De-Oiling Method in the Manufacture of Low Oil Potato Chips

Abstract

A method of de-oiling potato slices, which have been coated in oil, the steps of the method including providing a plurality of potato slices that were pre-treated in oil; and randomly feeding the potato slices onto an elongate longitudinal conveyor which is permeable to oil, water and air. Further, the method includes spraying water downwardly and upwardly onto the plurality of potato slices on the conveyor to displace and lift surface oil from the potato slices. Then, directing air blades to blow a mixture of oil and water from the potato slices as these move along the conveyor.

Claims

1. A method of de-oiling potato slices which have been coated in oil, the method comprising the steps of: (a) providing a plurality of potato slices, each slice having been pretreated in oil; (b) randomly feeding the potato slices onto an elongate longitudinal conveyor which is permeable to oil, water and air; (c) spraying water downwardly and upwardly from respective upper and lower water spray units onto the plurality of potato slices on the conveyor to cause the water to displace and lift surface oil on the potato slices; and (d) thereafter directing upper and lower air blades downwardly and upwardly, respectively, onto the plurality of potato slices on the conveyor to cause the air blades to blow a mixture of oil and water from the potato slices, wherein the air blades comprise a plurality of pairs of upper and lower air blades spaced along the conveyor.

2. A method according to claim 1 wherein in step (b) the potato slices are fed onto the conveyor in a substantially non-overlapping configuration.

3. A method according to claim 1, wherein the upper and lower water spray units are spaced a distance of from 50 to 150 mm, from the potato slices on the conveyor.

4. A method according to claim 1, wherein the upper and lower water spray units are adapted each to spray from 0.72 to 1.2 litres of water per hour per kg of potato slices per hour, towards the conveyor.

5. A method according to claim 1, wherein at least three pairs of parallel air blades are located in succession downstream of the water spray units.

6. A method according to claim 1, wherein air blades are generated from respective air exit apertures having a width of from 0.5 to 1.5 mm.

7. A method according to claim 6, wherein the air exit aperture is a distance from the conveyor of from 20 to 40 mm.

8. A method according to claim 1, wherein the air blade has an air velocity of from 30 to 60 metres per second.

9. A method according to claim 8, wherein the upper and lower air blades of a first pair of air blades located downstream of the water spray units have an air velocity of from 30 to 40 metres per second.

10. A method according to claim 9, wherein the upper and lower air blades of a second pair of air blades located downstream of the first pair of air blades have an air velocity of from 40 to 50 metres per second.

11. A method according to claim 10, wherein the upper and lower air blades of a third pair of air blades located downstream of the second pair of air blades have an air velocity of from 40 to 50 metres per second.

12. A method according to claim 1, further comprising the step, between steps (b) and (c) of directing at least one primary air blade downwardly towards the potato slices on a primary conveyor.

13. A method according to claim 12, wherein two primary air blades are provided which are longitudinally separated by a distance of from 100 to 300 mm.

14. A method according to claim 13, wherein the primary air blades are each generated from a respective primary air exit aperture having a width of from 0.5 to 1.5 mm.

15. A method according to claim 14, wherein the primary air exit aperture is a distance from the potato slices of from 20 to 40 mm.

16. A method according to claim 12, wherein the primary air blade has an air velocity of from 30 to 60 metres per second.

17. A method according to claim 1, wherein in step (a) the potato slices have an oil content of about 30 to 45 wt % oil, based on the dry weight of the final potato chip produced from the potato slice, and the potato slices after being de-oiled in step (d), have an oil content of about 10 to 15 wt % oil, based on the dry weight of the final potato chip produced from the potato slice.

18. A method according to claim 1, further comprising holding the slices on the conveyor at least one of the air-blower station by an upper belt located above the conveyor, the slices being fed between the conveyor and the upper belt.

19. A method of de-oiling potato slices which have been coated in oil, the method comprising the steps of: (a) lipophillically pretreating a plurality of potato slices in oil; (b) randomly feeding the pretreated plurality of potato slices onto an elongate longitudinal conveyor which is permeable to oil, water and air; (c) spraying water downwardly and upwardly onto the plurality of potato slices on the conveyor to cause the sprayed water to displace and lift surface oil off the potato slices; and (d) directing upper and lower air blades onto the plurality of potato slices on the conveyor to cause the air blades to blow a mixture of oil and water from the potato slices, wherein the air blades comprise a plurality of pairs of upper and lower air blades spaced along the conveyor.

20. A method according to claim 19, wherein after step (d) the plurality of potato slices have an oil content of about 10 to 15 wt % oil, based on the dry weight of a final potato chip product produced from the potato slice.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0022] FIG. 1 is a schematic side view of an apparatus for de-oiling potato slices, prior to microwave cooking, according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0023] An embodiment of an apparatus for de-oiling potato slices, prior to microwave cooking of the potato slices to form potato chips, according to one aspect of the present invention is illustrated in FIG. 1.

[0024] A primary endless belt conveyor 2 having a substantially horizontal orientation is provided. An inlet end of the conveyor 2 communicates with an exit of an oil flume 4 (illustrated schematically) comprising a lipophilic preconditioning unit for the potato slices 6. The conveyor 2 carries a succession of the potato slices 6 on its upper surface 8. The potato slices 6 have been randomly delivered onto the conveyor 2. The potato slices 6 are delivered onto the conveyor 2 in a slice distribution so as to have at least about 50% of the slices being single slices, i.e. not overlapping with an adjacent slice. In addition, at least 50% of the overlaps are no more than 50% of the area of each of the respective overlapping slices. Also, for each overlap no more than two slices 6 are stacked one upon the other on the conveyor 2. This substantially provides a monolayer of potato slices 6 across the length and width of the conveyor 2.

[0025] The potato slices 6 typically have a thickness of 1 to 2.5 mm, more typically about 1.3 mm (51 thousandths of an inch).

[0026] The potato slices 6 have been pre-treated in oil in the lipophilic preconditioning process and initially, prior to the de-oiling step, have about 30 to 45 wt % surface oil, typically about 40 wt % surface oil based on the dry weight of the final potato chip produced from the potato slice 6. In this specification the dry weight of the final potato chip assumes 2 wt % water content in the total weight of the final cooked and dried potato chip, prior to final seasoning of the potato chip. The oil typically comprises a vegetable oil such as sunflower oil, conventionally used for manufacturing potato chips. The oil is employed in the lipophilic preconditioning to provide the required organoleptic properties to the resultant potato chip, which has been cooked by the combination of the preliminary oil treating step and the subsequent microwave cooking step, and has not been fried, as for a conventional potato chip.

[0027] The conveyor 2 has a translational speed of from 0.1 to 0.5 m/second, typically about 0.2 m/second. As the potato slices 6 are carried on the upper surface of the primary conveyor 2, air is blown downwardly onto the potato slices 6 in a continuous manner at a primary air-blower station 18. The velocity of the air is typically from 30 to 60 metres per second, more typically from 40 to 50 metres per second, optionally from 45 to 50 metres per second. The primary air-blower station 18 comprises a set of a plurality of primary air knives 10, 12 which are mounted above the primary conveyor 2. In the embodiment, two longitudinally spaced air knives 10, 12 are provided. Each of the air knives 10, 12 typically has an air exit aperture 14 extending along the length of the air knife 10, 12, which extends transversely across the conveyor 2, for generating a downwardly-directed air blade 16 extending across the width of the conveyor 2. The air exit aperture 14 may have a width of from 0.5 to 1.5 mm, optionally 0.75 to 1.25 mm, further optionally about 1 mm. Each air knife 10, 12 is located so that a distance from the air exit aperture 14 to the upper surface 8 of the conveyor 2 carrying the potato slices 6 is from 20 to 40 mm, optionally 25 to 35 mm, further optionally about 30 mm.

[0028] The air knives 10, 12 generate downwardly directed parallel air blades 16, spaced in the direction of movement of the potato slices 6 along the conveyor 2, and act to blow excess surface oil on the potato slices 6 back into an oil supply for the lipophilic preconditioning apparatus. The air blades 16 most typically have an air velocity of 48 m/second.

[0029] For example, the excess oil removed by the air blades 16 is blown downwardly through the conveyor 2, and is captured by an oil capture device 20 located thereunder. The conveyor 2 is permeable to the oil and typically comprises an open mesh structure, for example comprised of a stainless steel balanced spiral wire mesh belt.

[0030] The air knives 10, 12 are parallel and longitudinally separated by a distance of, for example, a distance of from 100 to 300 mm, typically about 150 mm, so that each potato slice 6 is sequentially impacted by plural air blades 16 during the passage of the potato slice 6 through the primary air-blower station 18. Alternatively, the air knives 10, 12 may be separated by a distance which is less than a typical dimension of a potato chip, for example a distance of less than 50 mm, such as 30 to 40 mm, so that each potato slice 6 is simultaneously impacted by plural air blades 16 during at least a portion of the passage of the potato slice 6 through the primary air-blower station 18. Optionally, the air knives 10, 12 are inclined rearwardly so that the displaced oil is directed rearwardly into the oil capture device 20, which enhances oil capture.

[0031] After this preliminary step of blowing off excess surface oil with air blades, the conveyor 2 feeds the potato slices 6 to a de-oiler unit 21. The de-oiler unit 21 includes a second de-oiler belt conveyor 22 which, similar to conveyor 2, is an endless belt mounted substantially horizontally and has a belt speed of from 0.1 to 0.5 m/second, typically about 0.2 m/second. The conveyor 22 is also permeable to oil and water, and comprises a similar open mesh structure as conveyor 2, for example a stainless steel balanced spiral wire mesh belt. The de-oiler conveyor 22 conveys the potato slices 6 from an upstream end 24 to a downstream end 26 through a succession of de-oiling stations.

[0032] A first de-oiling station 28, located relatively upstream along the conveyor 22, comprises a water spray station 30 which sprays water onto the potato slices 6 which are carried on the upper surface 32 of the conveyor 22. The water is sprayed both downwardly from an upper water spray device 38, forming an upper spray 39, and upwardly from a lower water spray device 40, forming a lower spray 41. Typically, in each water-spray device 38, 40 a plurality of water pressure nozzles is provided across the width of the conveyor 22. Typically, the water exits of the water spray devices 38, 40 are located a distance of from 50 to 150 mm, optionally 75 to 125 mm, further optionally about 100 mm, from the conveyor upper surface 32 carrying the potato slices 6.

[0033] At the water spray station 30, water is sprayed onto both upper and lower major surfaces 34, 36 of each of the potato slices 6. The water spray impacts on the upper and lower surfaces 34, 36 of the potato slices 6 and acts to displace and lift surface oil from the surfaces of the slice 6.

[0034] A typical water feed rate from each of the upper and lower water devices 38, 40 is from 3 to 5 kilograms of water per minute, optionally from 4 to 4.5 litres of water per minute, most typically 4.2 litres/minute, for a typical potato slice throughput of 250 kilograms per hour, i.e. from 0.72 to 1.2 litres of water per hour per kg of potato slices per hour, optionally from 0.96 to 1.08 litres of water per hour per kg of potato slices per hour.

[0035] After this initial surface oil lifting step using water, a succession of pairs of oppositely directed secondary air knives, and directed towards each other, is employed to remove the lifted oil, mixed together with the residual water, from the surfaces 34. 36 of the potato slices 6. In the embodiment, three successive sets 42, 44, 46 of upper and lower air knives are employed, which sets 42, 44, 46 are located in a mutually spaced configuration extending along a portion of the length of the conveyor 22 downstream of the water spray station 30.

[0036] Accordingly, there are plural parallel sets 42, 44, 46 of upper and lower secondary air knives mounted above and below the conveyor 22 which are adapted to provide high velocity air, as a narrow blade-like flow extending across the width of the conveyor 22, with the high velocity air blade blowing the water and oil mixture from the surfaces 34, 36 of the potato slices 6. The velocity of the air is typically from 30 to 60 metres per second. The water and oil mixture which has been blown off the slices falls downwardly into a base 60 of the de-oiler unit for removal and reuse or recycling. The air blades produced from the sets 42, 44, 46 of upper and lower air knives are parallel.

[0037] A first air knife set 42 comprises upper and lower air knives 48, 50 each of which is arranged to blow an air blade 52, 54 at a high velocity onto the upper or lower surface 34, 36, respectively, of the potato slices 6 on the conveyor 6. For these air knives 48, 50 the air velocity may be from 30 to 40 metres per second, optionally from 32 to 37 metres per second. Typically, the upper air knife 48 has an air blade velocity of 34 m/second and the lower air knife 50 has an air blade velocity of 35 m/second.

[0038] A second air knife set 44 comprises upper and lower air knives 56, 58 each of which is arranged to blow an air blade 62, 64 at a high velocity onto the upper or lower surface 34, 36, respectively, of the potato slices 6. For these air knives 56, 58 the air velocity may be from 40 to 50 metres per second, optionally from 45 to 50 metres per second. Typically, the upper air knife 56 has an air blade velocity of 47 m/second and the lower air knife 58 has an air blade velocity of 47 m/second.

[0039] A third air knife set 46 comprises upper and lower air knives 66, 68 each of which is arranged to blow an air blade 70, 72 at a high velocity onto the upper or lower surface 34, 36, respectively, of the potato slices 6. For these air knives 66, 68 the air velocity may be from 40 to 50 metres per second, optionally from 45 to 50 metres per second. Typically, the upper air knife 66 has an air blade velocity of 46 m/second and the lower air knife 68 has a velocity of 47 m/second.

[0040] The use of a plurality of sequential successive pairs of oppositely directed air knives mounted both above and below the conveyor 22 in the de-oiler unit provides a greater degree of control in achieving a desired weight % of oil in the de-oiled potato slices 6 leaving the de-oiler unit 21.

[0041] For each of the air knife sets 42, 44, 46, a typical distance from the respective upper or lower air knife exit aperture 74, 76 to the upper surface 32 of the conveyor 22 carrying the potato slices 6 is from 20 to 40 mm, optionally 25 to 35 mm, further optionally about 30 mm. Each of the air knives 48, 50, 56, 58, 66, 68 has an exit aperture 74, 76 extending along the length of the air knife 48, 50, 56, 58, 66, 68, which exit aperture 74, 76 extends transversely across the conveyor 22, for generating an air blade 52, 54, 62, 64, 70, 72 extending across the width of the conveyor 22. The air exit apertures 74, 76 may have a width of from 0.5 to 1.5 mm, optionally 0.75 to 1.25 mm, further optionally about 1 mm.

[0042] Since the air knife sets 42, 44, 46 blow air upwardly as well as downwardly, in order to avoid the potato slices 6 being blown off the conveyor 22 a longitudinally oriented hold-down belt 80 is located above the conveyor 22 in the vicinity of the air knife sets 42, 44, 46. The potato slices 6 are conveyed between the lower conveyor 22 and the upper hold-down belt 80 and are held in position as they are conveyed successively past the air knife sets 42, 44, 46. The hold-down belt 80 is typically undriven, but it may alternatively be driven so as to assist the conveyor 22.

[0043] In the illustrated embodiment, there are three sets of air knives 42, 44, 46 downstream of the water spray station 30. In other embodiments a larger number of air knife pairs is provided, which can provide enhanced uniformity of oil content of the de-oiled potato slices. In contrast, since the air knives 10, 12 blow air only downwardly, a hold-down belt is not required. The potato slices 6 are agitated by the downwardly blown air from the air knives 10, 12, which agitation assists removal of free surface oil, but the slices remain on the conveyor 2.

[0044] The final oil percent amount in the de-oiled potato slices 6 is achieved by balancing the amount of water and the amount of air supplied. It is possible to use more air and less water and vice versa to fine tune the de-oiling operation and the final oil content. The target final oil content for the potato slices using the de-oiler is 12.5 wt % oil+/2 wt % based on the dry weight, having 2 wt % water content, of the final cooked and dried potato chip after microwave explosive dehydration and final drying.

[0045] In modifications to the illustrated embodiment, a single conveyor may be used instead of the combination of a primary conveyor and a de-oiler conveyor, and/or the number of air knives and/or water spray stations may be varied.