has a melting point from about 140°F to about 150°F, and the fat- encapsulated salt preferably has a salt content from about 35 to about 65 percent by weight.
  • the coating of fat-encapsulated salt is preferably from about 0.8 to about 1.2 percent of the potato strips by weight.
  • the finish fried potato strips prepared according to the above-outlined process are then frozen in a freezing tunnel cooled by liquid nitrogen vapor in a manner which substantially avoids desiccating the potato strips.
  • the potato strips are introduced on a conveyor belt system into a first zone in first end of the freezing tunnel which is cooled to a temperature from about -55°F to about -65°F by a gentle flow of liquid nitrogen vapor and passed through the tunnel to a second zone corresponding to the center of the freezing tunnel in which the potato strips are exposed to liquid nitorgen vapor at a temperature from about -40°F to about -50"F, and then passed through to a third zone in an opposite end of the tunnel, which is at a temperature from about -25°F to about -35°F.
  • the frozen potato strips which exit the freezing tunnel have an average internal temperature of about -20°F to about -30°F, and most preferably about -25°F.
  • the potato strips are preferably conveyed through each zone in about 3 minutes.
  • the frozen potato strips are then preferably packed into tightly sealed packages and stored at normal freezer temperatures.
  • the blanched potato strips may be parfried and frozen prior to finish frying.
  • the frozen parfried potato strips are preferably thawed in a temperature controlled environment kept at from about 20 ⁇ F to about 45 ⁇ F until the potato strips have an internal temperature from about 27 ⁇ F to about 33"F, and most preferably from about 29°F to about 30 ⁇ F, prior to dust-coating with potato granules and finish frying step.
  • composition of the fully cooked and frozen potato strips prepared according to the above-mentioned processes is substantially unchanged when the potato strips are reheated and maintained at a suitable consumption temperature by the apparatus of the present invention.
  • potato strips prepared according to other methods known in the art may be utilized in accordance with the present apparatus, with the possible of adjustment of the temperature and exposure time of the frozen potato strips within the reheating area. For example, if the frozen french fried potato strips must be further cooked to reach a ready-to-eat condition, the air temperature within the reheating area may be raised and/or the holding time for the potato strips within the reheating area increased.
  • the apparatus of the present invention is readily adapted for the preparation of other fried vegetables in addition to potato strips, including carrot, onion, turnip, celery, eggplant, zucchini, squash, cauliflower, brussels sprout, mushroom etc.

Abstract

An apparatus for reconstituting frozen french fries potato strips (7) is disclosed. Preferably the apparatus (1) has substantially see-through walls (1B, 1C, 1D) which allow the ultimate consumer to see and smell the potato strips (7) during the reconstitution process. Preferably, the frozen potato strips (7) which are to be prepared for consumption have previously been finish-fried to a cooked, ready-to-eat condition.

Description

APPARATUS FOR REHEATING FRENCH FRIES
FIELD OF THE INVENTION
The present invention relates to an apparatus and a method for reheating fully cooked and frozen potato strips and holding them at a palatable temperature for an extended period of time.
BACKGROUND OF THE INVENTION
The market for french fried potato strips, commonly referred to as french fries, is currently estimated at approximately 6.5 - 7 billion dollars annually. The bulk of this market is the fast-food restaurant business, wherein parfried and frozen potato strips are commonly purchased in bulk from commercial suppliers and stored at freezer temperatures until shortly before serving. The parfried and frozen potato strips are prepared for eating by deep fat frying in fat or oil, typically by finish frying in a medium consisting mainly of beef tallow at a temperature of 300-375°F for 1.5 - 3.5 minutes.
Fast food restaurants typically prepare french fries for consumption by the consumer by reconstituting frozen, parfried potato strips in a deep fryer. For example, McDonald's™ french fries, long considered the state-of-the art in the fast-food industry, apparently are processed according to the process disclosed in U.S. Patent No. 3,397,993 (Strong). Therein, raw potato strips are blanched by steam or hot water until generally translucent throughout, dehydrated in hot air to cause a weight loss of at least 20 percent, parfried for 30-60 seconds at 375° and then frozen to about 0°F. The frozen potato strips are shipped and/or stored until final frying is desired. They are finish fried by immersing in a deep fat or oil bath, usually containing a medium consisting mainly of beef tallow, at a temperature of about 300-375°F for 1.5 - 3.5 minutes.
Another method for preparing french fries for fast food restaurants is taught in U.S. Patent No. 3,649,305 (Wilder) , wherein potato strips are dehydrated to reduce their moisture content by 10-30 percent, blanched, parfried for 30-90 seconds at about 300-400βF and then frozen. The frozen strips are then fried in oil for 1.5 - 3 minutes at 325-375°F.
Deep-fat fryers are not well suited to vendors who have limited amounts of space and help. Nor is reconstitution by deep fat fryers suited to impulse purchases by consumers who might be enticed to purchase french fries by seeing and smelling the final product in its ready-to-serve form.
Both conventional and microwave ovens have been used to prepare frozen potato strips for consumption. However, such ovens are better suited to home use or for mass production in restaurants, etc. Furthermore, conventional ovens and microwave ovens are not well- suited to impulse purchases by consumers because it is virtually impossible to visualize or smell the french fries as they are being reconstituted.
Other methods for reconstituting french fries utilize air heated ovens. For example, U.S. 4,865,864 (Rijswijck) describes an air oven having a heating space into which materials such as french fries are introduced to be heated solely by swirling air heated by an electric heater. Other air heating systems are described in U.S. Patent Nos. 4,817,509 (Erikson) ; U.S. 4,491,065 (Poulson) ; U.S. 3,870,193 (Schneider); U.S. 4,167,585 (Caridis) ; U.S. 4,374,318 (Gilliom) ; U.S. 4,581,989 and 4,622,231, and 4,439,459 (Swartley) ; and U.S. 4,838,455 (Hoeberigs) . These methods, among other things, are not designed to hold the reconstituted french fries in a suitable condition for consumption over an extended period of time, nor do they not allow the consumer to visualize the reconstitution process.
It is an object of the present invention to provide an apparatus which can reconstitute frozen, french fried potato strips in a short period of time and hold the reheated french fries at a palatable temperature.
It is another object of the present invention to provide an apparatus for reconstituting frozen french fried potato strips which requires a relatively small area and which may be cleaned easily.
It is another object of the present invention to provide an apparatus for reconstituting frozen french fried potato strips which is adapted to allow the prospective purchaser to see and smell the potato strips while they are being reheated and held at a palatable temperature.
It is another object of the present invention to provide an apparatus for reconstituting frozen french fried potato strips and for holding the reheated potato strips at a palatable temperature for an extended period of time without the potato strips incurring structural damage and/or desiccation.
It is yet another object of the present invention to provide an apparatus for reheating fully cooked and frozen french fried potato strips and holding the reheated potato strips t a palatable temperature whereby the reheated potato strips have a crisp exterior and tender interior and which have a flavor, aroma, texture, mouthfeel, and total eating experience which closely resembles deep-fat fried french fried potatoes which may be purchase in fast-food restaurants.
SUMMARY OF THE INVENTION
One aspect of the present invention relates to a two-tiered apparatus for reconstituting frozen french fried potato strips for immediate consumption substantially without desiccating the potato strips, comprising a reconstituting area for reconstituting the potato strips to a condition suitable for consumption, and a holding area for holding the reheated potato strips at a suitable consumption temperature.
In a preferred embodiment, the apparatus further comprises transferring means for transferring reheated potato strips from the reconstitution area to the holding area when said potato strips attain said predetermined temperature.
Another aspect of the present invention relates to an apparatus for reconstituting frozen french fried potato strips in which the reheating area and holding area have substantially see-through walls so that the consumer can visualize and smell the potato strips as they are being reheated and maintained at a suitable consumption temperature.
Another aspect of the present invention relates to an apparatus for reconstituting frozen french fried potato strips which comprises a substantially transparent enclosure adapted to allow visual and olfactory inspection of the potato strips during reconstitution which includes reheating means for reconstituting the frozen french fried potato strips to a suitable consumption temperature comprising an air convection system, wherein the potato strips are reconstituted substantially without desiccation.
In a preferred embodiment of the present invention, the frozen potato strips which are to be reconstituted have previously been fully cooked to a ready-to-eat condition and frozen. In this embodiment, the potato strips are substantially only reheated rather than cooked. The resultant french fried potato product preferably has the flavor, aroma, texture, mouthfeel and total eating experience of fast food french fries which have been reconstituted by deep-fat frying.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings in which like reference characters indicate like parts are illustrative of embodiments of the present invention are not meant to limit its scope.
FIGURE 1 is a perspective view of a representative apparatus according to the present invention;
FIGURE 2 is a cross-sectional view illustrating one embodiment of the upper portion of the present apparatus;
FIGURE 3 is a cross-sectional view of one embodiment of an automated transferring means for transferring reheated potato strips from the reheating area to the holding area of the present apparatus.
DETAILED DESCRIPTION
The apparatus of the present invention provides a means for reconstituting frozen french fried potato strips which have previously been fully cooked and frozen such that the reheated potato strips have flavor, aroma, texture, mouthfeel and total eating experience closely resembling that of fast food french fries which are finally prepared for consumption by deep fat frying. The present apparatus responds to the need for a device which caters to practically impulse purchasing and on- the-spot preparation without the need for a deep fat fryer and associated machinery.
In preferred embodiments of the present invention, the frozen potato strips which are to be reheated are finish fried to a cooked ready-to-eat condition and frozen, preferably in a manner which substantially avoids desiccation or structural damage of the potato strips.
In one preferred embodiment of the present invention the apparatus is a compact, integrated structure for reconstituting frozen fully cooked french fried potato strips and for holding the reconstituted french fries at a suitable consumption temperature while displaying the product to the ultimate consumer.
Referring to Figure 1, such a compact integrated apparatus 1 having an enclosure comprising a top 1A, two side walls IB, a rear wall IC, a front wall ID, and a bottom IE is shown. Of course, a greater or lesser number of walls may be used to form the enclosure. An upper portion 2 of the apparatus 1 comprises a reheating area 3, an enclosed area 4 comprising a reheating means 6 for reheating the frozen potato strips to a suitable consumption temperature and necessary circuitry (not shown) , and a control means 5. The reheating means 6 is adapted to substantially evenly warm the frozen potato strips 7 to a palatable temperature substantially without structurally damaging or desiccating the potato strips.
A lower portion 8 of the apparatus 1 comprises a holding area 9 and means 10 for maintaining the temperature of the reheated french fries at a level suitable for consumption.
Preferably, a transferring means separates the reheating area 3 from the holding area 9. The upper surface 11A of the transferring means 11 forms the bottom of reheating area 3 while the bottom surface 11B of the transferring means 11 forms the top of holding area 9. When the frozen fμlly cooked potato strips 7 are reheated in the reheating area to the desired temperature, the transferring means 11 is adapted to transfer the reheated potato strips to the holding area 3. When it is desired to prepare the frozen fully cooked potato strips for consumption, the operator fills the reheating area by opening door 12 and dumping a premeasured amount of the frozen fully cooked potato strips 7 onto the upper surface of the transferring means.
The potato strips 7 are then reheated in the reheating area 3 via reheating means 6 until they attain an internal temperature that is suitable for consumption. Preferably, the potato strips 7 are reheated until they attain an internal temperature from about 140"F to about 215βF, most preferably from about 160βF to about 190'F.
In the present example, the reheating means 6 is an air convection system which heats the air and circulates the heated air within the reheating area to a temperature from about 200'F to about 300βF, and most preferably about 250"F.
In Figure l, the dimensions of the reheating area 3 may be, for example, about 8" high by about 18" wide by about 18" deep. In this embodiment, about 20-27 ounces (9-12 servings) of frozen potato strips which have previously been fully cooked to a ready-to-eat condition are placed onto the reheating area 3 at one time and attain an internal temperature of about 140-200"F in about 5-8 minutes.
The potato strips 7 are then transferred to the holding area 9. This step may be performed manually by removing the reheated potato strips from the reheating area through door 12 and immediately thereafter loading the reheated potato strips into the holding area 9 through door 13. It is preferred that the reheated potato strips 7 be transferred to the holding area 9 via transferring means 11. Transferring means may be manually operated, e.g., the transferring means may be rotatably mounted and the orientation of the transferring means.,is manually changed by a lever or tilting mechanism from substantially horizontal to an angle sufficient to dump the reheated potato strips from its upper surface 11A to the bottom of the holding area 9.
In a preferred embodiment of the present invention, the transferring means 11 automatically transfers the potato strips 7 to the holding area 9 when the potato strips attain the desired predetermined internal temperature. Preferably, the holding area includes means 10 for maintaining the internal temperature of the reheated potato strips 7 at a suitable consumption temperature, which in the present example are infrared heating elements. The infrared heating elements 10 in the present example maintain the temperature of the air within the holding area 9 from about 100°F to about 200βF, which is sufficient to maintain the internal temperature of the potato strips 7 within the holding area 9 at a temperature of about 140βF. The infrared heating elements may be, for example, ceramic radiant 120 watts hairpin with a reflector (single-fixed) . The dimensions of the holding area 9 in the present example may be, for example, about 12" high by about 18" wide by about 18" deep.
The reheated potato strips 7 may be maintained at a suitable consumption temperature in the holding area 9 for at least about one hour without substantial structural damage.
During this time, the reheated potato strips maintain their palatability and the total eating experience is substantially unchanged. Of course, door 13 may be opened at any time and one or more servings removed.
The control means 5 is adapted to control the reheating and holding of the potato strips 7. It may include, for example, an on/off switch 17, a timer 18 for controlling the amount of time the potato strips 7 spend in the reheating area 3, and temperature controls 19 and 20 for displaying and adjusting the temperature within the reheating area 3 and the holding area 9, respectively. While the display may be digital or analog, it is preferred that each of the temperature ' controls 19 and 20 are digital displays.
Referring to Figure 2, the enclosed area 4 includes a plenum 30 which houses a heater 31 and a blower assembly 32. The plenum is preferably composed of stainless steel. Air is circulated by the blower 33 into an air distribution plenum 34, which is a small compartment with a perforated plate 38 having holes which are smaller in the center of the plate and get increasingly larger toward its outer edges. This ensures substantially equal air distribution throughout the cavity.
Any blower known in the art may be used to circulate air. In the present example, the blower is a centrifugal blower which is designed to "scoop" ambient air and circulate the air to the heater 31. One example of a suitable commercially available blower is model numbers 50752D500 by Fasco.
The heater is preferably adapted to heat the circulated air to a temperature from about 260°F to about 270°F In one preferred embodiment, heater 31 has a serpentine shape through which the air flows. In the present example, the air heater is 1300 W. Of course, any number of smaller wattage heaters may be connected to provide the same effect. A suitable air heater is commercially available from Chromalox (1300W) .
The heated air which has circulated through heater 31 is then circulated into the reheating area 3 via a duct 35. The air which has circulated through the reheating area 3 is removed from the reheating area 3 via return duct 37 and blower 33. The blower 33 preferably operates at about 3000 revolutions per minute, and circulates the air within the apparatus of the present example at a rate from about 70 cubic feet per minute to about 130 cubic feet per minute, and most preferably at about 115 cubic feet per minute.
Referring to Figure 3, the transferring means may comprise trays 14A and 14B which are substantially oriented in a horizontal direction while the potato strips 7 in the reheating area 3 are being reheated. The trays are adapted to change their orientation to a substantially vertical direction when the potato strips 7 attain the desired temperature, thereby dumping the potato strips 7 into the bottom of the holding area 9. The orientation of the transferring means 11 may be controlled for example via a motorized system.
In the embodiment described in Figure 3, the movement of plates 14A and 14B is controlled via motors 41A and 4IB, respectively. The motors may be, for example, 2 RPM reversible motors model number 3002-001 or 3002-002 commercially available from Hurst, or Grainger model number 6Z535 or 6Z536.
Trays 14A and 14B are connected to motors 41A and 4IB, respectively, via motor shaft 42 square shaft and hole 43, and plate holding pin 46. The orientation of motorized trays 14A and 14B may be controlled by a switch or by a timer 18, which causes motors 41A and 4IB to activate when the potato strips within the reheating area 3 have attained the desired temperature. At such time, motors 41A and 4IB cause plates 14A and 14B to move from a substantially horizontal orientation to a substantially vertical orientation, thereby dumping the potato strips resting upon the upper surface HA of plates 14A and 14B into the holding area 9.
The transferring means may also utilize a counterbalance system (not shown) . This may be accomplished for example, by making the centrally disposed edges of trays 14 and 14B lighter in weight than the opposite edges (which are connected to the enclosure) . When potato strips are loaded into the reheating area, they tend fall to the center, thereby making the centrally disposed edges relatively heavier than the opposite edges. A solenoid having a tongue may be adapted to hold trays 14A and 14B horizontally such that when the warming cycle is over, the tongue disengages. The central portion of trays 14A and 14B are then forced downward by the weight differential, thereby unloading the reheated potato strips into the holding area 9.
Preferably, the upper surface 11A of trays 14A^and 14B include means (not shown) for aiding in preventing the potato strips from sticking on its upper surface 11A. Such means may comprise a plurality of strategically located raised areas or perforations on the upper surface 11A.
Preferably, the upper surface 11A of the transferring means 11 includes a plurality of substantially evenly spaced, round perforations. In one preferred embodiment, the plates have apertures measuring about 3/16 inch in diameter, the plates being about 51 percent perforated (open) area. In addition to aiding in preventing the potato strips 7 from sticking to the transferring means 11, the transferring means preferably includes a trough 48 below the perforations to allow for the drainage and collection of any excess oil which may be released from the surface of the potato strips 7 during reheating. An adsorbent pad (not shown) may be placed in trough 48 for this purpose. In addition, the trays 14A and 14B may be equipped with raised edges (not shown) to aid in preventing product from getting stuck between the walls of the enclosure and the trays.
Preferably, the apparatus 1 has see-through walls in whole, or in part, and is adapted for placement on a countertop in food service outlets, other mass feeding environments such as convenience stores, sandwich shops, train stations, airport kiosks, newspaper stands, other outlets that have a limited amount of space and no ovens, or even in the home of the ultimate consumer. The see-through walls may be made of any suitable material known in the art, such as tempered glass or plastic. The see-through walls or portions thereof, are adapted to show the french fries sufficiently to promote impulse purchasing of the product. Furthermore, the apparatus is preferably adapted to be able to utilize standard electrical outlets (120 volts, 15 amp).
The apparatus of the present invention advantageously provides a unique manner of reheating potato strips which enables the vendor/operator to sell potato strips substantially having the total eating experience of fast-food french fries which are reconstituted by deep-fat frying. The see-through feature of preferred embodiments of the present apparatus allows the consumer to visualize the reheated potato strips and smell the well-recognized french fry aroma which permeates the surrounding environmental air, making impulse buying by consumers in potential mass- feeding environments more practical. In comparison, a potential vendor seeking to reconstitute french fries via a deep-fat fryer would require a facility having sufficient space for a deep-fat fryer and associated machinery such as a hood, etc. The potential vendor would also need to employ an individual to operate the machinery and clean the area.
Furthermore, prior art methods for reconstituting french fries do not allow the ultimate consumer to visualize the procedure, thereby reducing the impulse buying potential of the french fries. These problems are overcome with the present apparatus. The possible compact size of the apparatus increases the domain of potential vendors for french fries outside of the sphere of vendors having the adequate space, machinery, and personnel to utilize deep-fat fryers or the like.
The present apparatus also minimizes employee/operator time needed to produce the ready-to- eat product, as well as the skill level of the operator. All the operator need do is dump a premeasured amount of potato strips into the reheating area and activate the timer.
In addition, the present apparatus is easily moved and easily cleaned as preferably all of the food-contact parts of the apparatus are easily removable.
In preferred embodiments of the present invention, the fully cooked and frozen potato strips may be prepared by blanching and otherwise pretreating potato strips obtained from whole potatoes; then optionally dust-coating the blanched potato strips with a coating (e.g. about 0.3 - 1.5 percent by weight of the potato strip) of fine potato granules; thereafter finish frying the potato strips to a cooked, ready-to-eat condition; and then freezing the potato strips. The above- mentioned process preferably includes coating the finish fried potato strips with toasted potato granules containing from about 0.1 to about 4 percent, and more preferably about 1 to about 3 percent moisture by weight. Preferably, the coating of toasted potato granules is about 0.1 to about 0.4 percent, and most preferably 0.2 percent of the potato strips, by weight.
Preferably, the potato strips are finish-fried to a moisture content from about 20 to about 46 percent, and a fat content from about 16 to about 30 percent, by weight. Most preferably, the potato strips are of the "shoestring" variety and are finish fried to a moisture content from about 36 to about 42 percent and a fat content from about 15 to about 18 percent by weight.
For commercial purposes the potato strips are preferably finish fried in a three-zone continuous fryer. The potato strips are introduced via a conveyor belt into a first zone in first end of the fryer in which the frying medium is heated to a temperature from about 360°F to about 380°F. The potato strips pass through the first zone and into a second zone of the fryer in which the frying medium is heated to a temperature from about 320°F to about 360°F. The potato strips then pass into a third zone in an opposite end of said frying in which the frying medium is heated to a temperature from about 300°F to about 340βF. The potato strips pass through each zone preferably in about one minute. The potato strips which exit said opposite end are in a fully cooked, ready-to-eat condition. The finish-fried potato strips may also optionally be coated with fat-encapsulated salt prior to freezing. The fat used to encapsulate the salt preferably has a melting point from about 140°F to about 150°F, and the fat- encapsulated salt preferably has a salt content from about 35 to about 65 percent by weight. The coating of fat-encapsulated salt is preferably from about 0.8 to about 1.2 percent of the potato strips by weight.
It is preferred that the finish fried potato strips prepared according to the above-outlined process are then frozen in a freezing tunnel cooled by liquid nitrogen vapor in a manner which substantially avoids desiccating the potato strips. Most preferably, the potato strips are introduced on a conveyor belt system into a first zone in first end of the freezing tunnel which is cooled to a temperature from about -55°F to about -65°F by a gentle flow of liquid nitrogen vapor and passed through the tunnel to a second zone corresponding to the center of the freezing tunnel in which the potato strips are exposed to liquid nitorgen vapor at a temperature from about -40°F to about -50"F, and then passed through to a third zone in an opposite end of the tunnel, which is at a temperature from about -25°F to about -35°F. The frozen potato strips which exit the freezing tunnel have an average internal temperature of about -20°F to about -30°F, and most preferably about -25°F. The potato strips are preferably conveyed through each zone in about 3 minutes. The frozen potato strips are then preferably packed into tightly sealed packages and stored at normal freezer temperatures.
Alternatively, the blanched potato strips may be parfried and frozen prior to finish frying. In this embodiment, the frozen parfried potato strips are preferably thawed in a temperature controlled environment kept at from about 20βF to about 45βF until the potato strips have an internal temperature from about 27βF to about 33"F, and most preferably from about 29°F to about 30βF, prior to dust-coating with potato granules and finish frying step.
The process for preparing the above-mentioned fully cooked potato strips is more completely set forth in U.S. Application Serial No. 374,325, filed June 30, 1989
(Shanbhag et al.), and PCT Application No. ,
(Shanbhag, Cousminer, and Milani) , filed concurrently on February 22, 1990, both of which are hereby incorporated by reference.
The composition of the fully cooked and frozen potato strips prepared according to the above-mentioned processes is substantially unchanged when the potato strips are reheated and maintained at a suitable consumption temperature by the apparatus of the present invention.
Alternately, potato strips prepared according to other methods known in the art may be utilized in accordance with the present apparatus, with the possible of adjustment of the temperature and exposure time of the frozen potato strips within the reheating area. For example, if the frozen french fried potato strips must be further cooked to reach a ready-to-eat condition, the air temperature within the reheating area may be raised and/or the holding time for the potato strips within the reheating area increased.
The apparatus of the present invention is readily adapted for the preparation of other fried vegetables in addition to potato strips, including carrot, onion, turnip, celery, eggplant, zucchini, squash, cauliflower, brussels sprout, mushroom etc.
The description of various components of the apparatus is not meant to be exclusive. Many other variations of the present invention would be obvious to those skilled in the art, and are contemplated to be within the scope of the appended claims.

Claims

CLAIMS ;
1. An apparatus for reconstituting frozen french fried potato strips comprising an enclosure, said enclosure being sufficiently transparent in at least selected areas to allow visual inspection of the potato strips during reconstitution, said apparatus including a reconstitution area having reconstitution means comprising an air convection system for heating said frozen potato strips in said reconstitution area to a condition suitable for consumption.
2. The apparatus of claim 1, further comprising a holding area for receiving reconstituted potato strips from said reconstitution area and maintaining said reconstituted potato strips at a suitable consumption temperature, and transferring means for transferring said reconstituted potato strips from said reconstitution area to said holding area.
3. The apparatus of claim 2, further comprising means disposed in said holding area for maintaining the temperature of said reconstituted potato strips comprising an infrared heating element.
4. The apparatus of claim 3, wherein said frozen potato strips have previously been finish fried to a cooked, ready-to-eat condition.
5. The apparatus of claim 4, wherein said air convection system heats the air in said reconstitution area to a temperature from about 200°F to about 300°F.
6. The apparatus of claim 3, wherein said infrared heating element heats the air in said holding area to a temperature from about 100°F to about 200°F.
7. The apparatus of claim 2, wherein said reconstitution area is mounted vertically above said holding area.
8. The apparatus of claim 7, wherein said transferring means is motorized and automatically transfers reheated potato strips from said reheating area, to said holding area when said potato strips attain said predetermined internal temperature.
9. The apparatus of claim 6 which is adapted to reheat said frozen, fully cooked potato strips to a suitable temperature for consumption substantially without changing the composition of said potato strips.
10. The apparatus of claim 9 which allows a french fry aroma to permeate the environmental air surrounding said apparatus.
11. A two-tiered apparatus for reheating and holding previously fully cooked, frozen potato strips in a ready-to-eat condition comprising a reheating area for reheating frozen fully cooked potato strips substantially without desiccation to a predetermined temperature suitable for consumption, a holding area for holding said reheated potato strips at or near said predetermined temperature, and transferring means for transferring said potato strips from said reheating area to said holding area after said potato strips attain said predetermined temperature, said apparatus being sufficiently transparent in at least selected areas to allow visual inspection of the potato strips within said apparatus and allowing the aroma of said reheated potato strips to permeate the environmental air surrounding said apparatus.
12. The apparatus of claim 11, wherein said reheating area includes reheating means adapted to heat the air within said reheating area to a temperature from about 200°F to about 300βF.
13. The apparatus of claim 12, wherein said reheating means comprises an air convection system.
14. The apparatus of claim 11, wherein said holding area includes means for heating the air in said holding area to a temperature from about 100βF to about 200"F.
15. The apparatus of claim 11, wherein said means comprises an infrared heating element.
16. The apparatus of claim 10, wherein the internal temperature of said reheated potato strips is from about 140"F to about 170βF.
17. The method of claim 11, further comprising providing automatic transfer means for removing said reheated potato strips from said reheating area and depositing said reheated potato strips in said holding area.
18. A method for reheating fully cooked, frozen french fried potato strips comprising transferring a suitable portion of fully cooked, frozen potato strips to an apparatus having substantially see-through walls on all sides which is adapted to reheat said potato strips to a suitable consumption temperature, and reheating said potato strips while allowing an observer to see and smell the potato strips during said reheating process.
19. The method of claim 18, further comprising providing said apparatus with a reheating area for reheating said potato strips to a suitable consumption temperature and a holding area disposed below said reheating are for maintaining said reheated potato strips at a suitable consumption temperature.
PCT/US1990/000909 1990-02-22 1990-02-22 Apparatus for reheating french fries WO1991012756A1 (en)

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