An apparatus for forming a food product

Abstract: An apparatus(10) for forming strands of semi-solid food product includes a pressure system(12,16,18) which supplies a slurry to a depositing assembly(24) which has a plurality or outlets(80). A valve mechanism(26) is provided which includes a plurality of valve members(130) each co-operating with one or more of the outlets(80). Each valve member may be moved between an open position, when food may be extruded through the co-operating outlet, and a closed condition in which the flow of food through the outlet is stopped. The operation of the valve members is co-ordinated so that at least one of the valve members is in the open position at any instant. This permits substantially continuous operation of the apparatus. The apparatus may be used for extruding potato slurry to form elements which can be cooked to form "Hash Browns".

Description: THE PRESENT INVENTION relates to an apparatus for forming a food product and more particularly relates to a device for extruding a food product. In particular, the present invention relates to an apparatus for forming strands of semi-solid food product which can subsequently be cooked to form "Hash Brown" potatoes. Hash Brown potatoes consist of potato strands, typically of varying length, the strands of potatoes being cooked by a frying technique. It has been proposed previously to make potato products by extruding a potato dough or slurry, the extruded material subsequently being cooked. Some prior proposed devices for extruding potato material do not operate in a continuous manner. US-A-3,937,608 discloses an arrangement in which a container is filled with a potato dough, and an extrusion machine is subsequently used to extrude the dough from the container through extrusion holes in a die plate. When the material has been extruded from the container, the container must be removed from the machine so that a fresh potato mix can be made within the container. GB-A-2,081,641 discloses an apparatus for forming substantially flat discrete elements from a dough, such as tortillas. Each tortilla can be deposited upon a conveyor-belt. The apparatus includes a depositing assembly which has an inlet and a single outlet hole opening. A pressure system coupled to the inlet forces a continuous flow of semi-solid food product through the depositing assembly and out through the outlet hole. A valve mechanism is provided comprising a single rotary element having a profiled exterior that co-operates with the outlet holes opening to perform a valve function. At any instant, part of the profiled exterior of the valve member is in a first state that permits the semi-solid food product to be forced through a cooperating part of the outlet hole, whilst a further part of the profiled exterior of the valve member is in a second state that stops or prevents the flow of semi-solid food product through part of the outlet hole. As the valve member completes a cycle of operation, a semi-solid food product element of circular form is created. The present invention seeks to provide an improved apparatus that can produce strands of a semi-solid food product in a substantially continuous manner. According to this invention there is provided an apparatus for forming elements of semi-solid food product, comprising: a depositing assembly having at least an inlet at a first end and outlet means at a second end; a pressure system coupled to the or each inlet of the depositing assembly for forcing a continuous flow of semi-solid food product through the depositing assembly and out through the outlet means; and a valve mechanism positioned adjacent the outlet means, the valve mechanism including: a movable valve member co-operating with the outlet means, the valve member having a first state that permits the semi-solid food product to be forced through a co-operating part of the outlet means and a second state that stops the flow of semi-solid food product through the said part of the outlet means to create a semi-solid food product element wherein the outlet means comprise a plurality of outlet holes and the valve mechanism includes a rotary valve component and a plurality of said valve members mounted on the rotary component and being movable relative to the rotary component, each valve member being in the form of a wiper, operation of the plurality of valve members being co-ordinated such that at least one of the plurality of valve members is in the first state that permits semi-solid food product through a co-operating outlet hole whenever any one of remaining valve members is in the second state, which stops the flow of semi-solid food product through a respective outlet hole, the semi-solid food product elements being in the form of strands. The preferred embodiment of the invention is an apparatus for producing strands of semi-solid food product which can subsequently be cooked to form "Hash Brown" potatoes. The apparatus thus operates with a potato slurry. The pressure system may include a storage receptacle for containing a supply of semi-solid food product - in this case the potato slurry - and a pump system coupled between the storage receptacle and the inlet of the depositing assembly, the pump system providing pressure to force the semi-solid food product through the plurality of outlets of the depositing assembly. The depositing assembly may include a cone-shaped dispersion member having at its upper end an entry port defined by the inlet of the depositing assembly and at its lower end an oval-shaped exit port, the dispersion member acting to disperse the flow of semi-solid food product to aid in equalising flow pressure at the exit port. An extrusion housing may be coupled to the lower end of the dispersion member, the extrusion housing including a plurality of upper extrusion holes in aligned registry with the exit port of the dispersion member and a plurality of sets of plural lower extrusion holes, the plurality of sets of lower extrusion holes defining the plurality of outlets of the depositing assembly. Each of the upper and lower extrusion holes may have a central axis, and the extrusion housing may further include a cylindrical bore having a longitudinal axis that extends substantially perpendicular to the central axes of the upper and lower extrusion holes, the cylindrical bore coupling the upper extrusion holes to the plurality of sets of plural lower extrusion holes such that the flow of semi-solid product travels from the inlet port of the dispersion member through the exit port, upper extrusion holes, and cylindrical bore and out of the extrusion housing through the plurality of sets of plural lower extrusion holes. The valve mechanism may include a rotary valve component rotatably mounted within the cylindrical bore of the extrusion housing; drive means coupled to rotary valve component for rotating the rotary valve component within the cylindrical bore relative to the upper and lower extrusion holes; and a plurality of wipers mounted on the rotary valve component, the wipers defining the valve members of the valve mechanism. Thus in a preferred embodiment an apparatus in accordance with the invention includes an extrusion housing including a cylindrical bore which contains the rotary valve component, the said at least one inlet communicating with the bore and the plurality of outlet holes communicating with the bore, there being drive means coupled to the rotary valve component for rotating the rotary valve component within the cylindrical bore. It is to be appreciated that since the valve members are co-ordinated such that at least one of the valve members is in the first state, which permits the semi-solid food product to be forced through an outlet hole, whenever any one of the other valve members is in the second state, in which the flow of semi-solid food products through the or each outlet hole which co-operates with that valve member is stopped, there is always at least one outlet hole which is effectively open. Consequently, at no time are all the outlet holes closed. This means that the pressure system may operate in a continuous manner, since there will be a continuous flow of semi-solid food product through the apparatus. It is to be appreciated that in the simplest embodiment of the invention there may be two valve members and two outlets. In such a case, whenever one valve member seals the co-operating outlet hole, the other outlet hole is open and vice-versa. In a more complicated embodiment there may be three valve members and three outlet holes, but in preferred embodiments of the invention each valve member co-operates with a plurality of outlet holes. Thus, in the preferred embodiment, when each valve member is in the second state, the valve member stops the flow of semi-solid food product through a plurality of outlet holes which co-operate with that valve member. In a preferred embodiment of the invention each of the wipers is defined by a root portion which engages the rotary valve component and a head portion connected to the root portion, the wiper being so located that on rotation of the rotary valve component the head portion of each wiper is moved from the first state in which the wiper is remote from the or each of said outlet holes which co-operate with the wiper, to a second stage in which the wiper is immediately adjacent the or each of the outlet holes which co-operate with the wiper, thus closing those outlet holes. It will be appreciated that in the preferred embodiment the head portion of each of the wipers is dimensioned to close off a plurality of outlet holes which are associated with that particular wiper when the valve constituted by the wiper is in its second state. Preferably the plurality of wipers provided on the rotary valve assembly are in a staggered relationship about the rotary valve component so that only about one-third of the said wipers are in the second state at any given time. It is to be understood that a lateral dimension of each of the head portions of the plurality of wipers may determine the length of the strands of semi-solid food product formed by the apparatus. If the lateral dimension of each portion is large the length of each extruded strand may be relatively short, whereas, if the lateral dimension of the head portions is small, the length of the extruded strands will be greater. In a preferred embodiment the rotary valve component includes a plurality of longitudinally extending surface supports having longitudinal channels, each channel removably receiving the root portion of a corresponding wiper. Preferably each wiper is movably mounted on the rotary valve assembly so that, in use of the apparatus, the head of each wiper is moved outwardly to ride against the side walls of the cylindrical bore. In use of the apparatus the hydraulic pressure provided by the semi-solid food product acts on the under-surface of the head of each wiper, thus forcing each wiper radially outwardly against the side walls of the cylindrical bore. Preferably between the surface supports the rotary valve component has longitudinal slots that permit the semi-solid food product to flow through the rotary valve component from the upper extrusion holes to the lower extrusion holes. This flow of semi-solid food product through the rotary valve helps minimise any hydraulic "shocks" which might occur if the flow were suddenly terminated, thus minimising the risk of any damage to the cells of the semi-solid food product. It is thus to be understood that in the preferred embodiment the rotary valve component has slots or passages that permit the semi-food product to flow through the rotary valve component from the said at least one inlet to at least one of the said outlet holes at any instant. The apparatus described above is preferably suitable for use when the semi-solid food product is starch based and in particular when the semi-solid food product is a potato slurry. In such a case the pressure system may operate at a low pressure to minimise damage to starch cells of the potato slurry, the pressure being approximately 3 to 10 atmospheres. The invention also relates to an arrangement for producing strands of semi-solid food product, which arrangement comprises a plurality of apparatus of the type described above, means being provided to drive the rotary valve components of the respective apparatus at respective different speeds to produce strands of semi-solid food product of different lengths. The speed of rotation of the rotary valve component in the extrusion housing does determine the time between successive instants at which a particular outlet is closed. At a substantially constant extrusion pressure, the length of an element extruded through an outlet depends upon the time of uninterrupted extrusion. The invention also relates to a method of making a food product comprising the steps of operating the pressure system of an apparatus as described above or an arrangement as described above to force a semi-solid food product through the depositing assembly and out through the outlet holes, and operating a valve mechanism so that each outlet hole is, from time-to-time, closed to stop the flow of semi-solid food, at least one outlet hole being open whenever any outlet hole is closed. In this way, there is always one outlet hole which is open, so that the pressure system may operate in a substantially continuous manner. Preferably the semi-solid food product is a potato slurry and the pressure system operates at a low pressure of less than 10 atmospheres. Conveniently the method may include the step of conveying the strands of semi-solid food product to a drier, drying the strands and subsequently cooking the strands to form "Hash Browns". The preferred embodiment of the invention is an apparatus for producing Hash Brown potato strands having varying lengths, from a potato slurry. The preferred apparatus incorporates a plurality of depositing assemblies each having an inlet and a plurality of outlet holes. A storage receptacle containing a supply of potato slurry is coupled to the inlets of the depositing assemblies via a pump member. The pump member provides pressure to force the potato slurry through the plurality of outlet holes of the depositing assemblies. A valve element associated with the pump member is configured such that any one or more of the plurality of depositing assemblies can be coupled to the pump member depending upon the desired quantity of dehydrated hash brown potato strands to be produced. The preferred depositing apparatus further includes a plurality of valve mechanisms. A single valve mechanism is positioned adjacent the outlets of each of the depositing assemblies. Each valve mechanism includes a plurality of moveable valve members that correspond to the plurality of outlet holes of the depositing assembly. Each valve member has a first state that permits the potato slurry to be forced through the corresponding outlet and a second state that stops the flow of potato slurry through the corresponding outlet to thereby create a hash brown potato strand. Operation of the valve members is coordinated such that at least one of the plurality of valve members is in the first state when at least one of the remaining valve members is in the second state. A conveyor mechanism is preferably positioned beneath the plurality of outlet holes of the depositing assemblies. The conveyor mechanism moves past the depositing assemblies such that formed hash brown potato strands are removed from the outlet holes by the conveyor mechanism. The hash brown potato strands are carried by the conveyor mechanism to a drier positioned distally of the outlets of the depositing assemblies. The drier dehydrates the formed hash brown potato strands as the conveyor mechanism moves through the drier. The speed at which each rotary valve component rotates relative to the outlet holes of the corresponding depositing assembly determines the length of the hash brown potato strands produced by that depositing assembly. Hence, each rotary valve component can be operated at a different rotational rate of speed so that the depositing apparatus produces hash brown potato strands of varying lengths. In addition, or as an alternative thereto, the length of the potato strands produced by the depositing apparatus can be controlled by using different sizes of wiper blades. Hence, each rotary valve component could be equipped with wiper blades of different sizes such that the size of the wiper blades varies from one rotary valve component to the next. In addition, or as an alternative thereto, the sizes of the wiper blades can be varied within a single rotary valve component to produce potato strands of varying lengths. Different speeds of the rotary valve components and different sizes of wiper blades alter the amount of potato slurry extruded through the outlet holes of the depositing assemblies and thereby the length of the hash brown potato strands. This depositing apparatus is relatively uncomplicated and can produce hash brown potato strands in a continuous banner through the use of valve mechanisms which only prevent the extrusion of potato slurry through one third of the depositing assemblies outlets at any given time. This results in minimal mechanical or hydraulic damage to the starch cells of the hash brown potato strands. In addition, the depositing apparatus is capable of producing hash brown potato strands of varying lengths to create a more natural looking and appealing food product. In order that the invention may be more readily understood and so that further features thereof may be appreciated, the invention will now described by way of example with reference to the accompanying drawings in which FIG. 1 is a perspective view of a hash brown depositing apparatus in accordance with the present invention, FIG. 2 is a side elevational view of a depositing assembly that forms part of an extrusion system of the depositing apparatus shown in FIG. 1. FIG. 3 is a sectional view of the depositing assembly taken along line 3-3 in FIG. 2, FIG. 4 is a top plan view of an extrusion housing that forms part of the depositing assembly shown in FIG. 2, FIG. 5 is an enlarged sectional view partially broken away of a portion of the depositing assembly of FIG. 2, FIG. 6 is an enlarged sectional view partially broken away of the extrusion housing of the depositing assembly taken along line 6-6 of FIG. 2, FIG. 7 is an elevational view of a valve mechanism that forms part of the depositing apparatus shown in FIG. 1, FIG. 8 is a generated view of the valve mechanism shown in FIG. 7, FIG. 9 is a sectional view partially broken away of the extrusion system, taken along line 9-9 in FIG. 1, in the process of forming hash brown potato strands, FIG. 10 is a sectional view partially broken away similar to FIG. 9 showing the hash brown potato strands being removed from the extrusion system by a conveyor mechanism, FIG. 11 is an end elevational view of a wiper blade that forms part of the valve mechanism, FIG. 12 is a side elevational view of the wiper blade shown in FIG. 11, FIG. 13 is an end elevational view of a further wiper blade, and FIG. 14 is an end elevational view of a still further wiper blade, An apparatus 10 for depositing semi-solid, starch based food products, such as strands of hash brown potatoes in accordance with the present invention, is illustrated generally in FIG. 1. The depositing apparatus 10 includes a reservoir 12 that contains a supply of potato slurry 14. The potato slurry 14 is formed by combining dehydrated potato granules and selected flavour and texture enhancing additives with water. This mixture is then heated to hydrate the potato granules until the desired consistency of the potato slurry 14 is achieved. A pump assembly 16 is coupled to the reservoir 12 through a supply line assembly 18. The pump assembly 16 is defined by a plurality of pump members 17. The pump members 17 take potato slurry 14 from the reservoir 12 and deliver the potato slurry 14 in a continuous flow to an extrusion system 20 defined by a plurality of extrusion devices 22 (three pump members 17 and three extrusion devices 22 being shown in FIG. 1). Each extrusion device 22 includes a depositing assembly 24, a valve mechanism 26 and a flow conduit 28. The flow conduit 28 of each extrusion device 22 is coupled to a respective pump member 17 of the pump assembly 16. The pump members 17 of the pump assembly 16 are coupled to the reservoir 12 via a valve element 30 located within the supply line assembly 18 upstream of the pump members 17. The valve element 30 can be set to couple the reservoir 12 (and thereby the flow of potato slurry 14) to any one or more of the pump members 17 associated with the extrusion devices 22, depending upon the desired quantity of hash brown potato strands 34 to be produced by the depositing apparatus 10. Each of the pump members 17 operates at a very low pressure, on the order of three to ten atmospheres. This low pressure prevents damage to the starch cells of the potato slurry 14. As seen in FIG. 1, hash brown potato strands 34 exiting the depositing assemblies 24 of the extrusion devices 22 are removed from and carried away from the extrusion system 20 via a conveyor mechanism 36 moving in the direction of arrow 38. The conveyor mechanism 36 is made out of a coarse, stainless steel wire weave that permits air to penetrate the conveyor mechanism 36 to facilitate drying of the hash brown potato strands 34. A drier 40 is positioned distally of the extrusion system 20. The drier 40 dehydrates the hash brown potato strands 34 as the conveyor mechanism 36 moves through the drier 40. The hash brown potato strands 34 are approximately 80% by weight moisture when they enter the drier 40. The drier 40 dries the hash brown potato strands 34 down to approximately 4% - 8% by weight moisture. Once the potato strands 34 have been dehydrated, they are packaged and then sent out to buyers. The extrusion devices 22 are substantially identical, hence, only one extrusion device 22 will be described with particularity. As seen in FIGS. 2 and 3, the depositing assembly 24 of the extrusion device 22 includes a cone shaped dispersion member 42 defined by a pair of substantially planar, triangular side walls 44 and curved end walls 46. The dispersion member 42 has at its upper end an entry port 48 in fluid flow communication with a distal end 50 of the flow conduit 28. The dispersion member 42 tapers outwardly and downwardly from the entry port 48 to an oval shaped exit port 52. A mounting plate 54 having a plurality of mounting apertures 56 is secured to bottom edge 58 of the dispersion member 42. The cone shape of the dispersion member 42 (see FIG. 2) acts to disperse the flow of potato slurry 14 to aid in equalizing slurry flow pressure at the exit port 52. As seen best in FIG. 3, a plurality of tie rods 60 extend between the side walls 44 to strengthen and rigidify the dispersion member 42. The depositing assembly 24 of the extrusion device 22 further includes an extrusion housing 62. The extrusion housing 62 is coupled to a lower surface of the mounting plate 54 of the dispersion member 42 by way of a plurality of T-bolts 64. As seen best in FIG. 3, the T-bolts 64 extend through the mounting apertures 56 of the mounting plate 54 to threadably engage threaded apertures 66 of the extrusion housing 62. As seen in FIG. 4, a top surface 68 of the extrusion housing 62 includes an oval shaped channel 70. The channel 70 is adapted to receive a rubber gasket 72 (see FIGS. 3 and 5) that forms a fluid tight seal between the top surface 68 of the extrusion housing 62 and the mounting plate 54 of the dispersion member 42. The top surface 68 of the extrusion housing 62 further includes an oval slot 74 which is dimensioned to match the oval shaped exit port 52 of the dispersion member 42. Beneath the oval slot 74 are a plurality of upper extrusion holes 76 arranged linearly along the oval slot 74. As seen best in FIGS. 3 and 5, the extrusion housing 62 further includes a cylindrical bore 78 that extends parallel to the longitudinal extent of the extrusion housing 62. The cylindrical bore 78 is in fluid flow communication with the upper extrusion holes 76. Beneath the cylindrical bore 78 are a plurality of lower extrusion holes 80 aligned end-to-end as with the upper extrusion holes 76. The lower extrusion holes 80 are in fluid flow communication with the cylindrical bore 78. Central axes of the upper and lower extrusion holes 82 and 84, respectively, are substantially parallel to one another and substantially perpendicular to a longitudinal axis 86 of the cylindrical bore 78. As seen in FIG. 6, each of the lower extrusion holes 80 has an oval shape, and it is this shape that determines the cross sectional shape of the hash brown potato strands 34. The number and size of the lower extrusion holes 80 depends upon the length of the extrusion housing 62 and the desired shape of the deposited hash brown potato strands 34. Each of the upper extrusion holes 76 is circular in shape. In addition, there are fewer upper extrusion holes 76 than lower extrusion holes 80 since the upper extrusion holes 76 are much larger than the lower extrusion holes 80. The large size of the upper extrusion holes 76 helps to evenly distribute the potato slurry 14 to the cylindrical bore 78. As seen in FIGS. 2 and 5, bearing supports 88 are mounted to the ends of the extrusion housing 62. Each bearing support 88 includes first and second bearing holders 90 and 92, respectively, that are adapted to carry an annular bearing member 94. Each bearing support 88 is secured to the extrusion housing 62 by way of T-bolts 96. The T-bolts 96 extend through the mounting apertures 98 of the bearing support 88 to threadably engage threaded apertures 100 of the extrusion housing 62. The annular bearing members 94 of the bearing supports 88 are adapted to rotatably support a drum shaped, rotary valve component 102 of the valve mechanism 26 within the cylindrical bore 78 of the extrusion housing 62. As seen in FIGS. 7 and 8, the rotary valve component 102 includes a cylindrical centre portion 104 and opposite cylindrical end portions or trunnions 106 and 108, respectively, that engage the bearing members 94. With the rotary valve component 102 supported by the bearing members 94, the bearing members 94 together with the bearing supports 88 and a seal located inward of the bearing members 94 prevent pressurized potato slurry 14 from leaking through the ends of the extrusion housing 62. The end portion 108 of the rotary valve component 102 includes a drive coupler 110. As seen in FIG.1, the drive coupler 110 is engaged by a drive shaft 112 of an electric drive motor 114. Actuation of the drive motor 114 rotates the rotary valve component 102 within the cylindrical bore 78. The centre portion 104 of the rotary valve component 102 is defined by a plurality of evenly spaced, longitudinally extending surface supports 116, and a centre attachment 118. The centre attachment 118 extends along the longitudinal axis 120 of the rotary valve component 102 between the end portions 106 and 108. As seen in FIGS. 9 and 10, the centre attachment 118 appears hexagonal in cross section whereas the surface supports 116 appear triangular in cross section. The centre attachment 118 adds structural rigidity to the rotary valve component 102. As seen best in FIG. 7, between the surface supports 116 the rotary valve component 102 has longitudinal slots 122. Directly beneath each longitudinal slot 122 are a plurality of circular through openings 124 arranged linearly along the longitudinal slot 122. The through openings 124 are of the same dimension as, and are aligned with, the upper extrusion holes 76 of the extrusion housing 62. The area between the lower edges of the surface supports 116 and the centre attachment 118 defines a void 126. Each surface support 116 includes plural longitudinal channels 128. Each longitudinal channel 128 is adapted to removably and movably support a valve member, such as a preferably T-shaped wiper blade 130 (see FIGS. 9 and 10). As seen in FIGS. 11 and 12, each T-shaped wiper blade 130 is defined by a root portion 132 and a head portion 134 having a lateral dimension 135. The root portion 132 is adapted to be removably received within the longitudinal channel 128 for limited radial movement relative to the rotary valve component 102. The head portion 134 of each wiper blade 130 has a curved top surface 136 that is adapted to ride along a side wall 138 of the cylindrical bore 78. As seen best in FIG 8, the longitudinal channels 128 from one surface support 116 to the next surface support are arranged in a staggered, stepwise manner. Therefore, the wiper blades 130 are arranged in a staggered stepwise fashion about the rotary valve component 102. A further alternative wiper blade 130a is illustrated in FIG. 13. The lateral dimension 135a of the wiper blade 130a is less than the lateral dimension 135 of the wiper blade 130. Another alternative wiper blade 130b is illustrated in FIG. 14. The lateral dimension 135b of the wiper blade 130b is greater than the lateral dimension 135 of the wiper blade 130. The speed at which each rotary valve component 102 rotates relative to the lower extrusion holes 80 of the corresponding depositing assembly 24 determines the length of the hash brown potato strands 34 produced by that depositing assembly 24. Hence, each rotary valve component 102 can be operated at a different rotational rate of speed so that the depositing apparatus 10 produces hash brown potato strands 34 of varying lengths. In addition, or as an alternative thereto, the length of the potato strands 34 produced by the depositing apparatus 10 can be controlled by using different sizes (i.e., lateral dimension) of wiper blades 130, 130a and 130b. For example, a larger head portion 134b lateral dimension 135b produces a smaller length potato strand 34, while a smaller head portion 134a lateral dimension 135a produces a potato strand 34 of longer length. Hence, each rotary valve component 102 could be equipped with wiper blades 130, 130a and 130b of different sizes such that the size of the wiper blades 130, 130a and 130b used varies from one rotary valve component 102 to the next rotary valve component 102. In addition, or as an alternative thereto, the sizes of the wiper blades 130, 130a and 130b used can be varied within a single rotary valve component 102 to produce potato strands 34 of varying lengths. Different speeds of the rotary valve components 102 and different sizes of wiper blades 130, 130a and 130b alter the amount of potato slurry 14 extruded through the lower extrusion holes 80 of the depositing assemblies 24 and thereby the length of the hash brown potato strands 34. In addition, the viscosity of the potato slurry 14 and the pump pressure of the pump members 17 can affect the length of the potato strands 34 to a minimal degree. Hash brown potato strands 34 of a single length can be produced by the depositing apparatus 10 by operation of all of the rotary valve components 102 at the same rotational rate of speed and the provision of wiper blades of the same size. Rotation of a rotary valve component 102 moves its respective wiper blades 130, 130a and 130b between a first state that permits the potato slurry 14 to be forced through corresponding lower extrusion holes 80 and a second state that stops the flow of potato slurry 14 through the corresponding lower extrusion holes 80 to create hash brown potato strands 34. Operation of the wiper blades 130, 130a and 130b is coordinated such that at least one of the plurality of wiper blades 130, 130a and 130b is in the first state when at least one of remaining wiper blades 130, 130a and 130b is in the second state. Extrusion pressure at the extrusion holes 80 is approximately on the order of one to three atmospheres. As is apparent from FIGS: 7 and 12, the wiper blades 130, 130a and 130b are long enough to eclipse a set (i.e., plural) lower extrusion holes 80 when that wiper blade 130, 130a and 130b is in its second state. Each of the extrusion devices 22 can be individually adjusted (as shown by the double headed arrows 140 in FIG. 1) relative to the conveyor mechanism 36 such that the distance between the extrusion devices 22 and the conveyor mechanisms can be varied to accommodate different strand lengths of potato strands 34. The dispersion members 42, extrusion housings 62 and the rotary valve components 102 are made of stainless steel. The wiper blades are made of plastic, such as DELRIN (a registered trademark of the Du Pont Co.). In operation, the pump members 17 pump potato slurry 14 from the reservoir 12 and through the valve element 30 to the extrusion system 20. As seen in Fig. 1 the valve element 30 is set such that all three pump members 17 and extrusion devices 22 are receiving potato slurry from the reservoir 12. The potato slurry 14 enters each extrusion device 22 through the entry port 48 of the dispersion member 42. The potato slurry 14 travels down the dispersion member 42 and out of the dispersion device 42 through the exit port 52 and into the extrusion housing through oval slot 74. The potato slurry 14 then passes through the upper extrusion holes 76 and into the cylindrical bore 78. The potato slurry 14 fills the entire area around and within the rotary valve component 102. The potato slurry 14 enters the rotary valve component 102 and flows into the void 126 of the rotary valve component 102 through the longitudinal slots 122 and the through openings 124 of the rotary valve component 102. Once the area within the cylindrical bore 78 is completely filled, pressure from the pump member 17 forces the potato slurry 14 out of the extrusion housing 62 through the lower extrusion holes 80. While the potato slurry 14 is being pumped through the extrusion device 22, the rotary valve component 102 is rotated within the cylindrical bore 78 via the drive motor 114. FIG. 9 shows a corresponding wiper blade 130, 130a or 130b in its first state which allows the potato slurry 14 to be extruded through the lower extrusion holes 80 to produce hash brown potato strands 34. As the hash brown potato strands 34 are deposited on the conveyor mechanism 36, movement of the conveyor pulls the hash brown potato strands 34 away from the lower extrusion holes 80. As seen in FIG. 10, as the corresponding wiper blade 130, 130a or 130b covers a respective set of plural lower extrusion holes 80, the extrusion of potato strands 34 through that set of plural lower extrusion holes 80 is cut off, and then the conveyor mechanism 36 acts to pull the potato strands 34 out of the lower extrusion holes 80. The conveyor mechanism 36 then carries the extruded hash brown potato strands 34 away from the extrusion devices 22 and to the drier 40, where the hash brown potato strands 34 are dehydrated. In one embodiment the rotary valve component 102 rotates in the direction of arrow 127 (see FIGS. 9 and 10) with movement of the conveyor mechanism 36 in the preferred direction of arrow 38. Alternatively, movement of the conveyor mechanism 36 relative to the extrusion devices 22 in a direction opposite to that indicated by the arrow 38 is possible. As the rotary valve components 102 rotate, the potato slurry 14 tends to push the head portions 134, 134a and 134b of the wiper blades 130, 130a and 130b against the sidewall 138 of the cylindrical bore 78. As the wiper blades 130, 130a and 130b become worn, the pressure of the potato slurry 14 tends to draw the wiper blades 130, 130a and 130b out of the longitudinal channels 128 such that the head portions 134, 134a and 134b of the wiper blades 130, 130a and 130b continuously ride against the sidewalls 138 of the cylindrical bores 78. Eventually, the wiper blades 130, 130a and 130b wear out and need to be replaced. The wiper blades 130, 130a and 130b are easily replaced by simply removing the worn wiper blades 130, 130a and 130b from the longitudinal channels 128 of the rotary valve components 102 and inserting new ones. In addition, radial movement of the wiper blades 130, 130a and 130b relative to the longitudinal channels 128 can occur so that the wiper blades 130, 130a and 130b can conform to the sidewalls 138 of the cylindrical bores 78, if the rotary valve components 102 are not sufficiently centred within the cylindrical bores 78. The depositing apparatus 10 is relatively uncomplicated and can produce hash brown potato strands 34 in a continuous manner through the use of valve mechanisms 26 which only prevent the extrusion of potato slurry 14 through one third of the lower extrusion holes 80 of the depositing assemblies 24 at any given time. This allows the pump members 17 to operate at a constant pump pressure (i.e., without pump pressure fluctuations that may occur if extrusion through all the extrusion holes is prevented at one time), which results in minimal mechanical or hydraulic damage to the starch cells of the hash brown potato strands 34. In addition, the depositing apparatus 10 is capable of producing hash brown potato strands 34 of varying lengths to create a more natural looking and appealing food product.

Claims: An apparatus (10) for forming elements of semi-solid food product, comprising: a depositing assembly(24) having at least an inlet(76) at a first end and outlet means at a second end; a pressure system(12,16,18) coupled to the or each inlet of the depositing assembly for forcing a continuous flow of semi-solid food product through the depositing assembly(24) and out through the outlet means; and a valve mechanism(26) positioned adjacent the outlet means, the valve mechanism including: a movable valve member(130) co-operating with the outlet means, the valve member having a first state that permits the semi-solid food product to be forced through a co-operating part of the outlet means and a second state that stops the flow of semi-solid food product through the said part of the outlet means to create a semi-solid food product element characterised in that the outlet means comprise a plurality of outlet holes(80) and the valve mechanism includes a rotary valve component(102) and a plurality of said valve members(130) mounted on the rotary component and being movable relative to the rotary component(102), each valve member being in the form of a wiper(130), operation of the plurality of valve members being co-ordinated such that at least one of the plurality of valve members is in the first state that permits semi-solid food product through a co-operating outlet hole(80) whenever any one of remaining valve members(130) is in the second state, which stops the flow of semi-solid food product through a respective outlet hole(80), the semi-solid food product elements being in the form of strands(34). An apparatus according to Claim 1 wherein the depositing assembly (24) includes an extrusion housing (62) including a cylindrical bore(78) which contains the rotary valve component(102), the said at least one inlet(76) communicating with the bore and the plurality of outlet holes(80) communicating with the bore, there being drive means(114) coupled to the rotary valve component(102) for rotating the rotary valve component within the cylindrical bore. An apparatus according to claim 1 or 2 wherein each of the wipers is defined by a root portion(132) which engages the rotary valve component (102) and a head portion(134) connected to the root portion, the wiper being so located that on rotation of the rotary valve component(102) the head portion(134) of each wiper(130) is moved from the first state in which the wiper is remote from the or each of said outlet holes(80) which co-operate with the wiper, to a second state in which the wiper is immediately adjacent the or each of the outlet holes(80) which co-operate with the wiper, thus closing those outlet holes. An apparatus according to any one of the preceding Claims wherein the plurality of wipers (130) provided on the rotary valve assembly(102) are in a staggered relationship about the rotary valve component(102) so that only about one-third of the said wipers(130) are in the second state at any given time. An apparatus according to Claim 2 or any Claim dependent thereon wherein each wiper(130) is movably mounted on the rotary valve assembly so that, in use of the apparatus, the head(134) of each wiper is moved outwardly to ride against the side walls (138) of the cylindrical bore(78). An apparatus according to any one of the preceding Claims wherein the rotary valve component (102) has slots or passages that permit the semi-solid food product to flow through the rotary valve component(102) from the said at least one inlet(76) to at least one of the said outlet holes(80) at any instant. An arrangement for producing strands of semi-solid food product, said arrangement comprising a plurality of apparatus according to any one of the preceding Claims, means being provided(114) to drive the rotary valve components(102) of the respective apparatus at respective different speeds to produce strands of semi-solid food product of different lengths. A method of making a food product comprising the steps of operating the pressure system of an apparatus(10) according to any one of Claims 1 to 6 or an arrangement according to Claim 7 to force a semi-solid food product through the depositing assembly(24) and out through the outlet holes(80), and operating the valve mechanism(26) so that each outlet is from time-to-time closed to stop the flow of semi-solid food, at least one outlet hole(80) being open whenever any outlet hole is closed. A method according to Claim 8 wherein the semi-solid food product is a potato slurry and wherein the pressure system operates at a low pressure of less than 10 atmospheres. A method according to any one of Claims 7 to 9 including the steps of conveying the strands of semi-solid food product to a drier, drying the strands, the strands being such that they can subsequently be cooked to form "Hash Browns".

Inventors: DEMARS JIMMY A, PEPLINSKI STEVEN W, USGAARD DENNIS, DEMARS, JIMMY A., PEPLINSKI, STEVEN W., USGAARD, DENNIS
Applicants: PILLSBURY CO, THE PILLSBURY COMPANY
Application year: 1993
Main classification: A21C3
IPC codes: A21C15, A21C3