Crimper roller

Abstract

The present invention concerns an apparatus and method utilizing a crimping roller which itself comprises a plurality of radially extending separating blades, with each blade comprising a central triangular cutting edge and two sealing portions extending from opposing sides of the base of the triangular cutting edge.

Claims

1. A food product separating apparatus comprising a separating roller having a circular outer forming surface and a plurality of radially extending separating blades, each separating blade extending across a width of the separating roller, wherein each separating blade comprises a triangular cutting edge configured to form a cut in the food product and being centrally located between two sealing portions extending from opposing sides of the base of the triangular cutting edge, said sealing portions being shaped to compress a region of the food product immediately adjacent the cut, and wherein each separating blade is in the form of a plurality of alternating portions, wherein adjacent portions extend in alternating directions having an angle between 90 and 150 degrees between the adjacent portions so as to form a serrated or zig-zag profile to each blade.

2. The apparatus as claimed in claim 1, wherein each triangular cutting edge comprises corresponding alternating portions defining a serrated or zig-zag edge profile.

3. The apparatus as claimed in claim 1, wherein the radial extension of the triangular cutting edge measured from the base of the triangle is between 0.5 mm and 2.5 mm.

4. The apparatus as claimed claim 1, wherein the two sealing portions extending from the base of the triangular cutting edge extend between 0.2 mm and 2 mm from the point at which each sealing portion intersects with the base of the triangular cutting edge.

5. The apparatus as claimed in claim 4, wherein the sealing portions are each perpendicular to a radial axis passing from the centre of the roller through the centre line of the triangular cutting edge.

6. The An apparatus as claimed in claim 1, wherein the angle between each side face of the triangular cutting edge is between 30 degrees and 120 degrees.

7. The apparatus as claimed claim 1 further comprising a second roller against which the separating roller is arranged to rotate.

8. The apparatus as claimed in claim 7, wherein the centres of rotation of the separating roller and second roller are spaced by a distance that is equal to or less than the sum of the outer radius of the second roller and the outer radius of the separating roller measured to the tip of a triangular cutting edge.

9. The apparatus as claimed in claim 7, wherein the second roller comprises a flexible outer cutting surface against which the separating roller can rotate and which deforms as consecutive blades contact its outer surface.

10. A cereal manufacturing machine comprising the apparatus as claimed in claim 7, further comprising a foodstuff feed-line arranged in use to feed a stream of foodstuff between the rollers and to cause the separating roller and second roller to rotate in opposite directions with respect to one another to cause the stream of foodstuff to pass over the separating blades.

11. A method of manufacturing a co-extruded food product with a co-extruded food product separating apparatus comprising a separating roller having a circular outer forming surface and a plurality of radially extending separating blades, each separating blade extending across a width of the separating roller, wherein each separating blade comprises a triangular cutting edge configured to form a cut in the food product and being centrally located between two sealing portions extending from opposing sides of the base of the triangular cutting edge, said sealing portions being shaped to compress a region of the food product immediately adjacent the cut, and wherein each separating blade is in the form of a plurality of alternating portions, wherein adjacent portions extend in alternating directions having an angle between 90 and 150 degrees between the adjacent portions so as to form a serrated or zig-zag profile to each blade and a second roller against which the separating roller is arranged to rotate, said method comprising supplying a stream of food product between the separating roller and the second roller to form a plurality of individual food items from the stream of food product.

12. A co-extruded cereal manufacturing apparatus comprising a pair of opposing rollers which are arranged in use to rotate in opposing directions, at least one of said rollers comprising a plurality of cutting blades configured to cut a stream of foodstuff into a plurality of discrete parcels, wherein each cutting blade comprises: (a) a first radially extending portion defining a cutting edge arranged in use to cut and separate adjacent parcels; and (b) a pair of circumferentially extending edges on opposing sides of the first radially extending portion arranged in use to compress the foodstuff along an edge of the parcel to create a seal; and wherein each cutting blade has portions arranged at alternating angles creating a non-linear cut and seal for each of said parcels.

13. The co-extruded cereal manufacturing apparatus as claimed in claim 12, wherein the roller not comprising the features (a) and (b) itself comprises a plurality of radially extending contact surfaces which are arranged to align with the cutting blades of the opposing roller, and wherein adjacent blades and adjacent cutting surfaces on the respective rollers define forming spaces there-between for forming the body of the cereal product.

14. The co-extruded cereal manufacturing apparatus as claimed in claim 12, wherein each of the pair of circumferentially extending edges has portions arranged at alternating angles creating a non-linear seal for each of said parcels.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiment of the invention will now be described by way of example with reference to the following figures.

(2) In accordance with one (or more) embodiments of the present invention the Figures show the following:

(3) FIG. 1 shows a schematic of the manufacturing apparatus according to an embodiment of the invention;

(4) FIG. 2 shows a crimping roller according to an embodiment of the invention;

(5) FIG. 3 shows a single cutting tooth or blade of the crimping roller of FIG. 2;

(6) FIG. 4 shows a second roller for rolling contact with the crimping roller of FIG. 2;

(7) FIG. 5 shows the crimping roller and second roller in rotational contact;

(8) FIG. 6 shows an embodiment of the invention in which the teeth or blades of the crimping roller penetrate the second roller;

(9) FIG. 7A illustrates a fully and partially formed parcel according an embodiment of the invention as a cross-section side elevation view through the rollers and co-extruded tube;

(10) FIG. 7B illustrates a fully and partially formed parcel according to the invention as a cross-section vertical view from the cutting roller side of the apparatus;

(11) FIG. 8 shows a cross-section of a blade of the crimping roller; and

(12) FIG. 9 shows a breakfast cereal parcel or pillow manufactured according to the apparatus and method of the invention.

(13) Any reference to prior art documents in this specification is not to be considered an admission that such prior art is widely known or forms part of the common general knowledge in the field.

(14) As used in this specification, the words “comprises”, “comprising”, and similar words, are not to be interpreted in an exclusive or exhaustive sense. In other words, they are intended to mean “including, but not limited to”.

(15) The invention is further described with reference to the following examples. It will be appreciated that the invention as claimed is not intended to be limited in any way by these examples.

DETAILED DESCRIPTION

(16) FIG. 1 is a schematic of the manufacturing apparatus according to an embodiment of the invention.

(17) The invention is generally concerned (but not limited to) the manufacture of a food product formed of a plurality of individual parcels; flakes or pillows. An example of a product of this general type is a breakfast cereal such as Nestlé Chocapic® Coeur fondant containing cereal flakes and pillows (manufactured by Nestle) which is provided as a plurality of flakes which the consumer pours into a bowl.

(18) The apparatus and method of the present invention is not concerned with flakes but instead with parcels or pillows which have an outer edible layer surrounding an inner edible or hollow core.

(19) As shown in FIG. 1, the manufacturing apparatus incorporating the invention comprises an extruding machine. Such machines are commercially available and manufactured by, for example, Bühler of Utzwil (Switzerland). The extruding machine is equipped with a co-extruder die head (2) which discharges a continuous tube or ‘rope’ of co-extruded food.

(20) The internal operation of the extruding machine is well understood in the art but put simply: components formed as recipes are loaded into the extruder by means of a hopper 3 (or other supply means) and the materials are processed internally to form the extruded tube or rope.

(21) In a co-extruding process relevant to the present invention, generally two different components are introduced into the extruder and are processed such that the extruded tubular output from the co-extruder has one of the components forming an outer layer and the second component contained within the outer layer and forming a core to the tube or rope.

(22) In an alternative, the co-extruded product may comprise an edible layer and a hollow core. In this case, only one component is supplied to the extruder.

(23) FIG. 1 also shows the crimping roller 4 of the invention and an opposing second roller 5. The crimping roller 4 and second roller 5 are rotatable mounted and arranged to rotate in opposing directions as shown by the arrows in FIG. 1.

(24) The crimping roller 4 and second roller 5 have rotational centres that are spaced apart by a predetermined distance which is discussed further below.

(25) In operation the co-extruder generates the tube or rope comprising the outer layer and inner core which is conveyed by a conveyor belt (or other suitable means—not shown) so as to pass into between the crimping roller 4 and second roller 5.

(26) The rollers are configured to rotate such that the peripheral speed of each roller is substantially the same as the linear flow speed of the co-extruded rope passing between the two rollers. The rollers may be arranged to rotate by a conventional drive means.

(27) As the tube passes between the two rollers, the rollers are simultaneously rotating and the tube is crimped and divided into a plurality of discrete parcels or pillows 6.

(28) The term ‘crimped’ refers to the compression that leads to the sealing of the tube. It usually leads to a separation, but does not consistently and reliably cause separation.

(29) The distinction between cutting and crimping should be recognized. Cutting is purely separating the tube into separate portions i.e. cut but not sealed resulting in an ‘open end’ to the tube.

(30) Conversely crimping according to the present invention is a combination or hybrid of cutting and sealing in a simultaneous process. Doing so allows a zig-zag shape to be formed.

(31) The parcels or pillows 6 can be conveyed away from the rollers, again using a suitable conveyor belt or the like (not shown).

(32) Specific details of the crimping and sealing operation that occurs between the opposing rollers will now be described.

(33) FIG. 2 shows a crimping roller 4 according to the invention.

(34) The crimping roller is in the form of a circular disc extending in an axial direction to form a ring with an outer surface. The outer surface is provided with a plurality of radially extending separating blades 6 positioned on the outer surface of the ring.

(35) The total number of blades 6 and the spacing between adjacent blades depends on the size of the parcels that are to be manufactured and the desired speed of manufacture.

(36) The blades 6 will now be described in more detail with reference to FIG. 3.

(37) FIG. 3 is a close up view of a single blade of the crimping roller shown in FIG. 2.

(38) Each blade comprises 3 sub-portions when looking at the blade in cross-section: a pair of sealing surfaces for sealing the edges of adjacent parcels; a blade tip and triangle for causing cutting and separation of adjacent parcels; and a root portion extending from the outer surface of the roller shown in FIG. 2 to the base of the triangle.

(39) Starting from the most distal part of the blade (measured from the centre of the crimping roller) the tip 7C defines the outer most portion of the blade defining the cutting edge of the crimping roller. As shown the tip is the upper part of a triangle which extends to intersect with a pair of opposing sealing portions 7A and 7B.

(40) The tip may be a sharp edge but is advantageously truncated i.e. flat at the top to reduce the danger of operator injury when maintaining the machinery and for food safety reasons. Also, the truncated tip enhances the seal which is generated between adjacent parcels.

(41) The sealing portions 7A and 7B, as illustrated in FIG. 3, intersect with the sides of the triangle extending from the tip towards the sealing portions. At the intersection of sealing portions and triangle surfaces a small radius may be provided which prevents the co-extruded tube from adhering to each of the teeth.

(42) The root portion 7D spaces the base of the triangle and sealing surfaces from the outer surface of the crimping roller shown in FIG. 2.

(43) The height of the root portion i.e. the length measured from the crimping roller surface to the base of the triangle shown in FIG. 3 is determined by the desired position of the seal along either side of the cut between adjacent parcels. Consequently this distance is variable.

(44) FIG. 3 also shows the zig-zag profile of each blade as viewed across the width of the roller. As shown each blade 6 is in the form of a zig-zag or serrated shape with the length of the blade being divided into portions at alternating angles shown by reference sign A. The angle A may range between 90 degrees and 150 degrees.

(45) Adjacent portions of the blade extend either in a first circumferential direction of the roller or a second opposing direction of the roller. As can be seen in FIG. 3 the root portion 7D, sealing surfaces 7A, 7B and tip 7C all follow the same zig-zag or serrated path across the width of the crimping roller.

(46) The zig-zag extends across the width of the crimping roller. The width of the roller is dependent on the size of the parcels/pillows to be manufactured. For example, the roller may have a width which is a multiple of the diameter of the tube, by making the width a multiple the roller does not require and side walls. It also allows for lateral movement of the tube as it moves from the extruder to the rollers. Making the roller several times wider than the tube allows the tube to move around freely without falling from the sides of the roller.

(47) The number of alternating portions forming each blade and the angle A between each adjacent portion is dependent on the desired geometry of the edge of the parcel/pillow to be manufactured. The angle A of each blade portion defines the angle of the serrations or zig-zags forming the two opposing edges that are created by the crimping roller.

(48) The geometry of the tip and sealing surfaces is discussed in more detail with reference to FIG. 8.

(49) As discussed above with reference to FIG. 1, the crimping roller 4 is arranged to rotate against an opposing second roller 5 as shown in FIG. 4.

(50) FIG. 4 shows an embodiment of an opposing roller with a plurality of contact surfaces 8 arranged around the periphery of the roller 5. The surfaces 8 all located on the same radius from the central axis of the second roller thereby defining uniform surfaces which can contact the blades of the crimping roller (discussed below).

(51) The portions 9 between each adjacent cutting portion have a profile mirroring the surfaces between adjacent blades on the crimping roller. Similarly the height of each cutting portion 8 measured from the surface 9 can be selected to correspond to the height of the base portion described above with reference to the blades. Thus, a parcel can be created with mirrored upper and lower surfaces (as described below).

(52) In another embodiment the roller may have a continuously smooth outer surface i.e. a single continuous cutting surface as opposed to a plurality of individual and discrete surfaces shown in FIG. 4. This would result in parcels substantially flat on one side and bulbous or convex on the opposing side.

(53) The plurality of cutting surfaces 8 as shown in FIG. 4 are spaced at circumferential spacings B corresponding to the circumferential spacings of the blades on the opposing crimping roller.

(54) In use, the crimping roller and opposing roller are configured such that as the two rollers rotate the blades 6 align with the centres of the cutting surfaces 8, as described further below.

(55) The crimping roller and second roller may be formed of different materials. For example, the crimping roller may be formed of a stainless steel (or other non-corroding material) and the opposing second roller of a non-metallic material. Such a material combination advantageously prevents metal-to-metal contact which could contaminate food or result in metal fragments being created and deposited in food. It furthermore prevents wear and additionally allows for deformation of the second roller when in contact with the crimping roller (as discussed below).

(56) In an alternative arrangement two plastic material could be used, the crimping roller having a hardness greater than that of the second roller.

(57) The crimping roller and second roller may advantageously be geared together such that rotation of one automatically caused rotation of the second. This avoids the need for accurate rotational control of the two rollers independently.

(58) FIGS. 5 and 6 illustrate the interaction between the blades of the crimping roller and the cutting surfaces of the second roller in more detail.

(59) As shown in FIG. 5 as the two opposing rollers rotate consecutive blades 6 align with opposing and consecutive cutting surfaces 8 of the second roller.

(60) As rotation occurs adjacent crimping roller blades and second roller cutting surfaces create a forming chamber 10 which moves as the two roller rotate.

(61) During production of the parcels the co-extruded tube of edible material is fed between the two rollers along the direction X shown in FIG. 5.

(62) As the co-extruded tube moves along the X axis shown in FIG. 5 it will be recognized that the blades 6 of the crimping roller 4 and the cutting surfaces 8 of the second roller 5 come together at point C (the cutting line) as they rotate in their opposing directions. As this rotation happens the tube of co-extruded material is compressed and crimped between the blade and the cutting surface.

(63) Because the tips of the blades are brought into actual contact (or very close contact) with the cutting surface, a line along corresponding to the selected shape of the tip is compressed and cut causing the tube of co-extruded material to be divided through the crimping action at point C.

(64) The cut i.e. the separation, is caused by the tip compressing the food material against the cutting surface.

(65) Simultaneously, two other processing steps occur.

(66) First, (referring to FIG. 3) the two sealing surfaces 7A, 7B compress the co-extruded tube against the cutting roller. The sealing surfaces are spaced radially from the tip and so instead of cutting the tube the material is instead compressed along two lines D on either side of the cut C. The compression creates a seal running along either side of the cut and having the same zig-zag/serrated profile.

(67) Thus, a cut and seal are formed with a predetermined shape corresponding to that chosen by the geometry of the blades.

(68) Secondly, rotation of the two rollers define consecutive forming chambers 10 which are bound at either end (along the X axis) by consecutive blades and cutting surfaces. As the rollers rotate, and as the co-extruded tube moves along the X axis, the tube is compressed (i.e. sealed) within the chamber.

(69) It should be noted from FIGS. 2, 4, 5 and 6 that the crimping roller and second roller have no walls defining sides to the chambers 10. This allows the co-extruded tube entering along axis X to expand in a direction parallel with the rotational axes of the two opposing rollers when the rollers are operating in a ‘moulding’ mode i.e. when the rollers are configured to create surface profiles on either side of the pillows.

(70) However, in a normal mode of operation the chambers 10 may be configured so that the outer surface of the pillows is not compressed; this allows a rounded pillow to be created.

(71) In a moulding mode of operation the tube is compressed into a generally oval or pillow shape by compression within the chambers and is then sealed and cut and either end (measured in the x-axis direction) to create a parcel or pillow. Each parcel or pillow is formed with two opposing ends having profiles corresponding to the blade profile and an outer profile mirroring the chamber profile. This is illustrated in FIG. 9.

(72) FIG. 6 shows an embodiment of the invention in which the separation of the opposing rollers has been reduced such that the tip of the blade penetrates the cutting surface as show by reference numeral 11. This embodiment increased the effectiveness of the cutting tip and can be achieved by selecting a rubber material (for example) as the material for the second roller's manufacture.

(73) FIGS. 7A and 7B illustrate a parcel being formed.

(74) FIG. 7A illustrates a snap-shot of the manufacturing process in cross-section in a side elevation in a moulding mode operational (as described above). The co-extruded tube 12 comprises an outer layer 12A and inner layer 12B and is being conveyed in a direction x towards to the opposing crimping roller 4 and cutting roller 5.

(75) It should be noted that normally it is not necessary to operate in a moulding mode to obtain a round pillow shape: when the tube enters the crimper, it is still sufficiently hot that it still retains some plasticity. Thus, the crimping operation in a non-moulding mode will naturally lead to a round pillow shape.

(76) A blade 6A and opposing cutting surface 8A are moving towards each other as the co-extruded tube 12 moves along the axis causing the tube 12 to begin to be compressed. A preceding blade 6B and preceding cutting surface 8B have already come into contact creating a cut and seal between the partially forced parcel 13 and fully formed parcel 14 which is discharged from the apparatus.

(77) The process operates continuously with a steady state flow of co-extruded tube 12 entering the apparatus and a plurality of formed parcels 14 being discharged from the apparatus. Each parcel has a shape as shown in FIG. 9.

(78) FIG. 7B shows the same parcels being formed in cross-section when view in a vertical direction from the cutting roller side of the apparatus. As in FIG. 7A the tube 12 flows in the X direction. Blade 6B of the crimping rollers has compressed and cut the tube to create a cut and seal as described above. A preceding parcel 14 can be seen being ejected from the apparatus. A following blade 6A is shown as a dotted line and is approaching the tube surface to create the next cut and seal in the continuous process. Thus, by rotation of the rollers can continuously form the parcels.

(79) FIG. 8 shows a blade 6 of the crimping roller in cross-section in more detail.

(80) Functional ranges for the parameters shown by the reference signs in FIG. 8 are as follows: d1 is between 0.5 mm and 2.5 mm; d2 is between 0.2 mm and 2 mm; d3 is between 0.05mm and 2 mm; and angle E is between 30 and 120 degrees

(81) The invention extends to the method of manufacturing a plurality of edible parcels using the apparatus as described above. It will be recognized that the precise geometry of the blades and the ingredients selected for the co-extrusion will determine the properties of the parcels which can be produced.

(82) Particularly, but not exclusively the apparatus may be used to manufacture a breakfast cereal of the type and shape shown in FIG. 9.

(83) Although the invention has been described by way of example, it should be appreciated that variations and modifications may be made without departing from the scope of the invention as defined in the claims. Furthermore, where known equivalents exist to specific features, such equivalents are incorporated as if specifically referred in this specification.