APPARATUS AND METHOD FOR PREPARING A FOOD MATERIAL

Abstract

An apparatus for texturizing emulsified protein and/or carbohydrate containing food materials into a textured fibrous meat simulating product, said apparatus comprising a treatment assembly comprising: a first stationary disc having an inlet opening for receiving a food material slurry, a second stationary disc arranged underneath the first stationary disc with a predetermined distance between said first and second stationary discs defining a treatment space between the discs, wherein one or both of the first and second stationary discs are configured for being heated; and a rotary paddle wheel with spokes configured for rotating around a rotation axis, wherein the rotary paddle wheel is arranged between the first and second stationary discs for during rotation of the rotary paddle wheel transporting the slurry from the inlet opening to the periphery thereby heating and texturizing the slurry.

Claims

1. An apparatus for texturizing emulsified protein and/or carbohydrate containing food materials into a textured fibrous meat simulating product, said apparatus comprising a treatment assembly comprising: a first stationary disc having an inlet opening for receiving a food material slurry; a second stationary disc arranged underneath the first stationary disc with a predetermined distance between said first and second stationary discs defining a treatment space between the discs, wherein one or both of the first and second stationary discs are configured for being heated; and a rotary paddle wheel with spokes configured for rotating around a rotation axis, wherein the rotary paddle wheel is arranged between the first and second stationary discs for during rotation of the rotary paddle wheel transporting the slurry from the inlet opening to the periphery thereby heating and texturizing the slurry.

2. An apparatus according to claim 1, wherein the apparatus further comprises a collection channel provided peripherally around the treatment assembly for receiving the treated product being discharged between the discs.

3. (canceled)

4. An apparatus according to claim 1, wherein the diameter of the first and second, heated stationary discs is between 0.50 to 2.00 m, and the predetermined distance between the discs is between 5 to 50 mm.

5. An apparatus according to claim 1, wherein the rotary paddle wheel has a height, which is the same as the distance between the two discs.

6. An apparatus according to claim 1, wherein the rotary paddle wheel comprises spokes formed as cleats such that the food material is scraped and pressed whilst being transported from the inlet opening to the periphery of the discs.

7. An apparatus according to claim 1, wherein apparatus comprises at least one motor configured for rotating the rotary paddle wheel.

8. An apparatus according to claim 1, wherein the rotary paddle wheel is driven by a central drive shaft connected to a drive source.

9. An apparatus according to claim 1, wherein the rotary paddle wheel is a drive gear sprocket with at least one drive motor provided to engage the periphery of said wheel.

10. An apparatus according to claim 8, wherein the drive source and/or the drive motor(s) is/are speed-adjustable.

11. An apparatus according to claim 1, wherein one or both of the first and second stationary discs has/have heating elements configured for heating the first and/or second stationary discs to a temperature of 100-200° C. or 70-120° C. or 60-100° C.

12. An apparatus according to claim 1, wherein one or both of the first and second stationary discs has/have an inner heating element, surrounded by a first outer annular heating element, wherein the heating elements are configured for heating the first and/or second stationary discs.

13. An apparatus according to claim 12, wherein the inner heating element(s) is/are configured for heating an inner section of the first stationary disc and/or the second stationary disc comprising between 0 to 40% and 0 to 60% of the radius of the first stationary disc and/or the second stationary disc, wherein the first annular heating element(s) is/are configured for heating a first annular section of the first stationary disc and/or the second stationary disc surrounding the inner section.

14. An apparatus according to claim 12, wherein the inner heating element is configured for being heated to a first temperature, and wherein the first outer annular heating element is configured for being heated to a second temperature, wherein second temperature is lower than the first temperature.

15. An apparatus according to claim 14, wherein the first temperature is 80-120° C., wherein the second temperature is 60-100° C.

16. An apparatus according to claim 14, wherein the first temperature is 60-100° C., wherein the second temperature is 55-85° C.

17. An apparatus according to claim 1, wherein the inlet opening comprises an inlet heating element configured for heating the inlet opening.

18. An apparatus according to claim 1, wherein a multiple set of stationary discs and a multiple set of rotary paddle wheels mounted over the other on a common central shaft.

19. An apparatus according to claim 1, wherein the inlet opening is positioned off the rotation axis of the rotary paddle wheel.

20. An apparatus according to claim 1, wherein the rotary paddle wheel comprises a first rotary paddle wheel with first spokes, and a second rotary paddle wheel with second spokes, wherein the second rotary paddle wheel has an annular shape and the first rotary paddle wheel is configured to rotate inside the second rotary paddle wheel.

21. An apparatus according to claim 20, wherein the first rotary paddle wheel and the second rotary paddle wheel are configured to rotate in opposite directions.

22. An apparatus according to claim 20, wherein the apparatus comprises a drive source configured for driving the first rotary paddle wheel by a central drive shaft and/or a drive motor configured for engaging and rotating a drive gear sprocket of the second rotary paddle wheel.

23. An apparatus according to claim 20, wherein the first rotary paddle wheel has an first outer diameter and the second rotary paddle wheel has an second outer diameter, wherein the first outer diameter is between 20% and 60% of the second outer diameter.

24. An apparatus according to claim 20, wherein the first spokes have first leading edges and the second spokes have second leading edges, wherein the first leading edges and the second leading edges are pushing the slurry when the first and second rotary paddle wheels are rotating, wherein the first leading edges form a first angle when the first leading edges intersect a radius originating in the rotation axis, wherein the second leading edges form a second angle when the second leading edges intersect the radius, wherein the first angle is greater than the second angle.

25. An apparatus according to claim 24, wherein first leading edges are convex.

26. A method of texturing an emulsified protein and/or carbohydrate containing food materials into a textured fibrous meat simulating product, said method comprising the steps of: supplying a food material slurry through an inlet opening of a first stationary disc, which is arranged on top of a second stationary disc arranged underneath the first stationary disc with a predetermined distance between said first and second stationary discs defining a treatment space between the discs, wherein one or both of the first and second stationary discs being heated; and compressing and heating the supplied food material slurry in the treatment space between the first stationary disc and the second stationary disc by rotating a rotary paddle wheel around a rotation axis with spokes arranged between the first and second stationary discs for transporting the slurry radially outwards from the inlet opening of the discs to the periphery while heating the slurry and thereby texturizing the slurry and obtaining a textured product at the periphery of the discs.

27. (canceled)

28. A method according to claim 26, whereby said inlet opening being in the central portion of said first stationary disc.

29. (canceled)

30. A method according to claim 26, whereby the rotary paddle wheel is placed between the two horizontally positioned heated stationary discs.

31. (canceled)

32. A method according to claim 26, whereby the method further comprises the step of controlling the rotating speed of the rotary paddle wheel and temperature of the stationary discs for the product to be sufficiently shifted and heat treated to have the textured fibrous meat simulating structure and colour.

33. A method according to claims 32, whereby the rotary paddle wheel is rotated with a speed of 5 to 30 rpm, and/or whereby one or both of the first and second stationary discs is/are heated to a temperature of 100-200° C. or 70-120° C. or 60-100° C.

34. (canceled)

Description

DESCRIPTION OF DRAWINGS

[0046] In the following the invention is described with reference to the accompanying drawings, in which

[0047] FIG. 1 is a perspective view of a disc assembly in an apparatus for texturizing according to an embodiment of the invention;

[0048] FIG. 2 is a cross-sectional side view of the disc assembly of FIG. 1;

[0049] FIG. 3 is a side view of a rotary texturizing apparatus with the disc assembly of FIGS. 1 and 2;

[0050] FIG. 4 is a top view of same;

[0051] FIG. 5 shows a rotary paddle wheel according to one embodiment of the invention;

[0052] FIG. 6 shows a rotary paddle wheel according to another embodiment of the invention;

[0053] FIG. 7 shows how the material is transported by the rotary paddle wheel;

[0054] FIG. 8 is a side view of a second embodiment of a rotary texturizing apparatus according to the invention;

[0055] FIG. 9 is a detailed perspective view of the rotary texturizing apparatus of FIG. 8;

[0056] FIG. 10 shows a rotary paddle wheel according to another embodiment of the invention; and

[0057] FIG. 11 shows a first stationary disc with an inlet opening offset from the rotation axis of the rotary paddle wheel.

DETAILED DESCRIPTION OF THE INVENTION

[0058] With reference to FIGS. 1 and 2, the rotary texturizing apparatus for texturizing emulsified protein or carbohydrate containing food materials into a textured fibrous meat simulating product comprises a disc assembly wherein the treatment of the food material takes place. The disc assembly comprises a first stationary disc 1, a second stationary disc 2, which is arranged concentrically underneath the first stationary disc 1 with a predetermined distance between the first and second stationary discs 1, 2. In the first stationary disc 1 there is provided an inlet opening 4 for receiving a food material slurry in the central region of the discs 1, 2.

[0059] The distance between the discs 1, 2 defines a treatment space between the discs 1, 2. In this space, a rotary paddle wheel 3 rotatable around a rotation axis is arranged between the first and second stationary discs 1, 2 for transporting the slurry from the centre of the discs 1, 2 to the periphery while heating the slurry food material, which is thereby being texturized.

[0060] The first and second stationary discs 1, 2 and the rotary paddle wheel 3 can be concentrically arranged on a centre shaft 6. The discs 1, 2 are arranged in a frame 11. The rotation axis and the centre shaft can be coincident.

[0061] The first and second stationary discs 1, 2 and the rotary paddle wheel 3 can be removably attached so that the first and second stationary discs 1, 2 and the rotary paddle wheel 3 can be easily removed for cleaning.

[0062] At least one of the first and second stationary discs 1, 2 are heated. In the embodiment shown in FIGS. 1, 3 and 4, the heat treatment is developed by heating both the stationary top and bottom discs 1, 2. The discs have a heating jacket, which can be heated by any heat source, but preferably by hot oil or steam. As shown in the figures, the first stationary disc 1 is provided with a heating media inlet 7 and a heating media outlet 8. The heating media may be heated oil heated to a temperature of up to 180° C. This temperature and supply of heating media may be controlled to ensure that the temperature across the heated discs 1, 2 can be adjusted for either keeping a constant temperature, or a controlled increase or decrease in temperature. The temperature during the texturizing is typically in the range of 100 to 200° C., preferably around 120° C. After some tests, it has turned out that the best results are actually achieved in the range of 70 to 120° C., preferably around 80° C., which also means a lower power consumption.

[0063] Around periphery of the second stationary disc 2, a collection channel 5 provided for receiving the treated product which is peripherally discharged from the treatment space between the discs 1, 2 by the rotation of the paddle wheel 3. In the embodiment of FIGS. 1-4, the paddle wheel 3 is provided with a toothed periphery 31 which is engaged by a drive system comprising a gear drive sprocket connected via a gear box 10 to an electric motor 9. In the embodiment shown in FIGS. 3 and 4, three sets of drive systems are arranged to rotate the paddle wheel 3.

[0064] In other embodiments, the rotary paddle wheel 3 is driven by a centre shaft 6 and shaft mounted gearbox 12 as shown in FIG. 8.

[0065] The rotary texturizer process is based on transferring mechanical and thermal energy into a meat emulsion in order to coagulate the protein and any potential sources of carbohydrate. This makes it possible to transform simple, meat-based formulas into a much textured meat-alike product. The emulsified composition is pumped from a mixing or storage tank (not shown) with low pressure by a positive pump, such as a slurry pump or a sausage filler, into the infeed opening 4 around the centre between the two horizontally positioned heated static discs 1, 2, which in a preferred embodiment have a diameter between 0.5 to 2.0 meter, preferably approx. 1.0 meter.

[0066] The slurry is fed-in through an opening 4 in the top disc 1 in or around the centre of the disc 1.

[0067] Between the two stationary discs 1, 2 the rotary paddle wheel 3 is provided with spokes 32 (see FIGS. 5 to 7) between the wheel hub 36 and the wheel rim 35. On the spokes 32 there are provided specially formed cleats 34, 37 e.g. of different height up to the distance between the two discs 1, 2, according to the required result of the finished textured product and/or the viscosity of the slurry composition. On the spokes, inner scraper cleats 37 of one type and one or more outer scraper cleats 34 may be arranged.

[0068] The cleats 34, 37 in the paddle wheel 3 are designed and positioned on the spokes 32 to receive and grasp the slurry from the infeed opening 4 in an infeed area 33 and intermittent transport, by scraping the product from the centre of the discs 1, 2 towards the periphery and discharge into the collection channel 5 placed around the treatment assembly. As the product during the interrupted transport is heat treated and at the same time the product is mechanically worked and shifted, which develop the structure of the textured fibrous simulated meat.

[0069] When the slurry is fed through the infeed or inlet opening 4 in the top disc 1, in or around the centre of the disc 1 and become in contact with the heated disc 1, 2, it expand slightly and is compressed by the rotation of the cleats 34, 37, whereby the emulsified slurry is worked and shifted, so it will be in contact and heated by both the top and bottom disc 1, 2.

[0070] The infeed opening 4 in the top disc 1 is preferably a little off the rotation axis so that the spokes can immediately act on the slurry when the slurry enters the paddle wheel 3 through the inlet opening 4. That the infeed opening 4 is a off the rotation axis means that the infeed area 33 will also be off the rotation axis.

[0071] The distance between the top and bottom heating discs 1, 2 is the same as the height of the cleats 34, 37. This distance can varied according to the composition of the slurry and final product, by replacing the cleats 34, 37 or the entire wheel with a higher wheel. This distance between the two heating discs 1, 2, being the same as the heights of the cleats 34, 37 on the rotary paddle wheel 3 is from 10 to 50 mm, preferably between 20 to 30 mm.

[0072] In the embodiment, where the paddle wheel 3 can comprise the toothed periphery 31, the toothed periphery can be connected to the distal end of the spokes 32 seen from the centre shaft 6 or the rotation axis of the paddle wheel. Where the toothed periphery and the spokes 32 connect, the toothed periphery and the spokes 32 will form a circle with an inside diameter. Preferably, the second stationary disc 2 has a circumferential edge with a diameter that is less than the inside diameter.

[0073] In an embodiment of the invention, the rotary paddle wheel 3 is preferably floating on the drive means, to give a certain pressure on the stationary bottom disc 2, as well as the stationary top disc 1 is preferably floating on the rotary wheel 3 to develop a low pressure on the wheel 3 and the product.

[0074] In another embodiment, however, the rotary paddle wheel 3 and the top disc 1 can have a mechanical stop to secure a minimum clearance and thereby less pressure on the product.

[0075] In an embodiment, the rotary wheel 3 turns with a speed between 5 and 30 rpm, preferably 10 and 15 rpm and is driven by a centre shaft 6 and shaft mounted gearbox.

[0076] Every composition of recipes will often require to be differently mechanical moved and stirred during the heat treatment, as well as different length (time) of treatment and different temperatures.

[0077] This can be adapted by the use of different wheels 3 with different shaped spokes 32 and cleats 34, 37 for smooth direct and continuous transport of the product over the heating discs 1, 2, or an interrupted intermittent transport controlled by the size, length, number and direction of the cleats 34, 37. Due to the direction of the cleats 34, 37, i.e. the positive and/or negative angle to the radius line, the product is pushed either in a forward or backwards direction. Thus, the design of the spokes 32 and cleats 34, 37 will control the transport time and how much the product is mechanically worked and shifted during the heating process.

[0078] Even in a situation where the direction of most or all of the cleats 34, 37 are positioned with negative angle, the product will still be forced outwards towards the edge of the discs 1, 2, due to the low constant pressure from the infeed product slurry and/or the centrifugal force.

[0079] The rotary texturizing process relies on constant flow/pressure and temperature as well as controllable rotation. All these parameters are controlled in an electrical control panel (not shown), which is part of the supply by means of a built in Micro-Processor/PLC-System connected to sensors at the production line collection flow-rate, pressure, rotation and temperature.

[0080] As mentioned above, the paddle wheels 3 can be designed to differently mechanically move and stir various recipes during the heat treatment, in order to control different handling, length (time) of treatment and various temperatures. In order to easily alter the design of the wheels 3, the paddle wheel 3 can be made in two half for easy for quick replacement, and also for easy cleaning.

[0081] In an advantageous embodiment, the paddle wheel 3 and the top disc 1 can be raised for cleaning purpose. A further advantage is that the rotary paddle wheel 3 can be made in two half, divided in the middle, in order to be removed quickly for cleaning.

[0082] The rotary texturizer according to the invention may advantageously also be provided with a “Clean in Place” system (also called a CIP system). Hereby, nozzles are provided in the stationary discs and connected via a high-pressure pump to a liquid reservoir, such as cleaning water, so that the entire inner space can be cleaned and disinfected automatically without having to disassemble the treatment assembly, i.e. lifting the upper stationary disc off. Instead cleaning liquid can be sprayed at high pressure and in suitable high volume through the material inlet. This cleaning operation could be performed at regular intervals.

[0083] With reference to the embodiment shown in FIGS. 8 and 9, a further advantageous embodiment of the invention is to have a multiple set of stationary discs 1′, 2′; 1″, 2″ and rotary paddle wheels 3′, 3″ mounted over the other on the same shaft 6 using the same feeder and collection of the finished product at the circumference of the unit. This will double, triple or more and bring the capacity up from 500 kg with a single rotary texturizer to 2000 kg per hour.

[0084] In FIG. 9 a detailed view of the heating assembly is shown with two sets of treatment assemblies, but where the first stationary disc 1′ of the uppermost set is removed. As shown in the figure, the there are two treatment assemblies, an upper assembly and a lower assembly. The upper comprising an upper rotary wheel 3′ on top of an upper second stationary disc 2′. The lower assembly similarly comprises a first stationary disc 1″, a second stationary disc 2″ and with a rotary wheel 3″ there between. The upper is surrounded by an upper collection tray 5′ and the lower assembly is provided with a lower collection tray 5″. The rotary wheels 3′ and 3″ are both driven by the centrally positioned vertical drive shaft 6, which is connected to the drive system 12 positioned on the top of the frame 11 (see FIG. 8).

[0085] Having a multiple set of stationary discs and rotary paddle wheels mounted over the other on the same shaft also give the advantage to mix finished product produced out of a different recipes fed into different levels of texturizing units and falling into the same collection bin, i.e. vegetable protein in one unit, ground meat in second and meat chunks in third unit.

[0086] FIG. 10 shows another embodiment of the texturizer, where the rotary paddle wheel comprises a first rotary paddle wheel 3a with first spokes 32a and a second rotary paddle wheel 3b with second spokes 32b, wherein the first rotary paddle wheel and the second rotary paddle wheel are concentric and rotating around the same rotation axis 51. The second rotary paddle wheel 3b having an annular shape surrounds the first rotary paddle wheel 3a. The first rotary paddle wheel 3a and the second rotary paddle wheel 3b are positioned in the same plane between a first stationary disc (not shown) and a second stationary disc 2. Preferably, the first rotary paddle wheel 3a and the second rotary paddle wheel 3b will have a thickness corresponding to the distance between the first stationary disc and the second stationary disc.

[0087] The second spokes 32b are attached to a toothed periphery 31, which is driven by in this embodiment three cogwheels 53 and motors 54. It is also possible to rotate the second rotary paddle wheel 3b by only one or two cogwheels and motors. The toothed periphery 31 has an inner diameter, where the toothed periphery 31 is attached to the second spokes 32b. The second stationary disc has a diameter less than the inner diameter thus defining an opening 56 in between, so that the textured food materials will be pushed and fall down through the opening 56 instead of being pushed over the toothed periphery 31, which would require that the toothed periphery 31 and the cogwheels 53 were cleaned more often. The food materials falling down through the opening 56 will be received by a collection channel (not shown).

[0088] The first rotary paddle wheel and the second rotary paddle wheel can be configured to rotate in the same direction at different rotational speeds. The first rotary paddle wheel can be configured to rotate in one direction and the second rotary paddle wheel can be configured to rotate in the opposite direction, which has turned out to effectively transport the food materials away from the inlet opening. The first rotary paddle wheel can be configured to rotate with a speed of 5 to 30 rpm, preferably 10 to 15 rpm. and the second rotating paddle wheel can be configured to rotate with a speed of 1-10 rpm.

[0089] Since the circular arc of a circle when the angle is kept unchanged increases in length when moving away from the centre of the circle, the area between the spokes of the rotary paddle wheel(s) increase too in the same direction. To keep the area or volume between the second spokes 32b filled with the food material it will beneficial to have the first rotary paddle wheel 3a configured to rotate faster than the second rotary paddle wheel 3b.

[0090] The first rotary paddle wheel 3a and the second rotary paddle wheel 3b can have all the features and advantages described above about the single rotary paddle wheel 3.

[0091] FIG. 11 shows the texturizer with a first stationary disc 1 placed on top of the rotary paddle wheel 3. The first stationary disc 1 has an inlet opening 4 positioned offset from the rotation axis of the rotary paddle wheel. With the inlet opening 4 positioned offset the slurry will fall down between two spokes of the rotary paddle wheel and easily be transported radially out. The offset inlet opening 4 can be combined with any embodiment of the rotary paddle wheel, where the rotary paddle wheel is driven by a drive source through a centre shaft 6, or where the rotary paddle wheel is driven by a drive motor through the periphery 31 of the rotary paddle wheel 3, or where the rotary paddle wheel has one or two the rotary paddle wheels.

[0092] Above, the invention is described with reference to some preferred embodiments. However, it is realised that other variant may be provided without departing from the scope of the invention as defined in the accompanying claims.