U.S. patent application number 17/675767 was filed with the patent office on 2022-06-02 for production of precooked formed meat patties.
This patent application is currently assigned to The Hillshire Brands Company. The applicant listed for this patent is The Hillshire Brands Company. Invention is credited to Kent BEARSON, Frederick DORSEY, Dejing FU, Liza JOHN, Nicholas MILLER.
Application Number | 20220167634 17/675767 |
Document ID | / |
Family ID | 1000006149763 |
Filed Date | 2022-06-02 |
United States Patent
Application |
20220167634 |
Kind Code |
A1 |
BEARSON; Kent ; et
al. |
June 2, 2022 |
PRODUCTION OF PRECOOKED FORMED MEAT PATTIES
Abstract
A cold forming process for forming a meat patty includes heating
a ground meat product to a temperature T.sub.1, wherein
T.sub.1.ltoreq.40.degree. F. The ground meat product is formed into
an uncooked patty at temperature T.sub.1. The uncooked patty is
precooked to form a precooked patty having a skin of depth D
comprising denatured protein. The skin is formed on at least an
area on the outside of the precooked patty. At least a first
portion of the meat product disposed beneath said skin is at
approximately T.sub.1. The precooked patty is cooked to form a
cooked patty, wherein said at least a first portion of the meat
product is at a temperature T.sub.2. The cooked patty is then
frozen and then packaged.
Inventors: |
BEARSON; Kent; (Naperville,
IL) ; FU; Dejing; (Lisle, IL) ; DORSEY;
Frederick; (Chicago, IL) ; MILLER; Nicholas;
(Downers Grove, IL) ; JOHN; Liza; (Downers Grove,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Hillshire Brands Company |
Chicago |
IL |
US |
|
|
Assignee: |
The Hillshire Brands
Company
Chicago
IL
|
Family ID: |
1000006149763 |
Appl. No.: |
17/675767 |
Filed: |
February 18, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16937911 |
Jul 24, 2020 |
11284628 |
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17675767 |
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16081591 |
Aug 31, 2018 |
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PCT/US16/31312 |
May 6, 2016 |
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16937911 |
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62302013 |
Mar 1, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A23L 5/10 20160801; A23L
13/67 20160801; A22C 7/0076 20130101; A22C 7/00 20130101; A22C
7/003 20130101; A23B 4/005 20130101; A23L 13/52 20160801; A23B 4/06
20130101 |
International
Class: |
A22C 7/00 20060101
A22C007/00; A23B 4/005 20060101 A23B004/005; A23B 4/06 20060101
A23B004/06; A23L 13/50 20060101 A23L013/50; A23L 13/60 20060101
A23L013/60; A23L 5/10 20060101 A23L005/10 |
Claims
1. A method for producing a cooked meat patty, the method
comprising the steps of: (a) grinding a meat product into a ground
meat product, the ground meat product at temperature T.sub.1; (b)
forming the ground meat product into an uncooked patty at
temperature T.sub.1 by depositing the ground meat product into a
mold, the mold moving as the ground meat product is deposited
therein; (c) precooking the uncooked patty in the mold to thereby
form a precooked patty having a skin of depth D comprising
denatured protein, wherein the skin is formed on at least an area
on the outside of the precooked patty, and wherein at least a first
portion of the precooked patty disposed beneath said skin is at
temperature T.sub.1; (d) releasing the precooked patty from the
mold; (e) cooking the precooked patty to form a cooked patty
wherein the at least a first portion of the cooked patty is at a
temperature T.sub.2; (f) freezing the cooked patty; and (g)
packaging the frozen cooked patty.
2. The method of claim 1, wherein the mold comprises a plurality of
form pans defining a pan conveyor.
3. The method of claim 2, wherein the step of releasing the
precooked patty from the mold is caused by rotating at least one of
the plurality of form pans.
4. The method of claim 2, wherein the mold does not include a top
and the step of precooking the uncooked patty in the mold comprises
moving the mold relative to a heating plate positioned above the
top of a linear segment of the pan conveyor.
5. The method of claim 1 wherein T.sub.2 is greater than
T.sub.1.
6. The method of claim 1, wherein the step of precooking the
uncooked patty includes applying infrared heating to the uncooked
patty.
7. The method of claim 1, wherein the step of precooking the
uncooked patty includes applying inductive heating to the uncooked
patty.
8. The method of claim 1, wherein the step of precooking the
uncooked patty includes applying heat to the uncooked patty using a
technique selected from the group consisting of: steam conduction
heating, electric conduction heating, thermal oil conduction
heating, application of a liquid, and combinations thereof.
9. The method of claim 1, wherein the mold does not include a top
or bottom and the step of precooking the uncooked patty comprises
moving the mold relative to a first heating plate positioned above
the mold and moving the mold relative to a second heating plate
positioned below the mold.
10. An apparatus for producing a precooked meat patty, the
apparatus comprising: a pan conveyor comprising a plurality of
molds each configured to hold a ground meat product to define an
uncooked patty; a pan conveyor driver configured to move the pan
conveyor along a conveyance path; and a heater configured to
precook each uncooked patty in each mold of the plurality of molds
to thereby form precooked patties each having a skin of depth D
comprising denatured protein, wherein the skin is formed on at
least an area on the outside of each precooked patty, and wherein
at least a first portion of the precooked patty disposed beneath
said skin is in an uncooked state; wherein the conveyance path
includes a curved end portion that causes each precooked patty to
fall from the pan conveyor as the pan conveyor moves along the
conveyance path.
11. The apparatus of claim 10, further comprising a former
positioned adjacent the pan conveyor and configured to deposit the
ground meat product in the plurality of molds.
12. The apparatus of claim 10, wherein the heater is positioned
between the former and the curved end portion.
13. The apparatus of claim 10, wherein each mold of the plurality
of molds does not include a top.
14. The apparatus of claim 13, wherein the heater is positioned
above the pan conveyor.
15. The apparatus of claim 14, wherein each mold of the plurality
of molds does not include a bottom.
16. The apparatus of claim 15, further comprising a second heater
positioned below the pan conveyor.
17. The apparatus of claim 10, further comprising a second heater
configured to cook the first portion of the precooked patty to a
cooked state.
18. The apparatus of claim 10, wherein the heater is selected from
the group consisting of: a steam conduction heater, an electric
conduction heater, a thermal oil conduction heater, a hot liquid
bath, and combinations thereof.
19. The apparatus of claim 10, wherein the heater is an induction
coil.
20. The apparatus of claim 10, further comprising: a former
positioned adjacent the pan conveyor and configured to deposit the
ground meat product in the plurality of molds; and a second heater
configured to cook the first portion of the precooked patty to a
cooked state.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of, and
claims priority benefit to, U.S. patent application Ser. No.
16/937,911 entitled "PRODUCTION OF PRECOOKED FORMED MEAT PATTIES"
and filed on Jul. 24, 2020 which is a divisional application of,
and claims priority benefit to, U.S. patent application Ser. No.
16/081,591 entitled "SYSTEM AND METHOD FOR PRODUCING FORMED MEAT
PATTIES" and filed on Aug. 31, 2018, which claims priority benefit
to, and is a national stage application of, PCT Application No.
PCT/US16/31312 entitled "SYSTEM AND METHOD FOR PRODUCING FORMED
MEAT PATTIES" and filed on May 6, 2016, which claims priority
benefit to U.S. Provisional Patent Application No. 62/302,013
entitled "SYSTEMS AND METHODS FOR PRODUCING A PRECOOKED SLICED MEAT
PRODUCT" and filed on Mar. 1, 2016, the entirety of each is hereby
incorporated herein by reference.
FIELD
[0002] The present disclosure relates generally to the field of
precooked food products, and more specifically, to systems and
methods for producing precooked formed meat patties.
BACKGROUND
[0003] Precooked meat products are very popular in today's
fast-paced world. For example, it is convenient to be able to
quickly prepare a meal using meat patties (e.g., frozen meat
patties) that have already been cooked previously and packaged.
Various techniques are known for producing and packaging meat
patties. Such techniques typically involve numerous processing
steps, some of which are relatively time-consuming and/or require
substantial manual labor.
[0004] Due to the labor-intensive manufacturing process,
high-quality precooked meat patties are difficult to manufacture.
Some prior attempts to simplify or expedite the meat patty
production process have encountered difficulties due to physical
characteristics of the meat (e.g., consistency of the meat and its
ability to withstand processing without disintegrating) or
considerations relating to the end consumer (e.g., taste and/or
texture of the patties). It is desirable to simplify, automate,
and/or expedite manufacturing of meat patties while improving the
quality of the patties.
SUMMARY
[0005] In some embodiments, a warm forming process for forming a
meat patty includes heating an uncooked ground meat product to a
temperature T.sub.1, wherein T.sub.1>32.degree. F. The uncooked
ground meat product is formed into an uncooked patty at temperature
T.sub.1. The uncooked patty is precooked to form a precooked patty
having a skin of depth D comprising denatured protein. The skin is
formed on at least an area on the outside of the precooked patty.
At least a first portion of the meat product disposed beneath said
skin is at approximately T.sub.1. The precooked patty is cooked to
form a cooked patty, wherein said at least a first portion of the
meat product is at a temperature T.sub.2. The cooked patty is then
frozen and then packaged.
[0006] In some embodiments, a cold forming process for forming a
meat patty includes coarse grinding a meat product. The coarse
ground meat product is blended with first ingredients to a
temperature T.sub.1 wherein T.sub.1<40.degree. F. The process
includes fine grinding the blended meat product and forming the
ground meat product into an uncooked patty at T.sub.1. The uncooked
patty is cooked to form a precooked patty having a skin of depth D
comprising denatured protein, wherein said skin is formed on at
least an area on the outside of the precooked patty at a
temperature T.sub.2, and wherein at least a first portion of the
meat product disposed beneath said skin is at approximately
temperature T.sub.1, and wherein T.sub.2>T.sub.1. The precooked
patty is chilled and then packaged.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a block diagram of a conventional system for
producing a precooked meat patty.
[0008] FIG. 2 is a block diagram of a system for producing a
precooked meat patty product in accordance with some embodiments of
the present disclosure.
[0009] FIG. 3 is a side view of an example system for forming and
precooking meat product patties in accordance with some
embodiments.
[0010] FIG. 4 is a top view of the system of FIG. 3.
[0011] FIG. 5 is a side view of two patty formers and a pan
conveyor of the system of FIGS. 3 and 4.
[0012] FIG. 6 is another side view of the two patty formers and the
pan conveyor of FIGS. 3-5.
[0013] FIG. 7 is a top view of the two patty formers and the pan
conveyor of FIGS. 3-6.
[0014] FIGS. 8A-8D are a set of illustrations of side, bottom,
isometric and cross section cut views of a flow block used to
funnel meat product into patty form pans with the patty formers of
FIGS. 3-7.
[0015] FIG. 9 is a side view of a first infrared oven used in the
system of FIGS. 3 and 4.
[0016] FIG. 10 is a top view of a patty flipping portion between
the pan conveyor and a patty conveyor of the system of FIGS. 3 and
4.
[0017] FIG. 11 is a side view of a third infrared oven of the
system of FIGS. 3 and 4.
[0018] FIG. 12 is a top view of the third infrared oven of FIG.
11.
[0019] FIG. 13 is a block diagram for a system in accordance with
another embodiment involving in-bag cooking of meat.
[0020] FIGS. 14A-14C are illustrations of a technique for forming
and precooking meat patties in accordance with some embodiments.
14A: top perspective view; 14B: bottom perspective view; 14C: top
perspective view with dual heat jackets.
[0021] FIGS. 15A-15B are elevation and top views, respectively, of
a system for patty formation and precooking in accordance with some
embodiments.
[0022] FIG. 16 is an illustration of a patty form disk in
accordance with some embodiments.
[0023] FIGS. 17A-17B are illustrations of patty forming apparatuses
in accordance with some embodiments.
[0024] FIGS. 18A-18B are illustrations of an apparatus that
provides uniform flatness to formed meat patties in accordance with
some embodiments. 18A: top view; 18B: partial sectional view.
[0025] FIG. 19 is a side view of a system for precooking meat
patties using a hot water treatment.
[0026] FIG. 20 a flow diagram of a process in accordance with some
embodiments that includes hot water treatment of meat patties.
[0027] FIG. 21 is a flow diagram for a process in accordance with
some embodiments.
[0028] FIG. 22 is a block diagram of a system in accordance with
some embodiments.
[0029] FIG. 23 is a flow diagram for a process in accordance with
some embodiments.
[0030] FIG. 24 is a block diagram of a system in accordance with
some embodiments.
[0031] FIG. 25 is a flow diagram for a process in accordance with
some embodiments.
[0032] FIG. 26 is a block diagram of a system in accordance with
some embodiments.
[0033] FIG. 27 is a flow diagram for a process in accordance with
some embodiments.
[0034] FIG. 28 is a block diagram of a system in accordance with
some embodiments.
[0035] FIG. 29 is a flow diagram for a process in accordance with
some embodiments.
[0036] FIG. 30 is a block diagram of a system in accordance with
some embodiments.
[0037] FIG. 31 is a flow diagram for a process in accordance with
some embodiments.
DETAILED DESCRIPTION
[0038] This description of the exemplary embodiments is intended to
be read in connection with the accompanying drawings, which are to
be considered part of the entire written description. In the
description, relative terms such as "lower," "upper," "horizontal,"
"vertical,", "above," "below," "up," "down," "top" and "bottom" as
well as derivatives thereof (e.g., "horizontally," "vertically,"
"downwardly," "upwardly," etc.) should be construed to refer to the
orientation as then described or as shown in the drawing under
discussion. These relative terms are for convenience of description
and do not require that any apparatus or process be constructed,
operated, or performed in a particular orientation.
[0039] Various embodiments of the present disclosure relate to new
systems and methods for producing meat patties. Efficiencies are
achieved in terms of time, space, and/or resource requirements
compared to prior meat patty production techniques. For example,
some systems and methods reduce or eliminate manual labor during
the patty production process, thereby speeding up the end-to-end
process and/or reducing energy expenditure. In some embodiments,
ground meat patties are produced with a crumbly texture that is
pleasing to consumers.
[0040] FIG. 1 is a block diagram of a conventional system 100 for
producing a precooked sliced meat product. Fat trimmings and lean
trimmings 105 are added to a first grinder 110 and coarsely ground
to about 3/8 to 5/8 of an inch. The ground meat is transferred from
the first grinder 110 to a blender and/or mixer 115 and combined
with other ingredients 120 such as salt, cure, spices, and other
flavorings. After being blended and/or mixed to form a coarsely
ground meat mixture, the coarsely ground meat mixture is
transferred to a heater and/or heat exchanger 125 (referred to as a
heater for convenience) and heated to 50-100.degree. F. The heated
meat mixture is then transferred to a second grinder 130 and more
finely ground to about 3/32 to 1/8 of an inch.
[0041] The finely-ground heated meat mixture is then transferred to
a log former and encaser 135. The log former and encaser 135 forces
the finely-ground heated meat mixture into plastic casings to form
logs of predetermined diameter such that, after cooking, slices of
the logs cut perpendicular to the center axis of the logs are of
the desired diameter for the final fully cooked product.
[0042] After the encased logs are formed, they are loaded into a
first freezer 140, to be fully frozen. This is done to accommodate
later slicing since the raw meat logs cannot easily be sliced even
when chilled to be somewhat firm, such as raw cased sausages bought
at a grocery store. The large logs may take up to 48 hours to
freeze fully to be sliced properly.
[0043] After being frozen in the first freezer 140, the logs are
stripped of the casings by a stripper 145. Stripper 145 may be a
combination of a casing cutter that cuts the casing along a length
of the log, and a worker that manually strips the casing from the
log. This manual stripping process is slow and tedious. The
stripped logs are then manually placed in a slicer 150.
[0044] Slicer 150 is able to slice the frozen logs using a band saw
blade or a solid metal blade. Since the logs are frozen, the slices
generally retain their shape while being sliced. This would not be
the case if the logs were not frozen prior to slicing. There will
be some significant loss of meat during the slicing process, about
3-6%.
[0045] The sliced frozen meat patties are then transferred to an
oven 155 where they are fully cooked to a temperature of above
165.degree. F. The fully cooked patties are then transferred to a
second freezer 160 to be frozen a second time. The frozen patties
are then bulk packed.
[0046] The total length of time to complete the processing of the
fully cooked meat product using the system 100, from grinding the
fat trimmings and trimmings 105 to packaging the frozen patties
with the packager 165, can take multiple days. Additionally, such a
process is labor-intensive, particularly if casings are stripped
manually and stripped logs are manually placed in slicer 150.
[0047] FIG. 2 is a block diagram of a system 200 for producing a
precooked meat patty product in accordance with some embodiments of
the present disclosure. The meat patty may correspond to any kind
of meat, e.g., chicken, beef, turkey, pork, or any combination
thereof. Fat trimmings and lean trimmings 205 are ground in a first
grinder 210, combined with other ingredients 220 in a blender
and/or mixer 215, and heated in a heater 225 (e.g., to a
temperature greater than 32.degree. F., in some cases to a
temperature between 35-110.degree. F., and in some cases to a
temperature simulating a pre-rigor state, such as 90.degree. F.).
The temperature to which the meat is heated may depend on the type
of meat. In some examples, for chicken, beef, turkey, and/or
combinations thereof, the meat is heated at heater and/or heat
exchanger 225 to between 30-50.degree. F. In other examples, for
pork, beef, turkey, and/or combinations thereof, the meat is heated
at heater and/or heat exchanger 225 to between 40-75.degree. F. In
yet other examples, the meat includes pork and is heated at heater
and/or heat exchanger 225 to between 76-110.degree. F. Optionally,
the meat is then finely ground in a second grinder 230. Instead of
using a log former/encaser 135, first freezer 140, casing stripper
145, and slicer 150, patties are formed at patty former 235 and
precooked at precooker 240. Various example implementations of
patty formation and precooking are described below.
[0048] Patty former 235 fills patty molds with finely-ground meat
from the second grinder 230 without the need for forming encased
logs of meat product, freezing the logs, and then slicing the
frozen encased meat logs. Because the meat is heated at heater
and/or heat exchanger 225, e.g., to a temperature above 32.degree.
F., this technique for forming patties is referred to as a warm
formation process. In other embodiments, heating is not performed
prior to patty formation (e.g., the heater and/or heat exchanger
225 is eliminated), and such a process is referred to as a cold
formation process.
[0049] By replacing the log forming/encasing, freezing, stripping,
and slicing steps of the prior process 100, the total time for
forming and cooking the meat patties may be reduced from two days
to about two hours or less, resulting in cost savings and increased
yield.
[0050] After the heated finely-ground meat has been directed into
the patty molds by the patty formers 235, precooker 240 sears at
least one side, and in some implementations both sides, of the
formed patties such that they are able to be removed from the patty
molds and remain intact during the entire precooking process.
Without such searing, the formed patties may have a consistency
that is similar to oatmeal which would complicate subsequent
processing, e.g., because the formed patties may have a tendency to
break apart when removed from patty molds. Precooking the formed
patties causes the patties to have a skin including denatured
proteins. The skin is formed on at least an area on the outside of
the precooked patties. At least a portion of the meat product
beneath the skin is at approximately the temperature to which the
patties were heated by heater and/or heat exchanger 225 (or at
approximately the temperature of the output of the second grinder
230 for the cold formation process).
[0051] In one embodiment, precooker 240 comprises at least one
infrared oven. Other examples of heating techniques that may be
used at precooker 240 include inductive heating, steam conduction
heating, electric conduction heating, thermal oil conduction
heating, application of a hot water shower, hot water spray,
application of another hot liquid that sets the surface protein on
contact, and combinations thereof. In an embodiment, precooker 240
may produce a heat on the order of about 550.degree. F. to about
600.degree. F., depending on the size of the patties. At such high
temperatures, the precooking/searing may take about 30 to 60
seconds to precook the patties. The time duration for precooking
may be a function of the species of the meat, the thickness of the
patty, the temperature of the precooking/searing, and/or the
precooking/searing method employed. With sufficient heat applied to
the surface of the meat, the protein will typically denature in
seconds, forming a skin of denatured protein at the surface Details
of examples of precooker 240 are described below.
[0052] After precooking/searing the patties such that the patties
remain intact when released from the patty form molds, the patties
are fully cooked in an oven 245. Oven 245 may be an impingement
oven or other type of oven, heat application device, a water bath,
or oil bath (fry), for example. Oven 245 cooks the patties to a
high temperature (e.g., 150-180.degree. F., and in some cases any
temperature over 165.degree. F.) such that the meat patties have
been fully cooked and are appropriate for human consumption. Thus,
in some examples, the temperature of the portion of the meat
product below the skin is raised from between 32-110.degree. F. to
between 150-180.degree. F. Because the patties were not frozen
prior to being cooked in precooker 240 and oven 245, the total
cooking process time is reduced compared to prior system 100.
[0053] The fully-cooked patties are transferred from oven 245 to a
freezer 250 to be frozen. When the patties have been frozen, they
are bulk packed or packed for shipment at packager 255.
[0054] FIGS. 3 and 4 are side and top views, respectively, of an
example patty forming and precooking system 300 that may be used as
the patty former 235 and precooker 240 in system 200 (FIG. 2). In
FIG. 3, the process flows from right to left. Upstream of the patty
formers 305 (to the right of patty formers 305 in the side view of
FIG. 3) are the heater and/or heat exchanger 225 (e.g., a scrape
surface heat exchanger for the warm formation process), and the
second grinder 230 (e.g., an inline grinder) that forms the final
grind as described above with reference to FIG. 2.
[0055] At the far right side of the patty forming and precooking
system 300 are two patty formers 305 that receive heated (e.g., at
pre-rigor temperature) meat, for the warm formation process, from
the second grinder 230 (not shown in FIGS. 3 and 4). A pan conveyor
310 moves a plurality of form pans under the patty formers 305. The
patty formers 305, details of which are described below, fill patty
form molds in the form pans with the heated ground meat. The pan
conveyor 310 conveys the filled form pans under a first infrared
oven 320-1. The first infrared oven 320-1 includes a plurality of
infrared burners 315 that are located above the pan conveyor 310.
The infrared burners 315 or pan conveyors 310 are capable of being
moved vertically in order to achieve the desired temperature and
intensity during precooking of the patties in the form pans.
[0056] As the form pans are conveyed by pan conveyor 310 through
the first infrared oven 320-1, infrared burners 315 precook/sear
the meat patties in the patty form molds from the top. Sufficient
heat is applied to patties to sear the surface, and during this
process product fat melts, which assists with patty release.
Additional heat sources might be required on the bottom of the pan
in the case of some products to release patties. An induction coil
may be used as such an additional heat source, with other examples
being a gas flame, thermal coil, or steam coil.
[0057] In some embodiments, when the form pans reach the far left
side of the pan conveyor 310, the form pans are rotated around the
left side of the pan conveyor 310, causing the partially precooked
patties to fall from the form pans of the pan conveyor 310 onto a
patty conveyor 350 such that the bottom of the patties in the form
pans are flipped up to be conveyed by the patty conveyor 350
through a second infrared oven 320-2 and a third infrared oven
320-3. FIG. 10 is a top view that shows how form pans 312 of pan
conveyor 310 move (from right to left in FIG. 10). Referring back
to FIGS. 3 and 4, infrared burners 315 in the second and third
infrared ovens 320-2 and 320-3 then precook/sear the second side of
the meat patties from above. The infrared heat provides a
relatively uniform brownness and retains the shape of the meat. The
use of the first infrared oven 320-1 to cook/sear a first side
along with the second and third infrared ovens 320-2 and 320-3 to
cook/sear the second side provides even browning on both sides of
the patties. This infrared heating process assists with patty
release and also establishes the shape of the patty. Temperature of
the patties exiting the infrared section may be in the range of
100.degree. F.-160.degree. F.
[0058] Thus, in some embodiments, precooker 240 (FIG. 2) includes a
first conveyor (pan conveyor 310), heating element for heating a
first side of each patty, a flipper (e.g., the curved end portion
of pan conveyor 310), a second conveyor (patty conveyor 350), and a
heating element for heating the second side of each patty. By
precooking/searing the first side of the patty, a skin including
denatured protein is formed on at least a portion of that first
side. Then, by precooking/searing the second side of the patty, a
skin including denatured protein is formed on at least a portion of
that second side. The depth of the skin formed on the first side
may be the same as or different than the depth of the skin formed
on the second side. The skin formed on each side makes the patty
less likely to break apart during subsequent processing or when
grasped.
[0059] In some embodiments, infrared ovens 320 have multiple
exhaust fans 325 that are used to control the temperature of the
infrared ovens 320. After the meat patties are conveyed through the
second and third infrared ovens 320-2 and 320-3, they are
transferred to another oven (not shown in FIGS. 3 and 4) for final
cooking, e.g., oven 245 described above in reference to FIG. 2.
[0060] Pan conveyor 310 and patty conveyor 350, as shown in FIG. 4,
may be mounted on rotating rails 360 such that the conveyors 310
and 350 may be moved away from the infrared ovens 320 to allow
servicing of the infrared ovens 320 and/or cleaning of pan conveyor
310 and patty conveyor 350.
[0061] Referring to FIG. 5, a side view of pan conveyor 310 shows
rollers 365 that assist in the moving of pan conveyor 310 and all
related equipment along rotating rails 360. Rotating rails 360 can
rotate from a position perpendicular to the conveyors to positions
parallel to the conveyors such that workers do not trip over
rotating rails 360.
[0062] FIG. 5 shows an enlarged view of a patty flipping portion
370 where pan conveyor 310 rotates around such that the form pans
turn vertical (see far left end of pan conveyor 310 in FIG. 10) and
then further rotate under pan conveyor 310, causing the patties to
flip out of the patty molds of the form pan and onto patty conveyor
350. The relative height between pan conveyor 310 and patty
conveyor 350 is controlled to ensure that the patties are rotated
during flipping in such a way that all or substantially all of the
patties land with the top side (i.e., the side that was facing
upwards while on pan conveyor 310) on patty conveyor 350 and with
the side that was touching the form pans (i.e., the side that was
facing downwards while on pan conveyor 310) facing upwards when on
patty conveyor 350.
[0063] FIGS. 6 and 7 show more detailed side and top views,
respectively, of patty formers 305 coupled to pan conveyor 310 of
FIGS. 3-5. Patty formers 305 include two pan filler hoppers 605
that are attached to a frame portion of the pan conveyer 310 above
individual form pans 312 (see FIG. 7). In the example of FIG. 7,
each form pan 312, in this example, defines twelve individual patty
molds 314 that the pan filler hoppers 605 fill with the heated
ground meat (for the warm formation process) when individual form
pans 312 pass under the pan filler hoppers 605. In an embodiment,
form pans 312 may have a pitch of about 3 inches. Each form pan 312
may be mounted on a set of chains. In one example, the chains may
be K1 chains, where K1 refers to the type of attachment holding the
form pans 312 to the chain.
[0064] The patty molds 314 in the form pans 312 are shown in FIG. 7
as being round, but they may be oval or any other desired shape.
Oval patty molds, for example, may have a long axis parallel to the
direction of movement of pan conveyor 310. It has been found that
fibers of the ground meat may be aligned by the patty former 605
and the flow block 680 and the fibers shrink more along the aligned
direction. Therefore, oval patty molds may result in a more
circular final product, which may be desirable. The same principle
of controlling the final shape based on expected fiber shrinkage
may also apply to rectangular patty molds, in the event that a
square product is desired.
[0065] A pan conveyor drive motor 685 is coupled to pan conveyor
310 to drive the individual form pans 312 with the pan conveyor 310
through the first infrared oven 320-1. A pair of traction roller
motors 690 cause the traction rollers 675 of respective pan filler
hoppers 605 to rotate inwardly and urge the heated ground meat
through respective flow blocks 680, at low pressure, to fill the
patty molds 314 of the form pans 312. In other words, the finely
ground heated meat mixture is funneled into patty molds 314 of
patty form pans 312 using patty formers 305, including traction
rollers 675, flow blocks 680 and traction roller motors 690. In an
embodiment, the combination of the height of the meat in the pan
filler hoppers 605 and the traction rollers 675 develops a pressure
of about 3-4 feet of water head which equates to about 1.5 to 2 psi
or so, depending on the size of the pan filler hopper 605 and the
traction rollers 675. The low pressure provides a loose texture to
the patties, which is desirable when pushing the ground meat into
the patty molds 314.
[0066] It has been found that because of the slipperiness of the
heated ground meat, smooth traction rollers 675 may not provide
enough pressure to adequately force the ground meat through the
flow block 680. The addition of grooves to the traction rollers 675
forces the heated ground meat into the narrow pathway of the flow
block 680 more effectively. The grooves are generally parallel to
the spin axis of the traction rollers 675 and may be, in an
embodiment, about 1/8 of an inch wide and deep. The narrowest
constriction in flow block 680, described below, may be about the
same size as the gap between traction rollers 675.
[0067] FIGS. 8A-8D are a set of illustrations of side (FIG. 8A),
bottom (FIG. 8B), isometric (FIG. 8C) and cross section cut (FIG.
8D) views of flow block 680 that may be used to funnel the heated
ground meat product (for the warm formation process) into patty
molds 314 of the patty form pans 312 with patty formers 305 of
FIGS. 3-7. As seen in FIGS. 8B-8D, funnel area 805 is formed in the
flow block 680 passing from a top portion of the flow block to a
bottom portion of the flow block 680.
[0068] As seen in FIG. 8D, funnel area 805 initially constricts to
a narrow choke area in the flow block and then expands to lower the
pressure of the meat while the meat is forced into the patty molds
314 of the form pans 312 in a manner similar to a
converging-diverging nozzle.
[0069] A handle 810 (seen in FIGS. 8A-8C) provides an operator with
a convenient means for pushing flow blocks 680 into a bottom
portion of pan filler hoppers 605. A faceplate 815 provides a seal
against form pans 312 such that the ground meat stays within funnel
area 805 while being urged into the patty molds 314. A
spring-loaded scraper 820 (seen in FIG. 8D) with a concave profile
is located downstream of traction rollers 675 and downstream of
funnel 805. Scraper 820 presses firmly against a top surface (e.g.,
aluminum or other metal) of the form pans 312 to scrape away most
of the heated ground meat product above patty molds 314 such that
the patties have a flat upper surface. Specifically, as form pans
312 move under the flow block 680, a rear angle edge of a chamfer
defined in funnel area 805 presses the ground meat into patty molds
314 (along with the pressure of pan filler hopper 605 and traction
rollers 675), and scraper 820 scrapes the top of form pans 312,
leaving the tops of form pans 312 clean and the patties flat.
[0070] Flow block 680 may be made of a plastic such as UHMW.
However, it has been found that the intense heat of the infrared
ovens 320 may heat form pans 312 to a point where an all-UHMW flow
block may warp. If a surface of flow block 680 that touches form
pans 312 includes a Teflon layer backed by an aluminum plate, which
are then attached to a top layer of UHMW, flow block 680 is more
resistant to warping. By making the top portion of flow block 680
out of UHMW plastic, flow block 680 and the bottom of pan filler
hopper 605 may be sealed.
[0071] Spring loaded scraper 820 may be a Teflon bar that sits in a
groove defined in the Teflon base layer of flow block 680. The
Teflon bar may have a set of aligning springs above it (not shown)
pushing spring loaded scraper 820 against form pans 312.
[0072] FIG. 9 shows a more detailed side view of the first infrared
oven 320-1 and a left portion of the pan conveyor 310 including the
patty flipping portion 370 that flips the meat patties, after the
top surfaces are precooked/seared by the first infrared oven 320-1,
onto the patty conveyor 350. As shown in FIG. 9, a pan preheater
905 (e.g., a radiant heating system, or possibly a conduction
system) under form pans 312 on pan conveyor 310, is configured to
preheat form pans 312 after being filled with the heated ground
meat. The preheating helps to ensure partial melting of the fat
trimmings in patty molds 314 to help to flip the meat patties out
of patty molds 314 at patty flipping portion 370.
[0073] A control panel 915 is used to set temperatures of the
first, second and third infrared ovens 320-1, 320-2 and 320-3, and
conveyance speed parameters of pan conveyor 310 and patty conveyor
350. In an embodiment, a first infrared oven compartment 920-1 is
cantilevered over pan conveyor 310 and houses infrared burners 315,
which can be moved up and down relative to pan conveyor 310 using
the control panel 915.
[0074] FIG. 10 is a top view of the patty flipping portion 370
between pan conveyor 310 and patty conveyor 350 of the system of
FIGS. 3 and 4. As shown in FIG. 10, when pan conveyor 310 exits the
first infrared oven 320-1, pan conveyor 310 reaches a reversal
point at patty flipping portion 370. When pan conveyor 310 revolves
around the reversal point at patty flipping portion 370, the
patties are caused to fall out of patty molds 314 in the form pans
312 and caused to flip over onto patty conveyor 350. After flipping
onto pan conveyor 350, the patties are conveyed on patty conveyor
350 into oven compartment 920-2 of the second infrared oven 320-2.
The relative height between the pan conveyor 310 and the patty
conveyor 350 is sized to ensure that the patties are rotated during
flipping in such a way that all the patties, or substantially all
the patties, land with the top side on patty conveyor 350 and with
the side that was touching form pans 312 facing upwards.
[0075] FIGS. 11 and 12 show a side view and a top view,
respectively, of the third infrared oven 320-3 shown in FIGS. 3 and
4. The third infrared oven 320-3 and the second infrared oven 320-2
are similar, in this example. The side view in FIG. 11 shows
infrared burners 315 in oven compartment 920-3, where infrared
burners 315 are also movable in a vertical direction to be a
selected distance from the patties being conveyed below on patty
conveyor 350. As also illustrated in FIG. 11, the third infrared
oven 320-3 (and the second infrared oven 320-2) is equipped with a
grease drain 1110 where grease that is expelled from the patties
and drips through grates of patty conveyor 350 drains into a
collection area to be disposed of. As described above, when the
patties reach the end of patty conveyor 350, they are conveyed
(e.g., via another conveyor or other conveyance means not shown in
FIGS. 11 and 12) to an impingement oven (not shown) for final
cooking.
[0076] FIG. 13 is a block diagram for a system in accordance with
another embodiment involving in-bag cooking of meat. A packager
1342 packages or bags each meat patty after it has been precooked
by precooker 1340. For example, the meat patties may be
individually wrapped in plastic bags. Then, the meat patties are
cooked while inside bags at oven 1345. In-bag cooking of meat
reduces the likelihood of certain types of meat contamination,
e.g., because bacteria such as listeria can be killed by heat in
oven 1345 and no bacteria or other undesirable organisms can enter
the bags surrounding the patties. Other aspects of FIG. 13 are
similar to aspects of FIG. 2 and do not require further
explanation.
[0077] FIGS. 14A-14C are illustrations of another technique for
forming and precooking meat patties. Referring to the top
perspective view of FIG. 14A, an apparatus 1400a includes a
conveyor 1402 that moves in the direction indicated by arrows 1410.
Conveyor 1402 includes multiple form pans 1403, with each form pan
defining one or more (in this example, three) individual patty
molds 1404. Form pans 1403 may be implemented in a manner similar
to form pans 312 shown in FIG. 7. Meat product (e.g., heated finely
ground meat from second grinder 230 for the warm formation process)
is fed into apparatus 1400a at inlet 1406, which directs the meat
into respective form patty molds 1404. As seen in the bottom view
of FIG. 14B, there is a bottom 1405 underlying patty molds 1404
along at least a portion of the length of the top portion of
conveyor 1402, but the patty molds in this embodiment do not have a
bottom at other locations along the conveyor, as evidenced by the
ability to see through the patty molds at certain places in FIGS.
14A-14B. As each patty 1408 proceeds along conveyor 1402, it is
heated by a heating plate 1420 and heating coil 1421, which may be
an inductive heating coil.
[0078] Although heating plate 1420 and heating coil 1421 are shown
in FIGS. 14A-14B in a configuration below the patties proceeding
along the top part of conveyor 1402, in some embodiments the
heating plate and heating coil may be positioned above the patties
proceeding along the top part of conveyor 1402, below the patties
proceeding along the bottom part of conveyor 1402, or above the
patties proceeding along the bottom part of conveyor 1402. In other
words, heating may be performed on either side of either of the
linear segments of conveyor 1402.
[0079] Another conveyor 1422, oriented, in the embodiment shown,
substantially perpendicular to conveyor 1402 and with molds
arranged and dimensioned to match patty molds 1404, moves in the
direction indicated by arrow 1430 and transports the patties
(heated by heating plate 1420 and heating coil 1421) for further
processing. In some embodiments, a mechanical knockout unit (not
shown) punches the patties out of molds 1404 to ensure that they
are released at the correct time, e.g., in order to fall into molds
of conveyor 1422.
[0080] FIG. 14C is a perspective view of another apparatus 1400b
that is similar to apparatus 1400b but includes a first heating
plate 1420a and first heating coil 1421a above form pans 1403, and
a second heating plate 1420b and second heating coil (not shown in
this view) below form pans 1403. By including two heating elements
on either side of the patties moving along conveyor 1402 (a
configuration referred to as top and bottom heat jackets or dual
heat jackets), the patties are quickly and efficiently heated in a
uniform manner. Although the dual heat jackets are shown in FIG.
14C as sandwiching the top linear segment of conveyor 1402, in some
embodiments they may sandwich the bottom linear segment of conveyor
1402.
[0081] FIG. 15A is an elevation view of a system 1500 in accordance
with some embodiments of the present disclosure. FIG. 15B is a top
view of system 1500. System 1500 includes a rotary forming
apparatus 1505 for forming meat patties. Rotary forming apparatus
1505 includes a drum 1510 that rotates in direction 1501 (shown as
a counterclockwise direction in the example view of FIG. 15A, but a
configuration having a clockwise rotation is also contemplated). A
plurality of patty form molds 1515, each of which may be round,
oval, or having any other desired shape, are positioned to receive
meat product that may be provided to rotary forming apparatus 1505
from a hopper via an inlet (not shown). In an embodiment, patty
form molds 1515 comprise sides with a bottom, where the top is
open. In another embodiment, patty form molds 1515 comprise sides
where both the top and bottom are open.
[0082] In an embodiment, patty form molds 1515 are filled with meat
product from the hopper when the patty form molds are at position A
as shown in FIG. 15A. Other positions for filling the patty form
molds with meat product are contemplated herein taking into account
the criteria that the meat product has a sufficient amount of time
to form a skin, as discussed below, in less than one full rotation
of the patty form molds around drum 1510. The meat product may
correspond to any meat species and may comprise, e.g., chicken,
beef, turkey, pork, and combinations thereof.
[0083] The meat product that fills patty form molds 1515 is
initially of a consistency that does not hold together sufficiently
well for handling and/or process purposes. As patty form molds 1515
are transported along a circular path by rotation of drum 1510, the
meat product within patty form molds 1515 is heated by one or more
induction coils 1520 embedded on the inside of drum 1510. In other
embodiments, induction coils 1520 may be disposed on the outside of
drum 1510 and/or on both the inside and outside of drum 1510.
Rotary forming apparatus 1505 may also include one or more
insulator plates 1530 for providing insulation, as well as one or
more cooling coils 1540 for providing cooling capability, e.g., to
control the temperature and thus the heating of the meat product in
patty form molds 1515. The placement of the induction coils 1520
and the cooling coils 1540 in FIG. 15A is exemplary only. Other
arrangements of the induction coils 1520 and the cooling coils 1540
are contemplated herein. Because drum 1510 becomes hot, it is
desirable to prevent excessive heat conduction to the working
mechanism of rotary forming apparatus 1505, because the thermal
expansion could cause excessive stress and wear. Cooling coils 1540
and insulator plate(s) 1530 are designed to keep the temperatures
of the working mechanism within their normal operational
limits.
[0084] Thus, the meat product is heated as drum 1510 rotates, and a
skin is set on the outside surface of each meat patty. The skin may
comprise denatured proteins from the meat product and the skin on
the meat patty may have a depth D. In some embodiments, the depth D
is a small fraction of the thickness H of the meat patty. In
certain embodiments 0.ltoreq.D.ltoreq.0.1H. In other embodiments,
0.01H.ltoreq.D.ltoreq.0.05H. In still other embodiments,
0.1H.ltoreq.D.ltoreq.0.25H. In further embodiments,
0.01H.ltoreq.D.ltoreq.0.33H. In still further embodiments,
0.ltoreq.D.ltoreq.0.49H. In all embodiments, portions of the meat
product in the meat patty that is located under the skin is not
fully cooked by the heating of the meat product to form the
skin.
[0085] The configuration of rotary forming apparatus 1505 makes
efficient use of available space and provides heating via induction
coil(s) 1520 that forms the skin completely around the meat patty.
The resulting skin makes patty 1580 hold together sufficiently well
for further handling and/or process purposes. A knockout unit 1550,
visible as a rectangular device in the side view of FIG. 15A, moves
in and out with respect to the central portion of the rotary
forming apparatus 1505, e.g., in the manner of a piston, and knocks
meat patties in patty form molds 1515 onto conveyor belt 1560 in
direction 1502. For embodiments where patty form molds 1515
comprise sides with a bottom, knockout unit 1550 strikes the bottom
of patty form molds 1515 with sufficient force to dislodge the meat
patty from the patty form molds onto conveyor belt 1560. For
embodiments where patty form molds 1515 comprise sides where both
the top and bottom are open, knockout unit 1550 directly contacts
the meat patty, thereby impelling the meat patty out of patty form
mold 1515 onto conveyor belt 1560.
[0086] Conveyor belt 1560 may be a solid stainless steel belt in
some embodiments. A meat patty 1580 that has landed on conveyor
belt 1560 is transported in direction 1503. An induction coil 1570
positioned under belt 1560 provides additional heating in some
embodiments. Additional processing may be performed, e.g., by
moving patty 1580 onto another conveyor belt or to another
apparatus in the meat processing system.
[0087] FIG. 15B is a top view of system 1500. In this example,
patty molds 1515 are arranged in groups of five on drum 1510, but
the patty molds may be arranged in other configurations.
[0088] FIG. 16 is an illustration of patty form disk 1610 in
accordance with some embodiments. Patty form disk 1610 defines
multiple patty form molds 1620 arranged in a starburst pattern,
emanating radially outward from a central region of patty form disk
1610.
[0089] FIG. 17A is an illustration of a patty forming apparatus
1700a in accordance with some embodiments. Patty forming apparatus
1700a includes patty form disk 1610 which defines patty form molds
1620. Meat product (e.g., heated ground meat, for the warm
formation process) inserted at inlet 1740 is funneled into patty
form molds 1620. Patty form disk 1610 rotates in rotational
direction 1730, and for a portion of the rotation heating is
provided via induction heater 1750. In this example, induction
heater 1750 covers approximately three-fourths of the angular
extent of patty form disk 1610, and that angular extent defines an
induction cooking zone. In other examples, induction heater 1750
may cover a different proportion of patty form disk 1610. In some
embodiments, a bottom is provided underneath form molds 1620 at the
region corresponding to induction heater 1750. When patties
proceeding along the rotational motion of patty form disk 1610 exit
the induction cooking zone, they may be released from patty form
disk 1610, e.g., if there is no bottom underlying the patties
there.
[0090] Although heater 1750 is shown positioned above patty form
disk 1610 in FIG. 17A, in various embodiments the heater may be
below the patty form disk, or two heaters may be provided above and
below the patty form disk, respectively. Although patty form disk
1610 rotates and heater 1750 remains fixed in the above example, in
other examples the patty form disk remains fixed and the heater
rotates, or both the patty form disk and the heater are rotatable.
By controlling the duration of exposure of patties in form molds
1620 to heating, the temperature of the patties and the degree of
cooking can be controlled.
[0091] FIG. 17B is a top view of a patty forming apparatus 1700b in
accordance with some embodiments. Patty forming apparatus 1700b is
similar in several respects to forming apparatus 1700a but varies
in some of the geometrical details regarding patty form molds 1620
and induction heater 1750. Patty form molds 1620 are filled with
meat product via nozzle 1706, which may be positioned at a given
angular position relative to heater 1750. Induction plate insert
1704 may be formed of a highly inductive material, and other
portions of patty form disk 1610 (e.g., at location 1712) may be
formed of a non-inductive material. Patty form disk 1610 rotates in
rotational direction 1702, causing meat patties to be
precooked/seared by heater 1750. When patties proceeding along the
rotational motion of patty form disk 1610 exit the induction
cooking zone corresponding to heater 1750, they may be released
from patty form disk 1610, e.g., if there is no bottom underlying
the patties there.
[0092] FIG. 18A is a top view of an apparatus 1800 that provides
uniform flatness to formed meat patties in accordance with some
embodiments. Apparatus 1800 is better understood with reference to
the partial sectional view (FIG. 18B) taken at the orientation
indicated by 1810. Referring to the partial sectional view of FIG.
18B, meat product (e.g., heated finely ground meat, for the warm
formation process) may be mixed with various ingredients and
dispensed from nozzle 1830 into patty form molds 1805 defined by
mold plates 1870 (e.g., made of stainless steel or other metal)
which moves as indicated by arrow 1802 in this example. Some of the
meat product may mound above the form mold 1805 as shown by 1804.
Plate 1860 (e.g., a high temperature resistant teflon plate) is
stationary. As the mold plates 1870 move, an air bladder 1840
inflates, causing a scraper 1850 to push downward (indicated by
arrow 1803) on the top surface of the meat patty thereby removing
the mound 1804 and flattening the top surface of the meat patty.
Then air bladder 1840 deflates (indicated by arrow 1803) causing
scraper 1850 to retract (e.g., by a spring (not shown)), and the
process continues for successive passing patties. The shape of the
scraper 1850 may be of any useful shape to perform the necessary
scraping action.
[0093] In some embodiments, a meat product is processed with a hot
water bath to improve the consistency of the meat product and
facilitate handling of the meat product by creating a skin of
denatured protein as discussed above. In some embodiments, the meat
product is in the form of a nugget which may comprise chicken. In
other embodiments, the meat product is a patty, as described above.
FIG. 19 is a side view of a system 1900 for precooking/searing meat
products using such a hot water bath. Referring to FIG. 19, a meat
product block (e.g., a nugget or patty) 1910, which may be a 1/4''
ground patty, is warm formed in the range of about 45-50.degree. F.
In some embodiments, meat block 1910 comprises finely ground
chicken, which is among the most difficult meat products to handle,
as it tends to come apart when one tries to hold or manipulate it.
The interior of meat block 1910 may have an interior that is raw
and at a temperature of about 40.degree. F. Meat block 1910 is
transported along conveyor belt 1920 in a direction corresponding
to arrow 1901 (left to right in the side view of FIG. 19) and is
processed by hot water bath 1930 in some embodiments. For example,
a pipe or faucet 1940 connected to a hot water source may supply
hot water to the hot water bath.
[0094] The hot water bath may include water at a temperature
between 140-212.degree. F., e.g., about 190.degree. F. Meat block
1910 may be treated with (e.g., immersed in) hot water bath 1930
for a few seconds. The duration of exposure to hot water bath 1930
may be dependent on the temperature of the water, e.g., with a
longer exposure as the temperature approaches 140.degree. F. and a
shorter exposure as the temperature approaches 212.degree. F.
[0095] In some embodiments, a sprayer or mister is used to apply
water (or other liquid, such as an edible oil), e.g., in liquid or
mist form 1960 (with or without bath 1930), to meat block 1910,
e.g., from above as meat block 1910 proceeds along conveyor 1920
belt in direction 1901. A sprayer or mister may also be positioned
below meat block 1910 (not shown) to apply an upward jet or mist to
the bottom of meat block 1910. In some embodiments using a hot
water bath 1930, meat block 1910 is immersed in the hot water bath
such that all portions of the meat block 1910 are exposed to the
hot water.
[0096] As a result of the hot water treatment, a skin is set on the
outside surface of meat block 1910 such that meat block 1910 does
not come apart when grasped or handled. The skin may be uniformly
present at the surface of meat block 1910. The skin may comprise
denatured proteins from the meat product and the skin on the meat
block may have a depth D. In some embodiments, the depth D is a
small fraction of the thickness H of the meat block. In certain
embodiments 0.ltoreq.D.ltoreq.0.1H. In other embodiments,
0.01H.ltoreq.D.ltoreq.0.05H. In still other embodiments,
0.1H.ltoreq.D.ltoreq.0.25H. In further embodiments,
0.01H.ltoreq.D.ltoreq.0.33H. In still further embodiments,
0.ltoreq.D.ltoreq.0.49H. In all embodiments, portions of the meat
product in the meat block 1910 that is located under the skin is
not fully cooked by the heating of the meat product to form the
skin.
[0097] In certain embodiments, meat block 1910 may then be
processed at breading/battering station 1950, where bread particles
or batter is applied to the meat block, e.g., with a dispenser that
is timed to apply (e.g., blow) bread or batter as meat block 1910
passes through, under, or near breading/battering station 1950.
[0098] Meat block 1910 may be subjected to additional processing,
e.g., cooking, freezing, and packaging. The task of moving meat
block 1910 onto another conveyor belt for additional processing is
greatly simplified because of the skin that holds meat block 1910
together in accordance with various embodiments.
[0099] FIG. 20 is a flow diagram of a process 2000 in accordance
with some embodiments. A patty (e.g., meat block 1910 shown in FIG.
19) is warm formed at block 2010. The patty is subjected to a hot
water treatment at block 2020. The patty is breaded and/or battered
at block 2030. Additional processing may be performed as well.
[0100] FIGS. 21-22 are a flow diagram for process 2100 and a block
diagram for system 2200 in accordance with some embodiments. Ground
meat product, which may include chicken, beef, turkey, pork, or
combinations thereof, is heated (block 2105) at heater 2205, e.g.,
to a temperature greater than 32.degree. F., in some cases between
35-90.degree. F., and in some cases approximately 90.degree. F. In
some examples, for meat including chicken, beef, turkey, or
combinations thereof, the meat is heated to a temperature between
30-50.degree. F. In other examples, for meat including pork, beef,
turkey, or combinations thereof, the meat may be heated to a
temperature between 40-75.degree. F. In yet another example, the
meat includes pork and is heated to a temperature between
76-110.degree. F.
[0101] The meat is optionally subjected to additional grinding
(block 2107) at grinder 2207, and used for forming patties (block
2110) at patty former 2210. In an embodiment, patty former 2210 may
include nozzle 1830, mold 1870, scraper 1850, and air bladder 1840
as shown in FIGS. 18A-18B. A mold preheater 2211 may also be used
to preheat the patty molds. In some embodiments, mold preheater
2211 includes an induction coil located beneath the mold plate. By
delivering controlled power to the induction coil, heat is
generated in the mold plate that enables the denatured protein skin
to form in the patty.
[0102] Patty formation may include disposing meat product into one
or more patty molds (block 2112) using nozzle 1830, and scraping an
excess portion of ground meat off the molds using scraper 1850
(block 2114). The uncooked patties produced by patty former 2210
are precooked (block 2115) at precooker 2215, thereby forming
precooked patties having a skin comprising denatured protein. The
skin is formed on at least a portion of the outside of the
precooked patties, and at least a portion of the meat product
beneath the skin is at the approximately the temperature to which
the meat was heated (block 2105) at heater 2205. Precooking 2115
(at precooker 2215) may include applying infrared or inductive
heating. The time duration for precooking 2115/2215 may be a
function of the species of the meat, the thickness of the patty,
the temperature of the precooking and/or the precooking method
employed.
[0103] The precooked patties are optionally packaged (block 2120)
at packager 2220 before being fully cooked (block 2125) at cooker
2225 such that they are suitable for human consumption. The
temperature of the meat due to cooking 2125 may be between
150-180.degree. F.
[0104] FIGS. 23-24 are a flow diagram for process 2300 and a block
diagram for system 2400 in accordance with some embodiments. Meat
(e.g., poultry meat product) is mixed (block 2305) at mixer 2405,
which may involve chilling with a coolant such as gaseous CO.sub.2,
and then ground coarsely (block 2310) at coarse grinder 2410. The
coarsely ground meat is heated (block 2315) at heater 2415 and then
ground finely (block 2420) at fine grinder 2420. The finely ground
meat is provided to patty former 2425, which forms patties (block
2325) that are precooked (block 2330) at precooker 2430. In an
embodiment, precooking 2330 may include precooking a first side of
each patty (block 2331) using a heating element 2431, flipping the
patties over (block 2332) using flipper 2432, and precooking a
second side of each patty (block 2333) using a heating element
2433. The precooked patties are processed by battering and breading
(block 2335) at batterer/breader 2435, par fried (block 2340) at
par fryer 2440, and fully cooked (block 2345) at a higher
temperature than precooking 2330 at oven 2445. The fully cooked
patties are frozen (block 2350) at freezer 2450 and packaged (block
2355) at packager 2455.
[0105] FIGS. 25-26 are a flow diagram for process 2500 and a block
diagram for system 2600 in accordance with some embodiments. Unlike
other examples involving warm forming disclosed herein, FIGS. 25-26
involve cold forming of meat patties, e.g., forming patties without
a prior heating stage. Trim meat (e.g., including chicken, beef,
turkey, pork, or combinations thereof) is reduced in size (block
2505) at a first size reducer 2605 and then blended (block 2510)
with other ingredient(s) at blender 2610. The blending may control
the fat percentage and may involve chilling to a target
temperature, which may be less than 40.degree. F., e.g., between
22-40.degree. F. A further size reduction (block 2515) is performed
at a second size reducer 2615, the output of which is passed to
patty former 2620 to form patties (block 2520) at the target
temperature resulting from the chilling.
[0106] In an embodiment, patty former 2620 includes a nozzle 1830,
mold 1870, scraper 1850, and air bladder 1840. In some embodiments,
mold 1870 includes a bottom and a side, and in other embodiments
mold 1870 does not include a bottom. Patty formation includes
disposing meat product into mold 1870 using nozzle 1830 (block
2521), and scraping an excess portion of ground meat off mold 1870
using scraper 1850 and air bladder 1840 (block 2522). Scraper 1850
may be engaged by inflating air bladder 1840. In some embodiments,
mold 1870 is heated (e.g., using an induction coil) prior to
disposing the ground meat product into the mold. In some
embodiments, mold 1870 is heated using a first induction coil above
the mold and a second induction coil below the mold.
[0107] The formed patties are cooked (block 2525) at cooker 2625,
which may be an oven. In some embodiments, cooking the uncooked
patties includes applying infrared or inductive heating to the
uncooked patties. Cooking the patties forms a precooked patty
having a skin of denatured protein. The skin is formed on at least
an area on the outside of the precooked patty at a higher
temperature (e.g., between 150-180.degree. F.) than the temperature
of a portion of the patty beneath the skin. The temperature of the
portion of the patty beneath the skin may be approximately the
target temperature. The time duration for cooking may be a function
of the species of the meat, the thickness of the patty, the
temperature of the precooking, and/or a cooking method
employed.
[0108] The cooked patties are chilled (block 2530) at chiller 2630
and packaged (block 2535) at packager 2635.
[0109] FIGS. 27-28 are a flow diagram for process 2700 and a block
diagram for system 2800 in accordance with some embodiments. FIGS.
27-28 are similar in several respects to FIGS. 25-26 but involve
warm forming instead of cold forming the patties, because heating
(block 2715) at heater 2815 is performed before the patties are
formed. Heating 2715 influences the texture of the patties, because
the temperature for heating 2715 can be controlled to determine the
degree of crumble of the patties. The temperature for optimal
crumbliness depends on the meat species. In some embodiments, the
temperature for heating 2715 is between 35-50.degree. F. for
chicken, beef, turkey, and combinations thereof. In other
embodiments, the temperature for heating 2715 is between
46-75.degree. F. for pork, turkey, beef, and combinations thereof.
For example, pork may be heated to about 75.degree. F., turkey may
be heated to about 65.degree. F., and beef may be heated to about
47.degree. F. In another embodiment, the temperature for heating
2715 is between 76-95.degree. F. for pork. Crumbliness may be
determined by texture analysis of the patties. The remaining
aspects of FIGS. 27-28 are the same as in FIGS. 25-26 and do not
require further explanation.
[0110] FIGS. 29-30 are a flow diagram for process 2900 and a block
diagram for system 3000 in accordance with some embodiments. FIGS.
29-30 are similar in several respects to FIGS. 25-26 but do not
involve a cooking stage between patty formation 2925 and chilling
2930. Additionally, patty mold 1870 is heated (block 2926) by mold
heater 2211. The remaining aspects of FIGS. 29-30 are the same as
in FIGS. 27-28 and do not require further explanation.
[0111] FIG. 31 is a flow diagram of a process 3100 in accordance
with some embodiments. One or more meat types are mixed (blending
3105), and seasoning ingredients may be added with additional
mixing. Blending 3105 may involve chilling the blended materials.
The blended meat product is coarsely ground (block 3110), and fed
to a controlled pump 3115, which pumps the meat at a uniform rate
to heater 3120, where the meat blend is warmed to a target
temperature. The heated meat is deposited to a metering hopper 3125
and directed to a controlled pump 3130. Metering hopper 3125 is a
hopper that acts as a buffer or accumulator to balance or smooth
out momentary starts and stops in the production system without the
need to shut down activities that are occurring upstream. In other
words, metering hopper 3125 is a balancing mechanism.
[0112] Controlled pumping at controlled pump 3130 refers to
maintaining consistent and stable pressure at the mold filling
point. To accomplish this, the pump is operated intermittently. In
other words, because the mold plates are moving on a conveyor there
are times when there is no place for the meat material to flow, so
if the pump were running continuously there would be buildup of
pressure in the pipe because of compression of the meat material.
Using controlled pumping, when the mold plate reaches the correct
position, there is a place for the meat material to flow, so the
pressure buildup is avoided. In some embodiments, when speed of the
conveyor is changed and the mold plates are either moving faster
under the filling nozzle or slower under the filling nozzle, the
controlled pump 3115 accommodates for this change in speed. Thus,
through controlled pumping overpressure situations (which would
cause meat to leak out excessively) and underpressure situations
(which would result in incomplete fills of the mold plate) are
avoided.
[0113] The pumped meat from controlled pump 3130 is ground finely
(block 3135) and directed to a former, where patties are formed
(block 3140). After the patties are formed, the patties are cooked
(block 3150), frozen (block 3155), and packaged (block 3160).
[0114] Although examples are illustrated and described herein,
embodiments are nevertheless not limited to the details shown,
since various modifications and structural changes may be made
therein by those of ordinary skill within the scope and range of
equivalents of the claims. Although certain details or parameters
are described above in the context of particular figures, flow
diagrams, or systems, such details or parameters may be applicable
to other figures, flow diagrams, or systems.
* * * * *