Abstract:
A method and apparatus for forming pressed food products can utilize up to 98% chicken breast meat in high profit margin products. Breast meat is marinated and then extruded into a slab which is then frozen and shaped into a plank. The plank is sliced into unit portions which are then pressed into shaped portions with a preferred, or other, press. One preferred press linearly reciprocates unit portions into the press. This or another preferred press imparts three dimension exterior shape to the pressed food products.

Description:
CLAIM OF PRIORITY 
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 13/106,447 filed May 12, 2011 which is a divisional application of U.S. patent application Ser. No. 12/032,729 filed Feb. 18, 2008. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a method and apparatus for forming unit portions of frozen food materials, and at least in a particular embodiment, shaping portions of meat such as chicken breast meat into a desired configuration whereby a significantly higher yield of breast meat from chickens can be utilized for high-quality chicken breast products. 
       BACKGROUND OF THE INVENTION 
       [0003]    The applicant has significant experience in the food preparation arena. Patents for processing chicken portions include U.S. Pat. Nos. 5,080,631 and 5,078,644. However, in processing food particularly chicken breast, it was observed by the applicant that a normal chicken breast as taken from a chicken is usually cut into only six chicken breast cutlets with the remainder of the chicken breast being utilized in other lower profit margin chicken products. Processors would normally covet 20 to 24 oz. chicken breasts, which would then be cut into six 2.5 oz. chicken breasts portions for a total usage of 15 of the 20 to 24 ounces. Thereby a maximum utilization of this type meat product would be around 62.5 to 75% at best for this high profit margin product. The remainder of the breast meat has been utilized in the past for lower profit margin products. 
         [0004]    Often the breasts are provided at 30 to 40 ounces. This translates into a highest percentage of yield of this type product to be around 50%, and could be as low as 37.5%. With this type product, the breast is usually cut symmetrically down the middle. A lower portion of the breast is then cut into a first breast portion and then a portion above that is cut into a second breast portion. The thicker of those two portions would be cut in half to provide the respective six chicken portions shaped like breasts as are often bought in the grocery store as de-boned chicken breasts or are provided as chicken cutlets for chicken sandwiches. The remainder of the chicken breast is then often processed into nuggets or other lower profit margin chicken products. 
         [0005]    In the fish industry, fishermen have been preparing fillets at sea and/or at fish processing units and then freezing fish filets as blocks. A box is normally filled and frozen containing the filets forming a block. Blocks are cut into slabs which are then cut into fish sticks such as is shown and described in U.S. Pat. Nos. 2,643,952 and 3,294,012. Furthermore, frozen fish can also be processed into desired shapes as shown and described in U.S. Pat. No. 4,474,823. 
         [0006]    However, in spite of this technology, there has still not been a good way to deal with efficiently utilizing poultry breast meat. Furthermore, although efforts have been made to produce desired shapes of food such as is shown in U.S. Pat. Nos. 6,203,838 and 6,521,280, the applicant believes that improvements to existing food processing equipment can be provided over prior art designs. 
       SUMMARY OF THE INVENTION 
       [0007]    It is an object of at least one embodiment of the present invention to provide an improved process and/or shaper for consistently providing a desired shape food product to the market with a higher percentage of higher profit margin products. 
         [0008]    It is another object of the present invention to provide an improved process and/or shaping station for providing shaped food products. 
         [0009]    It is another object of at least one embodiment of a presently preferred embodiment of the present invention to provide an improved process for utilizing a significantly higher percentage of chicken breast meat in higher profit chicken breast portions as has been previously provided to the market. Although chicken breast meat is a current focus of the applicant, other meats such as beef, pork, seafood of various varieties other than fish and even non-meat food such as vegetables, fruit or combinations of various foods could be treated with the method and apparatus as disclosed herein. Reference will be principally made throughout this disclosure referencing the chicken breast embodiment, but those of ordinary skill in the art will see how similar embodiments could be provided for various other food product embodiments. 
         [0010]    In accordance with a presently preferred embodiment of the present invention, a method for processing chicken breast meat into chicken portions includes providing a split breast which has been taken from a processed chicken, marinating and then placing the meat in a box, preferably while vibrating the box and then freezing the box thereby forming a frozen slab in the box. The frozen slab is then shaped into a symmetrical plank if not already symmetrically formed and then portions are then cut to a specific weight and shape. The cut portions are then fed into a shaper with a conveyor where the cut portions are shaped into a desired configuration such as the shape of a chicken breast as would be bought in a grocery store or the shape of a chicken breast as would be provided at a fast food restaurant as a chicken breast for a chicken breast sandwich or other use. Of course, other food and/or meat products can be utilized as well in other embodiments and shaped into suitable configurations. 
         [0011]    A rather unique shaper configuration which may have a linearly reciprocating tray which feeds cut pre-weighed portions into the shaper in a mold and/or other structure with at least one cavity at a shaping station while simultaneously ejecting a shaped portion. The formed product is then shaped with the mold and/or cavity. The mechanism is preferably all hydraulic and pneumatic to eliminate electrical issues which can occur in food processing plants due to harsh environments created during cleaning operations. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which: 
           [0013]      FIG. 1  is a schematic diagram of a method of processing food of a presently preferred embodiment of the present invention; 
           [0014]      FIG. 2  is a perspective assembly view of a shaper constructed in accordance with the presently preferred embodiment of the present invention as may be used in the method shown and described in  FIG. 1 ; 
           [0015]      FIG. 3  shows a bottom plan view of a shaping plate used with the shaper in  FIG. 2 ; 
           [0016]      FIG. 4  shows a top perspective view of the shaping plate shown in  FIG. 3  with bottom cavity portions shown in phantom; 
           [0017]      FIG. 5  shows a bottom plan view of a first alternative shaping plate configuration; 
           [0018]      FIG. 6  shows a bottom plan view of a second alternative embodiment of a shaping plate configuration; 
           [0019]      FIG. 7  shows a bottom plan view of a third alternative embodiment of a shaping plate configuration; 
           [0020]      FIG. 8  shows a schematic of an internal portion of a controller shown in  FIG. 2 ; 
           [0021]      FIGS. 9A-9F  show schematic views of the operation of the shaper of  FIGS. 2  in operation; 
           [0022]      FIG. 10  shows a schematic view of an alternative embodiment of a shaper imparting a top and bottom configuration to a shaped food portion as well as conveyor means which may at least partially assist in ejecting the meat portion from the shaper; and 
           [0023]      FIG. 11  shows a schematic view of the shaper of  FIG. 2  with an alternating prefabrication shaping station. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0024]      FIG. 1  shows a presently preferred embodiment of the present invention showing a method of providing high quality shaped food portions to the marketplace. Specifically, the process illustrated begins at step  10  where a split breast, whole butterfly or other food product is provided. The food product is preferably processed in that in the case of chicken, the feathers have been removed, it has been eviscerated and the particular meat to be processed, in this case, the chicken breast, has been removed from the bone and remainder of the chicken. For other food, such as vegetables, washing and or other processing steps may all that may be performed. Removal of seed pods, scales, bones, carcasses or shells may be performed for chicken and/or other food to provide processed food. 
         [0025]    Meat processing usually involves hide and/or feather removal, eviscerating and at least partially butchering at least one of poultry, beef, pork, fish, or other seafood product. Other food products may be treated as would be known by those of ordinary skill in the art. After obtaining the food such as meat product, it is preferably marinated either individually or together in batch, continuous or other process in step  12 . This may be optional in some processes but as it relates to meat and in particular poultry, marinating in a solution of salt, phosphate and water has been found to assist in extracting protein to a surface of the chicken. This has been found to make the chicken somewhat “sticky” as a raw material. Other food products may not require this step and/or this step may be skipped in some embodiments. 
         [0026]    Next, the food is preferably directed into a box, such as a wax coated box, which could be vibrated or shook while loading, for at least some embodiments, into a slab at step  14  along with other similar and/or dissimilar portions of food depending on the particular desired end product. Once a slab has been boxed, the slab in then preferably frozen in step  16 . After freezing the slab, it is preferably shaped into a plank of specific dimensions. One method of shaping is described below with reference to  FIG. 11 . Other methods of shaping may be employed with other embodiments. 
         [0027]    After forming the frozen slab, portions of the slab can be cut, or more preferably sliced, to a specific weight and/or shape so that each of the portions have a specific weight and shape depending on the formed shape for which they are to be provided. Portions are cut at step  20  after being shaped in a plank at step  18 . After cutting the portions for a specific size and/or weight at step  20 , they are then loaded or conveyed into feed plate at step  22  and/or directly into a shaping station in step  24 . Shaping station shapes the food item into a desired configuration as shall be shown and described in reference to the shaping station of the presently preferred embodiment as shown in  FIGS. 2-9F  and described below. 
         [0028]    Although a preferred shaping station can be utilized in conjunction with the above method, it is worth observing that any suitable alternative can be utilized in connection with the method as shown and described in reference to  FIG. 1 . When utilizing this method, it is estimated that at least about 80%, about 90%, and even up to about 98% of a chicken breast can be shaped into high quality chicken breast meat portions. Remember, by marinating the meat, the chicken becomes somewhat sticky on the surface. This is believed to be helpful in at least some embodiments. When a slab is cut into planks and is then cut into unit portions, those unit portions although possibly made up of more than one chicken breast portion are relatively securely stuck together so that when they are shaped into a chicken breast shape or other shape, the purchaser and person eating the product should not be able to tell that the shaped product is comprised of more than one piece of chicken as provided to the market place. 
         [0029]    In the past, chicken breast meat was at best 75% utilized for 2.5 ounce chicken breast portions, wherein the applicant&#39;s preferred method it is estimated that up to 98% of the split chicken breast can be utilized for high quality chicken breast consumer products like 2.5 ounce chicken breasts. As a worst case scenario, in a situation in which six 2.5 ounce breast portions are taken from a 40 ounce split breast, less than 40% were utilized for this high quality application. Therefore, the applicant&#39;s method providing a higher return to the food processor than has previously been known with prior art techniques. 
         [0030]    The applicant&#39;s method preferably utilizes the step of boxing into a slab prior to freezing. It may be that boxing directly into planks may be performed and/or other technology may employed such as that shown and described in U.S. Pat. No. 6,521,280 by AEW International Limited such that a slab could be sized and cut in portions of a desired weight and/or shape in other embodiments. 
         [0031]    Additionally, some embodiments of shaping the plank may provide a top down non-rectangular parallelogram cross section having a desired thickness so that particular cuts preferably with a knife or blade rather than a saw are known to produce a specific weight of meat and shape prior to shipping is also believed to be desirable in that there is almost no waste. Of course, other embodiments could take non-conforming sized portions and possibly join them together in their own plank and then continue the processing steps to shape them into a desired configuration. 
         [0032]    When portions are cut in step  20 , it is preferred to cut with a knife type arrangement as saws which have been previously utilized in the fish industry are known to produce fish sawdust which is believed to waste up to 20% of the block material which cannot then be easily processed into fish portions. Extremely little waste is experienced with knife cuts. 
         [0033]    When freezing the slabs in step  16 , it is anticipated to freeze to about zero degrees but other temperatures useful in a particular food segment could be utilized. When shaping the slab into a plank at step  18 , the presently shape is somewhat like a 2×4 except that it could have other dimensions depending on a particular outcome for a desired unit shape. 
         [0034]    Freezing can be done by the emersion of liquid nitrogen then to a mechanical freezer or a flip flop freezer and any other of the freezing techniques which are known in the art including freeze on paper, a plate freezer, etc. 
         [0035]    With a method similar to the preferred embodiment described above, beef could be formed in a cube steak or a formed steak of an exact proportion utilizing a similar technique. Furthermore, turkey, veal, fish, seafood, pork or other product could be similarly shaped into a desired shape of known physical volume. A pork loin could be formed or any other the other desired outcome could likely be achieved. 
         [0036]      FIG. 2  shows an assembled shaper  30  of the presently preferred embodiment of the present invention as may or may not be utilized in step  24  of  FIG. 1  as shown and described above. This shaper  30  is believed to have desirable features in the food processing industry. 
         [0037]    Conveyor  32  preferably provides cut portions  34  which are preferably sized of a known size, shape and/or weight to feed plate  36 . A magazine could also be utilized for some embodiments as long as care is taken so portions  34  do not stick together in the magazine. Feed plate  36  is preferably linearly or otherwise reciprocated with drivers  38  such as cylinders  40  connected to pistons  42 . As illustrated, feed plate  36  reciprocates in and out relative to shaping station  50  which will be explained in further detail with reference to other drawings. 
         [0038]    Limit switches  44 , 46  provide input to controller  80  shown in more detail in  FIG. 8  which will be described in further detail below. Basically, the cut portions  34  are preferably deposited in or on the feed plate  36  such as in receivers  48  at a loading station  49 . Feed plate  36  transports the cut portions  34  to the shaping station  50 .  FIGS. 9A-F  are useful in showing this process.  FIG. 9A  shows the cut portions  34  being placed in the feed plate  36 . In  FIG. 9B  the feed plate  36  is reciprocated onto first plate  52  which may be maintained parallel to feed plate  54  during this operation. Shaped product  56  may be ejected as will be explained in further detail below such as with a leading edge  58  of feed plate  36  in this presently preferred embodiment. The second plate  64  can then reciprocate relative to the first plate  52  such as through the feed plate  36  to shape product in  FIG. 9   b  and then retract to the position shown in  FIG. 9   b.    
         [0039]    In  FIG. 9C , the feed plate  36  is raised, such as at an end such as with a guide so that the cut portions  34  remain in the shaping station  50  while the feed plate  36  is lifted and then retracted towards the load configuration shown in  FIG. 9A . 
         [0040]    In the presently preferred embodiment, one or two cylinders  58 , 60  can be at least partially, if not fully, extended when in the configuration shown in  9 C. At least one of the two cylinders can then start retracting after the end  57  has cleared the shaping station  50 . Once at least one of the two cylinder,  58 , 60  has extended to the desired length of extension with rods  62  (the other rod not shown), the first plate  52  is preferably disposed against second plate  64  under a desired pressure to cause the cut portions  34  to conform to a predetermined exterior shape at least similar to the cavity portion  66  such as under about 1,000 psi or other appropriate pressure. Cavity portion  67  may extend into and/or relative to first plate  52  as well. After shaping to the configuration as shown in  FIG. 9   e  and lifting the feed plate  36 , at least one of the two cylinders  58 , 60 , if utilized, begins to retract to the retracted position thereby lowering the second plate  64  to the portion shown in  FIG. 9   b  (if raised higher such as shown in  FIG. 9   c ). Meanwhile, strike plate  68  is preferably moved relative to stationary plate  70  and/or second plate  64  so that pins  72  may extend downwardly into at least one cavity  66  to dislodge shaped food item  74  from cavity  66  if stuck therein. After reaching the position shown in  FIG. 9   e  which is somewhat similar to the position shown in  9   a , the process can begin again as shown in  FIG. 9   f  with the ejection of the formed product  56 . If product  56  remains in cavity portions  67 , then feed plate  36  can assist in ejection. 
         [0041]    During method of an embodiment as shown in  FIG. 9A , the first cylinder  58  may be extended with a second cylinder  60 , if utilized, retracted such as until the support plate  54  is lined up with the first plate  52 . This would provide a relatively linear surface for the feed plate  36  to slide across with linear reciprocation of the cylinders  38 . With the two cylinders  58 , 60  extended such as is shown in the representation of  FIG. 9C , there is preferably sufficient clearance for feed plate  36  to be retracted out of the shaping station  50  so that the loaded cut portions  34  can remain in the shaping station  50 . With the feed plate  36  retracted out of the way, one or both cylinders can retract a desired amount such as to fully retract as shown in  FIG. 9   d  to provide shaped product  56  until the first plate  52  becomes level with the feed plate  54 . As shown in  FIG. 9   e , the strike plate  68  can be utilized against pins  72  to at least partially assist in ejecting the shaped food portions  56  from the cavity  66  in this embodiment. Hydraulics are preferably provided to cylinders  58 , 60  although pneumatics or other drivers could also be utilized for that purpose. Relay switches  44 , 46  as well as switches  76 , 78  and possibly others preferably provide input to controller  80 . One or more cylinders  58 , 60  could be utilized in other embodiments. 
         [0042]    The internals of controller  80  of the presently preferred embodiment are shown in  FIG. 8  which provide input to relays  82 , 84 , 86 , 88 , 90 , 92 , 94  so that a sequence of events occurs every time. Specifically, with the preferred embodiment cylinders  58 , 60  are fully extended. Limit switch  77  is preferably contacted in the presently preferred embodiment which supplies instruction to at least one relay  82 , 84 , 86 , 88 , 90 , 92 , 94  for at least one of the cylinders  58 , 60  to begin operation. As one or more cylinder moves, the strike plate  68  can contact pin  72  to dislodge the shaped portions  56  from cavity  66 . On the down stroke, after the switch  79  is contacted switch  78  may be contacted and/or other switch to thereby indicate that the first plate  52  is level with feed plate  54  which can then start the process of cycling a loaded feed plate  36  into the shaping station  50 . After limit switch  44  is contacted, the second cylinder  60  can move cylinder  62  to clear the loaded cut portions  34  shown in  FIG. 9C . Once the second switch  76  is contacted, the feed plate  36  can be retracted back out to the position shown in  FIG. 2  to contact limit switch  46  which can start the process of moving one or both cylinders  58 , 60  until one or more limit switches is contacted again. Then the pneumatic sequence can continue again through the various relays. Other embodiments may employ more or fewer switchables, relays or other components. 
         [0043]    In the illustrated embodiment, relays  82 , 84 , 86 , 88 , 90 , 92 , 94  control operated valves for operation of various pneumatic and/or hydraulic compositions such as cylinders  58 , 60  and/or cylinder  38 . Cabinet  102  is useful to protect all these interior components during cleaning. A scarcity of electrical components (i.e., none in the presently preferred embodiment) makes the shaper  30  particularly attractive for hazardous cleaning environments such as are often found in poultry processing plants. 
         [0044]    FIGS.  5 , 6  and  7  show alternative embodiments of the second plate  64  as shown in  FIGS. 3 and 4  with pins  72  which may be utilized for ejection purposes from cavities  66 . The embodiment shown in  FIG. 3  is a breast configuration.  FIG. 5  shows a butterfly or double breast configuration.  FIG. 6  shows a thigh configuration and  FIG. 7  shows a nugget or cube configuration. Other configurations could be a stick configuration, pork loin configuration, pork chop configuration, steak configuration, shrimp configuration or other desired shape of product based on the particular desires of the manufacturer. One or more pin  72  extends through cavities  66  during ejection and are preferably spring loaded or otherwise resiliently biased with one or more springs  106  so that they do not interfere with the shaping process. When the strike plate  68  contacts pin(s)  72  at a sufficient force to overcome a resiliency of the springs  106 , pin(s)  72  extend down into the cavity  66  typically to assist in the ejection of a shaped product  56 . 
         [0045]      FIG. 10  shows a schematic of an alternative configuration of a shaper  120 . Shaper  120  preferably has a first plate  122  with cavity portion(s)  124  formed therein. Conveyor  126  preferably travels proximate to this bottom mold or first plate  122  to bring cut portions  128  from a magazine  130  into a shaping station  132 . Once the cut portions  128  are in the shaping station  132 , second plate  134  with cavities disposed therein may be downwardly directed so that the cut portions  128  are shaped between respective cavities  124  and  136  into a desired configuration. After shaping to the desired configuration, the second plate  134  may be retracted by cylinder  135 . Any shaped portion remaining in cavity  136  may be ejected preferably with a pin assembly such as with a strike plate technique possibly not too different from that shown in the embodiments of  FIGS. 2-9 . Additionally, conveyor  126  may preferably be at least resilient enough so that it conforms at least partially to the cavities  124  of the first plate  122 . As the second plate  134  is retracted away, conveyor  126  can then move and/or resiliently resume position to assist in removing shaped portions from cavities  124 . In this manner, the shaped food portions can have not only a shaped upper and/or side surface(s) conforming to a desired shape such as cutlets have been provided with other prior art techniques but also have a shaped bottom surface. This results in items that are not necessarily all planar on one side. These products can more closely resemble actual dimensions and/or shape of the intended shape such as a breast, double breast, thigh portion, etc., as so desired, particularly if those shapes are not in fact all planar on one side. 
         [0046]      FIG. 11  shows yet another shaper  200  in the presently preferred embodiment specifically first press plate. First plate  202  may move relative to second press plate  204  to shape slabs  206 , 208  therebetween. First plate  202  may have extensions  210 , 212  which may assist in providing ends  214 , 216  at an angle other than 90 degrees with the shaped slabs  206 , 208  of the preferred embodiment. As one can see, a cross section taken from a top down view of the shaped slabs  206 , 208  is that of a parallelogram and non-rectangular. The cross section taken along the lateral direction  210  through slab  206  remains a rectangular cross section in a preferred embodiment. The lateral direction  210  is illustrated perpendicular to the lateral axis  218  taken through the plank  206 . 
         [0047]    Slides can be utilized providing the shaped slab  206 , 208  configurations. Of course, in other embodiments, slides to at least assist in could enter from the left and right sides in addition to the front and back to provide the desired shape without the extensions  210 , 212  or extensions  226 , 228  illustrated. Divider  224  is illustrated fixed to second plate  204 , but as one skilled in the art can see, these shaped slabs  206 , 208  could be created with two or more slides  220 , 224  to provide shaped slabs  206 , 208 . Functionally, at least some of the shaper  200  can work similarly or dissimilarly to shapers  120  and/or  30 . 
         [0048]    Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. Having thus set forth the nature of the invention, what is claimed herein is: