MXPA96004410A - Method and apparatus for preparation and packaging of non-frozen baked wafles comercia - Google Patents

Abstract

Baked waffles, especially waffles for lunch, are brought to the market for commercial sale in an unfrozen condition, packed in aseptic sealed packages. The waffles are prepared by baking to a degree less than 100 percent and greater than approximately 80 percent baking, and at least until the temperature inside the waffle being baked has reached at least 72øC. The waffles are removed from their waffle form and transferred to a packing station while they are still hot, and placed in a heat-stable package that is sealed while each baked waffle remains at an elevated temperature, thus making the aseptic package. The sealed aseptic packages are cooled and stored in such a way that the baked waffles arrive for commercial sale in an unfrozen condition. Baked waffles, in their sealed aseptic packages, can have a shelf life of up to three months

Description

METHOD AND APPARATUS FOR PREPARATION AND PACKING OF NON-FROZEN COMMERCIAL FROZEN WAFERS FIELD OF THE INVENTION; The present invention relates to methods and apparatus for the production of commercial baked waffles, especially waffles for lunch, which are to be sold in an unfrozen condition in the commercial market. More particularly, the present invention relates to methods and to the preparation of waffles sold non-frozen in sealed aseptic packages, and which can have an exceptional shelf life.

BACKGROUND OF THE INVENTION: There are numerous baked waffles that are sold primarily in commercial retail markets for lunch consumption. However, without exception, these waffles are sold in a frozen condition. This means that, after the waffles have been baked in a commercial waffle bakery, they must be cooled in a significant way until they are frozen, they must be shipped in the frozen condition, they must be displayed for retail sale in the condition frozen, they must be transported by consumers buyers to their homes in the frozen condition, and they must be kept in the frozen condition until the moment they are removed from their packaging for consumption. Accordingly, this requires very substantial commitments of capital equipment, beyond bakery and packing equipment, to freeze, store, transport, store commercially, and retail commercially frozen waffles. What the waffles of the present invention have in common with the commercial lunch waffles that are currently available, is that they are pre-baked, and packaged for retail sale, and are prepared to be consumed by the customer by standing in an oven or toaster to overheat. What the baked waffles of the present invention do not have in common with the commercial waffles currently available, therefore, is that they are not frozen, and there is no need for additional significant capital expenditures. Of course, in order for the baked waffles to be brought to the market in an unfrozen condition, and still enjoy a significant shelf life, the package is required to be made aseptic. The present invention provides that, as will be described later, by ensuring that each waffle remains heated when placed in its packaging, and while sealing the package, to make the package aseptic. In general, this means that the internal temperature of the waffle, when it is being baked, must be raised to a temperature of at least 72 ° C. Subsequently, the internal temperature of the wafle should not be allowed to become depressed in a significant way; and this generally means that efforts should be made and measures taken to maintain the temperature of the inside of the waffle at least at or above about 72 ° C. In that way, there is enough heat retained in the baked wafla so that the heat is transferred to the interior of the package; and if the package is sealed very soon after, it will become aseptic. In the event that the internal temperature of the wafle has dropped below 72 ° C or so, after the package has been sealed, it can be reheated, usually at a temperature of up to about 90 ° C, to reheat the inside of the waffle back to at least approximately 72 ° C. It is unlikely that microbiological activity will occur if a product, such as a baked waffle, has been sealed in an aseptic environment at approximately 72 ° C, such that airborne spores or other contaminants do not have access to the product. inside the aseptic package. Consequently, products such as baked waffles can enjoy a substantial shelf life without deterioration, since no contaminant inside the waffle will have survived at 72 ° C, and because it can not become contaminated again. Of course, after a package containing a plurality of waffles has been opened keeping with the present invention, if several baked waffles remain without being consumed, they should be refrigerated. Moreover, there is a further advantage of the present invention, beyond precluding the need for capital expenditures for freezing and storage, transport, storage, and retail equipment in a frozen form; and there is no need to use chemical additives for waffle paste to be used as preservatives. The waffle pastes used by the present invention can be considered as "all natural", comprising at least water, flour, sweeteners, whole eggs, vegetable oil or butter and a yeast agent, such as baking powder or soda. to bake. The waffles that are manufactured maintaining the present invention, may further comprise a dairy product, such as whole milk, skimmed or partially skimmed milk, or whey, as well as lecithin, salt or other flavoring ingredients, such as vanilla or fruit additives. . Another factor that needs to be emphasized, with respect to the manufacture of baked waffles, is that the waffles are prepared from a waffle paste, as opposed to the preparation of breads prepared from dough. In addition, the differences between waffles and wafers must be distinguished; The waffles are relatively thick without a significant crust developing on them during baking, and they will still have a retained moisture content. The wafers, on the other hand, are relatively thin, may have a crust due to a higher sugar content, and in any case, they are baked until a moisture content of substantially zero is retained. Returning to the differences between the dough, from which the loaves are baked, and the dough, from which the waffles are baked, it is necessary that the dough is rolled and tested because in general it is raised using yeast. The waffle pastes are raised using a chemical yeast system, such as baking powder or baking soda, and can be poured, whereby, after preparation, the dough can be poured into a waffle shape. Moreover, the waffles are baked in an enclosed form, while the loaves can generally be raised during their baking process in trays or baking vats with the upper part open. Still further, the baking process by which the waffles are baked is more or less completed, at least to the degree desired, while the waffle is still in the form of a waffle or waffle iron, and while still It is in an oven that is kept at a high temperature. Accordingly, waffles can be partially baked, at least up to 80 percent baking, but less than 100 percent baking, and the baking process can be suspended at that time to be finished at a later time when the waffle goes to be consumed by your buyer. With few exceptions, such as with French bread comprising only flour, water, yeast and salt, it is not possible to partially bake the loaves, and then suspend the baking process until a later time. These factors are important when certain patents of the prior art have to be understood, which are discussed below. The energy savings that can be realized by keeping up with the present invention can be very significant. Comparing traditional frozen waffles for commercial sale - that are baked and then frozen, and that therefore must be kept in a frozen condition during storage, shipping and retail sale, and even in the consumer's home until they leave consume - with unfrozen waffles sold in sealed aseptic packages, the savings for the manufacturer, the distributor, the retail and finally the consumer, can be deep, as discussed later in this. These savings are in terms of both invested and operational capital, and in the energy expended. For the moment, it is merely necessary to note that until measures are taken to maintain the temperature of the waffles baked at a high temperature before packing, the costs to maintain the present invention and those of the production of traditional frozen waffles, they can be essentially identical; as well as the costs of packaging materials, as well as boxes, promotion and advertising, cost of sale, in order to bring the products to market. All other costs currently required for the production, storage, shipping and sale of frozen waffles are not all necessary to maintain the present invention. Moreover, the present invention provides a significantly new apparatus within which the waffles can be baked. In order to have an efficient preparation and bake waffles for commercial market purposes, significant automation must be applied to the process. This means that the apparatus used for the preparation of waffles for commercial sale, once designed and installed, must be capable of operating for extended periods of time, with minimum deactivation and / or maintenance, except as may be required for purposes of cleaning and hygiene, and for preventive maintenance of equipment that may be required. Frequently, the design and provision of machinery having as few moving parts as possible is the most desirable, and is carried out by baking equipment and especially waffle forms to maintain the present invention. As will be described in more detail later herein, the waffle shapes provided by maintaining these teachings are such that there is no need for upper and lower waffle shapes hinged in the sense of the traditional waffle plates. What is provided, as will be described later herein, are articulated chains that are physically mounted in such a way that the opening and closing of the waffle plate shapes, and the removal of the baked waffles from the forms of waffles, are realized merely as a consequence of the geometry of the apparatus.

DESCRIPTION OF THE PREVIOUS TECHNIQUE: Maintaining the foregoing discussions, there is no known prior art that specifically describes several of the key features of the methods and apparatus in accordance with the present invention. However, the following prior art is referenced for purposes of expressing and demonstrating the differences between the prior art and the features of the present invention. With respect to the prior art, which is particularly directed to methods by which bake products are prepared in substantially automated processes, and placed in a package for shipment to the retail market, the following patents are noted: KOMATSU et al. Patent of the United States of North America Number 3,892,058, refers to the high-temperature sterilization in a short time of packaged articles, such as soups or meat products. The food product is filled into a flexible container, and the non-condensable gases remaining in the container voids are excluded, after which the package is heat sealed. Subsequently, the packaged food is sterilized inside its own sealed package when heated at elevated temperatures for as short a time as possible. PLEMONS et al., U.S. Patent No. 3,979,525, relates to a method of producing pizza crusts, which are essentially loaves. Here, pizza crusts can be stored unsealed at room temperature, because they have been treated with ethyl alcohol. This can create significant marketing problems, since it is essentially unknown and it is unacceptable to add chemical compounds to a finished food product. U.S. Patent No. 4,120,984 to RICHARDSON et al., Refers to an apparatus for placing baked goods in a sterile package, and to prevent damage to the product as it is being cooled. The plastic sheet that is normally used is perforated; the invention relates in any case to baked bread products; and there is a requirement to direct sterile air into the package. JOULIN, U.S. Patent No. 4,357,356, discloses a method for producing a bread product that is baked, packaged in hermetically sealed packages under a partial vacuum, and then sterilized. The specific bread product discussed is French bread, which comprises only flour, water, salt and yeast; and, although French bread can actually be partially baked, it will nonetheless have a short shelf life before it becomes completely unpleasant. It should also be noted that the bread products specifically discussed by Joulin have much smaller surface areas per unit mass or per unit volume than the waffles. Moreover, wafers will contain at least eggs and perhaps milk ingredients, which can improve microbial activity, and therefore, until now the need to freeze waffles as the only way to inhibit microbial activity has been recognized. OTTO et al., U.S. Patent No. 4,426,401, discusses the packaging of perishable articles containing water, in aseptic packages. However, the package must include vents, through which steam can escape during the heat treatment of the items after they have been placed in the package. Subsequently, once the product has cooled, then the vents can be sealed. The Patent of the United States of North America Number 4,457,702 by MARCHETTI, describes the packing of food materials in polyethylene bags, which are then dropped into a hot water bath for subsequent reheating. DURST, Patent of the United States of America Number 4, 582,711, teaches the preparation of baked goods that can have a very long shelf life. However, these baked goods are effectively anhydrous, such as canned cake products, chocolate cookies or cakes, and the like. U.S. Patent No. 4,734,291 to RAFFENSPERGER refers to the preparation of al dente pasta products that can have a good shelf life. Here, the partially cooked pasta is extruded in a bag package; however, it is necessary to use enough water to reduce the pH to 4.6 or less. SUGISA A et al., U.S. Patent No. 4,777,057, refers to a semiprepared mass having a specific hardness, and which is loaded into a heat-resistant packaging container. After the package is sealed, then it is treated by heat. The mass system, in any case, is packed in its mass stage, after it vaporizes. United States Patent Number 4,911,939 to LOU et al. Refers to a cookie dough that is partially pre-baked, and then packaged and sealed. However, this cookie dough should have a high fructose content, and is intended specifically for microwave baking before consumption. SCHIRMER, U.S. Patent No. 4,928,474, discloses a refill container that can be filled with food that is sensitive to decomposition by contact with oxygen. The filled container is sealed by heat seal, then replicated, and then enclosed with an oxygen barrier material. The following patents of the prior art refer in particular to different apparatuses for the production of waffles, wafers or baked bread: The Patent of the United States of North America No. 4,058,039 of SCHMID teaches a waffle transfer machine, wherein the baked waffles are removed from a conventional waffle iron, cut out, and transferred to a transfer conveyor. In the illustrated embodiments, each waffle board comprises an articulated clam shell structure in which six waffles are baked at a time, and which subsequently require trimming, transfer, etc., for commercial packaging purposes. ESTOVER, United States Patent of North America Number 4,208,441, teaches a pair of cooking plates coupled auger, one on top of the other, each of which comprises a plate for cooking with bags that looks like a waffle iron. However, what is prepared is pizzas and the like, which are dough products raised with yeast. The dough requires mixing, rolling, cutting, and testing before baking. The dough sheets are placed between hot plates and closed by putting their edges in contact. The dough requires cutting, but it is essentially a bread dough. After the pizza dough has been baked, it can then be covered with pizza dressings, and then frozen. Two patents of HAAS and co-workers are Patents of the United States of North America Nos. 4,417,508 and 4,438,685. However, each of these patents relates to the preparation of wafers, which are prepared in a conventional hinged cover; and that, when baked, they are essentially anhydrous. U.S. Patent No. 4,769,245 of FARAR and co-workers, refers to the preparation of bread products that can be removed from their packaging for browning and serving. Special containers are provided for French bread, where the product is placed while it is hot enough to inactivate the microbial organisms that may be inside the product. However, a filter orifice orifice, which is small enough to allow the package to "breathe" to equalize the pressure inside and outside the package, is required. Care is taken that the air does not directly impact the packaged food product. HERTING, U.S. Patent No. 5,079,015, refers to a method of cooking at least partially multi-colored waffles in more or less conventional cooking forms, from which the waffles are then removed and passed to an oven to be finished. . The waffles are particularly intended to be used as ice cream cones and, therefore, are very thin and essentially anhydrous.

SUMMARY OF THE INVENTION: In accordance with one aspect of the present invention, a method is provided for the production of baked waffles for commercial sale in an unfrozen condition, in sealed aseptic packages. The method comprises the steps of: (a) Preparing a waffle paste, which has at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a yeast agent which can be baking powder or baking soda. (b) Dispense a measured quantity of waffle paste into a waffle form. (c) Close the waffle shape. (d) Place the waffle form closed and the wafie paste enclosed in it, in a baking oven. (e) Maintain the waffle form closed with the waffle paste in it in the oven at least until the waffle is baked to a degree less than 100 percent bake and greater than about 80 percent bake. The temperature of the inside of the waffle that is being baked must have reached at least 72 ° C. (f) Remove the waffle form and the baked waffle inside it from the baking oven. (g) Remove the hot baked waffle from the waffle shape. (h) Transfer the still hot baked waffle to a packing station. (i) Place the baked hot waffle in a heat stable package that is heat sealable. This step is taken while the baked waffle remains at an elevated temperature. Therefore, the package becomes aseptic. (j) Then the package is sealed. () Then the sealed aseptic package is allowed to cool to room temperature. (1) Finally, the cooled sealed package is placed in storage and handling facilities. Accordingly, then commercial sale of unfrozen baked waffles in sealed aseptic packages can be achieved. Keeping with another aspect of the present invention, there is provided an apparatus for the production of baked waffles for commercial sale in an unfrozen condition, in sealed aseptic packages. As noted above, baked waffles are prepared from a waffle paste that has at least flour, water,. sweeteners, whole eggs, vegetable oil or butter, and a yeast agent that can be baking powder or baking soda, as its constituents. The apparatus comprises a mixer in which the waffle paste is prepared, and a conveyor element for conveying the mixed waffle paste to a paste tank. The paste deposit has a control element to select a specific amount of waffle paste to be deposited in a waffle form; The waffle shape comprises lower and upper waffle iron covers that are configured to close together like a waffle iron inside of which a waffle will be baked. An oven is provided and will operate at a specified temperature, where the waffle iron and the waffle paste enclosed in it will be placed for a sufficient time to bake the waffle to a degree less than 100 percent baked and higher than approximately 80 percent baking. The baking process will continue, in any case, until the temperature of the inside of the waffle that is baking has reached at least 72 ° C. Items are provided to open and unload the waffle iron and remove the hot baked waffle from it to a conveyor, which transports the hot baked waffle away from the oven and into a packing station. At the packing station, the still hot baked waffle is placed in a heat stable package, while the baked waffle remains at a high temperature, to make the package aseptic. Elements are provided for sealing the heat stable package, cooling it to room temperature, and storing and handling the products for commercial sale of the baked waffles in an unfrozen condition. The lower and upper waffle plate covers, while maintaining a further aspect of the present invention, comprise links in continuous lower and upper chain slides of a plurality of similar waffle plate covers. The lower and upper chains are configured to pass through a tunnel furnace, and are separated to be sufficiently close to one another, so that each respective waffle iron is first opened and then closed in the respective upper and lower chains, and approach and move away from one another as they wrap around the respective drive and idle pinions for the respective chains.

BRIEF DESCRIPTION OF THE DRAWINGS: Now further details of all aspects of the present invention will be described by way of example, and in association with the accompanying drawings, in which: Figure 1 is a schematic drawing showing the main operating units that they comprise the apparatus of the present invention, and which show the flow of the product through the apparatus. Figure 2 is a schematic side elevation of an oven, keeping with the present invention. Figure 3 is a plan view of a typical link forming a chain of waffle iron covers, keeping with the present invention. Figure 4 is a cross-sectional view of a closed waffle iron, keeping with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED MODALITIES: Reference will now be made to Figures 1 to 4. First, with reference to Figure 1, a commercial apparatus 10 for the production of baked waffles, maintained with the present invention, will have the following main components or operative units: A mixer 12 is provided, where the waffle paste will be prepared. The waffle paste will generally comprise at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent which is usually baking powder or baking soda. As noted above, the waffle batter may additionally or optionally include a dairy product, which may be whole milk, skimmed or partially skimmed milk, or whey. Moreover, still an optional additional constituent of the waffle paste can be any one or more of lecithin, salt and flavoring ingredients, such as vanilla or fruit additives. Throughout the apparatus, there will be a variety of conveying elements, such as elements 13 or 15, which are suitably sized pipes through which the mixed waffle paste can be pumped. A containment tank 14 can be provided, as necessary. The waffle paste is transported as in 15 to a paste tank 16, which is configured to deposit the waffle paste in a waffle form, as described hereinafter. To ensure that each waffle to be prepared keeping the present invention has the same volume and mass, the control element 18 is associated with the paste tank 16 to select a specific amount of waffle paste to be deposited in a form of wafle. An oven 20 is provided, more details of which are described below, with respect to Figure 2. Furnace 20 has appropriate controls, such that it operates at a specified temperature, and can be fired by gas or electrically heated . The time during which the waffles are baked to a degree less than 100 percent bake, but greater than about 80 percent bake, and in any case, until the interior temperature of the waffle has reached at least 72 ° C, is discussed later. Again, the specifics of the waffle irons maintained with the present invention are discussed below, but it is clear that elements must be provided to open and unload the waffle irons after the waffles have been baked. The individual baked waffles come out of the oven 20, maintaining the usual arrangements of the present invention, where the waffles are passed through the oven on a conveyor, and they are passed on to another conveyor 22, which is configured to transport the waffles. hot baked goods moving away from the oven 20 and towards a packing unit 26. A sorter 24 can be interposed between the conveyor 22 and the packing unit 26, in such a way that selected numbers of waffles can be collected to be placed in packages for sale commercial. Intermediate conveyors 23 and 25 can also be provided. Inside the packing unit 26, there is a sealant 28 which is configured to seal the heat stable packages after the still warm baked waffles have been placed in them. Finally, next to other conveyors 29, generally identified elements are provided at 30, where the heat-stable packages sealed with the waffles baked therein, can be cooled, stored, put on pallets for boarding, and shipped. To the extent described so far, none of the operating components and units, with the exception of the heated conveyor 22, could be significantly different from what is found in any commercial waffle bakery. However, the presence of the conveyor 22 is important, because it ensures that the wafles, as they leave the oven 20, remain at elevated temperatures, to inhibit the microbial activity.

Turning to Figures 2, 3 and 4, other details of the furnace and waffle shapes are discussed in keeping with the present invention: • In general, furnace 20 comprises an insulated cover 40, inside of which there are two chain runners 42 and 44. The upper chain 42 is contained within the furnace 20, and the lower chain 44 extends beyond the inlet end 45 and the outlet end 47 of the furnace 20. Each chain slide 42 and 44 is wrapped around the impulse and crazy sprockets 46 and 48, which can be configured at either end of each chain as necessary and appropriate. The outlet from the paste reservoir 16 is shown at 51, being deposited on the upper range of the lower chain 44; the output of the separate baked waffles moves away from the lower chain 44 at 53. Turning to Figures 3 and 4, some details of the respective upper and lower chains 42 and 44 are discussed. Each chain is essentially identical to the other chain, except for the number of links comprising the respective chains, due to differences in their lengths. In Figure 3 a typical link 60 is shown. This link provides, in this case, a pair of waffle plate covers 62, each of which is identical to the other, and is configured in a typical waffle shape. Accordingly, each of the covers of the waffle plate may comprise a plurality of elevations 63 and indentations 65, as shown in Figure 4. Figure 4 also shows the manner in which the respective links of the chain slides upper and lower 42 and 44 are coupled together. Each of the links 60 is hinged to the links on either side by the connecting links (not shown) passed through the respective openings 66 and 68 to the left and right sides thereof, as shown. Each link 60 moves in the direction of either of the arrows 67 or 69. Accordingly, each of the upper and lower chains 42 and 44 passes through, or is contained in, the furnace 20, which is configured in the shape of a tunnel kiln. The respective upper and lower chain slides 42 and 44, as noted and shown in Figure 4, are sufficiently close to one another to form the waffle plate. As each of the lower and upper chain slides 42 and 44 approaches the other, when the upper chain 42 is wrapped around the pinion 46, as shown in Figure 2, each respective waffle plate will close. Then, when the upper chain 42 is wrapped around the pinion 48, each plate of respective waffles will open. Then, when the upper chain 42 is wrapped around the pinion 48, each respective wafle plate will open. Moreover, as each cover of the respective waffle board leaves the oven 20 at the outlet end 47, it is at least 80 percent baked and, consequently, is firmly formed so that it generally falls off the cover of the plate of waffles when the lower chain is wrapped around its respective pinion 48. Accordingly, the discharge element for the lower chain 44 is located beyond the outlet end of the furnace 20. If necessary, a selectively operated air jet can also be provided, either to blow the waffle at least 80 percent baked each respective waffle iron cover, or to lift it from the cover by vacuum. Once any baked waffle has been removed from its respective waffle plate cover 62 at the discharge station indicated generally by reference 53, it passes to conveyor 22. Here, as noted, the conveyor is such that it will ensure that the waffles , as they leave oven 20, remain at elevated temperatures. This is typically done by providing the conveyor 22 in the form of an additionally heated tunnel, where the temperature inside the tunnel is kept high enough so that the internal temperature of the waffles does not fall below anything less than 72 ° C. If the classifier 24 is present, its ambient temperature is also maintained at an elevated temperature, once again to preclude the cooling of the internal temperature of the freshly baked waffles below not less than 72 ° C. The purpose of the classifier is, particularly in an automated baked waffle manufacturing facility, to allow a selected number of waffles to be collected, so that they can be packaged together in a single package of, say, typically six or eight waffles, - for commercial sale purposes. The waffles, or groups of waffles, are then transported to the packing unit 26 by the complementary conveyor 25. In the packing unit 26, the waffles or the selected numbers of waffles are placed in their packages, while they are still hot. Preferably, as long as its internal temperature remains at least 72 ° C, to preclude or inhibit microbial activity after the waffle has cooled. Each package is generally formed of a heat stable polypropylene film having a heat sealable film laminated thereto. It is evident that any package can then be sealed by heat appropriately using a conventional heat sealing apparatus. Alternatively, the package may comprise a heat-filled plastic-filled heat-sealing cup, typically one that has been preformed using vacuum forming equipment, which can then be heat sealed or hermetically sealed by placing a cover film heat sealable or hermetically sealable on it. It is evident that, no matter what variety of package may be used, if the packaging material itself is stored and transported in an appropriate manner to the packing unit 26, and is filled and sealed in the sealant 28 while that at all times the internal temperature of the wafles that are placed in each heat sealed package remains above at least 72 ° C, then the heat retained inside each waffle will be sufficient to heat the air that can be captured in the package, and make the aseptic package in this way. It should be noted that, in general, the interior of the packing unit 26 and the sealant 28 is also maintained at elevated temperatures. In the case that the internal temperature of the waffles has cooled to less than approximately 72 ° C, or, in any case, for greater safety of the aseptic nature of the heat sealed package, since the material of the package supports temperatures of At least 90 ° C, it is possible to reheat the sealed aseptic packages to a temperature of approximately 90 ° C to reheat the baked waffles that are sealed in them. If the appropriate residence time is selected, then the internal temperature of each of the baked waffles will, once again, rise to at least 72 ° C. The importance of the temperature of approximately 72 ° C, of course, is that, at that temperature and higher, the microbial activity is substantially precluded, or the aseptic quality of the package is guaranteed; and if the sealed package becomes aseptic the moment it is sealed, or by subsequent subsequent or complementary heating, then the aseptic quality of the package will be ensured. Referring now to the pasta reservoir 16, it has associated with it a control element 18 whose purpose is to select and ensure that a specified amount of waffle paste is deposited in the waffle form. Typically, each waffle will weigh 30 to 75 grams. In any case, the volume of the waffle to be baked in each waffle plate shape is known, and since the density of the waffle paste is known, or can be easily determined, a precise quantity can therefore be deposited of pasta in each form of waffle iron. This ensures that there is no evaporation or spillage on the one hand, and that each waffle is fully developed and baked. It is obvious, of course, that any particular waffle shape and volume can be prepared by maintaining the present invention, merely by proper design of the covers of the waffle plate 62 and the links 60 in which they are formed. The material from which the links 60 are formed can conveniently be cast aluminum or other suitable materials, such as cast iron, and can be appropriately coated with a non-tacky material, such as PTFE. Moreover, a suitable vegetable oil spray can be used, by spraying on each respective waffle plate cover at an appropriate station at or near the inlet end 45 of the furnace 20. Of course, it is a simple matter, having determined the shape, volume, and weight of each waffle to be baked, calculate and set the appropriate temperatures inside the oven 20, and the residence time for each respective waffle plate shape, to pass through the oven 20, so that each waffle can be at least 80 percent baked, but less than 100 percent baked. Typically, the interior of the oven is maintained at approximately 170 ° C or 225 ° C, depending on the formulation. A typical residence time for each waffle, as it passes through oven 20, is approximately 95 seconds. Accordingly, the driving speed of the upper and lower chains 42 and 44 can be easily adjusted in an appropriate manner. In the same way, the interior of the conveyor 22, the sorter 24, and the packing unit 26, are normally maintained at least at about 75 ° C, usually at about 90 ° C. This guarantees that, once the inside of each waffle, when it has been baked, has reached the temperature of about 72 ° C, it will not cool below that temperature. Moreover, there is little incremental firing activity that continues after the waffles have been removed from their respective waffle irons, because there is no significant heat differential between the waffle temperature and the environmental temperature within which is maintaining. From all of the above, it follows that the steps taken for the production of baked waffles for commercial sale in an unfrozen condition in sealed aseptic packages, maintained with the present invention, will be essentially as follows: (a) First, prepare the Waffle paste. As noted, the waffle paste will have at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a yeast agent that is usually baking powder or baking soda. As noted, the waffle batter may further comprise a dairy product, such as whole milk, skimmed or partially skimmed milk, and whey; and may have an optional additional constituent, such as lecithin, salt, and flavoring ingredient, such as vanilla or a fruit additive. (b) A specific measured quantity of waffle paste is dosed in a waffle form. (c) Then the waffle shape is closed. (d) Then, the closed waffle shape, with the waffle paste inside it, is placed in an oven. Typically, as discussed, this involves the passage of a waffle shape such as a link or a portion of a link in a chain passing through a tunnel kiln, but other kiln and / or plate installations may also be employed. of waffles. (e) Each closed waffle form and the waffle paste inside it is kept in the oven for a sufficient residence time for the waffle to be baked to a lesser degree than 100 percent baked, but greater than about 80 percent baked. Moreover, the temperature of the oven and the residence time of each waffle form inside it, will be selected, in any case, so that the internal temperature of the waffle being baked reaches at least 72 ° C. (f) Then, the baked waffle shape and the waffle baked inside it will be removed from the oven. (g) The hot baked waffle will be removed from the waffle shape. (h) The still hot baked waffle will be transferred to a packing station. This normally requires, as noted above, that the hot baked waffle be passed through a heated zone on a conveyor, where its temperature is kept high enough so that the internal temperature of the baked waffle remains above at least 72 ° C. . (i) Moreover, while keeping the inside of the waffle above at least about 72 ° C, the waffle is placed in a heat-stable package, which can be sealed while the baked waffle still remains at an elevated temperature . This will make the aseptic package, as discussed above. (j) The package is then sealed, usually by heat sealing. (k) Subsequently, the sealed aseptic package is allowed to cool to room temperature. It is not necessary, in keeping with the provisions of the present invention, to lower the temperature of sealed aseptic packages with the waffles baked therein to less than room temperature.; specifically, it is not necessary to freeze the baked waffles. (1) Finally, sealed and cooled aseptic packages (at room temperature) of baked waffles are placed in storage or handling facilities from where they can be delivered to commercial distribution streams for commercial sale of non-frozen waffles in your aseptic packages sealed. As noted above, in general, each package will contain a selected number of sealed waffles; however, it is possible, for industries such as hospitality industry, hotels, hospitals and the like, that individual baked waffles may be distributed in their respective sealed aseptic packages. When waffles are removed from their sealed aseptic packages, they are generally intended to overheat when placed in a toaster or in a conventional oven for consumption. By reheating in a toaster or in an oven, which is heated by radiant heat that is transferred to the waffle, the discontinued baking procedure for the waffle will be completed. This is because there is still a significant moisture content inside the waffle, and because there is no significant crust that has formed on the outer surface of the waffle. Moreover, due to the nature of the waffle formation, they have a very high ratio of surface area to volume or mass, compared to bread or pizza doughs, and the like, and the transfer of heat to the waffle is very quickly. It is evident that there can be significant savings in terms of capital expenditure to build ps and equipment, operating costs to store and ship the baked waffles prepared by the present invention, and the energy expended, compared to the frozen waffles that are currently available. in the market. No need to build freezers, frozen storage facilities, frozen delivery facilities, and frozen retail cabinets; nor is there any need to expend energy to remove the heat from the baked waffles to freeze them and then keep them in a frozen condition. As stated above, the costs of the materials and the amount of materials used in keeping with the present invention, compared to frozen waffles currently commercially available, will be essentially the same. The waffles will be the same, the packaging will be essentially the same as the wrapping material, the retail boxes will be essentially the same, and even the shipping boxes will be essentially the same, except that they do not need to prepare especially for handling at extremely high temperatures low. The waffles prepared by killing themselves with the present invention are delivered to the consumer in an unfrozen condition, which means that the consumer does not need to provide special storage facilities, such as home freezers or the like for storing them before consumption. However, once removed from their aseptic packaging, the wafles that are not consumed should be refrigerated, since microbial activity could be restarted at that time. Otherwise, the baked waffles provided by the present invention to the market in an unfrozen condition in aseptic packages, may have a shelf life of three or four months. Accordingly, it follows that, baked waffles, remaining with the present invention, can be delivered to the consumer for a lower cost, and therefore, can be purchased by the consumer for a lower price. There are additional concerns for the environment, as there is no wasted energy required to freeze the waffles or to keep them in a frozen condition. All of the above is achieved, as noted, without the requirement of additional chemical additives or preservatives in the waffle paste., without the need to inject inert gases, such as carbon dioxide in the packages, and without the need to use vacuum technology to remove trapped air from the packaging. Still further, and in any case, the package that is provided in keeping with the present invention, will allow the sealed aseptic package to be reheated, if necessary and appropriate. However, this does not require irradiation or other sterilization or pasteurization techniques, since the waffles have been sealed in packages that become aseptic due to the incipient or specific heat that remains inside the waffles as they are placed in the package, and measuring in this way or precluding the microbial activity. Other modifications and alterations may be employed in the design and manufacture of the apparatus of the present invention, without departing from the spirit and scope of the appended claims.

Claims (20)

1. A method for producing baked waffles for commercial sale in an unfrozen condition in aseptic sealed packages, which comprises the steps of: (a) preparing a waffle paste having at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a yeast agent selected from the group consisting of baking powder and baking soda, as its constituents; (b) dosing a measured amount of waffle paste in a waffle form; (c) close the waffle shape; (d) placing the closed waffle shape and the wafle paste enclosed in it, in an oven; (e) keep the waffle shape closed and the waffle paste in the oven at least until the waffle is baked to a degree less than 100 percent baked and greater than about 80 percent baked, and until at least the temperature of the interior of the waffle being baked has reached at least 72 ° C; (f) remove the baked waffle form and the baked pasta from the oven; (g) stir the hot baked waffle from the waffle shape; (h) transferring the still-hot baked waffle to a packing station; (i) placing the still-heated baked waffle in a heat-stable package that can be sealed while the baked waffle remains at an elevated temperature, whereby the package becomes aseptic; (j) seal the package; (k) allow the sealed aseptic package to cool to room temperature; and (1) placing the sealed package cooled in storage and handling facilities for commercial sale in an unfrozen condition in the sealed aseptic package.

The method of claim 1, wherein the waffle batter may optionally further comprise a dairy product selected from the group consisting of whole milk, skimmed or partially skimmed milk, and whey; and an additional optional constituent selected from any one or more of the group consisting of lecithin, salt and flavoring ingredients.

3. The method of claim 1, wherein step (h) is performed by passing the baked waffle through a heated zone having a sufficiently high temperature to maintain the internal temperature of the baked waffle at least at 72 ° C until step (i) is completed.

4. The method of claim 1, wherein the aseptic package comprises a heat-stable polypropylene film having a heat-sealable film laminated thereto, to allow its heat sealing.

The method of claim 1, wherein the aseptic package comprises a heat-filled plastic-filled heat-seal cup, and a heat-sealable or hermetically sealed cover film.

The method of claim 1, wherein the heat-stable aseptic package will withstand temperatures of at least 90 ° C.

The method of claim 6, wherein, after step (j), the sealed aseptic package is reheated to a temperature of up to 90 ° C, to reheat the baked waffle sealed therein, at least until the temperature of the baked waffle should rise to at least 72 ° C.

The method of claim 1, wherein step (i) is repeated until a selected number of baked hot waffles are placed in the heat stable package, followed subsequently by step (j) and the following.

9. An apparatus for the production of baked waffles for commercial sale in an unfrozen condition in sealed aseptic packages, wherein the baked waffles are prepared from a waffle paste having at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a yeast agent selected from the group consisting of baking powder and baking soda, as its constituents, this apparatus comprising: a mixer for the preparation of the waffle paste; a conveyor element for transporting the mixed waffle paste to a paste tank; the paste container having a control element for selecting a specific amount of waffle paste to be deposited in a waffle form; a waffle shape comprising lower and upper waffle iron covers configured to close together like a waffle iron inside which a waffle will be baked; an oven operating at a specified temperature, in which the waffle iron is placed for a sufficient time to bake the waffle to a degree less than 100 percent baked, and greater than about 80 percent baked, and until the temperature of the interior of the waffle being baked has reached at least 72 ° C; an opening and unloading element for opening and unloading the hot baked waffle from the waffle iron; a conveyor element for transporting the hot baked waffle away from the oven and towards a packing station; a packing station where the baked hot waffle is placed in a heat stable package, while the baked waffle remains at an elevated temperature, whereby the package becomes aseptic; a sealing element for sealing the heat-stable package; a cooling element for cooling the stable package to the sealed heat and the baked waffle thereof, at room temperature; and a storage and handling element for placing a plurality of sealed and aseptic packages cooled in channels for commercial sale in an unfrozen condition.

The apparatus of claim 9, wherein a containment tank is interposed for the waffle paste mixed between the mixer and the paste tank.

The apparatus of claim 9, wherein the lower and upper waffle plate covers of the waffle plate each comprise a link in a respective continuous lower and upper chain of a plurality of similar waffle plate covers, wherein each chain is wrapped around respective impulse and idler sprockets at each end of the chain slider formed by the same; wherein each of the lower and upper chains is configured to pass through a tunnel oven in such a manner that the respective upper and lower waffle iron covers face each other to form the waffle iron, and the slides the respective lower and upper chain are separated sufficiently close to each other, and configured in such a way that each respective waffle plate is first opened and then closed as the upper cover approaches a respective lower cover; and wherein the opening element for the waffle iron is formed by the upper chain moving away from the lower chain as it is wrapped around a pinion at one end, and the discharge element is formed at least in part by the lower chain as it is wrapped around a pinion at its respective end.

The apparatus of claim 11, wherein each link of the lower and upper chains of the waffle plate covers comprises at least two similar waffle plate covers in a juxtaposed relation to each other, in a transverse direction with regarding the length of each of the chains.

The apparatus of claim 11, wherein the lower chain of the waffle iron covers extends beyond an inlet and outlet end of the tunnel kiln, wherein the pulp tank is located at the end of the tunnel. inlet for depositing a specific amount of waffle paste on each lower or respective waffle plate cover, and wherein the unloading element is located beyond the outlet end of the oven.

The apparatus of claim 11, wherein the packing station is configured to form aseptic packages for the baked waffles, wherein each package comprises a heat stable polypropylene film having a heat sealable film laminated thereto, to allow its heat sealing.

15. The apparatus of claim 11, wherein the packaging station is configured to form aseptic packages for the baked waffles, wherein each package comprises a heat-formed plastic filling cup and a heat-sealable cover film. hermetically sealed

16. The apparatus of claim 11, which further comprises, an area of the heated discharge conveyor located at the exit end of the furnace, where the temperature is kept sufficiently high in the area of the heated discharge conveyor, to maintain the internal temperature of each baked waffle at least at 72 ° C while each baked waffle is transported through it.

17. The apparatus of claim 11, wherein each heat-stable aseptic package in which the baked waffles are placed will withstand temperatures of at least 90 ° C.

18. The apparatus of claim 17, which further comprises a package reheat element, wherein the sealed aseptic packages of baked waffles can be reheated to a temperature of up to 90 ° C, to reheat the baked waffles sealed therein at least until its internal temperature rises to at least 72 ° C. The apparatus of claim 11, wherein the packing station is configured in such a way that a selected number of the baked hot waffles are placed in each stable aseptic package before each of these packages is sealed. The apparatus of claim 13, wherein the discharge element further comprises a selectively operated air jet to assist in the separation of a baked waffle from its respective lower waffle iron cover. SUMMARY Baked waffles, especially waffles for lunch, are brought to the market for commercial sale in an unfrozen condition, packed in aseptic sealed packages. The waffles are prepared by baking to a degree less than 100 percent and greater than about 80 percent baking, and at least until the temperature of the inside of the waffle being baked has reached at least 72 ° C. The waffles are removed from their waffle form and transferred to a packing station while they are still hot, and placed in a heat-stable package that is sealed while each baked waffle remains at an elevated temperature, thus making the aseptic package. The sealed aseptic packages are cooled and stored in such a way that the baked waffles arrive for commercial sale in an unfrozen condition. Baked waffles, in their sealed aseptic packages, can have a shelf life of up to three months. Conveniently, the baked waffles are prepared in an apparatus comprising two chains of opposing waffle sheet shapes passing through a baking oven. The sliders of the chains formed by a plurality of opposite waffle plates are placed in such a way that the waffle plates are closed and opened due to the geometry of the chains slides, whereby the loading is easily carried out and discharge of each respective waffle iron. In general, a zone of the heated discharge conveyor is located at the exit end of the furnace, in such a way that • v the temperature of the baked waffles remains at a high temperature throughout the entire period of time following baking, and until it is placed in the package. This makes the package aseptic; and after sealing the aseptic package, it is taken for its cooling and subsequent handling to the commercial market. Therefore, the baked waffles are brought to the market not frozen, in sealed aseptic packages. * * * * *