Abstract:
A system for removing trim from sheet dough including a belt defined by an upper edge, lower edge, an interior surface, and an exterior surface, wherein a plurality of brushes extend from the lower edge of the belt at an orientation substantially perpendicular to the lower edge, an idler sprocket in communication with the interior surface of the belt, and a motor configured to rotate the belt about the idler sprocket.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to apparatus and methods for fabricating packaged food products such as dough products. In particular, the present invention relates to a device and method useful for removing trim from raw dough products to create a straight and uniform product before packaging. 
       BACKGROUND OF THE INVENTION 
       [0002]    Many consumers enjoy the convenience of packaged food products such as dough products. In particular, raw dough products have gained commercial success as provided in frozen or refrigerated forms to enable consumers to make home-baked dough products. Such raw dough products are typically packaged in formats to facilitate consumer use, as desired. Potential consumers of such refrigerated or frozen dough products include individual in-home consumers, as well as in-store bakeries and restaurants that bake rolls or cookies on-site and sell the products to customers at the bakery or restaurant. 
         [0003]    Many dough products suitable for packaging as frozen or refrigerated products have been developed. For example, biscuits or breadsticks are frequently packaged in refrigerated or frozen forms, using a package that contains multiple portions in a spiral-wound can. In this format, the can must be opened, and the multiple products removed and prepared by the consumer. 
         [0004]    One processing format for dough used to form biscuits or breadsticks is sheeting. Such sheeted dough is typically more suitable for high-speed processes of manufacturing. Generally, sheeted dough possesses adequate cohesiveness to hold together during conveying, yet yields clean separations of the individual dough pieces as the various pieces are cut by a conventional apparatus. 
         [0005]    One known method for making sheeted dough on a mass production basis utilizes a conveyor. According to this process, appropriately formulated dough is fed from a hopper downwardly through a sheeting system, or series of rolling devices, which reduces the thickness of the dough sheet to less than 10 mm. As the dough leaves the rolling devices, it is then transferred onto the conveyor. Next, the dough is formed into a flat sheet with the potential for making multiple lanes of product. The dough can then be cut into strips using conventional means. The shape of the dough is then further manipulated, and collected into groups of multiple products for subsequent packaging and storage in refrigerated or frozen environments. These high-speed methods for sheeted dough typically produce thousands of products a minute, depending on the rate of manufacture. 
         [0006]    When transported on the conveyor, the portions of the dough at the outer edges of the sheet are typically rough, or otherwise uneven. Before subsequent processing, it is desirable to create straight or uniform edges on the sides of the stream of dough. Accordingly, this edge portion must be removed to create a uniform and aesthetically pleasing product before it is packaged. If not trimmed or removed, the outside lane of product would be malformed and unacceptable to the consumer. 
         [0007]    A variety of methods have been used to remove trim from the edge of the stream of dough as the dough travels on the conveyor. Manual removal by a production line operator yields a desirable result in terms of accuracy and integrity of the remaining dough product. However, manual removal is generally not feasible in high speed manufacturing processes that are practiced on a plant scale. 
         [0008]    Mechanical devices that have been used to remove trim from a dough stream are shown in  FIGS. 1 and 2 . In  FIG. 1 , a prior art mechanical device in the form of a stationary plow  2  is positioned downstream from the cutting wheel  4 . As the dough stream moves along the conveyor  28 , the trim  36  is separated from the main stream of dough when the cutting wheel  4  passes over the dough. As the trim  36  continues to move along the conveyor  28 , it contacts the plow  2 . The plow  2  forces the trim  36  to move in a direction away from the main stream of dough, and eventually off the conveyor  28 . 
         [0009]    An alternative prior art mechanical device for removing trim  36  from a dough stream is shown in  FIG. 2 . In this embodiment, a rotary brush  6  and motor  8  are positioned downstream from the cutting wheel. The rotary brush  6  is defined by a circular disk with bristles on the entire under-surface of the disk. The motor  8  is positioned directly above the brush  6 , and is configured to rotate the brush  6  about the axis of the motor&#39;s drive-shaft. During production, the motor  8  continuously rotates the brush  6 . As the dough stream moves along the conveyor, the trim  36  is separated from the main stream of dough when the cutting wheel passes over the dough. As the trim  36  continues to move along the conveyor, it comes into contact with the rotating brush  6 . The rotation of the brush  6  in the desired direction causes the trim  36  to move in a direction away from the main stream of dough, and eventually off the conveyor. 
         [0010]    The devices shown in  FIGS. 1 and 2  have a wide variety of shortcomings. For example, the stationary plow  2  is only able to move the trim a short distance. If the length of the plow  2  is increased with the intention of moving the trim  36  a longer distance, the frictional force of the trim  36  against the plow  2  is increased, often causing the trim  36  to bunch up, or twist onto the main dough stream. 
         [0011]    The rotary brush is also incapable of moving the trim large distances because the diameter of the rotating brush serves as a functional limitation. Furthermore, neither the plow nor the rotary brush devices are very reliable or consistent at “self-starting” the trim from the belt. For example, when a new dough stream, or previously broken dough stream moves down the conveyor, dough will often ball-up on the plow or ride over the top of the rotary brush. Moreover, a further drawback of the rotary brush embodiment is the drive motor that is generally located above the brush and over the product zone. In this configuration, additional care must be taken to avoid the possibility of machine particles or lubricants contacting the dough stream. 
         [0012]    In addition to the shortcomings discussed above, the alignments of mechanical removal devices are especially difficult when manufacturing sheet dough on a large scale. For example, the act of contacting a dough stream with a mechanical apparatus can alter the dough stream by inappropriately picking up the dough stream, deforming the dough stream, or moving the dough stream to an undesired location. These problems can be exacerbated at the high speeds of modern production processes described above. 
       SUMMARY OF THE INVENTION 
       [0013]    The apparatuses and methods according to the various embodiments of the present invention remove uneven trim efficiently from a food-product stream without causing damage to the dough product. The invention specifically includes a system for removing trim from sheet dough. The system comprises a belt defined by an upper edge, lower edge, an interior surface, and an exterior surface. A plurality of brushes extend from the lower edge of the belt at an orientation substantially perpendicular to the lower edge. An idler sprocket is in communication with the interior surface of the belt, and a motor is configured to rotate the belt. The motion of the belt causes the plurality of brushes adjacent to the idler sprocket to contact the trim and sweep it away from the food product. In a preferred embodiment, the motor is positioned adjacent to the conveyor, such that machine particles and lubricants cannot drop from the motor onto the conveyor. 
         [0014]    In an alternative embodiment, the invention includes a device for removing trim from sheet dough. The device comprises a belt defined by an upper edge and a lower edge. A plurality of brushes extend from the lower edge of the belt at an orientation substantially perpendicular to the lower edge. 
         [0015]    In yet another alternative embodiment, the invention includes a method of removing trim from a food product stream. The method comprises the steps of providing a system having a belt defined by an upper edge, lower edge, an interior surface, and an exterior surface. A plurality of brushes extend from the lower edge of the belt at an orientation substantially perpendicular to the lower edge. The belt is rotated about an idler sprocket to sweep trim away from the food product stream. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The embodiments of the present invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which: 
           [0017]      FIG. 1  is an isometric view of a prior art mechanical trim removal system. 
           [0018]      FIG. 2  is an isometric view of an alternative embodiment of a prior art mechanical trim removal system. 
           [0019]      FIG. 3  is an isometric view of the trim removal system according to an embodiment of the present invention; 
           [0020]      FIG. 4  is an isometric view of the trim removal system according to an alternative embodiment of the present invention; and 
           [0021]      FIG. 5  is a front view of a belt according to the present invention. 
       
    
    
       [0022]    While the present invention is amendable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the present invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims. 
       DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0023]    The system of the present invention can be used for a wide variety of sheeted dough products. Accordingly, the present invention is described by way of example in connection with, but is not limited to, the system  10 , as shown in  FIG. 3 . It should be understood that system  10  of the present invention is not in any way limited to such use and can be applied to a variety of other applications for food preparation. 
         [0024]    Referring to  FIG. 3 , system  10  according to an embodiment of the present invention generally includes motor  12 , belt  14 , and brushes  16 . Sprocket  18  is coupled to motor  12  such that sprocket  18  rotates when a rotational force is applied by motor  12 . Idler sprocket  20  is coupled to motor  12  by arm  22 . In a preferred embodiment, motor  12  includes a variable-speed motor capable of delivering up to 1800 rpm. However a wide variety of motors can be used while remaining within the scope of the invention. 
         [0025]    Belt  14  is disposed about sprocket  18  and sprocket  20 . Belt  14  includes upper edge  24  proximate to motor  12  and lower edge  26  on the side of belt  14  away from motor  12 . This configuration enables belt  14  to rotate about sprockets  18  and  20  when a force is applied by motor  12 . A plurality of brushes  16  extend from lower edge  26  of belt  14 . In a preferred embodiment, the plurality of brushes  16  are substantially perpendicular to lower edge  26 . 
         [0026]    In a preferred embodiment, belt  14  includes a timing belt. However, in alternative embodiments, belt  14  can also include a wide range of power transmission components including “V” belts, chains, narrow conveyor belts, or plastic belts, each with a plurality of brushes  16  that extend from such belts or chains in a substantially perpendicular direction. 
         [0027]    System  10  is preferably disposed over conveyor  28 . During the manufacturing process, food product  30  travels on conveyor  28  in a direction toward system  10 . Food product  30  is cut into strips  32  and  34 . Food product  30  also includes trim  36 . Trim  36  includes uneven edge  38 . It is desirable for trim  36  to be removed from the conveyor  28  because uneven edge  38  can create irregularities in the final product. 
         [0028]    In operation, motor  12  turns sprocket  18  in a counter-clockwise direction with respect to  FIG. 3 . This, in turn, causes belt  14  to rotate in a generally counterclockwise direction. As product  30  approaches system  10 , the plurality of brushes  16  adjacent to sprocket  20  contact product  30  between strip  34  and trim  36 . The rotation of belt  14  causes brushes  16  to pull trim  36  off conveyor  28  while leaving a straight edge  40  for further processing or packaging. 
         [0029]    In a preferred embodiment, sprocket  20  includes a relatively small radius to create a more effective “sweeping” motion to effectively pull trim  36  away from the remaining product  30 . In one embodiment, the radius of sprocket  20  is less than 4 inches (10.16 cm). In yet another embodiment, the radius of sprocket  20  is less than 2 inches (5.08 cm). 
         [0030]    With reference to  FIG. 4 , an alternative embodiment of system  10  will now be discussed. System  10  is mounted on shaft  42 . Shaft  42  is generally comprised of a stainless steel shaft collar that is one inch in diameter. However, a variety of shafts can be used while remaining within the scope of the invention. 
         [0031]    System  10  is vertically adjustable with respect to shaft  42  using handle  44 . Handle  44  can be loosened to move system  10  along shaft  42  until brushes  16  contact conveyor. Once the desired vertical adjustment is achieved, handle  44  is tightened to secure the position of system  10  with the force of friction. 
         [0032]    System  10  includes frame  46  to position belt  14  at a distance away from motor  12 . This configuration is desirable orient motor  12  adjacent to conveyor  28  to keep machine particles and lubricants from falling onto conveyor  28 . Motor  12  is mounted to frame  46  in a vertical orientation. In a preferred embodiment, motor  12  is comprised of a ½ hp electric motor capable of operating at about 180 revolutions per minute. However, a wide variety of motors may be used while remaining within the scope of the invention. 
         [0033]    The rotational force of motor  12  is transferred to belt  14  through drive belt  45 . In this embodiment, drive belt  45  is disposed about sprocket  18  such that the operation of motor  12  causes sprocket  18  to rotate. The rotational force of drive belt  45  is transferred to belt  14  at hub  48 . Hub  48  is mounted to frame  46  by shaft  50 . Arm  22  is pivotally coupled to frame  46  by shaft  50 . 
         [0034]    Belt  14  is disposed about idler sprocket  20  and hub  48 . In a preferred embodiment, the position of arm  22  can be adjusted with respect to frame  46  using handle  52 . This enables an operator to position sprocket  20  at a desired location so that the plurality of brushes  16  will be in an optimal position to remove trim  36  from product  30 . When arm  22  is in a desired position, the user can tighten handle  52  so that the force of friction will prevent arm  22  from pivoting with respect to frame  46 . 
         [0035]    With reference to  FIG. 5 , additional detail of belt  14  is shown. In one embodiment, belt  14  is comprised of urethane. In a preferred embodiment, belt  14  is comprised of reinforced urethane to provide additional strength and wear-resistance. 
         [0036]    Belt  14  includes upper edge  24 , and lower edge  26 . A plurality of brushes  16  are attached to lower edge  26  of belt  14  in an orientation that is substantially perpendicular to lower edge  26 . In one embodiment, multiple brushes  16  are disposed along the length of belt  14 . 
         [0037]    Brushes  16  are comprised of individual bristles  54 . Bristles  54  are generally comprised of nylon, although a variety of materials may be used while remaining within the scope of the invention. In a preferred embodiment, bristles  54  are stiff and fine enough so they will gently sweep the trim  36  off the conveyor in a controlled manner, without causing damage to the dough product. 
         [0038]    Bristles  54  can be defined by a wide variety of lengths while remaining within the scope of the invention. In one embodiment, bristles  54  are between 1 inch and 6 inches long (2.54 cm to 15.24 cm). In a preferred embodiment, bristles  54  are between 2 inches and 4 inches long (5.08 cm to 10.16 cm). 
         [0039]    The embodiments above are intended to be illustrative and not limiting. Additional embodiments are within the claims. In addition, although the present invention has been described with reference to particular embodiments, those skilled in the art will appreciate that changes can be made in form and detail without departing from the spirit and scope. Any incorporation by reference of documents above is limited such that no subject matter is incorporated contrary to the explicit disclosure herein.