Note: Descriptions are shown in the official language in which they were submitted.
218~520
METHOD & APPARATUS FOR PREPARATION & PACKAGING
OF COMMERCIAL UNFROZEN BAKED WAFFLES
FIELD OF THE INVENTION:
This invention relates to methods and apparatus for the production of commercialbaked waffles, especially breakfast waffles, which are to be sold in an unfrozen condition
in the commercial market. More particularly, the present invention is directed to methods
5 and preparation of waffles which are sold unfrozen in sealed aseptic packages, and which
may have exceptional shelf-life.
BACKGROUND OF THE INVENTION:
There are numerous baked waffles that are sold primarily in the commercial retail
10 markets for breakfast consumption. However, without exception, those waffles are sold in
frozen condition. That means that, after the waffles have been baked in a commercial
waffle bakery, they must be significantly cooled until they are frozen, they must shipped
in frozen condition, they must be displayed for retail sale in frozen condition, they must
be conveyed by the purchasing consumers to their homes in frozen condition, and they
15 must be stored in frozen condition until such time as they are removed from their
packaging for consumption. This requires, therefore, very considerable commitments of
capital equipment, beyond the baking and packaging equipment, for freezing, storing,
transporting, commercial warehousing, and commercial retail sale, of frozen waffles.
What the waffles of the present invention have in common with commercial
20 breakfast waffles that are currently available is that they are pre-baked, they are packaged
for retail sale, and they are prepared for consumption by the customer by being placed in
an oven or toaster for re-heating. What the baked waffles of the present invention do not
have in common with ~;ullelllly commercial available waffles is, therefore, that they are not
frozen, and there is no necessity for additional significant capital expenditures.
218~20
Of course, in order for baked waffles to be brought to the market in unfrozen
condition, and still enjoy significant shelf-life, requires that the packaging shall be rendered
aseptic. The present invention provides for that, as will be described hereafter, by ensuring
that each waffle remains heated when it is placed into its packaging and while the
5 packaging is sealed so as to render the package aseptic.
In general, that means that the interior temperature of the waffle, as it is being
baked, must be elevated to a temperature of at least 72C. Thereafter, the interior
temperature of the waffle should not be permitted to become depressed significantly; and
this generally means that efforts and steps should be taken to m~int~in the temperature of
10 the interior of the waffle at least at or above about 72C. In that manner, there is sufficient
retained heat in the baked waffle that the heat will transfer to the interior of the package;
and, if the package is sealed shortly thereafter, it will be rendered aseptic. In the event that
the interior temperature of the waffle shall have fallen below 72C or so, after the package
has been sealed it may be re-heated, usually at a temperature of up to about 90C so as to
15 re-heat the interior of the waffle back up to at least about 72C. Microbiological activity
is unlikely to occur if a product such as a baked waffle has been sealed into an aseptic
environment at about 72C, so that airborne mold spores or other cont~min~nl~ will not
gain access to the product within the aseptic package. Therefore, products such as baked
waffles can enjoy a substantial shelf-life without deterioration, since no cont:~min~nt within
20 the waffle will have survived 72C, and because it cannot become re-cont~min~ted. Of
course, after a package cor~ il-g a plurality of waffles in keeping with the present
invention has been opened, if several baked waffles remain unconsumed, they must be
refrigerated.
There is, moreover, a further advantage of the present invention, beyond precluding
25 the necessity for capital expenditures for freezing and frozen storage, transport,
warehousing, and retail sale equipment; and that there is no necessity for the use of
chemical additives to waffle batter for use as preservatives. The waffle batters utilized by
the present invention may be considered to be so-called "all natural", comprising at least
water, flour, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent such as
2184520
baking powder or baking soda. Waffles that are manufactured in keeping with the present
invention may further comprise a dairy product such as whole milk, skim or partially
skimmed milk, or whey, as well as lecithin, salt, or other flavoring ingredients such as
vanilla or fruit additives.
Another factor that needs to be stressed, in respect of the manufacture of bakedwaffles, is that waffles are prepared from a waffle batter, as opposed to the pl~al~lion of
breads which are prepared from dough. Further, the differences between waffles and
wafers must be distinguished; waffles are relatively thick without any significant crust
being developed thereon during their baked and will still have a retained moisture content.
Wafers, on the other hand, are relatively thin, they may have a crust due to a higher sugar
content, and in any event they are baked until there is substantially zero moisture content
retained.
Returning to the differences between dough, from which breads are baked, and
batter, from which waffles are baked, it is necessary for the dough to be sheeted and
proofed because they are generally leavened using yeast. Waffle batters are leavened using
a chemical leavening system such as baking powder or baking soda and are pourable
whereby, after preparation, the batter may be poured into a waffle form. Moreover, waffles
are baked in an enclosed form whereas breads are generally permitted to rise during their
baked process in open-topped baking pans or tins.
Still further, the baking process by which waffles are baked is more or less
concluded, at least to the extent that is desired, while the waffle is still in its waffle form
or waffle iron and while it is still in an oven which is m~int~ined at an elevated
temperature. Thus, waffles can be partially baked, at least up to 80% baked but less than
100% baked, and the baking process can be suspended at that time to be concluded at a
later time when the waffle is about to be consumed by its purchaser. With few exceptions,
such as with french bread which comprises only flour, water, yeast, and salt, it is not
possible to partially bake breads, and then suspend the baking process until a later time.
These factors are important when it comes to understanding certain prior art patents, which
are discussed below.
~184~20
The energy savings which may be accomplished in keeping with the present
invention may be very significant. Comparing traditional frozen waffles for commercial
sale--which are baked and then frozen, and which must therefore be maintained in frozen
condition during storage, shipping, and retail sale, and even in the home of the consumer
5 until they are to be consumed--with unfrozen waffles sold in sealed aseptic packages, the
savings for the manufacturer, the distributor, the retailer, and ultimately to the consumer,
may be profound, as discussed hereafter. Those savings are in terms of both invested and
operating capital, and energy expended. For the moment, it is merely necessary to note that
until such steps are taken as to m~int~in the temperature of baked waffles at an elevated
10 temperature prior to their packaging, the costs in keeping with the present invention and
of traditional frozen waffle production may be essentially identical; as may the costs of
packaging materials, as well as boxes, promotion and advertising, cost of sale, in order to
bring the products to the market. All other costs ~;ullelllly required for the production,
storage, shipping, and sale, of frozen waffles, are not at all necessary in keeping with the
15 present invention.
Moreover, the present invention provides significantly new apparatus within which
waffles may be baked. In order for efficient pr~lalion and baking of waffles forcommercial market purposes to be accomplished, there must be significant automation
applied to the process. This means that the apparatus that is used for the preparation of
20 waffles for commercial sale, once designed and installed, should be capable of being
operated over extended periods of time with minim~l shut-down and/or maintenance except
as may be required for purposes of cleanliness and hygiene, and for such preventative
m~int~n:~nce of equipment as may be necessarily required. Often, the design and provision
of machinery having as few moving parts as possible is desirable, and is accomplished by
25 baking equipment and especially waffle forms in keeping with the present invention. As
will be described in greater detail hereafter, the waffle forms that are provided in keeping
with these teachings are such that they have no necessity for hinge-mounted upper and
lower waffle forms in the sense of tradition waffle irons. What is provided, as will be
2184~
described hereafter, are articulated chains which are physically mounted in such a manner
that the opening and closing of the waffle iron forms, and removing of the baked waffles
from the waffle forms, is accomplished merely as a consequence of the geometry of the
apparatus.
DESCRIPTION OF THE PRIOR ART:
In keeping with the above discussions, there is no known prior art that specifically
teaches several of the key features of the methods and apparatus according to the present
invention. However, the following prior art is referenced for purposes of expressing and
demonstrating differences between the prior art and features of the present invention.
As to prior art which is particularly directed to methods by which baked products
are prepared in substantially automated processes, and placed into packaging for shipment
to the retail market, the following patents are noted:
KOMATSU et al United States patent No. 3,892,058 is concerned with short-time
high temperature sterilization of packaged articles such as soups or meat products. The
food product is filled into a flexible container, and non-condensible gasses which are left
in the voids of the container are excluded, after which the packaging is heat sealed.
Thereafter, the packaged food is sterilized within its own sealed package by being heated
to elevated temperatures for as short a time as may be possible.
PLEMONS et al United States patent No. 3,979,525 is directed to a method of
producing pizza crusts, which are essentially breads. Here, the pizza crusts may be stored
unsealed at room temperature, because they have been treated with ethyl alcohol. This may
create significant marketing problems, since it is essentially unknown and unacceptable to
add chemical compounds to a finished food product.
United States patent No. 4,120,984 to RICHARDSON et al is directed to an
apparatus for placing baked goods into a sterile package and for preventing damage to the
product as it is being cooled. The plastic sheet that is used is usually perforated; the
invention is directed in any event to baked bread products; and there is a requirement to
draw sterile air into the package.
~18gi5~0
..
JOULIN United States patent No. 4,357,356 teaches a method of producing a bread
product which is baked, packaged into hermetically sealed packages under partial vacuum,
and then sterilized. The specific bread product discussed is french bread which comprises
only flour, water, salt, and yeast; and, while french bread may, indeed, be partially baked,
5 it will nonetheless have a short shelf life before it becomes almost completely unpalatable.
It must also be remarked that the bread products specifically discussed by Joulin have much
smaller surface areas per unit mass or per unit volume than do waffles. Moreover, waffles
will at least contain eggs and perhaps milk ingredients, which may enhance microbial
activity, and thus the necessity to freeze waffles has heretofore been recognized as the only
10 way to inhibit microbial activity.
OTTOW et al United States patent No. 4,426,401 discusses the packaging of
perishable goods that contain water, in aseptic packages. However, the package must
include vents through which vapour can escape during heat treating of the goods after they
have been placed into the package. Thereafter, once the product has been cooled down,
15 the vents may then be sealed.
United States patent No. 4,457,702 to MARCHETTI teaches the packaging of
foodstuffs into polyethlyne bags, which are then dropped into a bath of hot water for
subsequent re-heating.
DURST United States patent No. 4,582,711 teaches the preparation of baked goods
20 that can have very long shelf life. However, those baked goods are effectively anhydrous,
being such as canned cake products, cookies, or brownies, and the like.
United States patent No. 4,734,291 to RAFFENSPERGER concerns itself with the
preparation with al dente pasta products which may have good shelf storage life. Here, the
partially cooked pasta is extruded into a pouch pack; however, it is necessary that sufficient
25 water be used so as to reduce the pH to 4.6 or less.
SUGISAWA et al United States patent No. 4,777,057 concerns itself with a semi-
prepared dough that has a specific hardness and which is charged into a heat resistant
packaging container. After the package is sealed, it is then heat treated. The dough
system, in any event, is packaged at its dough stage, after which it is steamed.
~18~2~3
United States patent No. 4,911,939 to LOU et al is directed to a cookie dough which
is partially pre-baked and then packaged and sealed. However, this cookie dough should
have high fructose content, and is specifically intended for microwave baking prior to its
consumption.
SCHIRMER United States patent No. 4,928,474 teaches a retort container which
may be filled with food that is sensitive to spoilage from oxygen contact. The filled
container is closed by being heat sealed, then retorted, and then enclosed with an oxygen
barrier material.
The following prior art patents relate particularly to various apparatus for theproduction of waffles, wafers, or baked bread:
United States patent No. 4,058,039 to SCHMID teaches a waffle transfer machine
in which baked waffles are removed from a conventional waffle iron, trimmed, andtransferred onto a transfer conveyor. In the embodiments illustrated, each waffle iron
comprises a clamshell hinged structure in which six waffles at a time are baked, and which
thereafter require trimming, transfer, etc., for commercial packaging purposes.
WESTOVER United States patent No. 4,208,441 teaches a pair of endless mated
cooking irons, one above the other, each of which comprises a pocketed cooking iron that
resembles a waffle iron. However, what is prepared is pizza shells and the like, which are
yeast leavened dough products. The dough requires mixing, sheeting, cutting, and proofing
before it is baked. The sheets of dough are placed between hot irons which are closed by
bringing their edges into contact. The dough requires to be trimmed, because it is
essentially a bread dough. After the pizza dough has been baked, it may then be covered
with pizza toppings, and then frozen.
Two patents to HAAS et al are United States patent No. 4,417,508 and No.
4,438,685. Each of those patents, however, is concerned with the preparation of wafers,
which are prepared in a conventional hinged shell; and which, when baked, are essentially
anhydrous.
~18452~
United States patent No. 4,769,245 to FARAR et al is directed to the pfepal~ion
of bread products which may be removed from their packaging for browning and serving.
Special containers for the french bread are provided, into which the product is placed while
it is hot enough to inactivate microbial org~ni~m~ that may be within the product.
5 However, a filter hole or aperture is required, which is small enough to allow the package
to "breath" so as to equalize the pressure within and without the package. Care is taken
that air does not impinge directly on the packaged food product.
HERTING United States patent No. 5,079,015 is directed to a method for at least
partially cooking multi-colored waffles in more or less conventional cooking forms, from
10 which the waffles are then removed and passed to an oven for fini.~hing. The waffles are
particularly intended for use as ice cream cones, and are thus very thin and essentially
anhydrous.
SUMMARY OF THE INVENTION:
In accordance with one aspect of the present invention, there is provided a method
for the production of baked waffles for commercial sale in unfrozen condition in sealed
aseptic packages. The method comprises the steps of:
(a) Preparing a waffle batter, which has at least flour, water, sweeteners, whole
eggs, vegetable oil or butter, and a leavening agent which may be baking powder or baking
soda.
(b) Dispensing a measured amount of waffle batter into a waffle form.
(c) Closing the waffle form.
(d) Placing the closed waffle form and the waffle batter enclosed therein into a
baking oven.
(e) Maintaining the closed waffle form with the waffle batter therein in the oven
at least until the waffle is baked to an extent less than 100% baked and greater than about
80% baked. The temperature of the interior of the waffle being baked must have reached
at least 72C.
2184S20
(f) Removing the waffle form and the baked waffle therewithin from the baking
oven.
(g) Removing the hot baked waffle from the waffle form.
(h) Transferring the still hot baked waffle to a packaging station.
(i) Placing the still hot baked waffle into a heat stable package that is heat
sealable. This step is taken while the baked waffle remains at an elevated temperature.
Thus, the package is rendered aseptic.
(j) The package is then sealed.
(k) The sealed aseptic package is then permitted to cool to ambient temperature.(l) Finally, the cooled sealed package is placed into storage and handling
facilities. Thus, commercial sale of the unfrozen baked waffles in sealed aseptic packages
may then be achieved.
In keeping with another aspect of the present invention, there is provided an
apparatus for the production of baked waffles for commercial sale in unfrozen condition
in sealed aseptic packages. As noted above, the baked waffles are prepared from a waffle
batter having at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a
leavening agent which may be baking powder or baking soda, as constituents thereof. The
apparatus comprises a mixer in which the waffle batter is prepared, and conveying means
for conveying the mixed waffle batter to a batter depositor. The batter depositor has
control means to select a specific amount of waffle batter to be deposited into a waffle
form; the waffle form comprises lower and upper waffle iron shells that are arranged so as
to be closed together as a waffle iron within the interior of which a waffle will be baked.
An oven is provided and will operate at a specified temperature into which the waffle iron
and the waffle batter enclosed therein will be placed for sufficient time so as to bake the
waffle to an extent less than 100% baked and greater than about 80% baked. The baking
process will continue, in any event, until the temperature of the interior of the waffle being
baked has reached at least 72C.
218~20
Means are provided for opening and unloading the waffle iron and removing the hot
baked waffle therefrom to a conveyor, which conveys the hot baked waffle away from the
oven and towards a packaging station. At the packaging station, the still hot baked waffle
is placed into a heat stable package while the baked waffle remains at an elevated
temperature, so as to render the package aseptic. Means are provided for sealing the heat
stable package, cooling it to ambient temperature, and storing and h~n~ling the products
for commercial sale of the baked waffles in unfrozen condition.
The lower and upper waffle iron shells, in keeping with a further aspect of thisinvention, comprise links in continuous runs of lower and upper chains of a plurality of
similar waffle iron shells. The lower and upper chains are arranged to pass through a
tunnel oven, and are spaced so as to be sufficiently close to one another that each
respective waffle iron is at first open and then closed as the respective upper and lower
chains approach and depart from each other as they wrap around respective drive and idler
pinions for the respective chains.
BRIEF DESCRIPTION OF THE DRAWINGS:
The novel features which are believed to be characteristic of the present invention,
as to its structure, organization, use and method of operation, together with further
objectives and advantages thereof, will be better understood from the following drawings
in which a presently preferred embodiment of the invention will now be illustrated by way
of example. It is expressly understood, however, that the drawings are for the purpose of
illustration and description only and are not intended as a definition of the limits of the
invention. Embodiments of this invention will now be described by way of example in
association with the accompanying drawings in which:
Figure 1 is a schematic drawing showing the principal operating units which
comprise the apparatus of the present invention, and showing the flow of product through
the apparatus;
218~20
Figure 2 is a schematic side elevation of a baking oven in keeping with the present
invention;
Figure 3 is a plan view of a typical link forming a chain of waffle iron shells in
keeping with the present invention; and
Figure 4 is a cross-sectional view of a closed waffle iron in keeping with the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS:
Reference will no be made to Figures 1 through 4.
First, with reference to Figure 1, a commercial apparatus 10 for the production of
baked waffles, in keeping with the present invention, will have the following principal
components or operating units:
A mixer 12 is provided, in which waffle batter will be prepared. The waffle batter
generally will comprise at least flour, water, sweeteners, whole eggs, vegetable oil or butter,
and a leavening agent which is usually either baking powder or baking soda. As noted
above, the waffle batter may further or may optionally further include a dairy product
which may be whole milk, skimmed or partially skimmed milk, or whey. Moreover, yet
a further optional constituent of the waffle batter may be any one or more of lecithin, salt,
and flavoring ingredients such as vanilla or fruit additives.
Throughout the apparatus, there will be a variety of conveying means such as themeans 13 or 15 which are suitably sized piping through which the mixed waffle batter may
be pumped. A holding tank 14 may be provided, as necessary.
The waffle batter is conveyed as at 15 to a batter depositor 16, which is arranged
so as to deposit waffle batter into a waffle form, as described hereafter. So as to ensure
that each waffle to be prepared in keeping with the present invention has the same volume
and mass, conkol means 18 are associated with the batter depositor 16 so as to select a
specific amount of waffle batter to be deposited into the waffle form.
~18~520
An oven 20 is provided, more details of which are described below, with respect to
Figure 2. The oven 20 has appropliate controls so that it operates at a specified
temperature, and it may be either gas fired or electrically heated. The length of time for
which waffles are baked to an extent less than 100% baked but greater than about 80%
5 baked, and in any event until the temperature of the interior of the waffle has reached at
least 72C, are discussed below. Again, the specifics of the waffle irons in keeping with
present invention are discussed below, but it is clear that means must be provided for
opening and unloading the waffle irons after the waffles have been baked. Individual
baked waffles exit the oven 20, in keeping with the usual provisions of the present
10 invention where the waffles are passed through the oven on a conveyor, and are passed at
21 to a further conveyor 22 which is arranged to convey the hot baked waffles away from
the oven 20 and towards a packaging unit 26.
There may be interposed between the conveyor 22 and the packaging unit 26 a
sorter 24, so that selected numbers of waffles may be collected together for placing into
15 packages for commercial sale. Intermediate conveyors 23 and 25 may also be provided.
Within the packaging unit 26, there is a sealer 28 which is arranged to seal heat
stable packages after the still hot baked waffles have been placed into them. Finally,
following further conveyors 29, there are provided means generally identified at 30 where
the sealed heat stable packages with the baked waffles therein may be cooled, stored,
20 palletized for shipping, and shipped.
To the extent so far described, none of the operating components and units, with the
exception of the heated conveyor 22, might be significantly different than is found in any
commercial waffle bakery.
However, the presence of the conveyor 22 is important, because it assures that the
25 waffles as they exit the oven 20 remain at elevated temperatures, so as to inhibit microbial
activity.
Turning to Figures 2, 3, and 4, further details of the oven and the waffle forms in
keeping with the present invention are now discussed:
218~520
-
In general, the oven 20 comprises an insulated shell 40, within which are two chain
runs 42 and 44. The upper chain 42 is contained within the oven 20, the lower chain 44
extends beyond the entrance end 45 and the exit end 47 of the oven 20. Each chain run
42 and 44 is wrapped around drive and idler pinions 46 and 48, which may be arranged at
either end of each chain as necessary and appropliate.
The output from the batter depositor 16 is shown at 51, being deposited on the
upper reach of the lower chain 44; the output of baked discrete waffles is taken away from
the lower chain 44 at 53.
Turning to Figures 3 and 4, some details of the respective upper and lower chains
42 and 44 are discussed. Each chain is essentially identical to the other chain, except for
the number of links that comprise the respective chains, due to the differences of their
lengths.
A typical link 60 is shown in Figure 3. This link provides, in this case, a pair of
waffle iron shells 62, each of which is identical to the other and is configured in typical
waffle fashion. Thus, each of the waffle iron shells may comprise a plurality of elevations
63 and indentations 65, as shown in Figure 4. Figure 4 also shows the manner in which
respective links from the upper and lower chain runs 42 and 44 will mate together.
Each of the links 60 is articulated to the links on either side of it by connecting
links (not shown) passed through respective openings 66 and 68 at the left and right sides
thereof, as shown. Each link 60 moves in the direction of either of arrows 67 or 69. Thus,
each of the upper and lower chains 42 and 44 passes through, or is contained in, the oven
20, which is arranged in the form of a tunnel oven. The respective upper and lower chain
runs 42 and 44 are, as noted and demonstrated by Figure 4, sufficiently closely spaced to
one another so as to form the waffle iron. As each of the lower and upper chain runs 42
and 44 approach each other as the upper chain 42 wraps around pinion 46 as shown in
Figure 2, each respective waffle iron will be closed. Then, as the upper chain 42 wraps
around pinion 48, each respective waffle iron will open. Moreover, as the baked waffle in
each respective waffle iron shell exits the oven 20 at exit end 47, it is at least 80% baked
2184520
and is therefore firmly formed so that it will generally fall from the waffle iron shell as the
lower chain wraps around its respective pinion 48. Thus, the unloading means for the
lower chain 44 is located beyond the exit end of the oven 20. If necessary, a selectively
operated air jet may also be provided either to blow the at least 80% baked waffle from
each respective waffle iron shell, or to lift it from the shell by vacuum.
Once any baked waffle has been removed from its respective waffle iron shell 62
at the unloading station indicated generally by the reference 53, it passes to the conveyor
22. Here, as noted, the conveyor is such that it will ensure that the waffles as they exit the
oven 20 will remain at elevated temperatures. This is typically accomplished by providing
the conveyor 22 in the shape of a further heated tunnel, where the temperature inside the
tunnel is maintained sufficiently high so that the interior temperature of the waffles will not
fall below anything less than 72C.
If the sorter 24 is present, its ambient temperature is also m~int~ined at an elevated
temperature, once again so as to preclude cooling of the interior temperature of the freshly
baked waffles below no less than 72C. The purpose of the sorter is, particularly in an
automated baked waffle manufacturing facility, to permit a selected number of waffles to
be collected so that they may be packaged together in a single package of, say, usually six
or eight waffles, for commercial sale purposes. The waffles, or groups of waffles, are then
conveyed to the packaging unit 26 by the supplementary conveyor 25.
At the packaging unit 26, the waffles or selected numbers of waffles are placed into
their packages, while still hot--preferably, while their internal temperature remains at least
at 72C, so as to preclude or inhibit microbial activity after the waffle has been cooled
down. Each package is generally formed of a heat stable polypropylene film, having a heat
sealable film l~min~tç~l thereto. It is evident that any such package may then be,
appropriately, heat sealed, using conventional heat sealing apparatus. Alternatively, the
package may comprise a heat stable formed plastic fill cup, usually one which has been
pre-formed using vacuum forming equipment, which may then be heat sealable or
hermetically sealable by placing a heat sealable or hermetically sealable cover film
thereover. It is evident that, no matter which variety of package may be used, if the
packaging material per se is a~plo~iately stored and conveyed into the packaging unit 26,
14
c~l84520
and filled and sealed at the sealer 28 while at all times the interior temperature of the
waffles being placed into each heat sealed package remains above at least 72C, then the
retained heat within each waffle will be sufficient to heat whatever air may be captured in
the package, and thereby render the package aseptic. It should be noted that, in general,
5 the interiors of the packaging unit 26 and sealer 28 are also m~int~ined at elevated
temperatures.
In the event that the interior temperature of the waffles has cooled below about72C, or, in any event, for greater surety of the aseptic nature of the heat sealed package,
provided the material of the package will withstand temperatures of at least 90C, it is
10 possible to re-heat the sealed aseptic packages up to a temperature of about 90C so as to
re-heat the baked waffles that are sealed therein. If the appropriate dwell time is chosen,
then the interior temperature of each of the baked waffles will, once again, be elevated at
least up to 72C.
The importance of the temperature of about 72C is, of course, that, at that
15 temperature and above, microbial activity is substantially precluded or the aseptic quality
of the package is assured inhibited; and if the sealed package is rendered aseptic at the time
that it is sealed, or by subsequent or supplemental heating thereafter, then the aseptic
quality of the package will be certain.
Referring now to the batter depositor 16, it has associated with it a control means
20 18 whose purpose is to select and assure that a specified amount of waffle batter will be
deposited into the waffle form. Typically, each waffle will have a weight of 30 to 75
grams. In any event, the volume of the waffle to be baked in each waffle iron form is
known and, since the density of the waffle batter is known or can easily be determined, a
precise amount of batter may therefore be deposited into each waffle iron form. This
25 assures that there will be no flash or spillover on the one hand, and that each waffle will
be fully developed and baked. It is evident, of course, that any shape and particular
volume of waffle can be prepared in keeping with the present invention, merely by
appropriate design of the waffle iron shells 62 and the links 60 in which they are formed.
~ls~s2a
The material from which the links 60 is formed may conveniently be cast aluminumor other appropriate materials such as cast iron, and it may be appropriately coated with a
non-stick material such as PTFE. Moreover, a suitable vegetable oil spray may be utilized
by being sprayed into each respective waffle iron shell at an applopliate station at or near
5 the entrance end 45 of the oven 20.
It is a simple matter, of course, having determined the shape, volume, and weight
of each waffle to be baked to calculate and establish the appropriate temperatures within
the oven 20 and the dwell time for each respective waffle iron form to pass through the
oven 20, in order that each waffle may be at least 80% baked but less than 100% baked.
Typically, the interior of the oven in maintained at about 170C or 225C, depending on
the formulation. A typical dwell time for each waffle as it passes through the oven 20 is
approximately 95 seconds. Thus, the speed of driving the upper and lower chains 42 and
44 may easily be adjusted ~plopliately.
Likewise, the interior of the conveyor 22, the sorter 24, and the packaging unit 26,
15 are normally m~int~ined at least at about 75C, usually about 90C. This assures that, once
the interior of each waffle as it has been baked has reached the temperature of about 72C,
it will not cool below that temperature. Moreover, there is little incremental baking activity
that continues after the waffles have been removed from their respective waffle irons,
because there is no significant heat differential between the temperature of the waffle and
20 the ambient within which it is being m~int~ined.
From all of the above, it follows that the steps taken for the production of baked
waffles for commercial sale in unfrozen condition in sealed aseptic packages, in keeping
with the present invention, will be essentially as follows:
(a) First, the waffle batter is prepared. As noted, the waffle batter will have at
25 least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent
which is generally baking powder or baking soda. As noted, the waffle batter may further
comprise a dairy product such as whole milk, skimmed or partially skimmed milk, and
whey; and it may have a further optional constituent such as lecithin, salt, and flavoring
ingredients such as vanilla, or a fruit additive.
16
218~520
(b) A specific measured amount of waffle batter is dispensed into a waffle form.(c) The waffle form is then closed.
(d) Then, the closed waffle form, with the waffle batter therewithin, is placed
into a baking oven. Typically, as discussed, this entails passage of a waffle form as a link
5 or a portion of a link of a chain passing through a tunnel oven, but other baking oven
facilities and/or waffle irons may also be employed.
(e) Each closed waffle form and the waffle batter therewithin is maintained in
the oven for a sufficient dwell time so that the waffle will bake to an extent less than 100%
baked but greater than about 80% baked. Moreover, the temperature of the oven and the
10 dwell time of each waffle form within it will be chosen, in any event, so that the interior
temperature of the waffle being baked will reach at least 72C.
(f) Then, the baked waffle form and the baked waffle therewithin will be
removed from the oven.
(g) The hot baked waffle will be removed from the waffle form.
(h) The still hot baked waffle will be transferred to a packaging station. This
usually requires, as noted above, that the hot baked waffle will be passed through a heated
zone on a conveyor, where the temperature thereof will be m~inl:~ined sufficiently high so
that the interior temperature of the baked waffle remains above at least 72C.
(i) Moreover, while m~int:~ining the interior of the waffle above at least about20 72C, the waffle is placed into a heat stable package which is sealable while the baked
waffle still remains at an elevated temperature. This will render the package aseptic, as
discussed above.
(j) The package is then sealed, usually by heat sealing.
(k) Thereafter, the sealed aseptic package is permitted to cool to ambient
25 temperature. It is not necessary, in keeping with the provisions of this invention, to lower
the temperature of the sealed aseptic packages with baked waffles therewith to below
ambient temperature; specifically, it is not necessary to freeze the baked waffles.
~18~20
,.
(l) Finally, the cooled (to ambient temperature) sealed aseptic packages of baked
waffles are placed into storage or handling facilities from whence they may be delivered
into commercial distribution streams for commercial sale of the unfrozen waffles in their
sealed aseptic packages.
As noted above, in general, each package will contain a selected number of sealed
waffles; it is possible, however, for such industries as the hospitality industry, hotels,
hospitals, and the like, that individual baked waffles in their own respective sealed aseptic
packages may be distributed.
When the waffles are removed from their sealed aseptic packages, it is generallyintended that they shall be re-heated by being placed into a toaster or conventional or
toaster oven for consumption. By re-heating in a toaster or oven, which is heated by
radiant heat which transfers to the waffle, the discontinued baking procedure for the waffle
will be fin~li7ed. This is because there still remains a significant moisture content within
the waffle, and because there is no significant crust that has been formed on the exterior
surface of the waffle. Moreover, because of the nature of the formation of the waffles, they
have a very high ratio of surface area to volume or mass, as compared with bread or pizza
doughs, and the like, and heat transfer to the waffle is accomplished quite quickly.
It is evident that there may be significant savings in terms of expenditures of capital
money to build plants and equipment, operating costs to store and ship baked waffles
prepared by the present invention, and energy expended, when compared to frozen waffles
that are currently available in the market. There is no need for the construction of freezers,
frozen storage facilities, frozen delivery facilities, and frozen retail sale cabinets; neither
is there any necessity for energy to be expended in removing heat from baked waffles so
as to freeze them and then m~int~ining them in a frozen condition.
As stated above, the cost of materials and the amount of materials used in keeping
with the present invention, as compared with presently commercially available frozen
waffles, will be essentially the same. The waffles will be the same, the packaging will be
essentially the same by way of the wrapping material, the retail boxes will be essentially
the same, and even the shipping cartons will be essentially the same except that they do not
need to be specially prepared for handling at extremely low temperatures.
18
~18~S2~
The waffles prepared in keeping with the present invention are delivered to the
consumer in unfrozen condition, which means that the consumer does not need to provide
special storage facilities such as home freezers or the like to store them prior to
consumption. However, once removed from their aseptic packaging, any waffles that are
5 not consumed should be refrigerated because microbial activity could be re-initiated at that
time. Otherwise, the baked waffles provided by the present invention to the market in
unfrozen condition in aseptic packages may have a shelf life of three or four months.
It follows, therefore, that the baked waffles in keeping with the present invention
may be delivered to the consumer for a lower cost, and may therefore be acquired by the
10 consumer for a lower price. There are further environmental concerns, since there is no
wasted energy required to freeze the waffles or to m~int~in them in a frozen condition.
All of the above is achieved, as noted, without the requirement for any additional
chemical additives or preservatives in the waffle batter, without the necessity for injecting
inert gasses such as carbon dioxide into the packages, nor without the necessity to utilize
15 vacuum technology to remove entrapped air from the packaging. Still further, and in any
event, the packaging that is provided in keeping with the present invention will permit the
sealed aseptic package to be re-heated, if necessary and appropriate. This does not require,
however, irradiation or other sterilization or pasteurization techniques, since the waffles
have been sealed into packages that are rendered aseptic due to the incipient or specific
20 heat which remains present within the waffles as they were placed into the packaging, thus
inhibiting or precluding microbial activity.
Other modifications and alterations may be used in the design and manufacture ofthe apparatus of the present invention without departing from the spirit and scope of the
25 accompanymg clalms.
19
