Abstract:
An apparatus and method for providing a layered seasoning to snack food products such as potato chips or tortilla chips using a vibratory scarf plate that is divided into two or more sections by one or more walls. A different seasoning is placed in each section. The scarf plate is placed into a rotating drum having snack food product. A seasoning from each section falls off the scarf plate to form a curtain. Each curtain provides a layer of seasoning on the snack food product.

Description:
BACKGROUND OF THE INVENTION 
   1. Technical Field 
   This invention relates to improvements in a method and apparatus for the distribution of seasonings, e.g., seasonings as placed on potato chips, corn chips, and like snack foods and more particularly, to a method and apparatus that permits layering of different seasoning materials during the manufacture of snack food items. 
   2. Description of Related Art 
   Food particulates are often added to foods, especially snack foods. Tortilla chips, pretzels, crackers, popcorn, and numerous other foodstuffs often have seasonings applied to them during processing. Seasonings used, usually in a powdered form, have included salt, cheese, chili, garlic, Cajun spice, ranch, sour cream and onion, among many others. 
     FIG. 1  is a schematic sectional elevation view of a prior art seasoning distribution system.  FIG. 2  is a schematic sectional view taken along line  2 - 2  of  FIG. 1 . Referring to  FIGS. 1 and 2 , the apparatus  10  generally comprises a cylindrical drum  14  and a non-rotating horizontal seasoning dispenser. Unseasoned snack food  12  enters a cylindrical drum  14  at one end through a funnel  16 . Drum  14  is tilted slightly at an angle of about 5 degrees and is axially rotated in the direction indicated by arrow  18 . The speed of rotation is generally between 4 and 15 RPM. The combination of tilt and rotation causes the snack food to travel continuously down the drum to exit  20 . Baffles  21  may be positioned radially on the drum perimeter to aid in mixing the snack food. A horizontal, non-rotating seasoning dispenser  22  has a tube portion  24  extending into the drum. Within the tube  24  is an auger  26  in close tolerance with the tube inner wall. The auger is rotated by a power source  28  such as an electric motor. This tumbling drum arrangement and the application in general of seasoning falling from a tube to snack food therein is well known and conventional in the art. Seasoning  30 , such as barbeque, sour cream, etc., is fed to the dispenser via a hopper  32  and is conveyed along the tube  24  by the auger  26 . A series of apertures in the bottom of the far end of the tube  24 , opposite the hopper  32 , allows the seasoning to drop by gravity onto the snack food. As indicated by arrows, the seasoning is distributed in the form of a dispersion “curtain”. 
   The seasoning dispenser  22  may be positioned offset from the cross-sectional center of the drum, as shown in  FIG. 2 , in order to distribute the seasoning over the location of maximum concentration of snack food. Because of the drum rotation, the snack food tends to migrate up the drum wall, and thus the maximum concentration is located at a point other than the lowest portion of the drum. The optimum position for the dispenser is, of course, dictated by the degree of migration of the snack food, which in turn is dependent on the speed of rotation and tilt angle of the drum, and the size and number of baffles along the drum perimeter. Those skilled in the art can readily ascertain the proper location for the dispenser based upon a given set of the above process parameters. 
   Achieving the optimum compromise between uniform seasoning coverage of the snack product along with minimum product breakage requires careful selection of tumbler drum size. A longer tumbler drum can result in higher, undesirable product breakage. 
   One problem with this prior art apparatus is the difficulty of providing a layered seasoning. For example, sour cream and onion seasonings often consist of a larger parsley flake seasoning mixed in with the smaller fine particulate seasoning. The smaller fine particulate seasoning, however, can cover and obscure the parsley making it appear as though less parsley is present than actually is present. Further, some fine, particulate seasoning may partially obscure the parsley flake, which can dull or dilute the green color. Thus, it is difficult to produce a snack food product having a clear color contrast. Unfortunately, prior art seasoning distribution systems currently require the two seasonings to be mixed and applied then applied to the substrate. 
   One solution to this problem is to add a second seasoning dispenser  22  having a series of apertures in the bottom of the near end of the tube  24 , closer to the hopper  32 , but situated such that seasoning curtain resides within the drum. Unfortunately, the space constraints of the flavoring drum make the use of multiple screw conveyors impractical, and also the cost of such a system may be prohibitive. 
   Another solution may be to use a second apparatus  10  as depicted in  FIG. 1  in series with a first apparatus  10  and thereby route the substrate through two seasoning drums having different seasonings. This solution, however, fails because in addition to significant capital costs for a second apparatus, such a configuration would result in higher than desirable product breakage. 
   Similarly, patents that relate to snack food seasoning in the prior art all fail to provide an economical apparatus that provides a layered seasoning on a snack food substrate. For example, U.S. Pat. Nos. 4,543,907, 5,090,593, 5,846,324, 6,619,226, and 6,588,363 all fail to disclose an apparatus capable of providing a layered seasoning on a snack food substrate. 
   Consequently a need exists for an apparatus that can provide a layered, uniform seasoning coverage onto snack products while minimizing product breakage. The method and apparatus should be adaptable to an existing product line where seasoning is applied to a snack food substrate. In addition, the apparatus should not result in an increase in product breakage. Thereby snack products with uniform layered seasoning coverage can be produced in an economical manner while avoiding product breakage. 
   SUMMARY OF THE INVENTION 
   The invention relates to a method and apparatus for layering a plurality of seasonings upon a snack food product. In one aspect, the invention comprises a rotating drum having a snack food product, and a vibratory scarf plate having a wall that divides the scarf plate into a first section and a second section. The first section terminates at a first edge and transports a first seasoning. The second section terminates at a second edge and transports a second seasoning. Scarf plate vibration causes the respective seasoning to fall off its respective edge to a first seasoning curtain and a second seasoning curtain. As snack food passes under the first seasoning curtain, the snack food acquires a first layer of seasoning. Similarly, when the snack food passes under the second seasoning curtain, the snack food acquires a second layer of seasoning. 
   Hence, this invention produces a method and apparatus whereby difference seasonings can be layered upon a snack food product to achieve a snack food product having superior aesthetic or organoleptic properties. The above as well as additional features and advantages of the present invention will become apparent in the following written detailed description. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein: 
       FIG. 1  is a schematic sectional elevation view of a prior art seasoning distribution system. 
       FIG. 2  is a schematic sectional view taken along line  2 - 2  of  FIG. 1 . 
       FIG. 3   a  is a partial cut-away perspective view of one embodiment of a seasoning distribution system in accordance with one embodiment of the present invention. 
       FIG. 3   b  is a schematic sectional elevation view of the seasoning distribution system in depicted in  FIG. 3   a.    
       FIG. 3   c  is a schematic top view of the seasoning distribution system depicted in  FIG. 3   a.    
       FIG. 3   d  is a product outlet end view of the seasoning distribution system depicted in  FIG. 3   a.    
       FIG. 4   a  is a schematic top view of the seasoning distribution system in accordance with one embodiment of the present invention. 
       FIG. 4   b  is a product outlet end view of the seasoning distribution system depicted in  FIG. 4   a.    
       FIG. 5  is a top view of a snack product seasoned in accordance with one embodiment of the present invention. 
   

   DETAILED DESCRIPTION 
     FIG. 3   a  is a partial cut-away perspective view of a seasoning distribution system in accordance with one embodiment of the present invention. A vibratory scarf plate  40  can be partially inserted into a seasoning drum  14 . A vibratory scarf plate  40  is available from Wright Machinery (bttp://www.wright.co.uk) of Oxbridge, England can be used. A first seasoning, flavoring or illustrative bits  50  can be metered from a first seasoning delivery device  52  (partially shown) onto a first scarf plate section  54 . Similarly a second seasoning, flavoring or illustrative bits  50  can be metered from a second seasoning delivery device  62  (partially shown) onto a second scarf plate section  64 . Although discharge portion of the seasoning device  52   62  is depicted as a round pipe, any way of placing metered seasoning onto the respective scarf plate sections can be used. For example, an endless conveyor or a half pipe can be used. The seasoning delivery device  52   62  can be a volumetric or gravimetric feeder. A metering screw feeder, available from Rospen Industries (http://www.rospen.com/) of Oldends Lane, Stonehouse, Gloucestershire can be used. Equivalent feeders are also available from Acrison (http://www.acrison.com/) of Moonachie, N.J. 
   A wall  70  disposed within the scarf plate  40  defines a first scarf plate section  54  and a second scarf plate section  64 . Termination of the first scarf plate section  54  within the seasoning drum  14  defines a first edge  56 . Similarly the second scarf plate section  64  terminates at a second edge  66 . The first scarf plate section  54  is the portion of the scarf plate  40  that transports the first seasoning  50  from the first seasoning delivery device  52  to the first edge  56 . Similarly, the second scarf plate section  64  is the portion of the scarf plate  40  that transports the second seasoning  60  from the second delivery device  62  to the second edge  66 . The wall  70  ensures no mixing of the first seasoning  50  with the second seasoning  60  within the confines of the scarf plate  40 . 
   In one embodiment, the first edge  56  when viewed from above, forms a bias cut or diagonal having an angle Θ that is less than about 45 degrees. Similarly, in one embodiment, the second edge  66 , when viewed from above, forms and angle that is less than 45 degrees. In the embodiment shown in  FIG. 3   a , the first edge  56  and second edge  66  comprise equal angles and form a continuous edge. However, it should be noted that the angles can be different and the first edge  56  and second edge  66  may be non-contiguous. In one embodiment, each edge  56   66  comprises a knife-like edge having a small bevel on the underside. 
   Upon exit from the first seasoning delivery device  52 , scarf plate  40  vibration causes the first seasoning  50  to travel from the seasoning end of the scarf plate  40  along the first scarf section  54  to the first edge  56 . The seasoning  50  then falls off the first edge  56  to create a first seasoning curtain  55 . Similarly, upon exit from the second seasoning delivery device  62 , scarf plate vibration  40  causes the second seasoning  60  to travel from the seasoning end of the scarf plate  40  along the second scarf section  64  to the second edge  66 . 
     FIG. 3   b  is a schematic sectional side view of the seasoning distribution system in depicted in  FIG. 3   a . Unseasoned snack food  12  enters the rotating cylindrical drum  14  at one end through, for example, a funnel  16 . Due to drum  14  rotation and tilt, the snack food travels continuously down the inside of the drum  14  towards the exit  80 . Baffles  21  can be positioned to aid in mixing the snack food. A snack food disposed within the upstream section of the drum  14  is first contacted with the first seasoning  50  as it travels beneath the first seasoning curtain  55 . The snack food  12  now having a first seasoning layer is next contacted with the second seasoning  60  as it travels beneath the second seasoning curtain  65  in the seasoning drum  14 . In one embodiment, the scarf plate  40  is substantially level in both the longitudinal and transverse directions. 
     FIG. 3   c  is a sectional top view of the seasoning distribution system depicted in  FIG. 3   a . As shown by  FIG. 3   c , once seasoning  50   60  exits its respective seasoning delivery device  52   62 , the seasoning can tend to pile immediately below its respective delivery device. Scarf plate  40  vibration alone may not uniformly spread the seasoning about the width of either scarf plate section  54   64 . If seasoning  50   60  is not uniformly distributed about the width, it may impact seasoning curtain  55   65  uniformity. Thus, in one embodiment (not shown), the seasoning delivery device  52   62  terminates across the width of the respective scarf plate section to minimize piling and provides a uniform amount of seasoning about the width of the scarf plate section  54   64 . 
   In an alternative embodiment, a spreader bar  72  is mated to the bottom of both the first scarf plate section  54  and the second scarf plate section  64  and extends the width of each section. The spreader bar  72 , in conjunction with the vibration caused by the scarf plate  40 , functions as a dam and causes seasoning to thinly spread out about the width of the respective scarf plate section  54   64  as seasoning  50   60  flows over the spreader bar  72 . The spreader bar  72  thus helps to uniformly spread the seasoning about the width of each scarf plate section  54   64 . Although the spreader bar  72  height can vary depending upon such factors including, but not limited to, vibration frequency, vibration pattern, spreader bar shape, and seasoning characteristics such as seasoning size and density, the height, in one embodiment, ranges from about 3 millimeters to about 6 millimeters. It is also preferable that the surface of the respective scarf plate sections  54   64  be highly polished to facilitate even flow of the seasoning. 
   The location of the wall  70  separating the first scarf plate section  54  and the second scarf plate section  64  can be based on a number of factors including, but not limited to, the physical properties (e.g. density, particle size) of the first and second seasoning, the desired finished appearance of the seasoned snack product, and the desired organoleptical properties (taste, smell, and texture) of the desired finished product. The physical properties of the seasonings may influence wall  70  placement because the rate of travel and thus final seasoning amount may be affected by the density and/or particle size of the seasoning. The desired finished appearance may influence wall  70  placement based upon the desired aesthetic appearance produced by the relative placement density of the first seasoning  50  and second seasoning  60  on the snack food product. The desired organoleptical properties may influence wall  70  placement based upon the desire for a snack food product to vary the intensity of an initial taste, smell, or texture aspect of a snack food product. For example, a seasoning having a strong smell may be used as a second seasoning  60 . In such a case, the second edge  66  may be longer than the first edge  56 . Thus, depending upon the desired finished product, the wall  70  can be placed anywhere within the scarf plate  40 . 
     FIG. 3   d  is a product outlet end view of the seasoning distribution system depicted in  FIG. 3   a . It should be noted that, unlike clothes in a household clothes dryer, the snack food product after it migrates upward with drum rotation  18 , gently rolls or slides down the side of the drum  14  and is generally not “spun” or “flung” around inside the seasoning drum  14 . Thus, the figure substantially portrays the relative location of the snack food product bed inside the seasoning drum  14 . In one embodiment, a snack food piece tumbles (follows the drum rotation up the sidewall of the drum and then rolls back down) between about 2 and about 9 times as the snack food navigates through the first curtain  55 . In one embodiment, a snack food piece tumbles about 2 times and about 9 times as the snack food navigates through the second curtain  65 . While snack food product generally is not carried beyond the top half of the drum, it is possible for seasoning to adhere to the sides of the drum. The potential then exists for such seasoning to fall onto the scarf plate  40 . This is undesirable because of the potential for the first seasoning  50  to fall into the second scarf plate section  64  or for the second seasoning  60  to fall into the first scarf plate section  54 , resulting in undesirable mixing of seasonings. Thus, in one embodiment, a protective hat (not shown) is disposed above the scarf plate  40  to shield the scarf plate from any potential contaminants. The scarf plate  40  is preferably placed off-center within the drum such that the seasoning curtains  55   65  fall substantially upon the snack food product bed below. 
   Although  FIGS. 3   a - 3   d  depict only one inner wall  70  on the scarf plate to form two scarf plate sections, those skilled in the art will recognize that additional walls  70  could be placed in the scarf plate  40  to increase the number of layers of seasoning disposed upon a seasoned snack food product. 
     FIG. 4   a  is a schematic top view of the seasoning distribution system in accordance with an alternative embodiment of the present invention.  FIG. 4   b  is a product outlet end view of the seasoning distribution system depicted in  FIG. 4   a . In this embodiment, the scarf plate  40  is placed into the drum at a diagonal and the first scarf plate edge  56  and second scarf plate edge  66  are substantially parallel to the longitudinal axis of the drum  14 . As a result, the first curtain  55  and second curtain  65  also reside in a plane parallel to the longitudinal axis of the drum  14 . In such an embodiment, the angle Θ can be less than about 30 degrees, more preferably less than about 20 degrees and most preferably less than about 10 degrees to permit optimal placement of the seasoning curtains over the snack food within the drum. 
     FIG. 5  is a top view of a snack food product seasoned in accordance with one embodiment of the present invention. As indicated by the figure a snack food product having a layered seasoning is achieved. In the embodiment shown, the second seasoning  60  providing a second layer is disposed upon first seasoning  50  providing a first layer. 
   In one embodiment, the second seasoning  60  comprises an average particle size that is different from the first seasoning  50 . In one embodiment the second seasoning comprises a texture that is different from the first seasoning. In one embodiment, the second seasoning comprises a color that is different from the first seasoning. In one embodiment, the second seasoning comprises a flavor different from the first seasoning. In one embodiment, the second seasoning comprises barley. 
   The instant invention results in a snack food product having a layered seasoning. There are several advantages with this invention. First, because the second seasoning is not obscured from mixing with the first seasoning, a lesser amount of a second seasoning can be used for the same apparent density. Second, the invention provides for a way to provide a more aesthetically pleasing snack food product. Because the second seasoning is not obscured by the first seasoning, the snack food product is able to exhibit a clear color contrast. Third, the invention provides a way to season a snack food with two or more distinct colors. Fourth, the invention provides a way to maximize the texture attributes of different seasonings. For example, if it is desired to have an outer (second) seasoning having a rougher texture and an inner (first) seasoning having a fine texture to produce a desired mouthful, the rough outer texture is not diluted by mixing with the fine inner texture seasoning. Further, in such an example, because the second seasoning is the outermost seasoning, addition of a second seasoning having strong texture attributes can be more fully appreciated upon initial consumption by a consumer. Fifth, because the second seasoning is the outermost seasoning, the first seasoning and second seasoning flavors can be varied to maximize desired flavor profiles. 
   While this invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.