Meat processing unit and method for the production of an extruded meat product

Abstract

The proposed invention includes an extruder apparatus (1) for a minced meat product with a distribution chamber (10) provided with an inlet opening (11) and with multiple outlet openings (12) of identical section, each one in communication with an extruder head (50) through a distribution duct (40) to produce the extrusion on a conveyor surface (2) movable through an air treatment unit (60), wherein each extruder head is connected to one of the distribution ducts and comprises a cutting device including a plunger inserted in the extruder head movable from an extruding position, in which the plunger does not interfere with the connection with the distribution duct, to a cutting position in which the plunger completely blocks said connection and in which the plunger reaches or goes beyond an extruding opening of the duct to eject all of the extruded meat product from the interior of the duct.

Claims

1. A meat processing unit for the production of an extruded meat product lacking a wrapping film and a gelled coating, the meat processing unit comprising: an extruder apparatus for a minced meat product including a distribution chamber comprising an inlet opening connected to an impeller pump for the minced meat product, the extruder apparatus further comprising a plurality of outlet openings, each one comprising an identical section, and disposed in communication with a corresponding one of an assembly of extruder heads, through a corresponding one of a plurality of distribution ducts for an extrusion of the minced meat product in the shape of elongated strings of the minced meat product, the elongated strings of the extruded minced meat product collectively defining the extruded meat product; a conveyor surface facing each one of the assembly of the extruder heads and configured to receive the extruded meat product; each one of the plurality of outlet openings disposed equidistant to the inlet opening and in a radial symmetry around a geometric axis defined by the geometric centre of the inlet opening in an annular arrangement; the distribution chamber further comprising a bottom wall oppositely disposed to the inlet opening and centred relative to the geometric axis; the distribution chamber further comprising a perimeter wall surrounding the inlet opening and the bottom wall; the perimeter wall comprising a radial symmetry around the geometric axis that corresponds to the radial symmetry of the outlet openings; each one of the plurality of outlet openings being disposed equidistant to the perimeter wall; each one of the plurality of distribution ducts comprising the same length between a corresponding one of the plurality of outlet openings and the corresponding one of the assembly of extruder heads; each one of the assembly of extruder heads comprising a cutting device; the conveyor surface being structured to move through a closed enclosure of an air treatment unit where a number of blow openings direct a treated air flow against the conveyor surface that supports the extruded meat product to apply an air current comprising a controlled temperature, humidity and speed, against the extruded meat product in a raw stage, thereby producing a hardened and dehydrated outer crust that provides cohesion and allows for a handling of the extruded meat product; each one of the assembly of extruder heads consisting of an extruder duct with a plunger opening disposed on one end thereof, and an extruding opening on an opposed end thereof; the extruding opening facing the conveyor surface for an ejection of the extruded meat product; each one of the assembly of extruder heads further comprising a side opening connected to a corresponding one of the plurality of distribution ducts, the side opening disposed between the plunger opening and the extruding opening; and the cutting device comprising a plunger inserted in the extruder duct through the plunger opening and movable within the extruder duct from an extruding position, in which the plunger does not interfere with the side opening, to a cutting position, in which the plunger completely blocks the side opening and in which the plunger reaches or goes beyond the extruding opening of the extruder duct to eject all of the extruded meat product from the interior of the extruder duct.

2. The meat processing unit according to claim 1 wherein the extruder duct comprises a cylindrical shape and the cutting device further comprises a guiding device, comprising an helical cam and a cam follower, connected to the plunger defining a helical movement of the plunger during a stroke between the extruding position and the cutting position.

3. The meat processing unit according to claim 1 wherein each one of the plurality of distribution ducts is a flexible duct.

4. The meat processing unit according to claim 1 wherein each one of the plurality of outlet openings of the extruder apparatus is disposed on the bottom wall or on the perimeter wall.

5. The meat processing unit according to claim 1 wherein the plurality of outlet openings of the distribution chamber are at least six outlet openings.

6. The meat processing unit according to claim 1 wherein the bottom wall comprises a circular shape and the perimeter wall comprises a frustoconical shape.

7. The meat processing unit according to claim 1 wherein an area of the extruding opening of each one of the assembly of extruder heads is at least 25 mm.sup.2.

8. The meat processing unit according to claim 1 wherein the combined area of all of the outlet openings is equal to the area of the inlet opening of the distribution chamber.

9. The meat processing unit according to claim 1 wherein the air treatment unit applies the air current with a temperature between 30° C. and 50° C. and with a relative humidity lower than 25%.

10. The meat processing unit according to claim 1 wherein an end of the plunger in contact with the minced meat product contained in the extruder duct is a flat end perpendicular to the movement direction of the plunger.

11. A method for obtaining an extruded meat product lacking a film wrapping and a gelled coating by a meat processing unit as described in claim 1, the method comprising the following steps: a) forcing the minced meat product through the extruder apparatus by the impeller pump, producing: a complete filling of the distribution chamber; an even distribution of the minced meat product through each one of the plurality of outlet openings of the distribution chamber, producing multiple homogeneous flows of the minced meat product each one flowing through a one of the plurality distribution ducts to the corresponding one of the assembly of extruder heads; and an extrusion of the minced meat product through each one of the extruder heads, producing multiple elongated strings of the extruded meat product, each one comprising an even extrusion flow; b) laying the elongated strings of the extruded meat product on the conveyor surface that moves at a speed coordinated with a delivery speed of the extruded meat product; selectively interrupting the extruded meat product elongated string by the cutting device disposed on each extruder head; c) conveying, by the conveyor surface, the extruded meat product through the air treatment unit that applies the air current with a controlled temperature, humidity and speed, against the extruded meat product in a raw stage, until obtaining an extruded meat product comprising a hardened and dehydrated outer crust to produce cohesion and allow for the handling of the extruded meat product; the cutting device of each extruder head is moved within the extruder duct from an extruding position, in which the plunger does not interfere with a side opening, to a cutting position, in which the plunger completely blocks the side opening and in which the plunger reaches or goes beyond the extruding opening of the extruder duct ejecting all of the extruded meat product from the interior of the extruder duct.

12. The method according to claim 11 wherein the air treatment unit applies the air current with a temperature between 30° C. and 50° C. and with a relative humidity lower than 25%.

13. The method according to claim 12 wherein the extruded meat product is treated by the air treatment unit until the dehydrated outer crust is produced comprising a relative humidity lower than 15% and a core with a relative humidity greater than 20%.

14. The method according to claim 11 wherein the extruder duct is a cylindrical duct and wherein the cutting device of each extruder head is driven at preset intervals moving from the extruding position to the cutting position while moving the plunger following the helical movement defined by the helical cam of the guiding device.

15. The method according to claim 14 wherein the cutting device is immediately returned to the extruding position after reaching the cutting position, resulting in the cut of the elongated string of the extruded meat product laid on the conveyor surface.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) The foregoing and other advantages and features will be more completely understood from the following detailed description of an exemplary embodiment with reference to the attached drawings, which must be taken by way of illustration and not limitation, in which:

(2) FIG. 1 depicts a schematic longitudinal sectional view of the proposed meat processing unit;

(3) FIG. 2 depicts a partially sectioned perspective view of the extruder apparatus, in which the distribution ducts are only shown as a phantom line;

(4) FIG. 3A depicts an exploded cross-section of an extruder head and of the associated cutting device;

(5) FIG. 3B depicts the same cross-section shown in FIG. 3A but assembled, the plunger being in the extruding position within the extruder head;

(6) FIG. 3C depicts the same cross-section shown in FIG. 3A but assembled, the plunger being in the cutting position within the extruder head;

(7) FIG. 4 depicts a horizontal section of the distribution chamber, showing the bottom wall and the outlet openings arranged on said bottom wall;

(8) FIG. 5 depicts a horizontal section of the distribution chamber, showing the bottom wall and the corresponding outlet openings arranged on the perimeter wall;

(9) FIG. 6 depicts a cross-section of an air treatment unit embodiment, in which a plurality of trays moves in an upward direction forming a column, and where, at end of each column, a device transfers the last tray of the column to another adjacent column that moves in a downward direction.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

(10) The attached figures show exemplary embodiments with a non-limiting, illustrative character of the present invention.

(11) According to a first exemplary embodiment shown in FIG. 1, the meat processing unit consists of an extruder apparatus 1, a conveyor surface 2 and an air treatment unit.

(12) FIG. 1 shows the conveyor surface as a conveyor belt but said conveyor surface may also be a plurality of stackable trays that that pass underneath the extruder heads 50.

(13) The stackable condition of the trays is achieved by means of protruding perimeter supports above and/or below the conveyor surface, preferably combined with a number of fitting elements that ensure the correct positioning of the stacked trays. The trays may also or alternatively include some protruding dragging elements configured to cooperate with a dragging device to achieve the movement of the trays.

(14) The extruder apparatus 1 receives a minced meat product flow impelled by an impeller pump 5 through a feeding duct from the minced meat product tank 3. It is recommended that said impeller pump 5 force the minced meat product with a pressure equal to or lower than 500 kPa to avoid the excessive melting of the fat nodules contained in the minced meat product, and avoiding its emulsification.

(15) The minced meat product flow is then passed into a distribution chamber 10 through a circular inlet opening 11 that defines a first vertical geometric axis 1E in its centre.

(16) The distribution chamber 10 has a geometry defined by the frustoconical perimeter wall 13 and by a circular bottom wall 14, shown in FIGS. 2,4 and 5, opposite the inlet opening 11. The perimeter wall 13 has an upper end of identical diameter as that of the inlet opening 11, and a lower end of identical diameter as that of the bottom wall 14.

(17) In the embodiment shown in FIGS. 2 and 4, the bottom wall 14 has multiple outlet openings 12 of the distribution chamber 10, distributed annularly, in radial symmetry around the geometric axis 1E; however, it also contemplated that the outlet openings 12 be annularly arranged on the perimeter wall, as shown in FIG. 5, equally in radial symmetry around the geometric axis 1E.

(18) In the shown embodiments, the distribution chamber consists of eight outlet openings 12, all of which are equidistant to the perimeter wall 13 and to the inlet opening 11, thereby resulting in identical speed, pressure and density of the minced meat product flow when it reaches each of said outlet openings 12 and, after passing therethrough, producing identical minced meat product strings with an identical feeding and delivery extruding speeds.

(19) The combined surface of all the outlet openings 12 will be equal to the surface of the inlet opening. It is proposed, for example, that each outlet opening 12 have a surface equal to or lower than 25 mm.sup.2.

(20) Each outlet opening 12 is connected through a distribution duct 40 to an extruder head 50. Said distribution ducts 40 have not been shown in the attached Figures, but their outline has been indicated by means of a phantom line in FIG. 2.

(21) It is proposed that the distribution ducts 40 be flexible ducts. It is important that all said distribution ducts 40 be of identical length and diameter, thereby achieving that the feeding speed and the density of each minced meat product string 4 should not be altered relative to the other strings 4 that travel through the other distribution ducts.

(22) Each distribution duct 40 communicates with one of the eight extruder heads 50, which in the present embodiment are arranged in alignment. In the embodiment shown in FIG. 2, four distribution ducts 40 are connected to four alternating extruder heads 50 from a side of the block that contains them through four elbow-shaped side openings, and the other four distribution ducts 40 are connected to the other four alternating extruder heads 50 from the other side of the block that contains them through side openings that remain hidden from the perspective represented in this FIG. 2.

(23) As shown in FIGS. 3A, 3B and 3C, each extruder head 50 consists of a hollow cylindrical duct 51 provided with a side opening 52, connected to one of the distribution ducts 40, and an extruding opening 53 facing the conveyor surface 2 for the ejection of the extruded meat product. Each extruder head 50 will also have a cutting device 55 built in.

(24) The minced meat product flow is passed into the cylindrical duct 51 from the distribution duct 40 through the side opening and, after filling it, it is extruded from the extruder head 50 through the extruding opening 53, from which it is laid on the conveyor surface 2, which will convey it to the air treatment unit 60, where its surface will be dehydrated to generate a crust, making it manageable.

(25) Said conveyor surface 2 moves at a speed coordinated with the delivery speed of the extruded meat product strings 4 to avoid interruptions or undue build-ups of said strings 4.

(26) Preferably, all of the extruder heads 50 will be aligned in a transverse direction to the feeding direction of the conveyor surface 2, laying parallel strings 4 of extruded meat product.

(27) It is also contemplated that each extruder head 50 incorporate a cutting device 55 to be able to interrupt the extruded meat product string 4 at will, abruptly generating a regular string end 4 without thinning or sharp ends that may end up becoming excessively dehydrated during the later air treatment process.

(28) The cutting device 55 includes a plunger 56 snugly movable within the cylindrical duct 51, from an extruding position, in which the plunger does not interfere with the side opening 52, allowing for the entrance of the minced meat product, and a cutting position, in which the plunger 56 completely blocks the side opening 52, preventing the entrance of minced meat product and pushing the minced meat product contained in the cylindrical duct 51 towards the extruding opening 53. Preferably, in the cutting position, the plunger 56 reaches the extruding opening 53 completely emptying the cylindrical duct 51.

(29) The plunger 56 is connected to a guiding device 57 that includes a cam 58 and a cam follower 59, which determines a helical movement of the plunger 56 between the extruding position and the cutting position. This rotation also prevents the adhesion of the string end 4 ejected through the extruding opening 53 to the plunger end 56 that will preferably be flat, lacking bevels.

(30) In the present embodiment, all plungers 56 are connected to an upper plate that can move vertically driven by a driving device—for instance, a plunger or a linear motor—, causing the simultaneous lowering of each of the plungers 56 and its rotation guided by the cam; however, other embodiments are also contemplated in which each plunger 56 may be driven independently.

(31) Additionally, in the case that the conveyor surface 2 is a series of trays, the previously mentioned cutting devices 55 will also have to be coordinated with the movement of the conveyor surface 2 to produce the cutting of the extruded meat product strings 4 coinciding with the transition between successive trays moved underneath the extruder heads 50, thereby avoiding that any strings 4 be left straddling between two successive trays.

(32) In the present embodiment, all of the extruder heads 50 are comprised in a single block; for example, machined in the same metal block. The side openings 52 of the contiguous extruder heads have been arranged in opposite sides of the block, thereby allowing to position the extruder heads 50 closer to each other.

(33) Each cylindrical duct 51 also includes a plunger opening in its upper end, thereby transforming the cylindrical duct 51 into a through-hole. Said plunger 56 is inserted in the cylindrical duct 51 through said plunger opening, protruding from its upper end, where a helical cam follower surrounding the protruding portion of the plunger 56 is located, which comprises one boss in the shape of a cam follower on its side that cooperates with said cam to guide the plunger 56.

(34) The present embodiment also contemplates that the extruded meat product strings 4 laid on the conveyor surface 2, which, as is to be recalled, are lacking a wrapping film and a gelled coating, will be conveyed by said conveyor surface to the air treatment unit 60, which will apply an air current with controlled temperature, humidity and speed against the raw extruded meat product.

(35) For example, it is proposed that the air current be applied with a temperature between 30° C. and 50° C. and with a relative humidity lower than 25%.

(36) In the embodiment shown in FIG. 6, the conveyor surface 2 consists of a plurality of trays that move adjacently underneath the extruder heads 50 at a speed coordinated with the delivery and extruding speeds, the cutting devices 55 also being coordinated with the movement of the trays to match the cut of the extruded meat product strings with the abutment between two adjacent trays. Said trays, once loaded with the extruded meat product, are passed into the air treatment unit 60 shown in FIG. 6 one by one. Said unit progressively raises each tray, overlapping them forming a column. An air duct system produces an air current that traverses the tray column removing the humidity of the extruded meat product. Upon reaching the top of the tray column, the trays may be moved to another adjacent column to start a downward movement, subject to the air flow as well.

(37) This process will cause the superficial drying of the minced meat product string 4, making it gain cohesion, and some flexibility, while, at the same time, its plasticity and adherence are reduced. All of this makes it possible for the extruded meat product strings 4 treated in the air-drying apparatus to be handled and, therefore, removed from the conveyor surface, whether for their storage or packaging, or to receive subsequent curing treatments.

(38) Preferably, the treatment will be continued until the humidity of the crust of the extruded meat product is equal to or lower than 15%, the inner humidity being greater; for instance, greater than 20%.

(39) It will be understood that the different parts that constitute the invention described in an embodiment may be freely combined with the parts described in other different embodiments, even if said combination has not been explicitly described, as long as the combination is not detrimental.