Abstract:
In accordance with the invention, a device and method for steaming and toasting food items is provided. The device is particularly suited for steaming and toasting hamburger sandwich bun heels and crowns. The device in accordance with the invention may include a steam outlet for steaming food items by impinging steam onto the food item. A conveyor moves the food item along a toasting pathway in which the food item is toasted by a heated platen extending along at least a portion of the toasting pathway.

Description:
FIELD OF THE INVENTION 
     The present invention relates to cooking devices and methods. More particularly, the present invention relates to a toasting device that also injects steam into the food item. 
     BACKGROUND OF THE INVENTION 
     Conveyorized toasting devices can be used in high-volume cooking applications for in-line toasting of food items. Typically, a toasting device is composed of a chamber having an inlet for receiving a food item, a heated platen, a conveyor for conveying the food item along a toasting pathway adjacent the heated platen, and an outlet for discharging the toasted food item. When the food items toasted are hamburger buns, the toasting device commonly has an inlet on each side of the heated platen for separately receiving a bun crown and bun heel (collectively, “bun”). The inside, cut faces of the bun crown and heel may be simultaneously toasted along conveyorized toasting pathways on opposite sides of the platen. 
     Toasting buns with current conveyorized toasting devices has been known to deform the shape of the buns, causing “cupping” of the toasted cut surfaces of the bun crown and heel. Moreover, current devices have a limited capacity to quickly toast a bun and produce quality results. For example, raising the platen temperature reduces the time required for a bun to reach a desired temperature, but the platen temperature must not be high enough to burn the surface of the bun. A need therefore exists for a high-volume toasting device that provides fast, quality toasting of a cut bread surface and which reduces or eliminates cupping. 
     BRIEF SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention, a device for steaming and then toasting food items is provided. The device includes a food inlet for receiving food items and a food outlet for discharging food items after steaming and toasting. A steam outlet is located between the food inlet and the food outlet, for steaming food items by impinging steam onto a food item, with a space being located adjacent the steam outlet for allowing a food item to be positioned adjacent the steam outlet. A heated platen is provided for toasting food items along a toasting pathway. A conveyor is located at least between the steam outlet and the food outlet, the conveyor for conveying along the toasting pathway and for permitting toasting while conveying a food item after steaming. The device in accordance with the invention may be configured particularly for the steaming and toasting of buns, such as hamburger sandwich buns. 
     In accordance with another embodiment, the device for steaming and toasting food items may further include a food item steaming pathway that is located upstream of the toasting pathway. The toasting pathway may have an entrance and the steaming pathway can terminate adjacent the entrance to the toasting pathway. In one embodiment, the steam outlet may be a narrow slit having a width perpendicular to the steaming pathway and the width may be approximately equal to the maximum width of the food item to be steamed and a substantially uniform height parallel to the steaming pathway. 
     In accordance with another embodiment of the invention, the steam outlet may have an opening that is approximately the same area and shape as a face of the food item to be steamed. The device in accordance with the invention may further include a food item retention assembly generally adjacent the steam opening. The food item retention assembly may include a support member that is at least generally parallel to the steam outlet, a food item release hatch hingedly attached to the support member remote from the food inlet, the support member and the release hatch being adapted to retain a desired portion, typically a face, of the food item in substantial alignment with the steam outlet when the release hatch is in a closed position at least generally perpendicular to the support member. A release hatch trip mechanism is provided that is tripped when a food item is inserted into the food item retention assembly, causing the release hatch to swing or otherwise move into an open position aligned with the support member that is at least generally aligned with the support member after the predetermined steaming time has elapsed. In this manner, the food item is allowed to drop down and out of the food item retention assembly and into engagement with the conveyor. In one embodiment, the release hatch automatically swings or otherwise moves back into the closed position once the food item is clear of the release hatch and typically also clear of the bottom of the food item retention assembly. 
     In accordance with another aspect of the present invention, an automatic food item feeder is part of the steaming and toasting device of the present invention. The feeder typically will have a housing and a feeder coil located within the housing. The feeder coil is mounted for rotatable movement and is adapted to hold a plurality of food items and feed the food items into the food inlet one food item at a time when rotated. Typically, the steam outlet, the heated platen, the conveyor and the axis of rotation of the feeder coil are oriented generally horizontally. The steaming and toasting device in accordance with the present invention may further include an inlet chute located between the discharge of the feeder coil and the food inlet. Typically, the inlet chute will have a top and a bottom with the top of the inlet chute adjacent the outlet of the feeder coil and the bottom of the inlet chute will be located adjacent the food inlet. The inlet chute is adapted to receive a vertically oriented food item, such as a hamburger bun crown or heel, for example, from the feeder coil to direct the food item into the food inlet oriented in at least a generally horizontal position. 
     In accordance with another aspect of the invention, a method of steaming and toasting a food item is provided. The method in accordance with the invention includes providing a steaming and toasting device as previously described herein. Thereafter, a food item is introduced into the device and placed into a position for steaming which may include introducing a food item into the steam injection device or alternatively introducing a food item so that it is adjacent the steam outlet. Thereafter, steam is injected into or impinged upon the food item by steam exiting the steam outlet to steam the food item. The steamed food item is then discharged from the steam injection device or otherwise transported from a position adjacent the steam outlet and introduced into the toasting portion of the steam and toasting device of the invention. The steamed food item is then toasted as it is conveyed along the toasting pathway and thereafter the steamed and toasted food item is discharged from the toasting device. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a side elevation sectional view of a vertical steaming and toasting device in accordance with the present invention; 
         FIG. 2  is a side elevation sectional view of a vertical steaming and toasting device with automatic bun heel and crown feeders; 
         FIG. 3  is a perspective view of a steamer device forming part of the steaming and toasting device of  FIG. 1 ; 
         FIG. 4  is a side elevation sectional view of an alternate embodiment vertical steaming and toasting device in accordance with the present invention, with one wall of the housing cut away to reveal the inside of the device; 
         FIG. 5  is a perspective view of a steamer device forming part of the steaming and toasting device of  FIG. 4 ; 
         FIG. 6  is a perspective view of a horizontal steaming and toasting device in accordance with another embodiment of the present invention; 
         FIG. 7  is a side elevation sectional view of the horizontal steaming and toasting device of  FIG. 6 ; 
         FIG. 8  is a side elevation sectional view of a horizontal steaming and toasting device similar to the view and device illustrated in  FIG. 6 , but with an automatic bun feeder in accordance with the invention; and 
         FIG. 9  is a perspective view of a horizontal steamer device forming part of the horizontal steaming and toasting devices of  FIGS. 6-8 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Improved steam toaster devices for faster and better quality toasting are disclosed in accordance with the invention. In particular, a vertical steaming and toasting device  10  with in-motion steaming is illustrated in  FIGS. 1-3 , a vertical steaming and toasting device  40  with stationary steaming is illustrated in  FIGS. 4 and 5 , and a horizontal steaming and toasting device  54  with in-motion steaming is illustrated in  FIGS. 6-9 , all in accordance with the various embodiments of the present invention. In accordance with the invention, devices  10 ,  40  and  54  are each capable of steaming the buns just prior to commencement of bun toasting. Steaming of the buns just prior to toasting provides a number of significant advantages. The significant advantages include: a refreshing of the bun surface (this is important for buns that are not utilized immediately upon receipt from the bakery), providing a more moist and tender bun after toasting (the amount of moisture prior to steaming and toasting can be essentially the same as the amount of moisture after toasting in accordance with the invention), steaming causes a preheating of the bun surface just prior to toasting thereby reducing the toasting time and reduces or prevents “cupping” of the bun as a result of toasting. As buns age, they lose moisture prior to toasting and thus lose weight prior to toasting. Steaming the buns just prior to toasting results in a weight gain which it is believed is dependent on the age or moisture loss of the buns prior to steaming. Consequently, it is believed that typically, the older the bun the higher the weight gain as a result of steaming. Typically, toasting a standard hamburger bun without steaming reduces the bun weight from about 1.3 to 1.6 percent. The combination of steaming and toasting in accordance with the invention typically results in a bun weight increase of from about 0.5 to about 1.5 percent, resulting in a net difference in bun weight of from about 1.8 to about 3.1 percent. Also, the steam toasted buns have a higher temperature immediately after toasting to the desired degree. Typical temperature differences are from about 10° F. to about 20° F. warmer for steam toasted buns compared to regular toasted buns (no steaming). In addition, a toasting time of about 13 seconds can be achieved compared to a current best toasting time of about 17 seconds for conveyor toasters that do not presteam buns. 
     Referring to  FIG. 1 , vertical steaming and toasting device  10  for in-motion steaming and toasting of hamburger buns is shown, encased in a housing  11  with one wall cut away to reveal the inside of the device. Vertical steaming and toasting device  10  has an in-motion vertical steamer  12 , steamer  12  composed of a steam inlet  14 , a condensate outlet  16 , and steam outlets  17 ; and a central heated platen  18 . Steamer  12  may have a single pair of opposed steam outlets  17 , as shown in the Figures, or more than one pair. A heel conveyor  19  and a crown conveyor  20  are adapted to convey hamburger bun heels BH and crowns BC in a heel feed direction HFD and a crown feed direction CFD, respectively, past steamer  12  and then platen  18 , for steaming and then toasting of their cut faces. Conveyors  19  and  20  are composed of rollers  21 ,  21 ′,  21   a  and  21   a ′, belts  22  and  22 ′, and tensioner assemblies  23  and  23 ′. Rollers  21  and  21   a  are driven or otherwise rotate in the food rotation direction indicated by arrows FR in  FIGS. 1 ,  2  and  4 . Tensioner assemblies  23  and  23 ′ may be adjustable to provide a desired tension on belts  22  and  22 ′, respectively, and a desired compression of bun halves BH and BC against central platen  18 , to achieve intimate heat transfer contact. A non-stick cooking sheet  26  may be draped over both sides of central platen  18  as shown, to provide a low-friction interface between the bun halves and central platen  18 . Bun halves to be steamed and toasted may be inserted into vertical steaming and toasting device  10  through a food inlet  28 , and steamed and toasted bun halves may be discharged through a food outlet  30  into a discharge chute  32 . 
     In  FIG. 2 , an alternative embodiment of vertical steaming and toasting device  10  is shown, incorporating automatic bun heel and crown feeders  34  and  35 , respectively. Feeders  34  and  35  are each composed of a feeder coil  36  encased in a housing  38 . Feeder coils  36  may be loaded with a plurality of bun heels BH and bun crowns BC, such that one bun heel and one bun crown are dispensed with each full rotation of the feeder coils as illustrated, causing the bun halves to enter food inlet  28  in a crown infeed direction CID and a heel infeed direction HID, respectively, and to engage conveyors  19  and  20 , where they are steamed and toasted as described with reference to  FIG. 1 . Feeders  34  and  35  improve the efficiency of vertical steaming and toasting device  10  by allowing a human operator to tend to other tasks while a plurality of bun halves are automatically fed into vertical steaming and toasting device  10 . Advantageously for a high-volume food service application, the human operator may load feeders  34  and  35  with a plurality of bun halves during a “down” time, thus eliminating the need to manually feed bun halves into vertical steaming and toasting device  10  one at a time during periods of busier operation when other tasks may be pressing. 
     Referring to  FIG. 3 , in-motion vertical steamer  12  is shown in perspective view. In some embodiments of the present invention, such as those illustrated in  FIGS. 1 and 2 , steam is directed through steam outlets  17  into the cut faces of the bun halves while the bun halves are in motion. Thus, the preferred shape of steam outlets  17  is a horizontal slit of uniform height, as shown in  FIG. 3 , to assure even distribution of steam across the width of the cut faces. Steam outlets  17  are preferably covered by a steam-permeable, heat resistant grid material  39  such as a silicone polyester screen or the like. 
       FIG. 4  is an illustration of vertical steaming and toasting device  40  with stationary steaming. Vertical steaming and toasting device  40  is similar to vertical steaming and toasting device  10 , with two important differences. First, vertical steaming and toasting device  40  has a stationary vertical steamer  42  with round steam outlets  44 , as shown in  FIG. 5 , a perspective view of steamer  42 . Steam outlets  44  are substantially the same size as the cut face of a bun half, so that they may evenly steam a stationary bun half. Second, vertical steaming and toasting device  40  additionally has a bun retention assembly  46 , adapted to retain the cut face of a bun half in alignment with steam outlets  44 . Bun retention assembly  46  is composed of vertical bun support members  48 , trip mechanisms  50 , and bun release hatches  52 . When a bun heel and crown are inserted into food inlet  28 , the bun halves trip trip mechanisms  50 , signaling steam outlets  44  to open and inject steam into the cut faces F. After a predetermined period of time, bun release hatches  52  automatically open, dropping the bun halves into engagement with heel conveyor  19  and crown conveyor  20 , respectively. The bun halves are next conveyed past hatches  52 , which hatches  52  then automatically close, allowing the next bun to be inserted. 
     Turning to  FIG. 6 , horizontal steaming and toasting device  54  enclosed in a housing  56  is shown in perspective view. In the embodiment illustrated in  FIG. 6 , a human operator may feed a bun crown BC and bun heel BH into horizontal steaming and toasting device  54  by placing bun halves BC and BH on a bun loading shelf  62  and sliding the bun halves forward in the feed directions indicated by arrows CFD and HFD, respectively, until the bun halves are engaged by a crown conveyor  58  and a heel conveyor  60 . As illustrated schematically in  FIG. 7 , conveyor  58  is advanced by a roller feed rotation indicated by arrows FR to convey bun crowns BC over a horizontal steamer  64 , where steam passes through a steam outlet  66  into their cut faces, and then over a horizontal heated platen  68  covered by a release sheet  26 , where the cut faces of the bun crowns are toasted. Bun heels are conveyed by conveyor  60  in a similar manner, although conveyor  60  is hidden from view in  FIGS. 7 and 8 . Upon reaching the end of platen  68 , the bun halves are conveyed out of horizontal steaming and toasting device  54  and onto a discharge chute  65 . 
     In an alternative horizontal embodiment, illustrated schematically in  FIG. 8 , horizontal steaming and toasting device  54  incorporates an automatic bun feeding system similar to that shown in  FIG. 2  for vertical steaming and toasting device  10 . As shown in  FIG. 8 , a horizontal crown feeder  70  has a feeder coil  36  rotatably mounted to a feeder housing  38 , the coil adapted to dispense bun crowns BC onto an inlet chute  72  leading to an inlet conveyor  74  which conveys the crowns into engagement with crown conveyor  58 . This embodiment incorporates a similar horizontal heel feeder alongside horizontal crown feeder  70  to dispense heels onto inlet chute  72 ; the horizontal heel feeder is not shown in  FIG. 8 , however, as it is hidden behind horizontal crown feeder  70  in the side view. 
     Referring to  FIG. 9 , horizontal steamer  64  of horizontal steaming and toasting device  54  is illustrated in perspective view. Similarly to in-motion vertical steamer  12 , horizontal steamer  64  has a steam outlet  66  in the form of a narrow slit of uniform length and a width approximately equal to the width of a bun to be steamed. Steam is provided to horizontal steamer  64  via steam inlet  14  and condensate exits steamer  64  through condensate outlet  16 . In contrast to in-motion vertical steamer  12 , however, horizontal steamer  64  has only one steam outlet  66 , rather than a pair of steam outlets on opposing faces, thus requiring a pair of horizontal steamers  64  to simultaneously steam a bun crown and bun heel, as best illustrated in  FIG. 6 . However, it should be noted that a horizontal steam toaster having a single steamer with a pair of opposed steam outlets for simultaneously steaming a bun heel and crown, so as to resemble vertical steaming and toasting device  10  as shown in  FIG. 1  turned on its side, is fully within the scope and spirit of the present invention. 
     While the invention has been described with respect to certain preferred embodiments, as will be appreciated by those skilled in the art, it is to be understood that the invention is capable of numerous changes, modifications and rearrangements, and such changes, modifications and rearrangements are intended to be covered by the following claims.