Patent Publication Number: US-2010107971-A1

Title: Convergent spray nozzle apparatus

Description:
FIELD OF THE DISCLOSURE 
     The field of the disclosure generally relates to a convergent spray nozzle apparatus and, more particularly, relates to an apparatus and method for preparing food in an automated fashion with a convergent spray. 
     BACKGROUND OF THE DISCLOSURE 
     Many foods today are prepared in a highly automated fashion. Examples include industrial sized bakeries, confectionaries and the like. In many of these instances, it is necessary to spray or otherwise apply various ingredients and seasonings to the food product being prepared. One example would be in the preparation of snack products, such as potato chips. After the potato chips have been processed, cut and deep fried, baked or otherwise prepared, it is often desirable to provide seasonings such as salt, spices or other flavorings often in powder form, to the prepared potato chip. In order to ensure that the seasonings adhere to the food product being prepared, a binder of sorts is often used as well. In the case of snack products, such a binder could be provided in the form of oil such as corn oil, vegetable oil, or the like. The binder and seasoning can be mixed prior to being dispersed or being separately applied. 
     However, currently, there are no commercially available foodspray applicators which can spray such seasonings, binders and additives in a uniform, adjustable and highly automated fashion. It would therefore be advantageous if a foodspray applicator were to be created which could convergently spray oils, liquid sugars, dry seasonings, and other items uniformly upon a food product being prepared. 
     SUMMARY OF THE DISCLOSURE 
     In accordance with one aspect of the disclosure, a food preparation system is disclosed which comprises a conveyor, at least one spray nozzle assembly, a supply of edible material, and a source of fluid. The conveyor is adapted to transport a supply of food product. The spray nozzle assembly is positioned proximate the conveyor. The supplies of edible material and fluid are each connected to the spray nozzle assembly. The spray nozzle assembly includes a first conduit, and a second conduit. The first conduit expels the fluid. The second conduit expels the edible material. The first and second conduits are arranged to produce an edible material spray pattern for applying to the food product. 
     In accordance with another aspect of the disclosure, a spray nozzle assembly for applying edible material to food products is disclosed which comprises a first conduit, and a second conduit. The first conduit is adapted to be connected to a supply of fluid. The second conduit is adapted to be connected to a supply of edible material. 
     In accordance with another aspect of the disclosure, a method of preparing food products is disclosed which comprises the steps of conveying a supply of food product, positioning at least one spray nozzle assembly over the food product, directing a supply of binder through the spray nozzle assembly directing a supply of edible material through the spray nozzle assembly, mixing the binder and edible material downstream of the spray nozzle assembly, and depositing the edible material and binder on the food product. 
     These and other aspects and features of the disclosure will become more apparent upon reading the following detailed description when taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic representation of one embodiment of a food preparation system constructed in accordance with the teachings of the disclosure; 
         FIG. 2  is a side view of one embodiment of an array of spray nozzle assemblies positioned in a food-conveying system constructed in accordance with the teachings of the disclosure; 
         FIG. 3  is a front view of the array of spray nozzle assemblies of  FIG. 2 ; 
         FIG. 4  is a sectional view of one of the spray nozzle assemblies of  FIG. 2  taken along line  4 - 4  of  FIG. 2 ; and 
         FIG. 5  is an enlarged front view of one spray nozzle assembly of  FIG. 2 . 
     
    
    
     While the following disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the disclosure to the specific forms disclosed but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the disclosure as defined by the appended claims. 
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Referring now to the drawings, and with specific reference to  FIG. 1 , one embodiment of a food preparation system constructed in accordance with the teachings of the disclosure is generally referred to by reference numeral  20 . While the depiction and following text will be made primarily with respect to the preparation of a food product such as snack products, it is understood that the teachings of the disclosure can be used in the preparation of many other food products including, but not limited to, baked goods, candies, cereals, and the like. 
     The system  20  may include a conveyor to transport a food product  24  along a production line. As shown in  FIG. 1 , the conveyor of the system  20  may include a tumbler  22  adapted to tumble, overturn, or otherwise expose all sides of a food product  24  in a repetitive fashion across a lateral width  26 . The tumbler may include a blade or the like for flipping the food products. As used herein, “conveyor” is understood to mean any mechanism for moving a food product, with a tumbler being but one example. It is also to be understood that the tumbler  22  would he provided as a component in a more extensive food preparation system wherein upstream of the tumbler  22  would be various stations for preparing the food product  24  to the condition they are in upon reaching the tumbler  22 , and downstream of the tumbler  22 , various stations would be provided for handling the product thereafter. For example, in the preparation of potato chips, stations for cleaning, cutting, deep frying and baking would be provided upstream of the tumbler  22 , and stations for packaging and transporting would be provided downstream of the tumbler  22 . If tumbling of the food product  24  is unnecessary, the conveyor could be a conveyor belt or other suitable mechanism (not shown) that moves the food product  24  without tumbling, overturning, or otherwise mixing. 
     As also shown in  FIG. 1 , the food preparation system  20  could include a plurality or array of spray nozzle assemblies  28  mounted over the tumbler  22  upon one or more support bars  30 . It is envisioned that the support bar  30 , and thus array of spray nozzle assemblies  28 , would be provided in the tumbler  22 , at a suitable distance to ensure adequate application of the seasoning on the food product  24 . For example, the spray nozzle assemblies  28  could be placed between approximately nine to twelve inches above the food product in the tumbler  22 . It will also be noted that the array of spray nozzle assemblies  28  may extend the entire lateral width  26  of the tumbler  22 , but could also extend for just a portion of the lateral width  26 . In addition to the spray nozzle assemblies  28 , the food preparation system  20  further includes a supply  32  of edible material, such as a powdered seasoning, or any other solid, liquid or gaseous product to be applied to the food product  24 . 
     The food preparation system  20  may include a supply  34  of edible material such as a hinder like oil, or other solid liquid or gaseous product to be applied to the food product or to assist with the application of the seasoning to the food product  24 . The food preparation system  20  also includes a supply  36  of a fluid, such as compressed air  36 , to assist with the application of the seasoning and, if utilized, the oil to the food product  24 . Such supplies  32 ,  34 ,  36  can be provided in any number of conventional forms with the depiction providing the supply  36  of air in the form of an industrial air compressor  37 , the supply  34  of oil in the form of a tank  38 , and the supply  32  of seasonings in the form of a loss-in-weigh feeder or hopper  39 . The air compressor  37  can be a conventional design adapted to produce any desired air pressure, such as but not limited to 80-115 psig. The hopper  39  could be provided with a screw conveyor  40  to enable the seasoning  32  to be moved through its outlet  41 . The seasoning can fall by gravity feed into a ventura air eductor  70  and be carried by eductor vacuum to the spray nozzle assembly  28 . A valve  41  or the like may be used to direct the compressed air to the spray nozzle assemblies  28  and the supply line  42  as will be described in further detail herein. A metering pump  43  may he provided to direct the oil from the tank  38  through a flow meter  78  and then to the spray nozzle assemblies  28  in a dynamically controllable manner. 
     Referring now to  FIG. 2 , a bottom view of the array of spray nozzle assemblies  28  is depicted in the tumbler  22 . As shown therein, each spray nozzle assembly  28  is mounted to the support bar  30  and provided with a number of inlet lines. More specifically, a supply line  44  connects the supply  34  of oil to each of the spray nozzle assemblies  28 , one or more supply lines  42 A and  42 B connect the supply  32  of seasoning to each of the spray nozzle assemblies  28 , and a supply line  46  connects the supply  36  of compressed air to each of the spray nozzle assemblies  28 . Lines  42 ,  44 ,  46  can be any number of conventional conduits, but as the structure is involved in food preparation, the material from which the conduit is constructed should be sterilizable. Accordingly, one suitable material would be Nylon®, although other polymeric and metallic materials are possible as well. A support bracket  47  may be provided to support the spray nozzle assemblies  28  and supply lines  42 - 46 , with scallops  49  being provided to secure each of the lines in position. 
     With reference now to  FIG. 4 , one of the plurality of nozzle assemblies  28  is shown in detail. As depicted therein in one embodiment, each spray nozzle assembly  28  includes a conduit  48 . Conduits  42 A and  42 B may be positioned relative to the conduit  48  so as to laterally flank the central conduit  48 , although other arrangements are possible. For example, conduits  42 A and  42 B could be positioned adjacent to the conduit  48  in a lateral, above or below orientation. In other embodiments, the multiple conduits  48 ,  42 A and  42 B could be positioned in linearly alternating fashion, a circular orientation or any other configuration suited to a given snack product applicator. 
     As shown best in  FIGS. 2 and 3 , the air supply line  46  directs compressed air into the conduit  48 . If the food product  24  requires such application, then the oil feed line  44  can direct a stream of oil (or other binder) into the conduit  48 . Accordingly, when a gun trigger  52  is activated, the oil and air are released through a nozzle outlet  54 . Given the presence of the pressurized air and the small dimension of the nozzle outlet, the oil is immediately atomized and released in a desired spray pattern  56  out of the nozzle outlet  54 . For example, the spray pattern could have a fan shape, although in other applications, the spray pattern could be substantially cylindrical, or extend in a rectangular ribbon shape, or in any number of other shapes and configurations. Actuation of the gun trigger  52  could remove a pin  57  from the nozzle outlet  54 , thus enabling the pressurized air and oil to be expelled. Compressed air provided through supply line  59  may be used to activate the gun trigger  52 . 
     In one embodiment, the fan spray pattern  56  results in an angular arc of sixty five degrees, but it is certainly possible to tailor the arc as desired by adjusting the air pressure or size and shape of the nozzle aperture. Concurrent with the oil spray, seasoning carried by compressed air is discharged from the outer conduits  42 A and  42 B in desired spray patterns  58  and  60 , which may overlap and converge with the spray pattern  56 . To facilitate this, the conduits  42 A and  42 B may include outlets from conduits  42 A and  42 B which are inwardly angled toward the conduit  48 . For example, the spray patterns could have fan shapes. As with spray pattern  56 , other types of spray patterns can be mounted, including, but not limited to, cylindrical, conical, ribbon, intermittent, oscillating or the like. 
     As a result of the foregoing, directly in front of the spray nozzle assembly  28  the oil and seasoning converge and mix prior to being deposited on the potato chips. To facilitate proper alignment of the outer conduits  42 A and  42 B relative to the central conduit  48 , and their resulting spray patterns, a plate  62  may be provided proximate a front side of the nozzle assemblies  28 . As shown in  FIG. 5 , the plate  62  may be provided with slots  64  to allow for lateral variability in the spray patterns. In addition, it will be noted that slots  64  are provided at offset heights related to the central conduit  48 , thus widening the spray pattern. More specifically, in the depicted embodiment, the slots are at offset heights in that one slot  64  and thus conduit  42 A is provided above the conduit  48 , and the other slot  64  and conduit  42 B is provided below the conduit  48 . In other embodiments, additional slots or other mechanisms could be provided to allow for adjustment of the conduits  42 A and  42 B in lateral or other directions as well. Moreover, in other embodiments, the conduit or conduits can be provided at the same height as the conduit  48 , or at different distances from the conduit  48  than that shown. 
     As depicted in  FIG. 4 , the system  20  could include a nozzle cleaning or blowoff system  66 . As shown, the cleaning system  66  may include an outlet or blower port  68  positioned proximate the outlets  54  of the spray nozzle assemblies  28 . The system  66  may include an inlet connected to the supply  36  of compressed air  36  that also feeds the conduits  42 . In so doing, a vacuum can be created to carry the powdered seasoning from the hopper  39 . The cleaning system  66  can be used continuously or intermittently so as to direct a stream of compressed air or other fluid to the outlet  54  and thus facilitate cleaning of the outlet  54  ensuring that the spray exiting therefrom is able to maintain consistency. 
     The food preparation system  20  can also include a protective cover  68  extending across the array of spray nozzles  28  and support bar  30  to thus ensure the sanitary nature of the operation. The protective cover  68  can be manufactured of stainless steel or other sterilizable and easily cleanable material. In addition, the nozzle  28  and cleaning system  66  are also preferably manufactured of stainless steel such as, but not limited to,  316  stainless steel for similar reasons. 
     In operation, the food preparation system  20  can be used to coat a food product  24  with an edible material  32  such as a seasoning or other powder, and can help secure such seasonings or powder to the food product  24  using another edible material  34  such as a binder like oil. By spraying the binder  34  and seasoning  32  in converging spray patterns, the two are able to sufficiently mix prior to being deposited upon the food product  24 . This prior mixing helps ensure a uniform coating of both the seasoning and oil on the food product itself. More specifically, once the food products  24  are communicated to the tumbler  22 , they are exposed to the convergent sprays. In the tumbler  22 , the food product  24  is continuously overturned or otherwise presented for coating with the oil  34  and seasonings  32 . Concurrent with such motion, gun trigger  52  is actuated to thus relieve the pressure within the conduit  48 , thereby expelling the oil  34  and air  36  through the nozzle  54 . In so doing, the oil  34  is immediately atomized and discharged from the nozzle  54  in the desired spray pattern  56 . 
     Adjacent the nozzle  54 , the conduits  42 A and  42 B similarly spray the seasoning  32  in spray patterns  58  and  60 . By controlling the air pressure within the conduits  42 A and  42 B, the spray patterns  58  and  60  are tailored so as to converge with the spray pattern  56  a suitable distance in front of the nozzle  54 , and prior to application upon the food product  24  moving within the tumbler  22 . Moreover, by providing a plurality of nozzle spray assemblies  28  across the lateral width  26  of the tumbler  22 , the uniform coating of the seasonings and binder are assured across the entire width and thus volume of the food product  24  being processed within the tumbler  22 . It is to be further understood that other alternative orientations are possible. For example, multiple rows of nozzle assemblies  28  could extend along the lateral width  26  of the tumbler, or in another direction across the tumbler. Moreover, the spray nozzle assemblies  28  could be mounted directly in the tumbler  28 . One of ordinary skill in the art will readily understand multiple other mounting orientations are possible with the scope of the present invention. 
     It can therefore be seen that the teachings of the disclosure can be used to provide a food preparation system ensuring a consistently produced application of seasoning and binder materials to a food product being prepared. Various modifications thereof can be employed as will become readily apparent to one of ordinary skill in the art.