WO2011005656A1

WO2011005656A1 - Automated ready-to-cook wonton production apparatus, system, and method

Info

Publication number: WO2011005656A1
Application number: PCT/US2010/040777
Authority: WO
Inventors: Chris Field; Myron M. Uecker; Jie Sun; Ralph Stenvik; Samuele Palagiano
Original assignee: General Mills Marketing, Inc.
Priority date: 2009-07-06
Filing date: 2010-07-01
Publication date: 2011-01-13
Also published as: CN101940230B; CN101940230A; HK1152843A1

Abstract

An automated method for producing a ready-to-cook wonton from a wonton intermediate product including a shell containing a filler material. The intermediate product is defined by a central portion and opposing end portions. The intermediate product is placed on a base plate, with the first end portion aligned with of a first engagement mechanism, and the second end portion aligned with a second engagement mechanism. The engagement mechanisms are operated to engage the first end portions at first and second centerlines, respectively. The second centerline is vertically off-set from the first centerline. The engagement mechanisms are rotated to wrap the first and second ends toward the central portion. Following rotation, the second end portion overlaps the first end portion. A pinching force is applied onto the overlapped first and second ends in forming a completed ready-to-cook wonton.

Description

AUTOMATED READY-TO-COOK WONTON PRODUCTION APPARATUS,

SYSTEM, AND METHOD

Background

The present disclosure relates to production of ready-to-cook wontons. More particularly, it relates to systems and methods for mass producing ready-to-cook wontons having shapes and other characteristics highly akin to a handmade ready-to-cook wonton.

Wontons are a highly popular food item, and generally consist of an outer dough or pasta shell containing an edible filler material (e.g., meat, shrimp, spices, etc.). Wonton preparation essentially consists of folding and sealing the outer dough wrapper about the filler material to form a ready-to-cook wonton, followed by cooking of the ready-to-cook wonton (e.g., boiling, deep frying, etc.).

Wontons are generally akin to other stuffed dumpling or pasta food items, such as tortellinis and even raviolis. However, in addition to having a distinctive taste and texture (that is otherwise a function of the ingredients used for the outer shell and filler material), wontons are characterized by a unique shape. As a point of clarification, in different regions of the world, wontons may have differing preferred shapes; for purposes of this disclosure, the "wonton shape" is in reference to the semi-pentagonal wonton traditionally served in China (e.g., chao shou in Sichuan cuisine) in which ends of the outer wrapper are folded and pressed into the middle. While the wonton shape is somewhat akin to that of a tortellini, there are clear differences that are readily apparent to avid consumers of wontons.

The art of hand-making a ready-to-cook wonton has been practiced for countless years, and mass production of ready-to-cook wontons continues to primarily be manual. Perhaps due to the somewhat similar shapes of wontons and tortellinis, some attempts have been made to employ automated tortellini machinery to mass produce ready-to- cook wontons. Unfortunately, such efforts have been met with limited success. For example, the inventors of the pending disclosure have discovered that while a ready-to- cook wonton manufactured from tortellini machinery may have a highly pleasing taste, the product itself does not "look" like a wonton; instead, it is shaped like a tortellini. As a point of reference, the production of both wontons and tortellinis generally entails depositing a volume of edible filler material onto a dough piece or form, and then folding the dough form onto itself. Subsequently, opposing ends of the so-folded shell are wrapped toward one another and pressed together, adhering or bonding the opposing ends to one another. With tortellinis, the adhered ends are positioned side-by-side and are spaced from a remainder (i.e., the middle) of the shell, such that the tortellini has a ring-like shape. In contrast, with wontons, the opposing ends are overlapped (i.e., positioned top-to-bottom) and pinched into close proximity to the filler material pocket. Further, the perimeter edge of a wonton is folded upwardly. It has been discovered that automated tortellini machinery cannot replicate this shape, and a seasoned consumer will quickly recognize the difference between a tortellini-shaped item and a wonton-shaped item. For example, the side-to-side arrangement of the tortellini ends is visually distinct from the top-to-bottom arrangement of wontons. Further, tortellinis effectively present eight layers of shell dough at the region of interface between the ends, as compared to four layers with wontons. This, in turn, creates differing cooking concerns and taste/textures.

In light of the above, a need exists for automated systems and methods for mass producing ready-to-cook wontons having the shape of a traditional wonton.

Summary

Some aspects in accordance with principles of the present disclosure relate to an automated method for producing a ready-to-cook wonton. The method includes providing a wonton intermediate product including a dough shell that forms a pocket containing an edible filler material. In this regard, the intermediate product is defined by a central portion, a first end portion, and a second end portion. The filler material is maintained at the central portion. The first and second end portions extend in an opposing fashion from the central portion. The so-provided intermediate product is placed on a base plate defining a plane, with the first end portion being aligned with a first engagement mechanism and the second end portion being aligned with a second engagement mechanism. The first engagement mechanism is operated to automatically engage the first end portion at a first engagement centerline. The second engagement mechanism is similarly operated to automatically engage the second end portion at a second engagement centerline. The second engagement centerline is vertically off-set from the first engagement centerline relative to the base plate plane. A motorized drive unit is operated to rotate the first engagement mechanism relative to the base plate to wrap the first end portion toward the central portion, as well as to rotate the second engagement mechanism relative to the base plate to wrap the second end portion toward the central portion. Following rotation of the first and second engagement mechanisms, the second end portion overlaps and overlies the first end portion. A pinching force is applied onto the overlapped first and second end portions to adhere the end portions in forming a completed ready-to-cook wonton. The first and second engagement mechanisms are released from the ready-to-cook wonton, and the completed product is ejected from the base plate. With this methodology, acceptably-shaped ready-to-cook wontons can be mass produced in an automated fashion, and are well-accepted by otherwise demanding consumers. In some embodiments, the method further includes applying a lifting force to the trailing side of the intermediate product simultaneously with rotation of the first and second engagement mechanisms.

Other aspects in accordance with principles of the present disclosure relate to a forming apparatus for producing ready-to-cook wontons from wonton intermediate products. The wonton intermediate product includes a dough shell forming a pocket containing an edible filler material, and defining a central portion and opposing first and second end portions. With this in mind, the forming apparatus includes a base plate mechanism, first and second engagement mechanisms, and a drive unit. The base plate mechanism includes a base plate defining a plane, with the base plate mechanism configured to selectively maintain an intermediate product on the base plate at a known spatial location having an intermediate product centerline. The first and second engagement mechanisms are arranged at opposite sides of the intermediate product centerline. Further, the engagement mechanisms include at least one finger forming an engagement surface. The finger is movable between a released state and an engagement state. Further, an engagement centerline is established at least in part by the engagement surface in the engagement state. In this regard, a vertical location of the engagement centerline of the first engagement mechanism relative to the base plate plane is different from a vertical location of the engagement centerline of the second engagement mechanism relative to the base plate plane. The drive unit is adapted to selectively rotate the first and second engagement mechanisms relative to the base plate. With this construction, the forming apparatus is adapted to locate an intermediate product on the base plate, engage and wrap the opposing end portions relative to the central portion in an overlapping arrangement via the engagement mechanisms and the drive unit, and apply a pinching force to overlapped segments in forming a completed ready-to-cook wonton. In some embodiments, the forming apparatus further includes a lifting mechanism associated with the base plate and adapted to apply an upward lifting force to a trailing side of an intermediate product disposed on the base plate.

Yet other aspects in accordance with the principles of the present disclosure relate to a system for producing ready-to-cook wontons. The system includes an intermediate product forming station and the forming apparatus described above. The intermediate product forming station includes an injector device and a folding mechanism, and operates to dispense a volume of filler material onto a dough form, and then fold the dough form to generate the intermediate product. A cutting device can also be provided with the system, adapted to form a dough piece from a dough sheet. In related embodiments, the folding mechanism forms an outlet from which the intermediate product is ejected, with the outlet being located adjacent the base plate of the forming apparatus.

Brief Description of the Drawings

FIG. 1 is a perspective view of a forming apparatus in accordance with principles of the present disclosure and adapted to produce a ready-to-cook wonton from a wonton intermediate product;

FIG. 2 is a perspective view of the apparatus of FIG. 1, illustrating a base plate mechanism in a stopping state;

FIGS. 3 A and 3 B are side views of the apparatus of FIG. 1, illustrating operation of the base plate mechanism;

FIG. 4 is a perspective view of the apparatus of FIG. 1, illustrating operation of the engagement mechanisms components in a grasping state;

FIG. 5 A is a front view of the apparatus of FIG. 4;

FIG. 5B is an enlarged, side view of portions of the apparatus of FIG. 5 A;

FIG. 6 is a perspective view of the apparatus of FIG. 1, illustrating rotation of the engagement mechanisms to a wrapped state; FIGS. 7 A and 7B are side views of the apparatus of FIG. 1, illustrating operation of a pinching mechanism;

FIGS. 8 A and 8B are side views of the apparatus of FIG. 1, illustrating operation of a lifting mechanism;

FIG. 9 is a block diagram of a wonton production system in accordance with principles of the present disclosure;

FIG. 10 is a simplified top view illustrating formation of a wonton intermediate product;

FIG. 11 is a cross-sectional view of a portion of the intermediate product of FIG. 10;

FIG. 12A is a side view of the apparatus of FIG. 1 during initial stages of processing an intermediate product;

FIG. 12B is a front view of the apparatus of FIG. 12 A;

FIG. 13 is a simplified, top perspective view of a wonton intermediate product during processing with the apparatus of FIG. 1 ;

FIG. 14 is a side view of the apparatus of FIG. 1, illustrating application of a lifting force on to a wonton intermediate product;

FIG. 15 A is a cross-sectional view of a portion of the apparatus of FIG. 1 in applying a pinching force on to a wonton intermediate product; and

FIG. 15B is a simplified, top perspective view of a ready-to-cook wonton manufactured in accordance with principles of the present disclosure

Detailed Description

One construction of a forming apparatus 20 in accordance with principles of the present disclosure for producing a ready-to-cook wonton from a wonton intermediate product is shown in FIG. 1. The apparatus 20 includes a base plate mechanism 22, a first engagement mechanism 24, a second engagement mechanism 26, an optional drive unit

28, a pinching mechanism 30, and an optional lifting mechanism 32 (referenced generally). Details on the various components are provided below. In general terms, however, the base plate mechanism 22 is operable to temporarily maintain an intermediate product at a known spatial location having an intermediate product centerline. The engagement mechanisms 24, 26 are configured at opposite sides of the intermediate product centerline to engage (e.g., grasp) and then wrap the intermediate product onto itself via operation of the drive unit 28. The pinching mechanism 30 is configured to apply a pinching force onto the intermediate product, whereas the lifting mechanism 32 applies a lifting force to a trailing edge of the intermediate product. With these actions, then, the forming apparatus 20 produces a completed, ready-to-cook wonton product having a shape and appearance highly akin to a hand-made wonton, including overlapped (e.g., top-to-bottom) ends via operation of the engagement mechanisms 24, 26. This desirable shape is marketedly distinct from products formed by tortellini machinery. Though not shown in FIG. 1, the apparatus 20 can include additional features, such as a frame to which one or more of the various components 22- 32 are assembled, as well as a controller that controls and coordinates operation of the components 22-32. The apparatus 20 may further comprise a device that prevents the intermediate product or the ready-to-cook wonton product from adhering to the components of the apparatus 20, for example, a device spreading powder (e.g. wheaten powder) onto the base plate mechanism 22. Such a device is commonly known in the art and thus will not be described in detail.

The base plate mechanism 22 can assume a variety of forms, and generally includes, in some constructions, a base plate 40 and a stop device 42. The base plate 40 establishes or forms a support surface 44 terminating at a leading end 46. An entirety of the support surface 44 can be planar; alternatively, a declining region 48 can be provided for reasons made clear below. Regardless, the support surface 44 establishes a planar surface at which at least a majority of an intermediate product will be retained at a known spatial elevation.

The stop device 42 is operably associated with the base plate 40, and can be articulated from a retracted state of FIG. 1 , in which the stop device 42 is retracted from the support surface 44, to a stopping state (FIG. 2) in which the stop device 42 intersects and projects beyond a plane of the support surface 44. For example, the stop device 42 can be assembled to a linkage 50 including a first bar 52 pivotably connected to a second bar 54. The second bar 54 is connected to a drive motor (not shown) that causes rotation of the second bar 54 about a pivot point 56 (counterclockwise relative to the orientation of FIG. 1). This motion, in turn, directs the first bar 52, and thus the stop device 42 attached thereto, upwardly relative to the base plate 40 (via, for example, one or more guides (not shown) that constrain movement of the first bar 52). It will be understood, however, that the stop device 42, as well as the linkage 50 and related drive components, can assume a variety of forms differing from those illustrated. Further, while only a single stop device 42 is illustrated, in other embodiments, two or more are provided. Also, the stop device 42 can be arranged "above" the base plate 40 and operated to move downwardly from a retracted state to a stopping state. Regardless, and with reference to FIGS. 3 A and 3 B, the stop device 42 establishes a stop surface 60 that is selectively maneuvered between the retracted state of FIG. 3 A and the stopping state of FIG. 3B. In the stopping state, the stop surface 60 projects from the support surface 44 of the base plate 40 immediately adjacent the leading end 46, temporarily retaining an intermediate product (not shown) at a known forward spatial location by limiting forward movement (e.g., leftward movement relative to the orientation of FIG. 3B) of the intermediate product (not shown) otherwise fed onto the support surface 44.

Returning to FIG. 1 and with additional reference to FIG. 4, the first and second engagement mechanisms 24, 26 can be highly identical, such that the following description of the second engagement mechanism 26 applies equally to the first engagement mechanism 24. The engagement mechanism 26 in some embodiments is akin to a jaw, and generally includes opposing, first and second fingers 70, 72, as well as a motorized drive mechanism 74 (referenced generally) operable to articulate the fingers 70, 72 relative to one another between an open or released state (FIG. 1) and a substantially closed or engagement state (FIG. 4). More particularly, the fingers 70, 72 each form an engagement surface 76, 78, respectively (it being understood that in the view of FIG. 1, the engagement surface 76 of the first finger 70 is visible, whereas the engagement surface 78 of the second finger 72 is hidden and thus is referenced generally). The engagement surfaces 76, 78 are substantially parallel (e.g., within 5° of a true parallel relationship), and a vertical spacing between the engagement surfaces 76, 78 is greater in the released state (FIG. 1) as compared to the engagement state (FIG. 4). In this regard, an established distance between the engagement surfaces 76, 78 in the engagement state is dictated by the drive mechanism 74, and approximates (e.g., is slightly smaller than) an expected thickness of an intermediate product portion disposed there between.

The engagement mechanism 26 can include a variety of different components that establish the above-described movable relationship between the first and second fingers 70, 72. For example, with some constructions, the first finger 70 extends from, or is attached to, a first arm 80, whereas the second finger 72 is attached to, or extends from, a second arm 82. The second arm 82 is slidably linked with the first arm 80 (e.g., via a pin 84 disposed within a slot 86 formed by the first arm 80). In some embodiments, the first arm 80 is stationary, with the drive mechanism 74 acting upon the second arm 82 to effectuate movement of the second finger 72 relative to the first finger 70. More particularly, with the one acceptable configuration of FIGS. 1 and 4, the second arm 82, and thus the second finger 72, is linearly driven relative to the first finger 70. Alternatively, the engagement mechanism 26 can be constructed such that the first finger 70 is movable relative to the second finger 72, or both of these fingers 70, 72 can be movable via operation of the drive mechanism 74. In yet other embodiments, non- linear movement between the fingers 70, 72 can be established.

While the engagement mechanisms 24, 26 can be similarly configured, an arrangement of the engagement mechanisms 24, 26 relative to the base plate 40 can vary in one or more respects. For example, for reasons made clear below, in some configurations the fingers 70, 72 of the first engagement mechanism 24 can be longitudinally forward of the fingers 70, 72 of the second engagement mechanism 26.

Stated otherwise, a longitudinal spacing between the fingers 70, 72 of the first engagement mechanism 24 relative to the leading end 46 (which may characterize the forward spatial location) of the base plate 40 is less than a longitudinal distance between the fingers 70, 72 of the second engagement mechanism 26 relative to the leading end 46.

Alternatively or in addition, in at least the engagement state of FIG. 4, the fingers 70, 72 of the first engagement mechanism 24 are slightly vertically below the fingers 70, 72 of the second engagement mechanism 26. For example, and as shown in FIG. 5 A, in the engagement state of the first and second engagement mechanisms 24, 26, a first engagement centerline 90 is established between the fingers 70, 72 of the first engagement mechanism 24, and a second engagement centerline 92 is established between the fingers 70, 72 of the second engagement mechanism 26. Relative to the orientation of FIG. 5 A, the first engagement centerline 90 is vertically below the second engagement centerline 92. Stated otherwise, the engagement surface 76 of the first finger 70 of the first engagement mechanism 24 is vertically below the engagement surface 76 of the first finger 70 of the second engagement mechanism 26. Thus, relative to a plane of the support surface 44 of the base plate 40, the engagement centerlines 90, 92 are vertically off-set from one another, with this relationship being more clearly illustrated in the enlarged side view of FIG. 5B in which relevant portions of the first and second engagement mechanism 24, 26 in the engagement state are shown side-by-side. Further, the engagement surfaces 76, 78 of the fingers 70, 72 of the first engagement mechanism 24 establish an angle of extension differing from that of the second engagement mechanism 26. In particular, relative to the leading end 46 of the base plate 40, the engagement surfaces 76, 78 of the first engagement mechanism 24 project upwardly (with an angle of about 7° in the embodiment) relative to the base plate 40 in rearward extension from the leading end 46. Conversely, the engagement surfaces 76, 78 of the second engagement mechanism 26 project downwardly (with an angle of about 7° in the embodiment) in rearward extension relative to the leading end 46. As described below, the disparate angles of extension and/or vertical elevations of the fingers 70, 72 of the engagement mechanisms 24, 26 in at least the engagement state promotes desired wrapping of a wonton intermediate product during manufacture.

Returning to FIG. 1, and with additional reference to FIG. 6, the drive unit 28 is operable to rotate the engagement mechanism 24, 26 between an initial state (FIG. 1) and a wrapped state (FIG. 6). In this regard, the drive unit 28 can assume a wide variety of forms commensurate with a construction of the engagement mechanisms 24, 26, and in some embodiments includes a motor-driven, rack and pinion-type arrangement. With this but one acceptable construction, a toothed rack 100 (best seen in FIG. 1) is driven in a linear fashion by a motor (not shown). Further, a corresponding gear body is coupled to each of the engagement mechanisms 24, 26, respectively. As a point of reference, the gear bodies are hidden in the views of FIGS. 1 and 6, but are identified in FIG. 5 A as gear bodies 102, 104. The first gear body 102 is coupled to the first engagement mechanism 24, whereas the second gear body 104 is coupled to the second engagement mechanism 26. Teeth provided with the gear bodies 102, 104 mesh with the teeth of the toothed rack 100. Thus, with movement of the rack 100, the gear bodies 102, 104 rotate, in turn applying a moment force onto the corresponding engagement mechanism 24, 26 to induce rotation thereof (e.g., the fingers 70, 72 of the first engagement mechanism 24 rotate as a single unit). In some constructions, the drive unit 28 operates such that the engagement mechanisms 24, 26 rotate at the same time, at least from the initial state (FIG. 1) to the wrapped state (FIG. 6). In other embodiments, the drive unit 28 is operable to incorporate a slight delay such that rotation of the first engagement mechanism 24 is initiated slightly before rotation of the second engagement mechanism 26. In yet other embodiments, the drive unit 28 can assume a variety of other forms that may or may not incorporate a rack and pinion design. For example, a separate, servo- controlled motor can be provided for each of the engagement mechanisms 24, 26; a cam- based device can be employed; etc. Thus, a "drive unit" in accordance with the present disclosure is inclusive of a single drive device that operates both of the engagement mechanism 24, 26, or two (or more) drive devices that independently operate the engagement mechanisms 24, 26 separately from one another.

With specific reference to FIG. 1, the optional pinching mechanism 30 can generally include a rod 110 and a bearing surface 112. The rod 110 terminates at a pressing end 114, and is linearly driven by a motor (not shown) between a raised state (FIG. 1) and a pinching state described below. The bearing surface 112 is axially aligned with the rod 110, and in some embodiments is formed by or on the stop device 42 described above.

Regardless of an exact construction, transitioning of the pinching mechanism 30 is best illustrated in FIGS. 7 A and 7B. In the raised state of FIG. 7 A, the pressing end 114 of the rod 110 is displaced from the bearing surface 112; conversely, in the pinching state of FIG. 7B, the pressing end 114 is brought into highly close proximity with the bearing surface 112. A distance between the pressing end 114 and the bearing surface 112 is predetermined in the pinching state, and is selected as function of an expected overall thickness of material to be located therebetween. More particularly, the distance is selected to achieve distinct pinching of wonton outer wrapper dough layers, but not overtly crush or puncture the dough. In some embodiments, the pressing end 114 and the bearing surface 112 are arranged to define corresponding, non-perpendicular angles relative to an axis of the rod 110. In other constructions, however, the pressing end 114 and the bearing surface 112 can be perpendicular relative to the axis of the rod 110. Also, the pinching mechanism 30 can assume a variety of other forms adapted to provide the desired pinching force that may or may not include a linearly-driven rod. In yet other embodiments, the engagement mechanisms 24, 26 can be configured to simultaneously effectuate a pinching action when wrapping the wonton intermediate product, such that the discrete pinching mechanism 30 can be eliminated.

Returning to FIG. 1, the optional lifting mechanism 32 can be provided as part of a roller device 120. The roller device 120 generally includes a driven roller 122 located adjacent the base plate 40 opposite the stop device 42. In some constructions, the roller 122 includes a cut-out region 124 extending along a length of the roller 122. As described below, the cut-out region 124 facilitates loading of an intermediate product onto the base plate 40. Regardless, and with additional reference to FIGS. 8A and 8B, the lifting mechanism 32 further includes a tab 126 extending radially from an outer circumference of the roller 122. The tab 126 can be centrally positioned relative to a length of the roller 122, and can assume a variety of shapes and sizes. The roller 122, and thus the tab 126, is arranged relative to the base plate 40 such that with rotation of the roller 122, the tab 126 selectively enters a region of the base plate 40, thus acting upon an intermediate product (not shown) lodged thereon.

More particularly, in the view of FIG. 8 A, the roller 122 is rotationally arranged such that the tab 126 is generally outside a region of the base plate 40. With rotation of the roller 122 from the arrangement of FIG. 8A (i.e., clockwise) to the rotational arrangement of FIG. 8B, the tab 126 enters a region of the base plate 40, and effectuates application of a lifting motion. As described below, this lifting motion is imparted upon an intermediate product stored on the base plate 40 to form a partial fold.

The above-described forming apparatus 20 can be used as part of a wonton production system for producing ready-to-cook wontons. One such system 150 is illustrated in block form in FIG. 9, and includes a cutting station 152, a filler material preparation station 154, an intermediate product forming station 156, the forming apparatus 20, and a collector station 158. The stations 152-158 can assume various forms known in the art. In general terms, the cutting station 152 operates to cut a sheet of dough or pasta into circular-like pieces or forms (or other desired shapes). The filler material preparation station 154 combines various filler material ingredients into a slurry-like consistency.

The intermediate product forming station 156 combines the dough forms from the cutting station 152 with desired quantities or volumes of filler material from the filler material preparation station 154, resulting in an intermediate product. In this regard, the intermediate product forming station 156 can include an injector device along with a folding mechanism as known in the art for dispensing the filler material onto the dough piece, and the folding the piece onto itself. For example, FIG. 10 illustrates, formation of an intermediate product 160 from a circular-like piece 162 and a quantity of filler material 164. The piece 162 is folded onto itself to define a shell 166 forming a pocket 168 within which the filler material 164 is contained. The intermediate product 160 can be described as having or defining a central portion 170, and opposing first and second end portions 172, 174. The filler material 164 is disposed within the central portion 170, with the end portions 172, 174 extending in an opposing fashion from the central portion 170. Further, the portions 170-174 combine to define a perimeter 176 (referenced generally) of the intermediate product 160 as including a leading side 178 and a trailing side 180. Relative to the top plan view of FIG. 10, the perimeter 176 has a D-like shape, with the leading side 178 being relatively straight and the trailing side 180 being curved, approximating a semi-circle. Alternatively, where the piece 162 has a shape other than curved (e.g., square, rectangular, etc.), the trailing side 180 will assume a shape other than a semi-circle. As further reflected in FIG. 11, the folded arrangement of the shell 166 establishes an upper layer 182 and a lower layer 184, with the upper layer 182 defining an upper surface 186 of the intermediate product 160 and the lower layer 184 defining a lower surface 188. The layers 182, 184 are pressed against one another along the trailing side 180, and are thus adhered.

With the above understanding of the intermediate product 160 in mind, the forming apparatus 20 operates to transition the intermediate product 160 into a completed, ready-to-cook wonton. For example, beginning at FIGS. 12A and 12B, the forming apparatus 20 is initially arranged to receive the intermediate product 160 from the intermediate product forming station 156 (shown in block form), for example via a feed mechanism 200 located immediately adjacent an outlet of the intermediate product forming station 156. The feed mechanism 200 can include the roller 122 described above, along with a second roller 202. The rollers 122, 202 lightly engage the intermediate product 160 as dispensed from the station 156, with the cut-out region 124 providing clearance about the enlarged pocket 168. As a point of reference, the engagement mechanisms 24, 26 are omitted from the view of FIG. 12A to better illustrate placement of the intermediate product 160 along the base plate 40.

Immediately prior to delivery of the intermediate product 160, the base plate mechanism 22 is operated to arrange the stop device 42 in the stopping state (i.e., the stop surface 60 projecting upwardly from the base plate 40), and the engagement mechanisms 24, 26 are rotated to the initial state. Further, the engagement mechanisms 24, 26 are actuated to the released state in which a substantial spacing exists between the corresponding fingers 70, 72. The intermediate product 160 is then fed onto the support surface 44 of the base plate 40, moving in a feed direction F (FIG. 12A) until the leading side 178 contacts the stop surface 60. The support surface 44 and the stop surface 60 thus combine to locate the intermediate product 160 at a known spatial location, with the first end portion 172 aligned with the first engagement mechanism 24 (e.g., disposed between the fingers 70, 72 of the first engagement mechanism 24), and the second end portion 174 similarly aligned with the second engagement mechanism 26 as shown in FIG. 12B.

The engagement mechanisms 24, 26 are then actuated to engage (e.g., grasp) the corresponding end portions 172, 174. For example, the second fingers 72 can simultaneously be linearly driven toward the corresponding first fingers 70. Regardless, the engagement mechanisms 24, 26 are transitioned to the engagement state described above (FIG. 4), and securely engage (e.g., grasp) the corresponding end portions 172, 174.

Simultaneously with, or immediately following, transitioning of the engagement mechanisms 24, 26 to the engagement state, the base plate mechanism 22 is transitioned to the retracted state in which the stop device 42 is displaced from the base plate 40. The drive unit 28 is then operated to rotate the engagement mechanisms 24, 26 from the initial state of FIG. 12B to the wrapped state described above with respect to FIG. 6. With this rotation, the engagement mechanisms 24, 26 wrap the corresponding end portions 172, 174 toward the central portion 170. In some embodiments, the above- described longitudinal off-set between the engagement mechanisms 24, 26 and/or timing of the drive unit 28 causes the first end portion 172 to be wrapped toward the central portion 170 slightly ahead of the second end portion 174. Further, the vertically off-set relationship between the engagement centerlines 90, 92 (FIG. 5A) positions the wrapped first end portion 172 slightly below the wrapped second end portion 174, and prevents the end portions 172, 174 from directly abutting one another during the wrapping movement. The optional declining region 48 (FIG. 1) of the support surface 44 serves to more completely guide the second end portion 174 over the first end portion 172.

Upon completion of rotation of the engagement mechanisms 24, 26 to the wrapped state, the second end portion 174 overlaps onto (e.g., overlies) the first end portion 172. This relationship is more clearly illustrated in FIG. 13. As shown, the leading side 178 of the first end portion 172 has been wrapped toward the leading side 178 of the central portion 170. The leading side 178 of the second end portion 174 has been similarly wrapped toward the central portion 170, but is partially located over or across the first end portion 172. Stated otherwise, the lower surface 188 (referenced generally in FIG. 13) of the second end portion 174 is located on top of the upper surface 186 of the first end portion 172. Also as can be understood from FIG. 13, each of the first end portion 172 and the second end portion 174 terminates at a tip; following rotation of the first and second engagement mechanisms 24 and 26, the tip of the second end portion 174 will contact an outer surface of the first end portion 172, and the tip of the first end portion 172 will contact an inner surface of the second end portion 174.

In some constructions, and as shown in FIG. 14, an additional lifting or folding force is applied to the trailing side 180 of the intermediate product 160 simultaneously with the above-described wrapping operation. For example, where provided, the optional roller 122 is continuously rotated during rotation of the engagement mechanisms 24, 26, with the tab 126 thus applying a lifting force onto the trailing side 180. As a result, the trailing side 180 is folded upwardly, with the fold angle being more prominent along the central portion 170.

Regardless of whether a lifting force is applied to the trailing side 180, with the engagement mechanisms 24, 26 maintained in the wrapped state, the pinching mechanism 30 is then operated to apply a pinching force onto the overlapped regions of the end portions 172, 174. For example, as shown in FIG. 15 A, the rod 110 is moved toward the bearing surface 112 (FIG. 1), thereby pinching the contacted portions of the intermediate product 160 therebetween. The pinching action effectuates adhesion or an effective bond between the overlapped regions of the end portions 172, 174 (i.e., the upper surface 186 of the first end portion 172 bonds with the lower surface 188 of the second end portion 174). Notably, FIG. 15A further reflects that at the region of interface between the end portions 172, 174, only four layers of dough are present (i.e., two layers of the first end portion 172 and two layers of the second end portion 174). This is consistent with a typical wonton, and is distinct from a tortellini in which, due to multiple folds or wrapping of the dough shell, eight layers of dough are present at the region of side-to-side interface between the end portions. Further, the wrapping and/or pinching action may bring the first end portion 172 into close proximity with the central portion 170. Notably, the vertically-applied pinch point is effectively applied at a centerline of the now completed ready-to-cook wonton 220 (e.g., identified in FIG. 15B as pinch point 222), and results in a tight seal to prevent deformation of the resultant ready-to-cook wonton product during a subsequent cooking process. Following application of the pinching force, the rod 110 (or other force-applying device) is retracted, and the engagement mechanisms 24, 26 transitioned to the released state. The engagement mechanisms 24, 26 are then rotated back to the initial state as shown in FIG. 1, and the now-completed, ready-to-cook wonton 220 is ejected or released from the base plate 40. For example, the base plate mechanism 22 can be operated to the stopping state (e.g., raised position), with the wonton 220 sliding downwardly along the bearing surface 112 and away from the forming apparatus 20 (in the feed direction F of FIG. 12A). The completed wonton 220 is then collected, along with other similarly-formed wontons in the collection station 158 (FIG. 9). At the same time, a new wonton intermediate product 160 is fed on to the support surface 44, and the wonton forming process repeated.

The ready-to-cook wonton-forming systems, apparatus and methods of the present disclosure provide a marked improvement over previous designs. Ready-to-cook wontons can automatically be produced on a mass production basis, and have shapes and other characteristics highly akin to handmade wontons, including top-to-bottom arrangement of the wonton ends (or wings). As a result, the systems, apparatus, and methods of the present disclosure are unique from tortellini manufacturing devices.

Although the present disclosure has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the present disclosure. For example, while the apparatus 20 has been described as having one processing station (i.e., one set of the engagement mechanisms 24, 26), in other constructions, the apparatus can be configured to simultaneously process two (or more) wonton intermediate products (e.g., by including two (or more) sets of the engagement mechanisms 24, 26). Also, the jaw-like format of the engagement mechanisms 24, 26 is but one acceptable construction in accordance with the present disclosure. In other embodiments, the engagement mechanisms 24, 26 can each include a single arm or finger (e.g., forming or terminating in a paddle) that is moveable relative to the base plate support surface 44. With this alternative construction, the support surface 44 can include the declining region 48 that in turn establishes the off-set engagement centerlines 90, 92 relative to the engagement mechanism arms. As a result, rotation of the engagement mechanism arms results in the overlapping arrangement of the wonton intermediate product ends as described above, and can also inherently apply the desirable pinching force with the need for a separate pinching mechanism.

Claims

What is claimed is:

1. An automated method for producing a ready-to-cook wonton, the method comprising:

providing a wonton intermediate product including a dough shell that forms a pocket containing an edible filler material, the intermediate product defined by:

a central portion at which the filler material is maintained,

a first end portion extending from the central portion,

a second end portion extending from the central portion opposite the first end portion;

placing the intermediate product on a base plate defining a plane, including the first end portion aligned with a first engagement mechanism and the second end portion aligned with a second engagement mechanism;

operating the first engagement mechanism to automatically engage the first end portion at a first engagement centerline;

operating the second engagement mechanism to automatically engage the second end portion at a second engagement centerline;

wherein the second engagement centerline is vertically off-set from the first engagement centerline relative to the base plate plane;

operating a motorized drive unit to rotate the first engagement mechanism relative to the base plate to wrap the first end portion toward the central portion;

operating a motorized drive unit to rotate the second engagement mechanism relative to the base plate to wrap the second end portion toward the central portion; wherein following rotation of the first and second engagement mechanisms, the second end portion overlaps and overlies the first end portion;

applying a pinching force to the overlapped first and second end portions to adhere the end portions in forming a completed ready-to-cook wonton;

operating the first and second engagement mechanisms to release the ready-to- cook wonton; and

ejecting the ready-to-cook wonton from the base plate.

2. The method of claim 1 , wherein a perimeter of the intermediate product is defined by a combination of the central portion and the first and second end portions and includes a leading side and a trailing side, and further wherein operating a motorized drive to rotate the first engagement mechanism includes wrapping the leading side of the first end portion toward the leading side of the central portion.

3. The method of claim 2, wherein operating a motorized drive unit to rotate the second engagement mechanism includes wrapping the leading side of the second end portion toward the leading side of the central portion.

4. The method of claim 3, wherein following rotation of the first and second engagement mechanisms, the leading side of the second end portion contacts the first end portion.

5. The method of claim 1, wherein the dough shell of the intermediate product includes upper and lower layers, and further wherein following rotation of the first and second engagement mechanisms, the lower layer of the second end portion is located above the upper layer of the first end portion.

6. The method of claim 1, wherein rotation of the first and second engagement mechanisms occurs substantially simultaneously.

7. The method of claim 1, wherein rotation of the first engagement mechanism is initiated immediately before rotation of the second engagement mechanism.

8. The method of claim 1 , wherein the second engagement centerline is vertically above the first engagement centerline.

9. The method of claim 1 , wherein each of the first and second end portions terminates at a tip, and further wherein following rotation of the first and second engagement mechanisms, the tip of the second end portion contacts an outer surface of the first end portion, and the tip of the first end portion contacts an inner surface of the second end portion.

10. The method of claim 1 , wherein the first engagement mechanism includes opposing fingers, and further wherein operating the first engagement mechanism includes linearly driving one of the fingers toward the other of the fingers.

11. The method of claim 1 , wherein placing the intermediate product on a base plate includes:

operating a stop device to establish a stop surface extending approximately perpendicular to the plane of the base plate; and

sliding the intermediate product along the base plate until the leading side contacts the stop surface.

12. The method of claim 11, wherein placing the intermediate product on a base plate further includes:

operating the stop device to retract the stop surface from contact with the leading side.

13. The method of claim 1 , wherein a perimeter of the intermediate product is defined by a combination of the central portion and the first and second end portions and includes a leading side and a trailing side, the method further comprising:

applying a lifting force to the trailing side of the intermediate product to form a trailing curvature in the completed ready-to-cook wonton.

14. The method of claim 13, wherein the step of applying a lifting force occurs substantially simultaneously with at least one of the steps of rotating the first engagement mechanism and rotating the second engagement mechanism.

15. The method of claim 13, wherein applying a lifting force includes:

providing a roller having a radially projecting tab; and

rotating the roller such that the tab contacts a lower surface of the trailing side.

16. The method of claim 1 , wherein applying a pinching force includes automatically driving a rod toward the base plate and into contact with a region of interface between the overlapped end portions.

17. An automated forming apparatus for producing a ready-to-cook wonton from a wonton intermediate product, the wonton intermediate product including a dough shell that forms a pocket containing an edible filler material and defined by a central portion and opposing first and second end portions, the apparatus comprising:

a base plate mechanism including a base plate having a plane, the base plate mechanism configured to selectively maintain an intermediate product on the base plate at a known spatial location having an intermediate product centerline;

first and second engagement mechanisms arranged at opposite sides of the intermediate product centerline, each of the engagement mechanisms including:

a first finger forming an engagement surface,

wherein the first finger is movable between a released state and an engagement state, an engagement centerline being established at least in part by the engagement surface in the engagement state,

and further wherein a vertical location of the engagement centerline of the first engagement mechanism relative to the base plate plane is different from a vertical location of the engagement centerline of the second engagement mechanism relative to the base plate plane; and

a drive unit for rotating the first and second engagement mechanisms relative to the base plate;

wherein the forming apparatus is adapted to locate an intermediate product on the base plate, engage and wrap the opposing end portions relative to the central portion in an overlapping arrangement via the engagement mechanisms and the drive unit, and apply a pinching force to overlapped segments of the end portions in forming a ready-to- cook wonton.

18. The apparatus of claim 17, wherein the first and second engagement mechanisms are arranged relative to the base plate such that the engagement centerline of the first engagement mechanism is vertically below the engagement centerline of the second engagement mechanism.

19. The apparatus of claim 17, wherein the base plate mechanism further includes a stop device for selectively establishing a stop surface in a plane substantially

perpendicular to the plane of the base plate for temporarily retaining an intermediate product at a known forward spatial location, and further wherein the first and second engagement mechanisms are rotatable between an initial state and a wrapped state, and even further wherein a longitudinal spacing between the finger of the first engagement mechanism in the initial state relative to the forward spatial location is different from a longitudinal spacing between the finger of the second engagement mechanism relative to the forward spatial location.

20. The apparatus of claim 17, further comprising:

a lifting mechanism associated with the base plate and adapted to apply an upward lifting force to a trailing side of an intermediate product disposed on the base plate at the known spatial position.

21. The apparatus of claim 20, wherein the lifting mechanism includes a roller having a radially projecting tab.

22. The apparatus of claim 17, wherein each of the first and second engagement mechanisms further includes:

a second finger forming an engagement surface opposite the engagement surface of the first finger;

wherein the first and second fingers combine to form a jaw.

23. The apparatus of claim 17, further comprising:

a pinching mechanism including a rod associated with the base plate between the engagement mechanisms and terminating in a pressing end, the rod being driven between a raised state in which the pressing end is spaced from the base plate and a pinching state in which the pressing end is in close proximity to the base plate for applying a pinching force onto an intermediate wonton product.

24. A system for producing ready-to-cook wontons comprising:

an intermediate product forming station for producing a wonton intermediate product from a circular form and a quantity of edible filler material, the wonton intermediate product including a dough shell that forms a pocket containing the edible filler material; and

a forming apparatus including:

a base plate mechanism including a base plate having a plane, the base plate mechanism configured to selectively maintain an intermediate product on the base plate at a known spatial location having an intermediate product centerline,

a first finger forming an engagement surface,

and further wherein a vertical location of the engagement centerline of the first engagement mechanism relative to the base plate plane is different from a vertical location of the engagement centerline of the second engagement mechanism relative to the base plate plane,

a drive unit for rotating the first and second engagement mechanisms relative to the base plate,

wherein the forming apparatus is positioned to receive the intermediate product from the intermediate product forming station, engage and wrap the opposing end portions relative to the central portion in an overlapping arrangement via the engagement mechanisms and the drive unit, and apply a pinching force to overlapped segments of the end portions in forming a ready-to-cook wonton.

25. The system of claim 24, wherein the intermediate product forming station forms an outlet from which the intermediate product is ejected, the outlet being located immediately adjacent the base plate.

26. The system of claim 24, further comprising:

a cutting device adapted to cut a shaped piece from a sheet of dough; and a filler material station adapted to mix ingredients in forming a slurry of the filler material.

27. The system of claim 26, wherein the intermediate product forming station includes:

an injector device for dispensing a volume of the filler material from the filler material station onto the shaped piece; and

a folding mechanism for folding the shaped piece onto itself in forming an intermediate product.

28. The system of claim 24, wherein each of the first and second engagement mechanisms further includes:

wherein the first and second fingers combine to form a jaw.

29. The system of claim 24, further comprising: