Abstract:
Devices, systems and methods for operating a deep fat fryer are shown and described. In one particular embodiment, the fryer incorporates a cooking pan, a burner, and flue wrap; the pan has a substantially flat base; the burner is positioned under the pan, and the flue wrap is adapted to receive gaseous combustion products from the burner and direct it toward the pan.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     This invention relates to deep fat fryers. While the expression “deep fat fryer” is commonly used, it will be appreciated that such fryers commonly use a vegetable oil as the cooking medium.  
         [0003]     2. Description of the Related Art  
         [0004]     The invention has particular reference to commercial or professional deep fat fryers. Such fryers are of course very well known, and those currently available may be categorized as being of one of two types.  
         [0005]     In a first type, the heat source is internal of the cooking pan and is constituted by electrical resistance heating tubes immersed in the cooking medium. Such tubes run horizontally along the pan which usually has a V-section base, often with a rather small dihedral angle, to provide a sedimentation zone for the collection of small food particles so that they may readily be removed by filtration. Cooking baskets used with deep fat fryers are conventionally flat-bottomed for ease of handling and to promote uniform cooking of the food charge. It will be clear that such a conventional flat-bottomed cooking basket cannot be lowered below the heating tubes, and in a typical arrangement between 30% and 40% of the cooking medium charge of the pan is located at or below the level of the heating tubes in the sedimentation zone.  
         [0006]     In a second type of deep fat fryer, the pan is heated externally, typically by gas burners. Such fryers also have a V-section base which serves as a heating and sedimentation zone below the cooking zone, and such fryers are typically designed with a large dihedral angle to provide an extensive wall area for heating. A large proportion of the volume of the cooking medium is contained within this sedimentation zone, often as much as 30%. Again, a conventional flat-bottomed cooking basket cannot be lowered into this sedimentation zone.  
         [0007]     We have found that current deep fat fryer pans are inefficient having regard not only to the consumption of cooking medium, but also thermally, thus contributing to high running costs, and it is an object of this invention to alleviate this problem.  
       BRIEF SUMMARY OF THE INVENTION  
       [0008]     According to this invention, there is provided a deep fat fryer comprising a cooking pan and a burner constituting a heat source for heating a cooking medium within the pan, characterized in that such pan has a substantially flat base which is located over said burner and in that the pan is provided with a flue wrap adapted to receive gaseous combustion products from the burner.  
         [0009]     We have found that mounting a flat-bottomed cooking pan over an external heat source enables a much greater proportion of the volume of the charge of cooking medium to be occupied by a cooking basket. This enables the use of a relatively low volume of cooking medium in relation to the food capacity of the pan and so promotes greater efficiency in the consumption of the cooking medium.  
         [0010]     Furthermore, by arranging the cooking pan above the heat source, it is rather easy to achieve a very efficient heat transfer. Thermal efficiency is further promoted by the use of the flue wrap which is adapted to receive flue gases from the burner. The use of such flue wrap allows heat which would otherwise be lost to be transferred from the flue gases to the cooking pan.  
         [0011]     The adoption of the invention promotes relatively low running costs in terms of the consumption of both cooking medium and fuel.  
         [0012]     The flue wrap and the cooking pan are suitably made from a metal such as a stainless steel, and the flue wrap may be welded to the cooking pan, and it suitably rises up the side(s) of the pan substantially to a designed fill level of the cooking medium.  
         [0013]     The flue wrap should be in thermal contact with at least one side of the cooking pan. In a preferred arrangement, such a flue wrap extends around three sides of a rectangular cooking pan for symmetrical communication with an outlet flue. It may be convenient to locate such outlet flue at the rear of the apparatus.  
         [0014]     The heat source could be an oil burner, but is most preferably a gas burner.  
         [0015]     In preferred embodiments of the invention, the burner comprises a plenum chamber surmounted by a surface combustion plaque beneath a combustion chamber whose upper surface is, or is in thermal contact with, the base of the cooking pan. This promotes excellent heat transfer and high fuel efficiency. The combustion chamber may also be welded to the cooking pan.  
         [0016]     A gas supply for the burner preferably includes means for supplying the burner with premixed gas and air. Such gas/air mixture is suitably substantially stoichiometric and may be ignited by spark electrodes projecting into the combustion chamber.  
         [0017]     In order to provide a sedimentation zone in the cooking pan and to assist draining of that sediment, or of the whole of the cooking medium when it is desired to replace it, it is preferred that the cooking pan should be installed and operated in a position such that its base is inclined to the horizontal. This inclination does not need to be large: 2° to 5° is quite sufficient. If the base of the cooking pan is inclined, it may be inclined downwardly to one side or the other, to the rear or to the front. It is preferably inclined downwardly to the front. This allows drained material to be collected at the front of the apparatus which is generally more convenient for the user.  
         [0018]     The burner may be correspondingly inclined or the combustion chamber may be tapered (wedge-shaped) to accommodate this inclination.  
         [0019]     A lower portion of the cooking pan may be provided with ribs, preferably external and preferably integral with the cooking pan. If provided on the base of the cooking pan, such ribs can act to stiffen that base and so militate against buckling due to thermal stresses. If provided externally of the pan, such ribs will not obstruct efficient cleaning of the pan, and they will also serve to increase the surface area of the exterior of the pan thus promoting heat transfer to the pan from the combustion chamber and/or the flue wrap.  
         [0020]     The base of the cooking pan is suitably provided with an outlet for the cooking medium (in such sedimentation zone if present). It is convenient to provide such cooking medium outlet with a control valve.  
         [0021]     A deep fat fryer according to the invention preferably includes means for recirculating the cooking medium. Such means for recirculating the cooking medium preferably comprises a reservoir feedable from said cooking medium outlet, and a pump feeding a line for returning cooking medium to the pan. It is suitable to provide a hollow wand for returning cooking medium to the pan at its rear. The wand may be arranged to terminate in a downwardly directed orifice which opens into the pan to minimize splashing. The recirculating means most preferably includes a filter which may be incorporated in a filtration pump.  
         [0022]     A filter may be incorporated between the cooking medium outlet and such a reservoir. This allows the removal of food fragments from the cooking medium before that medium reaches the reservoir. It is convenient to locate such valve and filter at the front of the apparatus for ease in valve switching and filter replacement during routine maintenance of the apparatus.  
         [0023]     If the pump operates to draw cooking medium from a reservoir, that reservoir can act as a buffer, helping to reduce any risk that the pump might overheat.  
         [0024]     Apparatus according to the invention preferably includes control means including an on/off switch and an operator controllable temperature selector switch. These switches may be combined if desired, and it is suitable to be able to select a cooking medium temperature.  
         [0025]     A thermostatic control is preferably provided which could suitably be graduated in steps of 10° C., from 130° C. to 190° C.  
         [0026]     Further control and/or monitoring means are preferably provided as follows: 
        means for controlling the gas ignition means;     means for monitoring combustion conditions;     means for controlling the supply of gas and air to the burner and for shutting down the supply of combustible gas in the absence of proper combustion conditions; and     display means connected to appropriate monitors for indicating: when the cooking medium has reached a pre-set temperature; possible overheating of the cooking medium; possible failure or misconnection of any thermostat in the system; possible ignition failure; and/or possible failure of the cooking medium to heat up at a predicted rate.        
 
         [0031]     Further control features might include means for inputting time and temperature parameters, means, e.g., digital means, for displaying such parameters, means for giving an audible and/or visual indication of the expiry of any cooking time set, and means for storing the inputted parameters for repeated use.  
         [0032]     A further level of control may be provided by allowing for “one touch” inputting of parameters appropriate for a particular foodstuff which is to be cooked by the operator. Thus, a fryer in accordance with the invention may incorporate memory means adapted to retain parameters appropriate for the cooking of a particular foodstuff and a “one touch” control operable to actuate and operate the fryer in accordance with those parameters.  
         [0033]     In some preferred embodiments of the invention, the fryer of the invention incorporates a basket lift. Such a basket lift is suitably controllable so as to lower the basket into the cooking medium under the control of an operator, or, optionally, when the cooking medium reaches a desired temperature, and automatically to raise the basket on the expiry of a pre-set cooking time.  
         [0034]     In some preferred embodiments of the invention, there are further provided means for monitoring the rate of temperature change in the cooking medium during cooking of a food load, which will be at least in part dependent on the weight of a food load, and for automatically adjusting the cooking parameters for a particular foodstuff in response thereto. Thus it will be possible, for example, to adjust the cooking time in relation to the weight of the load.  
         [0035]     Thus for example, for deep frying potato chips (French fries), a fully automatic apparatus could be arranged to operate on a “one touch” basis so that after charging of the basket with a load of chips, and pressing a “Chips” button, heating would be controlled to adjust the temperature of the cooking medium to, say, 130° C. when the basket lift would automatically lower the food into the pan for a time dependent on the automatically weighed charge of food. Without further intervention, the lift would raise partially cooked chips from the pan and the temperature of the cooking medium would be increased, for example to 190° C. whereupon the chips would again be lowered into the cooking medium for a second period of time, again dependent on the previously monitored weight. The cooked chips would then be lifted from the fryer ready for draining and serving. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0036]     A preferred embodiment of the invention will now be described with reference to the accompanying diagrammatic drawings in which:  
         [0037]      FIG. 1  is a front elevation of a deep fat fryer omitting oil recirculating means;  
         [0038]      FIG. 2  is a side elevation of the fryer of  FIG. 1  showing oil recirculating means;  
         [0039]      FIG. 3  is a side elevation of a basket lift suitable for the fryer of  FIG. 1 ; and  
         [0040]      FIG. 4  is a view of a control panel for the fryer. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0041]     As shown in  FIGS. 1 and 2 , a deep fat fryer generally indicated at  1  comprises a rectangular cooking pan  2  and a gas burner  3  constituting a heat source for heating a cooking medium (not shown) within the pan  2 . The fryer is characterized in that the pan  2  has a substantially flat base  4  which is located over the burner  3  and in that the pan is provided with a flue wrap  5  adapted to receive gaseous combustion products from the burner.  
         [0042]     The flue wrap  5  and the cooking pan  2  are suitably made from a metal such as a stainless steel, and the flue wrap  5  may be welded to the cooking pan, and it rises up the side(s) of the pan to a designed fill level  6  ( FIG. 3 ) of the cooking medium.  
         [0043]     The flue wrap  5  extends around three sides of the cooking pan  2  for symmetrical communication with an outlet flue  7  at the rear of the apparatus.  
         [0044]     The gas burner  3  comprises a plenum chamber  9  surmounted by a surface combustion plaque  10  beneath a combustion chamber  11  whose upper surface is, or is in thermal contact with, the base  4  of the cooking pan  2 . This promotes excellent heat transfer and high fuel efficiency. The combustion chamber  11  is also welded to the cooking pan. The combustion chamber  11  communicates with the flue wrap  5  via side ducts  8 .  
         [0045]     A gas supply for the burner  3  includes a fan  12  for mixing air into a supply of fuel gas (not shown) and a duct  13  for supplying the resulting premixed gas and air to the burner. Such gas/air mixture is suitably substantially stoichiometric and may be ignited by spark electrodes  14  projecting into the combustion chamber  11 .  
         [0046]     In order to provide a sedimentation zone in the cooking pan and to assist draining of that sediment, or of the whole of the cooking medium when it is desired to replace it, the cooking pan  2  is installed and operated in a position such that its base  4  is inclined to the horizontal. This inclination does not need to be large: 2° is quite sufficient. The base  4  of the cooking pan is inclined downwardly to the front. This allows drained material to be collected at the front of the apparatus which is generally more convenient for the user.  
         [0047]     The burner may be correspondingly inclined as shown, or the combustion chamber may be tapered (wedge-shaped) to accommodate this inclination.  
         [0048]     The base  4  of the cooking pan  2  is provided with optional external stiffening ribs (not shown). Such ribs act to stiffen that base and so militate against buckling due to thermal stresses. As they are provided externally of the pan, such ribs will not obstruct efficient cleaning of the pan interior, and they will also serve to increase the surface area of the exterior of the pan thus promoting heat transfer to the pan from the combustion chamber. Such ribs may also be provided over the area of the flue wrap  5 .  
         [0049]     The base  4  of the cooking pan  2  is provided with a gravity fed outlet  15  for draining the cooking medium and any sediment present. The cooking medium outlet  15  is illustrated in  FIG. 2  with a control valve  16 .  
         [0050]     A filter is incorporated between the cooking medium outlet  15  and a reservoir  17 . This allows the removal of food fragments from the cooking medium before that medium reaches the reservoir. It is convenient to locate such filter so that it is accessible from the front of the apparatus for ease in filter cleaning or replacement during routine maintenance of the apparatus. As shown, the filter comprises an inner basket filter  21  and a mesh filter  22 .  
         [0051]     The illustrated embodiment of deep fat fryer according to the invention includes means for recirculating the cooking medium. This includes the reservoir  17  arranged beneath the outlet  15  so that it can be fed with the cooking medium under gravity, and under control of the valve  16 . A pump  18  feeds a line  19  for returning cooking medium to the pan  2  via a downwardly directed hollow wand  20  at the rear of the pan. The wand may be arranged to terminate beneath the designed liquid level in the pan if desired. The pump  18  may be a filtration pump incorporating a filter. The pump  18  operates to draw cooking medium from the reservoir  17  via an oil suction line  23 .  
         [0052]     The cooking pan is surrounded and surmounted by a hob  24 , and it may be enclosed in a cabinet (not shown). The cabinet may be provided with wheels at its rear and legs at its front to allow for easy maneuverability for installation and maintenance while affording stability during use. The cabinet may have a door at the front for ready access to the filters  21 ,  22 .  
         [0053]     A thermocouple  25  is located in the bottom of the cooking pan  2 .  
         [0054]      FIG. 3  illustrates an optional basket lift for raising or lowering a cooking basket  30  from or into the cooking pan  2 . The lift incorporates a motor  32  and a basket support  33 . The lift system may incorporate means for shaking the basket when it has been raised out of the cooking medium.  
         [0055]     Apparatus according to the invention preferably includes control means  40  ( FIG. 2 ) including a microprocessor and a control panel  41  ( FIG. 4 ); and including an on/off switch  42  and an operator controllable temperature selector.  
         [0056]     Referring now to  FIG. 4 , the control panel  41  includes a power switch  42  which incorporates a power-on indicator light. A combined temperature mode selection switch and burner active indicator is shown at  43 . It is envisaged that the indicator should remain lit until a selected desired temperature is reached. A fat melt button  44  is provided for use when a fat rather than an oil is to be used as the cooking medium. Such indicator could be arranged to flash until the fat melt temperature was reached and then to remain illuminated.  
         [0057]     A program button and indicator  45  is provided for selecting a program function and for confirming values of cooking parameters entered using a set of navigation keys  46  which may also be used to scroll through settings and to select cooking parameters for pre-setting automatic cooking programs.  
         [0058]     Selectable illuminated symbols represent temperature ( 47 ), time ( 48 ), fat melt ( 49 ) and basket shake ( 50 ) which can be selected so that their values may be changed using the navigation keys  46 , while being displayed in LED display  51  which is also arranged to be able to display fault codes indicative of a possible malfunction of the apparatus, and the program selected.  
         [0059]     A set of program mode buttons  52  is provided for selecting one of up to four cooking programs which may be preset by the operator to allow for “one touch” setting of one of four pre-set cooking programs to be used on that particular apparatus.  
         [0060]     A multi-function indicator switch  53  is provided for executing any of the following functions: 
        a pre-selected program—press once to start, press again to halt program;     a timer; or     a basket lift—press once to lower and a second time to raise, for example before a pre-set time has elapsed.        
 
         [0064]     The indicator is suitably arranged to light up when the feature is selected and to go off when the cycle finishes or is manually stopped.  
         [0065]     The control means may incorporate an audible timer alarm or other alarm which can be cancelled by an alarm cancel indicator switch  54 .  
         [0066]     A fault indicator  55  is provided. An error code for the particular fault encountered may be shown in the display  51 . A further indicator  56  is provided for indicating that the filtration pump is active. The indicator  56  may be constituted as a pump switch. And a burner lockout indicator  57  is also provided.  
         [0067]     Temperature control is suitably graduated in steps of 10° C., e.g., from 130° C. to 190° C. This maximum temperature may be increased to the extent that local health and safety regulations permit.  
         [0068]     In some preferred embodiments of the invention, the thermocouple  25  is used to monitor the rate of temperature change in the cooking medium during cooking of a food load, which will be at least in part dependent on the weight of a food load, and the control microprocessor is arranged automatically to adjust the cooking parameters for a particular foodstuff in response thereto. Thus it will be possible, for example, to control the fuel supply to the burner, and/or to adjust the cooking time in relation to the weight of the load.  
         [0069]     All of the above U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, are incorporated herein by reference, in their entirety.  
         [0070]     From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.