Abstract:
A mold fill plate and mold fill assembly are characterized by a mold fill plate and mold shuttle plate each being a planar body defining a longitudinal extent and a transverse extent and each having a plurality of elongate slots arranged so that when the slots are in registry a flowable food product can pass through the slots into a mold chamber, the slots further being arranged along at least a portion of their longitudinal extent with each slot extending across at least a portion of the transverse extent.

Description:
BACKGROUND OF THE INVENTION 
     The present invention is directed to methods and apparatus for forming molded food products and, more particularly, to a method and an assembly for forming a molded food product from a fibrous material resulting in enhanced natural texture of the molded food product. Various types of food patties are molded in high-volume automated molding machines. These can include hamburgers, “ribs,” fish cakes, chicken patties, pork and others characterized by fiber in the product. An example of such a molding machine and the molding process is disclosed in the Sandberg et al., U.S. Pat. No. 4,372,008. 
     The Sandberg patent identifies one of the problems inherent in molding food products. While the molding machines can make products consistent in size, weight and volume, some have difficulty in producing a realistic food texture. The Sandberg patent addresses that problem by providing a food mold fill plate as illustrated in FIGS. 1 and 2 herein, and an associated fill assembly. As seen in FIGS. 1 and 2, a mold fill plate  60  formed as a generally rectangular planar metallic body  62  having a plurality of openings  64  formed in rows and columns through the surface thereof Mounting openings  66  are provided around the edge of the body  62 . 
     As will be explained in greater detail hereinafter, the food molding process involves forcing a flowable food product, such as ground meat, through a mold fill plate such as that illustrated in FIGS. 1 and 2, or one having an alternate configuration. The food product flows through the openings  64  in the mold fill plate. According to the prior mold plate illustrated in FIGS. 1 and 2, the food product flows into generally vertical plugs that expand radially outwardly to contact one another or the walls of the mold chamber. This produces a series of vertically aligned meat fibers that are loosely bound at the plug boundaries. This provides an initial step toward a more natural texture, especially with hamburger or ground pork. A more detailed description of the food molding process will follow hereinafter. 
     Even though the natural texture of a hamburger patty is enhanced by the use of the prior mold plate, other forms of food products do not achieve such a benefit with the prior configuration. For example, ribbed or rib patties are a popular item and are formed to resemble a natural meat product with defined ribs. The current state of the art does not allow the ribbed meat products to assume a more natural texture. Therefore, the need exists to provide a meat molding apparatus that will provide a ribbed food product with a natural texture. 
     SUMMARY OF THE INVENTION 
     It is accordingly an object of the present invention to provide a food mold assembly and method that will provide a more naturally textured, ribbed food product. 
     It is another object of the present invention to provide such a method and apparatus that will provide a ribbed product that tends to break at naturally appearing rib sections that will thus enhance the desirability of such a molded meat product. 
     To those ends, the present invention provides a mold plate, a mold plate assembly and a method for molding a food product to provide a food product that aligns fibrous food material to achieve a more natural texture than has been previously available. Accordingly, a mold plate for a food product molding machine is provided wherein a flowable food product containing fibrous material is injected through the mold fill plate into a mold chamber, the mold chamber being formed according to a predetermined food product configuration, and the flowable mixture thereby assuming the shape of the food product mold chamber and having a texture characterized by the fibrous material with the mold fill plate including a planar body defining a longitudinal extent and a transverse extent, the body being formed by the plurality of elongate slots arranged along at least a portion of the longitudinal extent. Each slot of the plurality of slots extending across at least a portion of the transverse extent. 
     The elongate slots are preferably formed in a generally parallel orientation and also preferably formed with graduated lengths. 
     The present invention also provides a mold fill assembly for a food product molding machine characterized above where the mold fill assembly includes a mold fill plate including a planar body defining a longitudinal extent and a transverse extent, the mold fill plate being formed by a plurality of elongate slots arranged along at least a portion of the longitudinal extent, each slot of the plurality of slots extending across at least a portion of the transverse extent. A shuttle plate is provided that is disposed adjacent the mold fill plate and slidably mounted thereto. The shuttle plate includes a plurality of elongate cavities corresponding to the slots formed in the mold fill plate and moveable in and out of registry therewith when the shuttle plate slides relative to the mold fill plate, whereby the flowable food product containing fibrous material is directed through the cavities and the slots and into the mold chamber with fibers within the fibrous mixture becoming generally aligned along the slots and cavities to provide a food product with enhanced natural texture. 
     It is preferred that the elongate slots formed in the mold fill plate are arranged in a generally parallel orientation and that the elongate slots in the mold fill plate are formed with graduated lengths. 
     The present invention may also be characterized as a mold fill assembly for a meat molding machine for forming a ribbed meat product wherein a flowable meat product containing fibrous material is injected through the mold fill assembly into a mold chamber, the mold chamber being formed with a ribbed meat product configuration, the flowable mixture thereby assuming the shape of the ribbed meat product and having a texture characterized by the fibrous material. The mold fill assembly includes a mold fill plate having a planar body defining a longitudinal extent and a transverse extent, the mold fill plate being formed in the plurality of elongate slots arrange along a portion of the longitudinal extent with each slot of the plurality of slots extending across a portion of the transverse extent. A shuttle plate is provided and disposed adjacent the mold fill plate and slidably mounted thereto. The shuttle plate includes a plurality of elongate cavities corresponding to the slots formed in the mold fill plate and moveable in and out of registry therewith when the shuttle plate slides relative to the mold plate, whereby the flowable meat product containing fibrous material is directed through the cavities and slots into the mold chamber with fibers within the fibrous mixture becoming generally vertically aligned along the slots and cavities to provide a ribbed meat product with enhanced natural texture including the tendency to separate along naturally appearing rib portions when urged. Preferably, the elongate slots formed in the mold fill plate are arranged in a generally parallel orientation. Further, the elongate slots formed in the mold fill plate are preferably formed with graduated lengths. 
     The present invention also provides a method for forming a rib meat product. The method for forming a ribbed meat product uses a meat molding machine wherein a flowable meat product containing fibrous material is injected into a mold chamber, the mold chamber being formed with a ribbed meat product configuration whereby the flowable mixture assumes the shape of the mold chamber and has a texture characterized by the fibrous material. 
     The method includes the steps of providing a meat molding machine having a mold chamber and characterized by a meat mold assembly including a mold fill plate having a planar body defining a meat molding machine having a mold chamber and characterized by a meat mold assembly including a mold fill plate having a planar body defining a longitudinal extent and a transverse extent, the mold fill plate being formed with a plurality of elongate slots arranged along a portion of the longitudinal extent with each slot of the plurality of slots extending across a portion of the transverse extent. A shuttle plate is disposed adjacent the mold fill plate and slidably mounted thereto with the shuttle plate including a plurality of elongate cavities corresponding to the slots formed in the mold fill plate and moveable in and out of a registry therewith when the shuttle plate slides relative to the mold fill plate. 
     The method further includes the steps of providing a supply of flowable meat product and injecting the flowable meat product through the mold fill assembly and into the mold chamber, whereby the flowable meat product containing fibrous material is directed through the cavities in the slots into the mold chamber with fibers within the fibrous mixture becoming generally vertically aligned along the slots and cavities. The present inventive method further includes the step of moving the shuttle plate relative to the mold fill plate to move the cavities out of registry with the slots to cut any meat product including fibrous material in the mold chamber away from the meat product supply, wherein the method thereby provides a ribbed meat product with enhanced natural texture, including the tendency to separate along naturally appearing rib portions when urged. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a plan view of a prior art mold fill plate; 
     FIG. 2 is a perspective view of the mold fill plate illustrated in FIG. 1; 
     FIG. 3 is a plan view of a mold fill plate according to present invention; 
     FIG. 4 is a perspective view of the mold fill plate illustrated in FIG. 3; 
     FIG. 5 is a plan view of a mold fill assembly according to the present invention; 
     FIG. 6 is a perspective view of the mold fill assembly illustrated in FIG. 5; 
     FIG. 7 is a diagrammatic view of a mold plate as used in accordance with the present invention; 
     FIG. 8 is a side view of the mold plate illustrated in FIG. 7; 
     FIG. 9 is a perspective view of the mold plate illustrated in FIG. 7; and 
     FIG. 10 is a diagrammatic view of a food product molding machine incorporating the mold fill assembly of the present invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIGS. 3 and 4 illustrate a mold fill plate in accordance with the present invention for use in a high-volume food patty molding machine as illustrated generally in FIG.  10 . Such a machine is described in detail in Richards, U.S. Pat. No. 3,887,964, and Sandberg et al., U.S. Pat. No. 4,372,008, and has been marketed as the Formax 26 machine by Formax, Inc. of Mokena, Ill. Such a machine is a floor standing machine containing hydraulic and electric actuating systems and a control system. It should be noted that while the present invention is described in relation to the Formax 26 machine, the present invention has application and utility with any meat molding machine. A molding machine is illustrated in relevant part at  40  in FIG.  10 . 
     Generally, and with continued reference to FIG. 10, a flowable food product such as meat containing fibrous material is illustrated at  46  and is obtained from a supply hopper (not shown) of the flowable meat product. A feed screw  42  is configured as an auger and drives the flowable product into a meat delivery chamber  46 . The meat delivery chamber  46  includes a plunger  44  mounted therein to force the meat horizontally toward the mold chamber. Such a meat molding machine  40  can mold multiple patties simultaneously and accordingly, includes a tube valve rotatably mounted within the meat delivery chamber  46 . The tube valve  48  includes generally tubular walls and a tube inlet  54  and a tube outlet  56 . The valve may be rotated for alignment of the selected meat delivery path. The valve inlet  54  and the outlet  56  align with similar inlets and outlets in the meat delivery chamber  46  to allow meat to flow through the tube valve  48  and toward the mold fill assembly  10 . 
     The mold fill assembly  10  is mounted across an opening existing between the mold chamber  52  and the meat delivery chamber  46 . The mold plate  30  is positioned within the mold chamber  52  to define the shape of the product to be formed by the mold process. A mold cover  58  covers the mold mechanism. Once the food product is formed, the mold is shifted outwardly from the mold chamber  52  and a knock-out cup  50  is provided for selective removal of food product from the mold. The foregoing describes the general operation of the food molding machine  40 . More detailed operation of such a machine is described in the aforesaid patents and it will be apparent to those skilled in the art of the use and advantages of the present invention when operating a food molding machine in accordance with the present invention. 
     Turning now to FIG. 3, a mold fill plate is illustrated generally at  12  and includes a generally planar metallic body  14  having a series of mounting openings formed around the edges  16 . The mounting openings allow firm and solid mounting of the mold fill plate  12  within the mold fill assembly. The generally rectangular mold fill plate  12  defines a transverse extent and a longitudinal extent along its short sides and long sides respectively. A plurality of elongate slots  18  are formed in a generally parallel arrangement and extend through the body  14  of the mold fill plate  12 . The slots  18  are formed as a group with graduated lengths, i.e. with one slot in a set having a different length than the next slot, with the length increasing or decreasing depending on perspective. As seen in FIGS. 3 and 4, four sets of eight slots are provided to form four separate food patties. It should also be noted that the slots need not be of graduated length and that the configuration and length of the slots is dictated by the desired configuration of the final food product. 
     Turning now to FIGS. 5 and 6, a mold fill assembly is illustrated and includes the mold fill plate  12  having a shuttle plate  20  attached thereto. The shuttle plate  20  includes a generally elongate body  22  having a transverse extent and a longitudinal extent along the short and long sides respectively. A plurality of cavities  24  are formed as elongate openings that correspond with the slots  18  in the fill plate  12 . The shuttle plate  20  is slidably mounted to the fill plate  12  using a series of track bars  26  that are attached to the mold fill plate  12  using bolts  28 . This arrangement allows the shuttle plate  20  to move under urging relative to the mold fill plate  12 . As seen in FIG. 10, this assembly is mounted to the mold machine between the mold cavity  52  and the meat delivery chamber  46 . 
     In order to form a ribbed meat product, a mold chamber  52  is defined by a mold plate  30  as seen in FIGS. 7,  8  and  9 . The mold plate  30  provides the general configuration of the resultant food product when it is filled with the meat product. As seen in FIG. 8, the surface texture of the ribbed meat product mold plate  30  includes a series of ridges  32  and valleys  34  for defining naturally appearing ribs in the meat product. As seen in FIG. 7, projections are formed along the side of the mold plate  30  to also give the appearance of natural ribs. 
     In operation, the mold plate  30  is mounted in the molding machine  40  to define the mold chamber  52  as seen in FIG.  10 . The mold fill assembly  10  is mounted to the framework of the mold machine  40  in a known manner and as has been previously described. A flowable meat product  45  is fed from a supply (not shown) using the feed screw  42  to drive the meat product  45  into the meat delivery chamber  46 . The tubular valve  48  is rotated to align the inlet  54  and outlet  56  with respective inlets and outlets in the meat delivery chamber. The plunger  44  is then used to force the meat product  45  through the tube valve  48  and upwardly through the openings defined by the cavities  24  and the slots  18  in the shuttle plate  20  and the mold fill plate  12 , respectively, resulting in the food product filling the mold chamber  52 . During this operations, the fibers within the fibrous meat product become generally vertically aligned and intertwined along the length of the slots and cavities and are loosely connected intermediate the slots and cavities. When the mold chamber  52  is filled, the hydraulic controls (not shown) are used to move the shuttle plate  20  relative to the mold fill plate  12  to bring the slots  18  and cavities  24  out of registry and allow the walls defining the cavities  24  in the shuttle plate  20  to cut the fibers and thereby define the final form of the ribbed meat product. The ribbed meat product is then moved out of the mold chamber  52  using hydraulic or electric actuators (not shown) and removed therefrom using the knock out cup  50  in a known manner. 
     The resultant ribbed meat product includes a series of transversely extending naturally appearing rib elements that, due to the fiber alignment provided by the present invention, will break naturally at the rib junctions when urged. 
     By the above, the present invention provides an effective device that will produce ribbed meat products with an enhanced natural texture. 
     It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof period.