Note: Descriptions are shown in the official language in which they were submitted.
CA 02697897 2010-06-02
HYBRID APPARATUS FOR APPLYING COATING TO PRODUCTS
AND METHODS OF USE THEREOF
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority based on United States Patent
Application
12/541,700 entitled "HYBRID APPARATUS FOR APPLYING COATING TO
PRODUCTS AND METHODS OF USE THEREOF" filed August 14, 2009, which in
turn claims priority under 35 U.S.C. 119(e) to U.S. Provisional Application
Serial
Number 61/218,510 filed on June 19, 2009 and also claims priority under 35
U.S.C.
120 to U.S. Application Number 12/271,632 filed on November 14, 2008 (the `632
application) and is a continuation-in-part thereof. The `632 application is a
continuation-
in-part application of U.S. Application Number 12/126,610 filed on May 23,
2008 (the
`610 application). The `610 application claims priority to U.S. Provisional
Application
Serial Number 60/940,247 filed on May, 25, 2007. The `610 application is a
continuation-in-part application of U.S. Application Number 11/396,202 filed
on March
30, 2006 and claiming priority to U.S. Provisional Application Serial Number
60/667,405 filed on April 1, 2005. The `632 application also claims priority
to U.S.
Provisional Application Number 61/083,777 filed on July 25, 2008 and U.S.
Provisional
Application Serial Number 60/990,566 filed on November 27, 2007. All of the
above
are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] The field of invention includes coating and conveying equipment.
BACKGROUND OF THE INVENTION
[0003] Prepared food products come in a wide variety of styles. Many prepared
food
products, whether ready-to-eat or those needing further cooking, are prepared
with a
coating that makes the food product more appealing. Such prepared food
products
include entrees, appetizers, desserts (such as pastries, donuts), etc., and
includes meats,
cheese, fruit and vegetables, etc. The types of coatings used on these food
products
include dry coatings such as flour, bread crumbs, corn meal, sugar and spice
and the like.
[0004] In the food preparation industry, food coatings are generally
classified by
appearance as flour breading, free flowing (such as cracker meal or bread
crumbs), and
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Japanese-style crumbs which tend to be elongate and crispy. Food coatings may
also
include seasonings, spices, shortening, etc., as needed to add flavor and
texture to the
food product. Other coatings such as ground cereal, dried vegetables or the
like, may
also be employed.
[00051 Each coating mixture has inherent characteristics that present
challenges to
machinery used to automatically and mechanically coat food products. For
example,
flour mixtures, which consist of finely ground dust-like particles, have a
tendency to
pack under pressure, thereby decreasing the free-flow properties of the
coating mixture
around the food product, which can decrease coating uniformity. Similarly,
coating
mixtures recognized as free-flowing include reasonably hard and roughly
spherical
particles ranging in size from dust to larger particles, such as cornmeal,
cracker meal or
the like. Free-flowing mixtures in automated coating processes can often flow
or leak
out of the machinery.
[0006) Japanese-style crumbs have no uniform shape, are very delicate, and are
crystalline-like in nature and appearance. So, the coating machine should be
able to
properly handle this type of breading material to avoid degradation of the
quality and
particle sizes thereof. Japanese-style crumbs consist of modified wheat flour
with small
percentages of yeast, salt, sugar, vegetable oil and other additives. The
Japanese-style
crumbs appear to be dried shredded white bread having particles ranging in
size from as
large as 1 /2 inch to as small as flour size particles.
[00071 Some food products have a batter applied to them before the coating or
topping is applied. When a batter applicator is used before the coating or
topping is
applied, time is saved when both the batter applicator and the coating or
topping run at
the same or similar speed and when both have the same or substantially similar
product
output width. This provides a continuous flow of food product during both
processes.
These attributes are also helpful in non-batter applications, such as going
from a
breading application to a flying application.
[00081 While the automation of the food coating process is economically
desirable,
another goal of the food coating process is to make the coating appear to be
"home-
made." However, most automatic food coating processes fail to make "home-
style"
appearing foods. In the commercial production of prepared foods, a large
variety of food
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products are machine-coated with breading, flour or the like before being
fried, (or
otherwise cooked) or simply frozen and packaged.
[00091 Some food products have what is called a "home-style breading," which
simulates a breaded food product prepared in the home. This can be done, for
example,
by dipping food, such as pieces of raw chicken, in a bowl with beaten egg and
then
placing the egg coated food into a bag containing flour and optionally spices,
herbs,
seasonings, shortening, etc., to form a coating which adds flavor and texture
to the
product. Other coating material such as ground cereal, dried vegetables or the
like may
be used as desired. The bag is moved back and forth to coat the many surfaces
of the
food product. This technique can be useful for coating food products having
many,
oftentimes hidden surfaces, such as chicken, because in moving the bag, the
surfaces of
the food products are exposed to the coating. The technique is also useful for
coating
various other food products. The flour coated food is then fried in a flying
pan or deep
fryer in the home.
[00101 Generally, the food industry prefers to use an automated and continuous
food
coating process wherever possible while still achieving a "home-style" look.
In the food
processing industry, home-style breading food products have been prepared
using a drum
type breading apparatus, wherein a food coating, such as flour, is added to a
hollow drum
with axial ribs along inner surfaces of the drum. The food products to be
coated are
added to the drum via a first conveyor that drops food products into the drum.
The drum
rotates so that the food products are tumbled along with the coating. The
tumbling
process unfolds food products that are folded and exposes surfaces of the food
products
to the coating. Although producing a desired coating appearance and texture,
particular
problems encountered in a drum breader include the food products being
collected in a
pile at the bottom of the drum. The pile of coated food products is deposited
on the
center of a second conveyor belt that takes food products away from the drum.
Therefore, food exiting on the second conveyor belt must be spread and aligned
along
the width of the conveyor belt before it goes to another operation, such as
freezing. This
adds another step to the processing of food products. It also can result in
low quality
food products if food is not properly redistributed along the conveyor width.
For
example, food can be clumped together and then the next step in the food
processing is
not carried out in an optimal way. Where food is frozen after being on the
second
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conveyor, clumps of food can be frozen together, making weighing, cooking, and
packaging of it very difficult and oftentimes resulting in costly waste. In
addition, drum
style breaders are often difficult to clean and require intensive maintenance.
[0011] The use of a drum breader has many disadvantages, particularly when
used on
a high capacity manufacturing line. The first disadvantage is that the product
is
discharged from a drum breader in a narrow pile and must be then spread back
out to the
typical line width which can be 3-4 times the pile width. This process is
often done with
an additional piece of equipment placed after the drum breader. Additionally,
many
processors also like to align and lengthen food products such as a chicken
strip before
they go into a fryer or freezer to maximize the line capacity and also provide
a more
visually appealing product. This task is also accomplished using an additional
piece of
equipment placed after the drum breader.
[0012] Further, the drum breader is not very effective at sifting flour that
has not
adhered to the food product. Because of this, excess coating is often
discharged from the
drum breader along with the food product where it either falls to the floor
causing waste
or is carried down stream causing problems with further processes such as
ruining the oil
in a fryer. Additionally, due to the size of the drum breader and because of
the ancillary
equipment that is often needed to spread and align the product after it, home
style lines
can get very long and therefore can be difficult to accommodate.
[0013] Other types of food coating devices employ endless mesh belts. For
example,
U.S. Patent 6,117,235 discloses a continuous coating and breading apparatus
which
includes a conveyor belt made of stainless steel mesh. The conveyor has
various stations
along its length. Food items are deposited on the belt at an infeed area and
are coated
with the coating mixture on the bottom surface. The conveyor belt carries the
food items
under a "waterfall" of food coating that covers the top surface of the food
items. The
conveyor passes under one or more pressure rolls that pat the coating mixture
onto the
food pieces, and/or a blow off device, removing excess coating. The coated
food product
is deposited at a discharge area. In commercial practice, such systems may
employ as
many as six conveyors to spread the coating mixture and achieve acceptable
consistent
operation and performance. Further, as it is customary to use a drum breader
for
applying a coating to durable food products that require agitation to fully
coat, such as
chicken, and a mesh conveyor belt to apply coating to fragile food products,
at least two
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machines are required. The use of two machines requires extra space and extra
maintenance.
BRIEF DESCRIPTION OF DRAWINGS
[0014] Embodiments of the invention are disclosed with reference to the
accompanying drawings and are for illustrative purposes only. The invention is
not
limited in its application to the details of construction or the arrangement
of the
components illustrated in the drawings. The invention is capable of other
embodiments
or of being practiced or carried out in other various ways. The drawings
illustrate a best
mode presently contemplated for carrying out the invention. In addition,
although not
used exclusively, when used, like numerals have been used to identify like
components
throughout. In the drawings:
[0015] Fig. 1 is a right side view of an exemplary embodiment of an apparatus
for
applying coating to food products including, a vibratory frame assembly, a pan
assembly,
and a coating recycle assembly.
[0016] Fig. 2 is a left side view of the apparatus for applying coating to
food
products of Fig. 1.
[0017] Fig. 3 is a top view of the apparatus for applying coating to food
products of
Fig. 1.
[0018] Fig. 4 is a discharge end view of the apparatus for applying coating to
food
products of Fig. 1.
[0019] Fig. 5 is a right side view of the vibratory frame assembly of Fig. 1.
[0020] Fig. 6 is a right side view of the pan assembly of Fig. 1.
[0021] Fig. 7 is a right side view of the recycle assembly of Fig. 1.
[0022] Fig. 8 depicts a system including a metering conveyor along with an
exemplary embodiment of an apparatus for applying coating to food products.
[0023] Fig. 9 depicts another exemplary coating recycle assembly.
[0024] Fig. 10 depicts a portion of an exemplary pan assembly.
[0025] Fig. 11 depicts an exemplary coating recycle assembly.
[0026] Fig. 12 depicts another exemplary coating recycle assembly.
CA 02697897 2010-06-02
[0027] Fig. 13 depicts an exemplary embodiment of the apparatus for applying
coating to food products including, a vibratory frame assembly, a pan
assembly, a
coating recycle assembly, a wire conveyor belt assembly in a production
position, a
frame and a swing frame portion.
[0028] Fig. 14 depicts the exemplary, vibratory frame assembly, pan assembly,
coating recycle assembly and auxiliary hopper.
[0029] Figs. 15A and 15B depict exemplary embodiments of a wire conveyor belt
assembly.
[0030] Fig. 16 depicts an exemplary embodiment of the wire conveyor belt
assembly, the frame and the swing frame portion.
[0031] Fig. 17 depicts an exemplary embodiment of the apparatus in Fig. 13,
wherein
the wire conveyor belt assembly is in a non-production position.
[0032] Fig. 18 depicts an exemplary embodiment of the wire conveyor belt
assembly, the recycle conveyor, the frame and the swing frame portion.
[0033] Fig. 19A is a side view of an exemplary embodiment of the hybrid
apparatus
for applying coating to products, including a feed assembly, a drum assembly,
a
discharge assembly and a coating recycle conveyor.
[0034] Fig. 19B is a side view of another exemplary embodiment of the hybrid
apparatus for applying coating to products, including a feed assembly, a drum
assembly,
a discharge assembly and a coating recycle conveyor.
[0035] Fig. 20 is a top view of the hybrid apparatus for applying coating to
products
of Fig. 19A.
[0036] Fig. 21 is a side view of the feed assembly of Fig. 19A.
[0037] Fig. 22 is a top view of the feed assembly of Fig. 21.
[0038] Fig. 23 is a side view of the drum assembly of Fig. 19A.
[0039] Fig. 24 is a back view of the drum assembly of Fig. 23.
[0040] Fig. 25 is a front view of the drum and ferris wheel of the drum
assembly of
Fig. 23.
[0041] Fig. 26 is a side view of the discharge assembly of Fig. 19A.
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[0042] Fig. 27 is a top view of the discharge assembly of Fig. 26.
[0043] Fig. 28 is a side view of an exemplary embodiment of the apparatus for
applying coating to food products, including the vibratory frame assembly, the
pan
assembly, and the coating recycle assembly.
DETAILED DESCRIPTION
[0044] In summary, a hybrid apparatus and method for coating products is
disclosed
herein. An exemplary apparatus comprises a vibration generating portion and a
food
product coating portion. The food product coating portion can include a
coating
application portion, a sifting portion, and an aligning portion. The exemplary
apparatus
can include a coating recycle portion as well. The vibration generation
portion further
comprises a motor vibration assembly secured to a frame wherein the frame is
in
communication with the food product coating portion, such as a pan assembly,
by
springs that move the pan assembly with a vibratory motion. The pan assembly
includes
at least one of the coating application portion, the sifting portion, and the
aligning
portion. The coating application portion is comprised of a series of
inclinations, such as
angled steps that guide the coating and vibrating food product upwards and
forwardly
while simultaneously allowing the food product to be bounced against the
coating resting
on the step surface. As the food product is vibrated over the edge of one or
more steps, it
tumbles and unfolds, thereby exposing non-coated portions to the coating.
[0045] The sifting portion succeeds the coating portion wherein the food
product
continues to vibrate across another series of angled steps of which
perforations are
formed therein. Unused or otherwise excessive coating on the food product
passes
through the perforations as the food product vibrates forward across the
steps. The
coating that passes through the perforations can be collected and guided into
a hopper
and/or a base recycle conveyor that conveys the coating back to the coating
portion
step(s).
[0046] The food product continues to the aligning portion that is comprised of
a
corrugated surface situated at an incline having channels formed by the
corrugations that
are substantially parallel with the length of the pan assembly from an intake
end to a
discharge end. The channels bias the food product such that it can be
elongated and
aligned from the vibration.
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[0047] An additional sifting portion can be provided that can include another
aligning portion having holes situated there-through to allow agglomerations
of coating
or undesirably small food product pieces to pass through and thereby be
removed from
the process. The coated, elongated, and substantially aligned food product can
then
advance to a subsequent process.
[00481 Further, another embodiment of the hybrid apparatus and method for
coating
food products is disclosed herein, wherein the recycle conveyor portion
includes a base
recycle conveyor and a waterfall recycle conveyor that supplies coating at an
intake end
of the coating application portion and receives coating at the discharge end
of the pan
assembly.
[0049] Additionally, another embodiment of the hybrid apparatus and method for
coating food products is disclosed herein, the apparatus comprising a
vibration
generating portion, a food product coating portion and a recycle conveyor
portion. The
vibration generating portion includes a motor-induced vibration assembly. The
food
product coating portion can include a pan assembly in communication with the
vibration
generating portion, and at least one of a food product path therealong the pan
assembly,
and a food product path along a wire conveyor belt assembly that is not
subject to the
vibratory component of the vibration generating portion. The recycle conveyor
portion
can include one or more recycle conveyors, such as a base recycle conveyor to
provide
coating to a loading surface and/or a waterfall recycle conveyor situated to
provide a
waterfall of coating to at least one of a bottom and top portion of a food
product. The
recycle conveyor(s) is configured to receive coating at a distal end of the
food product
path and return it to the proximal end of the food path. Further, the
apparatus can
include a swing frame portion that is secured to the wire conveyor belt
assembly such
that the wire conveyor belt assembly can be moved from a non-production
position,
wherein the food product path is along the pan assembly, and a production
position,
wherein the food product path is along the wire conveyor belt assembly.
Additionally,
the apparatus is not limited to the application of food based coating and food
products,
the apparatus can be used to provide a coating of non-food based material onto
a non-
food based object.
[0050] Still another embodiment of the apparatus and method of coating
products is
disclosed herein, the apparatus including a first vibratory frame assembly in
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I_.
communication with a first pan assembly, a second vibratory frame assembly in
communication with a second pan assembly, and a drum assembly situated between
the
first and second pan assemblies.
[0051] Yet another embodiment of the apparatus and method for coating products
is
disclosed herein, the method for applying coating to a product including: 1)
receiving
products and coating at the inlet end of a first pan assembly; 2) applying
coating to the
products and conveying the products and coating from the inlet end of the
first pan
assembly to an outlet end of the first pan assembly using vibratory motion; 3)
discharging the products and coating from the outlet end of the first pan
assembly into a drum assembly, wherein the drum assembly includes a drum
having a
drum intake end and a drum discharge end; 4) applying coating to the products
in the
drum using rotational motion; 5) discharging the coating and products from the
drum
discharge end into a second pan assembly; and 6) conveying the coating and
products
along the second pan assembly, wherein the products are at least one of
separated apart
and aligned as they are conveyed along the second pan assembly.
[0052] Still yet another embodiment of the apparatus and method for coating
products is disclosed herein, the apparatus for applying coating to products
includes a
first vibratory frame assembly in communication with a first pan assembly,
wherein the
first pan assembly receives a product and a coating and applies the coating to
the
products using vibratory motion. Additionally, a drum assembly is provided
that
includes a drum, wherein products and coating are received from the first pan
assembly
and the coating is further applied to the products using a rotational motion
of the drum,
and a second vibratory frame assembly is provided in communication with a
second pan
assembly, the second pan assembly having at least one of a separator tray
assembly and
an alignment tray assembly, wherein the second pan assembly receives the
products and
coating from the rotating drum and at least one of separates and aligns the
products using
vibratory motion.
[0053] Yet still another embodiment of the apparatus and method for coating
products is disclosed herein, the apparatus including: 1) a first vibratory
frame assembly
having vibratory frame side members, 2) a first pan assembly mounted to the
first
vibratory frame side members, 3) a plurality of first springs adapted to mount
the first
pan assembly to the first vibratory side members, the first springs mounted at
an angle 0'
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above horizontal, 4) a second vibratory frame assembly having second vibratory
frame
side members, 5) a second pan assembly mounted to the second vibratory frame
side
members, 6) a plurality of second springs adapted to mount the second pan
assembly to
the second vibratory side members, the second springs mounted at an angle 0"
above
horizontal, 7) a drum assembly, situated between the first and second pan
assemblies, 8)
at least one first motorized vibrator mounted and adapted to impart energy to
the first
vibratory frame side members at an angle R' below horizontal, 9) at least one
second
motorized vibrator mounted and adapted to impart energy to the second
vibratory frame
side members at an angle [3" below horizontal, 10) wherein the first and
second pan
assemblies are adapted to vibrate having longitudinal and vertical vector
components at a
predetermined amplitude and frequency, and 11) wherein the first and second
vibratory
frame assemblies are adapted to operate in a tuned and excited mode.
[0054] Figs. I and 2 depict an exemplary embodiment of an apparatus 2 for
applying
coating to food products, the apparatus 2 includes a vibration generating
portion, such as
a vibratory frame assembly 4, a food product coating portion, such as a pan
assembly 6,
and a coating recycle portion, such as coating recycle assembly 8.
Additionally, Fig. 1
depicts a left side of the apparatus 2, and Fig. 2 depicts a right side of the
apparatus 2.
Further, Fig. 3 shows a top view of the apparatus 2, more particularly, the
pan assembly
6 and the coating recycle assembly 8. Fig. 4 shows a discharge end view of the
apparatus 2 including portions of the vibratory frame assembly 4, the pan
assembly 6,
and the coating recycle assembly 8.
[0055] Fig. 5 shows an exemplary vibratory frame assembly 4 that comprises a
support frame 10, a plurality of isolators 12, at least two vibratory frame
side members
14, at least two vibratory cross-members 15, at least two motorized vibrator
assemblies
16, and a plurality of spring assemblies 18. The support frame 10 in one
embodiment
comprises two side tubular members 20 and each of front and back tubular
members 22,
24, respectively. The tubular members 20 can be square in cross-sectional view
and can
be secured adjacent their respective ends to form a substantially rectangular
shape. In
one embodiment, the length and width of the support frame 10 can follow the
footprint
of the vibratory frame side members 14, although it has been contemplated that
the
support frame 10 can comprise various shapes, dimensions and configurations to
provide
less or more support as necessitated by the operating conditions.
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[0056] In one embodiment, the vibratory frame side members 14 (shown in Figs.
4
and 5) are in the shape of an elongated plate having a thickness of about 5/8
inches, a
height of about 16 inches, and a length of about 96 inches. In another
embodiment, it
has been contemplated that the vibratory frame side members 14 can vary in
thickness by
about 1/4 inch to about 1-1/2 inches, in height by about 6 inches to about 24
inches, and
have a length that would be substantially similar to the length of the pan
assembly 6.
Further, because the apparatus 2 can vary in size to accommodate various types
of
process configurations of varying scale, the dimensions of the vibratory
assembly
components can vary substantially outside of these dimensions. Also, it has
been
contemplated that the vibratory frame side members 14 can vary in shape as
well, such
as triangular or square. Still further, in one embodiment, two cross-members
15 are
secured between, and substantially perpendicular to, the vibratory frame side
members
14 as shown in Figs. 4 and 5. In another embodiment, fewer or additional cross-
members 15 can be used to provide for various apparatus 2 configurations.
[0057] The support frame 10 is secured to the vibratory frame side members 14
by
the isolators 12. In one embodiment, the support frame 10 and the vibratory
frame side
members 14 each have mounts such as brackets 17 extending therefrom for
securing the
isolators 12 in a vertical orientation (as shown in Fig. 5), although it has
been
contemplated that the isolators 12 can also be secured in other ways, such as
using other
protrusions 43 or indentations, and at various angles. Further, although the
exemplary
embodiment depicted has four isolators 12 and eight brackets 17, it has been
contemplated that increasing or decreasing the number of these components can
provide
varying degrees of stability and support as required.
[0058] The isolators 12 are configured to provide support and isolation and
therefore
can vary in size and hardness. In one embodiment, the isolators 12 are
constructed using
a polyurethane tube that is about 6 inches in length and has about a 2-1/2
inch thick wall,
and a hardness rating of 40-60 durometers. Although in other embodiments, the
dimensions and hardness can vary depending on the application, for example
from about
2 inches to about 10 inches in length, about 2 inches in diameter to about 10
inches in
diameter, and about 40 to about 70 durometers in hardness. The dimensions and
weight
of the vibratory frame and pan assemblies 4, 6 can at least partially dictate
the
aforementioned parameters, and therefore the dimensions can vary
substantially.
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[0059] As discussed above, the vibratory frame assembly 4 further comprises a
motorized vibrator assembly 16 mounted to each of the vibratory frame side
members
14. The motorized vibrator assembly 16 is adapted to impart energy to the
vibratory
frame side members 1.4 at an angle (3 below the horizontal (as shown in Fig.
5). In an
exemplary embodiment, 0 ranges from about 15 degrees to about 60 degrees, for
example, about 45 degrees, although in other embodiments (3 can vary more or
less. In
an exemplary embodiment, the motorized vibrator assembly 16 includes a motor
28
coupled to a pair of eccentric vibrators 30, for example, a pair of rotary
magnetic
vibrators such as the Motomagnetic electric vibrator as manufactured by Martin
Engineering Nepoinset, IL Model ST12-1440. In one embodiment, the motor 28 is
speed-controlled by an inverter (not shown), such as the POWERFLEX 40 as
manufactured by Allen Bradley, although in another embodiment a hydraulic
speed
control can be used, for example of the type manufactured by Sun and Bosch.
Further,
the energy imparted to the vibratory frame side members 14 by the motorized
vibrator
assembly 16 is at least partially transferred from the vibratory frame
assembly 4 to the
pan assembly 6 by the plurality of spring assemblies 18.
[0060] Referencing Figs. 6 and 10, an exemplary embodiment of the pan assembly
6
is depicted comprising of a pan bottom portion 34, pan side portions 37, at
least one step
36, of which forms a coating application portion, at least one perforated step
assembly
39, of which forms a sifting portion, at least one alignment tray assembly 40,
of which
forms an alignment portion, and a recycle trough 42. The vibratory frame
assembly 4 is
in communication with the pan assembly 6 by way of the plurality of spring
assemblies
18, more particularly, the pan side portions 37 are connected to the vibratory
frame side
members 14 by the spring assemblies 18. In an exemplary embodiment, each
spring
assembly 18 comprises one or more springs 19 with a fastener 41 at both ends
of the
spring 19, where the fastener 41 secures the springs 19 adjacent to each other
and also
secures them to protrusions 43 on both the pan side portions 37 and the
vibratory frame
side member 14. In at least one embodiment, the springs 19 are leaf springs.
Further,
the springs 19 can be constructed from high performance composite materials,
such as,
but not limited to, E-glass/epoxy, carbon fiberglass/epoxy,
(carbon/glass)/epoxy,
fiberglass/polyester, and high temperature glass/epoxy in cross-ply, spring
orientation
and unidirectional (e.g., 80%) pre-preg constructions available from
Composiflex, Inc.,
Erie, PA. In an exemplary embodiment the protrusions 43 can be cast brackets
17 that
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are welded in place, although other spring assembly 18 fastening means have
been
contemplated. Further, in an exemplary embodiment, three springs 19 can be
used for
each spring assembly 18 and thirty-four spring assemblies 18 can be used
(seventeen
spring assemblies 18 located on each side of the apparatus 2). The number of
spring
assemblies 18 provided are largely dependent on the weight of the pan assembly
6
(greater weight requires more springs), and therefore, the number of spring
assemblies
18 can increase or decrease in quantity and size as is necessary to compensate
for the
weight.
[0061] The motorized vibrator assemblies 16 impart an oscillating force on the
pan
assembly 6. The frequency of the oscillating force imparted is dependent on
the speed of
the motor 28, with the speed of motor 28 being dependent on the accumulation
of the
spring constants of springs 19 versus the weight of the pan assembly 6, as
discussed
further below. In an exemplary embodiment the speed can vary from about 600
rpm to
about 1200 rpm, for example, about 850 rpm, although in other embodiments the
speed
can vary from about 100 rpm to about 2000 rpm.
[0062] The spring assemblies 18 are oriented at an angle 0 above the x-axis 13
(as
shown in Fig. 2). In an exemplary embodiment 0 can be between about 15 degrees
and
about 85 degrees, for example about 45 degrees, although in other embodiments
0 can
vary more or less. In at least one embodiment, the angle 0 can be
substantially equal to
the angle (3.
[0063] The selection of spring quantity and spring constants can be derived in
one
embodiment by the following: given a natural frequency (Fõ in cycles per
minute) and
pan assembly 6 mass (m in pounds-mass) (i.e., the total mass of the pan
assembly 6 and
the sum of all the individual spring constants (EK in pounds per inch)) is
equal to the
number of springs 19 (assuming each spring has the same constant) multiplied
by
(mFn/30)2(m/386). Thus, the spring constant for each spring 19 is EK divided
by the
number of springs 19.
[0064] In an exemplary embodiment, the spring constant is about 95
pounds/inch, the
width of each spring 19 is about 2-1/2 inches, the length of each spring 19 is
about 14
inches and the thickness of each spring 19 is about 1/4 inch, although other
values have
been contemplated. In another embodiment the spring 19 can range in length
from about
inches to about 20 inches, the spring 19 thickness can be from about 1/8 inch
to about
13
CA 02697897 2010-06-02
1 /2 inch and the spring 19 width can be from about 1 inch to about 4 inches,
although
other values have been contemplated. Additionally, the size of the spring 19
can control
the stroke (distance traveled by the pan assembly 6 as measured from the
oscillation
spring end secured to the pan assembly 6). In an exemplary embodiment the
stroke can
range from about 1/4 inch to 1-1/2 inches, more particularly about 1 inch,
although other
values have been contemplated. In terms of overall design, in an exemplary
embodiment
the spring constant is designed such that the operating frequency Fo of the
vibratory
frame side members 14 is about 20-40% of their natural frequency F,,, more
particularly,
F0 is about 33% of F,,, although other values have been contemplated. As
discussed
above, based on the desired size and resultant weight of the apparatus 2,
various
components, such as the aforementioned, can be sized differently as necessary
to produce
the desired vibratory action.
[0065] Further in reference to Fig. 6, the steps 36, the perforated step
assembly 39
and the alignment tray assemblies 40 are situated substantially in-line and
form a surface
for a food product to travel in order to apply a coating thereon. In an
exemplary
embodiment, the steps 36 are formed from a continuous piece of substantially
planar
material, such as metal or plastic that is bent or otherwise formed as a
series of steps 36
with each step 36 having a ramp portion 54 and a vertical drop portion 56. In
one
embodiment, the ramp portion 54 can have an inclination angle a from about 5
degrees
to 25 degrees, more particularly about 15 , degrees (as shown in Fig. 2),
although other
values for a have been contemplated. In at least one embodiment, the ramp
portion 54
and the drop portion 56 comprise substantially planar surfaces. Additionally,
a loading
plateau 58 for receiving food product thereon can be situated on or adjacent
to the first
step 36 located at an inlet end 55 of the pan assembly 6. Fig. 6 depicts an
exemplary
embodiment with 6 steps 36, although fewer steps 36 can be used to shorten the
process
time or apparatus length, and additional steps 36 can be used to provide a
more thorough
coating process. Further, the steps 36 can be formed from a single piece of
material or
can be grouped as one or more steps 36 that are formed from multiple pieces of
material,
thereby allowing selective removal of only a single step 36 or group of steps
36.
[00661 Outer step edges 60 (best shown in Fig. 3) of the steps 36 are secured
to the
pan side portions 37, by one of various methods such as welding, soldering or
formed
indentations that can receive the steps 36. In one embodiment, the piece of
material that
14
CA 02697897 2010-06-02
forms the steps 36 can also be used to form the pan bottom portion 34. The
material at
the bottom of an extended drop portion 57 can be formed at a substantially 90
degree
angle with respect to the extended drop portion 57, such that it forms an
extension off the
steps 36 that proceeds in a linear manner between the pan side portions 37,
such that it is
situated underneath the perforated step assemblies 39. Additionally, the pan
bottom
portion 34 can be secured to the pan side portions 37 using welds or a
fastener such as a
bolt. In another embodiment, the pan bottom portion 34 can be a separate piece
of
material that is secured to the extended drop portion 57.
[0067] Further, in an exemplary embodiment, the recycle trough 42 is formed as
a
portion of the pan bottom portion 34 (best shown in Figs. 3, 4 and 6) where
the recycle
trough 42 extends from the pan bottom portion 34 diagonally in the direction
of a
discharge end 59 of the pan assembly 6 and in a downward direction of about 10
degrees
with respect to the pan bottom portion 34, resulting in a trough end 48 being
situated
about 4 to about 6 inches below the pan bottom portion 34. Additionally, in
one
embodiment the downward direction of the recycle trough 42 can be from about 5
degrees to about 20 degrees. The recycle trough 42 further includes a bottom
portion 44
and a wall portion 46. The wall portion 46 provides a backstop for recycled
coating to
abut and therefore be directed downwards (substantially by vibration) along
the bottom
portion 44 exiting at the trough end 48. Alternative embodiments of the
recycle trough
42 can include various other coating exit paths.
[0068] Still referencing Fig. 6, in an exemplary embodiment, the pan side
portions 37
secured to the pan bottom portion 34 provide a space for insertion of the
perforated step
assembly 39 and the alignment trays 40. In one embodiment, the perforated step
assembly 39 comprises perforated steps 38 that are similar to steps 36, with
the addition
of a plurality of slots 50 formed therethrough (shown in Fig. 3). Fig. 6
depicts the
perforated step assembly 39 with three perforated steps 38, although fewer
steps 38 can
be used to reduce the apparatus 2 length or the processing time, and
conversely,
additional lengths can be added to further sift the coating from the food
product.
[0069] In one embodiment, the perforated step assembly 39 further comprises a
pair
of side panels 62 that are each secured to a perforated step edge 64 (also
shown in Fig. 3)
at a substantially perpendicular angle. The perforated step assembly 39 is
sized to be
situated adjacent the pan side portions 37, the extended drop portion 57, and
the
CA 02697897 2010-06-02
alignment tray assembly 40. A pan cross-member 66 comprising a rod 70 and a
spring
latch 72 extends through apertures in the pan side portions 37. When the
spring latch 72
is in a locked position, the perforated step assembly 39 is secured in the pan
assembly 6,
between the pan side portions 37 by the rod 70. The side panels 62 can further
include a
handle 68 formed on an upper portion for removal of the perforated step
assembly 39
from the pan assembly 6 for cleaning or replacement. In one embodiment, the
perforated
step assembly 39 can be permanently secured, such as welded in place or
temporarily
secured using a fastener, such as a bolt.
[0070] Further, regarding the slots 50 formed through the perforated steps 38,
in one
embodiment the slots 50 are situated at least partially non-parallel with
respect to the
length of the pan side portions 37. Additionally, in an exemplary embodiment,
the slots
50 are about 3/16 inches wide, have a length of about 3 inches and a center to
center
distance (with respect to width) of about 3/8, although in other embodiments
the slots 50
can vary in range from 3/16 inch to about 1/2 inch wide, have a length of
about 3 inches
to about 6 inches, and a center to center distance of about 3/8 inch to about
1 inch. The
slots 50 allow finer particles of coating situated on the perforated steps 38
to pass
therethrough and into the recycle trough 42, thereby removing excess coating
from the
perforated steps 38 and allowing the coating to be delivered to the coating
recycle
assembly 8 for re-use. It has been contemplated that other embodiments can
vary the
slot width, length and direction to accommodate various coatings; for example,
a very
course coating can require a larger size slot 50, and slots 50 situated at
specific angles
can be advantageous for some food products. Further, the slots 50 can be
formed by
various methods, for example drilling or punching the perforated steps 38.
[0071] In Fig. 6, the alignment tray assemblies 40 are shown situated adjacent
the
perforated step assembly 39, and between the pan side portions 37. In an
exemplary
embodiment, the alignment tray assemblies 40 are comprised of a pair of
alignment tray
sides 74 and a bottom tray portion 76, as shown in Fig. 3. The alignment tray
sides 74
are secured at substantially perpendicular angles at either side of the bottom
tray portion
76. Referring now to Fig. 6, another pan cross-member 66 extends through
apertures in
both of the pan side portions 37 such that when the cross-member 66 is in a
locked
position, the alignment tray assemblies 40 are secured between the pan side
portions 37
of the pan assembly 6. The alignment tray sides 74 can each further include a
tray
16
CA 02697897 2010-06-02
handle 77 (best seen in Fig. 4) formed on an upper portion for removal of the
alignment
tray assemblies 40 from the pan assembly 6 for cleaning or replacement.
Further, in at
least one embodiment, the alignment tray assemblies 40 are situated at angle
92 (Fig. 2)
that can range from about 10 degrees to about 20 degrees, for example 15
degrees,
although in another embodiment this angle can angle can further vary. The
upward
angling of the alignment tray assemblies 40,promotes elongation of the food
product as it
travels towards the discharge end 59.
[00721 In an exemplary embodiment the bottom tray portion 76 is formed as a
corrugated piece of metal having tray channels 78 formed by the corrugations,
wherein
the tray channels 78 have a top edge 80 and a bottom edge 82, as shown in
Figs. 3 and 4,
and are used to elongate and align the food products. In an exemplary
embodiment, the
inclusive angle between adjacent top edges 80 can range from about 60 degrees
to about
160 degrees, for example 90 degrees, although it has been contemplated that in
another
embodiment the angle can further vary. In an exemplary embodiment, the top
edges 80
can have a spacing there-between of about 3-5/16 inches, and a height from top
edge 80
to bottom edge 82 of about 1-9/16 inches, although it has contemplated that in
another
embodiment the top edges 80 can have a spacing there-between of about 2 inches
to
about 6 inches, and a height from top edge 80 to bottom edge 82 of about one
inch to
about four inches. Additionally, the spacing and height can be lesser or
greater as
dictated by the size of the food product being processed.
[00731 Additionally, one or more of the top edges 80 can include a separator
pin 84
to guide the food product off the top edge 80 of the tray channels 78. If
multiple
separator pins 84 are used, they can be in staggered positions as shown in
Fig. 3.
Staggering can reduce or prevent the blockage of the tray channels 78. The
separator
pins 84 provide a barrier to force the food product off the top edge 80 and
therefore can
be any protrusion that serves this purpose, such as a rod 70 having a circular
or triangular
cross-section, or a v-shaped metal divider that imparts separation
trajectories pointing
away from the oncoming food product. The separator pin 84 can extend in a
direction
that is towards the discharge end 59 of the pan assembly 6 and upward off the
top edge
80 at an angle of about 1 to about 90 degrees. Additionally, in an exemplary
embodiment the separator pin 84 can have a length of about 2-1/4 inches and a
diameter
of about 3-1/8 inches although it has been contemplated that in another
embodiment the
17
CA 02697897 2010-06-02
length can be from about 1 inch to about 3 inches, and the diameter can be
about 1/4 inch
to about 1-1/2 inches. Additionally, the length and diameter can be lesser or
greater as
dictated by the size of the food product being processed with a larger food
product
requiring a larger length and/or diameter.
[0074] Referring to Fig. 3, two exemplary alignment tray assemblies 40 are
shown,
the first having separator pins 84 and the second having a plurality of tray
holes 86
situated along the bottom edge 82 of the tray channel 78. The tray holes 86
can be
provided to remove larger agglomerations of coating and/or smaller pieces of
food
product from the bottom tray portion 76. The tray holes 86 can be of varying
diameter
and are sized to accommodate the particular type of coating and food product
being
processed, for example, in one embodiment the tray holes 86 can range from
about 1/4
inch to about 3/4 inch, and have a center to center spacing of about 3/8 inch
to about 1
inch. In an exemplary embodiment, one or more alignment tray assemblies 40
having
separator pins 84 can be used to lengthen and align the food products, and one
or more
alignment tray assemblies 40 having tray holes 86 can be used to remove
agglomerations, various combinations of alignment tray assemblies 40 can be
used
having both separator pins 84 and tray holes 86 or neither separator pins 84
and tray
holes 86. Further, as shown in Fig. 6, a dust cover 87 is mounted to the
support frame 10
and situated substantially over the pan assembly 6. The dust cover 87 serves
to minimize
the dust created by the coating process.
[0075] Referring to Figs. 3 and 7, an exemplary coating recycle assembly 8 is
depicted that can be used to recycle coating received from the recycle trough
42 and
deliver it to a loading surface 88 on or adjacent to step 36. The coating
recycle assembly
8 comprises a recycle hopper 90 that can be mounted to the support frame 10 or
to a
separate frame, and positioned such that recycled coating is directed into the
recycle'
hopper 90 from the recycle trough 42. Additionally, the recycle hopper 90 is
in
communication with a recycle auger 92 and recycle auger housing 93 that
transfers the
recycled coating into a feed hopper 94. The feed hopper 94 can be mounted to
the
support frame 10 or to a separate frame. The coating is then transferred by a
feed auger
96, situated adjacent a feed hopper bottom 97, through an opening 98 onto the
loading
surface 88 of the step 36. Alternatively, the coating can be distributed
without the use of
the feed auger 96, into a partially enclosed containment chamber (not shown)
as
18
CA 02697897 2010-06-02
discussed later. In an exemplary embodiment, the feed hopper 94 is situated at
a higher
vertical point than the recycle hopper 90; therefore the recycle auger 92 and
recycle
auger housing 93 are positioned to direct the recycled coating at an upwards
angle.
Additionally, in an exemplary embodiment, the recycle auger 92 and the feed
auger 96
can have about a 6 inch diameter and a pitch of about 6 inches. In another
embodiment,
the augers 92, 96 can have a diameter of about 4 to about 10 inches and a
pitch of about
2 inches to about 10 inches. Further, in other embodiments the augers 92, 96
can vary in
length, diameter and pitch as required by the size of the apparatus 2. In an
exemplary
embodiment the feed auger 96 is a cross-feed auger, although other embodiments
can be
modified to use various other styles of augers. Further, in an exemplary
embodiment, the
recycle auger 92 is driven by a recycle auger motor 99 and the feed auger 96
is driven by
a feed auger motor 101. Each motor can be a gear motor, although other drive
mechanisms can be used, such as a hydraulic drive.
[00761 Further, referencing Fig. 7, the opening 98 can include a metered slide
gate
100 that covers an opening (not shown) in a feed auger containment chamber 102
situated in the feed hopper 94. In one embodiment the adjustable opening 98
can be
manually operated, although it has been contemplated that the slide gate 100
can be
controlled automatically. Alternatively, the slide gate 100 can be omitted
and/or a fixed
opening can be used. In one embodiment, a coating level sensor 104 (shown in
Fig. 6),
such as an ultrasonic sensor, can be situated adjacent the loading surface 88
and used for
measuring the height level of the coating situated on the loading surface 88.
It has been
contemplated that the coating level sensor 104 can be one of a variety of
sensors
appropriate for use with particles, such as an inductive proximity sensor, a
laser or a
paddle wheel. In one embodiment, the coating level sensor 104 can be used to
signal the
feed auger 96 to slow down or speed up to control the flow of coating to the
loading
surface 88. Additionally, in another embodiment the coating level on the
loading surface
88 can be controlled by the speed of the -feed auger 96 and/or the recycle
auger 92, or the
speed of the feed auger motor 101 and/or recycle auger motor 99. In an
exemplary
embodiment, the desired depth of coating; can range from about 1/2 inch to
about 2
inches above the loading surface 88. Further, in an exemplary embodiment, a
relief
valve (not shown) such as an opening with a biased cover-flap, can be situated
adjacent
the feed auger containment chamber 102 to provide for the discharge of excess
coating.
19
CA 02697897 2010-06-02
[0077] To begin operation of the exemplary apparatus 2, the motorized vibrator
assemblies 16, recycle auger motor 99 and feed auger motor 101 are activated.
The
speed of the vibrator assemblies 16 is adjusted to achieve a predetermined
frequency and
amplitude. Coating is charged into the recycle hopper 90 and is fed via the
recycle auger
92 to the feed hopper 94. The feed hopper 94 funnels the coating into the feed
auger
containment chamber 102 and to the feed auger 96. The feed auger 96 then moves
the
coating onto the loading surface 88 through the metered slide gate 100. If the
coating
level sensor 104 detects that the coating level on the loading surface 88 is
sufficient, the
metered slide gate 100 will reduce or cease the flow of coating to the loading
surface 88.
The coating is then distributed from the loading surface 88 throughout the pan
assembly
6 and coating recycle assembly 8. As shown in Fig. 8, after the coating has
been
distributed, the food product is fed onto the loading plateau 58 by a means
such as a
metered conveyor 106 that is supplied by a conveyor hopper 108 or a batter
applicator
(not shown). The food product moves in a forward direction (from the inlet
portion end
55 of the pan assembly 6 towards the discharge end 59 of the pan assembly 6)
using the
vibrations transferred from the vibratory frame assembly 4 to the pan assembly
6. The
vibrations thrust the food product and the coating at about a 45 degree angle
towards the
discharge end 59, resulting in a forward movement up and over each of the
steps 36, with
the vertical component of the vibration patting coating to the underside of
the food
product and the horizontal component moving the food product forward. Further,
the
step 36 configuration results in the food product being rolled and tumbled as
it falls off
the drop portion 56, such that the food product is spread apart and coating is
applied to
multiple surface portions of the food product in a manner that is similar to a
home-style
application.
[0078] Once the coating has been applied to the food product along steps 36,
the
food product moves onto the perforated step assembly 39 and along the
perforated steps
38. The perforated steps 38 continue to roll or tumble the food product in the
same
manner as steps 36, resulting in some coating being further secured to the
food product
and some coating falling off of the food product and the perforated step
assembly 39, and
onto the bottom tray portion 76. The smaller coating particles then fall
through the slots
50 in the perforated steps 38 and down into the recycle trough 42. The food
product
continues moving forward onto the alignment tray assembly 40. As the food
product
enters the alignment tray assembly 40, it becomes biased by the tray channels
78 in the
CA 02697897 2010-06-02
bottom tray portion 76. As the food product moves along the bottom tray
portion 76, the
tray channels 78 tend to shift the food product from the top edges 80 into the
bottom
edges 82. Because the alignment tray assembly 40 has an inclination angle, the
food
product is elongated as it moves up the bottom tray portion 76. Food product
that is
positioned substantially across the top edge 80 of the bottom tray portion 76
can
encounter a separator pin 84, which tends to force the upward moving food
product to
shift off the top edge 80 towards the bottom edge 82. In an exemplary
embodiment, a
second alignment tray assembly 40 having tray holes 86 can be provided
adjacent the
first alignment tray assembly 40. The second alignment tray assembly 40
receives the
food product from the first alignment tray assembly 40 and similarly provides
further
elongation of the food product. The tray holes 86 allow undesirably small food
product
pieces and/or agglomerations of coating that did not fall through the slots 50
to fall
through the bottom tray portion 76 and be collected separate from the coating
collected
by the recycle trough 42, thereby removing unwanted material from the process.
The
food product continues to move across the second alignment tray 40 and onto an
off-
loading device such as a conveyor belt (not shown) to be further processed. In
other
embodiments, a single alignment tray 40 can be used having the separator pins
84 and/or
the tray holes 86. Additionally multiple alignment trays 40 can be used having
the
separator pins 84 and/or the tray holes 86, the number of alignment trays 40
being
largely dependent on the acceptable size of the apparatus 2.
[0079] The alignment tray 40 and other portions of the apparatus 2 can be
designed
to be the same width of conveyor belts and other devices used with the
apparatus 2 such
that the food product can move between the apparatus 2 and other devices
without
rearranging the width of path of the food product traveling through the
apparatus 2.
[0080] In addition, the food product exits the apparatus 2 at substantially
the same
elevation as it enters the apparatus 2, thereby avoiding having to adjust the
height of
other devices used with the apparatus 2 and avoiding having workers having to
adjust
their stance when working on the apparatus 2.
[0081] Still further, the pan assembly 6 can be configured to be as wide or
narrow as
other process equipment used in conjunction with the apparatus 2, such as a
conveyor
used to off-load food product. For example, the pan assembly 6 can be 24", 34"
or 40"
wide, although additional widths are also within the scope of the invention.
By using
21
CA 02697897 2010-06-02
pan assembly 6 widths that are the same width as other food processing
equipment
located either at the inlet end 55 or the discharge end 59 of the apparatus 2,
throughput of
food product is less likely to be inhibited throughout a process. In addition,
the use the
alignment tray assembly 40 can eliminate the need for a secondary process of
spreading
and aligning food product to a desired position, thereby improving throughput.
[00821 Further, regarding the coating recycle assembly 8, the coating that
falls
through the slots 50 in the perforated steps 38 is substantially received by
the wall
portion 46 and bottom portion 44 of the recycle trough 42. The coating is then
moved
substantially by the oscillating vibrations down the recycle trough 42 and
exits through
the trough end 48 into the recycle hopper 90. The coating in the recycle
hopper 90 is
transferred by the recycle auger 92 and recycle auger housing 93 to the feed
hopper 94,
thereby allowing the coating to be recycled and applied to incoming food
product.
100831 Another exemplary coating recycle assembly 200 that can be used with
the
apparatus 2, is shown in Fig. 9. The coating recycle assembly 200 can function
without
augers, wherein the use of an augerless coating recycle assembly 200 can be
more
suitable for fine and/or delicate coatings. The coating recycle assembly 200
includes a
fill hopper 204 and a recycle conveyor 210. Utilizing the recycle conveyor
210, the
coating recycle assembly 200 can recycle the coating without the need for one
or more
augers, thereby reducing the turbulence experienced by the coating during the
recycling
process. The recycle conveyor 210 includes a conveyor channel 212 that is
mounted to a
frame 206 and a drag-chain belt 214 situated at least partially within the
conveyor
channel 212. The conveyor channel 212 can include an inner side portion 213,
an outer
side portion 215, a bottom portion 217 and a removable top portion 219. In one
embodiment, the drag-chain belt 214 is a solid synthetic with tracking lugs
(or drive
cogs) (not shown) on one side and flights 216 on the opposite side. The lugs
can be
secured to the drag-chain belt 214 using a fastener or they can be integrally
molded with
the drag-chain belt 214 thereby eliminating crevices, fissures, hinges or
other structures
where coatings and/or topping can become lodged and impede cleaning of the
belt. In at
least one embodiment, the drag-chain belt 214 can be made of polyester thermal
plastic,
polyurethane, or another material that can be sufficiently cleaned to meet
food process
industry standards. An exemplary drag-chain belt 214 is a SuperDrive from
Volta of
Karmiel, IL. Another exemplary drag-chain belt 214 is a plastic flighted belt,
a Series
22
CA 02697897 2010-06-02
800 Open Hinge Impact Resistant Flight model available from Intralox, LLC of
Harahan,
LA.
[0084] The flights 216 can vary in size to accommodate the transport of more
or less
coating, although in one embodiment, the flights 216 are 6 inches by 6 inches.
Further,
the flights 216 can be oriented at various angles with respect to the inner
and outer side
portion 213, 215, and the bottom portion 217, although in one embodiment the
flights
216 are oriented perpendicular to each of the inner and outer side portion
213, 215, and
the bottom portion 217. Further, the flights 216 can be situated such that
free ends
thereof are perpendicular to and point toward the outer side portion 215.
[0085] In an exemplary embodiment, the recycle conveyor 210 is in a
rectangular
configuration having four corners, where one of the corners includes a
sprocketed drive
209 that engages the cogs of the drag-chain belt 214, and the other three
corners have
drive belt rollers 211 for guiding the abutted drag-chain belt 214, to form a
rectangular
shape. The sprocketed drive 209 is received on a drive shaft (not shown). An
overhung
load adaptor (not shown) and a conveyor motor (shown in Fig. 12 as 307), such
as a
hydraulic or electric motor, are used to rotate the drive shaft. Additionally,
the use of a
rectangular shaped recycle conveyor 210 permits the drag-chain belt 214 to be
wrapped
around the apparatus 2, thereby allowing a reduction in the overall footprint
of the
apparatus 2. Although the recycle conveyor 210 is shown and described as
rectangular,
other configurations can be used as well, for example, circular or square.
[00861 Further referencing Fig. 9, the conveyor channel 212 includes an upper
length
218, a lower length 220, an ascending portion 222, and a descending portion
224. The
upper length 218 includes a channel opening 202 in the conveyor channel 212
configured
to allow recycled coating to flow from the conveyor channel 212 onto a surface
below,
such as the loading surface 88 or a food product top surface.
[0087] With the coating recycle assembly 200, the coating is initially fed
into the fill
hopper 204 where it is carried by the drag chain belt 214 up the ascending
portion 222
and across the upper length 218 of the coating recycle assembly 200. It is
then deposited
through a base channel opening 202 in the center of the upper portion of
conveyor
channel 212. Coating that passes through the base channel opening 202 can be
collected
in a feed hopper 94 (Fig. 7) or the coating can proceed directly to the
loading surface 88
or the loading plateau 58, as discussed below. The coating flow can then be
metered out
23
CA 02697897 2010-06-02
of the feed hopper 94 by an adjustable opening (not shown) where it can be
directed into
a distribution portion such as channels (not shown) and a trough (not shown).
The
distribution portion can deposit substantially equal amounts of coating onto
each side of
the loading surface 88, wherein the coating is then spread across the width of
the loading
surface 88 by the use of a transverse distribution means (not shown) and/or
with the
assistance of a conveying device such as an auger (not shown). The coating is
then
carried forward by the vibratory action and moves up the ramp portion 54 (as
seen in Fig.
6) and down the drop portion 56 until it reaches the discharge end 59 (Fig. 6)
of the pan
assembly 6 (Fig. 6) and is deposited into the lower length 220 of the recycle
conveyor
210.
[00881 In another embodiment as shown in Fig. 11, a coating recycle assembly
200A
is provided that can include a fill hopper (not shown) and a base recycle
conveyor 210A.
The base recycle conveyor 210A has a channel opening 202A to provide a flow of
coating into a containment chamber 225A situated adjacent to the loading
surface 88 (not
shown). The containment chamber 225A includes three barrier walls 228A that
extend
from the channel opening 202A towards the loading surface 88. The barrier
walls 228A
are combined with a partial dam wall 221A and a chamber opening 230A to form a
perimeter about the containment chamber 225A. The chamber opening 230A can be
metered with a chamber dam 232A. The chamber dam 232A is movably attached to
the
partial dam wall 221A, wherein the chamber dam 232A can be positioned closer
or
farther away from the loading surface 88 to open or close the chamber opening
230A
thereby metering the amount of coating that exits the containment chamber 225A
onto
the loading surface 88. Further referencing Fig. 11, the base recycle conveyor
210A
includes a drain trap 245A. The drain trap 245A provides an exit path for
removing
coating situated in the base recycle channel 21 OA. The drain trap 245A
includes a drain
barrier 248A that is slidingly adjustable to allow the recycle coating in the
conveyor
channel 212A to flow out of the conveyor channel 212A only when desired.
[00891 Although some processes can use a single recycle conveyor 210A to
provide
coating to a food product, other processes can benefit from the use of more
than one
recycle conveyor 210A. The use of multiple conveyors provides added
flexibility to the
apparatus 2 to provide coating at various positions along the pan assembly 6
and on
various surfaces of the food product. For example, as shown in Fig. 12, an
exemplary
24
CA 02697897 2010-06-02
coating recycle assembly 200B can include a fill hopper (not shown), a base
recycle
conveyor 210A and a waterfall recycle conveyor 2lOB. In one at least one
embodiment,
the base recycle conveyor 21 OA utilizes a containment chamber 225A to provide
a
supply of coating to the loading surface 88 (see Fig. 6), for covering at
least the bottom
portion of the food product. In addition, the waterfall recycle conveyor 210B
includes a
containment chamber 225B to provide a supply of coating via a chamber opening
230B
adjacent the loading plateau 58 (see Fig. 6) to cover at least a top portion
of the food
product. Alternatively, the coating that exits the chamber opening 230B can be
deposited onto a waterfall ramp 252B (see Figs. 10 and 13). The waterfall ramp
252B
provides a planar surface for receiving the coating. The waterfall ramp 252B
extends as
necessary to direct the coating to fall upon the food product situated below,
for example
adjacent the pan assembly 6. The waterfall. ramp 252B is mounted to the pan
assembly 6
and as a result, is subjected to the vibration of the pan assembly 6. The
waterfall ramp
252B can be mounted at a descending angle, such that the vibrations cause the
coating,
situated thereon, to flow along and off the waterfall ramp 252B in a waterfall
manner to
provide a wall of coating as the food product is passed underneath. In another
embodiment, a sifting plate (not shown) can be situated below the waterfall
channel
opening 202B or the chamber opening 230B to at least partially catch the
coating, with
the sifting plate being secured to a portion of the apparatus 2 that vibrates,
such as the
pan assembly 6. In one embodiment the sifting plate is rectangular with a
plurality of
slots therethrough. The sifting plate can be inclined so as to act as a dam
allowing the
coating that falls thereon to spread more evenly, and in at least one
embodiment can
provide a metered distribution.
[00901 As discussed previously, coating that does not adhere to the food
product is
discharged at the discharge end 59 of the pan assembly 6. Discharged coating
can flow
into either the base recycle conveyor 21OA or the waterfall recycle assembly
210B to be
recycled. As the demand for coating can vary between the containment chambers
225A
and 225B, a metering plate 254 (Fig. 13) is situated adjacent the discharge
end 59 of the
pan assembly 6. The metering plate 254 can comprise of a planar meter portion
256 that
has a meter opening 258 therein, controlled by a sliding planar meter plate
260. The
meter plate 254 receives the coating at the discharge end 59 and can direct at
least a
portion of it, over the waterfall recycle conveyor 210B and into the base
recycle
CA 02697897 2010-06-02
conveyor 210A. The metering is provided by moving the metering plate 254 in
position
to cover or uncover the meter opening 258.
[00911 When utilizing the base recycle conveyor 210A and the waterfall recycle
conveyor 210B in combination, the coating recycle assembly 200B can use a
single
conveyor motor 262B to drive both drag-chain belts and use a single fill
hopper 204B (as
shown in Fig. 14 mounted on a waterfall recycle conveyor 210B). Although, in
at least
some embodiments, separate conveyor motors 262B can be used to drive each of
the
drag-chain belts (Fig. 13) and the fill hopper 204B can be situated on one or
both of the
conveyors 210A and 210B. Additionally;, an auxiliary hopper/conveyor 264B can
be
used to supply coating to the fill hopper 204B, as seen in Fig. 14.
[00921 The aforementioned coating recycle assemblies 200, 200A and 200B can be
used with an apparatus 2 that includes a wire conveyor belt assembly 400 (see
Figs. 15A
and 15B) as described below. The coating of fragile food products that can not
endure
the rigors of traveling along the steps of the pan assembly 6 can be
accommodated by the
wire conveyor belt assembly 400. Further, the use of wire conveyor belt
assembly 400
can allow for the application of a coating or topping to only a top or bottom
portion of
the food product. In at least one embodiment, when the wire conveyor belt
assembly 400
is used with the coating recycle assembly 200B, the base recycle conveyor 210A
can
provide a fresh or recycled supply of coating to a loading surface of the wire
conveyor
belt assembly 400 for coating at least a bottom portion of a food product, and
the
waterfall recycle conveyor 210B can provide fresh or recycled coating to at
least a top
portion of a food product situated on the wire conveyor belt assembly 400. An
exemplary embodiment of the wire conveyor belt assembly 400, as seen in Figs.
15A and
15B, includes a proximal end 401 for the intake of coating and food product
and a distal
end 405 for offloading the food product. The wire conveyor belt assembly 400
further
comprises a housing 403, a wire conveyor belt 402 and a drive shaft 404 for
actuating the
belt 402. Various rollers are included such as support rollers 408 and a hold
down roller
410 for altering the path of the belt 402. Additionally, an adjustable roller
412 is
included to take up slack in the belt 402. Further, a roller 414 is moveably
received in an
arcuate groove 416 of a sidewall 418 of the housing 403, as described below.
The wire
conveyor belt assembly 400 also includes two roller cylinders 426 situated
above the belt
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CA 02697897 2010-06-02
402 to press coating and/or topping onto the food product as it passes along
the wire
conveyor belt 402.
[00931 Further, the wire conveyor belt 402 includes an upper conveying surface
422
and a lower conveying surface 424. The arcuate groove 416 allows reorientation
of the
upper conveying surface 422 with respect to the lower conveying surface 424
and thus,
reorientation of the wire conveyor belt 402. Placing the roller 414 at the
upper end of the
arcuate groove 416 results in the food product moving off the upper conveying
surface
422 and landing on the lower conveying surface 424 with the side of the food
product
that contacted the upper conveying surface 422 now being opposite the side of
the
product that contacts the lower conveying surface 424. That is, the food
product is
flipped when it transfers from the upper conveying surface 422 onto the lower
conveying
surface 424. A benefit of flipping the food product is that when coatings or
toppings are
lightweight and airy materials, such as flour, flipping food product removes
unattached
coatings or toppings. As seen in Fig. 15A, in at least one embodiment the wire
conveyor
belt assembly 400 includes a belt support pan 420 situated underneath a
portion of the
lower conveying surface 424. The belt support pan 420 provides support to the
wire
conveyor belt 402 and to the coating that is situated under the wire conveyor
belt 402.
As the wire conveyor belt 402 travels along, it carries at least a portion of
the coating
situated underneath.
[00941 To provide an apparatus 2 that is capable of universally and
selectively
applying coatings and toppings to one or more portions of both durable and
fragile food
products, an exemplary apparatus 2 can include the wire conveyor belt assembly
400,
wherein the wire conveyor belt assembly 400 is at least partially removably
situated in a
position that is adjacent the pan assembly 6, as discussed below. Referring to
Figs. 16
and 22 (the vibratory frame assembly 4 and pan assembly 6 are not shown for
clarity
purposes), in an exemplary embodiment, the wire conveyor belt assembly 400 is
suspended by a swing frame portion 500 to create a wire belt swing assembly
501. The
swing frame portion 500 can be secured to a separate swing frame 506 or to at
least one
of the frames 10 and 306 (Figs. 5 and 12, respectively). The swing frame
portion 500 is
configured to support the wire conveyor belt assembly 400 such that it is
isolated from
vibrations of the vibratory frame assembly 4 and pan assembly 6. The wire
conveyor
belt assembly 400 is suspended by the swing frame portion 500 with arms 502 on
either
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CA 02697897 2010-06-02
side. The arms 502 are hinged at both the swing frame portion 500 and at the
wire
conveyor belt assembly 400. In reference to Figs. 16 and 22, the arms 502 are
hinged at
ends of proximal and distal transverse supports 508, 510, which are supported
on the
upper side members 512, 514 by brackets 516. The arms 502 have a geometry that
allows the wire conveyor belt assembly 400 to swing out of an operating
position (Fig.
16) and into a non-operation position (as shown in Fig. 21). The swinging
motion can be
powered by a hydraulic cylinder 518, a pneumatic cylinder, or the like. The
hydraulic
cylinder 518 is connected to a torque arm 520 and then to a lever shaft 522
that makes up
one of the upper hinge points. The lever shaft 522 transmits torque into one
set of the
arms 502 to create a motion that swings the wire conveyor belt assembly 400
into the
non-operating position. The motion could also be accomplished using a rotary
actuator,
an electromechanical jack, or similar devices.
[0095] Referring to Figs. 13 and 18, the wire belt swing assembly 501 can be
utilized
with one of the various coating recycle assemblies 200A, 200B. Additionally,
the wire
belt swing assembly 501 can be utilized in conjunction with a combination of
the coating
recycle assembly 200A, 200B, the vibratory frame assembly 4 and the pan
assembly 6.
Further, the wire belt swing assembly 501 can be configured such that the wire
conveyor
belt assembly 400 can swing in and out of a production position without making
contact
with other equipment, such as the coating recycle assembly 200A, 200B, the
vibratory
frame assembly 4 and pan assembly 6.
[0096] In at least one embodiment, the recycle assembly 200B and the wire belt
swing assembly 501 can be secured to the frame 10 of the vibratory frame
assembly 4,
and used in conjunction with the pan assembly 6 (Fig. 13). This provides the
apparatus 2
with the versatility to apply a multitude of coatings, breading and toppings
to numerous
types of food products. For example, as shown in Fig. 17, the wire conveyor
belt
assembly 400 can be placed in a non-production position to enable unfettered
use of the
pan assembly 6, for coating multiple sides of durable food products, as
previously
described. In this position, the base recycle conveyor 210A is used to convey
coating to
the loading surface 88 via the base containment chamber 225A. As the food
product and
coating are moved by vibratory action across the pan assembly 6, the food
product is
coated. Discarded coating that reaches the discharge end 59 of the pan
assembly 6 is
deposited into the lower length 220A of the base recycle conveyor 21 OA by
adjusting the
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CA 02697897 2010-06-02
metering plate 328 (Fig. 13) so that the coating avoids the waterfall recycle
conveyor
21OB. Additionally, although not necessary, the waterfall recycle conveyor
210B can be
used to provide additional coating onto the food product if desired and can be
subsequently recycled as well by adjusting the metering plate 328.
[0097] Alternatively, the wire conveyor belt assembly 400 can be situated in a
production position to substantially by-pass the steps 36 of the pan assembly
6. This
position can be used for coating less durable food products that cannot
tolerate the
agitation of the steps 36. Additionally, this position allows selective
coating of the top
and/or bottom portions only of the food product. When using the wire conveyor
belt
assembly 400, the pan assembly 6 is modified to facilitate moving coating onto
the
proximal end 401 of the wire conveyor belt assembly 400 (Figs. 15A and 15B),
as
opposed to the steps 36 (Fig. 6). The pan assembly 6 is also modified to catch
and
remove unwanted portions of food product and coating that fall off of the belt
support
pan 420. To load coating onto the wire conveyor belt assembly 400, the
proximal end
401 is situated such that coating will be deposited thereon, instead of
continuing along
the steps 36 of the pan assembly 6. In one embodiment, step 36 that is part of
or
succeeds the loading plateau 58 (see Fig. 6) can be removed, to allow the
proximal end
401 of the wire conveyor belt assembly 400 to be inserted under the loading
plateau 58.
In another embodiment as seen in Fig. 13, a modified step 36A having a loading
plateau
58A can replace the step 36, wherein the modified step 36A is similar to the
first series
of steps 36 with the exception that the loading plateau 58A extends as to
allow the
proximal end 401 of the wire conveyor belt assembly 400 to be positioned
underneath
the loading plateau 58 and in position to receive coating that is vibrated off
the loading
plateau 58.
[0098] While the wire conveyor belt assembly 400 is operating the pan assembly
6,
situated underneath, acts to catch and remove portions of food product and
coating that
fall off the belt support pan 420 and through the drag-chain belt 214. In one
embodiment, the perforated step(s) 38 of the pan assembly 6 can be removed and
replaced with one of various filtering configurations to accommodate a
particular size
and texture of breading, although the perforated steps 38 can also be utilized
to provide
the filtering. In addition, other steps or trays can be utilized along the pan
assembly 6 to
provide filtering. The coating that falls through the filtering configuration,
such as the
29
CA 02697897 2010-06-02
perforated steps 38, is vibrated towards the discharge end 59. Coating at the
discharge
end 59 is then vibrated across or through the metering plate 328 and into at
least one of
the base recycle conveyor 210A and waterfall recycle conveyor 210B. The larger
agglomerations of coating and food product that have been separated from the
recycled
coating are vibrated across the top of the perforated steps 38 and deposited
into a waste
receiver (not shown). Further, the aforementioned apparatus 2, without the
wire belt
swing assembly 501, can be used with the coating recycle assembly 200, 200A,
200B as
a stand alone food coating apparatus. Alternatively, the apparatus 2 can be
used with the
coating recycle assembly 200, 200A, 200B and the wire belt swing assembly 501,
to
form a multi-use coating apparatus 2.
[00991 Although the aforementioned embodiments are used in the majority of
product coating applications, another exemplary embodiment of the apparatus 2
with
both the vibratory frame assembly and the pan assembly bisected by a drum
assembly,
can be suitable when a specific coating. appearance on a product is desired.
Toward this
end, the apparatus 2' is depicted in Figs. 19A-27, wherein like reference
numerals,
including the use a prime (') or double-prime (") symbol thereafter,
correspond to like
elements in previously discussed embodiments.
[01001 Referring to Figs. 19A and 20, the apparatus 2' includes a feed
assembly 3', a
drum assembly 5', a discharge assembly 7", and a coating recycle assembly
200A' (see
Fig. 11 for more detail). In general, products and a coating are deposited at
an inlet end
55' of the feed assembly 3' where some of the coating is applied to the
products, and the
coating and products are funneled/guided into the drum assembly 5' via
vibratory
motion. The drum assembly 5' further applies the coating to the products via a
rotational
action. The coated products are then discharged from the drum assembly 5' onto
the
discharge assembly 7', wherein the coated products are separated and/or
aligned, via
vibratory motion, for further processing by hand or other machines and
subsequently
discharged at a discharge end 59'. In addition, excess/unused coating is
removed by the
discharge assembly 7' and received by the coating recycle assembly 200A',
wherein the
recycled coating is conveyed to the feed assembly 3' and reused.
[01011 Further referring to Fig. 19A, the drum assembly 5' and discharge
assembly
7' are configured to allow the products to enter and exit the apparatus 2' at
approximately the same elevation. This configuration obviates the need for
another
CA 02697897 2010-06-02
piece of equipment to elevate products from a lower discharge height back to
the input
height elevation to continue along a processing line. Although the apparatus
2' depicted
in Fig. 19A is configured to discharge the coated product (at the discharge
end 59') at
approximately the same elevation as the inlet end 55', the apparatus 2' can be
configured
to exit the coated products at an elevation that is higher than the inlet end
55' or lower
(as shown in Fig. 19B) to, for example, accommodate the requirements of
various types
of processing equipment.
[0102] As seen in Fig. 19A, similar to aforementioned embodiments, a frame 10'
and
isolators 12', 12" are utilized to provide support and isolation for various
components.
The feed assembly 3' and discharge assembly 7' utilize the isolators 12', 12"
and can be
secured to a single frame 10' or separate frames (not shown). In addition, the
drum
assembly 5' includes a drum frame 52' that can be secured to the frame 10' or
a separate
frame can be utilized as well. In addition, the coating recycle assembly 200A'
can be
secured to the frame 10' or utilize a separate frame.
[0103] Referring now to Figs. 21 and 22, the feed assembly 3' includes a
vibratory
frame assembly 4' in communication with a pan assembly 6'. Similar to
aforementioned
embodiments, the frame assembly 4' includes a pair of vibratory frame side
members
14', each with a motorized vibrator assembly 16' mounted thereon, a cross-
member (not
shown), and a plurality of spring assemblies 18'. Each motorized vibrator
assembly 16'
is adapted to impart energy to the vibratory frame side members 14' at an
angle 0' below
the horizontal (as shown in Fig. 21). In an exemplary embodiment, 3' ranges
from about
.15 degrees to about 60 degrees, for example, about 45 degrees. In another
exemplary
embodiment, angle (3' can range from 0 degrees to about 80 degrees, although
in other
embodiments 0' can vary more or less. The spring assemblies 18' are secured to
the pan
assembly at an angle 8' above the horizontal (as shown in Fig. 21). In an
exemplary
embodiment 0' can be between about 15 degrees and about 85 degrees, for
example,
about 45 degrees. Although in other embodiments, 0' can vary more or less. In
at least
one embodiment, the angle 0' can be substantially equal to the 90 degrees
minus angle
0'.
[0104] Further, the pan assembly 6' includes a pair of pan side portions 37'
having
secured therebetween, a loading surface 88', a loading ramp 21', and a
collector portion
25', wherein the pan assembly 6' is secured to the plurality of spring
assemblies 18' and
31
CA 02697897 2010-06-02
is imparted with vibratory motion via the spring assemblies 18'. As shown in
Fig. 22,
the collector portion 25' includes one or more collector walls 26', one or
more collector
ridges 27' and a chute 29' for directing products and coating.
[01051 Coating is deposited at the inlet end 55' of the feed assembly 3', more
particularly, on the loading surface 88' at the channel opening 202A' (see
Fig. 20) of the
coating recycle assembly 200A', and product is deposited on or adjacent to the
loading
ramp 21'. The vibratory motion of the pan assembly 4' moves the coating and
product
over the loading ramp 21' and onto the collector portion 25'. As the coating
and
products are vibrated, the coating is applied to at least a portion of the
product surface.
The coating and products are directed into the chute 29' by the biasing
created by the
ridges 27' and the abutment of the walls 26', each of which are aligned away
from the
pan side portions 37' and towards the chute 29'. The product and coating fall
into the
chute 29' with the chute 29' terminating at an outlet end 11' of the pan
assembly 4', and
the outlet end 11' is positioned to deposit the coating and product into the
drum assembly
5' (as seen in Fig. 19A). In one embodiment, the chute 29' is semi-circular,
although
other embodiments can include other shapes or configurations, for example, a
narrowing
flat sheet with sidewalls.
[01061 Referring again to Fig. 19A, the drum assembly 5' is shown positioned
to
receive the coating and product from the feed assembly 3' at a drum intake end
31' and
to discharge product and coating onto the discharge assembly 7' from a drum
discharge
end 32'. As seen in Figs. 23-25, the drum assembly 5' includes a drum 45' with
a ferris
wheel portion 3 5' at the drum discharge end 32'. Further, the drum assembly
5' includes
a drum drive motor 47' that drives a belt 49' that in turn rotates rollers 51'
on either side
of the drum 45' to rotate the drum 45'. In one embodiment, the drive motor 47'
is an
electric motor and two rollers 51' are situated about each side of the drum,
wherein the
motor 47' and rollers 51' are secured to a drum frame 52'. Although not
discussed in
detail herein, the drum 45' can be rotated using one of numerous other systems
known in
the art, for example, a hydraulic drive system. Further, with the exception of
the ferris
wheel portion 35', the drum 45' can be a typical breading drum as used in the
industry,
for example serial no. 120-3000E as manufactured by MP Equipment.
Additionally, the
drum 45' can include a tapered portion 33' at the drum intake end 31' to limit
the coating
and product from exiting the drum 45' via the intake end 31'.
32
CA 02697897 2010-06-02
[0107] As coating and product are introduced into the drum intake end 31' they
are
rotated inside the drum 45', wherein the drum 45' provides a rolling and
falling motion
to the product and coating resulting in various surface portions/folds of the
product being
exposed and pressed against the coating. As seen in Fig. 19A, the drum 45' is
situated at
a downward angle co' with respect to the horizontal, such that coating and
product move
from the intake end 31' towards the drum discharge end 32' as the drum 45' is
rotated.
In one exemplary embodiment, angle co' can range from about 1 degree to about
15
degrees, for example, about 5 degrees. In another exemplary embodiment, angle
co' can
range from 0 degrees to about 80 degrees, although in other embodiments, w'
can vary
more or less. Alternatively, although not discussed in detail herein, in at
least one
embodiment the drum 45' can be situated at an upward angle.
[0108] As the products and coating are being discharged from the drum 45',
they
enter the ferris wheel portion 35'. The ferris wheel portion 35' is provided
to lift the
product and coating from a lower elevation of the lowest point of the drum
discharge end
32' to a higher elevated entry point of the discharge assembly 7'. As
discussed above,
this allows the apparatus to discharge products and coating at approximately
the same
elevation as they are received. In at least some embodiments, where the
increase in
product elevation is not desired, the product and coating can be deposited
onto the
discharge assembly 7' directly from the drum 45' without the assistance of the
ferris
wheel portion 35', as shown in Fig. 19B.
[0109] Referencing Figs. 23 and 25, the ferris wheel portion 35' is secured to
the
drum discharge end 32' and includes a plurality of pockets 53' at least
partially formed
and separated by a plurality of panels 61'. As the drum 45' and ferris wheel
portion 35'
rotate, the coating and product are deposited in the pockets 53' situated at a
lower
elevation of the ferris wheel portion 35'. Subsequently, as the pockets 53'
rotate to a
higher elevation, the product and coating are released (via gravity) onto the
discharge
assembly 7'. The pockets 53' can include various shapes and contours designed
to assist
in accepting, separating, and discharging the products and coating.
[0110] In at least some embodiments, the drum assembly 5' includes a drum
slide
63' (see Fig. 19A) situated adjacent to the drum discharge end 32' for
receiving and
directing the products and coating that falls from the pockets 53'. The drum
slide 63'
deposits, via gravity, the received products and coating onto the discharge
assembly 7'.
33
CA 02697897 2010-06-02
Further, the drum slide 63' includes a slide bottom portion 91' that is shaped
to allow the
coated product to slide downwards towards the discharge assembly 7' while
maintaining
some degree of separation of the product, for example a flat shape, although
in other
embodiments, the slide bottom portion 91' can be shaped differently to
accommodate,
for example, various processing requirements. Further, any remaining portions
of the
drum slide 63' can be shaped and dimensioned to best contain and funnel the
coating that
becomes airborne as it falls from the ferris wheel portion 35'.
[0111] Referring to Figs. 26 and 27, the discharge assembly 7' includes a
vibratory
frame assembly 4" in communication with a pan assembly 6". Similar to
aforementioned embodiments, the frame assembly 4" includes a pair of vibratory
frame
side members 14" each with a motorized vibrator assembly 16" mounted thereon,
a
cross-member (not shown), and a plurality of spring assemblies 18". Each
motorized
vibrator assembly 16" is adapted to impart energy to the vibratory frame side
members
14" at an angle (3" below the horizontal (as shown in Fig. 21). In an
exemplary
embodiment, (3" ranges from about 15 degrees to about 30 degrees, for example,
about
22 degrees. In another exemplary embodiment, angle (3" can range from 0
degrees to
about 80 degrees, although in other embodiments, (3" can vary more or less.
The spring
assemblies 18" are secured to the pan assembly at an angle 0" above the
horizontal (as
shown in Fig. 21). In an exemplary embodiment 0" can be between about 15
degrees
and about 85 degrees, for example, about 68 degrees. Although in other
embodiments
0", can vary more or less. In at least one embodiment, the angle (3' can be
substantially
equal to the 90 degrees minus angle 0'.
[0112] Further, the pan assembly 6" includes a pair of pan side portions 37"
having
secured there between, a pan bottom portion 34", wherein the pan bottom
portion 34"
extends along an upper surface 79" to accommodate a load spreader 69" and then
extends downward to a lower surface 81 " to accommodate at least one of a
separator
tray assembly 71" and an alignment tray assembly 73". Similar to
aforementioned
embodiments, the tray assemblies 71 ", 73" can be self-contained and removable
to
facilitate cleaning of the apparatus 2'.
[0113] Referring to Figs. 26 and 27, the load spreader 69" is positioned about
the
upper surface 79" of the pan bottom portion 34" to receive the product from
the drum
assembly 5'. The spreader 69" is configured to spread the received product
along a
34
CA 02697897 2010-06-02
width of the pan bottom portion 34" as the product is conveyed along the pan
bottom
portion 34" by the vibratory motion. In at least one embodiment, the spreader
69"
includes a semi-conically shaped ramp 75, although other embodiments can
include
various other configurations to facilitate spreading the products apart from
each other.
[0114] Product and coating that is spread and vibrated along the upper surface
79"
of the pan bottom portion 34" is subsequently conveyed onto the separator tray
assembly
71" that is positioned above the lower surface 81". In at least one
embodiment, the
separator tray assembly 71 " has corrugations 83' that are oriented in an
outward
direction towards the pan side portions 37". These corrugations 83' provide
high and
low points that serve to separate the products apart from each other and
spread them
along the approximate width of the separator tray assembly 71 " as the
products and
coating are vibrated.
[0115] In addition to, or in place of, separating the products, the products
can also be
aligned. The alignment tray assembly 73" is situated above the lower surface
81" of the
pan bottom portion 34" and can replace or succeed the separator tray assembly
71".
Similar to the separator tray assembly 71 ", product and coating are vibrated
onto and
along the alignment tray assembly 73". In one embodiment, the alignment tray
assembly 73" includes corrugations 85" that are situated in parallel rows with
respect to
the pan side portions 37", the corrugations 85" align the coated product as it
is vibrated
along the alignment tray assembly 73". Further, the alignment tray 73" can
include tray
holes 86" that serve to allow coating not adhered to the products to be sifted
away from
the products. As discussed above, the separator tray assembly 71 " and
alignment tray
assembly 73" are both supported atop or above the pan bottom portion 34", this
allows
the lower surface 81 " of the pan bottom portion 34" to catch the coating
sifted by the
tray holes 86". Sifted coating that falls to the lower surface 81 " is
subsequently
vibrated into the lower portion 220A' (see Fig. 20) of the recycle conveyor
200A'. The
recycle conveyor 200A' conveys the sifted coating to the feed assembly 3' for
reuse.
[0116] Another exemplary embodiment of the apparatus 2 is depicted in Fig. 28
wherein product coating portion coating is applied to the food product using
vibrational
forces to move the food product and coating down a series of steps 36C. As the
food
product falls from an upper step 36C to a lower step 36C, the food product can
flip and
twist allowing folded portions of the food product to unfold. The unfolded
portions of
CA 02697897 2010-06-02
the food product are then exposed to the coating situated along the steps 36C,
thereby
allowing the application of coating to multiple surfaces of the food product
as it
progresses down the steps 36C. Similar to the aforementioned embodiments
discussed
above, the apparatus 2C provides a coating to a pan assembly 6C, wherein the
pan
assembly 6C is connected to a vibratory frame assembly 4C by spring assemblies
18C.
Motorized vibrator assemblies 16C are mounted on the vibratory frame side
members
612 to provide the vibratory energy. While this embodiment illustrates the use
of two
motorized vibrator assemblies 16C, a single motorized vibrator assembly 16C
may be
used. In all embodiments, one, two, or more vibrator assemblies 16C can be
used.
[01171 Further, in the embodiment shown in Fig. 28, the pan assembly 6C
includes a
continuous series of steps 36C. The number of step 36C can vary depending upon
the
food product being coated. In the exemplary embodiment shown in Fig. 28 there
are six
steps 36C. In addition, the vibrator assemblies 16C are mounted to impart
energy to the
vibratory frame side members 14C at an angle (3 below x-axis 13C. In one
embodiment,
this angle can be about 22.5 degrees, although other angles, such as about 45
degrees,
have been contemplated. Further, the spring assemblies 18C are mounted at an
angle 0
below the x-axis 13C that, in at least one embodiment, is substantially equal
to P.
[01181 In use, coating is provided to a feed hopper 94C as discussed below.
The
feed hopper 94C distributes the coating onto a loading surface 88C of a
metered
conveyor 106C. The metered conveyor 106C is also used to distribute the food
product
to a loading plateau 58C situated on the uppermost step 36C of the pan
assembly 6C.
Food product is deposited from the metered conveyor 106C onto the loading
plateau
58C. The vibrational forces. imparted on the pan assembly 6C move the food
product
forward along the uppermost step 36C. When food product travels to the end of
the
uppermost step 36C, it falls onto the next step 36C, that is, the next surface
of the pan
assembly 6C. Coating that has not adhered to the food product also moves along
the
steps 36C and coats the food product as both travel along the steps 36C. When
the
coated food product reaches the end of the pan assembly 6C, it is discharged
onto
another device, such as a discharge conveyor (not shown). The coating that has
traveled
along the pan assembly 6C that does not adhere to the food product is also
discharged.
The discharged coating can be removed as waste or it can be recycled using a
coating
recycle assembly 200C that includes a recycle conveyor 210C. The discharged
coating
36
CA 02697897 2010-06-02
is dropped into the recycle conveyor 210C directly or through a filter
component, such as
a scalping screen (not shown), and the recycle conveyor 210C transports the
coating to
the feed hopper 94C. A channel opening (not shown) in the recycle conveyor
210C
allows coating to be discharged from the recycle conveyor 210C into the feed
hopper
94C. In addition, in at least one embodiment, the recycle conveyor 210C can
deposit
coating directly onto the loading surface 88C thereby eliminating the feed
hopper 94C as
discussed above.
[0119] In an exemplary embodiment and as discussed above, the apparatus 2 can
apply coatings and toppings including but not limited to, flour, breading,
sugar, cheese
and spices, to food products, such as pizzas, vegetables, fruits, durable and
fragile meat
products, and confections. Additionally, in other embodiments, the apparatus 2
can be
suitable for applying various consistency coatings and toppings to various
food products.
Further, although an exemplary apparatus 2 has been described above with
respect to
coating food products, it has been contemplated that in other embodiments the
apparatus
2 can be used with non-food products as well, for example, applying non-food
particulates of varying size to the outside of a non-food product, for
example, applying
glitter to an ornament.
[0120] The components and sub-components of the aforementioned apparatuses 2
can be formed from metal, such as stainless steel, although it has been
contemplated that
other materials may be used such as plastic or mild steel with a protective
coating.
Further, the apparatuses 2 can be configured to be wider or narrower to
accommodate
space constraints and food production capacity requirements. Additionally, the
numerical ranges in this disclosure are approximate, and thus may include
values outside
of the range unless otherwise indicated.
[0121] In addition, all of the hydraulic and electronic components discussed
herein
can be controlled by a programmable device such as a programmable logic
controller
(PLC) or can be provided with various manual or automatic discreet controls,
for
example hand operated starters and drive controllers.
[0122] While this invention has been described in conjunction with the
exemplary
embodiments outlined above, various alternatives, modifications, variations,
improvements, and/or substantial equivalents, whether known or that are or may
be
presently unforeseen, may become apparent to those having at least an ordinary
skill in
37
CA 02697897 2010-06-02
the art. Accordingly, the exemplary embodiments of the invention as set forth
above are
intended to be illustrative, not limiting. Various changes may be made without
departing
from the spirit and scope of the invention. Therefore, the invention is
intended to
embrace all known or earlier developed alternatives, modifications variations,
improvements and/or substantial equivalents. It is specifically intended that
the present
invention not be limited to the embodiments and illustrations contained
herein, but
include modified forms of those embodiments including portions of the
embodiments
and combinations of elements of different embodiments as come within the scope
of the
following claims.
38
