Note: Descriptions are shown in the official language in which they were submitted.
76~
1 B~CKGR~ND oF THE INY~NT~
Thl~ lnvention relate~ to the production o~ a novel
centerfilled ~ood product and to the ~ethod and apparatus for lts
production. More partlcularl~, the lnvention ls dlrected to a
method and apparatus ~or ~roducin~ a c~lindxical-shaped, baked ~ ~
product, such as a coolcle, cracker, biscuit, snack item and the ;
like, havlng a rigid, friable baked outer shell and a core of
edible material surrounded b~ the shell.
A number of methods have been used hereto~ore to provide
cylindrical center~illed ~ood products. Such prior methods fre-
~uently have involved extruding a mixture of a ~arinaceous material
and water through a restricted-orifice into a tubular configuration,
under conditions such that the tubular product is pu~ed or
expanded as lt emerges ~rom the orl~ice. The tubular product is
cut to length and coolèd, and a deslred ~illing is in~ected lnto
the core of the puffed tubular bod~. ~uch methods suf~er from the
disadvantage that a number o~ sep~xate steps are involved, each
requiring separate handling of the ~ragile expanded tubular
~ product~ AlSo, because of the high temperatures and pressures to
which the mix i5 subjected in the extruder, the ingredients which
~ay be u.sed ln the mix are lL~ited. For e~ample, i the mix has a
sugar content o above ~bout 10%,the product tends to scorch or b~rn
during extrusion. ~s a xesult, such expanded, extruded products
must have a shell which consists esse~tially o~ cereal.
Another procedure which has been disclosed hereto~ore
involves mounting a plurality o~ cylindrlcal molds on an endless
conve~or, each o~ the molds having a rod extending horizontally
into its interior. A dough is ~illed lnto the mold, and the mold
carried lnto an oven for baking. The baked dough tubes are then
stripped ~rom the rods and held in ~ su~table manner to permit
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1 filling. This procedure also suffers from the disadvantage that
separate shell forming and filling steps are required, each
requiring separate handling of the product.
It is readily apparent that a process for making baked
centerfilled food products in which the shell is filled
simultaneously with its formation would be desriable for it would
reduce the number of handling steps involved. Heretofore the only
procedure disclosed for such a simultaneous shell forming
and filling operation involves a co-extrusion operation in which
a shell of cereal dough is extruded around a core of a filling
material. However, as noted above, due to the temperatures and ~;~
pressures to which materials are exposed in the extruder, the
ingredients which can be used in such a co-extrusion operation
are restricted to thereby limit the type of products produced.
SUMMARY OF THE INVENTION
,. . .
Brie1y, the product of the present invention is a
baked, centerfilled product which comprises a rigid tubular shell ;
of baked comestible thermoplastic material having a closed
longitudinal, non-overlapping or butted seam and a core of
edible material such as confectionary creme, fruit paste, meat
paste and the like, surrounded by the tubular shell.
The method of this invention involves baking a contin-
uous layer of a semi-liquid batter mixtuxe having a relatively
high sugar content to form a continuous ribbon or sheet
having a controlled thickness, the continuous sheet being thermo- ~-
plastic while at a temperature of about 212F and above, due to
its high sugar content. The continuous baked sheet, while
warm and pliable, is rolled around its longitudinal axis until
the edges of the sheet are butted together to form a continuous
30 tube having a closed longitudinal, non-overlapping seam. An ;~
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1 edible m~terial i~ ~n~ected ox othex~e depos~ted into the core
o~ the continuous baked tube, as the tube is ~ormed to ~ill the
core, and the center~illed tube, ls cooled. Upon cooling, the baked
outer shell becomes rigid, cris~ and ~x~able so that it retains ;~
its tubular shape wlthout opening o~ the closed butted seam. The
cooled,centerfilled tubular ~roduct is then cut into pieces of
de~ired lengths.
, The apparatus o~ the present invention includes heating,
means ~or baking a layer of a semi~ uid batter into a continuous
strip or sheet having a substantially unlform controlled thickness.
Tube forming means positionea adjacent the heating means receives
the continuous sheet of baked material discharged from th~ heating ,
means while the baked sheet is still in a plastic or pliable state.
The tube ~orming means iB adapted to xoll the continuous sheet
around its longitudinal a~is un~il the edge~ o~ the sheet are
butted together to thereb~ Eorm a contlnuous tube having a
longitudinal, butted or non-overlapping seam. A filling tube
extends axially into the tube orming, means ~or ~illing the core
o~ the contlnuous tube with an edible material. The centerfilled
~20~ tube is retained in the tube forming means until the baked outer
shell has cooled su~iciently to be.come rigid and ~riable. A
cutter is positioned adjacent the discharge end of the tube form-
lng mean~ ~or cutting the,continuous aenkex~illed tube into piece~
of desired lengths.
B~IEF DES~RIPTION OF THE DRAWINGS
Pig. 1 ls a schematic drawing illustrating a pre~erred
embodiment o~ the present invention.
Pig. 2 is a side elevational view o~ heating means for
forming a continuous baXed sheet having a substantially uniform ''
controlled thickness.
:
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~Lo~4r~6~
1 Fig. 3 is a side elevational view of apparatus in
which a continuous baked thermoplastic sheet is ~ormed into a
continuous center:Eilled tube.
Fig. 4 is a top plan view of the apparatus of Fig. 3.
Fig. 5 is a fragmentary perspective view of a product
of the present invention.
Fig. 6 is a corss-sectional view of the product taken ~ ~ -
along the lines 6-6 of Flg. 5.
Fig. 7 is a fragmentary perspective view of the tube
forming and filling apparatus of this invention.
DETAILED DESCRIPTION OF THE INVENTION
:
In accordance with the present invention, the baked
outer shell portion of the centerfilled product of this
invention is formed rom a batter which has as its principal
ingredients sugar, flour, and edible fat or oil, egg white
and water. These ingredients are mixed to provide a homo-
genous semi-liquid batter which is formed into a relatively
thin continuous layer and heated to form a continuous
elongated baked sheet or ribbon having a substantially uniform,
controlled thickness. The batter has a relatively high sugar
content, so that the baked sheet is theremoplastic, that is,
it is soft and pliable when at a temperature above about 210F,
but becomes hard and rigid upon cooling. It is essential that
the thickness of the batter layer be controlled during baking
so that the finished baked sheet will have a thickness e~ual to
the desired thickness o the baked outer shell portion of the
centerilled product of this invention. The thickness of the -
baked sheet will depend on the desired shell to filling ratio and
overall tube diameter of the product, which affects the texture, .
flavor and mouthfeel of the product. Thus, the baked sheet has a
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10 51~76~
1 substantiall~ unl~ox~ thickness wh~ch m~ n~e ~rom about 1/32"
to 1/4" or more, with a thickness ~n the range o~ between 1/16"
to 5/32" being pre~erred.
The th~ckness of the baked sheet is controlled b~ carry-
ing a layer o~ the seml~ uid batter between a pair o~ moving
heated surfaces which are verticall~ spaced apart a distance equal
to the desired thickness o~ the baked sheet, with the heated
surfaceg moving in the same direction at the same linear speed. The
batter ma~ be retained between these movin~ heated surfaces until
it has been baked to the desired extent. Alternativel~, the batter
ma~ be retained between these moving heated sur~aces only until
the surfaces of the batter la~er have been set, so that the
partiall~ baked batter la~er will xetain this controlled thickness.
The partiall~ baked sheet ma~ then be transferred to a conventional
baking means, such as a continuous band oven ~or completion of `
baking.
The batter la~er is baked until its moisture content has
been reduced to ~bout 5~ or less, preferabl~ between 2%-3%. ~t -~
this moisture level the baked sheet is sufficiently cohesive to
~orm a continuous sheet and has sufficiènt tensile strength,
elasticit~ and pliabilit~ to enable the baked sheet to be rolled
into a tubular shape while ~arm,and to become rigid, crisp and
~riable upon coolin~ so that when cooled lt retalns its tubular
.
shape, that is, there is no separation or opening o~ the
longitudinal butted seam.
The temperature at which the semi~ uid bat~er la~er
is baked to ~orm the continuous sheet will depend upon the formu- ~
lation o~ the batter and the desired thickness of the baked sheet, ~-
but should be at least 210F or above and usuall~ is in the range
from about 275~ to 550F. Genexall~ lt is prefexred that the
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1 moving heated sur~aces between which the ~atter layer is carried
are both at approxlmatel~ the same temperature. '. ~ ~`
The time o~ bakin~ will depend on the thickness of the "
batter layer, the ~ormulation of the batter and the baking . '~
temperature and ma~ range ~rom a ~ew seconds to 10 minutes or more.
In the embodiment o~ the invention shown in Fig. 1,. the
semi~ uid batter is deposited in co~trolled amounts on a first ~ :
or lower heated endless belt which carries the batter as it is
heated and baked to form a continuous baked sheet. A second or ~ :
upper endless belt havin~ a heated lower run i9 disposed parallel
to and overlies the lower endless belt, with'the heated facing
belt runs being vertically spaced apart so that a ~ap is provided
between the ~acin~ runs. The lower run of the upper belt is
su~ficiently pxoximate the upper run o~ the lower belt so as to
contact the upper surface of the batter layer being aaxried on ..
the lower belt and gauge the thickness o~ the batter layer. Thus, `'- ?
the facing runs o~ the lower and upper endless belts, which move
in the same direction at substantiall~ the same linear speed, are
vertically spaced apart a distance e~ual to the desired thickness
20 of the baked shell portion of the product of this invention, that ~
is, about 1/32" to 1/~" or more. Heating units, such as xadiant . '.
heaters, ribbon burners, and'the llke, axe po~itioned ad~acent the
facing runs of both the upper and lower endless belts to bake the : :~
- batter la~er into;a continuous sheet as lt is carried by the lower
belt. The speed o~ the belts and the baking temperature are
coordinated so that the continuous baked sheet, at the completion ~ ~'
: of the baking step, will have a temperature of about 210~F or
.
above and a moisture content of no more than about 5% by weight, ` ~
preferabl~' between 2% - 3~ by weight. While a uniform ~.;
30 temperature may be provided throughout this baking'step, it ;~
'~ ' is usually preferred to reduce the temperature in one or .
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1 more steps as the batter layer is baked. This may be carried out
by providing a plurality of heating units, which can be independ-
ently controlled in temperat~lre, adjacent ~he facing runs of the
belts. For example, at the start o~ the baking cycle, when the
batter is first deposited between the belts, the temperature is
relatively high, e.g., 500F, to facilitate rapid setting of the
surfaces of the sheet. One or more intermediate temperature zones
having a slightly lower temperature, e.g. 450F, and a final
heating zone at a lower temperature, e.g. 400F are provided to
complete baking of the batter layer and reduce the moisture con-
tent of the baked batter layer to no more than about 5%.
Alternatively, the batter layer may be maintained
between the vertically spaced heated endless belts only until
the surfaces of the batter layer have been set, so that the
partially baked batter layer will retain this controlled thick-
ness. The partially baked sheet may then be transferred to
conventional baking means, such as a continuous band oven or the
like for completion of the baking step.
- The types and amounts of ingredients used in the batter
Z are such that the baked sheet will maintain a uniform thickness,
be sufficiently cohesive to form a continuous sheet, and have
sufficient tensile strenyth, elasticity and pliability to enable
the continuous baked sheet to be continuously rolled into a
tubular shape while warm and to become rigid and friable upon
cooling, so that the cooled tube retains its shape. As noted
hereinabove, sugar, flour, and edible fat or oil, egg white
and water are the principal ingredients of the batter. The
batter has a relatively high sugar content, that is, between
about 20%-45% by weight, and preferably from about 30%-40% `
by weight, of the batter mix. Such a level of sugar in the
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~(~8~76g~
1 batter provides the baked batter layer with a texture and
structure such that it is thermoplastic, that is, the baked sheet
is soft and pliable while at a temperature of about 210F and
above, but becomes crisp, rigid and ~riable upon cooling. Suit-
able sugars which may be used include sucrose, dextrose, invert
sugar, corn syrup solids, including low D~E. corn syrup, lactose,
hydrolyzed cexeal solids and the like. Generally, it is pre~
ferred to use cane or beet sugar in either powdered or granulated
form in the batter.
The flour component may comprise from 10%-20% by weight
of the batter mix, with amounts of between about 12% and 16% by
weight beiny preferred. The flour may be derived from wheat,
corn, rye, soy, barley, and the like, and mixtures thereof.
Wheat flour is preferred.
Any of the edible plastic animal and vegetable æats
and oils generally used in baked foods may be used in the batter
., . ......................................................... j, .
mi~, including for example, butter, lard, margarine and hydro- `
genated vegetable oil shortenings made from oils such as soybean
oll, cottonseed oil, corn oil, peanut oil, coconut oil, palm oil
~ and the like, and mixtures thereof. The fat or oil component may
constitute from about 5%-15% by weight of the batter mix, with
amounts of between about 10% and 13% by weight being preferred~
Egg whites, which ~unation as a binding material or
toughener, are incorporated in the batter mix in either liquid,
frozen or dry form (as egg white solids) in amounts o from about
: ... .
2.5%-15% by weight of the mix. Water, or other aqueous liquids,
is present in the batter mix in an amount sufficient to provide ~ -
the batter with a semi-liquid consistency, generally constituting
from about 15%-30% by weight of the batter mix. Of course, minor
3~ amounts of other ingredients may be incorporated in the batter
,~
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`` 1084764
1 mlx, suc~ a~ ~or example, salt, ~l~vor~n~s, emul~i~lexs,
leavening agents~ starch, lecithin and the llke. The selection
and quantit~ o~ such other ingredlen-t~ wlll depend largely upon
the character and texture desired ~or th~ end produat.
~ n preparing the battex, the ingredients, except ~or the
~at or oil and emulsifier (i~ used~ a~e thoroughly mixed with
water until all of the dry ingredients are moistened. Fat or oil
and emulsi~ier are then added to the mix with agitation to pro-
vide a homogeneous b~tter having a semi~ uid consistency. As
noted above, the batter is deposited as a continuous layer on .
heating and conve~ing means which heat and bake the batter layer
to form a con~inuous baked sheet havlng a controlled thickness.
~ enerall~ it is pre~erred that the tubular center~illed
product o~ thls invention have an outside diameter in the range
o~ ~rom about 3/8" to 1", depending on the intended use o~ the
product, that is, a cookie, snack item, and the llke. Accordingl~, ;
the baked b~tter layer must have a width at least su~ficient to
~orm a tube having the outside diameter desired in the finished ~
~ .
product, when the sheet is rolled around its lon~itudinal axis
and the edges o~ the sheet butted together. Thus, the width o~
the baked sheet which is ~olled into a tube is equal to the
circumference o~ the ~inished centèr~llled pxoduct. When the
semi~ uid batter is deposited on the lower endless belt and
baked to ~orm the continuous sheet, the width o~ the batter layer
being baked ma~ be contxolled to provide a continuous baked sheet
havin~ a width such that when it is rolled around its longitudinal
axis and the edges of the sheet butted together, it ~orms a tube
having the desired outsLde diametex~ Alternativel~, a relativel~
wide layer o~ b~tter ma~ be de~osited on the heated endless belt
and b~ked to ~oxm a continuous sheet Which ls continuousl~ cut
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- 108~76~ `:
;lnto strips o~ a desi~ed width upon co~plet~,on ~f bakln~, such as
by a pluralit~ of spaced rota~ or ~tat~onar~ kn~ves disposed at
or near the dischar~e end o~ the lo~er conve~or and cut into strip~
o~ the deslred W~dth upon completion o~ ~aklng~
When the continuou~ b~tter la~er has been baked to the
desired extent, the resulting contlnuous sheet is transferred
~rom the baking means and, while still warm and pliable, is formed
lnto a continuous~ tube havin~ a longitudinal, non-overlapping or
butted seam. Thus, the baked sheet, h~vlng a desired width, is
tranferred onto a ~lexible, deformable, forming conveyor belt
which has lts feed end located adjacent the discharge end of the
lower heated endless belt, and moves in the same direction and at
. .
the same linear speed as the lower heated conve~or belt. This `
forming conve~or belt carries the dough ~heet, while warm and
pliable, through a form1ng tube in Whlch the continuous baked
shee~ is formed into a c~lindrical tube. As this belt, which iæ
~lexible and de~ormable, enters the forming tube, the lateral ~ ;
edges of the flat belt are progressivel~ raised and the belt
progressively curvèd u~til the edgeæ o~ the belt meet to form a
20 closed cylindrical tobe. The pliable, thermoplastic baked sheet ``
which is carxied on the ~lexible forming belt con~orms in shape
to the shape o~ the belt and is also formed into a closed cylin-
drical tube with the edges o~ ~he sheet butted together to provide
the tub~ wlth a non-overlapping lon~itudinal seam.
The baked sheet has a moisture content of no more than
..
about 5% and a temperature of at least about 210F when it is ~ ~
:j ., .
~ormed into a tubular shape, so that the baked sheet will be
sufficiently pliable to be formed into a closed cylindrical tube
without cracking of the sidewalls of the tube.
The c~lindrical tube thus ~oxmed 1s con~ined until it
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1 has cooled to an extent to become sufficiently rigid to retain
its tubular shape without opening or separation of the longi-
tudinal seam. The baked cylindrical tube is retained in the
forming tube until the baked batter has cooled to a temperature
below about 200F, preferably between about 95-100F or below.
Because of its relatively high sugar content, the baked batter
is rigid, crisp and friable at such temperatures, so that upon
cooling, the closed cylindrical tube retains its shape with no
separation or opening of the closed longitudinal seam. In
order to facilitate cooling of the baked batter tube, the forming
tube through which the baked sheet is carried is surrounded by a
cooling jacket through which a refrigerant, such as cold water
or glycol, is circulated.
An edible filling material is continuously deposited
into the center of the baked tube as it is carried through the
forming tube to fill the core o the tube. While the nature of
the filling material may vary depending on the intended use of
the product, it is generally preferred to use a viscous material
such as a confectionary creme, fruit paste, meat paste, cheese
paste, and the like, which has a viscosity such that it is
sufficiently fluid to be pumpable when warm but upon cooling will
be sufficiently stif and firm to be retained within the baked
tubular shell. When such a viscous filling material is used, it
is injected into the baked tubular shell at a point after the
baked strip is rolled into tubular shape and the edges of the
baked strip are butted together. This gives the haked material `
an opportunity to cool somewhat before the introduction of the
filling, thereby eliminating problems which may arise relating
to melting or thermal degradation of heat sensitive fillings. It
also reduces the risk of filling material escaping from the
ic~"
~ 3476~
1 tubular shell. This ~a~ be accompllshed ~ pumping the ~llliny
materlal -throu~h a center ~illlng tube which extends axially into
the ~orming tube to a point be~ond that at which the edges of the
baked strip are butted toyether. The ~illing materia~ is
introduced lnto the center of the c~lindr~cal tubular shell at a
velocity substantially e~ual to the velocit~ at which the tubular
shell is carried through the for~ing tube, so that the center
filling is continuous and uniform within the shell. Other edible
filling materials such as, for example, dr~ granular powders and
solid materials, may be filled into the core of the baked tube by
suitable means.
~ ccording to an embodiment of ~he invention, a con-
~ectionar~ creme is filled into the center o~ a continuous, baked
tube to provide a cylindrical, center~llled cookie product. Such
a ~illin~ material contains as its principal ingredients between ~ ;
about 20~-50% b~ weight o~ a sugar, such as granulated sugar,
powdered sugar, brown sugar, dextrose, corn s~rup soLids, and the
like, and combinations thereof, and between about 20%-40~ b~
weight o~ an edible plastic animal or vegetabLe ~at or oiL, such
~O as butter, lard, h~drogenated vegetable oil shortenings, and
~, .
the like, and combinations thereo~. Minor amounts of other
ingxedients, such as salt, ~Lavoring, antio~idant, emulsi~iers, ~ `~
and the like, ma~ be 1ncluded, i~ desired. ~n a pre~erred ;`
embodim~nt, a proteinaceous material is included in the sugar-fat -
mix to provide a protein forti~ied cookie product. Pre~erabl~
non-~at dry milk solids are incorporated in the sugar-~at mix in
amounts up to about 40~ b~ wei~ht o~ the mix, usualLy bètween
10~-~0% b~ weight. Other suitable pxotein source materials may
also be used, such as,~for example, sodium caseinate, calcium - ;
30 caseinate, ye~etable protein isolates, and the like. Yitamins, - -~
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1 mineral~ and other nutrients ma~ also ~e lncluded 1~ desired. In
preparing such a ~illing mlx, the plastlc shortening and emulsi~ier
are melted and cooled to a temperature of about 100-110F. The
cooled ~t mixtuxe is then combined With a blend o~ the dry
ingredients tsuch as powdered sugar, non~at milk solids, salt,
etc. ~ in a mixer e~uipped with sultable agitating means until the
texture ls cream~ and uniform. The mix then is pumped by a meter-
ing pump throu~h an overrun control device that whips the filling
mix until it becomes slightl~ sti~ and has an overrun which may
range from 30~-100%. The mix is them pumped through a filling tube
which extends axiall~ into the forming tu~e to continuously
deposit the ~illing in the baked tubular shell at a point after
the tubular shell has been ~ormed.
The continuous ~illed tube, aXter being cooled to a
temperature below 200~ is carrieA ~rom ~he forming tube b~ the
forming belt and is subse~uentl~ cut into pieces o~ desired lengthr
say ~rom about 1-3 inches, b~ an~ suitable cutting means such as
a reciprocating kni~e, rotar~ cutting blade, high speed saw,
guillotine kniXe, water knife, and the like, and packaged in
suitable moisture impermeable packaging material. The ratio b~
weight of the filling material to the baked dough shell in the
Xinished product may range ~rom about 0.33-1.5:1, depending on
the nature and intended use o~ the product. The product has a `
relati~el~ high bulk densit~, on the order o~ about 10-50 lbs.
per cu. ~t., and has a water activit~ ~w~ of about 0.1-0.25.
Referring now more particularl~ to the drawings, the
apparatus oX the present invention includes a general Xrame 10
servlng as a support and mounting ~or a baking unit 11, tube
~orming and Xilling means 12 and cutting means 14.
The baking unit 11 comprlses a lo~er endless conve~ox
- 13
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V~7~
belt lS adapted to recelve a seml~ u~d b~tter and carr~ a la~er
o~ batter as it is baked into a continuous sheet, an upper endless
belt 16 disposed ~arallel to and verticall~ spaced a predetermined
distance above lower conve~or belt 15 to gauge the thickness o~
the batter la~er, and heating means 31 and 32 dlsposed adjacent
the facing runs of lower and upper belts 15 and 16 respectively
to bake the batter la~er as it is carr~ed on the lower belt.
As shown in Fig. 2, lower endless conveyor belt 15
having a substantially horizontal upper run 25, extends longitud-
inally along the frame and extends around idler pulley 20 anddrive pulley 21 at the feeding and discharge ends;respectivel~ of
conve~or belt 15. Pulle~s 20 and 21 are freely rotatable about `
shafts 22 and 23 which are horizontal and parallel to one another,
the sha~ts being mounted in bearings ~not shown) secured to the
~rame. Lower conve~or belt lS preferabl~ comprises an imper~orate
stainle~s steel band fox suitable ri~idit~, althou~h other suit- ,
able materials ma~ be used. ;:~ `
Upper endless belt 16 having a substantiall~ horizontal
lower run 24 is disposed above conve~or belt 15, parallel thereto,
20 with the lower run 24 of belt 16 being uniforml~ verticall~ ``"
spaced above the upper run 25 of the conveyor belt 15 a distance
e~ual to the desired thickness o the ba~ed shell portion o~ the
product of this invention, generall~ a distance o~ between about
1/32" to 1/4"~ Upper endless belt 16 extends around idler pulley
26 and drive pulle~ 27 which are mounted ~or rotation about
horiæontal shafts 28 and 29 respectivel~ which are parallel to
one another and mounted in bearings ~not shown) secured to the
frame.
~ As -~hown in Fig. 2, upper enless belt 16, which is made
o~ the same material as the lower belt, overlies a substantial
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8476~
1 portion o~ lower conve~or belt 15, W~th the feed end o~ upper
belt 16 being longitudinall~ spaced a short dlstance from the feed
end o~ the lower con~e~or belt. Disposed abo~e the endle~s con-
ve~or belt 15~intermediate the ~eed end oE lower conve~or belt
15 and the feed end o upper belt 16 is nozzle 30 adapted to
deposit a uniform predetermined ~mount of semi-liquid batter on
the upper run 25 of conve~or belt 15. ~eeding means (not shown~
associated with nozzle 30, cooperate with the nozzle to deposit
a continuous la~er o~ the semi-liquid batter onto the upper run of
belt 15 with the batter la~er havin~ a thlckness at least equal
to the desixed thickness of the ba~ed shell portion of the
product of this invention.
Thus the upper run 25 o~ belt 15 and lower run 24 o~ -
belt 16 are axiall~ aligned and vert~call~ spaced apart to
provide a gap therebetween, with the layer o~ semi-li~uid batter
being carried on the lower belt lS into the gap to thereby gauge
the thickness o~ the batter la~er. Lower run 24 of belt 16 is
su~ficientl~ proximate to upper xun 25 of belt 15 to contact the
upper sur~ace of the batter la~er being carried on upper run 25.
One or mora~heating units 31 and 32 are mounted adjacent
both facing belt runs 24 and 25 substantiall~ the entire length '
o~ the faaing belt runs. The heating units are adapted to hea~ ;
the batter la~er disposed between the ~acing runs and bake it
into a continuous elongated sheet. Preferabl~ a number of
independently aontrolled heating units are mounted adjacent the
facin~ xuns 24 and 25~ so that several temperature zones are
~xovlded over the length o~ the facing runs. However, in any
given temperature zone, the heating units adjacent the upper and
lower ~acing belt xuns should be substantiall~ the same tempexa-
ture. An~ suitable heatin~ means capable of heatin~ the batter
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1 la~er to a temperature o~ between ~out 275C~F~550~ may be used,
such aq ~'or example, g~s burner~, electrical heatlng coils,
resistance heating elements, and the like.
Lowex ~nd up~er endless belts 15 and 16 are driven by
motor mean~ 33 to move in the same d~rection at the same linear
speed. Drive chain 35 connects the motor 33 to the main drive
shaft 36 mounted tn speed reduction means 34. Drive chain 37
connects the drive pulle~ 27 of the upper endless belt 16 and
drive pulle~ ~1 of the lower endless conve~or 15 with the main
drive shaft 36 through idler sprockets 38a, 38b and 38c, so that
the upper belt 16 moves in the same direct~on as and uni~ormly
with the lower conveyor belt 15 in the direction indicated b~
the arrows.
' .' ' ::.' .:
~ccordin~ to one embodiment o~ the invention, a `~
vertically d~sposed endless belt 40, made o~ the same material as
conveyor belt 15/ is mounted adjacent both edges of the lower
conveyor belt 15 at the feeding end thereo~ to confine the semi-
li~uid batter and t~ereb,y control the ~idth o~ the semi-liquld
batter on the lower conveyor belt. Thus, the vertical belts 40
extend from ~ po~nt ~orw~rd of nozzle 30 to a point where the
semi~ uid batter has been baked suf~icientl~ that it is no
,
lonqer ~lowable. Each vertical belt extends around an idler
pulle~ 41 and a drive pulle~ 42 which are ~reel~ rotatable about
.
; vertical sha~ts 43 a~nd 44 respectiyel~, the sha~ts being mounted
~n bearlnys ~ttached to the ~ame. Drive chain 53 connec~s drive
pulley 42 With the m~ln drive shaft 36 so that the vertical
endless belts 40 ~ove in the same direction and at the same `~
linear speed as lower and upper horizontal endless belts 15 and -
16.
~n this embodiment, both lowex ~nd upper belts 15 and
. ` ~ ~ ' ' `
~ -16- ~
' ' , .
.. :
... .. . . ... .. .. . . .
lOB~r76i4
1 16 have a width su~st~ntlally e~ual to the de~red clrcu~ference
o~ the tubula~ shell portio~ o~ the pxoduct o~ this invention.
Since the vertical endle~s belts ~0 con~ine the edges of the
batter la~er, the baked batter layer will also have a width sub-
stantiall~ e~ual to the desired circumference o~ the tubular shell.
I~ desired, endless belts 15 and 16, and the batter
layer carried therebetween, may have a width substantially greater
than the desired circumference of the tubular shell. In such event,
a pluralit~ o~ suitable cutting means, such as stationary or roll-
ing knives (nnt shownl are provided at or near the discharge endof the baking means to cut the continuous wide baked sheet into
continuous strips having a width substantiall~ e~ual to the
desired clrcu~erence o~ the tubular shell.
The lower and upper endless belts 15 and 16 may both
have a length su~lcient that the batter la~er is completel~ baked ;~
(i.e.,it has a moisture content of no more than 5%) when the batter
layer reaches the discharge end of lower conve~or 15. Alternatively, ~ ;~
the lower heated run 24 o~ upper endless belt 16 may overlie
~ ~ lower endless belt 15 onl~ adjacent to the ~eed end of the lower
;~ 20 belt;a;distance su~icient to ~a~ge the thickness and heat the
batter la~er until it has become set, 80 that the batter la~er
will retain its set thickness~ Thereafter, the batter la~ex ma~
be heated onl~ on the lower endless belt 15 or ma~ be transferred
to other conventional baking means such as a continuous band oven
.
for completion of baking of the batter la~er.
Located adjacent the discharge end of the lower endless
conve~or 15 is the ~eed end of tube orming and filling means 12
~which is adapted to receive the continuous baked batter sheet~
from conve~or belt 15. The tube formLng and fillin~ means 12
comprises a deform~ble, ~lexible endless conye~or belt 45 made of
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, : :
764
canvas, cotton, ~llled dacron or other ~u~ta~le ~l~xible and
deformable material, arranged so a~ to have a sub~tantially
horizontal upper run 46 which is axiall~ ali~ned and substantiall~
co-planar with upper run 25 of endless conve~or belt 15. Thus,
de~ormable endleqs belt 45 is disposed end to end in longitudinal
line with endless conve~or 15, the deformable belt 45 having a
feed end located adjacent the discharge end of lower endless ~ ' ! '
conve~or 15 and adapted to xeceive from the lower endless conveyor ~ -
the continuous baked sheet, with the baked sheet being transferred ;` `~
~o onto the upper run 46 thereof. Deformab].e endle~s belt 45 extends
.
around idler pulle~ 47 and drive pulle~ 48 at the ~eed and `
discharge ends respectivel~. Pulle~s 47 and 48 are xotatably
mounted in bearlngs (not shown~ mounted on the frame. Drive chain
49 connects the drlve pulle~ 48 o~ flexible conve~or belt 45 with
the drive pulley 21 o~ lower endless conve~or belt 15 so that the
~lexible conve~ox belt 45 moves in the same direction and at the
same linear speed as lower endless conveyor belt 15.
.
The upper run 46 of ~lexible belt 45, which carries the
,
continuous baked sheet, passes through tubular member 50, which
~2Q has a converging guide 51 at the inlet thereof, and through guide
ring ~2 Which is secured to the frame 10 intexmediate the dischargq
end o~ tubular member SO and drive pulle~ 48. 'rubular member 50
is surrounded b~ a aooling jacket through whlch a refxigerant
such as aold water, gl~col, and the like is circulated through `~
inIet 55 and outlet 56. Tubular member 50 has a bore extending
therethrough, the bore having a dlameter which is substantiall~
equal to the desired outside diameter of the center~illed product `
of this invéntion, which may be in the range o~ from about 3/8'l
to 1". Flexible conve~or belt 45 has a width which is substantially
30 equal to the circumference of the bore ~hich extends through
: `
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~
.
1 tubular me~ber 50. ~s the ~lexible con~e~or ~elt 45 ~oVe~ through
converging guide member 51 into the tu~ular member 50, the lateral
edges o~ the ~lat belt are pro~ress~vel~ raised and the belt
progres~ivel~ curYed until the edges o~ the belt meet to form a
closed cylindxical tube at a point adjacent the inlet end of the
tubular member. The belt is retained in this tubular configuration
until the belt moves through guide ring 52. ~he continuous baked
thermoplastic sheet which is carried on belt 45 has a width ~ ,
substantiall~ e~ual to the width o~ de~ormable belt 45. The baked
sheet, as lt is carried into tubular member 50, is at a temperature
o~ about 210~ ox above so that it is flexlbl.e and pliable so'that -
it conforms ln shape to the shape o~ belt 45. Accordingly, as the ~,
baked sheet is carried b~ the ~lexible,conveyor belt 45 through ,.
conver'ging guide 51 into tubular member 50, the lateral edges of . .'
the sheet are progxessivel~ raised and curved until the edges of ~ ,
the sheet are butted together to ~oxm a closed c~lindrical tube . '
having a longitudinal butted or non-overlapping seam. As the
cylindrical tube ~ormed from the baked sheet is carried through
tu~ular membex 50 lt is cooled to an e~tent that it becomes rigid
' 20 and friable so that as the continuous baked tube is carxied
b~yond guide rin~ 52 it is sufficientl~ rigid to xetain its.
tubular shape without opening or separation of the longitudinal
seam.
. Fllling tube 58 extends axiall~ into the tubular member .
S0 to a point be~ond that at which the edges of the baked sheet
are butted together to form the cylindrical tube,for continuously
lntroducing a ~iscous edible fillin~ material lnto the center :
portion of the tube. The illing material, which has an overrun : .
~ o~ about 30%-lO0~, is pumped ~rom meter~ng c~linder 59 through
30 the ~illln~ tube 58 into the center'of the c~lind~lcal baked
, . -19- , :
~ ,, .~,
: ~: '
t tube at a velocit,y ~ubstanti~ e~u~l to the relocit~ at Which
the baked tube ls carried through tubular member 50 so that the
center ~illing is cont.inuous and uni~orm and completel~ ~ills the
core o~ the baked tube. ~s the cente~ lled tube is carried
through tubular member 50 it ls cooled su~ficientl~ that the ~ill- ;;
ing material beco~es ~irm and i9 retained within the tubular shell.
As the continuous center-~llled tubular product is dis- ;
charged ~rom flexible conve~or belt 45 it is cut into pieces of
desired length b~ su1table cutting means 14 provided at the -
discharge end of belt 45, and the cut pieces ~ackaged in any
suitable manner in moisture-impermeable packaging material.
~s seen in Figs. 5 and 6, the product of this invention
comprises a rigid, tubular baked shell 64 which surrounds and
encases a core 65 o~ edible material, the tubular shell having a
longitudinal, non-overlapping butted seam 66.
The invention will be disclosed With more particularit~
in the ~ollowing e~ample, Which is lntended to illustrate the
present invention. ` ;~
- EXa~PLE
A tubular center~illed food product Was made using the
apparatus shown in the accompan~in~ drawings. A semi-liquid
batter Was prepared ~rom the ~ollowing ingredients:
Percenk
b~ Wt.
Sugar 35.5
Wheat Flour 13.5
Shortening 1l.5 ;
Cocoa 9-0
Egg White Solids 3.4
Pregelatinized corn starch 2.5
Leavening 1.6
Salt 0.5
Emulsifier ~ 0.5
~ater 22.0
.
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. ~ .
.
, . , '
.
~.
~08~7~4
., .
1 ~n preparing the batter the dr~ ~n~redient~ were
thoroughl~ mixed and the water added to the mix. The emulsi~ier
and shortening were then added With ag~tat~on to ~orm the batter. ::
The semi~lt~uld batter was deposited as a continuous
la~er on the upper heated run o~ a lower, lmper~orate stainless
steel endless belt 1-3/4" wide. A vertical, ~mper~orate stainless :~.
steel belt, approximatel~ 1" wide, was provided adjacent both
lateral edges of the lowex endless belt to contain the semi- ~ ~
liquid batter on the lowex belt. ~n u~per imper~orate stainless : .. : `.
10 steel endless belt, also 1-3/4" wide was disposed above the lower ~'
endle'ss belt with the lower run of the upper belt being verticall~
spaced 1/8" above the upper run o~ the lower endless belt. ~he .
batter la~er w~s carried on the lower endless belt into the gap
between the ~acing belt runs to provide the batter la~er with a
uniform thickness o~ 1/8". Heating units disposed ad;acenk the
.~acing belt runs heated the batter la~er to a temperature of
about 4000-500D~ as it ~as caxried.on the lower endless belt, with
the batter la~er being retained between the heated belt runs until '~
the molsture content o the batter layer was reduced to about'~
: 20 ~: The continuous baked sheet, 1-3/4" wide x 1/8" thick, `
.
was trans~exred~from.the lower endless belt ~o a ~lexible'dac.ron ! i ::
endles~ belt, also 1-3/~"~in Width, dlsposed end to end in longi-
tudinal li~e with the lower endless belt, and car~ied on the
~lexible endles~ belt th~ough a forming tube having an internal .-
diameter of 9/16". r The baked sheet carried on the flexible belt '~
had a temperature of above 210~ as it entered the forming tube.
~s it was carried through the for~lng tube,.the late.ral edges of
: the baked sheet were progressivel~ raised and curved until the ' ;.
: edges were butted together to form a cont~nuous tube having a .. ; .. '~ .
3G longitudinal non~o~exl~pping seam.
~21~
.~~ ~ . '
,~ ~o~76~
1 ~n ed~ble ~ ng material w~s prepa~ed ~ro~ the
~ollowlng ingredients: `
Percent
b~ Wt.
Sugar 40 0
Shortening 30.0
Non-fat dr~ milk 20.0 ~ : :
Butterfat 7 5
Emulsi~ler 2.2
Salt ~ `
Flavor, antioxidant 0.1
ln preparing tha ~illing, the dr~ ingxedients were
thoroughly mixed and added to a mixture of fat and emulsifier,
which was at a temperature of about 100-110F. The resulting mix
wa~ whipped untll it became slightl~ sti~f. The filling was then
pumped through a ~illing tube which extended axiall~ into the
forming tube to continuousl~ deposlt the ~illing ma~erial into the `~
core o~ the tube of baked batter, With the ~illing being in~ected
at a point after the edges o~ the baked sheet had been butted
toffether. The ~illed tube Was retained in the forming tube until
the temperature~of the shell was reduced to below 150F so that
the ~hell was rlgld and friable.
The cooled ~illed tube was then carried on the flexible
~belt from the forming tube to cutting means whiah cut the contin-
~ . .
uou~ ~llled tube into pieces about 3" in length.
The center~illed product thus produaed had an out~ide ~ ;diam~ter o~ 9/16" With a baked shell thicknesS o~ 1/8". The ~
ing material completel~ ~illed ~he core of the tube. There was no
opening or separatlon o the longitudinal butted seam o~ the
cooled shell.
While the inYention has been described and illustrated
with re~erence to a paxticular pre~erred embodiment, it is to be
,
~understood that this is onl~ illustrative and not intended to
limit the scope o~ the invention. Rather, the lnventlon encompasses `~
modi~ications, variations and rearrangements o~ parts which fall
with1n the scope o~ the appended claims.
22-
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