Abstract:
A system and process for producing an agglomerated potato product from dried flakes and/or granules, and pre-blended dry and wet ingredients. The system and process include pre-blending of dry and wet ingredients such as salt, powdered milk, butter flavors, with warm water and/or oil, followed by mixing with dry potato flakes or the like to produce an agglomerated potato product having a crumbly consistency. This product is delivered by an auger to a conveyor for passage beneath a rotary driven roller for converting the product into a thin layer of small agglomerate type particles which are then delivered to a fluidized bed dryer for reducing the moisture content of the agglomerated potato product to about 6-8%. The resultant dried, agglomerated potato product has a generally granular consistency and is suitable for long-term storage preparatory to finish preparation by water addition to provide a flavorful potato product.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates generally to an improved system and process for producing an agglomerated potato product from dried potato flakes and/or potato granules. More particularly, the system and process relates to improvements in thorough mixing of wet and dry ingredients with the dried potato flakes and/or granules to produce an agglomerated potato product which can then be dried to a substantially granular or particulate state suitable for long-term storage preparatory to finish preparation by suitable addition of warm water. 
       SUMMARY OF THE INVENTION 
       [0002]    In accordance with the invention, a system and process are provided for producing an agglomerated potato product from relatively dry potato flakes and/or granules and pre-blended wet and dry ingredients. The potato flakes or the like are thoroughly mixed with the pre-blended wet and dry ingredients, and then delivered onto a conveyor for close passage beneath a rotatably driven roller to convert the mixed or agglomerated and now-granular or particulate product into a thin layer of relatively small agglomerate type particulates. This thin layer of small particulates is delivered by the conveyor to the input end of a dryer, which reduces the overall moisture content of the agglomerated product to a relatively low level, such as about 6-8% by weight, suitable for long-term storage. 
         [0003]    The system and process comprise pre-blending of wet and dry ingredients such as ingredients including, e.g., salt, milk powders, butter flavors, and the like with water (and preferably warm water) and/or oil in selected proportions within a pre-blender or pre-mixer device. In a preferred form, warm water at a temperature of about 140° F. is added in selected proportion with the dry ingredients into the pre-blender device. Oil, such as a soy oil, is then added in selected proportion to the water and dry ingredients. One preferred pre-blender device comprises a blender produced by Lanco Products Corporation, New York, N.Y., under the model designation Likwifier LDD. This pre-blender is operated at a selected time and speed setting for thoroughly pre-blending or pre-mixing the wet and dry ingredients. 
         [0004]    In a mixing device, preferably such as a mixer produced by Hobart Corporation of Troy, Ohio, under the model number 80, relatively dry potato flakes or the like, such as those obtained from a flake production line, wherein the potato flakes or the like are dried in that production line to a moisture content of about 6-8% by weight, are added together with addition of the pre-blended wet and dry ingredients. These flakes and the pre-blended wet and dry ingredients are mixed gently and for a relatively short time period in the mixing device to form the flake-based (and/or granule-based) agglomerated product, and then transferred as by an auger onto a conveyor having a moving conveyor belt. 
         [0005]    The conveyor belt of the conveyor passes beneath a closely spaced and rotatably driven roller which converts the augered agglomerated product into the form of a relatively thin layer of small agglomerate type particles on the conveyor belt. In one preferred form, the conveyor belt moves at about 0.5 feet per second, whereas the roller comprises a roller element that is rotatably driven in the same direction as roller belt movement, but at a much higher rate of speed. For example, in the preferred form, the roller element is about 1.5 inches in diameter, and is rotatably driven at about 1,000-1,100 revolutions per minute (rpm). Such rotary speed converts to about 7.0 feet per second, or about 14-15 times the speed of the conveyor belt. This roller is positioned above the moving conveyor belt by a distance of about 3/32 inch. 
         [0006]    The thus-produced thin layer of the agglomerated product has a generally particle-like or granular constituency. This thin layer of agglomerated product is supplied into a dryer, such as fluidized bed dryer of the type produced by Idaho Steel Products, Idaho Falls, Id. This dryer reduces the overall moisture content of the agglomerated product to about 6-8% in a particle-like or granular form suitable for long-term storage. The dried agglomerated product can be reconstituted when desired by mixture with water to produce a flavorful mashed potato-like comestible. 
         [0007]    Other features and advantages of the invention will become more apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The accompanying drawings illustrate the invention. In such drawings: 
           [0009]      FIG. 1  is a flow chart depicting system and process steps of the present invention; 
           [0010]      FIG. 2  is a fragmented perspective view illustrating addition of water to a pre-blender device; 
           [0011]      FIG. 3  is a fragmented perspective similar to  FIG. 2 , but showing addition of dry ingredients to the pre-blender device; 
           [0012]      FIG. 4  is a fragmented perspective similar to  FIGS. 2 and 3 , but showing addition of oil to the pre-blender device; 
           [0013]      FIG. 5  is an enlarged fragmented perspective view showing the interior of the pre-blender device and illustrating a rotary mixing blade therein; 
           [0014]      FIG. 6  is a fragmented perspective view similar to  FIG. 5 , but depicting mixing of the dry and wet ingredients within the pre-blender device; 
           [0015]      FIG. 7  is a fragmented perspective illustrating removal of the mixed dry and wet ingredients from the pre-blender device; 
           [0016]      FIG. 8  is another fragmented perspective view showing delivery of a selected quantity by weight of dry potato flakes; 
           [0017]      FIG. 9  is an enlarged and fragmented perspective view showing a mixing device with the dry potato flakes therein, and further illustrating addition of the pre-blended dry and wet ingredients from the pre-blender device thereto; 
           [0018]      FIG. 10  is another enlarged and fragmented perspective view showing the mixing device for preparing the intermixed or agglomerated flake-based potato product; 
           [0019]      FIG. 11  is an enlarged and fragmented perspective view similar to  FIG. 10 , but depicting a watch or clock indicating elapsed mixing time; 
           [0020]      FIG. 12  is a fragmented perspective view showing scooped removal of the agglomerated flake-based product and placement thereof into an auger hopper; 
           [0021]      FIG. 13  is a fragmented perspective view depicting auger delivery of the agglomerated flake-based product onto a conveyor having a moving conveyor belt; 
           [0022]      FIG. 14  is an enlarged and fragmented perspective view of the conveyor, and illustrating a roller for converting the product into a thin layer of relatively small agglomerate type particulates on the moving conveyor belt; 
           [0023]      FIG. 15  is a fragmented perspective view showing a downstream end of the conveyor delivering the agglomerated flake-based product into an entrance chute of a fluidized bed dryer; 
           [0024]      FIG. 16  is a perspective view showing an upstream or inlet entrance end of the fluidized bed dryer; and 
           [0025]      FIG. 17  is a perspective view depicting a downstream or exit end of the fluidized bed dryer. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0026]    As shown in the exemplary drawings, an improved system and process referred to generally in  FIG. 1  by the reference numeral  10  is provided for producing an agglomerated potato product  12  from potato flakes  14  and/or granules or the like, and mixtures thereof. The invention generally comprises pre-blending wet and dry ingredients  16  ( FIGS. 2-7 ) before mixing them with the potato flakes  14  ( FIGS. 8-11 ), followed by a conveyor  18  ( FIGS. 13-15 ) having a moving belt  20  in combination with a rotatably driven roller  22  ( FIG. 14 ) mounted over the belt  20  in closely spaced relation and driven at a speed significantly greater than the belt speed. As a result, the agglomerated or mixed flakes  14  and wet/dry ingredients  16  are converted to a thin layer  24  ( FIGS. 14-15 ) of small agglomerate type particulates before being delivered to a final dryer  26  ( FIGS. 15-17 ) wherein the agglomerated product  12  is dried to a relatively low moisture content. 
         [0027]    In general terms, the final or finished dried agglomerated potato product  12  of the present invention has a particle-like or granular geometry that is not pasty or sticky at any point in the process. The dried agglomerated potato product  12 , or agglomerate  12 , is thus conducive to long-term storage to await finish preparation by placement thereof into a selected quantity of warm or heated water for reconstitution. The resultant finish prepared potato product exhibits a desirably high degree of product uniformity including texture and flavor. Although described and shown in terms of a preferred embodiment using potato flakes  14 , persons skilled in the art will recognized that other types of dried potato products, such as potato granules and the like, and/or mixtures thereof, can be used in lieu of potato flakes  14 . 
         [0028]    As illustrated best in  FIG. 2 , the wet ingredients particularly such as water  27  is placed or poured into a pre-blender  28  in a selected quantity, according to the particular formulation of the wet and dry ingredients  16 . In a preferred batch-type process, about  22  pounds of water  27  heated to a moderate or warm temperature within the range of about 125° to about 160° F., and more preferably about 140° F., for mixture with about 25 pounds of potato flakes  14  (as will be described herein in more detail). Persons skilled in the art will recognize and appreciate that the specific quantity or weight of water  27  added to the pre-blender  28  can vary according to the particular formulation of the ingredients  16  as well as the size of batch of the agglomerated potato product  12  to be produced. Persons skilled in the art will also understand that alternative water temperatures, such as tap water at a relatively moderate temperature as low as about 40° F., or a tepid temperature, can be used. 
         [0029]      FIG. 3  shows addition to the pre-blender  28  of dry ingredients  30 . In one preferred form, the dry ingredients  30  comprise ingredients such as about  130  grams of flavor and texture enhancers such as buttermilk powder, lactic acid, and sodium stearoyl lactylate, and/or mixtures thereof, and coloring agents such as annatto (about 0.25 grams) and tumeric (about 0.125 grams). Again, persons skilled in the art will understand that the specific ingredient mixture can vary by ingredient type and/or the end result desired, and/or the amount of agglomerated potato product  12  to be produced. 
         [0030]      FIG. 4  shows addition to the previously added water  27  ( FIG. 2 ) and the dry ingredients  30  ( FIG. 3 ) of an oil or oil mixture  32  into the pre-blender  28 . In this regard, in a preferred form, this oil mixture  32  comprises a soy oil (about 0.5 pounds). 
         [0031]    The pre-blender  28 , in the preferred form of the invention, comprises a model Likwifier LDD marketed by Lanco Products Corporation, New York, N.Y. As shown in  FIG. 5 , this pre-blender  28  has a stainless steel receptacle  34  having a small blender-like multi-rotor blade  36  upstanding a short distance into a central bottom region thereof. This blade  36  is rotatably driven by an electric motor (not shown) or the like at a relatively high rate of speed (about 1,780 rpm in a preferred embodiment), and for a time period of about 3 minutes. Persons skilled in the art will appreciate, however, that the mixing blade  36  can be rotatably driven at a different (higher or lower) speed and for a different time period (shorter or longer) sufficient to thoroughly pre-mix the wet and dry ingredients  16 . 
         [0032]      FIG. 6  illustrates the wet and dry ingredients  16  within the receptacle  34  of the pre-blender  28  during mixing or blending, i.e., during rotation of the mixing blade  36  ( FIG. 5 ).  FIG. 7  depicts tapping off of the pre-blended wet and dry ingredients  16  via a tap pipe  38  into a suitable container  40 . 
         [0033]      FIG. 8  shows pouring of a predetermined quantity of a selected processed and dried potato product, such as the illustrative potato flakes  14 , from a bag  42  into a primary mixer  44  including an upwardly open mixing bowl  46 . The bowl  46  is shown on a scale  48  with a digital or similar display  50  for providing a read-out of the weight of the potato flakes  14  added thereinto. In a preferred form, as previously mentioned, 25 pounds of the potato flakes  14  are poured into the mixing bowl  46 . Persons skilled in the art will recognize and appreciate, of course, that the specific quantity or weight of flakes  14  poured into the mixing bowl  46  will vary according to the quantity of agglomerated product  12  to be produced. Persons skilled in the art will also appreciate that the flakes  14  can be obtained from a dryer (not shown) or the like at the conclusion of a known flake-making process, and/or that alternative processed and dried potato products such as granules can be used. 
         [0034]      FIG. 9  depicts pour-in addition of the pre-blended wet and dry ingredients  16  from the container  40  into the mixing bowl  46  of the mixer  44 , while stirring or mixing the constituents by means of rotation of a mixing blade  52 . These wet and dry ingredients  16  are added into the mixer  44  for contact with and gentle mixing with the flakes  14  over a relatively short period of time, about 60 seconds in the preferred process, to raise the moisture level of the mixed or agglomerated product  12  to about 30% to about 55% by weight. Further product mixing or agglomeration is shown in  FIG. 9 , whereas  FIG. 11  depicts further agglomeration with a stopwatch  54  indicating a total mixing time of about 2 minutes. One preferred mixer  44  comprises a model 80 mixer available from Hobart Corporation, Troy, Ohio, with the illustrated mixing blade  52  being rotatably driven at about 55-75 rpm, and more preferably about 65 rpm. Again, persons skilled in the art will understand that these parameters can vary in accordance with the quantity or weight of the agglomerated product  12  to be produced in each batch. 
         [0035]      FIG. 12  shows the agglomerated product  12  from the mixer  44  being delivered by means of a manual scoop  56  or the like into an auger hopper  58 . An auger  60  ( FIG. 13 ) at a lower end of the hopper  58  feeds the agglomerated product  12  substantially continuously from the hopper  58  onto the moving belt  20  of the conveyor  18 . The auger  60  beneficially smooths out the delivery of the agglomerated product  12  onto the conveyor  18 , but it is noted that the agglomerated product  12  includes the wet components of the ingredients  16  and thus transfers onto the belt  20  in the form of small clumps. However, despite the presence of the wet ingredients, the agglomerated product  12  has a generally particulate form that is sufficiently crumbly for relatively easy breaking apart upon auger feeding onto the conveyor belt  20  and subsequent handling. 
         [0036]    Downstream from the auger  60 , in accordance with the movement direction of the belt  20 , the roller  22  ( FIG. 14 ) is disposed in slight spaced and generally parallel relation over the belt  20 . In a preferred form, the roller  22  is spaced above the belt  20  by a short distance or gap on the order of about 3/32 inch. The roller  22  is rotatably driven by an electric motor  62  (shown schematically in  FIG. 14 ) to rotate at a speed significantly greater than the moving speed of the conveyor belt  20 . In particular, in the preferred form of the invention, the belt is driven or translated linearly at a speed of about 0.5 feet per second. The roller  22  comprises a removable and cleanable component having a plastic outer surface or the like of about 1.5 inch diameter disposed over the moving belt  20  by a short gap of about 3/32 inch. The motor  62  rotatably drives the roller  22  at a rotational speed directionally common with the direction of belt driving, but at a speed within the range of about 1,000-1,100 rpm, and more preferably on the order of about 1,050 rpm. This relatively high rate of roller rotational speed translates, given the roller diameter of about 1.5 inches, to a speed of about 7.0 feet per second, or about 14-15 times the speed of the belt  20 . 
         [0037]    In use, this arrangement between the belt  20  and the closely overlying roller  22  effectively spreads or flattens or thins the crumbly agglomerated product  12  into the relatively thin layer  24  of relatively small agglomerate type particles. In this regard, the illustrative drawings show the agglomerated product  12  as having a particle-like or substantially granular post-mixer construction suitable for fracturing easily into relatively uniform size small particles upon passage beneath the roller  22 . This thin sheet  24  of the agglomerated product  12  is particularly suitable for entry into and through an entrance chute  64  ( FIG. 15 ) of the dryer  26  ( FIGS. 15-17 ), such as a conventional fluidized bed dryer of the type available from Idaho Steel Products, Idaho Falls, Id. In the dryer, the agglomerated product is substantially continuously dried to a moisture content of about 6-8% by weight. Such relatively low moisture for the agglomerated product  12  is achieved, in the preferred form, by an internal dryer temperature of from about 110° F. to about 285° F., and more preferably within a narrower range of from about 140° F. to about 180° F., and with a dryer air flow rate of about 1,250-1750 cubic feet per minute (cfm), and more preferably about 1,500 cfm, for a time period of between about 10-40 minutes. The illustrative dryer  26  has three air inlet zones pressurized to about +3 inches of water beneath an internal bubble plate (not shown), with the pressure above the bubble plate being about −0.5 inches of water. With these parameters, dried agglomerated potato product  12  is produced with substantially thorough mixing between the potato and pre-blended wet/dry constituents, at a rate in the preferred and above-discussed batch process of about 30 pounds per hour, and is discharged from the dryer  26  via an exit chute  68  of the dryer  26  ( FIGS. 16-17 ) into a suitable receiver  70  ( FIG. 17 ) for further product processing, such as packaging and the like. 
         [0038]    A variety of further modifications and improvements in and to the improved system and process for producing a flake-based potato product of the present invention will be apparent to those persons skilled in the art. By way of specific example, persons skilled in the art will recognize and appreciate that the batch process shown and described herein can be converted to a flow-through continuous production process, if desired. Accordingly, no limitation on the invention is intended by way of the foregoing description and accompanying drawings, except as set forth in the appended claims.