Note: Descriptions are shown in the official language in which they were submitted.
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1 Methods and Apparatus for Forming Coated Popcorn Bars
CROSS REFERENCE
The present application is a continuation-in-part of
application Serial No. 29/028,479 filed September 16, 1994.
5 BACKGROUND
The present invention generally relates to methods
and apparatus for forming shaped popcorn products,
specifically to methods and apparatus for forming popcorn
bars, and particularly to methods and apparatus for
forming coated popcorn bars.
With the increasing awareness of nutrition and healthy
eating, popcorn has become increasingly popular as a snack.
Typically, kernel popcorn is popped such as in a microwave
oven and consumed as popped popcorn. It can then be
appreciated that in addition to the time and effort
required to pop the kernel popcorn, popped popcorn is also
not as easily handled and consumed as other snack products
such as candy bars or the like which can be stored for
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1 indefinite time periods, can be easily transported in a
pocket, brief case, lunchpail, or the like, and can be
immediately consumed when removed from the wrapper or
other packaging.
Although popcorn balls and other shaped popped popcorn
products such as described in U.S. Patent No. 4,849,233
exist, such products have not achieved significant market
success. Specifically, in addition to taste and other
market appeal factors including handling and aesthetics,
10 the shapes of the products are made by compression in
stamping, molding, or similar devices, either manually or
mechanically. Such methods of manufacture increase the
cost of the product and detract from their competitiveness
with other types of snack-type foods.
Thus, a need exists for shaped popcorn products which
overcome the disadvantages and limitations of prior
popcorn balls and other shaped popcorn products and
provide a healthy, competitive alternative to other types
of snack-type foods. In this respect, it is an aim to
20 provide unique methods and apparatus for forming shaped
popcorn products and in particular popcorn bars.
SUMMARY
These needs and other problems in the field of shaped
popcorn products are solved by providing a popcorn bar,
25 in the preferred form, formed by apparatus and methods
where popped popcorn coated with molten binder in the
most preferred form of a caramel syrup is compressed into
a sheet in the most preferred form by being drawn into
and passing between an input conveyor and a compressing
30 conveyor arranged at a non-parallel angle and with
decreasing spacing to the input conveyor and is cut into
a plurality of strips in the most preferred form by
parallel, spaced, rotating, slitter knives and then the
strips are cut to the desired lengths in the most
35 preferred form by a guillotine knife, with the bars in
the preferred form being drizzled with a confectionery
coating in a zig-zag pattern.
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1 These and further aspects and advantages of the
present invention will become clearer in light of the
following detailed description of an illustrative
embodiment of this invention described in connection
with the drawings.
DESCRIPTION OF THE DRAWINGS
The illustrative embodiment may best be described by
reference to the accompanying drawings where:
Figure 1 shows a perspective view of a popcorn bar
10 formed utilizing methods according to the preferred
teachings of the present invention.
Figure 2 shows a top plan view of the popcorn bar of
Figure 1.
Figure 3 shows a front elevational view of the popcorn
15 bar of Figure 1.
Figure 4 shows a right side elevational view of the
popcorn bar of Figure 1.
Figure 5 shows a left side elevational view of the
popcorn bar of Figure 1.
Figure 6 shows a rear elevational view of the popcorn
bar of Figure 1.
Figure 7 shows a bottom plan view of the popcorn bar
of Figure 1.
Figure 8 shows a diagramatic view of apparatus for
25 forming the popcorn bar of Figure 1 and utilizing methods
according to the preferred teachings of the present
invention.
Figure 9 shows a partial, plan view of the belting of
the conveyors of the apparatus of Figure 8 taken along
30 view line 9-9 of Figure 8.
All figures are drawn for ease of explanation of the
basic teachings of the present invention only; the
extensions of the Figures with respect to number,
position, relationship, and dimensions of the parts to
35 form the preferred embodiment will be explained or will
be within the skill of the art after the following
teachings of the present invention have been read and
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1 understood. Further, the exact dimensions and dimensional
proportions to conform to specific force, weight, strength,
and similar requirements will likewise be within the skill
of the art after the following teachings of the present
s invention have been read and understood.
Where used in the various figures of the drawings,
the same numerals designate the same or similar parts.
Furthermore, when the terms "top", "bottom", "first",
"second", "end", "edge", "side", "front", "back", "length",
10 "width", "outer", and similar terms are used herein, it
should be understood that these terms have reference only
to the structure shown in the drawings as it would appear
to a person viewing the drawings and are utilized only to
facilitate describing the invention.
15 DESCRIPTION
An apparatus for forming a coated popcorn bar
utilizing methods according to the preferred teachings
of the present invention is shown in the drawings and
generally designated 10. Apparatus 10 generally includes
20 a popcorn popper 12 which in the preferred form is of the
air-popping variety, with a Cretors commercial air popper
being utilized in testing. In the most preferred form,
mushroom variety popcorn is popped in popper 12.
Apparatus 10 further includes a device 14 for receiving
25 the popped popcorn from popper 12, for removing any
unpopped, underpopped, and/or partial kernels, and for
transporting the popped popcorn to a surge hopper 16.
Device 14 can include bucket or similar elevators,
suitable conveyors, surge hoppers, and separators as
30 desired for convenience of placement and operation of
popper 12 and hopper 16. Popped popcorn is removed from
hopper 16 at a uniform rate by a suitable device 18 such
as a weigh belt feeder.
Apparatus 10 further generally includes a device 20
35 for evenly coating the popped popcorn with a molten binder,
which in the most preferred form is a caramel syrup.
Device 20 in the preferred form is a steam-jacketed auger
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1 mixer. Caramel syrup is formed in the most preferred form
from a mixture of water, sugar, corn syrup, molasses, salt,
oil and lecithin heated to a temperature in the order of
180F (82C) such as in a steam-jacketed kettle 22. The
mixture is then cooked at a temperature in the order of
300F (149C) in an evaporator 24, with a Groen commercial
scraped surface evaporator being utilized in testing.
In addition to the popped popcorn from device 18 and the
cooked, molten syrup from evaporator 24, oil is sprayed
10 by sprayer 26 into the auger mixer 20 to keep the popcorn
from sticking to the sides and the screw of auger mixer 20
such that the popped popcorn is evenly coated with cooked,
molten caramel and oil in the most preferred form. In the
preferred form, the coated popcorn is discharged from
15 auger mixer 20 at a temperature in the range of 250F
(121C) to 270F (132C) and in the most preferred form
in the order of 260F (127C). If the temperature at
discharge is too cold, the coated popcorn is too brittle
to form into sheets, strips, or bars. On the other hand
20 if the temperature at discharge is too hot, more energy
is required to cool the coated popcorn.
The coated popcorn is discharged from auger mixer 20
into a spreader box 28 which generally evenly distributes
the coated popcorn onto the input conveyor 30 of a
25 compressing and sheeting device 32, with input conveyor
30 moving in a conveying direction. Device 32 further
generally includes a compressing conveyor 34 arranged at
a non-parallel angle of a decreasing spacing in the
conveying direction from conveyor 30. In the preferred
30 form, conveyors 30 and 34 are formed from flexible
plastic, continuous belting 36 extending around parallel
end rollers 38. In the preferred form, end roller 38 of
conveyor 34 at the entrance of device 32 is driven whereas
belting 36 of conveyor 30 is driven by a drive roll 39
35 located intermediate and below end rollers 38, with drive
roll 39 including suitable idler rolls for increasing the
amount that belting 36 is wrapped on roll 39. Suitable
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1 support for belting 36 between end rollers 38 must be
provided on the surface of conveyors 30 and 34 which
engages the coated popcorn. In the preferred form,
support for belting 36 of conveyor 30 is in the form of
5 a plate 40 over which belting 36 slides. In the preferred
form, support for belting 36 of conveyor 34 is in the form
of a multiplicity of parallel rollers 41. It was found
that the use of a multiplicity of parallel rollers to
support belting 36 for both conveyors 30 and 34 did not
10operate in a satisfactory manner in apparatus 10 according
to the preferred teachings of the present invention.
Further, belting 36 of conveyors 30 and 34 includes a
textured or rough-type surface and in the most preferred
form is in a diamond pattern or as cubes arranged along
15a diagonal pattern as best seen in Figure 9. In the most
preferred form, the length of the side of the cube in the
pattern of belting 36 is generally equal to 2 millimeters.
If belting 36 was smooth and did not have a rough-type
surface, coated popcorn would not be drawn into and would
20not pass between conveyors 30 and 34. On the other hand,
if the depressions are too deep in the texture of the
surface of belting 36, the depressions have a tendency to
leave marks on the final product. In the most preferred
form of the present invention, the cubes of belting 36
25have a depth in the order of 1 millimeter.
In the preferred form, an air manifold 37 is provided
to direct cooled air towards the outer, textured surface
of belting 36 on the upper surface of conveyor 34 adjacent
to the entrance of device 32. In the preferred form, the
30cooled air from manifold 37 cools belting 36 to reduce
the tendency of the coated popcorn to stick thereto.
Furthermore, the cooled air tends to be deflected at a
90O angle along the upper surface of belting 36. In
the preferred form, spreader box 28 has an upper extent
35above the upper surface of conveyor 34 and is positioned
adjacent to the entrance of device 32 and air manifold
37. Thus, the deflected cooled air cools spreader box
28, passes between auger mixer 20 and spreader box 28 and
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1 cools the coated popcorn passing therebetween, and is also
deflected by the spreader box 28 towards the coated popcorn
positioned on input conveyor 30 prior to the entrance of
device 32 formed by compressing conveyor 34. It should be
5 noted that the surfaces of the mass of coated popcorn on
input conveyor 30 can not be too cold as the outer pieces
in the mass of coated popcorn will be too hard and will
tend to squash as the mass is compressed into the
compressed sheet by device 32. In the preferred form, the
lOcoated popcorn leaving spreader box 28 has a temperature
in the order of 230F (110C) and has a temperature
entering device 32 in the order of 210F (99C).
The coated popcorn is compressed and sheeted by
device 32 in the most preferred form into a sheet having
15a thickness in the order of 3/4 inch (1.9 cm) and a width
in the order of 24 inches (61 cm) and specifically in
the range of less than 24 inches (61 cm) to more than
24 inches (61 cm) such as but not limited to 32 inches
(81 cm). The sheet leaving device 32 has a reduced
20temperature which is in the range of 170F (77C) to
190F (88C) and in the order of 180F (82C) in the
preferred form. The sheet is then further, partially
cooled to solidify the binder and bind the popped popcorn
in the sheet by a cooling device 42 which in the
25preferred form shown is an ambient air cooling conveyor.
Specifically, the belting of conveyor 44 is in the form
of a mesh which allows exposure to air of the surface of
the sheet which abuts with the belting. As all surfaces
of the sheet are exposed to air, faster and more even
30heat transfer occurs through the sheet than if the sheet
were supported on nonpermeable-type belting. In the
preferred form shown, a multiplicity of fans 46 are
arranged longitudinally parallel to the movement direction
of the sheet and conveyor 44 and are positioned above and
35below conveyor 44 of device 42 to direct air towards the
surfaces of the sheet abutting with and parallel to the
belting of conveyor 44. In the preferred form, fans 46
direct ambient air towards the sheet; however, cooled air
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1 can be utilized if desired and/or necessary. Further,
in the preferred form, fans 46 are mounted to a movable
carrier such as a wheeled support for removal from
conveyor 44 for servicing and/or cleaning thereof.
Apparatus 10 according to the present invention
includes a device 48 for cutting the sheet into individual
bars. Specifically, in the preferred form, device 48
includes parallel, spaced, rotating, slitter knives 50
for cutting the sheet into longitudinal strips having
10 generally the desired widths of the popcorn bars which are
the same for all strips in the order of 1% inches (3.2 cm)
in the preferred form. After cutting, the longitudinal
strips are separated by a spreader 52 before being cut by
a knife 54 to the desired length of the popcorn bars which
15 are the same for all bars in the order of 4 inches (10 cm)
in the preferred form such as by guillotine cutter 54 in
the preferred form. In the preferred form, spreader 52
is located before knife 54 because it is more difficult
to separate the popcorn bars after they are cut to the
20 desired length and it is desired that the popcorn bars
are laterally separated and do not stick together in later
processing steps. When guillotined, the strips have a
surface temperature in the range of 95-125F (35-52C)
and in the preferred form, the temperature of the top
25 surface is in the order of 105F (41C), of the bottom
surface is in the order of 120F (49C), and of the center
is in the order of 180F (82C). If the temperature of
the sheet or strips when cut or guillotined is too hot,
the bound popcorn won't be cut or tends to reattach, and
30 strings of sugar extending from the cut surfaces may
result which is aesthetically undesirable. On the other
hand, if the temperature is too cold, the bound popcorn
is too brittle and tends to break or shatter. In this
regard, if knives 50 and cutter 54 are operable in a
35 satisfactory manner at higher temperatures, cooling device
42 could be repositioned after cutter 54 and/or knives 50
with cutter 54 and/or knives 50 providing a cleaner cut
without breakage or shattering of the popped popcorn in
the compacted sheet and strips.
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1 After being cut to length, apparatus 10 includes a
drizzling device 56 for drizzling the laterally separated,
individual bars with a confectionery coating such as milk-
chocolate or caramel flavoring. In the preferred form,
5 the confectionery coating is drizzled on the top of the
bars in a zig-zag pattern with a pitch of approximately
3/8 inch (1 cm). The confectionery coating is typically
drizzled at a temperature above the setting temperature of
the confectionery coating which in the most preferred form
lOis in the order of 103F (39C) and in the most preferred
form is in the range of 112-115F (44-46C). Drizzling
device 56 is of a conventional design in the most
preferred form. After being drizzled, the bars have a
surface temperature in the range of 115-145F (46-63C)
15and a center temperature generally less than the center
temperature before drizzling and in the preferred form
in the order of 180F (82C). The bars are then cooled
such as in a cooling tunnel 58 to a temperature to firmly
set the confectionery coating and in the preferred form
20to a temperature in the order of 80-90F (27-32C).
After cooling tunnel 58, apparatus 10 according to
the present invention includes a suitable device 60 for
individually wrapping each of the individual bars and
placing the wrapped bars in suitable packaging for sale.
The temperatures set forth are for forming popcorn
bars according to the preferred teachings of the present
invention during testing. It can then be appreciated
that temperatures may be different in actual production
of popcorn bars according to the present invention based
30upon several variables including but not limited to the
particular components of and their arrangement in
apparatus 10, the location and other environmental factors
where production takes place, the particular ingredients
utilized in formation of the popcorn bars, and the like.
It can then be appreciated that coated popcorn bars
formed by the methods of the present invention such as by
apparatus 10 have a top and bottom defined by the popped
popcorn coated with the caramel syrup binder in a molten
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1 form compressed into the sheet, with the distance between
the top and bottom defining a thickness which in the
preferred form is in the order of 3/4 inch (1.9 cm). The
popcorn bar further includes first and second sides formed
5 by cutting the sheet with knives 50, with the distance
between the sides defining a width which in the preferred
form is in the order of 1% inches (3.2 cm). The popcorn
bar further includes first and second ends formed by
cutting the strips with knife 54, with the distance
lObetween the ends defining a length which in the preferred
form is in the order of 4 inches (10 cm). As the popcorn
bars are laterally spaced when the confectionery coating
is drizzled thereon, the coating is in a zig-zag pattern
on the top and may extend partially on the first and
15second sides of the popcorn bar.
The popcorn bars according to the present invention
then provide a healthy, competitive alternative to other
types of snack-type foods. Specifically, in addition to
the taste, nutrition, and other healthy attributes of
20popcorn, the popcorn bars are very shelf stable and can be
easily handled, consumed, and transported as a snack food.
In addition, the popcorn bars have the aesthetics and
other market appeal factors of a candy bar without the
high levels of fat and other undesirable attributes.
25Likewise, the methods of the present invention allow the
popcorn bars to be easily and rapidly produced, thus
increasing their economic competitiveness with other
types of snack foods.
Thus since the invention disclosed herein may be
30embodied in other specific forms without departing from
the spirit or general characteristics thereof, some of
which forms have been indicated, the embodiments
described herein are to be considered in all respects
illustrative and not restrictive. The scope of the
35invention is to be 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 intended to be embraced therein.
