CA2184520A1 - Method & Apparatus for Preparation & Packaging of Commercial Unfrozen Baked Waffles - Google Patents

Abstract

Baked waffles, especially breakfast waffles, are brought to the market for commercial sale in unfrozen condition, being packaged in sealed aseptic packages. The waffles are prepared by being baked to an extent less than 100% and greater than about 80% baked, and at least until the temperature of the interior of the waffle being baked has reached at least 72°C. The waffles are removed from their waffle form and transferred to a packaging station while still hot, and are placed into heat stable package that is sealed while each baked waffle remains at an elevated temperature, thereby rendering the package aseptic. The sealed aseptic packages are cooled and stored so that the baked waffles arrive for commercial sale in unfrozen condition. The baked waffles, in their sealed aseptic packages, may have a shelf-life of up to three months. Conveniently, the baked waffles are prepared in an apparatus which comprises two chains of opposed waffle iron forms which pass through an oven for baking. The chain runs formed by a plurality of opposed waffle irons are positioned so that the waffle irons are closed and opened due to the geometry of the chain runs, whereby loading and unloading each respective waffle iron is easily effected. Generally, a heated discharge conveyor zone is located at the exit end of the oven so that the temperature of the baked waffles remains at an elevated temperature throughout the period of time following its baking and until it is placed into the packaging. This renders the package aseptic; and after sealing the aseptic package, it is taken for subsequent cooling and handling into the commercial market. Thus, the baked waffles are brought to the market unfrozen, in sealed aseptic packages.