Patent Publication Number: US-2022212817-A1

Title: Apparatuses and methods for enclosing a filling in a food product

Description:
BACKGROUND 
     The present disclosure relates generally to apparatuses and methods for enclosing a filling in a food product. More specifically, the present disclosure is directed to a supply assembly for introducing a viscous filling, such as a gravy, into a loaf matrix so that the filling remains enclosed by the loaf matrix after retorting. 
     Conventional loaf-type food products are typically coagulated emulsions sold in containers bearing the shape of the loaf-type food products. Loaf-type food products are commonly used as pet foods because they are easily manufactured, readily digested by the animals, very palatable to the animals, and readily formulated to contain necessary nutrients and trace elements. 
     Pet owners are continually seeking appealing canned food forms or varieties for their pets. Although a loaf product containing a filling may be such a pet food, consistently creating a loaf-type food product having a substantial and defined filling is difficult to accomplish. Devices for forming such loaf-type food products often have problems of dispensing too little or too much filling into the loaf product. 
     SUMMARY 
     The present disclosure is directed to a filler device comprising a modified vacuum-filling head that introduces a viscous filling, such as a gravy, into a loaf matrix so that the filling remains enclosed by the set loaf matrix after retorting, The filling may remain as a viscous gravy or may set as a gel, depending on the formulation of the filling. The viscous filling is distributed horizontally into the loaf matrix during a brief pause in the descent of the can away from the filling device. 
     In the present application, the filler device may comprise a first supply assembly that directs a first composition, such as the loaf matrix, and a second supply assembly that directs a second composition, such as the viscous filling, to a filling head. Through operation of the filler device, first and second channels within the filling head direct the first and second compositions, respectively, into a can positioned within the filling head. 
     During use, the first supply assembly is operated to fill the can with a predetermined amount of the first composition. The second supply assembly is then operated to inject the second composition into the first composition within the can. 
     In the embodiments described herein, the second supply assembly utilizes a dosing piston to direct a predetermined amount of the second composition into the first composition in the can. The dosing piston is first operated to withdraw the predetermined amount of the second composition from a second supply container through a third channel, and then operated to dispense the predetermined amount of the second composition through a hose to the second channel adjacent the filling head. 
     The second supply assembly may include one or more rotary valves to control fluid flow through the hose and channels. In a first embodiment of the second supply assembly, a first valve is positioned at an outlet of the dosing piston to switch between a connection to the second supply from the container and a connection to the hose. A second valve is positioned between the hose and the second channel to control flow as it enters the second channel and is directed into the filling head. Each of the first valve and the second valve is a rotary valve driven by a mechanical cam. 
     In a second embodiment of the second supply assembly, the second supply assembly includes a first valve positioned at the outlet of the dosing piston to control flow from the dosing piston into the hose. The first valve is a rotary valve driven by a mechanical cam. The second supply assembly also includes a second valve or rotatable seal within the filling head. A valve channel on the second valve connects the second channel with a nozzle through which the second composition is dispensed from the filling head. The second valve moves between an open position, where the valve channel is aligned with the second channel and the nozzle, and a closed position, where the valve channel is out of alignment with the second channel and the nozzle. 
     An advantage of the present disclosure is to provide an apparatus and a method that form a canned pet food product containing a first composition that substantially or completely encloses a second composition utilizing components that consistently provides a loaf-type food product having a well-defined, appropriate amount of the second composition within the first composition. 
     A further advantage of the present disclosure is to provide an apparatus and a method for forming a canned pet food product that utilizes mechanically-driven components, thereby reducing the chance of failure of the supply assembly. 
     Additional features and advantages are described herein and will be apparent from the following Detailed Description and the Figures. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1A  shows a perspective view of a pet food product containing a first composition completely encasing a second composition in an embodiment provided by the present disclosure. 
         FIG. 1B  shows a perspective view of the pet food product of  FIG. 1A  after the product has been cut open. 
         FIG. 2  shows a flowchart of an embodiment of a method provided by the present disclosure. 
         FIG. 3  is a schematic view of a filler device including a first embodiment of a second supply assembly including two rotary valves. 
         FIGS. 4A and 4B  are schematic views of a first embodiment of the second supply assembly of  FIG. 3 . 
         FIGS. 5A-5E  are schematic views of the first embodiment of the second supply assembly of  FIG. 3  and show operation thereof. 
         FIG. 6  is a schematic view of a filler device including a second embodiment of a second supply assembly including a single rotary valve. 
         FIGS. 7A-7C  are schematic views of a second embodiment of the second supply assembly of  FIG. 6 . 
         FIGS. 8A-8E  are schematic views of the second embodiment of the second supply assembly of  FIG. 6  and show operation thereof. 
         FIG. 9  shows a perspective view of an embodiment of a nozzle provided by the present disclosure. 
         FIGS. 10A and 10B  are schematic views of a first embodiment of a mechanical cam assembly of the second supply assembly of  FIGS. 5A-5E . 
         FIGS. 11A and 11B  are schematic views of a second embodiment of a mechanical cam assembly of the second supply assembly of  FIGS. 5A-5E . 
     
    
    
     DETAILED DESCRIPTION 
     As used in this disclosure and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. The words “comprise,” “comprises,” and “comprising” are to be interpreted inclusively rather than exclusively. Likewise, the terms “include,” “including,” and “or” should all be construed to be inclusive, unless such a construction is clearly prohibited from the context. However, the devices and methods disclosed herein may lack any element that is not specifically disclosed. Thus, a disclosure of an embodiment using the term “comprising” includes a disclosure of embodiments “consisting essentially of’ and “consisting of’ the components and steps identified. 
     The term “enclosed” means that the enclosed composition is completely or substantially enclosed in a food product. The enclosed composition is “substantially enclosed” if less than 20% of the enclosed composition is visible on the surface of the food product, preferably less than 10%, more preferably less than 5%, most preferably less than 1%. 
     The term “can” means a rigid retortable container, for example a metal container such as a metal or metal alloy cart a plastic container, a glass container, and combinations thereof. The term “canned” means that a food product is contained in a can. 
     The term “pet” means any animal which could benefit from or enjoy the food products provided by the present disclosure, The pet may be an avian, bovine, canine, equine, feline, hircine, lupine, murine, ovine, or porcine animal. The pet may be any suitable animal, and the present disclosure is not limited to a specific pet animal. The term “companion animal” means a dog or a cat. The term “pet food” means any composition intended to be consumed by a pet. 
     Ranges are used herein in shorthand to avoid listing every value within the range. Any appropriate value within the range may be selected as the upper value or lower value of the range. Moreover, the numerical ranges herein include all integers, whole or fractions, within the range. 
     All percentages expressed herein are by weight of the total weight of the food composition unless expressed otherwise. When reference is made to the pH, values correspond to pH measured at 25° C. with standard equipment. As used herein, “about” or “approximately” in reference to a number is understood to refer to numbers in a range of numerals, for example the range of −10% to +10%, preferably −5% to +5%, more preferably −1% to +1%, and even more preferably −0.1% to +0.1% of the referenced number. 
       FIGS. 1A and 1B  generally show an embodiment of a food product  10  comprising a first composition  11 , and the first composition  11  forms an outer matrix enclosing a second composition  12 . These figures show the first composition  11  completely enclosing the second composition  12 , but some embodiments of the food product  10  have the first composition  11  substantially enclosing the second composition  12 . 
     The food product  10  may have a shape corresponding to the shape of the interior of the can in which the food product  10  is formed. For example, the food product  10  may be substantially cylindrical. However, the food product  10  is not limited to a specific shape and may have any shape. 
     In an embodiment, the second composition  12  is substantially centered in the food product  10  and has a spherical or ovoid shape. For example, the center of the second composition  12  is about the same as the center of the food product  10 . Nevertheless, the food product  10  is not limited to the specific embodiment shown in  FIGS. 1A and 1B . 
     The food product  10  may be a pet food, preferably for a companion animal. The food product  10  may be formed in a can as discussed in more detail later in this application. The first composition  11  and the second composition  12  may comprise any suitable amount of the food product  10 . For example, the first composition  11  may comprise from about 25% to about 75% of the food product  10  while the second composition  12  may comprise the remaining 75% to 25% of the food product  10 . 
     In an embodiment, the food product  10  may be one of the food products disclosed by U.S. patent application Ser. No. 13/896,470 to Watelain et al. filed on May 17, 2013 and published as U.S. Patent App. Publication No. 2013/0309372 on Nov. 21, 2013, herein incorporated by reference in its entirety. However, the food product  10  is not limited to the food products disclosed therein. 
     In an embodiment, the first composition  11  and the second composition  12  are not miscible or have low miscibility and thus form two different phases in the food product  10  that do not mix. This embodiment of the food product  10  comprises two separate phases, namely an outer phase corresponding to the first composition  11  and an inner phase corresponding to the second composition  12 . 
     In an embodiment, the first composition  11  is an emulsion, for example a meat emulsion. The meat emulsion may comprise any suitable ingredients, for example fibrillar protein and polysaccharides. Suitable fibrillar proteins include myosin, actin, actomyosin, collagen, and mixtures thereof, such as protein from bovine, equine, ovine, avian, porcine, caprine, ovine, and piscine sources. Examples of suitable polysaccharides include starches, gums, or mixtures thereof. 
     In an embodiment, the second composition  12  is a dispersion, such as a colloid dispersion, for example a hydrocolloid dispersion. For example, the second composition  12  is a flowable sol, an emulsion, or a gel. As discussed in further detail below, the food product  10  may be retorted; depending on the formulation of the second composition  12 , the second composition  12  may retain the original form in which it is injected into the first composition  11  or, alternatively, retorting may change the form of the second composition. For example, the second composition  12  may be injected into the first composition  11  as a flowable sol or an emulsion, and retorting of the food product  10  may change the form of the second composition  12  to a gel. 
     In one embodiment, the second composition  12  is a gravy comprising a thickener that is at least one of a starch or a gum, Examples of suitable gums are gellan gum, xanthan gum, locust bean gum, pectin, carrageenan (e.g., kappa, iota, and/or lambda), cellulose gum (e.g. carboxy methyl cellulose), gum arabic, konjac, guar gum, agar agar, cassia gum, alginate, and the like, and combinations thereof. Suitable starches include native starches, starch esters, starch ethers, and modified starches, such as starch modified with erythorbic acid, and combinations thereof. Starch sources may include wheat, barley, rice, tapioca, potato and corn, for example. The gravy may also comprise dextrose and/or glycine and may also include a colorant as desired. Ingredients that add flavor and/or aroma to the gravy may also be included as desired. 
     The first composition  11  and/or the second composition  12  may optionally include additional ingredients. For example, the first composition  11  and/or the second composition  12  may comprise visible pieces of real or simulated ingredients for aesthetic appeal or nutritional function. In some embodiments, at least one of the first composition  11  and the second composition  12  comprise solubilized or dispersed nutritional ingredients, flavor or aroma compounds, or encapsulated flavors or nutrients for release during retorting, in the mouth, or in the alimentary tract. 
       FIG. 2  shows an embodiment of a method  100  by which a canned food product may be made. The method  100  may comprise forming a first composition and a second composition, preferably separately from each other, in Step  102 . In an embodiment, the first composition is an emulsion, for example, a meat emulsion. In an embodiment, the second composition is a dispersion, for example a gel, a flowable sol or an emulsion, in one embodiment, a gravy comprising a thickener that is at least one of a starch and a gum. 
     The method  100  may further comprise dispensing the first composition from a filler device into a can in Step  104 . Then the can may begin descent away from the filler device in Step  106 , preferably after the dispensing of the first composition into the can is completed. 
     Then a nozzle extending from the filler device may horizontally inject the second composition into the first composition in Step  108 . In one embodiment, this horizontal injection comprises injection of the second composition in a direction that is, at least initially, substantially perpendicular relative to the pathway within the nozzle and/or the vertical axis of the can. 
     In one embodiment, the descent of the can away from the filler device may be briefly paused, and the nozzle may horizontally inject the second composition into the first composition during a time period consisting of this pause. This pause may be 1.5 seconds or less, for example, 0.25 to 1.5 seconds. 
     In Step  110 , the descent of the can away from the filler device continues, and the nozzle is removed from the can. In an embodiment, the first composition encloses the second composition in this step. Optionally, the nozzle may be washed after removal from the can, for example by a water flush, in Step  112 . 
     The method  100  may further include placing a lid on the can after the first and second compositions have been dispensed into the can, in Step  114 ; sealing the can, for example hermetically, in Step  116 ; and retorting the can, in Step  118 . The can may be retorted at any suitable temperature for a suitable amount of time. For example, the can may be retorted a temperature from about 121° C. to about 128° C. for a time from 25 to 50 minutes. The filled can may optionally be inverted before retorting. 
     Then the can may be cooled by a device and/or allowed to equilibrate to room temperature in Step  120 . For example, the can may be cooled to a temperature of 20° C. to 35° C. In an embodiment, the can is cooled to a temperature of 22° C. to 26° C. The resulting food product may comprise a firmly set first composition, such as a meat emulsion, forming an outer matrix enclosing the second composition, such as a gravy. For example, the resulting food product may be the food product  10  disclosed above. 
       FIGS. 3 and 6  show embodiments of a filler device  200  that may form the food product  10  comprising the first composition  11  enclosing the second composition  12 . For example, the filler device  200  may be used in the method  100 , such as Steps  104  and  106  of the method  100 . However, the present disclosure is not limited to the embodiment of the filler device  200  disclosed herein and shown in the figures. In some embodiments, the food product  10  may be made by a different filler device, and the method  100  may be performed by a different filler device. 
     The filler device  200  may comprise a first supply assembly  210  that provides the first composition  11  and a second supply assembly  220 ,  320  provides the second composition  12 . The filler device  200  may comprise a filling head  230 . First and second embodiments of the second supply assembly  220 ,  320  are described below. 
     A first channel  232  may extend through the filling head  230  so that the filling head  230  may dispense the first composition  11  from the first supply assembly  210  into a can  300  that is positioned under the filling head  230 . A second channel  234  may extend through the filling head  230  so that a nozzle  242  extending from the filling head  230  may dispense the second composition  12  from the second supply assembly  220  into the can  300 . A port  236  may extend through the filling head  230  so that a vacuum may be formed in the can  300  which is used to draw the first composition into the can  300  from the first supply assembly  210 . The first channel  232 , the second channel  234 , and the port  236  are not shown in all figures so that the other components are easily viewed, and the absence of one of these components from a figure does not imply that the component is no longer present in the filler device  200  at that stage. 
     A lifting plate  250  may position the can  300 ; for example, the can  300  may be placed on the lifting plate  250  so that movement of the lifting plate  250  moves the can  300  correspondingly. In an embodiment, the lifting plate  250  is configured to move the can  300  vertically toward and vertically away from the filling device  200 . For example, the lifting plate  250  may be or may not be formed on a rotating cam. The lifting plate  250  may be one of a plurality of lifting plates, such as ninety lifting plates as a non-limiting example. The plurality of lifting plates may be rotated such that each lifting plate is aligned with the filler device  200  in turn. 
     A first embodiment of the second supply assembly  220  is shown in  FIGS. 3, 4A, 4B, and 5A-5E . The second supply assembly  220  may be connected to the second channel  234  through a series of conduits in order to be injected into the can  300 . To reach the second channel  234 , the second composition  12  first travels from the second supply container  218  through a third channel  238  to a dosing piston  240 . Operation of the dosing piston  240  directs the second composition  12  through a hose  222  to the second channel  234 . 
     In the illustrated embodiment, the second supply assembly  220  includes first and second valves  224 ,  226 . The first valve  224  is positioned between the dosing piston  240  and the hose  222 . Operation of the first valve  224  determines whether the second composition  12  will be dispensed into the can  300 . The second valve  226  is positioned between the hose  222  and the second channel  234 . During the vacuum-filling of the can  300  with the first composition  11 , closure of the second valve  226  of the second supply assembly  220  prevents the second composition  12  from being drawn into the can  300  and mixing with the first composition  11 , which would cause the loaf product to have a poorly defined viscous filling. Each of the first valve  224  and/or the second valve  226  is a rotary valve driven by a mechanical cam. Enlarged views of the first valve  224  and the second valve  226  are provided in  FIGS. 4A and 4B , respectively. 
       FIGS. 5A-5E  illustrate the process of dispensing the second composition  12  from the second supply  220  during the operation of the filler device  200 . In the beginning of the cycle shown in  FIG. 5A , the first and second valves  224 ,  226  are closed. The suction of the piston  240  causes the second composition  12  to fill the third channel  238  leading to the dosing piston  240 . The first and second valves  224 ,  226  remain closed and the dosing piston  240  remains empty while the can  300  is filled with the first composition  11 . 
     In the next stage of the cycle shown in  FIG. 5B , the dosing piston  240  is operated to create a suction and fill the dosing piston  240  with a predetermined amount of the second composition  12  driven by the piston stroke. The first and second valves  224 ,  226  remain closed during this step. The filling head  230  is rotated to align the second channel  234  with the nozzle  242  to enable the second composition  12  to be injected into the first composition  11 . 
     Once the dosing piston  240  is filled with the appropriate amount of the second composition  12 , the next step is to open the first and second valves  224 ,  226  to allow the second composition  12  to be discharged from the dosing piston  240  into the hose  222 . The first and second valves  224 ,  226  are opened as seen in  FIG. 5C . 
     Referring to  FIG. 5D , the dosing piston  240  is then operated to discharge the second composition  12  from the piston  240  through the hose  222  and second channel  234  into the first composition  11  within the can  300 . Once the injection is complete, the valves  224 ,  226  are closed, as seen in  FIG. 5E . The filling head  230  is rotated to move the second conduit  234  out of alignment with the nozzle  242 . 
     A second embodiment of the second supply assembly  320  is shown in  FIGS. 6, 7A-7C, and 8A-8E . The second supply container  318  may be connected to the second channel  334  through a series of conduits in order to be injected into the can  300 , similar to the first embodiment described above. To reach the second channel  334 , the second composition  12  first travels from the second supply  320  through a third channel  338  to a dosing piston  340 . Operation of the dosing piston  340  directs the second composition  12  through a hose  322  to the second channel  334 . 
     In the illustrated embodiment, a first valve  324  is positioned between the dosing piston  340  and the hose  322 . The first valve  324  is a rotary valve driven by a mechanical cam. Operation of the first valve  324  determines whether the second composition  12  will be dispensed into the can  300 , similar to the first valve  224  of the first embodiment of the second supply assembly  220 . An enlarged view of the first valve  324  is provided in  FIG. 7A . 
     The second supply assembly  310  also includes a fixed plate  326  underneath the filling head  230  containing a plate channel  346  that connects the second channel  334  and a filling head channel  231  with the nozzle  242  when in an open position, thereby allowing the second composition  12  to flow through the second channel  334  and nozzle  242  into the can  300 . The rotating filling head  230 , along with the internal filling head channel  231 , rotates in such a way that the second channel  334  is not in fluid connection with the plate channel  346  and nozzle  242 , thus preventing the second composition  12  from reaching the nozzle  242 . During the vacuum-filling of the can  300  with the first composition  11 , positioning the filling head  230  in the closed position, i.e., such that the filling head channel  231  is out of alignment with the second channel  334  and nozzle  242  as shown in  FIG. 8A , prevents the second composition  12  from being drawn into the can  300  and mixing with the first composition  11 , similar to the operation of the second valve  226  of the first embodiment of the second supply assembly  220 .  FIG. 8B  illustrates the filling head  230  in an open position such that the filling head channel  231  is aligned and in fluid connection with the second channel  334  and nozzle  242 .  FIGS. 7A-7C  provide enlarged views of the first valve  324  and the plate  326 . 
       FIGS. 8A-8E  illustrate the process of dispensing the second composition  12  from the second supply assembly  320  during the operation of the filler device  200 . In the beginning of the cycle shown in  FIG. 8A , the first valve  324  is closed. The suction of the piston  340  causes the second composition  12  to accumulate in the third channel  338  leading to the dosing piston  340 . The first valve  324  remains closed and the plate  326  remains in a closed position by means of the rotating filling head  230  while the can  300  is filled with the first composition  11 . 
     In the next stage of the cycle shown in  FIG. 8B , the dosing piston  340  is operated to prepare for filling the can  300  with a predetermined amount of the second composition  12 . The first valve  324  remains closed while the filling head  230  is rotated to align the second channel  334  with the plate channel  346  of the plate  326  to enable the second composition  12  to be injected into the first composition  11 . After the dosing piston  340  is filled with the appropriate amount of the second composition  12 , the next step is to open the first valve  324  to allow the second composition  12  to be discharged from the dosing piston  340  into the hose  322 . The first valve  324  is opened as seen in  FIG. 8C . The plate  326  is aligned with the second channel  334  and the filling head channel  231  at this point. 
     Referring to  FIG. 8D , the dosing piston  340  is then operated to discharge the second composition  12  from the piston  340  through the hose  322  and second channel  334  into the first composition  11  within the can  300 . Once the injection is complete, the first valve  324  is closed and the filling head  230  is rotated so that the second channel  334  and the filling head channel  231  are no longer aligned, thus closing the fluid connection with the plate channel  346 , as seen in  FIG. 8E . 
     In some embodiments, the nozzle  242  may comprise horizontally-facing apertures  244  that may be positioned in lateral surfaces of the nozzle  242  as shown in  FIG. 9 . The horizontally-facing apertures  244  may be at the same height on the nozzle  242  and may be evenly spaced from each other on the nozzle  242 . For example, the nozzle  242  may comprise four of the horizontally-facing apertures  244 , spaced ninety degrees apart in the nozzle  242 . In an embodiment, the horizontally-facing apertures  244  are positioned at the approximate center of the first composition  11 , both horizontally and vertically, during injection of the second composition  12 . The horizontally-facing apertures  244  may be any suitable diameter, for example a diameter of about 5 mm. 
       FIGS. 10A-11B  illustrate exemplary embodiments of first and second assemblies  400 ,  420  driving the first and second valves  224 ,  226  of the second supply assembly  220 . In  FIGS. 10A and 10B , the first mechanical assembly  400  includes a first mechanical cam  402  that drives the first valve  224  and a second mechanical cam  404  that drives the second valve  226 . Cams  402  and  404  move between the closed and open positions as shown in  FIGS. 10A and 10B , respectively. 
       FIGS. 11A and 11B  illustrate the second mechanical assembly  420  driving the first valve  224  and the second valve  226  of the second supply assembly  220 . In  FIGS. 11A and 11B , the mechanical assembly  420  includes first and second mounting levers  422 ,  424  onto which the first and second valves  224 ,  226 , respectively, are secured and which are connected by a rod  428 . A pneumatic piston  426  is connected to a proximal end of the first lever surface  422 , and the rod  428  extends between distal ends of the first and second mounting lever  422 ,  424 . Pressure applied through the pneumatic piston  426  causes the first and second mounting lever  422 ,  424  to rotate simultaneously, as shown in  FIGS. 11A and 11B . 
     In both embodiments  400 ,  420 , a pneumatic piston may be used to drive rotation of the valves. The compressed air may be supplied to the pneumatic piston through a pneumatic distributor. In some embodiments, the pneumatic distributor may be mechanically driven or remotely via wireless communications from a control mechanism of the filler device  200  described in greater detail below. 
     In an embodiment, the filler device  200  is connected to a control mechanism, for example a computer or another device comprising a processor. The filler device  200  may also include and/or be connected to a mechanical cam system. The control mechanism and/or mechanical cam system may control the progression of the first and second supply assemblies  210 ,  220 ,  320  of the filler device  200  through the stages shown in  FIGS. 5A-5E and/or 8A-8E . For example, the control mechanism and/or mechanical cam system may control and coordinate operation of the valves  224 ,  226 ,  324  and/or plate  326 , the dosing piston  240 ,  340 . In an embodiment, the control mechanism and/or mechanical cam system controls the relative timing of these components of the filler device  200 ; for example, the control mechanism may synchronize the first and second valves  224 ,  226  so that the valves are opened and/or closed at the same time. 
     It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.