Abstract:
An apparatus and method for depositing flowable solids onto articles located on a moving conveyor. A flowable solid is placed on a vibrating trough and dispensed to an article on the moving conveyor through a slot in the trough. A third planar surface placed beneath the slot receives the flowable solid from the slot and provides an even dispersing pattern of the flowable solid onto the articles.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims the benefit of U.S. Provisional Application No. 60/338,275, filed Dec. 6, 2001. 

   FIELD OF THE INVENTION 
   The present invention relates to an apparatus and method for depositing flowable solids onto articles on a moving conveyor. More particularly, this invention relates to an apparatus for depositing flowable solid flavor crystals, salts, or seasonings onto oven cooked, fried, and/or raw food products. 
   BACKGROUND OF THE INVENTION 
   Snack foods, particularly savory snacks, are extremely popular with consumers. Such snack foods include but are not limited to potato chips, nachos, tortilla chips, corn chips, other extruded snacks, and the like. Such snack foods are typically flavored, or seasoned, with a flowable solid, such as spices and/or seasonings (“seasonings”) by sprinkling the seasonings on the surface of the individual snack items. Examples include potato chips seasoned with salt, barbecue flavoring, sour cream and onion flavoring, vinegar flavoring, etc. Similarly, corn chips and other snack foods are seasoned with various flavorings. The distribution of seasoning is accomplished by sprinkling seasoning on the surface of the products after the products have been cooked and prior to their packaging. The application and distribution of such seasoning greatly affects the product quality. That is, if seasoning is distributed in clumps some chips can be too strongly seasoned while other portions of the same batch of chips, or even portions of the same chip, can be too lightly seasoned, creating a poor quality product. Also, quite importantly, the distribution of seasoning greatly affects the economy of manufacturing. There is a continuing desire to economically measure and uniformly and evenly distribute the seasoning over the snack food during the manufacturing process. 
   Almost all seasonings vary in their flow properties. The metering of seasonings ensures that a proper amount is applied. Distribution of a seasoning on a product is important to ensure that the seasonings are evenly distributed over the product. Common seasonings in favor with consumers of snack food products can include, for example, barbecue, sour cream and onion, cheese, are sticky, lumpy, and very difficult to dispense. Generally, most seasonings present problems in distribution, not only the above-mentioned seasonings. 
   Typically, the seasonings are applied with the use of a “flavoring drum” which is a barrel-like container that rotates about an axis that is tilted relative to a horizontal axis. The snack food product to be coated is fed into an elevated open end of the flavoring drum by a speed controlled weigh conveyor. A seasoning feeder, extending horizontally into the drum produces a discharge of seasoning that is applied to the surface of the product located in the drum. As the flavoring drum rotates, the product rotates and is coated as the product mixes with the seasoning within the flavoring drum. Gravity then causes the product to pass to an open discharge end of the flavoring drum and collected on a take-away conveyor. 
   However, the flavoring drum application method is problematic. The seasoning is typically hygroscopic and tends to agglomerate and plug-up or bridge openings in any associated drum nozzles or slots within the flavoring drum. This can require extensive down time with clean up and sanitation operations to ensure operation of the apparatus. Further, if the product is too dry, the seasoning will not typically adhere to the product surface. If the product is too moist, there can typically be an excess accumulation of seasoning on only portions of the product or in well-defined, discrete regions of the product. Therefore, a device that promotes a consistent, even distribution of a seasoning onto the surface of a product can be highly advantageous. 
   Another process for the application of seasoning to a product involves the use of a screw conveyor feed system. The typical system includes a screw feeder generally positioned near the center-line and extending into a discharge end of a flavoring drum or a screw feeder positioned above a product passing underneath by conveyor. Seasoning placed in a hopper immediately above the screw feeder flows by gravity into the feed inlet. As the screw feeder turns, the seasoning is enclosed between screw flights and forced along the bottom of the feeder through fine slots or nozzles in order to sprinkle the seasoning on the food product as the food product rotates within the flavoring drum. 
   However, the screw conveyor system is inefficient and difficult to clean and maintain. The action of the screw feeder packs the seasoning during operations, causing seasoning build-up within the screw feeder and external to the screw feeder housing. Thus, frequent cleaning is required. Additionally, screw feeders can be problematic in that they can add shear stresses to the conveyed seasoning, potentially altering the physical properties of the seasoning. Further, all seasoning build-up is a waste of seasoning that significantly increases the costs associated with processing due to product losses, clean-up and processing down-time. 
   Other processes can also be used to apply a seasoning to a snack product and are used in the industry. This includes, but is not limited to, belt coaters, roll coaters, brush coaters, blade coaters, electrostatic coaters, and air impingement coaters. All of these methods produce generally unsatisfactory results and have similar high maintenance requirements to maintain an efficient and high throughput. 
   Examples of flavoring drum applicators are disclosed in U.S. Pat. Nos. 3,606,099; 4,513,918; 4,715,315; 4,755,390; 4,760,778; 5,090,593; 5,386,939; 5,964,146; and 6,113,960. Examples of screw conveyor feed systems are disclosed in U.S. Pat. Nos. 4,493,442; 4,614,162; 4,907,720; 5,287,801; 5,386,939; and 5,846,324. Other coating methods, including belt coaters, roll coaters, brush coaters, blade coaters, electrostatic coaters, and air impingement coaters are disclosed in U.S. Pat. Nos. 3,693,840; 4,936,489; 5,139,801; 5,150,798; 5,353,959; 5,385,086; 5,707,448; 5,855,671; 5,957,332; 6,054,154; and 6,145,708. 
   SUMMARY OF THE INVENTION 
   In one aspect, the invention relates to a flowable solids dispensing apparatus comprising a first surface and a second surface disposed about an axis. The second surface is disposed below the first surface. The first surface and said second surface form a slot therebetween and an angle therebetween. A flowable solid can then progress from the first surface to the second surface through the slot. 
   In another aspect, the invention relates to a flowable solids dispensing apparatus comprising A flowable solids dispensing apparatus comprising a first surface and at least two second surfaces disposed about the axis. Both of the at least two second surfaces are disposed below the first surface. The first surface and both of the second surfaces form at least one slot therebetween. Further, the first and second surfaces form an angle therebetween. A flowable solid can then progress from the first surface to at least one of the second surfaces through the at least one slot. 
   Another aspect of the present invention provides a method of applying a flowable solid to a substrate. First, a first surface disposed about an axis is supplied. Next, a second surface is supplied that is disposed beneath the first surface and forms an angle therebetween. The surface and the second surfaces form a slot therebetween. Third, a substrate is disposed upon a conveyor proximate to the second surface. The conveyor has an axis substantially parallel to the axis of the first and second surface. Fourth, a flowable solid is supplied to the first surface. The first surface is then vibrated with a vibrator so that the vibrator progresses the flowable solid substantially along the first surface. Next, the flowable solid is substantially disposed from the slot disposed on the first surface to the second surface. The flowable solid is then substantially dispensed from the second surface to the substrate. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a flowable solids dispensing apparatus in accordance with the present invention; 
       FIG. 1A  is a perspective view of an alternative embodiment of a flowable solids dispensing apparatus; 
       FIG. 1B  is a perspective view of an alternative embodiment of a flowable solids dispensing apparatus; 
       FIG. 1C  is a perspective view of an alternative embodiment of a flowable solids dispensing apparatus; 
       FIG. 1D  is a cross-sectional view of an alternative embodiment of a flowable solids dispensing apparatus; 
       FIG. 2  is a top elevational view of the flowable solids dispensing apparatus with the feed hopper removed; 
       FIG. 3  is a cross-sectional view of the apparatus of  FIG. 2  taken along the line  3 - 3 ; 
       FIG. 4  is a cross-sectional view of the apparatus of  FIG. 2  taken along the line  4 - 4 ; 
       FIG. 5  is a cross-sectional view of the apparatus of  FIG. 2  taken along the line  5 - 5 ; 
       FIG. 6  is a cross-sectional view of the apparatus of  FIG. 2  taken along the line  6 - 6 ; 
       FIG. 7  is a cross-sectional view of the apparatus of  FIG. 2  taken along the line  7 - 7 ; 
       FIG. 8  is a cross-sectional view of the apparatus of  FIG. 1  taken along the line  8 - 8 ; 
       FIG. 9  is an exemplary granule dispersal pattern from use of the apparatus of  FIG. 1 ; and, 
       FIG. 10  is a perspective view of an alternative embodiment of a flowable solids dispensing apparatus. 
   

   DETAILED DESCRIPTION 
   The present invention is generally related to a flowable solids dispensing apparatus that has a first surface and a second surface disposed about a central axis. The first surface and the second surface are generally disposed about the central axis to form an angle therein. The second surface is generally disposed below the first surface and forms a slot with the first surface so that a flowable solid material will progress from the first surface to the second surface through the slot. The purpose for progressing a flowable solid material from a first surface to a second surface is not limited to, but includes, the ability to provide an even distribution of a flowable solid onto a product positioned beneath the flowable solids dispensing apparatus. Providing an even distribution of a flowable solid material, such as a seasoning, to a snack food product can provide a snack food product that is more evenly coated, and thereby more evenly seasoned, thus providing a more consistently coated and/or flavored snack food. A more consistently flavored snack food can provide the snack food consumer with a more flavorful and enjoyable snack food consumption experience. 
   Referring to  FIGS. 1 and 2 , an exemplary flowable solids dispensing apparatus  10  generally comprises a first surface  14  and a second surface  15 . First surface  14  and second surface  15  are generally arranged about an axis. Preferably, surface  14  and surface  15  are parallel to the axis and surface  15  is disposed below surface  14  to form slot  18  so that a flowable sold material  19  can traverse surface  14 , pass through slot  18  onto surface  15 . The flowable solid material  19  can then traverse surface  15  and then be disposed upon an object passing or disposed thereunder upon leaving surface  15 . Surface  14  and/or surface  15  can be provided as planar surfaces, substantially planar surfaces, inward or outward frustoconical surfaces, inward or outward substantially frustoconical surfaces, corrugated surfaces, inward or outward vortically-shaped surfaces, “V”-shaped surfaces, concave surfaces, convex surfaces, and combinations thereof. In any regard, it is preferred that surface  14  and surface  15  be selected in order to provide an efficacious and/or even distribution of a flowable solids material  19  upon an object passing under flowable solids dispensing apparatus  10 . 
   Flowable solids dispensing apparatus  10  can optionally comprise trough  12  having a longitudinal axis and a generally planar shape. Trough  12  can be disposed above surface  14  or can be unibodily attached to surface  14 . In any regard, if trough  12  is utilized with flowable solids dispensing apparatus  10 , it is preferred that a flowable solids material  19  be capable of traversing trough  12  until contacting surface  14 . Further, at least one optional oscillator or vibrator (vibrator)  13  can be attached to flowable solids dispensing apparatus  10  and/or trough  12 . If trough  12  and surface  14  are present in a unibody form, vibrator  13  can oscillate or vibrate both trough  12  and surface  14 . Further, if trough  12 , surface  14 , and surface  15  are provided in a unibody form, vibrator  13  can oscillate or vibrate all surfaces thereto attached. It is also believed that vibrator  13  can oscillate or vibrate one or more selected surface of flowable solids dispensing apparatus  10  if so desired. However, as would be known to one of skill in the art, any conveying methodology can be utilized that channels a flowable solid through a finger applicator. 
   Exemplary, but non-limiting flowable solids  19  including spices, seasonings, confections, sprinkles, nuts, powdered coatings, other topical coatings and/or additives, and the like, can be introduced to first surface  14  and/or trough  12  via hopper  11 . However, it should be realized that it is possible to introduce any metered and/or unmetered flowable solids  19  by numerous methodologies to surface  14  and/or trough  12  that include, but are not limited to, conveyor belts, screw augers, blades, rotary valves, feeder rolls, chutes, vibratory trays, and combinations thereof. It is also preferred that flowable solids  19  be fed evenly across the dimension of first surface  14  and/or trough  12 . However, one of skill in the art could also provide flowable solids  19  directly to surface  14  and/or trough  12  without the use of hopper  11 . 
   As a non-limiting example, vibrator  13  can be attached to flowable solids dispensing apparatus  10  and/or trough  12  through a mounting bracket. In a preferred embodiment, trough  12  extends approximately the length of flowable solids dispensing apparatus  10  and terminates at wall  17 . Wall  17  can be a device such as a weir, however, wall  17  should preferably retain flowable solid  19  within the confines of trough  12 . Preferably, trough  12  is generally substantially planar, however, other non-limiting geometries can be used, such as “V”-shaped, “U”-shaped, and/or a corrugated shape. However, it should be realized that the geometry chosen should permit flowable solids  19 , such as granules, to flow continuously and uniformly across the surface of trough  12 . When the vibrator  13  is activated, the attachment of the vibrator  13  to surface  14  and/or trough  12  causes surface  14  and/or trough  12  to vibrate. Any vibrator  13  common in the industry can be used and the rate of vibration, and/or vibration amplitude can be varied by user controls on vibrator  13  or by any electronic controller directly on or remote to vibrator  13 . 
   In the preferred embodiment of  FIG. 1 , hopper  11  is positioned relative to trough  12  so the outlet of hopper  11  aligns with trough  12 . It is preferred that hopper  11  be isolated from the vibration of trough  12  so that hopper  11  and trough  12  do not directly contact each other. This can allow the flowable solids  19  contained within trough  12  to migrate toward wall  17  during vibration of trough  12  by vibrator  13 . Additional flowable solids stored within or about hopper  11  can replenish flowable solids  19  used in processing. 
   As  FIG. 2  shows, a flowable solid can be oscillated or vibrated in a direction generally parallel to the longitudinal axis of trough  12  toward break  20  in trough  12 . In a preferred embodiment surface  14  and trough  12  generally define break  20 . Surface  14  preferably extends away from trough  12  in a direction generally normal to the surface (the negative z-direction) and elongate axis of trough  12 . It is preferred that trough  12  and surface  14  be generally substantially planar. To this end, it was surprisingly found that planar surfaces could promote an even flow of flowable solid  19 . One of skill in the art will also realize that break  20  can extend entirely or partially across the entirety of trough  12 . 
   As is further shown in  FIGS. 4-7 , slot  18  and break  20  generally define surface  14 . The relative area of surface  14  generally increases as flowable solids  19  move in the direction A of the longitudinal axis of trough  12 . It should be remembered that slot  18  should be at least slightly larger than the maximum diameter of flowable solid  19  in order to facilitate movement of flowable solid  19  through slot  18  to surface  15 . Without desiring to be bound by theory, it is believed that dimensioning slot  18  to be smaller than the average diameter of flowable solid  19  could cause degradation of flow in flowable solid  19 . As flowable solids approach break  20 , the general direction of movement changes from direction A to direction B that can be generally parallel to surface  14 . While the flowable solids  19  traverse surface  14 , flowable solids  19  can still have movement in the direction of the elongate axis of trough  12 . However, it is believed that flowable solids  19  will move in a direction substantially perpendicular to the elongate axis of trough  12  due to the normal force of gravity and the angle selected for surface  14 . It should also be recognized that slot  18  can be completely or partially co-extensive along the length of surface  14 . 
   It is also preferred that the angular displacement of surface  14  with respect to the horizon be uniformly maintained. It has been found that this angle should be maintained from about zero degrees from horizontal to about 90 degrees from horizontal. However, it has been preferably found that about a 40-degree angle from the horizon provides the best flow characteristics for generally most flowable solids  19 . It is also possible that other multi-angular surfaces can be used to facilitate the movement of flowable solid  19  across surface  14 . 
   As particularly shown in  FIG. 2 , the terminus of break  20  is selected so that remaining flowable solids  19  that reach surface  14  at the terminus of break  20  and a sidewall of trough  12  will contact surface  14 . Without wishing to be bound by theory, it is believed that the location of the terminus of break  20  is believed to be dependent upon the physical and flow characteristics of flowable solid  19 . It is also believed that the position of the terminus of break  20  is dependent on the amount of forward vibration needed to move flowable solid  19 . Thus, the terminus of break  20  can be placed to facilitate movement of flowable solid  19  onto surface  14  properly. However, it is preferred that the placement of break  20  be related to both the angle of surface  14  and the type of flowable solid  19  to provide for flowable solid  19  to reach the end of slot  18  and not contact wall  17 . Additionally, the distal end of surface  14  can be linear, curved, discontinuous, or have any shape or design. It was surprisingly found that forming the distal end of surface  14  in a triangular shape could provide increased flexibility when conveying or transporting materials having varying flowabilities. In any regard, it is preferred that the flowable solid  19  not contact wall  17 . 
   Referring to FIGS.  2  and  4 - 7 , after flowable solid  19  contacts and traverses surface  14 , flowable solid  19  flows through slot  18  toward surface  15 . Surface  15  is generally angled away from the plane of surface  14  and/or trough  12 . Surface  15  can have an angle with respect to the horizon from about zero degrees to about 90 degrees. Further, surface  15  can form an angle with respect to surface  14 , this angle preferably being an acute included angle. However, it was found that an angle of about 30 degrees with respect to the horizon produced generally the best flow characteristics for a generally wide array of flowable solids  19 . Surface  15  is preferably generally planar, however one having skill in the art would be able to provide surface  15  in any shape, including those of surface  14 , as described supra, including, but not limited to “C”-shaped, “U”-shaped, and/or triangular shaped. 
   As shown in  FIG. 8 , a portion of surface  15  has at least one opening  16  disposed thereon. The opening or openings  16  can have any dimension or shape. Exemplary and non-limiting opening  16  shapes include round, curvilinear, triangular, convex curved, concave curved, mesh, screen, and combinations thereof. It should be realized that openings  16  should be dimensioned to provide the most efficacious dispersal of flowable solid  19 . As a non-limiting example, the use of a triangular, or serrated pattern, as shown in  FIG. 8  can produce the general flowable solid  19  dispersal pattern as is shown in  FIG. 9 . 
   Without wishing to be bound by theory, as is shown in  FIG. 8 , it is believed that the dimension “W” should be determined by the average particle size of flowable solid  19 . This can reduce clogging and facilitates the flow of large particles from surface  15 . It is also believed that dimension “L” can determine the total width of dispersion achieved by flowable solid  19 . Thus, it is believed that openings  16  should be dimensioned to have a ratio of “L” to “W” greater than one in order to provide for an efficacious deposition of a flowable solid onto an object positioned and/or passing thereunder. 
   The materials used to construct the flowable solids dispensing apparatus  10  can range from a wide variety of materials. In a preferred embodiment, flowable solids dispensing apparatus  10  is constructed from stainless steel or food-grade plastic. However, one of skill in the relevant art would be able to select a material that would be suitable for construction of the flowable solids dispensing apparatus  10 . Further, the flowable solids dispensing apparatus  10  can have a surface coating applied thereto or inherently reside therein or thereon to provide flowable solids dispensing apparatus  10  with non-stick surface characteristics. 
   Referring again to  FIGS. 2 and 8 , while dimension “L” of opening  16  can provide flowable solid  19  distribution across the width of a product processing, or conveyance, line, the length of the slot  18  and surface  15  provide the length of distribution or the residence time for the flowable solids  19  in trough  12 . It was surprisingly found that dispersing flowable solids  19  over the proper width (of the product) could provide total coverage of the surface of the product. Further, dispersing flowable solids  19 , such as a seasoning, over an extended length can provide a longer residence time for the surface of the product and the applied flowable solid  19  to meet. Thus, it is believed that flowable solids  19  should completely impact a processing line passing proximate to surface  15  between the initiation and terminus of slot  18 . Thus, the lengths of slot  18  and break  20  can be set by the required residence time needed for the application of the flowable solids  19  onto the product located proximate to surface  15 . Without wishing to be bound by theory, it is believed that slot lengths from four to 12 inches, more preferably from about 8 inches to about 12 inches in length, provide the optimal residence time required for most flowable solids  19  for a typical snack food product. Typical products, or snack foods, believed suitable include, but are not limited to: potato chips, nacho chips, tortilla chips, corn chips, breads, cookies, cakes, pies, doughnuts, other extruded snacks, other baked snacks, other fried snacks, candies, other food items, and combinations thereof. 
   Additionally, trough  12  can be disposed to allow flowable solid  19  to impinge on a product in a drum feeder. As product traverses the length of the drum feeder, the product passes under flowable solids dispensing apparatus  10 . Flowable solid  19  is dispersed from flowable solids dispensing apparatus  10 , as discussed supra, and impinges the product as the product passes substantially parallel to trough  12 . In this manner, it is possible for flowable solids dispensing apparatus  10  to impinge flowable solid  19  onto any number of sides of product. 
   Additional exemplary flowable solids dispensing embodiments are shown in  FIGS. 1A ,  1 B,  1 C, and  1 D. In  FIG. 1A , flowable solids dispensing apparatus  10 A is shown without a flowable solids storage hopper. This can facilitate the supply of flowable solids  19  by a conveyor belt, screw auger, blade, rotary valve, feeder roll, chute, vibratory tray, and combinations thereof, or other device to dispensing apparatus  10 A. 
     FIG. 1B  shows an alternative embodiment of flowable solids dispensing apparatus  10 B. Trough  12 B can have at least a portion of the trough extend vertically to allow for a region of acceleration for flowable solids  19  prior to contact with the first surface  14 . 
     FIG. 1C  shows an alternative embodiment of flowable solids dispensing apparatus  10 C. As shown, divider  21  has been placed on trough  12 C to effectively divide trough  12 C into at least two discrete flowable solids dispensing lines. Divider  21  can completely separate any number of troughs  12 D,  12 E, so that flowable solids  19  are confined to one trough. Optionally, divider  21  can only partially separate the trough to provide a common trough area  12 C. While trough  12 C is vibrating, flowable solids  19  can be placed in trough  12 C and divided into two sub-troughs  12 D,  12 E through the vibratory process described supra. The divided flowable solids  19  are then dispensed onto a passing substrate in accordance with the disclosure supra. It is fully intended that flowable solids  19  can be divided into any number of lanes to suit the application. Further, divider  21  can have virtually any design. This includes simple geometric splits at the same point in the trough  12 C, and staged splits where-a divider  21  splits flowable solids  19  flow into two lanes that can further subdivide downstream with additional dividers  21 . Additionally, it is envisioned that dividers  21  can be adjustable to provide point-of-source flow to allow a specific flowable solid  19  to be concentrated in a particular trough, for example  12 D or  12 E. Further the adjustable dividers can be adjusted in situ if such a need would arise. 
     FIG. 1D  discloses yet another embodiment in which surface  15  can be positioned so flowable solid  19  flows directly from surface  14  to surface  15 . As shown, the flow direction of flowable solid  19  on surface  15  remains substantially parallel to the direction of flow of flowable solid  19  on surface  14 . It is also believed that one of skill in the art would be able to fabricate either of surface  14  or surface  15  to encompass the benefits derived by combining both surface  14  and surface  15  into one surface without the need for an angular displacement between surface  14  and surface  15 . 
   As shown in  FIG. 10 , an alternative flowable solids dispensing apparatus  10 F is provided with a first surface  14 F having an inverted substantially vortical shape and centered about an axis. In this regard, hopper  11 F can provide a flowable solids material (not shown) in direction A of first surface  14 F. As flowable solids material (not shown) traverses first surface  14 F, flowable solids material (not shown) progresses along first surface  14 F in direction B. When the flowable solid reaches the terminus of first surface  14 F, the flowable solid (not shown) progresses across break  18 F onto second surface  15 F. The flowable solid material (not shown) then progresses along second surface  15 F to opening  16 F wherein the flowable solids material (not shown) then impinges a product positioned and/or passing thereunder. The flowable solids material (not shown) can be released from surface  15 F through openings  16 F onto a substrate disposed and/or passing thereunder. 
   While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.