Abstract:
A centrifuge operative in successive low speed and high speed modes serves to remove surface cooking oil from a continuous stream of fragile snack food products wherein the oil removal occurs in the high speed mode and products are discharged from the centrifuge with relatively low kinetic energy in the low speed mode.

Description:
FIELD OF THE INVENTION 
     This invention relates to removal of excess surface oil from fried snack foods and similar products in a continuous manner, such products including pellet based snacks, potato chips and pork rinds. The salient characteristics of these products are their bulk, relatively fragile pieces consisting of discrete, often irregularly shaped pieces measuring typically 10 to 100 mm across. 
     BACKGROUND OF THE INVENTION AND THE PRIOR ART 
     By way of background, snack foods are commonly prepared or cooked in an hot oil bath and upon being removed from the cooking oil bath, a quantity of cooking oil is carried out adhering to the surfaces of the snack food products. In many cases the “carry-out” of the cooking oil is undesirable both from the standpoint of ultimate product taste as well as the cost of cooking oil which may often be more costly than the base snack product. 
     Conventionally these products have been de-oiled in batch type centrifuges. A batch centrifuge employs a generally cylindrical or conical basket rotatable about its vertical axis. In operation, the basket is filled while in the stationary condition and the product charge is retained by a discharge gate or valve in the bottom of the basket. The basket is then rotated at a speed sufficient to produce a high centrifugal acceleration, typically on the order of between 30 and 60 g or even higher, at its periphery. The high speed rotation may be maintained for as little as 1 or 2 seconds or for 15 seconds or more depending on the nature of the product and the degree of de-oiling required. The rotation of the basket is then stopped and the discharge gate or valve is opened to discharge the batch. Finally, the gate or valve is closed and the basket may be re-filled with the next batch of product to be de-oiled. Typically the batch type centrifuge must be integrated into a continuous process system wherein several disadvantages may be encountered. 
     One disadvantage is that a batching hopper or other means of surge accumulation must be provided to control the flow of product into the batch centrifuge. Another disadvantage is that frequently de-oiling by centrifuge is time critical being that the product must be spun as soon as practical after frying and before it begins to cool. It is understood that as the product cools the oil may become more viscous and/or be absorbed into the product, thereby inhibiting its removal by centrifuging. Obviously, the age difference between the oldest and newest product in a batch entering the centrifuge must be some time interval greater than the actual de-oiling time, i.e. the time spent under high centrifugal acceleration. Thus we see that the degree of de-oiling may vary within a batch depending on the age of each portion of the batch. Yet another disadvantage is the perception of many equipment customers that a batch process renders non-continuous an otherwise continuous process. Having regard to the variable time element described above, that perception is quite valid. 
     A centrifuge of the purely continuous type would appear to be a solution to the above disadvantages if it were capable of being successfully integrated into a snack food processing line for products of the type described above. In the prior art there many known types of continuous centrifuges. The milk clarifying centrifuge of U.S. Pat. No. 2,264,665, and those like it, served to separate liquids of different densities. U.S. Pat. Nos. 4,205,999 and 6,267,899 disclose apparatus and processes for separating liquids from solids or to recover liquids while discharging solid contaminants as waste. Also such apparatus may be adapted to the recovery of solids when those solids are sufficiently robust to survive the discharge process. 
     Prior art continuous centrifuges typically rotate at constant speed. Therefore both liquid and—of particular significance—solid fractions must exit the rotor in a state of high kinetic energy. A number of known centrifuges such as those disclosed in U.S. Pat. Nos. 4,462,570 and 6,521,120 discharge the solid components at a point of maximum rotor internal diameter and in these cases the kinetic energy will be very high. Fried snack food products of the types to be treated by the present invention are quite fragile. Upon discharge from one of the prior art centrifuges they would shatter or be severely damaged through impact with the centrifuge static shroud or outer wall. This issue was recognized in U.S. Pat. No. 6,267,899 wherein particular deflection structure was disclosed to ameliorate the impact forces upon the sugar crystals in the discharge step. A further limitation of such a centrifuge is the very short residence time for the solids in the rotor and the resulting de-oiling would be minimal. U.S. Pat. Nos. 5,160,441 and 6,712751 disclose conveying the solid fraction mechanically so as to discharge closer to the rotor axis wherein the solid factions would exit with reduced kinetic energy. In the interest of achieving a good throughput capacity, the discharge port of a practical rotor must be of a reasonable diameter but nevertheless the solids would still exit with a significant kinetic energy. And additionally, forcing the product to traverse the inner surface of the rotor under the influence of very high gravitational forces would be a source of product damage. We believe the problem of product damage upon discharge is solved through the cyclic rotational speed of a quasi-continuous centrifuge wherein the product is discharged only at very low rotational speeds and with very low kinetic energy. 
     SUMMARY OF THE INVENTION AND OBJECTS 
     In summary the invention resides in a method of removing an oil coating from the surfaces of a snack food product through use of a quasi-continuous centrifuge. The method steps include feeding a continuous stream of product from an oil cooker into the centrifuge whereupon the product is subjected to gravitational forces on the order of 30 or more g&#39;s. Such forces are maintained on the product for about 3 to 6 seconds and then deceleration to less than 1 g occurs, held there for about 1 to 4 seconds, and then accelerated to the 30 g plus realm, again deceleration, all for a sufficient action to strip surface oil from the products which are relatively fragile and to release the food product from the centrifuge at low kinetic energy. 
     The quasi-continuous centrifuge of the invention includes an exterior shroud mounted upon a frame and encircling a central drum having perforate walls. The drum is equipped with a plurality of internal downward projecting, frusto-conical chutes. A central drive shaft extends upwardly through the drum and carries a plurality of conically formed baffles mounted on the drive shaft. A drive motor is coupled to the shaft and is regulated by a controller to operate in a cycle so that the drum accelerates from 0 to about 550 rpm, more or less depending upon the diameter of the drum and desired g&#39;s, and holds there for about 3 to 6 seconds at which time product in the drum is subjected to g-forces on the order of 60 to 70 g&#39;s stripping oil from the product. The motor controller then acts to cause drum deceleration to a minimal g-force whereupon the food product and oil exit the drum at low kinetic energy. After a few seconds a subsequent cycle is commenced. 
     A general object of the invention is to provide in a food processing system employing an oil cooker a method and apparatus for removing the surface oil from the product through centrifuge action while minimally affecting the shape and texture of the product. 
     Another object of the invention is to provide a centrifuge for oil stripping action upon a relatively delicate food product that achieves minimal product damage by operating at cyclic rotational speeds so as to discharge the product at very low rotational speeds and with very low kinetic energy. 
     Still another object is to provide a multi-stage, quasi-continuous, oil stripping centrifuge that minimizes the time elapsed from the product exiting the fryer through completion of oil stripping. 
     In connection with the previous object, it is yet another object to initiate and complete the oil stripping centrifuge action in a manner that provides little opportunity for the fried food product to cool as contrasted to the manner typical of batch centrifuge action. 
     A further object is to provide a quasi-continuous centrifuge apparatus which in its simplicity of design and cyclic operation is adaptable to receive a continuous stream of hot oil coated food products, strip the surface oil and discharge the products relatively damage free and at low kinetic energy. 
     The above and additional objects and features of the invention will appear from the following specification in which a preferred embodiment has been set forth in detail and illustrated in the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an elevation view of the centrifuge of one preferred form of the present invention, the view being partially in cross-section; 
         FIG. 2  is an isometric view of the centrifuge shown in  FIG. 1  shown partially cut away to depict the major centrifuge components and the annular oil collection trough and oil discharge tube; 
         FIG. 3  is an isometric view on a larger scale showing the centrifuge drum with the perforate inner shell and associated conical baffles and conical chutes; 
         FIG. 4  is a sectional view taken in the direction of the arrows  4 - 4  of  FIG. 1  illustrating the flow and distribution of the product while the centrifuge drum is rotating at high speed; 
         FIG. 5  is a view like  FIG. 4  taken in the direction of the arrows  5 - 5  of  FIG. 1  illustrating the flow and accumulation of product entering, traversing and exiting the centrifuge while the drum is stationary or rotating at low speed; and 
         FIGS. 6 and 7  are respectively curves of time versus the centrifuge speed in rpm&#39;s and acceleration in g loads of the centrifuge operational cycles. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     An improved centrifuge apparatus  10 , in accordance with the method of the present invention, is equipped to remove surface oil from a delicate snack food product  11  upon its emergence from an oil fryer (not shown) and is depicted in the drawings,  FIGS. 1 and 4  particularly. The apparatus  10  is a quasi-continuous centrifuge and includes a support frame  12 , an external shroud  13 , a vertically extending drive shaft  14  and shaft drive means comprising an electric motor  16  with drive pulleys  17 - 18  and timing belt  19 . A programmable motor controller is also provided, either integral with the motor  16  or mounted remotely. 
     Referring to  FIGS. 2 and 3 , an internal drum  21  having perforate side walls  22  is mounted on the shaft  14  for rotation radially inwardly of the shroud  13 . Three frusto-conically shaped product chutes  23  are mounted to the side walls  22  of the drum  21  concentric with the drive shaft  14 . Mounted on the shaft  14  above each chute  23  is a conical baffle  24 . Top  26  and bottom  27  bearing assemblies mounted on top and bottom horizontal frame members  28  and  29  respectively serve to rotatably support the drive shaft  14  with respect to the frame  12 . Together each baffle  24  and chute  23  form a centrifuge operational stage and thus there is disclosed a three stage centrifuge. 
     As shown in FIGS.  1 , 2   4  and  5 , a product feed assembly  31  is mounted with respect to the top horizontal frame member  28  so as to receive a continuous supply of food product  11  from a source (not shown) and to disperse the same in downward streams onto the uppermost conical baffle  24  within the drum  21 . A product discharge chute  32 , as shown in  FIGS. 1 and 2 , is mounted on the frame so as to receive product descending from the lower most chutes  23  upon completion of the oil removal action of the centrifuge  10 . A stiffening ring  33  is fixed to the drum  21  at the lower chute  23  as shown in  FIG. 3 . Similarly, an upper stiffening ring  34  is fixed to an upper portion of the drum  21 . 
     Referring specifically to  FIGS. 4 and 5  where we see depicted two distinct operational modes of the centrifuge apparatus  10 .  FIG. 5  shows the disposition of the food products  11  when the rotational speed of the drum  21  is on the order of 0 to 30 rpm and the “g” loads approach 0. (As used herein the symbol “g” refers to gravity forces which are applied to the products  11  by operation of the centrifuge  10 . These g forces are in the range of 0 ((normal)) to as much as 60 to 70 g&#39;s.)  FIG. 4  shows the disposition of the food products  11  when the rotational speed of the drum  21  is on the order of 200 to 600 rpm and the g loads are in the higher range, 30 to 70 g&#39;s. Note that product  11  may be introduced into the infeed chute  31  continuously irrespective of the rotational speed of the drum  21  while product  11  may discharge form the discharge chute  32  when the drum is at low rotational speed. Thus it will be understood that as the drum  21  rotates in the low speed mode as shown in  FIG. 5 . food product  11  drops downwardly initially from the infeed chute  31  onto the uppermost conical baffle  24  to dwell there until the drum rotates in the acceleration mode where upon the product takes the positions as shown in  FIG. 4 . Upon drum rotation in the deceleration mode, the product cascades downwardly as indicated by the arrows  36  in  FIG. 5 . It will be further understood that as the drum rotation subjects the product  11  to high g forces, the surface cooking oil adhering to the product is stripped away and penetrates the drum wall perforations. In the low speed mode the oil so stripped moves downwardly along the inner walls of the shroud  13  and is received in a collection trough  37  and thence to a discharge tube  38 . The oil thus recovered may be reused or not as the plant operator chooses. It has been observed that some snack products may be effectively de-Quasi-Continuous oiled using accelerations as low as 30 g and may be damaged by higher g forces. As will be recognized by those skilled in the art, the g force is dependent upon both drum rotational speed and drum diameter. Therefore, we prefer as a practical range of useful drum diameters between about 400 mm and about 1200 mm. A preferred range of high g rotational speeds can be between about 200 and 600 rpm. The rotational speed range of 0-50 rpm is suitable for maintaining less than 1 g for that range of diameters. 
     With reference to  FIGS. 6 and 7  where typical drum speeds and g loads are charted, three examples of product treatment are given below from use of the centrifuge  10 . 
     EXAMPLES 
     Example 1 
     Expanded pellets of approximately rectangular shape 50 mm by 40 mm by 4 mm thick and having irregular, wavy surface texture and shape were fed continuously at a rate of 60 kg/hr, directly from the fryer into a centrifuge having a 3-stage, 400 mm diameter drum. The centrifuge was running at 9.2 seconds cycle duration, as follows:
         1) 0.2 seconds acceleration time;   2) 5 seconds at high speed of 550 rpm;   3) 1 second deceleration time;   4) 3 seconds at low speed of 30 rpm.       

     Samples of pellets taken before and after the centrifuge treatment were compared. Directly from the fryer, the pellets appeared wet, with a liberal coating of oil on the surface of each pellet, and the total oil content of the sample was measured ay 14.4%. After centrifuging the pellets appeared noticeably dryer than before and the total oil content of the sample was measured at 9.6%. 
     Example 2 
     Expanded pellets in the shape of small donuts of approximately 22 mm outside diameter and 7 mm cross-sectional diameter were fed continuously at a rate of 220 kg/hr, directly from the fryer into a centrifuge having a 2-stage, 400 mm diameter drum. The centrifuge was running at 6.2 seconds cycle duration, as follows:
         5) 0.2 seconds acceleration time;   6) 4 seconds at high speed of 550 rpm;   7) 1 second deceleration time;   8) 1 second at low speed of 30 rpm.       

     Samples of pellets taken before and after the centrifuge treatment were compared. Directly from the fryer, the pellets appeared wet, with a substantial quantity of oil retained in the spaces between pellets, and the total oil content of the sample was measured ay 27.1%. After centrifuging the pellets appeared noticeably dryer than before and the total oil content of the sample was measured at 13.7%. 
     Example 3 
     Expanded pellets in the shape of sticks approximately 150 mm long and oval, approximately 6 mm by 8 mm, in cross section were fed continuously at a rate of 150 kg/hr, directly from the fryer into a centrifuge having a 2-stage, 400 mm diameter drum. The centrifuge was running at 6.2 seconds cycle duration, as follows:
         9) 0.2 seconds acceleration time;   10)4 seconds at high speed of 550 rpm;   11) 1 second deceleration time;   12) 1 second at low speed of 30 rpm.       

     Samples of pellets taken before and after the centrifuge treatment were compared. Directly from the fryer, the pellets appeared wet, with a substantial quantity of oil retained on the surfaces of the sticks, and the total oil content of the sample was measured ay 20.5%. After centrifuging the pellets appeared noticeably dryer than before and the total oil content of the sample was measured at 13.1%. In all 3 examples, the degree of de-oiling was similar to that typically achieved in a conventional, batching centrifuge. 
     The embodiments disclosed herein together with the examples of use of the invention were chosen to best explain and describe the principles of the invention and its practical application to thereby enable any others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention is to be defined by the claims appended hereto.