Abstract:
A combination toaster/caramelizer oven for treating food products comprising: a housing; at least one heating element; a removable platen; and at least one conveyor disposed opposite the platen for conveying the food products through the housing, wherein the platen is disposed between the heating element and the conveyor. Optionally, the caramelizer oven can further include at least one moisture injector that introduces moisture to the surface of the food product which is in contact with the platen.

Description:
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/520,916, filed Nov. 18, 2003, the contents of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a combination toaster/caramelizer oven that is capable of toasting and/or caramelizing food products. More particularly, the present invention relates to a combination toaster/caramelizer oven that is capable of toasting food products using infrared heating or, by inserting a platen between the food products, caramelizing food products. Still more particularly, the present invention relates to a combination toaster/caramelizer oven that is capable of using infrared heating for toasting food products and/or caramelizing food products that are transported on a conveyor. 
     2. Description of the Related Art 
     In the fast food industry, there is an ongoing need for rapid high quality toasting of food products. Fast food establishments have a need for toasting flat buns or flat breads of different thicknesses for sandwiches. Also, fast food establishments need to both toast food products during their breakfast operation and later caramelize the surface of food products during their afternoon and dinner operations. Due to the crowded foodservice equipment configurations of most fast food establishments, it would be highly desirable to not have to include two separate pieces of equipment, such as a separate toaster and a separate caramelizer. 
     The same fast food establishments may have a need to caramelize bread for sandwiches, may also need to toast muffins and pastries that are normally not caramelized. The toasting and heating of the muffins and pastries must be even and quick to meet customer expectations. 
     Therefore, there is a continued need to provide quick and rapid heating of food products of different types by the fast food industry. The present inventors have also discovered that there is a need for an oven which has the capability of both toasting and caramelizing food products. 
     SUMMARY OF THE INVENTION 
     A combination toaster/caramelizer oven for treating food products comprising: a housing; at least one heating element; a removable platen; and at least one conveyor disposed opposite the platen for conveying the food products through the housing, wherein the platen is disposed between the heating element and the conveyor. 
     Preferably, the heating element is an infrared heating element and the conveyor is an endless belt-type conveyor. 
     Optionally, the oven comprises at least a first conveyor and a second conveyor in spaced relationship to either the heating element and/or the platen to define first and second toasting and/or caramelizing paths, respectively. The first toasting path comprises a first product inlet and a first product outlet opposite the first product inlet and the second toasting path comprises a second product inlet and a second product outlet opposite the second product inlet. It is preferable, that the platen be disposed opposite to both the first and second conveyors. 
     The heating element are typically fixedly secured to an upper surface of the housing and the housing further comprises guide rails for receiving the removable platen. It is also preferable that the spacing between the conveyor and either the heating elements or the removable platen is adjustable. Also, the spacing between the first conveyor and either the heating elements or the removable platen is adjustable and wherein the spacing between the second conveyor and either the heating element or the removable platen is adjustable, wherein the first and second conveyors are adjustable independent of each other, whereby food products of differing dimensions can be either toasted or caramelized to substantially the same degree while passing through the oven at substantially the same time. 
     Additionally, the conveyor is in spaced relationship to either the heating elements or the platen to define a toasting and/or caramelizing path, wherein the toasting and/or caramelizing path comprises a food product inlet and a food product outlet, wherein the food product outlet is disposed at an end of the conveyor opposite to the food product inlet, and wherein the oven further comprises an outlet tray which is operably associated with the housing to receive the food products exiting the food product outlet. Optionally, the outlet tray is heated. 
     According to another embodiment of the present invention, the combination toaster/caramelizer oven can be angularly adjustable from a horizontal position to a vertical position. 
     Still yet another embodiment of the present invention provides a caramelizer oven for caramelizing food products comprising: a housing; at least one heating element; a platen; at least one conveyor disposed opposite the platen for conveying the food products through the housing; and at least one moisture injector that introduces moisture to the surface of the food product which is in contact with the platen. During operation, the conveyor is capable of pressing the food product against the platen to caramelize the food product. 
     The conveyor is in spaced relationship to the platen to define a caramelizing path, wherein the caramelizing path comprises a food product inlet and a food product outlet, and wherein the at least one moisture injector is disposed about that portion of the platen adjacent to the food product inlet. In this embodiment it is preferable to have the heating element embedded within the platen. The heating element heats water to form steam which is passed through the moisture injectors into the food products. 
     A method of caramelizing food products in an oven having at least one heating element and a platen, the method comprising: conveying food products through the oven along a toasting path; providing moisture (e.g., steam) to the food products; and caramelizing the moisture laden food products by contacting a surface of the food products with the platen which has been heated via the heating element. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other and further objects, advantages and features of the present invention will be understood by reference to the following specification in conjunction with the accompanying drawings, in which like reference characters denote like elements of structure and: 
         FIG. 1  is a perspective view of a first embodiment of the combination toaster/caramelizer oven of the present invention; 
         FIG. 2  is a front view of the combination toaster/caramelizer oven of  FIG. 1 ; 
         FIG. 3  is a perspective view of a second embodiment of the combination toaster/caramelizer oven of the present invention; 
         FIG. 4  is a front view of the combination toaster/caramelizer oven of  FIG. 3 ; 
         FIG. 5   a  is a perspective view of a third embodiment of the combination toaster/caramelizer oven of the present invention, having four combination toaster/caramelizer oven modules; 
         FIG. 5   b  is a perspective view of the third embodiment of the combination toaster/caramelizer oven of the present invention, having separate moisture portions in the four combination toaster/caramelizer oven modules; 
         FIG. 6  is a perspective view of a fourth embodiment of the combination toaster/caramelizer oven of the present invention; 
         FIG. 7  is a cross-sectional view of the combination toaster/caramelizer oven of the embodiment of  FIG. 6 ; and 
         FIG. 8  is a view of the combination toaster/caramelizer oven of the embodiment of  FIG. 6 , with the platen removed. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIGS. 1 and 2 , a first embodiment of the combination toaster/caramelizer oven  10  of the present invention includes a pair of combination toaster/caramelizer oven modules  20  and  40  disposed side by side in a combination toaster/caramelizer oven housing  12 . Module  20  includes a first upper endless conveyor  22  and a first lower endless conveyor  24 . Module  40  includes a second upper endless conveyor  42  and a second lower endless conveyor  44 . Modules  20  and  40  have a metallic plate or platen  30  disposed between upper conveyors  22  and  42  and lower conveyors  24  and  44 . Infrared heater elements  26  heat food products  36  and function as rollers as part of upper conveyors  22  and  42  and lower conveyors  42  and  44 . Infrared heater elements  26  also heat platen  30  to caramelize food products when they come in close contact with platen  30 . 
     The upper conveyors  22  and  42  are adjustable toward and away from platen  30  so as to adjust for food products  36  of different heights. For example, cam adjusters  48  may be provided to raise and lower conveyers  22  and  42 . Food products  36 , which are being caramelized, are inserted at an upper inlet  16  (to the right in  FIG. 1 ) and pressed against the platen  30  by upper conveyors  22  and  42  while being conveyed to an outlet  14  (to the left in  FIG. 1 ). The infrared heater elements  26  heat platen  30  to a temperature that will caramelize food products  36 . Infrared heater elements  26  are capable of heating much more quickly than traditional conductive heaters. Examples of food products that are caramelized include bun halves, flat bread, sandwich rolls and the like. When the food products  36  exit outlet  14 , they slide down inner housing to a tray  46 . 
     Food products  36 , which are not being caramelized, are conveyed by lower conveyors  24  and  44  from an inlet  18  (to the right in  FIG. 1 ) toward an outlet  38  (to the left in  FIG. 1 ). Lower conveyors  24  and  44  are spaced from platen  30  so that those food products  36  being carried are not pressed against platen  30 , but rather are heated by the infrared heater elements  26 . Examples of food products for which may not require caramelizing include muffins, bagels, sliced bread and the like. When the food products exit the outlet, they slide down a frame portion to tray  46 . 
     The height of inlets  16  and  18  are independently adjustable in the two modules  20  and  40  of  FIGS. 1 and 2  to accommodate food products of different heights. For example, module  20  can be adjusted to caramelize bun tops and module  40  can be adjusted to caramelize bun bottoms. In addition, modules  20  and  40  may be angularly adjustable between the horizontal position shown in  FIGS. 1 and 2  the vertical position to any desired angular position from zero to 90°. 
     Tray  46  catches food products  36  after they has been toasted or caramelized. Tray  46  incorporates vulcanized heating using resistive coils, electrical heating or lamps. Tray  46  has a Teflon® coating to prevent food products  36  from sticking. Tray  46  prevents food products  36  from cooling before they are consumed. Tray  46  is an optional feature particularly for commercial use. 
     It will be apparent to those skilled in the art that the combination toaster/caramelizer oven embodiment of  FIGS. 1 and 2  may employ more or fewer modules than the two modules that are shown. 
     Referring to  FIGS. 3 and 4 , a second embodiment of combination toaster/caramelizer oven  50  of the present invention includes three combination toaster/caramelizer oven modules  52 ,  54  and  56  disposed side by side and spaced from platen  66 . Each module  52 ,  54  and  56  includes a conveyor  58 ,  60  and  62 , respectively. Food products  36 , which are being caramelized, are inserted at an inlet  68  (to the right in  FIG. 3 ) and pressed against a surface of platen  66  by conveyors  58 ,  60  and  62  while being conveyed to an outlet  70  (to the left in  FIG. 3 ). Platen  66  is located between infrared heating elements  72  above, and conveyors  58 ,  60  and  62  below that support and transport food products  36  from inlet  68  to outlet  70 . When food products  36  exit outlet  70 , they slide down a frame portion to tray  46 . In this embodiment tray  46  is also heatable to maintain the temperature of food products before consumption. 
     The platen  66  is shaped and dimensioned for easy removal to expose the infrared heating elements  72  to the food products  36  for toasting. In the preferred embodiment, platen  66  is formed as a flat metallic plate that is easily removable. Platen  66  is inserted into brackets in housing  12  and held in place by it own weight. Alternatively, platen  66  can be formed as a U-shaped structure with the infrared heater being disposed in the U portion. Platen  66  is inserted in combination toaster/caramelizer oven frame and mates with mating parts in the combination toaster/caramelizer oven frame  12  and is secured by one or more suitable fastening elements (not shown). For removal, the fastening elements are unfastened, and the U-shaped structure is easily removed. 
     The inlet height is adjustable independently in the three modules to accommodate food products  36  of different sizes. In addition, the modules may be angularly adjustable to any desired angular position from zero to 90°, zero being the horizontal position and 90° being the vertical position. 
     It will be apparent to those skilled in the art that the combination toaster/caramelizer oven embodiment of  FIGS. 3 and 4  may employ more or fewer modules than the three that are shown. 
     Referring to  FIG. 5   a , a third embodiment of the combination toaster/caramelizer oven  80  of the present invention includes four combination toaster/caramelizer oven modules  82 ,  84 ,  86  and  88  disposed side by side and spaced from platens  90 . Each module  82 ,  84 ,  86  and  88  includes a conveyor  92 ,  94 ,  96  and  98 , respectively, disposed in spaced apart relationship to platens  90 . Food products  36 , which are being caramelized, are inserted at an inlet  102  (to the top in  FIG. 5   a ) and pressed against platen  90  by conveyor  92 ,  94 ,  96  and  98  while being conveyed to an outlet  104  (to the bottom in  FIG. 5 ). Platens  90  are heated by an infrared heater elements  106  that may be disposed on the opposite side thereof with respect to the caramelizing side as shown in  FIGS. 3 and 4 . Alternatively, the infrared heater elements  106  are embedded in platens  90 . When food products  36  exit outlet  104 , they slide down inner housing  110 . 
     In a region of the platens  90  adjacent inlet  102 , one or more steam injectors  108  are disposed in the platen to inject moisture into the food products  36 . One or more steam injectors  108  are located only at the portion of platens  90  near inlet  102 . One or more steam injectors  108  are centrally located beneath platens  90  to provide even distribution of moisture in food product  36 . The caramelizing process then occurs along the remainder of platens  90  towards outlet. Moisture injection is used to maintain moisture levels in bread during the caramelizing process. Additionally, moisture injection may, optionally, be used to inject additional flavors into bread using spices in the water. Moisture injection refreshes food products that may become dry if they are not immediately consumed. In this embodiment, platens  90  are not removable. Alternatively, as shown in  FIG. 5   b , steam injectors  108  are located on a separate unit  112  from infrared elements  106 . 
     In this embodiment, the inlet height is adjustable independently in the three modules to accommodate food products  36  of different sizes. In addition, the modules may be angularly adjustable to any desired angular position from zero to 90°, zero being the horizontal position and 90° being the vertical position. 
     It will be apparent to those skilled in the art that the combination toaster/caramelizer oven embodiment of  FIG. 5  may employ more or fewer modules than the four that are shown. 
     In each of the three embodiments, the width of the modules can be varied to accommodate food products of various shapes. For example, an elongated roll may be arranged side ways on a wider conveyor. 
     A fourth embodiment of combination toaster/caramelizer oven is shown in  FIGS. 6 through 8 . Referring to  FIG. 6 , combination toaster/caramelizer oven  120  has a housing  122 , a platen  124  and an endless conveyor  130 . Housing  122  also has in inlet  136  into which food products are placed for transport on conveyer  130  from inlet  136  to outlet  140 . Combination toaster/caramelizer oven  120  also has a heating tray  142  onto which food products fall after being either toasted or caramelized. Platen  124  has variable thickness to accommodate food products of different heights. For example, side  126  has a lower surface to caramelize bun bottoms and side  128  has a higher surface to accommodate but tops, which are generally thicker. 
       FIG. 7  shows a cross-section view of combination toaster/caramelizer oven  120 , in which platen  124  is in a partially removed position. Platen  124  is held in position under its own weight as it rests against brackets  144  connected to the side of housing  122 . Infrared heater element  146  is placed above platen  124 . When caramelizing is needed for food products, platen  124  is installed. Alternatively, when toasting is desired, platen  124  is removed and food products on conveyor  130  are toasted by heater element  146 . 
     A method for toasting food products in the combination toaster/caramelizer oven of the present invention will be described with regard to  FIG. 5 . Food products  36  are placed in inlet  102  on any of platens  90  beneath conveyors  92 ,  94 ,  96  or  98 . Flat food products are transported form inlet  102  to outlet  104  by movement of conveyors  92 ,  94 ,  96  and  98 . Moisture is provided to food products  36  when they are placed on platens  90  by steam injectors  108 . Steam injectors  108  are located centrally in platens  90 . Steam is provided to food products  36  before the caramelizing process begins. Once food products  36  have been transported along platens  90  to outlet  104 , the caramelization is completed and the food products slide down inner housing for further preparation to be consumed.  FIG. 8  shows combination toaster/caramelizer oven  120  with platen  124  removed. 
     The present invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein.