Patent Description:
Precooked meat products are very popular in today's fast-paced world. For example, it is convenient to be able to quickly prepare a meal using meat patties (e.g., frozen meat patties) that have already been cooked previously and packaged. Various techniques are known for producing and packaging meat patties. Such techniques typically involve numerous processing steps, some of which are relatively time-consuming and/or require substantial manual labor.

Due to the labor-intensive manufacturing process, high-quality precooked meat patties are difficult to manufacture. Some prior attempts to simplify or expedite the meat patty production process have encountered difficulties due to physical characteristics of the meat (e.g., consistency of the meat and its ability to withstand processing without disintegrating) or considerations relating to the end consumer (e.g., taste and/or texture of the patties). It is desirable to simplify, automate, and/or expedite manufacturing of meat patties while improving the quality of the patties.

<CIT> describes a process of preparing raw animal livers. The livers are frozen to a solid state and then comminuted to eliminate any toughness therein, while maintaining the livers frozen. Thereafter, the comminuted liver is packed into a loaf form while maintaining the frozen state thereof. The loaf is sliced to provide frozen patties of a desired thickness. The outer surface of each patty is seared to provide a cooked coagulated layer enclosing raw liver. The patties are again subjected to a freezing operation. <CIT> describes a process for preparing meat patties. Blocks of meat products are delivered at a temperature of approximately -<NUM> along a conveyor. The block of meat product is coarsely ground to a size of from <NUM> to <NUM>. The ground pieces of meat are minced to a size of <NUM> to <NUM>. The minced meat is blended with added ingredients. The blended minced meat is conveyed to a former in which rows of minced meat patties are formed such that the patties in each row are staggered across the width of a former lead-out conveyor. The formed patties are led through a freezer to freeze the patties to a temperature of about -<NUM>. The frozen patties are stacked, and the stacks of patties are packaged. In "<NPL>) provides general ground beef information including information on production, processing, receiving, storing, grinding, mixing/blending and packaging of beef. Freezing systems for beef basically includes blast freezing, mechanical freezing and cryogenic freezing. Beef may be stored at different temperatures depending on whether fresh beef. fresh vacuum packed ground beef, frozen ground beef, refrigerated cooked ground beef or frozen cooked ground beef. <NPL>, describes conditions required to produce commercial sterility in processed meat products. Ingredients such as acid, solids, protein, fat and water affect the thermal performance of meat products. Accordingly, the heat treatment duration and the internal temperature to be reached for a sterile meat product may vary. <CIT> describes a machine for forming hamburger patties having a generally thickened periphery surrounding a central depression. The central depression is filled with cheese, egg or sauces. An auger-fitted hopper feeds a cylinder and piston assembly which fills an open-faced mold covered by a pneumatically shiftable sheet-like diaphragm. During mold filling, the diaphragm is displaced inwardly into the mold and, after the forming of the patty, the diaphragm moves outwardly serving as an aid in ejecting the patty from the mold for transport to a cooking station. <CIT> describes a molding apparatus for forming patties from an agglomerable edible material. The apparatus includes a rotating turret with a plurality of mold cavities and reciprocable pistons. The turret rotates between a feed station where the edible material is fed upwardly under pressure into the mold cavities and a discharge station where the formed patties are ejected and separated by a continuous cut-off band. The band in a cut-off band is disposed at a slight angle to facilitate its entry into the interfaces between the bottom surfaces of the pistons and the formed patties. The leading corners of the pistons are chamfered to receive the blade. The band is looped between a pair of pulleys on adjustable supports for providing the desired inclination of the band. Scrapers and spray nozzles are provided to maintain the cleanliness of the band and the pulley grooves. <CIT> describes a method for producing flat processed meat products such as flat casingless hot dogs. A material containing substantial amounts of the meat protein is formed prior to cooking into a flat form of a predetermined thickness by pressing the uncooked material. The flat form is then heated either simultaneously with the forming or thereafter to a temperature and for a time sufficient to congeal a sufficient amount of the protein to stabilize the shape of the flat form but insufficient to cause any substantial rendering of the material. The surface of the congealed flat form is then treated by smoke, drying or both to establish its texture and flavor, and the treated flat form is then finally cooked into the food product. The flat form is cut into discrete flat shaped patties either at the beginning of the method or subsequent to cooking or chilling. <CIT> describes an electromagnetic heating hamburger machine, comprising a housing, a mould heating plate, a hamburger model, a heat-isolating plate, a coil, a magnetic stripe and a control circuit. The mould heating plate is rectangular and born above the housing. The longitudinal sections of the hamburger model and the heat-isolating plate are inverted-U-shaped. A circular groove is formed below the flat plate of the heat-isolating plate. The heat-isolating plate is located below the mould heating plate and sleeved at the outer side of the hamburger model. The coil is a solenoid which is fixedly sleeved outside the wall of the circular groove of the heat-isolating plate and electrically connected with the control circuit. The magnetic stripe is installed outside the coil.

The present invention is set out in the independent claim. Particular examples of the present invention are defined by the features of the dependent claims.

In some embodiments, a warm forming process for forming a meat patty includes heating an uncooked ground meat product to a temperature T<NUM>, wherein T<NUM> > <NUM> (<NUM>°F). The uncooked ground meat product is formed into an uncooked patty at temperature T<NUM>. The uncooked patty is precooked to form a precooked patty having a skin of depth D comprising denatured protein. The skin is formed on at least an area on the outside of the precooked patty. At least a first portion of the meat product disposed beneath said skin is at approximately T<NUM>. The precooked patty is cooked to form a cooked patty, wherein said at least a first portion of the meat product is at a temperature T<NUM>. The cooked patty is then frozen and then packaged.

In some embodiments, a cold forming process for forming a meat patty includes coarse grinding a meat product. The coarse ground meat product is blended with first ingredients to a temperature T<NUM> wherein T<NUM> < <NUM> (<NUM> °F). The process includes fine grinding the blended meat product and forming the ground meat product into an uncooked patty at T<NUM>. The uncooked patty is cooked to form a precooked patty having a skin of depth D comprising denatured protein, wherein said skin is formed on at least an area on the outside of the precooked patty at a temperature T<NUM>, and wherein at least a first portion of the meat product disposed beneath said skin is at approximately temperature T<NUM>, and wherein T<NUM> > T<NUM>. The precooked patty is chilled and then packaged.

This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as "lower," "upper," "horizontal," "vertical,", "above," "below," "up," "down," "top" and "bottom" as well as derivatives thereof (e.g., "horizontally," "vertically," "downwardly," "upwardly," etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that any apparatus or process be constructed, operated, or performed in a particular orientation.

Various embodiments of the present disclosure relate to new systems and methods for producing meat patties. Efficiencies are achieved in terms of time, space, and/or resource requirements compared to prior meat patty production techniques. For example, some systems and methods reduce or eliminate manual labor during the patty production process, thereby speeding up the end-to-end process and/or reducing energy expenditure. In some embodiments, ground meat patties are produced with a crumbly texture that is pleasing to consumers.

<FIG> is a block diagram of a conventional system <NUM> for producing a precooked sliced meat product. Fat trimmings and lean trimmings <NUM> are added to a first grinder <NUM> and coarsely ground to about <NUM>/<NUM> to <NUM>/<NUM> of <NUM>,<NUM> (an inch). The ground meat is transferred from the first grinder <NUM> to a blender and/or mixer <NUM> and combined with other ingredients <NUM> such as salt, cure, spices, and other flavorings. After being blended and/or mixed to form a coarsely ground meat mixture, the coarsely ground meat mixture is transferred to a heater and/or heat exchanger <NUM> (referred to as a heater for convenience) and heated to <NUM> - <NUM> (<NUM> - <NUM> °F). The heated meat mixture is then transferred to a second grinder <NUM> and more finely ground to about <NUM>/<NUM> to <NUM>/<NUM> of <NUM> (an inch).

The finely-ground heated meat mixture is then transferred to a log former and encaser <NUM>. The log former and encaser <NUM> forces the finely-ground heated meat mixture into plastic casings to form logs of predetermined diameter such that, after cooking, slices of the logs cut perpendicular to the center axis of the logs are of the desired diameter for the final fully cooked product.

After the encased logs are formed, they are loaded into a first freezer <NUM>, to be fully frozen. This is done to accommodate later slicing since the raw meat logs cannot easily be sliced even when chilled to be somewhat firm, such as raw cased sausages bought at a grocery store. The large logs may take up to <NUM> hours to freeze fully to be sliced properly.

After being frozen in the first freezer <NUM>, the logs are stripped of the casings by a stripper <NUM>. Stripper <NUM> may be a combination of a casing cutter that cuts the casing along a length of the log, and a worker that manually strips the casing from the log. This manual stripping process is slow and tedious. The stripped logs are then manually placed in a slicer <NUM>.

Slicer <NUM> is able to slice the frozen logs using a band saw blade or a solid metal blade. Since the logs are frozen, the slices generally retain their shape while being sliced. This would not be the case if the logs were not frozen prior to slicing. There will be some significant loss of meat during the slicing process, about <NUM>-<NUM>%.

The sliced frozen meat patties are then transferred to an oven <NUM> where they are fully cooked to a temperature of above <NUM> (<NUM> °F). The fully cooked patties are then transferred to a second freezer <NUM> to be frozen a second time. The frozen patties are then bulk packed.

The total length of time to complete the processing of the fully cooked meat product using the system <NUM>, from grinding the fat trimmings and trimmings <NUM> to packaging the frozen patties with the packager <NUM>, can take multiple days. Additionally, such a process is labor-intensive, particularly if casings are stripped manually and stripped logs are manually placed in slicer <NUM>.

<FIG> is a block diagram of a system <NUM> for producing a precooked meat patty product in accordance with some embodiments of the present disclosure. The meat patty may correspond to any kind of meat, e.g., chicken, beef, turkey, pork, or any combination thereof. Fat trimmings and lean trimmings <NUM> are ground in a first grinder <NUM>, combined with other ingredients <NUM> in a blender and/or mixer <NUM>, and heated in a heater <NUM> (e.g., to a temperature greater than <NUM> (<NUM> °F), in some cases to a temperature between <NUM> - <NUM> (<NUM> - <NUM> °F), and in some cases to a temperature simulating a pre-rigor state, such as <NUM> (<NUM> °F)). The temperature to which the meat is heated may depend on the type of meat. In some examples, for chicken, beef, turkey, and/or combinations thereof, the meat is heated at heater and/or heat exchanger <NUM> to between - <NUM> - <NUM> (<NUM> - <NUM> °F). In other examples, for pork, beef, turkey, and/or combinations thereof, the meat is heated at heater and/or heat exchanger <NUM> to between <NUM> - <NUM> (<NUM> - <NUM> °F). In yet other examples, the meat includes pork and is heated at heater and/or heat exchanger <NUM> to between <NUM> - <NUM> (<NUM> - <NUM> °F). Optionally, the meat is then finely ground in a second grinder <NUM>. Instead of using a log former/encaser <NUM>, first freezer <NUM>, casing stripper <NUM>, and slicer <NUM>, patties are formed at patty former <NUM> and precooked at precooker <NUM>. Various example implementations of patty formation and precooking are described below.

Patty former <NUM> fills patty molds with finely-ground meat from the second grinder <NUM> without the need for forming encased logs of meat product, freezing the logs, and then slicing the frozen encased meat logs. Because the meat is heated at heater and/or heat exchanger <NUM>, e.g., to a temperature above <NUM> (<NUM> °F), this technique for forming patties is referred to as a warm formation process. In other embodiments, heating is not performed prior to patty formation (e.g., the heater and/or heat exchanger <NUM> is eliminated), and such a process is referred to as a cold formation process.

By replacing the log forming/encasing, freezing, stripping, and slicing steps of the prior process <NUM>, the total time for forming and cooking the meat patties may be reduced from two days to about two hours or less, resulting in cost savings and increased yield.

After the heated finely-ground meat has been directed into the patty molds by the patty formers <NUM>, precooker <NUM> sears at least one side, and in some implementations both sides, of the formed patties such that they are able to be removed from the patty molds and remain intact during the entire precooking process. Without such searing, the formed patties may have a consistency that is similar to oatmeal which would complicate subsequent processing, e.g., because the formed patties may have a tendency to break apart when removed from patty molds. Precooking the formed patties causes the patties to have a skin including denatured proteins. The skin is formed on at least an area on the outside of the precooked patties. At least a portion of the meat product beneath the skin is at approximately the temperature to which the patties were heated by heater and/or heat exchanger <NUM> (or at approximately the temperature of the output of the second grinder <NUM> for the cold formation process).

In one embodiment, precooker <NUM> comprises at least one infrared oven. Other examples of heating techniques that may be used at precooker <NUM> include inductive heating, steam conduction heating, electric conduction heating, thermal oil conduction heating, application of a hot water shower, hot water spray, application of another hot liquid that sets the surface protein on contact, and combinations thereof. In an embodiment, precooker <NUM> may produce a heat on the order of about <NUM> (<NUM> °F) to about <NUM> (<NUM> °F), depending on the size of the patties. At such high temperatures, the precooking/searing may take about <NUM> to <NUM> seconds to precook the patties. The time duration for precooking may be a function of the species of the meat, the thickness of the patty, the temperature of the precooking/searing, and/or the precooking/searing method employed. With sufficient heat applied to the surface of the meat, the protein will typically denature in seconds, forming a skin of denatured protein at the surface Details of examples of precooker <NUM> are described below.

After precooking/searing the patties such that the patties remain intact when released from the patty form molds, the patties are fully cooked in an oven <NUM>. Oven <NUM> may be an impingement oven or other type of oven, heat application device, a water bath, or oil bath (fry), for example. Oven <NUM> cooks the patties to a high temperature (e.g., <NUM> - <NUM> (<NUM> - <NUM> °F), and in some cases any temperature over <NUM> (<NUM> °F)) such that the meat patties have been fully cooked and are appropriate for human consumption. Thus, in some examples, the temperature of the portion of the meat product below the skin is raised from between <NUM> - <NUM> (<NUM> - <NUM> °F) to between <NUM> - <NUM> (<NUM> - <NUM> °F). Because the patties were not frozen prior to being cooked in precooker <NUM> and oven <NUM>, the total cooking process time is reduced compared to prior system <NUM>.

The fully-cooked patties are transferred from oven <NUM> to a freezer <NUM> to be frozen. When the patties have been frozen, they are bulk packed or packed for shipment at packager <NUM>.

<FIG> and <FIG> are side and top views, respectively, of an example patty forming and precooking system <NUM> that may be used as the patty former <NUM> and precooker <NUM> in system <NUM> (<FIG>). In <FIG>, the process flows from right to left. Upstream of the patty formers <NUM> (to the right of patty formers <NUM> in the side view of <FIG>) are the heater and/or heat exchanger <NUM> (e.g., a scrape surface heat exchanger for the warm formation process), and the second grinder <NUM> (e.g., an inline grinder) that forms the final grind as described above with reference to <FIG>.

At the far right side of the patty forming and precooking system <NUM> are two patty formers <NUM> that receive heated (e.g., at pre-rigor temperature) meat, for the warm formation process, from the second grinder <NUM> (not shown in <FIG> and <FIG>). A pan conveyor <NUM> moves a plurality of form pans under the patty formers <NUM>. The patty formers <NUM>, details of which are described below, fill patty form molds in the form pans with the heated ground meat. The pan conveyor <NUM> conveys the filled form pans under a first infrared oven <NUM>-<NUM>. The first infrared oven <NUM>-<NUM> includes a plurality of infrared burners <NUM> that are located above the pan conveyor <NUM>. The infrared burners <NUM> or pan conveyors <NUM> are capable of being moved vertically in order to achieve the desired temperature and intensity during precooking of the patties in the form pans.

As the form pans are conveyed by pan conveyor <NUM> through the first infrared oven <NUM>-<NUM>, infrared burners <NUM> precook/sear the meat patties in the patty form molds from the top. Sufficient heat is applied to patties to sear the surface, and during this process product fat melts, which assists with patty release. Additional heat sources might be required on the bottom of the pan in the case of some products to release patties. An induction coil may be used as such an additional heat source, with other examples being a gas flame, thermal coil, or steam coil.

In some embodiments, when the form pans reach the far left side of the pan conveyor <NUM>, the form pans are rotated around the left side of the pan conveyor <NUM>, causing the partially precooked patties to fall from the form pans of the pan conveyor <NUM> onto a patty conveyor <NUM> such that the bottom of the patties in the form pans are flipped up to be conveyed by the patty conveyor <NUM> through a second infrared oven <NUM>-<NUM> and a third infrared oven <NUM>-<NUM>. <FIG> is a top view that shows how form pans <NUM> of pan conveyor <NUM> move (from right to left in <FIG>). Referring back to <FIG> and <FIG>, infrared burners <NUM> in the second and third infrared ovens <NUM>-<NUM> and <NUM>-<NUM> then precook/sear the second side of the meat patties from above. The infrared heat provides a relatively uniform brownness and retains the shape of the meat. The use of the first infrared oven <NUM>-<NUM> to cook/sear a first side along with the second and third infrared ovens <NUM>-<NUM> and <NUM>-<NUM> to cook/sear the second side provides even browning on both sides of the patties. This infrared heating process assists with patty release and also establishes the shape of the patty. Temperature of the patties exiting the infrared section may be in the range of <NUM> - <NUM> (<NUM> °F - <NUM> °F).

Thus, in some embodiments, precooker <NUM> (<FIG>) includes a first conveyor (pan conveyor <NUM>), heating element for heating a first side of each patty, a flipper (e.g., the curved end portion of pan conveyor <NUM>), a second conveyor (patty conveyor <NUM>), and a heating element for heating the second side of each patty. By precooking/searing the first side of the patty, a skin including denatured protein is formed on at least a portion of that first side. Then, by precooking/searing the second side of the patty, a skin including denatured protein is formed on at least a portion of that second side. The depth of the skin formed on the first side may be the same as or different than the depth of the skin formed on the second side. The skin formed on each side makes the patty less likely to break apart during subsequent processing or when grasped.

In some embodiments, infrared ovens <NUM> have multiple exhaust fans <NUM> that are used to control the temperature of the infrared ovens <NUM>. After the meat patties are conveyed through the second and third infrared ovens <NUM>-<NUM> and <NUM>-<NUM>, they are transferred to another oven (not shown in <FIG> and <FIG>) for final cooking, e.g., oven <NUM> described above in reference to <FIG>.

Pan conveyor <NUM> and patty conveyor <NUM>, as shown in <FIG>, may be mounted on rotating rails <NUM> such that the conveyors <NUM> and <NUM> may be moved away from the infrared ovens <NUM> to allow servicing of the infrared ovens <NUM> and/or cleaning of pan conveyor <NUM> and patty conveyor <NUM>.

Referring to <FIG>, a side view of pan conveyor <NUM> shows rollers <NUM> that assist in the moving of pan conveyor <NUM> and all related equipment along rotating rails <NUM>. Rotating rails <NUM> can rotate from a position perpendicular to the conveyors to positions parallel to the conveyors such that workers do not trip over rotating rails <NUM>.

<FIG> shows an enlarged view of a patty flipping portion <NUM> where pan conveyor <NUM> rotates around such that the form pans turn vertical (see far left end of pan conveyor <NUM> in <FIG>) and then further rotate under pan conveyor <NUM>, causing the patties to flip out of the patty molds of the form pan and onto patty conveyor <NUM>. The relative height between pan conveyor <NUM> and patty conveyor <NUM> is controlled to ensure that the patties are rotated during flipping in such a way that all or substantially all of the patties land with the top side (i.e., the side that was facing upwards while on pan conveyor <NUM>) on patty conveyor <NUM> and with the side that was touching the form pans (i.e., the side that was facing downwards while on pan conveyor <NUM>) facing upwards when on patty conveyor <NUM>.

<FIG> and <FIG> show more detailed side and top views, respectively, of patty formers <NUM> coupled to pan conveyor <NUM> of <FIG>. Patty formers <NUM> include two pan filler hoppers <NUM> that are attached to a frame portion of the pan conveyer <NUM> above individual form pans <NUM> (see <FIG>). In the example of <FIG>, each form pan <NUM>, in this example, defines twelve individual patty molds <NUM> that the pan filler hoppers <NUM> fill with the heated ground meat (for the warm formation process) when individual form pans <NUM> pass under the pan filler hoppers <NUM>. In an embodiment, form pans <NUM> may have a pitch of about <NUM> (<NUM> inches). Each form pan <NUM> may be mounted on a set of chains. In one example, the chains may be K1 chains, where K1 refers to the type of attachment holding the form pans <NUM> to the chain.

The patty molds <NUM> in the form pans <NUM> are shown in <FIG> as being round, but they may be oval or any other desired shape. Oval patty molds, for example, may have a long axis parallel to the direction of movement of pan conveyor <NUM>. It has been found that fibers of the ground meat may be aligned by the patty former <NUM> and the flow block <NUM> and the fibers shrink more along the aligned direction. Therefore, oval patty molds may result in a more circular final product, which may be desirable. The same principle of controlling the final shape based on expected fiber shrinkage may also apply to rectangular patty molds, in the event that a square product is desired.

A pan conveyor drive motor <NUM> is coupled to pan conveyor <NUM> to drive the individual form pans <NUM> with the pan conveyor <NUM> through the first infrared oven <NUM>-<NUM>. A pair of traction roller motors <NUM> cause the traction rollers <NUM> of respective pan filler hoppers <NUM> to rotate inwardly and urge the heated ground meat through respective flow blocks <NUM>, at low pressure, to fill the patty molds <NUM> of the form pans <NUM>. In other words, the finely ground heated meat mixture is funneled into patty molds <NUM> of patty form pans <NUM> using patty formers <NUM>, including traction rollers <NUM>, flow blocks <NUM> and traction roller motors <NUM>. In an embodiment, the combination of the height of the meat in the pan filler hoppers <NUM> and the traction rollers <NUM> develops a pressure of about <NUM>-<NUM> feet of water head which equates to about <NUM> · <NUM><NUM> to <NUM> · <NUM><NUM> Pa (<NUM> to <NUM> psi) or so, depending on the size of the pan filler hopper <NUM> and the traction rollers <NUM>. The low pressure provides a loose texture to the patties, which is desirable when pushing the ground meat into the patty molds <NUM>.

It has been found that because of the slipperiness of the heated ground meat, smooth traction rollers <NUM> may not provide enough pressure to adequately force the ground meat through the flow block <NUM>. The addition of grooves to the traction rollers <NUM> forces the heated ground meat into the narrow pathway of the flow block <NUM> more effectively. The grooves are generally parallel to the spin axis of the traction rollers <NUM> and may be, in an embodiment, about <NUM>/<NUM> of <NUM> (an inch) wide and deep. The narrowest constriction in flow block <NUM>, described below, may be about the same size as the gap between traction rollers <NUM>.

<FIG> are a set of illustrations of side (<FIG>), bottom (<FIG>), isometric (<FIG>) and cross section cut (<FIG>) views of flow block <NUM> that may be used to funnel the heated ground meat product (for the warm formation process) into patty molds <NUM> of the patty form pans <NUM> with patty formers <NUM> of <FIG>. As seen in <FIG>, funnel area <NUM> is formed in the flow block <NUM> passing from a top portion of the flow block to a bottom portion of the flow block <NUM>.

As seen in <FIG>, funnel area <NUM> initially constricts to a narrow choke area in the flow block and then expands to lower the pressure of the meat while the meat is forced into the patty molds <NUM> of the form pans <NUM> in a manner similar to a converging-diverging nozzle.

A handle <NUM> (seen in <FIG>) provides an operator with a convenient means for pushing flow blocks <NUM> into a bottom portion of pan filler hoppers <NUM>. A faceplate <NUM> provides a seal against form pans <NUM> such that the ground meat stays within funnel area <NUM> while being urged into the patty molds <NUM>. A spring-loaded scraper <NUM> (seen in <FIG>) with a concave profile is located downstream of traction rollers <NUM> and downstream of funnel <NUM>. Scraper <NUM> presses firmly against a top surface (e.g., aluminum or other metal) of the form pans <NUM> to scrape away most of the heated ground meat product above patty molds <NUM> such that the patties have a flat upper surface. Specifically, as form pans <NUM> move under the flow block <NUM>, a rear angle edge of a chamfer defined in funnel area <NUM> presses the ground meat into patty molds <NUM> (along with the pressure of pan filler hopper <NUM> and traction rollers <NUM>), and scraper <NUM> scrapes the top of form pans <NUM>, leaving the tops of form pans <NUM> clean and the patties flat.

Flow block <NUM> may be made of a plastic such as UHMW. However, it has been found that the intense heat of the infrared ovens <NUM> may heat form pans <NUM> to a point where an all-UHMW flow block may warp. If a surface of flow block <NUM> that touches form pans <NUM> includes a Teflon layer backed by an aluminum plate, which are then attached to a top layer of UHMW, flow block <NUM> is more resistant to warping. By making the top portion of flow block <NUM> out of UHMW plastic, flow block <NUM> and the bottom of pan filler hopper <NUM> may be sealed.

Spring loaded scraper <NUM> may be a Teflon bar that sits in a groove defined in the Teflon base layer of flow block <NUM>. The Teflon bar may have a set of aligning springs above it (not shown) pushing spring loaded scraper <NUM> against form pans <NUM>.

<FIG> shows a more detailed side view of the first infrared oven <NUM>-<NUM> and a left portion of the pan conveyor <NUM> including the patty flipping portion <NUM> that flips the meat patties, after the top surfaces are precooked/seared by the first infrared oven <NUM>-<NUM>, onto the patty conveyor <NUM>. As shown in <FIG>, a pan preheater <NUM> (e.g., a radiant heating system, or possibly a conduction system) under form pans <NUM> on pan conveyor <NUM>, is configured to preheat form pans <NUM> after being filled with the heated ground meat. The preheating helps to ensure partial melting of the fat trimmings in patty molds <NUM> to help to flip the meat patties out of patty molds <NUM> at patty flipping portion <NUM>.

A control panel <NUM> is used to set temperatures of the first, second and third infrared ovens <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>, and conveyance speed parameters of pan conveyor <NUM> and patty conveyor <NUM>. In an embodiment, a first infrared oven compartment <NUM>-<NUM> is cantilevered over pan conveyor <NUM> and houses infrared burners <NUM>, which can be moved up and down relative to pan conveyor <NUM> using the control panel <NUM>.

<FIG> is a top view of the patty flipping portion <NUM> between pan conveyor <NUM> and patty conveyor <NUM> of the system of <FIG> and <FIG>. As shown in <FIG>, when pan conveyor <NUM> exits the first infrared oven <NUM>-<NUM>, pan conveyor <NUM> reaches a reversal point at patty flipping portion <NUM>. When pan conveyor <NUM> revolves around the reversal point at patty flipping portion <NUM>, the patties are caused to fall out of patty molds <NUM> in the form pans <NUM> and caused to flip over onto patty conveyor <NUM>. After flipping onto pan conveyor <NUM>, the patties are conveyed on patty conveyor <NUM> into oven compartment <NUM>-<NUM> of the second infrared oven <NUM>-<NUM>. The relative height between the pan conveyor <NUM> and the patty conveyor <NUM> is sized to ensure that the patties are rotated during flipping in such a way that all the patties, or substantially all the patties, land with the top side on patty conveyor <NUM> and with the side that was touching form pans <NUM> facing upwards.

<FIG> and <FIG> show a side view and a top view, respectively, of the third infrared oven <NUM>-<NUM> shown in <FIG> and <FIG>. The third infrared oven <NUM>-<NUM> and the second infrared oven <NUM>-<NUM> are similar, in this example. The side view in <FIG> shows infrared burners <NUM> in oven compartment <NUM>-<NUM>, where infrared burners <NUM> are also movable in a vertical direction to be a selected distance from the patties being conveyed below on patty conveyor <NUM>. As also illustrated in <FIG>, the third infrared oven <NUM>-<NUM> (and the second infrared oven <NUM>-<NUM>) is equipped with a grease drain <NUM> where grease that is expelled from the patties and drips through grates of patty conveyor <NUM> drains into a collection area to be disposed of. As described above, when the patties reach the end of patty conveyor <NUM>, they are conveyed (e.g., via another conveyor or other conveyance means not shown in <FIG> and <FIG>) to an impingement oven (not shown) for final cooking.

<FIG> is a block diagram for a system in accordance with another embodiment involving in-bag cooking of meat. A packager <NUM> packages or bags each meat patty after it has been precooked by precooker <NUM>. For example, the meat patties may be individually wrapped in plastic bags. Then, the meat patties are cooked while inside bags at oven <NUM>. In-bag cooking of meat reduces the likelihood of certain types of meat contamination, e.g., because bacteria such as listeria can be killed by heat in oven <NUM> and no bacteria or other undesirable organisms can enter the bags surrounding the patties. Other aspects of <FIG> are similar to aspects of <FIG> and do not require further explanation.

<FIG> are illustrations of another technique for forming and precooking meat patties. Referring to the top perspective view of <FIG>, an apparatus 1400a includes a conveyor <NUM> that moves in the direction indicated by arrows <NUM>. Conveyor <NUM> includes multiple form pans <NUM>, with each form pan defining one or more (in this example, three) individual patty molds <NUM>. Form pans <NUM> may be implemented in a manner similar to form pans <NUM> shown in <FIG>. Meat product (e.g., heated finely ground meat from second grinder <NUM> for the warm formation process) is fed into apparatus 1400a at inlet <NUM>, which directs the meat into respective form patty molds <NUM>. As seen in the bottom view of <FIG>, there is a bottom <NUM> underlying patty molds <NUM> along at least a portion of the length of the top portion of conveyor <NUM>, but the patty molds in this embodiment do not have a bottom at other locations along the conveyor, as evidenced by the ability to see through the patty molds at certain places in <FIG>. As each patty <NUM> proceeds along conveyor <NUM>, it is heated by a heating plate <NUM> and heating coil <NUM>, which may be an inductive heating coil.

Although heating plate <NUM> and heating coil <NUM> are shown in <FIG> in a configuration below the patties proceeding along the top part of conveyor <NUM>, in some embodiments the heating plate and heating coil may be positioned above the patties proceeding along the top part of conveyor <NUM>, below the patties proceeding along the bottom part of conveyor <NUM>, or above the patties proceeding along the bottom part of conveyor <NUM>. In other words, heating may be performed on either side of either of the linear segments of conveyor <NUM>.

Another conveyor <NUM>, oriented, in the embodiment shown, substantially perpendicular to conveyor <NUM> and with molds arranged and dimensioned to match patty molds <NUM>, moves in the direction indicated by arrow <NUM> and transports the patties (heated by heating plate <NUM> and heating coil <NUM>) for further processing. In some embodiments, a mechanical knockout unit (not shown) punches the patties out of molds <NUM> to ensure that they are released at the correct time, e.g., in order to fall into molds of conveyor <NUM>.

<FIG> is a perspective view of another apparatus 1400b that is similar to apparatus 1400b but includes a first heating plate 1420a and first heating coil 1421a above form pans <NUM>, and a second heating plate 1420b and second heating coil (not shown in this view) below form pans <NUM>. By including two heating elements on either side of the patties moving along conveyor <NUM> (a configuration referred to as top and bottom heat jackets or dual heat jackets), the patties are quickly and efficiently heated in a uniform manner. Although the dual heat jackets are shown in <FIG> as sandwiching the top linear segment of conveyor <NUM>, in some embodiments they may sandwich the bottom linear segment of conveyor <NUM>.

<FIG> is an elevation view of a system <NUM> in accordance with some embodiments of the present disclosure. <FIG> is a top view of system <NUM>. System <NUM> includes a rotary forming apparatus <NUM> for forming meat patties. Rotary forming apparatus <NUM> includes a drum <NUM> that rotates in direction <NUM> (shown as a counterclockwise direction in the example view of <FIG>, but a configuration having a clockwise rotation is also contemplated). A plurality of patty form molds <NUM>, each of which may be round, oval, or having any other desired shape, are positioned to receive meat product that may be provided to rotary forming apparatus <NUM> from a hopper via an inlet (not shown). In an embodiment, patty form molds <NUM> comprise sides with a bottom, where the top is open. In another embodiment, patty form molds <NUM> comprise sides where both the top and bottom are open.

In an embodiment, patty form molds <NUM> are filled with meat product from the hopper when the patty form molds are at position A as shown in <FIG>. Other positions for filling the patty form molds with meat product are contemplated herein taking into account the criteria that the meat product has a sufficient amount of time to form a skin, as discussed below, in less than one full rotation of the patty form molds around drum <NUM>. The meat product may correspond to any meat species and may comprise, e.g., chicken, beef, turkey, pork, and combinations thereof.

The meat product that fills patty form molds <NUM> is initially of a consistency that does not hold together sufficiently well for handling and/or process purposes. As patty form molds <NUM> are transported along a circular path by rotation of drum <NUM>, the meat product within patty form molds <NUM> is heated by one or more induction coils <NUM> embedded on the inside of drum <NUM>. In other embodiments, induction coils <NUM> may be disposed on the outside of drum <NUM> and/or on both the inside and outside of drum <NUM>. Rotary forming apparatus <NUM> may also include one or more insulator plates <NUM> for providing insulation, as well as one or more cooling coils <NUM> for providing cooling capability, e.g., to control the temperature and thus the heating of the meat product in patty form molds <NUM>. The placement of the induction coils <NUM> and the cooling coils <NUM> in <FIG> is exemplary only. Other arrangements of the induction coils <NUM> and the cooling coils <NUM> are contemplated herein. Because drum <NUM> becomes hot, it is desirable to prevent excessive heat conduction to the working mechanism of rotary forming apparatus <NUM>, because the thermal expansion could cause excessive stress and wear. Cooling coils <NUM> and insulator plate(s) <NUM> are designed to keep the temperatures of the working mechanism within their normal operational limits.

Thus, the meat product is heated as drum <NUM> rotates, and a skin is set on the outside surface of each meat patty. The skin may comprise denatured proteins from the meat product and the skin on the meat patty may have a depth D. In some embodiments, the depth D is a small fraction of the thickness H of the meat patty. In certain embodiments <NUM> ≤ D ≤ <NUM>. In other embodiments, <NUM> ≤ D ≤ <NUM>. In still other embodiments, <NUM> ≤ D ≤ <NUM>. In further embodiments, <NUM> ≤ D ≤ <NUM>. In still further embodiments, <NUM> ≤ D ≤ <NUM>. In all embodiments, portions of the meat product in the meat patty that is located under the skin is not fully cooked by the heating of the meat product to form the skin.

The configuration of rotary forming apparatus <NUM> makes efficient use of available space and provides heating via induction coil(s) <NUM> that forms the skin completely around the meat patty. The resulting skin makes patty <NUM> hold together sufficiently well for further handling and/or process purposes. A knockout unit <NUM>, visible as a rectangular device in the side view of <FIG>, moves in and out with respect to the central portion of the rotary forming apparatus <NUM>, e.g., in the manner of a piston, and knocks meat patties in patty form molds <NUM> onto conveyor belt <NUM> in direction <NUM>. For embodiments where patty form molds <NUM> comprise sides with a bottom, knockout unit <NUM> strikes the bottom of patty form molds <NUM> with sufficient force to dislodge the meat patty from the patty form molds onto conveyor belt <NUM>. For embodiments where patty form molds <NUM> comprise sides where both the top and bottom are open, knockout unit <NUM> directly contacts the meat patty, thereby impelling the meat patty out of patty form mold <NUM> onto conveyor belt <NUM>.

Conveyor belt <NUM> may be a solid stainless steel belt in some embodiments. A meat patty <NUM> that has landed on conveyor belt <NUM> is transported in direction <NUM>. An induction coil <NUM> positioned under belt <NUM> provides additional heating in some embodiments. Additional processing may be performed, e.g., by moving patty <NUM> onto another conveyor belt or to another apparatus in the meat processing system.

<FIG> is a top view of system <NUM>. In this example, patty molds <NUM> are arranged in groups of five on drum <NUM>, but the patty molds may be arranged in other configurations.

<FIG> is an illustration of patty form disk <NUM> in accordance with some embodiments. Patty form disk <NUM> defines multiple patty form molds <NUM> arranged in a starburst pattern, emanating radially outward from a central region of patty form disk <NUM>.

<FIG> is an illustration of a patty forming apparatus 1700a in accordance with some embodiments. Patty forming apparatus 1700a includes patty form disk <NUM> which defines patty form molds <NUM>. Meat product (e.g., heated ground meat, for the warm formation process) inserted at inlet <NUM> is funneled into patty form molds <NUM>. Patty form disk <NUM> rotates in rotational direction <NUM>, and for a portion of the rotation heating is provided via induction heater <NUM>. In this example, induction heater <NUM> covers approximately three-fourths of the angular extent of patty form disk <NUM>, and that angular extent defines an induction cooking zone. In other examples, induction heater <NUM> may cover a different proportion of patty form disk <NUM>. In some embodiments, a bottom is provided underneath form molds <NUM> at the region corresponding to induction heater <NUM>. When patties proceeding along the rotational motion of patty form disk <NUM> exit the induction cooking zone, they may be released from patty form disk <NUM>, e.g., if there is no bottom underlying the patties there.

Although heater <NUM> is shown positioned above patty form disk <NUM> in <FIG>, in various embodiments the heater may be below the patty form disk, or two heaters may be provided above and below the patty form disk, respectively. Although patty form disk <NUM> rotates and heater <NUM> remains fixed in the above example, in other examples the patty form disk remains fixed and the heater rotates, or both the patty form disk and the heater are rotatable. By controlling the duration of exposure of patties in form molds <NUM> to heating, the temperature of the patties and the degree of cooking can be controlled.

<FIG> is a top view of a patty forming apparatus 1700b in accordance with some embodiments. Patty forming apparatus 1700b is similar in several respects to forming apparatus 1700a but varies in some of the geometrical details regarding patty form molds <NUM> and induction heater <NUM>. Patty form molds <NUM> are filled with meat product via nozzle <NUM>, which may be positioned at a given angular position relative to heater <NUM>. Induction plate insert <NUM> may be formed of a highly inductive material, and other portions of patty form disk <NUM> (e.g., at location <NUM>) may be formed of a non-inductive material. Patty form disk <NUM> rotates in rotational direction <NUM>, causing meat patties to be precooked/seared by heater <NUM>. When patties proceeding along the rotational motion of patty form disk <NUM> exit the induction cooking zone corresponding to heater <NUM>, they may be released from patty form disk <NUM>, e.g., if there is no bottom underlying the patties there.

<FIG> is a top view of an apparatus <NUM> that provides uniform flatness to formed meat patties in accordance with some embodiments. Apparatus <NUM> is better understood with reference to the partial sectional view (<FIG>) taken at the orientation indicated by <NUM>,. Referring to the partial sectional view of <FIG>, meat product (e.g., heated finely ground meat, for the warm formation process) may be mixed with various ingredients and dispensed from nozzle <NUM> into patty form molds <NUM> defined by mold plates <NUM> (e.g., made of stainless steel or other metal) which moves as indicated by arrow <NUM> in this example. Some of the meat product may mound above the form mold <NUM> as shown by <NUM>. Plate <NUM> (e.g., a high temperature resistant teflon plate) is stationary. As the mold plates <NUM> move, an air bladder <NUM> inflates, causing a scraper <NUM> to push downward (indicated by arrow <NUM>) on the top surface of the meat patty thereby removing the mound <NUM> and flattening the top surface of the meat patty. Then air bladder <NUM> deflates (indicated by arrow <NUM>) causing scraper <NUM> to retract (e.g., by a spring (not shown)), and the process continues for successive passing patties. The shape of the scraper <NUM> may be of any useful shape to perform the necessary scraping action.

In some embodiments, a meat product is processed with a hot water bath to improve the consistency of the meat product and facilitate handling of the meat product by creating a skin of denatured protein as discussed above. In some embodiments, the meat product is in the form of a nugget which may comprise chicken. In other embodiments, the meat product is a patty, as described above. <FIG> is a side view of a system <NUM> for precooking/searing meat products using such a hot water bath. Referring to <FIG>, a meat product block (e.g., a nugget or patty) <NUM>, which may be a <NUM> (¼") ground patty, is warm formed in the range of about <NUM> - <NUM> (<NUM> - <NUM> oF). In some embodiments, meat block <NUM> comprises finely ground chicken, which is among the most difficult meat products to handle, as it tends to come apart when one tries to hold or manipulate it. The interior of meat block <NUM> may have an interior that is raw and at a temperature of about <NUM> (<NUM> oF). Meat block <NUM> is transported along conveyor belt <NUM> in a direction corresponding to arrow <NUM> (left to right in the side view of <FIG>) and is processed by hot water bath <NUM> in some embodiments. For example, a pipe or faucet <NUM> connected to a hot water source may supply hot water to the hot water bath.

The hot water bath may include water at a temperature between <NUM> - <NUM> (<NUM> - <NUM> °F), e.g., about <NUM> (<NUM> oF). Meat block <NUM> may be treated with (e.g., immersed in) hot water bath <NUM> for a few seconds. The duration of exposure to hot water bath <NUM> may be dependent on the temperature of the water, e.g., with a longer exposure as the temperature approaches <NUM> (<NUM> °F) and a shorter exposure as the temperature approaches <NUM> (<NUM> °F).

In some embodiments, a sprayer or mister is used to apply water (or other liquid, such as an edible oil), e.g., in liquid or mist form <NUM> (with or without bath <NUM>), to meat block <NUM>, e.g., from above as meat block <NUM> proceeds along conveyor <NUM> belt in direction <NUM>. A sprayer or mister may also be positioned below meat block <NUM> (not shown) to apply an upward jet or mist to the bottom of meat block <NUM>. In some embodiments using a hot water bath <NUM>, meat block <NUM> is immersed in the hot water bath such that all portions of the meat block <NUM> are exposed to the hot water.

As a result of the hot water treatment, a skin is set on the outside surface of meat block <NUM> such that meat block <NUM> does not come apart when grasped or handled. The skin may be uniformly present at the surface of meat block <NUM>. The skin may comprise denatured proteins from the meat product and the skin on the meat block may have a depth D. In some embodiments, the depth D is a small fraction of the thickness H of the meat block. In certain embodiments <NUM> ≤ D ≤ <NUM>. In other embodiments, <NUM> ≤ D ≤ <NUM>. In still other embodiments, <NUM> ≤ D ≤ <NUM>. In further embodiments, <NUM> ≤ D ≤ <NUM>. In still further embodiments, <NUM> ≤ D ≤ <NUM>. In all embodiments, portions of the meat product in the meat block <NUM> that is located under the skin is not fully cooked by the heating of the meat product to form the skin.

In certain embodiments, meat block <NUM> may then be processed at breading/battering station <NUM>, where bread particles or batter is applied to the meat block, e.g., with a dispenser that is timed to apply (e.g., blow) bread or batter as meat block <NUM> passes through, under, or near breading/battering station <NUM>.

Meat block <NUM> may be subjected to additional processing, e.g., cooking, freezing, and packaging. The task of moving meat block <NUM> onto another conveyor belt for additional processing is greatly simplified because of the skin that holds meat block <NUM> together in accordance with various embodiments.

<FIG> is a flow diagram of a process <NUM> in accordance with some embodiments. A patty (e.g., meat block <NUM> shown in <FIG>) is warm formed at block <NUM>. The patty is subjected to a hot water treatment at block <NUM>. The patty is breaded and/or battered at block <NUM>. Additional processing may be performed as well.

<FIG> are a flow diagram for process <NUM> and a block diagram for system <NUM> in accordance with some embodiments. Ground meat product, which may include chicken, beef, turkey, pork, or combinations thereof, is heated (block <NUM>) at heater <NUM>, e.g., to a temperature greater than <NUM> (<NUM> °F), in some cases between <NUM> - <NUM> (<NUM> - <NUM> °F), and in some cases approximately <NUM> (<NUM> °F). In some examples, for meat including chicken, beef, turkey, or combinations thereof, the meat is heated to a temperature between - <NUM> - <NUM> (<NUM> - <NUM> °F). In other examples, for meat including pork, beef, turkey, or combinations thereof, the meat may be heated to a temperature between <NUM> - <NUM> (<NUM> - <NUM> °F). In yet another example, the meat includes pork and is heated to a temperature between <NUM> - <NUM> (<NUM> - <NUM> °F).

The meat is optionally subjected to additional grinding (block <NUM>) at grinder <NUM>, and used for forming patties (block <NUM>) at patty former <NUM>. In an embodiment, patty former <NUM> may include nozzle <NUM>, mold <NUM>, scraper <NUM>, and air bladder <NUM> as shown in <FIG>. A mold preheater <NUM> may also be used to preheat the patty molds. In some embodiments, mold preheater <NUM> includes an induction coil located beneath the mold plate. By delivering controlled power to the induction coil, heat is generated in the mold plate that enables the denatured protein skin to form in the patty.

Patty formation includes disposing meat product into one or more patty molds (block <NUM>) using nozzle <NUM>, and scraping an excess portion of ground meat off the molds using scraper <NUM> (block <NUM>). The uncooked patties produced by patty former <NUM> are precooked (block <NUM>) at precooker <NUM>, thereby forming precooked patties having a skin comprising denatured protein. The skin is formed on at least a portion of the outside of the precooked patties, and at least a portion of the meat product beneath the skin is at the approximately the temperature to which the meat was heated (block <NUM>) at heater <NUM>. Precooking <NUM> (at precooker <NUM>) may include applying infrared or inductive heating. The time duration for precooking <NUM>/<NUM> may be a function of the species of the meat, the thickness of the patty, the temperature of the precooking and/or the precooking method employed.

The precooked patties are optionally packaged (block <NUM>) at packager <NUM> before being fully cooked (block <NUM>) at cooker <NUM> such that they are suitable for human consumption. The temperature of the meat due to cooking <NUM> may be between <NUM> - <NUM> (<NUM> - <NUM> °F).

<FIG> are a flow diagram for process <NUM> and a block diagram for system <NUM> in accordance with some embodiments. Meat (e.g., poultry meat product) is mixed (block <NUM>) at mixer <NUM>, which may involve chilling with a coolant such as gaseous CO<NUM>, and then ground coarsely (block <NUM>) at coarse grinder <NUM>. The coarsely ground meat is heated (block <NUM>) at heater <NUM> and then ground finely (block <NUM>) at fine grinder <NUM>. The finely ground meat is provided to patty former <NUM>, which forms patties (block <NUM>) that are precooked (block <NUM>) at precooker <NUM>. In an embodiment, precooking <NUM> may include precooking a first side of each patty (block <NUM>) using a heating element <NUM>, flipping the patties over (block <NUM>) using flipper <NUM>, and precooking a second side of each patty (block <NUM>) using a heating element <NUM>. The precooked patties are processed by battering and breading (block <NUM>) at batterer/breader <NUM>, par fried (block <NUM>) at par fryer <NUM>, and fully cooked (block <NUM>) at a higher temperature than precooking <NUM> at oven <NUM>. The fully cooked patties are frozen (block <NUM>) at freezer <NUM> and packaged (block <NUM>) at packager <NUM>.

<FIG> are a flow diagram for process <NUM> and a block diagram for system <NUM> in accordance with some embodiments. Unlike other examples involving warm forming disclosed herein, <FIG> involve cold forming of meat patties, e.g., forming patties without a prior heating stage. Trim meat (e.g., including chicken, beef, turkey, pork, or combinations thereof) is reduced in size (block <NUM>) at a first size reducer <NUM> and then blended (block <NUM>) with other ingredient(s) at blender <NUM>. The blending may control the fat percentage and may involve chilling to a target temperature between -<NUM> and <NUM> (<NUM> - <NUM> °F). A further size reduction (block <NUM>) is performed at a second size reducer <NUM>, the output of which is passed to patty former <NUM> to form patties (block <NUM>) at the target temperature resulting from the chilling.

In an embodiment, patty former <NUM> includes a nozzle <NUM>, mold <NUM>, scraper <NUM>, and air bladder <NUM>. In some embodiments, mold <NUM> includes a bottom and a side, and in other embodiments mold <NUM> does not include a bottom. Patty formation includes disposing meat product into mold <NUM> using nozzle <NUM> (block <NUM>), and scraping an excess portion of ground meat off mold <NUM> using scraper <NUM> and air bladder <NUM> (block <NUM>). Scraper <NUM> may be engaged by inflating air bladder <NUM>. In some embodiments, mold <NUM> is heated (e.g., using an induction coil) prior to disposing the ground meat product into the mold. In some embodiments, mold <NUM> is heated using a first induction coil above the mold and a second induction coil below the mold.

The formed patties are cooked (block <NUM>) at cooker <NUM>, which may be an oven. In some embodiments, cooking the uncooked patties includes applying infrared or inductive heating to the uncooked patties. Cooking the patties forms a precooked patty having a skin of denatured protein. The skin is formed on at least an area on the outside of the precooked patty at a higher temperature (e.g., between <NUM> and <NUM> (<NUM> - <NUM> °F)) than the temperature of a portion of the patty beneath the skin. The temperature of the portion of the patty beneath the skin may be approximately the target temperature. The time duration for cooking may be a function of the species of the meat, the thickness of the patty, the temperature of the precooking, and/or a cooking method employed.

The cooked patties are chilled (block <NUM>) at chiller <NUM> and packaged (block <NUM>) at packager <NUM>.

<FIG> are a flow diagram for process <NUM> and a block diagram for system <NUM> in accordance with some embodiments. <FIG> are similar in several respects to <FIG> but involve warm forming instead of cold forming the patties, because heating (block <NUM>) at heater <NUM> is performed before the patties are formed. Heating <NUM> influences the texture of the patties, because the temperature for heating <NUM> can be controlled to determine the degree of crumble of the patties. The temperature for optimal crumbliness depends on the meat species. In some embodiments, the temperature for heating <NUM> is between <NUM> - <NUM> (<NUM> - <NUM> °F) for chicken, beef, turkey, and combinations thereof. In other embodiments, the temperature for heating <NUM> is between <NUM> - <NUM> (<NUM> - <NUM> °F) for pork, turkey, beef, and combinations thereof. For example, pork may be heated to about <NUM> (<NUM> °F), turkey may be heated to about <NUM> (<NUM> °F), and beef may be heated to about <NUM> (<NUM> °F). In another embodiment, the temperature for heating <NUM> is between <NUM> - <NUM> (<NUM> - <NUM> °F) for pork. Crumbliness may be determined by texture analysis of the patties. The remaining aspects of <FIG> are the same as in <FIG> and do not require further explanation.

<FIG> are a flow diagram for process <NUM> and a block diagram for system <NUM> in accordance with some embodiments. <FIG> are similar in several respects to <FIG> but do not involve a cooking stage between patty formation <NUM> and chilling <NUM>. Additionally, patty mold <NUM> is heated (block <NUM>) by mold heater <NUM>. The remaining aspects of <FIG> are the same as in <FIG> and do not require further explanation.

<FIG> is a flow diagram of a process <NUM> in accordance with some embodiments. One or more meat types are mixed (blending <NUM>), and seasoning ingredients may be added with additional mixing. Blending <NUM> may involve chilling the blended materials. The blended meat product is coarsely ground (block <NUM>), and fed to a controlled pump <NUM>, which pumps the meat at a uniform rate to heater <NUM>, where the meat blend is warmed to a target temperature. The heated meat is deposited to a metering hopper <NUM> and directed to a controlled pump <NUM>. Metering hopper <NUM> is a hopper that acts as a buffer or accumulator to balance or smooth out momentary starts and stops in the production system without the need to shut down activities that are occurring upstream. In other words, metering hopper <NUM> is a balancing mechanism.

Controlled pumping at controlled pump <NUM> refers to maintaining consistent and stable pressure at the mold filling point. To accomplish this, the pump is operated intermittently. In other words, because the mold plates are moving on a conveyor there are times when there is no place for the meat material to flow, so if the pump were running continuously there would be buildup of pressure in the pipe because of compression of the meat material. Using controlled pumping, when the mold plate reaches the correct position, there is a place for the meat material to flow, so the pressure buildup is avoided. In some embodiments, when speed of the conveyor is changed and the mold plates are either moving faster under the filling nozzle or slower under the filling nozzle, the controlled pump <NUM> accommodates for this change in speed. Thus, through controlled pumping overpressure situations (which would cause meat to leak out excessively) and underpressure situations (which would result in incomplete fills of the mold plate) are avoided.

Claim 1:
A method for cold forming a meat patty, the method comprising the steps of:
(a) coarse grinding a meat product;
(b) blending the coarse ground meat product with first ingredients to a temperature T1 wherein -<NUM> (<NUM> °F) ≤ T1 ≤ <NUM> (<NUM> °F);
(c) fine grinding the blended meat product;
(d) forming the ground meat product into an uncooked patty at T1 by disposing the ground meat product into a mold and scraping an excess ground meat product off said mold;
(e) cooking the uncooked patty to thereby form a precooked patty having a skin of depth D comprising denatured protein, wherein said skin is formed on at least an area on the outside of the precooked patty at a temperature T2, wherein <NUM>,<NUM> (<NUM> °F) ≤ T2 ≤ <NUM>,<NUM> (<NUM> °F), and wherein at least a first portion of the meat product disposed beneath said skin is at temperature T1, and wherein T2 > T1;
(f) chilling the precooked patty; and
(g) packaging the precooked patty.