U.S. patent application number 10/271497 was filed with the patent office on 2003-10-09 for restaurant food preparation line.
This patent application is currently assigned to TACO BELL CORPORATION. Invention is credited to Hyatt, Donnie W. Jr., Hyatt, Donnie W. Sr., Rose, Eric L., Saunders, William A., Tsern, Micah, Winfree, Rick C..
Application Number | 20030188929 10/271497 |
Document ID | / |
Family ID | 21901136 |
Filed Date | 2003-10-09 |
United States Patent
Application |
20030188929 |
Kind Code |
A2 |
Winfree, Rick C. ; et
al. |
October 9, 2003 |
RESTAURANT FOOD PREPARATION LINE
Abstract
A food preparation line having a generally U-shaped
configuration. A first section providing a heated storage
compartment. A second section providing a cooled storage
compartment. The first section arranged to be substantially
perpendicular to the second section. A third section attached to
the second section and having a pass-through area. The heated
storage compartment has two access openings such that the
compartment may be restocked and emptied from two different
locations respectively.
Inventors: |
Winfree, Rick C.; (Mission
Viejo, CA) ; Rose, Eric L.; (Newport Beach, CA)
; Saunders, William A.; (San Luis Obispo, CA) ;
Tsern, Micah; (Santa Ana, CA) ; Hyatt, Donnie W.
Sr.; (Corona, CA) ; Hyatt, Donnie W. Jr.;
(Torrance, CA) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET
FOURTEENTH FLOOR
IRVINE>
CA
92614
|
Assignee: |
TACO BELL CORPORATION
17901 Von Karman
Irvine
CA
92614
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 0034208 A1 |
February 20, 2003 |
|
|
Family ID: |
21901136 |
Appl. No.: |
10/271497 |
Filed: |
October 15, 2002 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10271497 |
Oct 15, 2002 |
|
|
|
09026824 |
Feb 20, 1998 |
|
|
|
60038653 |
Feb 21, 1997 |
|
|
|
Current U.S.
Class: |
186/38 |
Current CPC
Class: |
A47F 10/06 20130101 |
Class at
Publication: |
186/38 |
International
Class: |
E04H 003/04 |
Claims
What is Claimed is:
1. 32. A steam cabinet comprising a steam chamber defined by at
least enclosing three side walls, a side wall with an opening, a
ceiling panel and a floor panel, a steam flow within the steam
chamber, a fan located outside of the steam flow, and an air
curtain defined by a laminar air flow extending across the
opening.
2. 33. The steam cabinet of Claim 32 further comprising a swinging
door which extends partially into the opening, the swinging door
contacting the air curtain.
3. 34. The steam cabinet of Claim 33 further comprising a heater
arranged on the ceiling and an exhaust system positioned above the
heater and on the outside of the steam cabinet on the ceiling
panel.
4. 35. An ingredient dispenser comprising a hopper connected to a
positive displacement pump wherein the positive displacement pump
delivers a metered amount of an ingredient.
5. 36. The ingredient dispenser of Claim 34 wherein the positive
displacement pump forces the ingredient through a nozzle on a food
preparation line.
6. 37. The ingredient dispenser of Claim 34 wherein the positive
displacement pump is a piston-type pump which operates with a
two-position valve.
7. 49. A steam cabinet for maintaining food product, said cabinet
comprising four sides, a top and a bottom being spaced by said
sides, a first access opening extending through at least one of
said four sides, a fan being positioned inside of said cabinet, a
first heating element being positioned proximate said fan, a
laminar air passage being in fluid communication with said fan and
at least a portion of said air passage being disposed along said
bottom, a steam well being disposed above at least a portion of
said air passage, a second heating element being disposed within
said steam well, an air curtain extending over said first access
opening, an partial swinging door being disposed above said first
access opening and extending part way into said first access
opening, an exhaust system being disposed at said top, said exhaust
system comprising a manually operated vane, said vane being adapted
to direct discharge from said exhaust system, a third heating
element being disposed within said cabinet and being disposed
generally below said exhaust system.
8. 50. The steam cabinet of Claim 49 further comprising a second
access opening, said second access opening being generally enclosed
by an access door, said door being capable of being secured in a
closed position by a latch, a drip edge and a channel being
disposed below at least a portion of said door, said channel
sloping downward and said drip edge being generally aligned with
one side of said channel51. The steam cabinet of Claim 50, wherein
said channel communicates with said steam well52. The steam cabinet
of Claim 50, wherein said channel communicates with an area outside
of said cabinet.
9. 53. The steam cabinet of Claim 49 further comprises shelving
that is disposed generally above said steam well.
10. 54. The steam cabinet of Claim 53, wherein said shelving is
disposed between said steam well and said third heater.
11. 55. A steam cabinet comprising a first side and a second side,
a top and a bottom being vertically spaced by said first side and
said second side, a first access opening extending through said
first side, a fan being positioned inside of said cabinet, a first
heating element being positioned proximate said fan, an air passage
extending between said fan and said access opening, a steam well
being disposed in said bottom of said steam cabinet, a second
heating element being disposed within said steam well, a swinging
door depending downward from said first side into said first access
opening, air from said air passage flowing upward to said swinging
door and defining an air curtain, an exhaust system being disposed
at said top, said exhaust system comprising a manually operated
vane, said vane being adapted to control air flow from said cabinet
and a third heating element being disposed within said cabinet at a
location generally below said exhaust system.
12. 56. The steam cabinet of Claim 55 further comprising a second
access opening defined in said second side, said access opening
being generally covered by a latchable door.
13. 57. The steam cabinet of Claim 56 further comprising a drip
channel being disposed beneath said door when said door is in a
closed position.
14. 58. The steam cabinet of Claim 57 further comprising a wiping
edge that contacts said door when said door is opened.
15. 59. The steam cabinet of Claim 57, wherein said channel is in
fluid communication with said steam well.
Description
Detailed Description of the Invention
Cross Reference To Related Applications
[0001] This application is a divisional of U.S. Patent Application
No. 09/026,824, filed February 20, 1998, which claims the benefit
under 35 U.S.C. .sctn. 119(e) of U.S. Provisional Application
Serial No. 60/038,653, filed February 21, 1997.
Background of Invention
[0002]
Field of the Invention
[0003] The present invention relates in general to the efficient
preparation of a comestible product. In particular, the present
invention relates to an improved food preparation line of the type
used in a restaurant.
Related Art
[0004] Restaurants, including quick-service restaurants, typically
employ food preparation lines. For example, a common food
preparation line is a straight line having several work stations.
The workers build a meal as it progresses from a starting end,
through several work stations, to a serving end. At the serving
end, the end food product can be readied for serving or packaged
for take-out or delivery orders. Accordingly, these food
preparation lines require many workers and an accompanying large
working area.
[0005] Prior straight food preparation lines have several
additional drawbacks. The preparation lines require interruptions
in the preparation process while being stocked with food product.
The typical food preparation line also merely prepares the food
while others package it for the customers. In addition, the workers
commonly must transfer the food across the relatively large
distances between the preparation line and the counter space used
to serve the customers. The long transfer requires more time, can
result in food product dropping, and results in larger food
preparation areas or decreased seating capacity.
Summary of Invention
[0006] Accordingly, there is a need for a restaurant which employs
a food preparation line of ergonomic construction which requires
fewer workers. In addition, there is a need for a food preparation
line which allows the food product supply to be maintained without
interrupting the workers preparing the food products. There is a
further need for a food preparation line which allows the workers
preparing the food product to readily package a food product for
the customer.
[0007] An aspect of the present invention thus involves a food
preparation line comprising a first section and a second section.
The second section lying generally normal to the first section. A
third section positioned next to and extending away from the second
section. A heated storage compartment positioned on one of the
sections and a cooled storage compartment positioned on another one
of the sections. In a preferred mode, the preparation line is
formed in a U shape by three sections: a first section, a second
section and a third section. The first and third sections form the
legs of the U-shaped line, while the second section forms the bite
of the U (i.e., the section of the U-shaped line that extends
between the side legs). A hot ingredient well (e.g., a steam table)
is positioned near a corner formed either by the first and second
sections or by the third and second sections. The hot ingredient
well is arranged to lie at or near a working level of the
preparation line. An open produce bin is arranged on the second
section of the line. At least one order display is positioned on
the line at approximately eye level. The order display(s) can be
arranged at a location either near the hot ingredient well and/or
near the produce bin. On the third section of the line, a tray
lowerator is located generally near an outer end (i.e., distal of
the second section) of the third section.
[0008] In a preferred embodiment, one of the order displays is
located proximate to the first section of the line and the other
order display is located proximate to the third section of the
line. This allows the line workers on either side of the line to
easily view the order displays.
[0009] The food preparation line also includes a steam cabinet that
is arranged on the first section generally near the hot ingredient
well. In between the steam cabinet and hot ingredient well, a bean
cup dispenser is positioned. A hot cabinet desirably is positioned
generally below the steam cabinet on the first section of the
preparation line.
[0010] An ingredient dispenser is preferably located near the hot
ingredient well to dispense a variety of hot foods, such as, for
example, but without limitation, ground beef and beans. A heated
shelf also is located near the ingredient dispenser. The heated
shelf desirably is adapted to store a variety of food ingredients,
including, but without limitation, taco shells, tortilla shells and
like masa-based products. In a preferred embodiment, nozzles of the
ingredient dispenser lie above the hot ingredient well, and the
heated shelf lies above and behind the ingredient dispenser
nozzles. This portion of the food preparation line desirably lies
at the corner formed by the first and second sections. At least one
indicator is located near the hot ingredient well and cooperates
with a diagnostic system that continuously monitors the function of
the hot ingredient well. The indicator for this diagnostic system
preferably is an audio alarm (either sound or voice), a visual
display or a light indicator. Located near the hot ingredient well
and the indicator is a diagnostic system for a hot ingredient well.
The diagnostic system assesses the water level within the hot
ingredient well (if applicable), the functioning of the heating
elements, and the automatic fill procedure (if applicable), and
triggers the indicator upon sensing an abnormal condition for any
of these elements or in any of the procedures.
[0011] The food preparation line includes a timing system that
clocks the time that each ingredient batch is on the line. Once the
measured time reaches a preselected time for the particular
ingredient, the timer signals the indicator to alert the line
worker. In this manner, ingredients do not remain on the food
preparation line for longer than an established time set in
accordance with safety standards.
[0012] In a preferred embodiment, the food preparation line also
includes a hanging storage system that is desirably used to store
packaging materials, such as, for example, wraps, containers,
boxes, and/or bags; however, the storage system can also be used to
store other items as well. The hanging storage system desirably is
located on the second section of the preparation line, above the
produce bin.
[0013] The food preparation line additionally can include a taco
rail. The taco rail desirably is located in front of the produce
bin on the second section of the line.
[0014] A waste container preferably is located below the taco rail
in a position to receive waste accumulated near the produce bin and
the taco rail.
[0015] A number of additional features can be incorporated into the
present food preparation line. For instance, the preparation line
can include an improved quesadilla warmer that has a split lid. The
split lid permits access to the warmer through one lid while the
second remains closed. The efficiency and the warmer"s capacity
thus is improved over prior warmers.
[0016] The third section of the line also desirably includes a
packaging storage compartment located near a tray dispenser. A bag
opening device is used to open bags and is located on the line near
the packaging storage compartment and tray dispenser.
[0017] In accordance with another aspect of the present invention,
disclosed is a steam cabinet with a fan unit positioned outside the
steam flow. The steam chamber is formed by a plurality of side
panels. One side of the steam chamber is defined by a laminar air
flow extending across an open section of the chamber thereby
creating an air curtain.
[0018] In a preferred embodiment, the steam cabinet also includes a
swinging door that extends partially across the open side of the
chamber. The bottom edge of the swinging door is in contact, along
its entire length, with the laminar air curtain. A heater is be
positioned within the steam chamber on the top surface. The heater
emits heat of a sufficient degree to prevent condensation from
forming on the top surface within the steam chamber. An exhaust
system is positioned on the top surface of the steam chamber, above
the heater.
[0019] In accordance with another aspect of the present invention,
an ingredient dispenser for pumping predetermined quantities of
food ingredients is disclosed. The ingredient dispenser includes a
hopper that holds enough ingredient to sufficiently supply the food
preparation line for a period of time. The hopper is connected to a
positive displacement pump device which draws ingredient from the
hopper in metered amounts. The positive displacement pump device
further forces the withdrawn ingredient portion through a separate
nozzle on the food preparation line for dispensing the
ingredient.
[0020] In a preferred embodiment, the positive displacement pump is
a piston-type pump and operates with a two-position valve. The
valve includes a chamber with an inlet port that communicates with
the hopper, an outlet port that communicates with the nozzle, and a
port to which the pump is connected. A valve member is moved within
the chamber to selectively connect the pump with the hopper and
with the dispensing nozzle. To withdraw ingredient from the hopper,
the valve member is moved (e.g., rotated) to a position which
connects the pump to the hopper and closes off the connection to
the nozzle. The pump"s piston moves away from the valve to draw
ingredient from the hopper. The degree of piston movement is
proportion to the volume of withdrawn ingredient so as to meter the
amount of ingredient being dispensed. The valve member is then
moved to a position in which the pump is connected to the nozzle.
In this position the valve member closes off the connection between
the hopper and the pump. The pump then moves toward the valve in
order to force ingredient through the nozzle. Again, the degree of
piston movement controls the amount of ingredient dispensed.
[0021] In accordance with an additional aspect of the present
invention, a wrap storage system is disclosed. The system includes
hanging modular shelves with attachment means for hanging the
shelves. Positioned within the shelves are removable wrap
containers and carton dispensers.
[0022] In a preferred embodiment, the shelves have hooks located on
the top edge of the side panels. The hooks are configured to
receive a rod extending along an food preparation line. The shelves
are further configured to receive wrap containers of varying sizes
and form. Within the wrap containers are cartons of product
wrappers for various menu items. An elongated slot, cut along the
inside of the bottom panel of the shelf, receives an elongated
flange on the wrap containers. The elongated flange on the wrap
containers fit at an angle within the slot in the shelf. The
shelves are hung on a rod mounted at any point along the food
preparation line.
[0023] A further aspect of the present invention involves a food
preparation line having two portions. The first portion abuts the
second portion. Desirably, the first portion includes a warmer and
a heating device which are positioned to be within the arm span of
a single worker. The second portion desirably includes an
accompaniments container located proximate the heating device. The
second portion also includes a packaging dispenser. The
accompaniments container and the packaging dispenser are
advantageously located within about six feet of each other so as to
be within the arm span of a single worker.
[0024] Further aspects of the present invention will be apparent in
view of the disclosure below.
Brief Description of Drawings
[0025] These and other features of the invention will now be
described with reference to the drawings of two preferred
embodiments which are intended to illustrate and not to limit the
invention, and in which:
[0026] Figure 1 is a top plan view of a food preparation line that
is configured in accordance with a first preferred embodiment of
the present invention;
[0027] Figure 2 is a front elevational view of a first section of
the preparation line as viewed in the direction of lines A-A of
Figure 1;
[0028] Figure 3 is front elevational view of a second section of
the preparation line as viewed in the direction of lines B-B of
Figure 1;
[0029] Figure 4 is a front elevational view of third section of the
preparation line as viewed in the direction of lines C-C of Figure
1;
[0030] Figure 5 is a front elevational view of a corner section of
the preparation line as viewed in the direction of lines D-D of
Figure 1;
[0031] Figure 6A is a sectional side view of a steam cabinet
configured in accordance with a preferred embodiment of the present
invention;
[0032] Figure 6B is an enlarged sectional view of the area within
circle 6B of Figure 6A and illustrates a door drip edge;
[0033] Figure 7 is a rear elevational view of the steam cabinet of
Figure 6A;
[0034] Figure 8 is a perspective view a shelf of a hanging storage
system that is shown in Figure 1 and is configured in accordance
with a preferred embodiment of the present invention;
[0035] Figure 9 is an enlarged perspective view of the area within
Circle 9 of Figure and illustrates a hook of the storage shelf;
[0036] Figure 10 is a perspective view of a container holder of the
hanging storage system of Figure 1;
[0037] Figure 11 is a side elevational view of the container holder
of Figure 10;
[0038] Figure 12 is a perspective view of a wrap holder of the
hanging storage system of Figure 1;
[0039] Figure 13 is a side elevational view of an ingredient
dispenser of the food preparation line of Figure 1;
[0040] Figure 14A is an enlarged, partial sectional, side view of a
pump and valve assembly of the ingredient dispenser of Figure 13,
and illustrates the pump in a metering stoke of the dispensing
cycle;
[0041] Figure 14B illustrates the pump and valve assembly with the
pump in a delivery stroke of the dispensing cycle; and
[0042] Figure 15 illustrates a top plan view of a food preparation
line that is configured in accordance with another preferred
embodiment.
Detailed Description
[0043] Figure 1 illustrates a food preparation line 1 that is
configured in accordance with a first embodiment of the present
invention. The preparation line 1 is designed to improve the speed
of service (i.e., shorten individual food preparation time) while
reducing the number of employees on the preparation line, as well
as to improve the consistency of ingredient portions between like
products. In particular, the food preparation line of the present
invention advantageously allows two workers to efficiently perform
the work of at least three workers in a quick-service restaurant
environment. The preparation line 1 is also preferably self
monitoring to indicate the malfunction of any of the various
components of the line. In addition, the preparation line measures
the duration of time that ingredients remain on the line for health
concerns. The preparation line 1 thus has particular utility in
quick-service restaurants. The preparation line 1 is accordingly
illustrated and described in connection with a quick-service,
mexican-entree restaurant, such as, for example, a Taco Bell.RTM.
restaurant. It shall be understood, however, that the skilled
artisan can readily adapt the preparation line 1 to be used in
other types of food preparation facilities or restaurants.
[0044] Figure 1 best illustrates a desired U shape of the food
preparation line 1. For this purpose, the preparation line 1
includes a first section 3, a second section 5, and a third section
7 that are arranged to form a U shape. The second section 5 extends
between corresponding ends of the first and third sections 3, 7,
while the first and third sections 3, 7 extend generally parallel
to each other. Each section 3, 7 terminates at an outer end 2, 52.
The modular nature of the line 1 created by the separate sections
3, 5, 7, however, allows the line to be arranged in other
configurations. The line 1 need not be formed in a perfect U-shape
with the first and third sections 3, 7 parallel to each other and
the second section 5 perpendicular to the other sections 3, 7, as
will be described below.
[0045] A heated storage compartment is provided along the first
section of the preparation line. The heated storage compartment can
be any of a number of devices designed to maintain food products at
an elevated temperature. In the illustrated embodiments, the heated
storage compartment can be either the steam cabinet 100 or the
heating cabinet 14. One skilled in the art will appreciate that the
heated storage compartment can also comprise a bun warmer, hot
plate or other similar devices.
[0046] A heating device is also provided along the preparation
line. The heating device of the illustrated embodiments is a steam
table 20. The heating device can either maintain food at an
elevated temperature or cook food items being prepared along the
food preparation line. One skilled in the art will readily
recognize that the heating device can be an oven, a grill, a range
top, a hot plate or other similar devices.
[0047] A cooled storage compartment is provided along the second
section of the preparation line. The cooled storage compartment can
be any of a number of devices designed to maintain food products at
a temperature below room temperature. In the illustrated
embodiments, the cooled storage compartment can be either the open
produce bin 32 or the refrigerators 38. One skilled in the art will
appreciate that the cooled storage compartment can also comprise a
cool rail, ice chest or other similar devices.
[0048] As is common to each section, a counter top 17, 34, 47
extends along the length of the first, second and third sections 3,
5, 7, respectively, at about waist height (e.g., 21/2 to 4 feet
high). Along the edges of the counter tops 17, 34, 47, as well as
along the edges of the shelves and cabinets, a plurality of
mounting studs 19 (Figure 2) can be placed. The mounting studs 19
desirably are spaced apart at eight (8) inch intervals, center to
center, and are shaped to cooperate with key holes formed in a
variety of movable line components, such as, for example, removable
shelving, dispensers and storage devices.
[0049] Along this line, the line 1 can include one or more
removable shelves attached to a side edge of one of the counter
tops. For instance, in the illustrated embodiment, a removable
angled shelf 42 is positioned at the corner 11 between the second
and third sections 5, 7. The angled shelf 42 is positioned at the
surface level of the preparation line 1, even with the counter tops
34, 47, so that food items can be set upon the shelf before they
are packaged. The angled shelf 42 includes a plurality of key holes
formed along side edges of the shelf which cooperate with the
mounting studs 19 to releasably attach the shelf 42 to the second
and third sections 5, 7.
[0050] A second removable angled shelf 43 desirably is located at
the corner 9 between the first and second sections 3, 5. The angled
shelf 43 is positioned at the surface level and is releasably
attached to the sections 3, 5 using the mounting studsAs
illustrated in Figures 1 and 2, the first section 3 includes a
steam cabinet 100 near the outer end 2 of the section 3. Because
the preparation of many food items initially begin with tortillas,
the steam cabinet is arranged at the starting point of the
preparation line 1. As Figures 1 and 2 illustrate, the steam
cabinet 100 desirably lies on a shelf above of the counter top 17
of the first section 3.
[0051] The steam cabinet 100, which will be described in detail
below, has a semi-enclosed steam chamber. In the exemplary
application, the steam cabinet 100 stores flour tortillas and keeps
them warm pending use during food product preparation. For this
purpose, the steam cabinet produces 90-100% humidity within the
steam chamber and maintains a temperature ranging between
120-140.degree. F within the chamber.
[0052] The steam chamber desirably has a sufficient size so as not
to require restocking during extended periods of use. For example,
the quantity of supply should be sufficient to not require any
additional stocking during a three-hour lunch period in the middle
of the afternoon. For this purpose, the steam chamber
advantageously includes four shelves which are sized to hold 192
tortillas of 10.5 inch diameter and 288 tortillas of 6.5 inch
diameters.
[0053] The steam cabinet 100 has an open face which opens directly
into the steam chamber. An air curtain keeps the steam within the
chamber, as described below. The open face eliminates the need to
constantly open and close a front door when getting a tortilla.
[0054] The steam cabinet 100 also includes a rear door that opens
directly into the steam chamber. The rear access to the steam
chamber allows tortillas to be loaded into the steam cabinet 100
without interfering with the operation of the worker on the
preparation line 1.
[0055] Directly below the steam cabinet 100 is wrap storage station
12. From this location, a worker places a tortilla from the steam
cabinet 100 directly on a wrap (i.e., paper and/or foil
sheets).
[0056] The wrap storage station 12 includes a plurality of tiered
compartments that are sized to hold wraps in a flat manner. This
layout makes the wraps easier to discern from one another, easier
to access and easier to grab. Finger holes are also provided to
further assist with the latter advantage. The storage station
desirably includes at least six compartments which are adequately
sized to hold a sufficient amounts of wraps to last through a
three-hour rush period (e.g., a daily lunch period).
[0057] The storage station 12 sits atop the counter top 17 with the
steam cabinet 100 sitting on the storage station 12. The counter
top 17 in front of the station 12 can be used to prepare food
items. For example, flour tortillas removed from the steam cabinet
100 can begin their preparation on the counter top 17.
[0058] A heated cabinet 14 is located on the line"s first section
at a position directly below the wrap storage station 12. The
heated cabinet 14 is configured to maintain a predetermined
quantity of ingredients before the ingredients are placed on the
line. The quantity of ingredients desirably is sufficient to not
require restocking during extended periods of use. For example, the
quantity of supply can be sufficient to not require any additional
stocking during a three-hour lunch period in the middle of the
afternoon.
[0059] In the illustrated embodiment, a half height heating cabinet
14 is used. The cabinet 14 desirably includes a front door and a
rear door to allow loading from the rear so as not to the disturb
the line workers. A suitable heating cabinet 14 is commercially
available from Bevles, of Chino, California.
[0060] Located adjacent to the steam cabinet 100 is a bean cup
dispenser 16. In the illustrated embodiment, the bean cup dispenser
16 is attached to the steam cabinet with key hole slots to allow
the dispenser 16 to be movable. The bean cup dispenser 16 is an
enclosed sanitary chamber configured to receive a predetermined
quantity of cups. Any of a variety of conventional cup dispensers
can be used for this purpose. A suitable cup dispenser is available
from Antunes, of Addison, Illinois. It also will be understood that
the bean cup dispenser 16 can store cups for products other than
pinto beans. For example, extra red sauce, nacho cheese, meat, or
other food items can be placed in the cups. Accordingly, the line 1
can include more than one cup dispenser positioned at or near this
location.
[0061] The cup dispenser 16 desirably includes a plurality of
mounting studs 19 that extend vertically along the dispenser 16. As
best seen in Figure 2, one or more paper wrap dispensers 45 (e.g.,
soft taco wrap dispensers) are removably attached to the side of
the dispenser 16 for easy access by the line worker.
[0062] Below the bean cup dispenser 16 is a section of the
generally flat working counter top 17. This space also can be used
as a food preparation surface.
[0063] A water filtration system 18 is located below the bean cup
dispenser 16 and the counter top 17. The filtration system filters
and regulates the water used in a steam well 20 on the line.
[0064] A steam table lies at the corner 9 formed between the first
and second sections of the line 1 in the illustrated embodiments.
As best seen in Figure 5, the steam table 20 is positioned at the
surface level of the counter top 17 which allows food to be served
quickly and smoothly. The steam table 20 maintains a
high-temperature water bath heated by heating elements. In the
illustrated embodiment, the steam table 20 includes three full size
compartments. Each compartment is heated by a 20 amp heating
element. Though the line is described as including a steam table,
it is understood that a drop-in dry hot well system can be used as
well. Additionally, as will be appreciated by those skilled in the
art, the steam table may also be replaced by a grill or other
cooking surface.
[0065] Pans holding an assortment of food ingredients are placed in
the steam table 20. It will be understood that the steam table 20
can accommodate pans of various sizes. For example, three one-third
pans can fit within each compartment of the steam table 20, as will
18 one-sixth pans and 27 one-ninth pans. The pans contain
ingredients that need to be kept at a warm temperature. For
example, additional meat, beans and red sauce are stored in pans in
the steam table 20. In addition to these ingredients, green sauce,
nacho cheese and chili, as well as other ingredients, are stored in
pans within the steam table 20.
[0066] Figures 1 and 3 illustrate a steam well digital control
panel 28 positioned on the second section 5 adjacent to the corner
9 and the steam well 20. In applications having a steam table, the
water level in the steam table 20 is controlled by the digital
control system 28, which is located on the second section 5 below
the surface level 34, as seen in Figure 3. The digital control
system 28, through the use of probes in the steam table, operates
the water fill system 18 (Figure 1), which, in turn, adds water to
the steam table 20. A manual drain is used to drain water from the
steam wells when cleaning the line. Should the water level drop
below a certain level and remain below after the fill operation (as
would be the case if a line worker left the manual drain open), the
digital control system 28 will alert the line worker of this
abnormal condition and will turn off the heating elements if the
problem persisted.
[0067] The digital control system 28 also monitors the conditions
of the heating elements in the steam table 20 to ensure they are
operating properly. The digital controls 28 found to be suitable
for controlling the steam table 20 of the present invention are
commercially available from Digital Knights of Aliso Viejo,
California.
[0068] Above the digital controls 28 are indicators 26. It will be
understood that the indicators 26 can be lights, audio alarms
(either verbal or non-verbal), or visual displays. The indicators
26 indicate diagnostic changes in the water level and water
temperature in the steam table 20.
[0069] As shown in Figure 2, above the order display 22 is a timer
21 that, for food health reasons, monitors the length of time that
food ingredients have been exposed or open to the atmosphere. The
timer 21 preferably has twenty-one channels, each assigned to a
different ingredient. The timer 21 can monitor the time in which up
to twenty-one ingredients have been in their respective
environments. The timer 21 counts down from a maximum period of
time in which each ingredient can safely remain in its particular
environment. The preferred timer 21 counts down from this
predetermined time towards zero. When the timer 21 counts down to
zero for a particular ingredient, the timer 21 will indicate that
the exposure time for the ingredient has lapsed, and a line worker
will replace the ingredient with a fresh supply of the
ingredient.
[0070] With reference to Figures 1 and 5, an ingredient dispenser
120, which will be described in fuller detail below, is located
behind the steam table in the corner 9 between the first and second
sections 3, 5. The ingredient dispenser 120 includes nozzles 126
that are arranged above the steam table 20 for easy access. The
ingredient dispenser precisely pumps predetermined amounts of
ingredient when activated, as well as dispenses ingredients more
quickly than can be accomplished by hand.
[0071] For this purpose, the ingredient dispensing unit 120
includes a positive displacement pump to dispense food ingredient
in precise, predetermined portions. The ingredient dispenser 120
can be used to dispense a number of different ingredients. For
example, refried beans, ground beef and red sauce can be dispensed
through the ingredient dispensing unit 120. Each food ingredient
would require its own separate ingredient dispenser.
[0072] As illustrated in Figures 1 and 5, in corner 9, defined by
the joining of the first section 3 and the second section 5, is a
heated shelf 24. The heated shelf 24 is heated by one or more lamps
and is positioned above the ingredient dispensing unit 120 at
approximately eye level and is designed to store a predetermined
quantity of ingredient. The quantity of ingredient advantageously
is sufficient to not require restocking during extended periods of
use. For example, the quantity of supply desirably is sufficient so
as not to require any additional stocking during a three-hour lunch
period in the middle of the afternoon. In the exemplary
application, the heated shelf 24 desirably stores ingredients such
as taco shells, tostada shells, nachos and other food items that
need to be kept crisp. The ingredients are, thus, kept at a
predetermined, warm temperature.
[0073] As best seen in Figures 2 and 5, the order display 22 is
positioned above the steam table, on the back facing, below the
heated shelf 24. The line worker can easily read the orders to
coordinate product preparation from the display. The display 22
desirably is a flat screen, such as the type available commercially
from Datalux, of Winchester, Virginia, in order to save space on
the line.
[0074] As illustrated in Figure 3, an auxiliary ingredient
dispenser 27 is positioned above the digital control panel 28. The
ingredient dispenser 27 permits line workers to dispense
ingredients such as, for example, but without limitation, sour
cream, guacamole and/or beef, in accurate portions. Moreover, the
easy accessibility of the ingredient dispenser 27 increases the
speed in which food items can be prepared. An ingredient dispenser
found to be suitable in the food preparation line 1 is a dispenser
commercially available from Frymaster of Shreveport, Louisiana.
[0075] A wrap storage station desirably is positioned between the
auxiliary ingredient dispenser 27 and the control panel 28. The
storage station is convenient located in proximity to the heated
shelf 42, ingredient dispensers 120, 27 and the steam table 20.
[0076] On the second section 5, adjacent to the auxiliary
ingredient dispenser 27, is a cheese melter 32. The cheese melter
32 is located on a shelf 51 that extends above the counter top 34.
The cheese melter 32 desirably uses hot steam heat to melt cheese
on some products. For this purpose, a source of filtered water is
connected to the cheese melter 32.
[0077] A quesadilla warmer 53 is located on the counter 47 of the
third section 7. The quesadilla warmer 53 preferably has two
independent lids. The quesadilla warmer 53 has a pair of lids
whereby one lid to the quesadilla warmer 53 can remain closed while
the other lid is opened to insert or remove product from the warmer
53. This configuration permits a line worker to place a quesadilla
into the quesadilla warmer 53 via one lid while another quesadilla
is already inside the quesadilla warmer 53. Line workers thus can
cook a second quesadilla without waiting for the first cycle to
complete. That is, the split lid allows the quesadilla warmer 53 to
function essentially as two quesadilla warmers 53 in the space of
one. A warmer found to be suitable as a quesadilla warmer 53,
without the split lid improvement, is a warmer manufactured by Star
Manufacturing of St. Louis, Missouri.
[0078] As illustrated in Figures 1 and 3, a produce bin 36 is
located on the second section 5, below the cheese warmer 33. The
produce bin 36 receives and store predetermined amounts of produce.
The quantity of produce stored within the bin 36 and an on-line
refrigerator 38 desirably is sufficient so as not to require
restocking during extended periods of use. For example, the
quantity of supply can be sufficient to go without resupply for a
three-hour period in the middle of the afternoon. In the preferred
embodiment, the produce bin 36 holds a variety of produce to be
added to food ingredients as they proceed along the preparation
line 1 from the ingredient dispenser 120 or steam table 20. For
example, accompaniments such as lettuce, tomatoes, olives as well
as cheese and sour cream are added to the food items that proceed
to the second section 5 of the preparation line 1. The produce bin
36 can hold five one-third pans and five one-sixth pans which, in
turn, store the produce. The produce bin may be located proximate a
Bloomington Rail, manufactured by the Delfield Co. of Mount
Pleasant, Michigan.
[0079] As shown in Figures 1 and 3, above the produce bin 36 is a
wrap storage system 150. The wrap storage system 150, which will be
described in fuller detail below, is configured to receive
predetermined quantities of product packaging. The wrap storage
system 150 hooks on to the preparation line 1 and stores containers
which, in turn, hold product packaging used to wrap the final
product before delivery to the customer. The modular nature of the
wrap storage system 150 allows it to be hung anywhere along the
food preparation line 1. Such optimal positioning advantageously
permits easy accessibility to product packaging.
[0080] Positioned in front of the produce bin 36 in Figure 3 is a
taco rail 40. The taco rail 40 sits on the counter top 34 and is
configured to receive tacos and maintain them in an upright
position. The taco rail 40 positions tacos that have already been
loaded with meat and/or beans in an upright position to permit the
worker to load produce on the taco without the taco tipping and
spilling produce. Accordingly, as shown in Figure 3, the taco rail
extends between the steam table and the third section of the
preparation line.
[0081] Below and proximate the counter top 34 and taco rail 40 is a
waste container 30. Adjacent to the waste container 30 and below
the produce bin 36 is another waste container 31. Produce that has
fallen from food items during food preparation and settled on the
counter top 34 or taco rail 40 can be easily swept into the waste
containers 30, 31 to ensure that the preparation line 1 remains
sanitary. Waste containers 30, 31 found to be suitable for use with
the present invention are commercially available from Rubbermaid of
Winchester, Virginia.
[0082] Below the waste container 31 are dual refrigerators 38 to
store cold items. The dual refrigerators are located, generally, at
the floor level. Using two refrigerators 38 at this position
increases storage capacity. For example the dual refrigerators 38
hold six full pans (or eighteen one-third pans), a quantity
sufficient to fully supply the food preparation line 1 during a
three hour peak period.
[0083] Figure 4 illustrates a monitor 50 proximate to the corner
11, formed by second section 5 and the third section 7. The monitor
50 is positioned on a shelf 41 that extends at approximately eye
level along the third section 7. The monitor 50 indicates orders
taken from the drive-through window. As the food items continue
down the preparation line 1 from the ingredient dispenser 120 to
the produce bin 36, line workers can reference the monitor 50 to
determine what orders need to be prepared for the drive-through
window. As the drive-through orders are prepared, they are handed
through the pass-through area 49 to employees working the
drive-through window.
[0084] On the third section 7, adjacent to the order display 50, is
the wrap storage system 150. The wrap storage system 150, which
will be described in fuller detail below, is configured to receive
predetermined quantities of product packaging. The wrap storage
system 150 holds product packaging corresponding to different food
items. The wrap storage system 150 provides easy access to the
packaging to further expedite food preparation. In addition, the
wrap storage system 150 is modular so as to be removably mounted
anywhere along the preparation line 1.
[0085] A bag opener 48 can be located adjacent to the wrap storage
system 150, on the third section 7. As one bag is removed, the next
is automatically opened. With the bag partially open, the worker is
able to load the packaged items into the bag more quickly. This may
enhance product flow through the entire preparation line 1. The bag
opener 48 also has an increased bag capacity holding 130 #4 and 110
#6 bags. This supply is sufficient to eliminate any need to restock
the bag opening 48 during a three hour lunch peak.
[0086] At the end of the preparation line 1, on the third section
7, is a tray dispenser 46. The tray dispenser 46 stores stacked
trays within the lower level cabinet and dispenses the trays
through an aperture in the counter top 47. By placing the trays in
the cabinet, a sufficient supply of trays can be stacked in the
dispenser 46 to eliminate the need to frequently stock the
dispenser 46. The packaged food items, if not placed in the bags
for a carry-out order, are placed on the trays to be delivered to
the customer. The illustrated embodiment utilizes a tray
lowerator.
[0087] A hand sink 45 and sanitizer 45a are positioned at the end
of the third section 7 near the tray dispenser 46. The hand sink 45
has running water and a drain positioned on the bottom interior
surface of the sink 45. Line workers entering the food preparation
line 1 use the sink 45 to wash their hands in order to maintain
sanitary conditions on the food preparation line 1. Similarly, when
line workers exit the food preparation line, they can wash their
hands in the sink 45. Moreover, as line workers prepare products on
the food preparation line 1, any ingredients that come in contact
with the line workers" hands can be quickly washed away. The sink
45 permits the line workers to conveniently and quickly wash their
hands in order to maintain a sanitary food preparation line 1.
[0088] The sanitizer 45a is preferably located adjacent to the sink
45 as illustrated in Figure 1. The sanitizer is provided with a
drain and desirably cannot be filled using the faucet associated
with the sink. In use, the sanitizer holds a cleaning solution and
towels. The cleaning solution can be either poured directly from a
bottle or diluted using water transferred from the sink. No faucet
is provided in the sanitizer to eliminate the possibility of
accidental dilution of the cleaning solution.
[0089] Positioned in the corner 11 formed by the second section 5
and the third section 7, is a cash register (not shown). The cash
register faces away from the line workers on the food preparation
line 1 and towards the drive-through window. The register is
accessible through the pass-through area 49 to employees working
the drive-through window. The position of the register desirably
permits employees working the drive-through window to conveniently
enter orders and pick-up prepared products in the same
location.
[0090] In the corner 11, underneath the surface level, is a
refrigerator 38 (Figure 4). The refrigerator 38 can be accessed
from the rear of the preparation line 1. The rear access
refrigerator 38 is accessible to workers stationed at the
drive-through window. The drive-through workers, thus, do not have
to walk around the preparation line 1 to the refrigerator 38 to
obtain milk, juice and other refrigerated items. Rather, these
items can be stored in the rear access refrigerator 38 and accessed
from behind the third section 7.
[0091] The above described preparation line 1 desirably is sized
and arranged to allow just a few workers to handle the line. In the
illustrated embodiment, the line 1 can be formed to have a
foot-print of approximately 12 feet by six feet and be configured
to allow two line workers to efficiently prepare ordered meals. The
arm-span of the workers, positioned at the two inside corners of
the preparation line, can cover the entire preparation line. Thus,
advantageously, two workers can remain relatively stationary and
complete each of the tasks along the food preparation line. Labor
costs of course are reduced with the use of less workers on the
line. The increased capacity of on-line storage within the produce
refrigerator, heating cabinet and packaging storage stations, also
eliminates the need to restock the line during times of peak
production, such as, for example, during a three-hour lunch rush.
As a result, a full time stock or prep person does not have to be
employed, thereby further reducing labor costs.
[0092] In addition to reducing labor costs, the arrangement of the
line 1 also improves the flow of meal preparation. That is,
preparation proceeds in a more orderly fashion along the line. The
speed of service in the restaurant advantageously increases.
[0093] The modular nature of several of the components of the line
also readily accommodates changes to the restaurant"s product menu.
Special ingredients and packaging for new products are easily
integrated into the overall arrangement of the preparation
line.
[0094] The following will now elaborate upon the steam cabinet 100,
the hanging storage system 150 and the ingredient dispensing system
120 of the food preparation line 1 described above.
[0095] Figure 6A illustrates a steam cabinet 100. A steam chamber
114 is generally defined by the walls of the steam cabinet 100. A
fan unit 102 is desirably positioned outside the steam flow within
the steam chamber 114. Adjacent to the fan unit 102 is a heating
element 104. A laminar air flow passage 106 extends within and
along the bottom of the steam cabinet 100. The air flow passage 106
further extends partially along the side the steam cabinet 100. An
air curtain 110 defines a side of the steam chamber 114. Above and
adjoining the air curtain 110 is a swinging door 112 that extends
partially down along the open side of the steam cabinet 100. An
exhaust system 116 is positioned at the top of the steam chamber
114. The exhaust system 116 includes a manual vane 111 (Figure 2).
Directly below the exhaust system 116, and positioned at the top of
the steam chamber 114, is a heating element 118. Within the steam
chamber 114 is a shelving unit 113. The rear panel 115 of the steam
chamber 114 is a door. As best illustrated by Figure 7, a latching
mechanism 119 is mounted to the rear access door 115.
[0096] Flour tortillas or other food ingredients are placed within
the steam chamber 114 on the shelving unit 113 to be heated. The
cabinet is configured to maintain a predetermined quantity of
tortillas. The quantity of tortillas desirably is sufficient to not
require restocking during extended periods of use. For example, the
quantity of supply can be sufficient to not require any additional
stocking during a three-hour lunch period in the middle of the
afternoon.
[0097] A steam well 108 is positioned at the bottom of the steam
chamber 114, and within the steam well 108 are heating elements
117. A water bath is maintained in the steam well 108.
[0098] Figures 6A-7 illustrate a rear access door 115 comprising
the back panel of the steam cabinet 100 and providing access to
steam chamber 114. A latch unit 119 is mounted on the rear access
door 115 and steam cabinet 100. A drip edge channel 101 is provided
below the door as illustrated in Figure 6B. The drip edge 101 and
sloping surface channels away any condensation which may accumulate
on the inner surface of the door. Specifically, as shown in Figure
6B, any condensation which may form on the inside of door 115 will
be pulled downward by gravity. The condensation will fall from the
bottom of the door into the channel 101. Any condensation remaining
on the bottom of the door 115 will be swept into the channel by the
edge 101a. Thus, the drip edge channel 101 traps condensation which
forms of the inside and bottom surfaces of door 115. The channel
can be configured to drain the condensation back into the steam
well 108. As will be appreciated by those skilled in the art, the
channel may also be drained to a location outside of the steam
cabinet.
[0099] As illustrated by Figure 6A, the heating element 104 heats
the air within the air flow passageway 106. The fan unit 102 forces
the heated air through the air flow passageway 106. The heated air
extends across the open side of the steam chamber 114 to the
swinging door 112 thereby creating a laminar air curtain 110. The
laminar air curtain 110 acts as a seal to prevent steam and heat
from escaping into the atmosphere from the steam chamber 114.
[0100] As mentioned above, a water bath is maintained in the steam
well 108. The water is heated to a predetermined temperature by the
heating elements 117 thereby creating steam. The steam rises into
the steam chamber 114 and permeates the inside of the steam chamber
114. Food ingredients placed on the shelving unit 113 within the
steam chamber 114 are kept warm by the rising steam and the heat
radiated by the upper element 117. As the steam continues to rise
within the steam chamber 114, it reaches the top of the steam
chamber 114 where it comes into contact with the heating element
118. The heating element 118 emits heat of a predetermined
temperature sufficient to cause the steam to dissipate thereby
preventing moisture from accumulating on the top surface within the
steam chamber 114 and raining down on the food ingredients
positioned on the shelving unit 113. The exhaust system 116 expels
steam from the steam chamber 114 to permit newly formed steam to
circulate within the steam chamber 114. The manual vane 111
included in the exhaust system 116 is manually adjustable to create
a gap at the top of the steam chamber 114. The gap, which can be
widened or closed, permits steam and heat within the chamber to
escape into the atmosphere. The gap is manually adjusted to create
a gap of a certain width to allow steam and heat to be expelled
from the steam chamber 114, while maintaining a temperature within
the steam chamber 114 that is sufficient to keep the ingredients
warm.
[0101] The laminar air curtain 110 permits an individual to reach
into the steam chamber 114 to withdraw food ingredients without the
having to open a door. The swinging door 112 decreases the distance
which the heated air flow must span to create an effective air
curtain 110. An access door 115, located in the rear of the steam
cabinet 100, permits an individual to load food ingredients into
the steam chamber 114 to be prepared, while not interfering with an
individual withdrawing food ingredients through the air curtain
110.
[0102] Figures 8-12 illustrate a wrap packaging storage system 150.
The system involves a wrap storage shelf 152 configured to receive
a container 158, 162. A securing slot 156 extends along
substantially the full length of the bottom surface 153 of the wrap
storage shelf 152. The bottom surface 153 is desirably indented
along substantially its entire length to form the slot 156. The
side panels 155 of the wrap storage shelf 152 are configured with
an attachment means 154 for hanging the wrap storage shelf from at
least one rod 157. For example, the hooks 154 defined by or
attached to the side panels 155 of the wrap storage shelf 152 would
be suitable attachment means. The hooks 154 define an aperture 159
and are configured to receive a rod 157.
[0103] As mentioned above, it will be understood that the wrap
storage shelf system 150 is modular in nature and may be positioned
at any point along the preparation line 1 where a rod 157 is
mounted. The wrap storage shelves 152 can be produced in any number
of sizes as well to fit within the preparation line 1 where
necessary. Moreover, shelves 152 can accommodate wrap containers
162, 158 of varying shapes and sizes to accommodate different
packaging corresponding to different products.
[0104] The wrap storage shelves 152 are configured to receive
containers 162, 158. As shown in Figures 10 and 11, the container
162 is defined by two side panels 165,169, a rear panel 167, a
front panel 163 and a bottom panel 171. An aperture 168 is
configured on the front panel 163. Flanges 164, 166 are mounted on
the bottom surface 171 of the container 162. Flange 164 is angled
forward to a sufficient degree to permit it to interlock with the
slot 156 of the wrap storage shelves 152. Flange 164 may
alternatively be angled backward. Flange 166 will extend
approximately perpendicular to the bottom surface 171 of the
container 162. A hole 170 is defined by the perpendicular flange
166, the front panel 163 and side panels 165,169.
[0105] As best illustrated by Figure 12, a wrap container 158 is
fitted with a flange 160 which depends approximately perpendicular
from the bottom surface 175 of the wrap container 158. The bottom
surface 175 further defines a lower shelf of the wrap container
158. A second shelf is defined by an intermediate panel 177
positioned between side panels 178,179 and parallel to the bottom
panel 175.
[0106] The wrap storage shelf 152 hangs from the rod 157 through
the hook 154. The rod 157 is mounted along needed points on the
preparation line 1. Placed at predetermined points along the rod
157 are supports. The supports are mounted to the food preparation
line 1 and are connected to the rod 157. The supports are spaced at
a distance that is sufficient to prevent the rod 157 from bowing
under the load of the shelf 152 and containers 162, 158.
[0107] Wrap containers 162 and 158 are placed in the wrap storage
shelf 152. The angled flange 164 underneath the bottom surface 171
of the container 162 will slide into the slot 156 on the inside
bottom surface 153 of the wrap storage shelf 152. This will prevent
the container 162 from sliding off the shelf 152 when a carton is
removed from the container 162. The product packaging is removed
from the wrap container 162 through the hole 170. Advantageously,
an individual can secure the product packaging at aperture 168 and
pull the packaging out through the hole 170.
[0108] The perpendicular flange 166 will prevent the wrap container
162 from being pushed backwards thereby displacing the angled
flange 164 on the container 162 from the slot 156 on the wrap
storage shelf 152. To remove the container 162 from the wrap
storage shelf 152, the container 162 is lifted from the thumb hole
168 in a vertical direction to a height sufficient for the
perpendicular flange 166 to clear the front edge 151 of the wrap
storage shelf 152. Then the wrap container 162 is pushed backwards
so that the angled flange 164 can clear the slot 156 at which time
the entire wrap container 162 can be lifted out of the wrap storage
shelf 152.
[0109] The wrap container 158 does not have an angled flange
fitting into the slot 156 of the wrap storage shelf 152. Instead,
the wrap container 158 is positioned within the wrap storage shelf
152. The wrap container 158 stores product packaging on shelves
175, 177, and the product packaging is pulled from the top of a
pile of packaging on each shelf 175, 177.
[0110] As illustrated in Figures 13-14B, the ingredient dispenser
120 is positioned in the corner 9 of the product line 1. The
ingredient dispenser 120 is positioned within a cabinet 121 out of
plain view. The cabinet 121 includes a heated compartment in which
the hoppers 124 of the system 120 are located. Access to the
hoppers 124 is gained through a rear access door located on the
rear side of the first line section 3. A controller 33 (Figure 3)
communicates with internal sensors within the heated compartment
and regulates the corresponding heating elements to control the
temperature of the ingredients within the hoppers 124.
[0111] A mixing motor 123, positioned within the cabinet 121 and
above the hopper 124, operates a mixer 122. The mixer 122 extends
into the ingredient (not shown) within the hopper 124. The hopper
124 is in communication with a two-position valve 130. In the first
position, as illustrated in Figure 14a, the valve 130 is connected
to the piston chamber 144. In the second position, as illustrated
in Figure 14b, the valve 130 is in communication with an outlet
port 136. The outlet port 136, in turn, is in communication with an
outlet tube 125. Dispensing nozzles 126 are configured at the end
of the outlet tube 125. Desirably, each tube 125 is wrapped with a
conventional heating blanket (not shown), such as those
commercially available from Watlow of St. Louis, Missouri, to
maintain the ingredient within the tube 125 at a desired
temperature. A controller 33 (Figure 3) operates the heating
blankets. The dispensing nozzles 126 hang down from an overhead
cabinet 128.
[0112] A positive displacement pump assembly 140 and valve 130
found to be suitable as components of the ingredient dispenser 120
of the present invention is a pump and valve assembly manufactured
and distributed by Itoh Kouki of Japan.
[0113] Figure 14A illustrates a two-position valve 130 in
communication with a piston pump assembly 140. An inlet port 134 is
interposed between the hopper 124 and the two-position valve 130.
An outlet port 136 is interposed between the two-position valve 130
and the outlet tube 125. The valve member 132 of the valve 130 is
in an intake position. A piston chamber 144 extends outward from
the valve 130. Within the piston chamber 144, a piston 142 is
withdrawn from the piston chamber 144.
[0114] As illustrated in Figure 14B, the valve member 132 is in an
outlet position. Further, the piston 142 is fully inserted within
the piston chamber 144.
[0115] The hopper 124, which holds a predetermined amount of
ingredient 127, is loaded from the top when it becomes low. The
quantity of ingredient 127 in each hopper 124 desirably is
sufficient to not require restocking during extended periods of
use. For example, the quantity of supply can be sufficient to not
require any additional stocking during a three-hour lunch period in
the middle of the afternoon.
[0116] As illustrated in Figures 13 and 14A, to operate the
ingredient dispenser 120, compressed air drives an actuator 129
which, in turn, drives the piston 142. A conventional compressor
supplies the compressed air to the air cylinders.
[0117] To dispense ingredient, the piston 142 is fully withdrawn
from the piston chamber 144. This pulls ingredient 127 from the
hopper 124, through the inlet port 134 and into the valve chamber
133 and piston chamber 144. The back-pull of the piston 142
withdraws a precise, predetermined amount of ingredient 127 into
the valve chamber 133 and piston chamber 144. In doing so, the
valve member 132, within the valve chamber 133, is rotated by a
second actuator 138 (Figure 13) in a counter-clockwise direction to
the position illustrated in Figure 14B. As illustrated in Figures
13 and 14B, the air cylinder 129 then drives the piston 142 forward
within the piston chamber 144. This, in turn, forces the ingredient
127 through the piston chamber 144, into the valve chamber 133, and
out through outlet port 136. Because a quantity of ingredient 127
is perpetually present in the outlet tube 125, the same proportion
of ingredient withdrawn from the hopper 124 by the piston 142 and
driven through the outlet port 136 will expel through nozzle
126.
[0118] The counterclockwise rotation of the valve member 132 from
the position illustrated in Figure 14A to the position illustrated
in 14B, effectively blocks the inlet port 134 and then the piston
142 forces the ingredient 127 through outlet port 136. This
operation will repeatedly dispense approximately the same
proportion of the ingredient 127.
[0119] The ingredient dispenser 120 also includes a red sauce
dispensing mechanism in which a submergible pump is located within
a container of red sauce. The container is positioned within the
heated compartment within the cabinet 121. A delivery line extends
from the pump to a discharge nozzle located adjacent the dispenser
nozzle 126.
[0120] Figure 15 illustrates another embodiment of a food
preparation line. The embodiment of Figure 15 in generally
configured in accordance with the embodiment of Figure 1. The third
section in the embodiment of Figure 15, however, desirably is
angled relative to the first section. The angle is preferably about
45.degree. but may vary over a broad range as can be appreciated by
those skilled in the art. Importantly, the distance between the
open produce bin 32 and the packaging containers 150 is less than
about six feet. The distance is desirably determined by the average
arm span of a worker. Additionally, the distance between the heated
storage container and the steam table is similarly determined by
the average arm span of a worker and is less than about six
feet.
[0121] Although the foregoing invention has been described in terms
of an illustrated embodiment, other embodiments will become
apparent to those of ordinary skill in the art, in view of the
disclosure herein. Accordingly, the present invention is not
intended to be limited by the recitation of illustrated
embodiment.
* * * * *