U.S. patent number RE35,259 [Application Number 07/541,537] was granted by the patent office on 1996-06-04 for high humidity steam cooker with continuously running conveyor.
This patent grant is currently assigned to Hester Industries, Inc.. Invention is credited to Charles E. Williams.
United States Patent |
RE35,259 |
Williams |
* June 4, 1996 |
High humidity steam cooker with continuously running conveyor
Abstract
A steam cooker processes large quantities of food products such
as meat, fish, poultry and produce passed therethrough in a spiral
conveyor path. The continuously running conveyor is provided with
loading and unloading stations outside the cooker and with a
continuously operable spray detergent cleaning bath. Efficient
cooking is achieved without loss of humidity, flavor or appearance
by maintaining water drop free steam at near 100.degree. C. and
100% humidity at a pressure greater than atmospheric and by
features of the apparatus including control of steam flow out of
the cooking chamber and introduction of cold air thereinto. Two
separate steam sources, internal and external, are provided with
the internal source comprising a heated pool of water on the floor
of the cooker chamber, which is agitated for heat transfer
efficiency and to remove fat or drippings from the cooking
products. Sanitation means include mounting of machinery parts
outside the cooker, access to all sides of the cooking chamber for
cleaning, an internal cleaning spray system and other apparatus
features.
Inventors: |
Williams; Charles E.
(Moorefield, WV) |
Assignee: |
Hester Industries, Inc.
(Moorefield, WV)
|
[*] Notice: |
The portion of the term of this patent
subsequent to January 1, 2008 has been disclaimed. |
Family
ID: |
26740611 |
Appl.
No.: |
07/541,537 |
Filed: |
June 21, 1990 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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182203 |
Apr 15, 1988 |
33510 |
|
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Reissue of: |
060986 |
Jul 26, 1979 |
04582047 |
Apr 15, 1986 |
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Current U.S.
Class: |
126/369;
99/443C |
Current CPC
Class: |
A23B
4/0053 (20130101); A23L 3/06 (20130101); A23L
3/185 (20130101); A47J 27/16 (20130101); A47J
37/044 (20130101); Y02P 60/85 (20151101) |
Current International
Class: |
A23L
3/06 (20060101); A23L 3/02 (20060101); A23L
3/16 (20060101); A23L 3/18 (20060101); A23B
4/005 (20060101); A47J 27/16 (20060101); A47J
37/04 (20060101); A23L 003/06 () |
Field of
Search: |
;99/352,339,362,366,370,404,425,443C,467,473,475,477
;62/264,265,412 ;15/256.5 ;98/36 ;126/273R ;198/229,482,494
;210/DIG.25,242,540 ;426/510,571 ;432/64,65,242 |
References Cited
[Referenced By]
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602402 |
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0740870 |
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746035 |
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Mar 1956 |
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0861993 |
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1423791 |
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GB |
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Other References
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Fennema, Food Industries, Oct. 1934, pp. 452-453. .
"Typical Recirculating and Non-Circulating Oven", Eugene J.
Skerkoske, Eclipse Fuel Engnr. Co., Rockford, IL, IHEA Industr.
Combustion School Ses. 14, pp. 343-347 (Date Unknown). .
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4-page brochure, Futitetsumo Co., Ltd. 816 Black Diamond Way, Lodi,
CA 95241-9317 (Date Unknown). .
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|
Primary Examiner: Stinson; Frankie L.
Attorney, Agent or Firm: Nixon & Vanderhye
Parent Case Text
.Iadd.This is a continuation of Reissue application Ser. No.
07/182,203, filed Apr. 15, 1988, U.S. Pat. No. Re. 33,510 now
allowed, which is based on original U.S. Pat. No. 4,582,047.
.Iaddend.
Claims
I claim: .[.
1. A food cooking system cooking solely with steam foods such as
fish, fowl, meats or produce carried through a cooker on a
continuously running conveyor belt, comprising in combination, a
cooker housing, means passing said conveyor belt through said
housing to expose food products within the cooker housing only to
said steam as the sole cooking medium, and two sources of steam
providing said steam to cook the food products, nozzles for
releasing steam located inside said housing, one comprising a steam
generator supplying supplemental steam into said housing at said
nozzles located thereinside to maintain the atmosphere together
with the other steam source at near 100% humidity 100.degree. C.
and a pressure above atmospheric, and the other source of steam
comprising a pool of water within said housing with heating means
for boiling the water to create steam..]. .[.2. The system defined
in claim 1 having a steam exhaust pipe, and heat control means for
said pool of water regulated as a function of the temperature at
said exhaust pipe..]. .[.3. The system defined in claim 1 having an
opening in said housing into which said conveyor belt passes, and
means establishing said steam pressure at a sufficient magnitude to
discharge steam at a controlled rate from said housing about the
entering conveyor belt..]. .[.4. The system defined in claim 3 with
an opening in said housing out of which the conveyor belt passes,
and having a steam flow path created within said housing by said
nozzles tending to draw air into the latter said opening to produce
a flow path out of the former opening thereby circulating air and
steam..]. .[.5. A system as defined in claim 1 including means
driving said conveyor belt through said housing with all mechanisms
requiring lubrication mounted in a compartment outside the housing
thereby to avoid food contamination..]. .[.6. A system as defined
in claim 1 wherein the housing is positioned within a secondary
housing such as a room where the pressure is maintained above
atmospheric..]. .[.7. A system as defined in claim 6 including a
station for loading food products through which said conveyor belt
passes outside said secondary housing so that the food products are
maintained at atmospheric pressure until they enter the cooker
system whereby the increased pressure and high humidity cause
efficient penetration of heat into the products to cook them evenly
throughout by establishing a temperature approaching 100.degree.
C..]. .[.8. A system as defined in claim 1 adapted for processing
meat and fowl products which may drip fat into said pool of water,
including means continuously skimming the fat
from the top of the water to improve the steam capacity thereof..].
.[.9. A system as defined in claim 8 wherein the fat skimming means
comprises a paddle wheel on one side of the pool generating waves
travelling to the other side of the pool and a fat skimmer
receiving the crest of the waves and fat residing therein and
removing such from the pool of water..]. .[.10. A system as defined
in claim 8 wherein the heating means for the pool of water comprise
heat exchange elements at the bottom of said housing, including
means circulating the water over said heat exchange elements to
improve the effective steam output efficiency..]. .[.11. A system
as defined in claim 1 wherein said housing has access doors for
entry thereinto on all sides..]. .[.12. A system as defined in
claim 1 wherein the conveyor belt is passed inside said housing in
a spiral path coiling downwardly to carry said foods through said
housing from an upper to a lower position in said near 100%
humidity atmosphere which prevents water dripping downwardly upon
the foods being cooked on the belt..]. .[.13. A system as defined
in claim 1 including means pre-moistening the food products on said
conveyor belt before entry into said housing to thereby create an
efficient heat interchange surface on the food products for heating
by said steam..]. .[.14. The system defined in claim 13 wherein the
conveyor belt path passes from a loading station at atmospheric
pressure into an enclosure above atmospheric pressure and said
moistening means comprises means located within said enclosure
producing a fine spray mist covering the surface of the food
product on the belt without droplets or steaming..]. .[.15. A
self-contained continuous meat cooking system comprising:
a cooker housing which establishes an interior space;
meat-conveyance means for introducing meat into said interior space
at an inlet of said cooker housing and for removing the meat from
said interior space at an outlet of said cooker housing vertically
spaced from said housing inlet;
said meat-conveyance means defining a spiral path of conveyance for
said meat in said interior space, which spiral path includes a
predetermined number of convolutions so as to establish a
sufficient dwell time for the meat in said interior space as the
meat is continually translated along said defined path between said
housing inlet and said housing outlet;
said cooker housing including (i) an internal pool of water having
a surface level below a lowermost one of said convolutions of said
meat-conveyance means, and (ii) means in heat-exchange relationship
to said pool of water for converting a quantity of water in said
pool to steam which is contained within said interior space of said
housing to thereby provide a steam atmosphere within said interior
space to at least in part cook the meat during the continual
translation of the meat along said spiral path, whereby cooked meat
exits the cooker housing at said outlet thereof..]. .[.16. A meat
cooking system as in claim 15, which further comprises skimmer
means for continually removing a residual floating film of
meat-cooking by-products from said surface level of said pool of
water..]. .[.17. A meat cooking system as in claim 16, wherein said
skimmer means includes a skimmer adapted to collect the removed
meat-cooking by-products, and means for creating travelling
disturbances on said surface level of said pool of water which
cause said floating film to move towards said skimmer to be
collected thereby..]. .[.18. A meat cooking system as in claim 15,
wherein,
said meat-conveyance means includes an endless conveyor for
supporting said meat during its continual translation along said
spiral path and which includes a return path exterior of said
cooker housing between said outlet and inlet, and wherein the
system further comprises
means located along said return path exterior of said cooker
housing for cleaning said endless conveyor before it reenters said
cooker housing
inlet..]. .Iadd.19. A system for at least partially cooking
substantially uncovered food products such as poultry parts, said
cooking being performed at least in part with steam, said system
comprising:
a housing defining an internal volume having a spiral conveyance
path therein,
a conveyor belt disposed along said spiral conveyance path, said
conveyor belt adapted for supporting and carrying said uncovered
food products through said internal volume,
a belt drive mechanism coupled to said conveyor belt, said belt
drive mechanism driving said conveyor belt to continually translate
said belt along said spiral conveyance path through said housing to
expose said supported and carried uncovered food products to a high
humidity steam atmosphere,
a steam source operatively coupled to said housing, said steam
source providing said high humidity steam atmosphere within said
internal volume, said steam atmosphere directly contacting and at
least partially cooking the uncovered food products, and
an internal cleaning spray arrangement at least in part disposed
within said housing, said internal cleaning spray arrangement, in
use, spraying the inside of said housing with a sanitizing
solution. .Iaddend.
.Iadd. A cooking system for cooking food products such as poultry,
said cooking system comprising:
a housing including thermally insulated walls, said housing
defining a spiral conveyance path therein;
a conveyor belt defining an open grating, said belt being disposed
along said path, said conveyor belt adapted for supporting exposed
food products;
a drive mechanism mechanically coupled to said belt, said drive
mechanism moving said belt and said exposed food products supported
thereon along said spiral path, said path having sufficient
convolutions to retain said translating food products within said
housing for a desired dwell time so as to heat said poultry
products within said housing to a desired temperature;
a steam source coupled to said housing, said steam source providing
a high humidity steam atmosphere within said housing, said high
humidity steam atmosphere directly contacting outer surfaces of
said exposed food products so as to at least in part heat and cook
said food products; and
an internal cleaning spray arrangement at least in part disposed
within said housing, said internal cleaning spray arrangement, in
use, spraying the inside of said housing with a sanitizing
solution. .Iaddend. .Iadd.21. A cooking apparatus adapted for
cooking food products such as poultry parts having an outer fat
layer, said apparatus comprising:
a housing defining a spiral conveyance path therein;
an endless belt at least partially disposed along said spiral path,
said belt adapted for supporting and continually translating
exposed food products along said spiral conveyance path; and
a steam source providing high humidity steam within said housing in
direct contact with the outer surfaces of said exposed food
products supported and translated by said belt so as to at least in
part cook said food products while said food products are within
said housing;
an arrangement coupled to said housing which continually removes
fat byproducts from said housing while said food products are
cooking within said housing; and
an internal cleaning spray arrangement at least in part disposed
within said housing, said internal cleaning spray arrangement, in
use, spraying the inside of said housing with a sanitizing
solution. .Iaddend.
.Iadd. A meat cooking apparatus as in claim 21 further including an
automatic cleaning arrangement disposed outside said housing and in
proximity to a portion of said belt, said cleaning arrangement
continually cleaning said belt. .Iaddend. .Iadd.23. A cooking
apparatus adapted for cooking food products such as poultry parts
having an outer fat layer, said apparatus comprising:
a housing defining a spiral conveyance path therein;
an endless belt at least partially disposed along said spiral path,
said belt adapted for supporting and continually translating
exposed food products along said spiral conveyance path;
a steam source providing high humidity steam within said housing in
direct contact with the outer surfaces of said exposed food
products supported and translated by said belt so as to at least in
part cook said food products while said food products are within
said housing; and
an arrangement coupled to said housing which continually removes
fat byproducts from said housing while said food products are
cooking within said housing,
said cooking apparatus further including a premoistening
arrangement disposed in proximity to a loading portion of said
belt, said premoistening arrangement premoistening surfaces of said
exposed food products supported by said belt before said food
products enter said housing so as to reduce insulation
characteristics of said fat layer to thereby facilitate more rapid
cooking of said food products by said steam.
.Iaddend. .Iadd.24. A spiral steam cooker for at least partially
cooking exposed food products in a high humidity steam atmosphere,
said cooker comprising:
a housing defining an internal volume therein;
an endless conveyor belt at least partially disposed along a spiral
conveyance path within said internal volume, said conveyor belt
adapted for supporting and carrying said food products in an
exposed manner through said internal volume;
a belt drive mechanism coupled to said conveyor belt, said belt
drive mechanism driving said conveyor belt to continually translate
along said spiral conveyance path,
a steam source providing said high humidity steam atmosphere within
said internal volume, said high humidity steam atmosphere directly
contacting and at least partially cooking the exposed food
products, and
an internal cleaning spray arrangement at least in part disposed
within said housing, said internal cleaning spray arrangement, in
use, spraying the inside of said housing with a sanitizing
solution. .Iaddend.
.Iadd. A spiral steam cooker for heating and at least partially
cooking exposed food products, said cooker comprising:
a housing defining an internal volume therein;
an endless conveyor belt at least partially disposed along a spiral
conveyance path within said internal volume, said conveyor belt
for, in use, supporting and carrying said exposed food products
through said internal volume, said conveyor belt being adapted to
continually translate along said spiral conveyance path through
said housing,
a steam source disposed within said housing, said steam source
providing a steam atmosphere within said internal volume, said
steam atmosphere directly contacting and at least partially cooking
the exposed food products, and
at least one additional source of heat introducing heat into said
housing. .Iaddend. .Iadd.26. A cooker as in claim 25 further
including means for
continually removing liquified fat from said housing. .Iaddend.
.Iadd.27. A cooker as in claim 25 wherein said steam source
includes a heated pool of water disposed at the bottom of said
housing. .Iaddend. .Iadd.28. A spiral steam cooker for at least
partially cooking exposed food products, said cooker
comprising:
a housing defining an internal volume therein;
a conveyor belt at least partially disposed along a spiral
conveyance path within said internal volume, said conveyor belt
for, in use, supporting and carrying said exposed food products
through said internal volume, said conveyor belt adapted to
continually translate along said spiral conveyance path through
said housing; and
a steam source operatively coupled to said housing, said steam
source providing a high humidity steam atmosphere within said
internal volume, said high humidity steam atmosphere directly
contacting and at least partially cooking the exposed food
products, said steam source including at least one steam pipe for
injecting steam into said housing and for substantially filling
said housing with said high humidity steam atmosphere. .Iaddend.
.Iadd.29. A food cooking system for cooking food products with
steam as said food products are supported on a moving conveyor
belt, said food cooking system comprising:
a cooker housing,
means disposed within said housing for defining a conveyance
path,
a conveyor belt disposed along said conveyance path for supporting
and carrying said food products along said path,
means coupled to said belt for causing said belt and said food
products supported thereby to substantially continually translate
along said conveyance path through said housing to expose food
products within the housing to steam, said path retaining said
translating food products within said housing for at least a
desired dwell time, and
a source of steam providing steam to contact and cook the food
products, said steam source comprising at least one of the
following:
an external steam generator supplying steam into said housing,
and
a pool of water within said housing with heating means
communicating with said pool of water for creating steam,
wherein said steam source provides high humidity steam and said
food products are directly exposed to said high humidity steam.
.Iaddend.
.Iadd.0. A food cooking system for cooking food products with steam
as said food products rest on a moving conveyor belt, said food
cooking system comprising:
a cooker housing,
means disposed within said housing for defining a conveyance
path,
a conveyor belt disposed along said conveyance path for supporting
and conveying said food products along said path,
means coupled to said belt for causing said belt and said food
products supported thereby to substantially continually translate
along said conveyance path through said housing to expose food
products within the housing to steam, said path retaining said
translating food products within said housing for at least a
desired dwell time, and
a source of steam providing steam to contact and cook the food
products, said steam source comprising at least one of the
following:
an external steam generator supplying into said housing, and
a pool of water within said housing with heating means
communicating with said pool of water for creating steam,
wherein steam within said housing condenses into a condensate and
said steam source recirculates at least some of said condensate as
steam.
.Iaddend. .Iadd.31. A continuous food cooking system for cooking
food products with steam, said food cooking system comprising:
a housing;
means for defining an internal conveyance path within said
housing;
means disposed along said internal conveyance path for supporting
and substantially continually translating food products along said
internal path, said food products cooking while within said housing
and producing a by-product, said path having sufficient
convolutions to retain said translating food products within said
housing for a desired dwell time; and
a steam source providing steam to contact and cook the food
products, said steam source comprising at least one of the
following:
an internal steam generator supplying steam into said housing,
and
a pool of water within said housing with heating means
communicating with said pool of water for creating steam,
wherein said steam source provides high humidity steam and said
food products are directly exposed to said high humidity steam.
.Iaddend.
.Iadd.2. A continuous food cooking system for heating and at least
partially cooking food products with steam, said continuous food
cooking system comprising:
a housing;
a belt disposed along an internal spiral conveyance path within
said housing, said belt, in use, supporting said food products such
that said food products rest directly upon an upper surface of said
belt, said belt substantially continually translating along said
conveyance path within said housing so as to heat and at least
partially cook said food products while said food products are
within said housing;
a steam providing arrangement disposed, at least in part, within
said housing for providing steam within said housing, said steam
providing arrangement providing a high humidity steam atmosphere
within said housing, said high humidity steam atmosphere which
contacts, heats, and at least partially cooks said food products as
said food products translate along said path;
a by-product removing arrangement for continually removing, from
said housing, by-products such as fat released by said cooking food
products; and
an internal cleaning spray arrangement at least in part disposed
within said housing, said internal cleaning spray arrangement, in
use, spraying the inside of said housing with a sanitizing
solution. .Iaddend. .Iadd.33. A system as in claim 32 wherein said
by-product removing arrangement is located at least partially
within said housing. .Iaddend. .Iadd.34. A system as in claim 32
wherein said steam providing arrangement provides said high
humidity steam atmosphere at near 100% humidity. .Iaddend.
.Iadd.5. A system as in claim 32 wherein said by-product removing
arrangement prevents fat released by said cooking food products
from being broken down into a residue gas which would adversely
flavor the food products. .Iaddend. .Iadd.36. A system as in claim
32 wherein said by-product removing arrangement cooperates with
said housing to substantially prevent fat released by said cooking
food products from forming a scum within said housing that is not
easily removable from said housing. .Iaddend. .Iadd.37. A system as
in claim 32 wherein said housing has first and second walls, and
said system includes at least one access door in each of said first
and second walls. .Iaddend. .Iadd.38. A system as in claim 32
wherein said system further includes a spray wash unit, wherein
said belt passes through said spray wash unit so as to clean said
belt. .Iaddend. .Iadd.39. A system as in claim 38 wherein said belt
cleaning is performed on a substantially continuous basis.
.Iaddend. .Iadd.40. A system as in claim 38 wherein said spray wash
unit includes at least one spray nozzle which generates a liquid
spray, and said belt has an open grating upon which the products
rest, said open grating permitting said liquid spray to flow
through said belt. .Iaddend. .Iadd.41. A system as in claim 38
wherein said spray wash unit includes a continually running
motor-pump which continually recirculates at least a portion of
said liquid spray through said spray wash unit. .Iaddend. .Iadd.42.
A system as in claim 41 wherein said spray wash unit further
includes a filter for filtering at least a portion of said liquid
spray prior to recirculating. .Iaddend. .Iadd.43. A system as in
claim 38 wherein said spray wash unit includes a sump for holding
said liquid spray and permitting recirculation thereof. .Iaddend.
.Iadd.44. A system as in claim 38 wherein said spray wash unit is
adapted to spray a detergent spray solution. .Iaddend. .Iadd.45. A
system as in claim 38 wherein said spray wash unit includes
sufficient spray nozzles and provides sufficient spray pressure to
as to dislodge crumbs and/or drippings remaining on the belt after
said food
products are unloaded from the belt. .Iaddend. .Iadd.46. A system
as in claim 32 further including an outlet stack which lets steam
flow out of said housing in a controlled amount. .Iaddend.
.Iadd.47. A system as in claim 32 wherein convolutions of said belt
disposed within said housing are not lubricated. .Iaddend.
.Iadd.48. A system as in claim 32 further including a fan coupled
to said housing for creating a flow of high humidity steam within
said housing. .Iaddend. .Iadd.49. A system as in claim 32 further
including a fan coupled to said housing for creating a gas flow
which is counter to the direction of travel of said belt. .Iaddend.
.Iadd.50. A system as in claim 32 wherein said belt is wide enough
to support several side-by-side pieces of meat, produce, fish or
poultry. .Iaddend. .Iadd.51. A system as in claim 42 wherein said
system has a throughput capacity of in excess of a ton of food
product per hour. .Iaddend. .Iadd.52. A system as in claim 32
wherein said system is capable
of providing a dwell time of at least twenty minutes. .Iaddend.
.Iadd.53. A system as in claim 32 wherein said system is capable of
heating said food products to a temperature of at least 97 degrees
centigrade. .Iaddend. .Iadd.54. A system as in claim 32 wherein
said internal cleaning spray arrangement includes a spray pipe not
used by said steam providing arrangement. .Iaddend. .Iadd.55. A
system as in claim 32 wherein said steam providing arrangement
provides a constant circulating flow of high humidity steam about
the products being carried on said belt. .Iaddend.
.Iadd.56. A system as in claim 32 wherein said steam providing
arrangement includes means for flowing steam in a direction counter
to the direction of translation of said belt to create a
circulation path. .Iaddend. .Iadd.57. A system as in claim 32
wherein said steam providing arrangement creates a circulation of
steam within said housing. .Iaddend. .Iadd.58. A system as in claim
32 further including a circulation fan for introducing a desired
ratio of outside air into the housing for
circulation. .Iaddend. .Iadd.59. A system as in claim 32 wherein a
portion of said belt is disposed along a path outside of said
housing, and a belt cleaning system continually cleans said portion
of said belt outside of said housing. .Iaddend. .Iadd.60. A system
as in claim 32 further including an arrangement for recovering said
removed by-products so as to permit said by-products to be useable.
.Iaddend. .Iadd.61. A system as in claim 32 wherein said housing
has at least one opening through which said belt travels, and said
system further includes means for resisting the flow of hot air or
steam out of said housing. .Iaddend. .Iadd.62. A system as in claim
32 wherein said by-product removing arrangement prevents any
accumulation of fat film on a surface near the bottom of said
housing. .Iaddend. .Iadd.63. A system as in claim 32 wherein said
by-product removing arrangement includes a means outside of said
housing for segregating fats from said by-product. .Iaddend.
.Iadd.64. A system as in claim 32 further including a belt drive
mechanism disposed outside of said housing, said belt drive
mechanism causing said belt to translate. .Iaddend. .Iadd.65. A
system as in claim 32 wherein said belt path has as many
convolutions as necessary to retain particular specialty products
within the housing for a desired dwell time and belt travel speed.
.Iaddend. .Iadd.66. A system as in claim 32 wherein said housing
walls are insulated to preserve heat and to produce a safe and
lower temperature outside wall environment. .Iaddend. .Iadd.67. A
system as in claim 32 wherein said steam providing arrangement
includes a steam generator unit external to said housing. .Iaddend.
.Iadd.68. A system as in claim 67 wherein said steam providing
arrangement has components made of stainless steel. .Iaddend.
.Iadd.69. A system as in claim 67 wherein said steam providing
arrangement is adapted to be coupled to a boiler.
.Iaddend..Iadd.70. A system as in claim 67 wherein said steam
providing arrangement is adapted to be supplied with sanitary
steam, and includes a stainless steel sanitary steam pipe with pipe
insulation having sanitary jacketing. .Iaddend. .Iadd.71. A system
as in claim 32 wherein said
housing has a floor with a drain therein. .Iaddend. .Iadd.72. A
continuous food cooking system for heating and at least partially
cooking food products with steam, said continuous food cooking
system comprising:
a housing;
a belt disposed along an internal spiral conveyance path within
said housing, said belt, in use, supporting said food products such
that said food products rest directly upon an upper surface of said
belt, said belt substantially continually translating along said
conveyance path within said housing so as to heat and at least
partially cook said food products while said food products are
within said housing;
a steam providing arrangement disposed, at least in part, within
said housing for providing steam within said housing, said steam
providing arrangement providing a high humidity steam atmosphere
within said housing, said high humidity steam atmosphere which
contacts, heats and at least partially cooks said food products as
said food products translate along said path; and
a by-product removing arrangement for continually removing, from
said housing, by-products such as fat released by said cooking food
products,
said system further including:
a gas discharge stack for discharging steam from said housing;
and
a temperature sensor coupled to said gas discharge stack, said
temperature sensor sensing the temperature of the steam discharged
by said gas
discharge stack. .Iaddend. .Iadd.73. A system as in claim 72
wherein said steam providing arrangement is responsive to said
sensed temperature. .Iaddend. .Iadd.74. A system as in claim 72
wherein said steam providing arrangement provides an amount of
steam responsive to the temperature sensed by said temperature
sensor. .Iaddend. .Iadd.75. A continuous food cooking system for
heating and at least partially cooking food products with steam,
said continuous food cooking system comprising:
a housing;
a belt disposed along an internal spiral conveyance path within
said housing, said belt, in use, supporting said food products such
that said food products rest directly upon an upper surface of said
belt, said belt substantially continually translating along said
conveyance path within said housing so as to heat and at least
partially cook said food products while said food products are
within said housing;
a steam providing arrangement disposed, at least in part, within
said housing for providing steam within said housing, said steam
providing arrangement providing a high humidity steam atmosphere
within said housing, said high humidity steam atmosphere which
contacts, heats and at least partially cooks said food products as
said food products translate along said path; and
a by-product removing arrangement for continually removing, from
said housing, by-products such as fat released by said cooking food
products,
said system further including a heat source in addition to said
steam providing means, said additional heat source introducing
additional heat into said housing for heating and at least in part
cooking said food
products. .Iaddend. .Iadd.76. A continuous food cooking system for
heating and at least partially cooking food products with steam,
said continuous food cooking system comprising:
a housing;
a belt disposed along an internal spiral conveyance path within
said housing, said belt, in use, supporting said food products such
that said food products rest directly upon an upper surface of said
belt, said belt having an open grating which permits steam and
liquid to flow through said belt, said belt substantially
continually translating along said conveyance path within said
housing so as to at least partially cook said food products while
said food products are within said housing;
a steam providing arrangement disposed within said housing for
providing steam within said housing, said steam providing
arrangement providing a high humidity steam atmosphere within said
housing, said high humidity steam atmosphere contacting and at
least partially cooking said food products as said food products
translate along said path; and
an internal cleaning spray arrangement at least in part disposed
within said housing, said internal cleaning spray arrangement, in
use, spraying the inside of said housing with a sanitizing
solution. .Iaddend.
.Iadd. A system as in claim 76 wherein:
said housing further includes a floor with a drain; and
said system further includes means for selectively permitting said
sanitizing solution to exit said housing through said drain.
.Iaddend.
Description
TECHNICAL FIELD
This invention relates to cookers and more particularly it relates
to cookers through which are transported food products on a
continuously moving conveyor belt.
BACKGROUND ART
In the field of industrial cooking requiring the rapid cooking and
throughput of large quantities of food it has been customary to
pass the food through a cooker on a conveyor belt. Typical examples
of such prior art are as follows:
U.S. Pat. No. 3,982,481--E. T. Console et al. This shows a chamber
through which a conveyor belt passes to carry produce for blanching
in a steam spray.
Certified Manufacturing, Inc., Lynwood, Calif. 90262 has marketed
gas fired broilers with A conveyor belt transport therethrough.
U.S. Pat. No. 1,491,958--J. F. Logan et al., uses a spiral conveyor
to transport food in cans through a dry heat chamber.
However, in this type of prior art there are many unsolved problems
relating to the cooking, the efficiency and the sanitation of
conveyor type cooking systems.
Thus, particularly with rapid cooking techniques, the juices,
essences and moisture is withdrawn from food products changing the
appearance, flavor and texture thereof.
Also the cooking may not be uniform to the center of such products
as meat which needs be cooked at the inner bone structure.
In general the food products present an interface to the heating
medium that does not efficiently transfer heat, such as the fat
skin layer of a piece of fowl. Also, such residue as fat drippings
can significantly decrease heating efficiency.
Whenever a continuously running conveyor is used it tends to carry
heat out of the cooker and cool air into it. This wastes energy and
establishes an uncomfortable working environment for loading the
conveyor.
Also the amount of energy carried out of a hood or exhaust system
is significant, and in the case of steam heat for example, there
can be significant heat loss by condensation of the steam into
droplets.
The conveyor belts are difficult to sanitize, particularly in those
systems that pass the belt back through the cooker to bake on
residue. Other movable and irregularly shaped parts in or near
cookers are apt to accumulate contaminating residue and breed
bacteria. Also accessibility of the systems is in many cases
difficult for takedown and entry into interior compartments for
cleaning and sanitation.
Accordingly, it is an object of this invention to provide an
improved, efficient, sanitary conveyor type cooker for food
products that resolves the foregoing problems, and provides other
features and advantages which will be found throughout the
following text.
BRIEF DISCLOSURE OF THE INVENTION
Food products such as fish, meat, fowl or produce are carried on a
conveyor belt in a spiral path through a steam cooking chamber. The
chamber is kept near 100.degree. C. and 100% humidity by two steam
sources both supplied with pure water and at a pressure above
atmospheric in order to produce efficient rapid cooking without
loss or humidity and with protection to appearance and flavor.
One steam source comprises a heat exchange surface in a pool of
water on the floor or the chamber stirred to create heating
efficiency and to skim off fat drippings from chicken or meat
products. The other externally located steam generator has steam
piped into the chamber.
The continuously running conveyor belt is passed on a return path
outside the cooker through a continuously run spray detergent
cleaning and sanitizing bath, and the internal parts of the cooker
are all accessible by doors on all sides thereof. Driving machinery
and elements requiring lubrication are all located outside the
cooker to present simple sanitary surfaces for cleaning and
sanitation. An internal cleaning spray system is also provided.
Other features are found hereinafter in the more detailed
description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system schematic diagram showing the various features
of the invention;
FIG. 2 is a side elevation sketch of the cooker cabinet afforded by
the invention;
FIG. 3 is a diagrammatic view, partly broken away, of a continuous
conveyor belt spray cleaner afforded by the invention;
FIG. 4 is a diagrammatic view in perspective, partly broken away,
showing the spiral conveyor path within the cooker as afforded by
this invention;
FIG. 5 is a diagrammatic view in perspective, partly broken away,
showing the steam supply means for the cooker as afforded by this
invention; and
FIG. 6 is a perspective view of the cooker cabinet array as
provided by this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The overall system and combinational aspects of the cooking system
provided by this invention are set forth in FIG. 1. Thus, it is
seen that food products 10 to be cooked are loaded on a conveyor
belt 11 at the loading station 12 outside the cooker room wall 13.
Preferably the food products are substantially uniform in size and
weight such as chicken legs, sized fish filets, steaks, etc. The
products thus are loaded on the conveyor belt 11 at atmospheric
pressure at loading station 12 outside the cooker room 14 which is
kept at a pressure above atmospheric. This not only keeps the
working conditions more comfortable but improves the cooking
efficiency as hereinafter shown.
The products first undergo an optional pure water spray mist
process at station 15 to wet the surface of the products for better
heat interface exchange with the steam inside cooker housing 16. It
should be recognized that particularly in the case of meat products
which are covered by a fat, this wetting step is important to
reduce the insulation characteristics and to achieve more efficient
and rapid cooking.
The products are then passed through a duct 17 or opening in upper
part of the cooker housing and through a spiral conveyor path 18 to
assure the proper dwell time within the cooker at the chosen
conveyor speed. The conveyor belt is of stainless steel for
sanitary purposes and is not lubricated, since that would introduce
contamination for food products.
The conveyor exits the cooker housing 16 at a lower duct 19 which
is in the form of a trap reducing the steam and heat energy leaving
the cooker on the conveyor belt 11. Thus baffles 20 resist flow of
hot air or steam out of the cooker housing 16 and fan 21 creates a
counter flow of air at least sufficient to prevent any significant
unnecessary outward flow of heat energy by way of gases carried
outwardly by conveyor 11. This fan can control the rate of fresh
air flow into cooker housing 16 as later discussed.
The cooked food products 10' are then conveyed to unloading station
22 outside cooker room 14 on the outside of wall 23. The conveyor
belt is typically wide enough for several side-by-side pieces of
meat, produce, fish or poultry, for example, and a typical
throughput is over a ton of raw products per hour with typical
cooking times of 20 minutes between input loading station 12 and
output unloading station 22. The cooked product temperature is
uniformly in the order of 97.degree. C.
The cooking is solely with water droplet free steam near
100.degree. C. and 100% humidity at a pressure above atmospheric.
The high humidity atmosphere prevents losses of humidity of the
product as it passes through the cooker and helps retain juices,
essences and flavor of the product. Also it improves the heating
steam interface heat exchange at the product surface for more
efficient cooking.
The higher pressure not only produces a pressure-cooker like
cooking efficiency to the cooking process, but is critical in
connection with the flavor and conveyor type product flow as well.
Thus, consider products loaded at the conveyor loading station 12
at atmospheric pressure when introduced into the cooking chamber
will then tend to draw the steam internally within the cellular
structure of the product for faster more intimate contact and
quicker more uniform cooking throughout. This action also resists
the leaking and removal of juices and essences of the product for
better flavor control.
Part of the steam, typically 25%, is provided by an external steam
generator 30 with filter to remove water droplets as supplied with
pure water 31 to prevent contamination. This is piped to various
locations 32, 33 within the cooker to assure a constant circulating
flow of steam near 100% humidity 100.degree. C. atmosphere about
the products being carried on belt spiral 18. Also, for example, a
jet 33 may flow steam in a direction counter the belt flow path to
create a circulation path preventing undesired loss of steam out of
duct 19 as the belt leaves the cooker, and together with fan 21 can
create a desired ratio of input of outside air for circulation.
For this purpose an outlet stack 35 will let out of the cooking
housing 16 an amount of steam flow controlled by valve means
36.
The remaining steam is provided by an internal boiler having the
pool of water 40 on the floor of the cooking chamber as heated by
the heat exchange element 41, To assure the right amount of steam
and pressure within the cooking chamber, the power is controlled as
a function of the temperature at the gas discharge stack 35 as
sensed by temperature sensor 43.
For better steam producing efficiency the water in pool 40 is
circulated by means such as paddle wheel 45 and electric motor 46.
This is additionally used to improve steam production efficiency by
creating a wave flow 47 travelling toward fat skimmer 48 which
receives the crest of the waves on which the fat rides and removes
the fat in the manner of a swimming pool skimmer mechanism. This
prevents any accumulation of an insulating fat film on the pool 40
that prevents or reduces steam output, and further it removes a
substance which could cause both sanitation and flavor problems if
resident long in the cooker chamber. The fat is not thus broken
down into a residue gas which would flavor the product adversely
nor a scum which would not be easily sanitized. Also the fat may
constitute a useable by-product.
To further improve sanitation, those elements which require
lubrication or access for maintenance are located outside the
cooking chamber, as exemplified by motor 46 and belt conveyor drive
mechanism 49. Also the belt 11 is returned from unloading to the
loading station outside the cooking chamber as shown by the view of
FIG. 2 where there is a niche 50 in the cooker housing 16 to permit
a short return path through a conveyor duct 51. The access doors 52
are supplied on all sides of the housing for accessibility for
maintenance and sanitation.
Additionally a detergent spray system provides for continuous
cleaning of the belt at 55 and for a spraying of the cooking
chamber as depicted at spray outlet 56 with a sanitary detergent
solution.
The belt cleaning spray mechanism is shown in detail in FIG. 3,
which with all succeeding figures uses similar reference characters
for common features to facilitate comparison.
Installed in the return duct 51' about the stainless steel conveyor
belt 11 is a spray wash unit 55 powered by continuously running
motor-pump 57. The belt has interconnected stainless steel segments
which permit travel around guide rollers 58, 59 and other flow
paths within the system. The conveyor belt 11 has a central open
grating upon which the products rest which permits steam and
detergent spray solution 60 to flow through the belt into sump 61
for recirculation by motor-pump 57.
Sufficient spray nozzle arms 62 are provided with nozzle
construction and spray pressure such as to dislodge any crumbs or
drippings of the product remaining on the belt after cooking and
unloading. A sanitary detergent solution is used to provide a
sanitary belt for receiving a new loading of products at station 12
without contamination from the continuously running belt. Because
the belt 11 does not return through the cooker, there is less
tendency to bake on any residue and the cleaning function is
simplified. Brushes may be used if desired and the brush 64 removes
moisture from the roller 58 to keep the belt drier. It dries
rapidly because it is warm after leaving the cooker and the reduced
atmospheric pressure outside wall 13 permits quick evaporation of
residue moisture. The solution in sump 61 is filtered for removing
residue before recirculation by the pump, and the detergent
solution can be changed as often as necessary to maintain strict
sanitary conditions without possibility of introducing bacteria or
retaining contaminating residue. Note all mechanisms such as pump
57 are kept outside the sanitary cooking compartment and ductwork
17', 51' keeping any foreign substances off the belt 11.
Features shown in FIG. 4 include the spiral path 18 taken by the
belt 11 through the cooker chamber, access doors 52, etc. for
internal access, maintenance and sanitation and the placement of
drive means such as chain sprocket 68 for driving the conveyor belt
through the spiral path 18 and its associated drive mechanisms. The
catwalk array 69 gives a size perspective of the cooker housing 16,
and provides access to top entry panels and the mechanism 68 for
maintenance. The spiral belt path may have as many convolutions as
necessary to retain particular specialty products within the
cooking chamber a desired dwell time for the desired belt travel
speed.
Details of the heating mechanisms are shown in FIG. 5. For sanitary
purposes stainless steel is used wherever possible and the interior
walls of the housing 16 are smooth to avoid any surfaces that could
cause dripping or collect contamination, The interior 70 of the
housing walls is insulated to preserve heat and to produce a safe
and lower temperature outside wall environment around operational
personnel.
The steam generator unit 30 could be any standard commercially
available steam generator unit and is preferably made of stainless
steel. It is coupled to a boiler for a supply of sanitary steam
from pure water by means of piping 71. Approved pure water make-up
is entered from source 31 to assure sanitary steam. All piping is
stainless steel sanitary steam pipe with pipe insulation having
sanitary jacketing.
The floor water may be pumped out by pump 75 through drain 76 when
sanitizing by detergents from piping 56.
The fat skimmer duct 48 has internal baffling to reduce the loss of
hot water and it leads to a settling tank (not shown) for
segregation of fats.
The external steam is preferably disposed through piping 78 to the
four corners of the cooking chamber and steam is released at
nozzles 32', 33' or along the length of the piping such as shown at
79 to provide proper mixture and saturation along the spiral
conveyor path with the steam evaporated from the lower water
pool.
Externally the cooking cabinet 16 is shown in FIG. 6. The top
housing 80 encloses the mechanisms for driving the spiral conveyor
system within housing 16 and the top access door 81 permits entry
for maintenance, inspection, sanitation and the like.
It is therefore evident that the steam cooking system provided by
this invention has advanced the state of the art and provided many
improved features. Those novel features believed descriptive of the
spirit and nature of the invention are set forth with particularity
in the appended claims.
INDUSTRIAL APPLICATION
Large volumes of food products are processed on a continuously
running conveyor belt passing through an energy efficient steam
cooker which preserves product humidity, flavor and appearance.
Thus, fish, meat, poultry, produce and like food products can be
cooked. There are self-cleaning and apparatus features for meeting
the strictest of sanitation requirements.
* * * * *