Apparatus and methods for cooling and tempering processed food products

An apparatus (10) for cooling and tempering bacon slabs supported upon wheeled trucks (24) which can be rolled on the floor (14) inside a cooler (12) includes an evaporator (26) having multiple fans (34) for moving air through refrigerated coils (32) and in the cooler (12). Moisture collecting on the refrigerated coils (32) drops into a drain pan (30) and is drained through pipes (38) outside the cooler (12). The fans (34) are alternately rotated in opposite directions for equal time segments and baffles (40) are provided inside of the cooler (12) to assure uniform air chilling. A controller (46) operates the evaporator (26) so that the air inside of the cooler (12) is cooled to a temperature less than the internal product temperature which is greater than freezing and specifically in the preferred form at a desired temperature differential of 20.degree. F. (11.degree. C.) until an intermediate internal product temperature is reached. Then the evaporator (26) maintains the air temperature inside the cooler (12) below the final internal product temperature until the final internal product temperature is reached when the air is then maintained in the cooler (12) at the final internal product temperature.

BACKGROUND 
The present invention generally relates to apparatus and methods for 
cooling and tempering processed food products and in the most preferred 
form to apparatus and methods for cooling and tempering bacon slabs or 
bellies. 
In the processing of bacon, bacon slabs are cooked and smoked in a smoke 
oven for approximately 71/2 to 8 hours. After leaving the smoke oven, the 
bacon slabs have a warm internal temperature in the order of 90.degree. F. 
(32.degree. C.) or more. In a conventional processing plant, the bacon 
slabs were sent through a liquid brine chiller until the internal 
temperature was in the order of 24.degree. F. (-4.5 C.) The bacon slabs 
would then go into a bacon tempering cooler for a period of 24 to 36 hours 
so that the bacon slabs were tempered enough to allow pressing into a 
block form to square the sides and ends and then through a slicer to slice 
the squared bacon slabs. It can be appreciated that chilling the bacon 
slabs too fast such that freezing occurs is undesirable as resulting in 
shattered slices during the slicing operation. 
It can then be appreciated that due to the long periods of time to cool and 
temper the bacon slabs, the smoke oven could be run intermittently to 
match the capacity of the cooling/tempering phases of the processing line 
thereby increasing operational as well as capital expenses. Alternately, 
the capacity of the cooling/tempering phases of the processing line could 
be increased to match that of the smoke oven which significantly increased 
capital expenses but which also significantly increased the floor space 
requirements. 
Others have attempted to reduce the time requirements by providing blast 
chillers, but such prior blast chillers were deficient. Specifically, one 
chiller has been designed where a water spray is introduced during the 
chilling operation which is alleged to keep the process uniform. However, 
actual operation of the chilling operation is very inconsistent and 
irregular. Additionally, the moisture is allowed to fly around the 
chilling cabinet and is only eventually removed by going down a floor 
drain in the chilling cabinet. 
Thus, a need exists for apparatus and methods which are able to cool and 
temper bacon slabs in generally the same amount of time required to cook 
and smoke the bacon slabs and without freezing the bacon slabs. Thus, it 
is possible to continuously cook and smoke as well as cool and temper 
bacon slabs in an oven and in a cooling and tempering apparatus having the 
same capacity. 
SUMMARY 
The present invention solves this need and other problems in the field of 
cooling and tempering processed food products by providing, in the most 
preferred form, cooling of the air within a cooler at a temperature 
differential slightly below the internal temperature of the processed food 
products with the cooled air resulting in heat transfer from the processed 
food products to the cooled air resulting in a reduced internal 
temperature and maintaining the air at the temperature differential until 
the processed food products have an intermediate internal temperature, 
then maintaining the air in the cooler at the temperature differential at 
the intermediate internal temperature until the processed food products 
have a final internal temperature, and then cooling the air within the 
cooler at the final internal temperature for a time necessary to create 
tempering of the processed food products. In the most preferred form, 
moisture is eliminated from the cooler while the air is being cooled 
inside of the cooler. 
In other aspects of the present invention, the air inside of the cooler is 
alternately moved in opposite directions by alternately rotating fans 
inside of the cooler for equal time segments of the period of time of 
operation. In most preferred aspects, baffles are provided in the cooler 
around which the air must move. The changing of direction of air movement 
and the baffles assure uniformity of air chilling and thus of the 
temperature of the processed food products anywhere within the cooler. 
Thus, it is an object of the present invention to provide novel apparatus 
and methods for cooling and tempering processed food products. 
It is further an object of the present invention to provide such novel 
cooling and tempering apparatus and methods for bacon slabs or bellies. 
It is further an object of the present invention to provide such novel 
cooling and tempering apparatus and methods which cool and temper bacon 
slabs in generally the same amount of time required for cooking and 
smoking the bacon slabs. 
It is further an object of the present invention to provide such novel 
cooling and tempering apparatus and methods which cool and temper bacon 
slabs without freezing. 
It is further an object of the present invention to provide such novel 
cooling and tempering apparatus and methods which cool and temper bacon 
slabs for optimizing yields in the slicing and packaging operations. 
It is further an object of the present invention to provide such novel 
cooling and tempering apparatus and methods which do not need defrosting. 
It is further an object of the present invention to provide such novel 
cooling and tempering apparatus and methods having total control and 
elimination of condensation. 
It is further an object of the present invention to provide such novel 
cooling and tempering apparatus and methods assuring uniformity of 
temperature of the processed food products anywhere within the cooler. 
These and further objects and advantages of the present invention will 
become clearer in light of the following detailed description of an 
illustrative embodiment of this invention described in connection with the 
drawings.

All figures are drawn for ease of explanation of the basic teachings of the 
present invention only; the extensions of the figures with respect to 
number, position, relationship, and dimensions of the parts to form the 
preferred embodiment will be explained or will be within the skill of the 
art after the following description has been read and understood. Further, 
the exact dimensions and dimensional proportions to conform to specific 
force, weight, strength, and similar requirements will likewise be within 
the skill of the art after the following description has been read and 
understood. 
Where used in the various figures of the drawings, the same numerals 
designate the same or similar parts. Furthermore, when the terms "top", 
"first", "second", "inside", "outer", "upper", "lower", "height", "width", 
"length", "end", "side", "horizontal", "vertical", and similar terms are 
used herein, it should be understood that these terms have reference only 
to the structure shown in the drawings as it would appear to a person 
viewing the drawings and are utilized only to facilitate describing the 
illustrative embodiment. 
DESCRIPTION 
An apparatus for cooling and tempering processed food products from a warm 
temperature usually in the order of 90.degree. F. (32.degree. C. or more 
to a cooler temperature for United States Department of Agriculture 
regulations in the order 40.degree. F. of (4.4 C. or less utilizing 
methods according to the preferred teachings of the present invention is 
shown in the drawings and generally designated 10. In the most preferred 
form of the present invention, apparatus 10 is utilized to cool bacon 
slabs referred to in the trade as bellies to a temperature for maintaining 
optimum yields in the slicing and packaging operation of the food 
processing plant and particularly to a temperature in the order of 
24.degree. F. (-4.5 C. plus or minus 1.degree. F. (0.5.degree. C.) and to 
do so in generally the same time that it takes to cook and smoke the bacon 
slabs or bellies. 
In particular, apparatus 10 includes a cooler 12 including a floor 14, 
first and second side walls 16, a top wall 18, and first and second end 
walls 20. In the most preferred form, cooler 12 is in the shape of a 
hollow, rectangular parallelepiped having a length between end walls 20 
which is a multiple of the width between side walls 16 and with a height 
between floor 14 and top 18 generally equal to the width between side 
walls 16. Floor 14 and walls 16, 18 and 20 are formed by any suitable 
insulated construction as desired. Access to the interior of cooler 12 can 
be provided by any suitable doors 22 or the like, with two doors 22 being 
provided in each of the end walls 20 in the most preferred form. 
In the most preferred form, apparatus 10 includes a plurality of wheeled 
trucks 24 for holding the desired processed food products and in the most 
preferred form are in the form of smoke trucks 24 in which bacon slabs or 
bellies are cooked and smoked. Specifically, in the preferred form, each 
truck 24 holds approximately 550 pounds (250 kg) of bacon slabs or 
bellies. The cooking and smoking time in the processing of bacon slabs or 
bellies in trucks 24 is approximately 71/2 . In the most preferred form, 
cooler 12 holds ten trucks arranged in two rows of five trucks 24 between 
end walls 20. 
Cooler 12 generally includes an evaporator 26 located in the interior and 
in the most preferred form hung or supported from top wall 18 above trucks 
24 and centered between side walls 16. In the most preferred form, 
evaporator 26 includes a housing 28 in the shape of a hollow, rectangular 
parallelepiped. The bottom of housing 28 is formed by a drain pan 30. 
Refrigerated coils 32 of a conventional design are positioned in the 
interior of housing 28. Air is circulated through housing 28 and 
specifically past coils 32 by fans 34 mounted for rotation about 
horizontal axes in vertical openings formed in one of sides 36 of housing 
28. According to the teachings of the present invention, fans 34 can be 
alternately rotated at constant speeds in either clockwise or 
counterclockwise directions in differing time segments. It can be 
appreciated that moisture will collect on coils 32 as droplets and will 
drop into drain pan 30. Water dropping into drain pan 30 will drain from 
drain pan 30 through any suitable pipe 38 extending through cooler 12 to a 
floor or any suitable drain that is located outside of cooler 12. Thus, it 
can be appreciated that moisture is eliminated from the chilling process 
according to the teachings of the present invention. In the most preferred 
form, four fans 34 are provided each creating about 44,000 cubic feet 
(1,250,000 liters) per minute of air flow. The other of sides 36 is open 
while the ends of housing 28 are closed. Coils 32 are sized to provide 16 
tons of refrigeration at a temperature difference of 8.degree. F. 
(4.5.degree. C.) and include fins in a conventional manner to increase 
area of heat transfer. 
In the most preferred form, baffles 40 are provided in cooler 12 
intermediate evaporator 26 and trucks 24 and in the most preferred form 
are formed by elongated plates extending parallel to top wall 18 at a 
height generally equal to that of drain pan 30 and spaced from side walls 
16 and sides 36. In the most preferred form, baffles 40 have a width equal 
to one-fourth of the spacing of side 36 from side wall 16 and is located 
about double the spacing from side 36 than from side wall 16. It can be 
appreciated that baffles 40 can take other desired forms and placements 
for directing air inside of cooler 12. 
Apparatus 10 further includes suitable provisions 42 for sensing the 
internal temperature of the processed food products and in the preferred 
form a temperature probe. In the most preferred form, probe 42 is inserted 
in one of the bacon slabs or bellies of a perceived average or larger size 
in one of trucks 24 located inside cooler 12. Additionally, cooler 12 
includes a suitable temperature sensor 44 for sensing the temperature of 
the interior of cooler 12. Further, a suitable controller 46 in the 
preferred form of a programmable microprocessor receives input signals 
from probe 42 and sensor 44 and controls operation of evaporator 26. In 
this regard, probe 42 and sensor 44 are suitably electrically connected to 
controller 46. 
Now that the basic construction of apparatus 10 according to the preferred 
teachings of the present invention has been explained, a method of 
operation of apparatus 10 can be set forth and appreciated. Specifically, 
processed food products are introduced into the interior of cooler 12. 
Particularly and for the sake of explanation, it will be assumed that ten 
trucks 24 of bacon slabs or bellies have completed the cooking and smoking 
process steps. The typical initial internal temperature of the bacon slabs 
or bellies on trucks 24 introduced into cooler 12 is in the order of 
90.degree. F. (32.degree. C.) or higher. The trucks 24 are removed from 
the cooking and smoking process portion of the food processing line and 
rolled through doors 22 on floor 14 and into the interior of cooler 12. In 
the most preferred form of the present invention, trucks 24 from prior 
operation of apparatus 10 can be removed through doors 22 from one end 
wall 20 as trucks 24 for the next operation of apparatus 10 are being 
inserted through doors 22 at the other end wall 20. 
After trucks 24 are located in the interior of cooler 12 and doors 22 are 
closed, evaporator 26 is operated to cool the air within the interior of 
cooler 12. In particular, refrigerant is passed through coils 32 so that 
the air inside of cooler 12 is cooled at a temperature differential 
slightly below the internal temperature of the processed food product and 
in the most preferred form is held 20.degree. F. (11.degree. C.) below the 
internal temperature of the bacon slabs or bellies in trucks 24. It can be 
appreciated that since the product internal temperature is greater than 
the air temperature inside of cooler 12, heat transfer occurs from the 
bacon slabs or bellies to the cooled air inside of cooler 12 resulting in 
a reduction of the internal temperature of the bacon slabs or bellies. As 
the internal temperature of the bacon slabs or bellies drops, the air 
temperature inside of cooler 12 is also reduced to maintain the desired 
temperature differential. 
It should be appreciated that as the temperature of the bacon slabs or 
bellies drops, moisture will be released in the form of vapor from the 
bacon slabs or bellies. This moisture then condenses on coils 32 where it 
drops into drain pan 30 and drains from cooler 12 through pipe 38. Thus, 
moisture is thereby eliminated in the chilling process according to the 
teachings of the present invention. In actual practice, the majority of 
moisture that is eliminated occurs within the first couple of hours of 
operation of apparatus 10. It should be appreciated that since the 
processed food products are introduced at a warm temperature and the air 
temperature inside of cooler 12 is maintained at a temperature 
differential of 20.degree. F. (11.degree. C.) and the majority of moisture 
from the processed food product is eliminated while the air temperature in 
cooler 12 and the internal product temperature is above freezing, problems 
of moisture freezing on coils 32 and the defrosting thereof are not 
encountered utilizing apparatus 10 of the present invention. 
Operation of apparatus 10 continues in this manner for a first portion of 
time until the temperature of the air inside of cooler 12 reaches 
18.degree. F. (-7.8.degree. C. or in other words when the internal 
temperature of the bacon slabs or bellies is in the order of 38.degree. F. 
(3.3.degree. C.). In actual practice, operation of apparatus 10 in this 
first portion of time to reach the 18.degree. F. (-7.8.degree. C.) 
temperature takes in the range of approximately 3 to 4 hours, depending 
upon the size of the bacon slabs or bellies. At this point in the most 
preferred form, controller 46 controls operation of evaporator 26 so that 
the air temperature inside of cooler 12 is maintained at the temperature 
differential at the intermediate internal temperature which in the 
preferred form is 18.degree. F. (-7.8.degree. C.) until the internal 
temperature of the bacon slabs or bellies reaches its desired final level 
which in the preferred form is in the order of 24.degree. F. (-4.5.degree. 
C.). In actual practice, operation of apparatus 10 in this subportion of 
time for the internal product temperature to decrease from 38.degree. F. 
(3.3.degree. C.) to 24.degree. F. (-4.5.degree. C.) takes in the order of 
approximately 4 hours. When the internal temperature of the bacon slabs or 
bellies reaches its desired final level, controller 46 controls operation 
of evaporator 26 so that the air temperature inside of cooler 12 is 
generally equal to the desired final internal temperature of the bacon 
slabs or bellies. This last subportion of time of operation of apparatus 
10 is to create tempering time to achieve firmness for the pressing 
operation before slicing of the bacon slabs or bellies. The actual time 
for this last period of operation of apparatus 10 in this subportion of 
time will vary slightly depending upon the size of the bacon slabs or 
bellies but typically takes in the range of approximately 1 hour. 
In the most preferred form of the present invention, fans 34 are operated 
to alternately rotate in one direction such as clockwise and then to 
rotate in the opposite direction such as counterclockwise for equal time 
segments, such as 30 minutes, with the period of time of full operation of 
evaporator 26 in the preferred form of 8 to 10 hours being a multiple of 
the time segments in which fans 34 are alternately rotated. The reversal 
of rotation of fans 34 and the use of baffles 40 according to the 
preferred teachings of the present invention assure uniformity of air 
temperature and chilling inside of cooler 12. This is important to insure 
that product anywhere in any of trucks 24 has the final internal 
temperature within a tolerance of plus or minus 2.degree. F. (1.1.degree. 
C.). 
It can then be appreciated that apparatus 10 according to the preferred 
teachings of the present invention is able to cool bacon slabs or bellies 
having an initial internal temperature of approximately 90.degree. F. 
(32.degree. C.) or more to a final internal temperature in the order of 
24.degree. F. (-4.5.degree. C.) and also to maintain the desired internal 
temperature for a sufficient time to optimize yields in the slicing and 
packaging operation and within a total time of 8 to 10 hours and 
specifically for approximately the same amount of time as it takes to cook 
and smoke the bacon slabs or bellies. 
Thus since the invention disclosed herein may be embodied in other specific 
forms without departing from the spirit or general characteristics 
thereof, some of which forms have been indicated, the embodiments 
described herein are to be considered in all respects illustrative and not 
restrictive. The scope of the invention is to be indicated by the appended 
claims, rather than by the foregoing description, and all changes which 
come within the meaning and range of equivalency of the claims are 
intended to be embraced therein.