Note: Descriptions are shown in the official language in which they were submitted.
VO ~/15473 1 2 1~ 3 410 PCT~S94100200
LARGE ENCASED ME~T PRODUCT WITH FLAT ENDS
RELATED APPLICATION
This is a continuation-in-part of U.S. Patent
Application Serial No. 07/982,027, filed November
24, 1992 in the names of John H. Beckman, et al,
which is a continuation of U.S. Patent Application
Serial No. 07/714,189 (now abandoned), filed June
12, 1991 in the names of John H. Beckman, et al.,
the entire interest of which is owned by the
assignee of the present application.
BACKGROUND OF THE INVENTION
The present invention relates to improved
packages for forming and heat processing of food,
particularly meat, and more specifically relates
to dimensionally uniform pro~s~ meat products
for high efficiency production and slicing.
In the manufacture of sausage products, meat
emulsion is prepared from comminuted meat together
with fillers, seasonings, spices, etc. A tubular
food casing, such as one containing nonedible
cellulose, is loaded onto a stuffing horn of a
filling machine and stuffed with the meat
emulsion. In the case of small sausage products,
like frankfurters, the filled casings are twisted,
tied or clipped into suitable links at
predetermined intervals and further processed.
For larger sausage products, like bologna, salami,
and the like, the meat emulsion is introduced into
WO94/1~473 2 1 S 3 4 1 0 PCT~S94/00200
larger heavier walled casings or casings having
fibrous reinforcements, and formed into chubs or
lengthy individual sausage sticks or logs. The
manufacture of other types of processed meats is
carried out using the same general method.
In preparing larger diameter processed meat
products, like bologna, an important consideration
is the maintenance of accurate size control over
the entire length of the log. It is important
that the diameter of larger products be controlled
very carefully so that meat packers are able to
cut the log into slices of predetermined thickness
and diameter for repackaging. The objective is to
have a given number of slices weigh a precise
predetermined amount for each package. That is to
say, a given number of slices should weigh as
close as practical to one pound or some other
preselected weight. In addition, precise diameter
control alone is important for vacuumized packages
where the product must support the package and
where varying diameters would be objectionable.
A further important consideration in the
preparation of larger diameter processed meat
products for repackaging concerns end portions.
Processed logs which have rounded ends provide
poor yields. Some degree of taper is usually
present with round ends and further decreases
yield. The end portions of a bologna log, for
21.53,~1o PcTnJs94l0020
example, which are normally rounded and which may
also be tapered can result in the loss of several
inches of meat from each end of the sausage.
Significantly undersized sliced product is not
usable in most vacuumized display packages and
must be reworked at significant cost.
In an effort to maximize yields of sliced
product for repackaging, methods have been
developed for eliminating rounded and undersized
ends. One popular approach to this problem has
been to prepare cylindrically shaped sausage
products having flat ends by utilizing a variety
of methods and apparatus. While such attempts
have attained some degree of success, none has
proven to be entirely satisfactory.
For example, U.S. 3,777,331 discloses
apparatus for preparing sausage products with flat
ends in which the meat mass is placed in a loading
chamber having an undersized flat end plate at
each end. The meat mass is compressed and
extruded from the chamber and through a stuffing
horn with one end plate at each end of the meat
mass. A continuous length of tubular casing is
filled with successive charges of the meat mass
and end plates by transporting the free end of the
casing with a conveyor onto the end of the horn
from which the charges of meat mass are extruded.
. The casing end is clamped onto the stuffing horn
W094/15473 ` PCTtUS94tO0200
and the conveyor retracted to its starting
position whereupon the meat mass and end plates
are extruded into the casing. Because the end
plates and meat mass pass through the inside of
the stuffing horn while the casing is clamped on
the outside of the horn, the casing has the
potential for a relatively loose fit over the
encased meat product and end plates. This is
undesirable because of possible "fat-out" and
jelly pocket formation from an accumulation of
water with fat and/or gelatin. Such products have
an unappetizing appearance, and consequently, have
poor customer acceptance. The casing of U.S.
3,777,331 must be stretched substantially to
prevent fat out, etc., which can result in
tapering of each product end as it approaches the
end plates which are no larger, and slightly less
than the diameter of the unstretched casing.
U.S. Patent No. 4,650,774 discloses a casing
structure with flat ends attached to thick end
plates wherein the casing is clamped against the
broad peripheral surface of the end plates by
rings with a tapered bore. The casing is filled
through a hole in one of the end plates. U.S.
Patent No. 4,650,774 also does not recognize the
importance of casing stretch on product quality,
nor the affect of casing stretch upon end taper
~0g4/1~73 21 S3~1 o PCT~S94/002
when the end plates have the same periphery as the
casing prior to stretching.
Other representative examples of devices for
preparing dimensionally uniform encased sausage
- 5 products with flat ends are disclosed by U.S.
4,551,884 and 4,466,465, both of which employ
elaborate end plate assemblies having central
openings which are costly to fabricate. These end
plates, called "flattening annular disks" require
a central opening because they are mounted onto
the end of the stuffing horn. The hole, however,
makes it necessary to gather the casing over the
face of the disk and apply a clip to close the
opening and avoid loss of meat emulsion during
filling. However, this is not enough to prevent
substantial loss of emulsion pressed through the
hole during stuffing which fills the space between
the disk and the gathered and clipped casing.
Consequently, it is nec~ss~ry to use a thin
tubular film connecting the disks.
Large producers make 80% of processed meat in
casing for slicing and repackaging. Each plant
may make thousands of logs daily from each
automatic stuffing machine which typically has one
operator. The operator loads the logs into
processing racks as well as tends to the stuffing
machine, and replenishes casing and clips. For
the sole operator to apply clamps to each end of
W094/1~73 2`1`S 3 ~ 1 0 PCT~S94/~200
, .
each log, as required by the system shown in U.S.
Patent No. 3,777,331, for example, would
substantially increase labor cost.
In addition, the bulk of each clamp would
cause problems when the logs are loaded onto the
horizontal processing racks. The logs are placed
lengthwise upon parallel spaced rods that support
the full length of the log. Clamps on each end of
a log would prevent the log ends from lying
æmoothly on the rods and cause the product to be
misshapen after processing. In addition, clamps
added to the thick flat end plates double the
number of extraneous parts that must be handled by
the processors.
Accordingly, it would be highly desirable to
have an improved system of packaging for encased
meat products, including those which are suitable
for filling with whole muscle and chunk style
products to produce dimensionally uniform
products, and which have flat ends to maximize
yields of sliced products for repackaging. This
would especially include large size fibrous
cellulose casing packages for forming and heat
processing of meat and other food that provide
dimensional uniformity for high efficiency
production and slicing.
A U.S. patent application Serial No.
07/714,189, filed June 12, 1991, in the name of
V094/15473 S3~1 o
the present inventor as a coinventor, describes a
casing with reinforcements on its terminal ends
that can coact with end plates to resist the axial
forces generated when the casing is stuffed with
5 food product and processed under pressure. This
application Serial No. 07/714,189 is incorporated
herein by reference.
-
WO94115473 ~`~ PCT~S94/00200
2153410
SUMMARY OF THE INVENTION
It is therefore an object of the invention to
provide a food package for processing meat
comprising a tubular casing stretched tightly over
a contained meat product with one or both ends of
the tubular casing held at the peripheral zone of
a rigid flat end unit of the same diameter as the
stretched casing and with minimum casing length
requirement for a given quantity of sliced meat.
It is a further object of the invention to
eliminate rounded and tapered ends on processed
meat for preslicing prior to repackaging for sale
and thereby to reduce rework to a minimum.
It is a further object of the invention to
provide an alternative to clips presently used to
close the ends of casing before and after stuffing
and to eliminate the cost of clips and clipping
apparatus as well as their safety hazards and
maintenance problems.
It is a further object of the invention to
provide a food package with flat ends for forming
and processing meat that can utilize a variety of
casings including: cellulosic, fibrous reinforced
cellulose and othe~ plastic films such as
polyamide, polyester, saran and others having
suitable properties, such as copolymers and
coextrusions and coated films.
WO941154M l $~l o PCT~S94/00200
It is a further object of this invention to
provide a food package that can effectively
utilize shrinkable film as well as stretchable
film.
: 5 It is yet a further object of this invention
to provide end units that are capable of securely
holding the end portions of the casing package,
enlarged to the same diameter as the body of the
package, without the need for external clamping
devices to resist axial forces tending to separate
them.
It is yet a further objective of this
invention to provide for the holding of food
product casing together with end plates without
resorting to clamping around the edge of the end
plates.
It is yet a further object of this invention
to provide suitable methods of assembling a food
package of the previous objectives.
It is yet a further object of the invention
to utilize end plates of non-circular
configuration as well as circular, so the product
can be produced with non circular cross section if
desired. This would include ovals to accommodate
flattened ham squares and rectangles for
externally restrained stuffing and D-shaped
product.
WO94/154732 1 S ~ ~ 1 0 PCT~S94/00200
It is yet a further object of the invention
to provide an optional food product in which one
end has a flat end plate without a clip and the
other end being rounded and clipped.
5It is another object of the invention to
provide good handling characteristics to the logs
and the end units, for product production in
modern high production facilities.
It is a further object of this invention to
10provide a food package that can be produced on
high speed automatic machines with minimum labor.
It is yet a further object of this invention
to provide a food packaqe that can be efficiently
made from flat casing in long lengths and
15therefore does not require preshirred casing.
These and other objects of the invention are
achieved in the tubular food casing embodiments
disclosed herein which relate principally to large
size food casings manufactured from materials like
20regenerated cellulose or regenerated cellulose
supported by a fibrous web, such as hemp paper.
Such casings are commonly referred to as large
cellulose casings and fibrous casings,
respectively. These casings are employed in the
25manufacture of large sausage and meat products,
such as cooked salami and bologna, chunked and
formed ham, chicken and turkey, cooked and smoked
ham butts, and the like. They are also used for
21 53 ~ 1 ~ PCT~S94/~200
WO94/15473
11
dried sausage which is not cooked and for other
foods such as cheese.
While large cellulose casings and fibrous
cellulose casings, including coated fibrous type
casings, are most widely used and preferred, this
invention is also intended to include other
nonedible food grade type polymeric casings, such
as those comprised of polyvinylidene chloride
(PVDC), polyamide and polyester. In addition,
this invention also contemplates co-extruded type
casings prepared with more than one type of
polymeric film. The casings prepared according to
this invention may also be manufactured from films
having commonly used internal and external
treatments, coatings and impregnations, e.g. meat
release agents, meat bonding agents, as well as
plasticizer and humectants, various levels of
moisture, including premoisturized, ready-to-
fill/no-soak type casings and those having
additives, such as antimycotic agents and liquid
smoke.
W094/15473 2 153 41 12 PCT~S94/00200
BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a partial side view of a prior
art orthodox large sausage package comprised of a
tubular casing, contained meat and an end clip.
FIGURE 2 is a partial side view of a prior
art flat end large sausage product comprised of a
tubular casing, contained meat, a flat end unit
and an end clip.
FIGURE 3 is a partial side view of an
improved flat end large sausage product comprised
of a tubular casing, contained meat and a flat end
unit.
FIGURE 4 is a partial cross sectional side
view of an adhesive joint system of Figure 3.
FIGURE 5-7 are partial cross sectional side
views of alternative adhesive joint arrangements.
FIGURES 8-12 are partial cross sectional side
views of various joint systems for clamping the
terminal end of a casing to a flat end unit.
FIGURES 13-15 are partial cross sectional
side views of various joint systems that combine
adhesive bonding with clamping of the terminal end
of a casing to a flat end unit.
FIGURE 16 is a side view of a flat end unit
which holds the terminal end of the casing by
means of piercing pins formed at the periphery of
the flat end plate.
W094/1~732 1 5 3 4 1 0 PCT~S94,00200
13
FIGURE 17 is a front view of the flat end
unit of Figure 16.
FIGURE 18 is a front end view of the flat end
unit of Figure 17 with its piercing pins bent
5radially inwardly.
FIGURE 19 is a partial side cross-sectional
view of a sizing disc for permitting ease of
assembly of the casing to the flat end unit of
Figure 16.
10FIGURE 20 is a perspective view of a flat end
unit bearing two circular rows of piercing pins.
FIGURE 21 is a partial cross-sectional view
showing a triangular piercing pin of a flat end
unit.
15FIGURE 22 is a front view of a plurality of
triangular pins of Figure 21.
FIGURES 23-25 are partial cross sectional
side views showing stages in the attachment of the
casing to triangular pins of Figure 21.
20FIGURE 26 is a side view of a casing having
tension bands.
FIGURE 27 and 28 are partial side views of an
improved product using the casing of FIGURE 26.
FIGURE 29 is an end view of the product of
25FIGURE 28.
FIGURE 30 is a schematic view of steps in a
stuffing procedure.
WO94/15473 2 -1 S 3 4 1 0 PCT~S94/00200
14
FIGURE 3l is a detailed top view of a portion
of FIGURE 30.
FIGURE 32-34 are detailed side views of
portions of FIGURE 30.
FIGURE 35 is a side view cross section of the
stuffing horn assembly.
FIGURES 36-43 are the schematic side views of
apparatus and steps for assembling the encased
food product with flat ends.
WO94/1~73 , 1 S3~1 o
1~
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to Fig. 1, a typical large sausage
product 51 such as bologna, chunked and formed ham
or other food products is generally tubular in
form for permitting slicing and stacking for
repackaging. Product 51 is closed at each end by
gathering the outer casing 53 and clipping the
open terminal end 55 closed by a clip 57. The
manufacture of such a meat product 51 provides two
rounded end portions 59, that contain meat. Such
end portions 59 are not suitable for inclusion in
modern sliced meat packages that require slices of
uniform diameter. In addition, a few slices
adjacent to the round ends are usually undersize
due to the taper caused by the rounded ends.
The meat from rounded end portion 59 is
normally ground and mixed with virgin meat
emulsion or used in other meat products, often of
lower grade. In either event, a significant cost
is associated with reworking meat from the rounded
ends. The amount of reworked meat is typically 1
to 1% lbs. for a product used for packaged
slices. The rework cost may be about 10¢ to 20¢
per lb.
Referring to Fig. 2, prior art methods of
reducing this rework including the use of a flat
disc 61 (are being shown) at each end of the
product 63. Disc 61 is made of tin plated steel
WO94/15473 ~ 2 1~ 3 4 1 0 PCT~S94/~2~
16
resembling the end units of cylindrical food cans.
Disc 61 is inserted into a tubular casing 65 which
had been previously clipped on one end by a clip
67. Disc 61 is manipulated into an orientation at
right angles to the casing axis before the casing
65 is stuffed with meat emulsion. Orienting disc
61 is an awkward manual operation that is
difficult to mechanize. An important factor in
the problem is that the meat casing must be
stretched 10~ to 20% in diameter during stuffing
and hence the disc 61 should be 10-20~ larger in
diameter than the casing 65. This insures full
sized slices. Each disc 61 is held in place by
the end portion 69 of the casing which is gathered
to the center axis of the disc and clipped.
Almost as much casing is used at the end of
product 63 as with the rounded end meat product 51
(Fig. 1) so that the flat disc 61 has little
compensating savings of production costs. The
cost of the discs and additional labor subtracts
substantially from the savings of rework costs.
Referring to Fig. 3, a flat end encased meat
product 71 includes a casing holding system 73
formed at each end of the product. Holding System
73 (one end being shown) eliminates most of the
cost of gathered casing and clips, and more than
compensates for the cost of a flat end disc 75
which is used at each end of the product. Disc 75
`~094/15473 ! ; 1 S3~1~ PCT~S94/00200
17
is inserted into a tubular cylindrical casing 77
and the plane of disc 75 is orienting at right
angles to the casing axis 79. Disc 75 is circular
in shape and includes a flat inner surface 88.
Disc 75 may be made from tin plated steel or other
rigid materials, as for example, plastic. Disc 75
may also be oval shaped, rectangular, etc.
depending on the cross-sectional shape of product
71.
Disc 75 is located near the end of the
casing, generally indicated by reference numeral
81. Casing end 81 is stretched in diameter and
drawn tightly over the circumferential edge of
disc 75. The outer end edge 83 of casing 77 is
unsupported and therefore remains or contracts to
or near its original unstretched diameter. A
terminal portion 85 of the casing end is located
between end edge 83 and the circumferential edge
of disc 75. Terminal portion 85 of the casing is
bonded onto the outer surface 87 of the disc. The
bonding of the terminal portion 85 to the outer
surface of disc 75 holds the casing in a state of
axial and radial tension when casing 77 is stuffed
under pressure by an emulsion pump (not shown).
Referring to Fig. 4, flat end system 73 is
shown in more detail and shows an adhesive layer
89 which holds the terminal portion 85 of casing
77 to the outer surface 87 of disc 75. The
wo g4/ls473 2 1 S 3 ~ 1 0 PCT~S94/00200
portion of the outer surface beneath terminal
portion 85 is referred to herein as the peripheral
boundary 84. Adhesive layer 89 may be formed from
fast setting adhesives such as temperature
resistant cyanoacrylate or heat sealing adhesives.
The preferred adhesive is heat sealable saran
which is described in U.S. Patent No. 4,610,742.
The saran adhesive has adeguate strength at
cooking temperatures and is resistant to hot water
and animal fats. The saran adhesive is also FDA
approved for direct contact with food.
The bonding surfaces of the end plates, disc
75, are preferably precoated with the adhesive.
Heating of the adhesive may be carried out by
contact with heated forms that fit the surfaces.
Alternatively, the heating may be carried out by
electronically heating the metal surface in the
area of the bond or by electromagnetically heating
the metal surfaces in the area of the bond or
heating adhesives containing magnetically
responsive particles.
It should be noted that precoating of the
bonding surfaces on the end plates with adhesive
is suitable only for disposable end plates. It
would not be practical for typical meat processors
to recoat the bonding surfaces with adhesives, as
would be required for reusable end plates.
W094/15473 21$3 PCT~S94/00200
The food product which is pumped into the
casing provides an axial force fl against the
inner surface 88 of disc 75 tending to force disc
75 outwardly away from casing 77. In addition,
S the food product provides a radial or peripheral
force f2 against the casing tending to expanding
the diameter or peripheral boundary of the casing.
The holding of the terminal portion against the
outer surface 87 of the disc by adhesive 89 serves
to couple the axially outward force fl of the food
product with the axial tension f3 of the casing.
Adhesive 89 prevents the terminal portion 85 of
the casing from being pulled back over the
peripheral edge of disc 75. Adhesive 89 is
located within the peripheral boundary of the disc
leaving the area outside of the peripheral
boundary free from obstruction.
Referring to Fig. 5, a holding system 73'
includes an adhesive layer 89 which secures casing
77 to disc 75. A metal cylindrical member 93 is
integrally formed at the peripheral edge of disc
75. Metal members 93 extends outwardly and normal
to disc 75 along its outer periphery as shown, and
includes a casing confronting side surface 9O.
Adhesive layer 89 attaches the terminal portion 85
of casing 77 to the side surface 9O of metal
member 93.
WO94/1~73 2 1 S 3 4 1 0 PCT~S94/~200
The holding system of Fig. 5, however, is
limited to use for product that does not require
high internal pressure and temperatures such as
uncooked dry sausage. It is a known
characteristic of adhesive bonds that they tend to
fail when one substrate stretches under load and
the other does not follow. Stretching under this
condition concentrates the load at the edge of the
bond and causes progressive failure. The holding
systems of Fig. 3, 4, and 6 are significantly less
susceptible to stretch induced bond failure
because of friction induced by the sharp downturn
of the casing over the edge of the end plate disc.
It has been found that rounding the edge reduces
the effectiveness of the downturn.
Referring to Fig. 6, a holding system 73"
includes an adhesive layer 89 which holds the
terminal portion 85 of casing 77 to disc 75.
Similar to Fig. 5, a metal cylindrical member 93
is integrally formed at the peripheral edge of
disc 75. Casing terminal portion 85 is drawn over
an outer edge surface 95 of metal member 93 and
back inwardly along inside surface 97 of metal
member 93, as shown. Adhesive layer 89 may be
generally L-shaped being positioned against outer
edge surface 95 and inside surface 97 for holding
casing terminal portion 85 onto metal member 93.
As will suggest itself, shapes of the adhesive
VO94/15473 21 S~ PCT~S94/00200
other than L-shaped may be used, and adhesive
layer 89 may be disposed only on surface 97.
Member 93 may be flared outwardly, at a small
obtuse angle relative to the longitudinal axis of
- 5 the product rather than being located normal to
outer surface 87 of disc 75. This provides a
nesting of adjacent discs prior to implantation,
for shipment, storage or location in the stuffing
machine magazine. With the holding system 73" of
Fig. 6, a snubbing action is caused by the
terminal portion 85 of the casing being bent
around metal member 93, which serves to reduce the
stress on adhesive layer 89.
Referring to Fig. 7, a holding system 73'''
includes a metal member 93' which is integrally
formed at the outer periphery of disc 75. Metal
member 93' is formed having a cross-sectional
configuration, as shown, which presents an
outwardly facing adhesive receiving surface 99
which is normal to the casing axis. Member 93'
also provides an upwardly facing annular surface
101 for supporting casing 77. Adhesive 89 holds
the terminal portion 85 of the casing onto
receiving surface 99.
Referring to Figs. 8a and 8b, a holding
system is shown in which a metal member 103 is
formed integral to the peripheral edge of disc 75.
Metal member 103 includes a small cylindrical
WO94/15473 - Z 1 5 ~ PCT~S94/00200
22
offset portion 105 which extends outwardly from
and normal to the outer surface 87 of disc 75.
Metal member 103 also includes an annular
depending portion 107 which extends radially
inwardly from the outer edge 109 of cylindrical
portion 105. Depending portion 107 is spaced
generally parallel to the outer surface 87 of the
disc.
Casing 77 is stretched over disc 75 including
the cylindrical offset portion 105 leaving a
terminal portion 111 of the casing. Terminal
portion 111 is unsupported and therefore returns
or attempts to return to its original diameter, as
shown in Fig. 8a. As shown in Figure 8b, the
casing end portion 113 of the terminal portion 111
is forced or tucked between the depending portion
107 and the outer surface 87 of disc 75. After
the casing end portion 113 is tucked into place,
the metal member 103 is forced toward the outer
surface of disc 75 clamping the end casing portion
113 against the outer surface 87 of the disc. The
clamping action serves to hold the casing relative
to the disc.
As shown in Figs. 9a and 9b, another
emho~iment is illustrated similar to the
embodiment of Figs. 8a, 8b wherein the end edge
115 of the metal member 103 is curled to provide
a smooth curve surface for contact against the
W094/15473 2 1 ~ 3 ~ 1 OPCT~S94/00200
2~
casing during clamping. This avoids a sharp
clamping edge and improves the holding ability of
the metal member 103.
As shown in Fig. 10, another embodiment is
illustrated similar to the embodiment of Figs. 8
and 9. A metal member 117 is formed integral to
the peripheral edge of disc 75. Metal member 117
has a curled cross sectional configuration as
shown and is continuous around the full extent of
the peripheral edge of disc 75. The end 119 of
the terminal portion of the casing is tucked
behind the curl-shaped metal member 117 as shown
in Fig. lOb. Thereafter, the curl-shaped metal
member 117 is flattened for clamping the terminal
end 119 of the casing against the outer surface 87
of the disc 75.
As shown in Fig. 11, a metal member 121 is
formed integral to the peripheral edge of disc 75.
Metal member 121 includes two arms 125, 127 which
are disposed in a generally V-shaped cross
sectional configuration, as shown, and are
continuous in length around the full extent of the
peripheral edge of disc 75. The end 123 of the
terminal portion of the casing 77 is pulled over
disc 75 and then inserted into the open V-shaped
mouth of the metal member 121 between arms 125,
127, as shown in Fig. lla. Thereafter, metal
member 121 is flattened so as to close the opening
WO94/15473 2 1 ~ 3 4 1 0 PCT~S94/00200
24
of the V-shaped mouth, as shown in Fig. llb, to
extent that the two arms 125, 127 of the V-shaped
configuration are clamped together grasping the
terminal end 123 of the casing therebetween. This
serves to grip the casing preventing its removal
from disc 75.
Referring to Fig. 12, a metal member 129 is
secured to the peripheral edge of disc 75. Metal
member 129 includes three separate leg portions,
131, 133, and 135. Legs 131, 133 are connected in
a V-shape configuration similar to that shown in
Fig. 11. Leg 135 extends from the terminal end of
leg 133 inwardly toward the open area of the V
mouth formed by legs 131, 133. The terminal end
123 of casing 77 is pulled over disc 75 and
inserted into the V mouth formed by legs 131, 133.
The terminal end 123 of the casing is inserted
within the V mouth to a position radially inward
of the terminal end of leg 135. After the casing
end 137 is in position, the metal member 129 is
flattened together serving to hold the terminal
portion of the casing 77 relative to disc 75.
Referring to Fig. 13, a metal member 141
similar to that shown in Fig. 8a is secured to the
outer peripheral edge of disc 75. The casing 77
is pulled over disc 75 leaving a terminal end 140,
as shown in Fig. 13a. An adhesive layer 143 is
positioned between metal member 141 and the outer
NO94/15473 ~1 0 PCTtUS94tO0200
surface of disc 75. As shown in Fig. 13a,
adhesive layer 143 is located on the outer surface
of disc 75 as well as on metal member 141. As
shown in Fig. 13b, the terminal end 111 of casing
77 is tucked between the layers of adhesive and
thereafter metal member 111 is flattened in order
to clamp the casing end relative to disc 75. This
combination of both clamping and adhesion tends to
supplement one another. Whereas a clamping
structure may tend to slip in some instances, the
adhesion layer may require longer cure time prior
to moving of the product. In addition, adhesion
may fail ~G~ essive due to the stretchability of
the casing. Clamping can lend its force where
needed to reduce stretchability affects.
Likewise, an adhesive layer may be provided
with respect to the clamping structures of Figs.
9, 10, 11 and 12. More particularly, Figs. 14 and
15 illustrate the use of adhesive layers. As
shown in Fig. 14, an adhesive layer 145 is located
at the outer peripheral edge of disc 75. The
terminal end 147 of the casing is tucked between
the metal member 149 and the adhesive layer 145
prior to flattening of metal member 149.
As shown in Fig. 15, an adhesive layer 151 is
located on both legs 153, 155 of a V-shaped cross-
sectional configuration of a metal member 157.
After the casing end 159 is positioned within the
wo g4~ls473~ 2 1 5 3 4 1 0 PCT~S94l00200
26
V mouth of metal member 157, legs 153, 155 are
flattened together as shown in Fig. 15b.
Referring to Figs. 16 and 17, a flat end disc
161 includes a plurality of piercing members or
5pins 163 which are disposed for facing outwardly
from the disc 161. The piercing members are
equally spaced around the outer most radial
circumference of disc 161 as shown in Fig. 17.
Casing 77 is stretched over the edge of disc 161
10to an extent so as to provide a terminal portion
167 of casing 77. Portion 167 is pierced by
piercing pins 163 and retracts to its original
diameter 166 as shown in Fig. 17.
As shown in Fig. 18, piercing pins 163 may be
15bent radially inward for operator safety.
Further, they may be bent flat against the
terminal portion of the casing for assisting in a
mechanical holding of casing 77 relative to disc
161.
20Referring to Fig. 19, a sizing member 171 may
be used to avoid premature engagement of piercing
pins 163 with the terminal portion of the casing.
Disc 161 is positioned within a holding aperture
173 of the sizing member 171. An extending lip
25175 extends axially outward to a position further
extended than piercing pins 163. The casing 77 is
pulled over sizing member 171 and the terminal
portion of the casing is stretched over lip 175
wo ~/l~ S3~1 ~ rCT~4/00200
and permitted to extend radially inwardly to its
original diameter. The terminal portion of the
casing will be spaced adjacent to points 163 but
will not be in contact with the pins.
- 5 An ejection member 177 is pushed in order to
move disc 161 out of its holding aperture 173 for
causing points 163 to pierce the terminal portion
of the casing. A magnet 179 may be used to hold
disc 161 within its receiving aperture 173 until
ejection member 177 is actuated. When stuffing
begins, meat pressure against disc 161 will push
the disc forward, separating it from sizing disc
171. The casing will move over sizing disc 171
until stuffing is complete.
The use of piercing pin members which are 1/8
inch in length and spaced apart by 1/4 inch were
found to hold an equivalent of 4 PSI internal
casing pressure when the casing was moist but
unheated. In order to increase the holding
capability without the decreasing the piercing
capability, smaller, shorter pins may be
incorporated between larger pins. Such a system
provides a two stage piercing action for ease of
piercing. It was found that this raised the
holding capability to the equivalent of 6-9 PSI
without bending the pins. The easy piercing with
alternative pin lengths permits reduced sharpness,
so bending was not necessary for safety. This
WO94115473 ; -' PCT~S94/00200
215~110
2~-
permits reuse of the end plates upon washing and
provides substantial operating cost reductions.
Referring to Fig. 20, a second row of
piercing pins 181 may be positioned on the outer
surface of disc 161. The second circular row of
pins 181 is located at a radial circumference
smaller than the first row of piercing pins 163.
In addition, the outer row of pins is located
radially inward from the periphery of disc 161.
This has the effect of gaining some snubbing
effect that adds to the holding ability of these
and other types of pins. The pins 181 of the
second row are staggered relative to the pins 163
in the first row. It has been found that the
second row of pins increases the holding capacity
to 6 or 7 PSI. Pins shown are round, but could be
of other shapes without departing from the two row
concept. Fig. 21 shows piercing pins shaped as
truncated triangles.
As shown in Fig. 21, disc 75 includes a
single row of truncated triangular pins 183
although two rows may be used and are preferred.
A frontal view of triangular pins 183 is
illustrated in Fig. 22. As shown in Figs. 23 and
24, casing 77 is stretched over the edge of disc
75. The terminal portion 185 of casing 77 is
permitted to retract to its original diameter.
The terminal portion is pressed against triangular
`~094/15473~S3~ PCT~S94/00200
pins 183 which pierce the casing so as to hold the
casing relative to disc 75. It has been found
that the triangular profile cuts out a 4-sided
hole having a slit along three sides with the
- 5fourth side remaining uncut and attached to the
casing. Thus, no debris occurs.
As shown in Fig. 25, a backup ring 187 and a
casing bump ring 189, comprised of a rigid metal
ring 191 and an elastomer contact ring 193, may be
10utilized to carry out the piercing action of pins
183 through the terminal portion 185 of casing 77.
It has been found that a substantial impact force
is required to achieve consistent piercing.
The term "flat", describing an end plate is
15used broadly. True-flatness can ideally,
eliminate reworking of the first slice. This is
desirable but is not a ne~eCcity.
The flat end plates of Fig. 20-25 are
preferably reusable upon washing and are
20preferably made of durable plastic. A preferred
plastic for the product to be cooked while under
the pressure of fibrous casing at maximum diameter
is polysulfone or its related plastics. It has
adequate bending strength at 200F, is resistant to
25hydrolysis, is resistant to animal fats, is
resistant to alkaline washing solutions, is
resistant to crazing, and has reasonable impact
value and wear resistance. It is readily moldable
wo g4~ls473 2 1 5 3 ~1~ PCT~S94/00200
and cost affordable. Other plastics with
comparable properties should be acceptable.
Stainless steel end plates made as per Figs.
16-19 would be a second choice for reusable
service.
Tin plated steel would be preferred for
disposable service as in Figs. 3-15. Tin plated
steel end plates could also be made with piercing
pins as in Figs. 16-19.
Referring to Fig. 26, a casing 201 includes
tension bands 203 which are preapplied to the end
zones 205 of the casing. The particulars of this
casing structure are set forth in the U.S. Patent
Application S.N. 07/714,189, filed June 12, 1991,
referred to above.
Referring to Fig. 27, a disc 207 is
positioned in the end zone of casing 201 which
serves to expand the casing enlarging its
diameter. Terminal portion 209 of the casing is
held against the outer side of disc 207 against
the axial tension of the casing caused by the food
product forced against the inner side of disc 207.
Tension band 203 prevents the terminal end 211 of
the casing from stretching to the diameter of disc
207 caused by the force of the food product
against the inner surface of disc 207. As shown
in Figs. 28, 29, during the application of heat,
tension band 203 will flatten against the backside
WO ~/1~73 ~ ~ 0
of disc 207 due to the yielding of the band edge
nearest to the disc because that edge initially
carries the concentrated load of the meat pressure
force on the disc. As that band edge stretches
and moves toward the periphery, it pulls the rest
of the band after it and the entire band width
becomes flat against the flat end plate if the
band strength and width are appropriate.
Various apparatus and methods may be used to
make the food product with the particular holding
systems described above. For example, U.S. Patent
Application, Serial No. 07/714,189, referred to
above discloses apparatus and a sequence of steps
which may be performed in preparing dimensionally
uniform stuffed meat products with flat ends,
using the holding system of the present Figures
26-29.
Referring to Fig. 30, a length of flat casing
209 is pulled and severed from a continuous casing
supply reel 211. As schematically represented in
Fig. 30, casing 209 travels vertically upward from
reel 211 to a pair of driving rollers 213.
Rollers 213 feed the casing horizontally with the
casing being supported by a conveying belt 232.
A moveable cutter 215 is positioned above casing
209 and is operable for cutting the casing into
individual lengths for subsequent stuffing.
Conveying belt 232 continues the horizontal
W09411~73 ; 2 1 ~ ~ ~ 1 0 PCT~S94/00200
32
movement of the casing length to a turning roll
217 which feeds the casing vertically downward to
a casing opener 219 upon which cutter 215 is
activated. A clear plastic enclosure (not shown)
may be used to enclose the conveying apparatus in
order to reduce moisture loss to ambient air that
would reduce casing stretchability.
Referring to Fig. 31, casing opener 219
utilizes vacuum on the outside surface of casing
209 to spread the flat casing apart so as to open
the casing for movement onto a sizing disc 221,
somewhat similar to sizing disc 171 of Fig. 19.
Referring to Figs. 32 and 33, a casing puller
223 receives the edge of the casing located on the
forward plane of sizing disc 221 and pulls the
forward casing edge downward and then beneath the
lowest edge of sizing disc 221. The casing puller
continues its movement of the casing along the
outer sleeve 225 of the stuffing horn assembly
226, as indicated by the dotted line in Fig. 30.
Casing puller 223 may grip the casing edge in a
number of ways including the use of a mech~nical
gripping member 222.
Referring to Figs. 34 and 36, two high
friction elastomeric shirring rolls 227 engage the
casing after it has been moved into position and
released by puller 223. Rolls 227 move the casing
in an aft direction along the outer sleeve 225 of
~094/15473 33 3~1D
the stuffing horn assembly. The aft end of the
casing is drawn through shirring rolls 227 and
onto sleeve 225 to form multiple low density soft
casing pleats. Although the casing on the upper
side of sleeve 225 is severely bunched together as
shirring begins, the bunching disappears and the
casing becomes centered on the sizing disc. The
casing is pulled over the sizing disc until a
terminal end portion 229 remains (Fig. 36).
Thereupon, the shirring rolls are disengaged from
the casing.
Referring to Fig. 35, sizing disc 221 has a
slot 232 in the upper half of its rim for
insertion of end plate 75. Plate 75 is made of
1/4 inch thick polysulphone plastic and has two
concentric rows of triangular pins for holding the
casing. End plate 75 is automatically removed
from a feed magazine (not shown) and is placed
through slot 232 to rest inside the outer edge 228
of sizing disc 221. This end plate 75 is known as
the first end plate.
Sizing disc 221 is fixedly attached to outer
sleeve 225 which is axially moveable relative to
a stuffing horn 234. An annular ring push plate
235 is nested within the sizing disc and is
attached to an inner cylindrical sleeve 233 which
is also axially moveable relative to stuffing horn
234 and relative to sleeve 225. Push plate 235 is
W094l1~73 ~ 2 1 5 3 g 1 0 PCT~S94/~2~
34
moveable for forcing end plate 75 into piercing
engagement with the terminal end portion 229 of
the casing.
Push plate 235 is faced with a flat ring 236
of 80A Durometer polyurethane and a smaller
diameter flat ring 237 of closed cell polyethylene
foam. Stuffing horn 234 ~ G~ ~S both sleeves
233, 225 and is held stationary.
After first end plate 75 is moved into place
within sizing disc 221, the casing delivery system
of Figs. 30-34 moves a length of casing into place
as shown in Fig. 36. A stuffing head 238 is
positioned several inches adjacent and forward of
sizing disc 221, and provides clearance for the
casing delivery system of Figs. 30-33. After
casing placement onto the horn assembly, stuffing
head 238 interacts with the casing and with end
plate 75 so as to secure the casing to the end
plate via the two rows of triangular pins.
Stuffing head 238 is roughly rectangular in
outer dimensions and supported on two shafts (not
shown) that move axially parallel to the axis of
stuffing horn 234. The center area of stuffing
head 238 is open to provide a clear path for the
stuffed product as n~A~. A slot 239 provides a
guide for end plates as they are transferred from
the magazine to slot 232 in sizing disc 221.
`NO94/15473 21 S PCT~S94/00200
Stuffing head 238 includes twelve brake
fingers 240. Fingers 240 are equally spaced in a
circular array and serve to hold the casing onto
the sizing disc during stuffing. Each brake
finger 240 is radially moveable and carries a
braking surface 241 for engagement against the
casing as described hereinafter.
Stuffing head 238 includes a plurality of
bump fingers 244. Fingers 244 are moveable
radially inwardly. Each finger 244 carries an
elastomer ring segment 242 having a 80A Durometer
polyurethane pad 243. Bump fingers 244 are used
to press the aft terminal end portion 229 of the
casing against the triangular pins on the first
end plate for attaching the casing to the end
plate.
Referring to Fig. 37, push plate 235 is moved
forward approximately 5/8 inch and sizing disc 221
moves forward approximately 1/4 inch. Bump
fingers 244 move radially inward and stuffing head
238 is moved rapidly to impact polyurethane pads
243 against casing end 229 and impale the terminal
end zone of the casing onto the pins of flat end
unit 75.
Referring to Fig. 38, bump finger assemblies
242-244 move radially outward. Brake fingers 241
move radially inward pressing with a controlled
force against casing 209. The meat pump begins
WO ~/1~73 PCT~S94/~2~
2153410 36
pumping meat emulsion through the stuffing horn
234 and into the casing. The first end plate 75
is pushed forward by the force of the meat
emulsion. The casing is pulled over the sizing
disc and under the brake fingers, as shown in Fig.
38.
Referring to Fig. 39, the meat emulsion pump
is stopped by a sensor (not shown) located in the
path of the extending product being stuffed. Push
plate 235 and sizing disc 221 are returned to the
original position of Fig. 36. The terminal end of
the casing 209 has been stopped and held securely
by the brake fingers 241.
End plate 75 has passed through guide 239 and
into slot 232 of the sizing disc. Recognizing
that such precise stopping is difficult, it is
observed that the flat-end plate 75 will push
excess casing into the slot, being assisted by the
natural tPn~ency of stretched casing to return to
its original size.
In Fig. 40, push plate 235 moves the second
end plate 75 forward beyond the edge of the sizing
disc 221 while brake fingers 241 continue to
firmly hold the end of casing 209. As the second
end plate moves forward while the meat emulsion
pump is idle a void 245 is formed that assists in
the separation of end plate 75 from the meat
emulsion.
VO94/15473 ~S3 PCT~S94/00200
37 ~ ~
Referring to Fig. 41, bumper fingers 244 move
radially inward, depressing the encased product
forward of the peripheral zone of second end plate
75 and gripping its edge and the casing 209 with
ring segment 242.
As shown in Fig. 42, brake finger 240 move
radially outward, releasing terminal end of casing
209 from sizing disc 221 when stuffing head 238
moves forward. When released from the sizing
disc, the terminal end of the casing returns
toward its original size and is in position to be
impaled upon the pins of second end unit 75 when
impacted by advancing push plate 235.
As shown in Fig. 43, the bumper fingers 243
have moved radially outward to release second end
plate 75 and stuffing head 238 has moved aft to
align the end plate guide 239 with slot 232 in
sizing disc 221. This completes the cycle and the
next cycle begins with the insertion of first end
plate 75 in Fig. 35.
A useful enrAs~ food product with only a
first flat end and the second end gathered to a
round end and clipped is a contemplated
embodiment. It would have the advantage of
simplifying the stuffing machine although
operating savings would be less.
Because the single unit end closures are made
of lightweight tough plastic and only 1/4 inch
WO94/15473 215 3 ~ 10 PCT~S94/00200
38
thick, the end units may be placed into compact
magazines by the person peeling the casing off the
product for slicing. Each pair of end plates are
placed into -the magazine directly after removal
from the product. They remain in the collecting
magazine through ultrasonic washing, through
storage, transport and placement into the stuffing
machine for reuse.
While several preferred embodiments of the
invention has been described hereinabove, those of
ordinary skill in the art will recognize that the
embodiments may be modified and altered without
departing from the central spirit and scope of the
invention. Thus, the preferred embodiments
described hereinabove are to be considered in all
respects as illustrative and not restrictive, the
scope of the invention being indicated by the
appended claims, rather than by the foregoing
description, and all changes which come within the
meaning and range of equivalency of the claims are
intPn~ to be embraced herein.
