WO2016107652A1 - Appareil de fabrication de nougat à base de pop-corn - Google Patents

Appareil de fabrication de nougat à base de pop-corn Download PDF

Info

Publication number
WO2016107652A1
WO2016107652A1 PCT/EP2014/079462 EP2014079462W WO2016107652A1 WO 2016107652 A1 WO2016107652 A1 WO 2016107652A1 EP 2014079462 W EP2014079462 W EP 2014079462W WO 2016107652 A1 WO2016107652 A1 WO 2016107652A1
Authority
WO
WIPO (PCT)
Prior art keywords
popcorn
nougat
station
compartments
pan
Prior art date
Application number
PCT/EP2014/079462
Other languages
English (en)
Inventor
Carlos Arcusin
Gustavo Alfredo Garcia
Claudio SCHENA
Original Assignee
Carlos Arcusin
Gustavo Alfredo Garcia
Schena Claudio
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Carlos Arcusin, Gustavo Alfredo Garcia, Schena Claudio filed Critical Carlos Arcusin
Priority to PCT/EP2014/079462 priority Critical patent/WO2016107652A1/fr
Publication of WO2016107652A1 publication Critical patent/WO2016107652A1/fr

Links

Classifications

    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/30—Puffing or expanding
    • A23P30/38—Puffing or expanding by heating
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
    • A23G3/00—Sweetmeats; Confectionery; Marzipan; Coated or filled products
    • A23G3/02—Apparatus specially adapted for manufacture or treatment of sweetmeats or confectionery; Accessories therefor
    • A23G3/0236—Shaping of liquid, paste, powder; Manufacture of moulded articles, e.g. modelling, moulding, calendering
    • A23G3/0252—Apparatus in which the material is shaped at least partially in a mould, in the hollows of a surface, a drum, an endless band, or by a drop-by-drop casting or dispensing of the material on a surface, e.g. injection moulding, transfer moulding
    • A23G3/0289—Compression moulding of paste, e.g. in the form of a ball or rope or other preforms, or of a powder or granules
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
    • A23G3/00—Sweetmeats; Confectionery; Marzipan; Coated or filled products
    • A23G3/34—Sweetmeats, confectionery or marzipan; Processes for the preparation thereof
    • A23G3/36—Sweetmeats, confectionery or marzipan; Processes for the preparation thereof characterised by the composition containing organic or inorganic compounds
    • A23G3/48—Sweetmeats, confectionery or marzipan; Processes for the preparation thereof characterised by the composition containing organic or inorganic compounds containing plants or parts thereof, e.g. fruits, seeds, extracts
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/161—Puffed cereals, e.g. popcorn or puffed rice
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/161—Puffed cereals, e.g. popcorn or puffed rice
    • A23L7/174—Preparation of puffed cereals from wholegrain or grain pieces without preparation of meal or dough
    • A23L7/183—Preparation of puffed cereals from wholegrain or grain pieces without preparation of meal or dough by heating without using a pressure release device
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/161—Puffed cereals, e.g. popcorn or puffed rice
    • A23L7/174—Preparation of puffed cereals from wholegrain or grain pieces without preparation of meal or dough
    • A23L7/183—Preparation of puffed cereals from wholegrain or grain pieces without preparation of meal or dough by heating without using a pressure release device
    • A23L7/187—Discontinuously-working apparatus
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P10/00—Shaping or working of foodstuffs characterised by the products
    • A23P10/20—Agglomerating; Granulating; Tabletting
    • A23P10/28—Tabletting; Making food bars by compression of a dry powdered mixture

Definitions

  • the present invention is directed to the field of everyday- life needs and, specifically, to the field of food production. More particularly, it is directed to an apparatus for manufacturing popcorn nougat through a series of stations, where popcorn is processed to obtain a nutritious nougat-type food product comprising compressed popcorn units.
  • puffed rice cakes For example, several apparatus are known for producing so-called puffed rice which is used, in a further section of the same apparatus or in a different one, to obtain a compressed food product known as puffed rice cakes.
  • This kind of apparatus comprises means for moistening rice, controlling the water provided for this purpose and then dispensing said moistened rice into moulds heated to a certain temperature. Inside the moulds, the rice is simultaneously subjected to a certain temperature and hydraulic pressure for a variable period of time depending on the type and/or size of the cake. The apparatus performing this process operate such that the moulds are adjusted for releasing the pressure and open quickly and suddenly. Under these conditions, the rice draws air in, expands and occupies the entire mould cavity. Therefore, these apparatuses operate by expansion moulding of a cereal which is simultaneously subjected to pressure and temperature .
  • this method is widely used and employs microwave ovens for heating the moisture encapsulated in the kernel, so that it will burst and expand.
  • sugar is added after obtaining the popcorn, which is carbonized in the microwave oven due to the high temperature at which kernel expansion occurs.
  • the product obtained is highly caloric and will undergo a change of its organoleptic characteristics over time, after manufacturing the product, due to interactions of the oil with the other components .
  • US patent 4,652,456 discloses a commercially available apparatus for making popcorn balls from hardened caramel- coated popcorn.
  • the apparatus comprises a rotary conveyor on which multiple closed compartments and means for varying compartment size and for opening them are mounted. Rotation of the conveyor cause the compartments to move from a pop-corn loading input towards a nougat output, stopping at stations comprising, firstly, a hopper with a dispenser for loading preset volumes of popcorn into temporarily opened compartments, followed by a combination of a blower and an electrical resistance which force one or more intermittent short bursts of hot air of 0,1 sec into the compartments to heat and soften the coating; then a compression station; where the compartments are subjected to compression in order to compress the popcorn to slightly less than one-half its original volume to form spherical compressed units and, finally, a station ejecting the popcorn balls from the compartments .
  • US patent 5,215,770 discloses an additive formulation for popcorn including polydextrose, as a sugar substitute, at a ratio of not less than 30%, preferably of 40%-70%, and sweeteners. Cooking temperatures are in the order of 150°C.
  • US patent 6,200,611 discloses a popcorn nougat bar and teaches a process for forming a coated popcorn food product wherein firstly popcorn is made to burst and then is mixed with a precooked binding molass (sugar) so as to provide an even coating. The popcorn reaches a temperature of about 127°C (within a range of 121° to 132°) so that it will not become too hard and brittle for the process of cutting it into bars.
  • This temperature is then lowered to 99°C when entering the compression station and then to 82°C (within a range of 77° to 88°) when it is discharged from the compression station.
  • the coated popcorn is then formed into sheets by means of belt conveyors. The popcorn enters the compression station at 110°C and leaves it at 82°C.
  • the present invention substantially consists in an apparatus for manufacturing popcorn nougat comprising an intermittent conveyor with mobile compartments successively travelling through a loading station, a heating station, a compression station, a ejection station and a packing station.
  • a cooking station and a refining station may also be added to the loading station.
  • the manufacturing process comprises a series of steps comprising dispensing popcorn, heating it at a temperature below toasting temperature, compressing it, ejecting the compressed products and packing them.
  • the present invention is mainly directed to a nougat manufacturing apparatus using popcorn impregnated with a sweetener, such as sugar or dextrose, inside the expanded kernel. It further includes an apparatus for cooking and popping corn kernels to obtain impregnated popcorn to be fed into the nougat manufacturing apparatus.
  • the invention includes an industrial plant with the cooking apparatus physically arranged at the start of a production line that extends into the manufacturing apparatus, optionally including a refining apparatus.
  • stations are arranged along the nougat manufacturing line with multiple compartments driven by a substantially horizontal conveyor.
  • the stations of the manufacturing apparatus include, in the machine direction of the compartments filled with popcorn:
  • a loading station for loading the compartments with a preset amount of popcorn dispensed by an apparatus cooking Everta corn
  • a heating station preferably a tunnel-type oven, which raises the temperature of the impregnated popcorn to a certain level so as to soften it and increase its binding capacity
  • a compression station for compressing the popcorn in the compartment to provide a compact dense mass
  • a ejection station for ejecting a nougat formed by the compact dense mass from the compartment
  • the conveyor unit comprises a turntable or a linear conveyor and the compartments are partially formed by openings in the mobile table.
  • the compression station comprises at least one compressing piston perpendicularly movable relative to the conveyor unit inside a compartment that is momentarily held at the compression station for compressing popcorn, until its volume is reduced from 15% to 30%, preferably from 18% to 27% and, more preferably, from 20% to 25% of its original volume.
  • the ejection station also comprises a piston which may be actuated synchronously with the compressing piston at each stop of the conveyor unit.
  • spraying devices are arranged for applying bursts of an anti-stickiness fluid, such as corn oil, over the piston bases and inside the compartments which have just been discharged every time the conveyor unit stops.
  • an anti-stickiness fluid such as corn oil
  • the apparatus for cooking and popping corn kernels to obtain impregnated popcorn comprises:
  • pans for containing corn kernels and sweet-iener at specific ratios
  • a heater device in each pan such as an electrical resistance housed within the wall of each pan, adjusted to heat the pan to a temperature higher than 180 °C, preferably 200 ⁇ 10°C, and to keep the pan at this temperature until more than 80%, preferably more than 90% and most preferably more than 95% of the corn kernels have been cooked, expanded and burst,
  • a tilting device so as to pour the contents of the pan onto a collector, preferably a conveyor belt.
  • each pan comprises a container having a side wall and a bottom wall which pivots at a preset angle around a fixed axle of the apparatus in order to tilt the pan from its initial position during cooking to a final post-cooking position in order to empty it by dumping its contents.
  • the pan is covered by two half-lids which are hinged on a bridge spanning across the pan opening along its diameter, the bridge being movably mounted on the upper rim of the pan, thereby facilitating its removal for cleaning and maintenance.
  • the homogenizing device comprises one or more stirring blades which are attached to the lower end of a shaft, the shaft being supported by the bridge by means of a bearing and driven by a shaft which is common to all pans and runs parallel to the fixed tilting axle of the apparatus by means of meshed conical gears.
  • the axle of the mixing device moves away from the driving shaft thereby disengaging the gears.
  • the rotation direction of the driving shaft is selected so as to exert a net torque which tends to keep the gears meshed .
  • the industrial manufacturing plant includes a series of sieves located between the collecting belt of the cooking apparatus and another conveyor belt feeding the loading station of the nougat manufacturing apparatus, including a rotatory sieve consisting in a horizontal cylinder arranged with its axle slightly inclined towards its outlet end, the side wall of which comprises a screen which provides an output for kernels of unwanted dimensions while keeping the popped popcorn inside the cylinder.
  • Short blades are attached to the inner walls of the cylinder following the trace of an imaginary screw or a theoretical helix, for alternately lifting and dropping the popcorn, thus increasing the dwelling time of kernels within the cylinder.
  • the outlet from the cylinder may be fitted with a step, in order to stop the progression of the heaviest kernels and favour the output of more expanded and lighter popcorn kernels.
  • One advantage is that the different stations of the apparatus are arranged in sequence and prepared for a continuous process, without interruptions or lenghly down-time periods, which results in a high production capacity of the apparatus.
  • Another advantage of the present apparatus is its ability to operate under controlled temperatures.
  • Another advantage of the present apparatus is its adaptability to several industrial plants and building requirements, since it may operate either as an intermittent circular conveyor or as an intermittent linear conveyor. In either case, stations are arranged in the most convenient way and yield like production rates.
  • Another advantage is that different means may be assembled to allow for the feed of corn kernels or popcorn through the inlet and obtaining compressed food of high nutritional quality and excellent organoleptic properties at the outlet. Another advantage is that it affords a new type of food based on compressed popcorn, which does not require additives or binders .
  • the apparatus only operates with two suitably balanced natural components: the Everta strain and a sweetener.
  • An additional advantage is that it leads to a product that is very stable over time, devoid of fat and free from the degrading effect of oil or other fat matter.
  • Another advantage of the present apparatus is that it lacks frying means and, nevertheless, the food thus produced has similar properties regarding crispiness and flavour to that obtained from expanding corn kernels in caramelized sugar.
  • Figure 1 is a perspective view of the present apparatus for manufacturing nougat from popcorn, showing its general constitution and the location of its main parts for an embodiment in which the conveyor is a rotary-type conveyor.
  • the insert shows magnified details of compacting and ejecting means, represented in the upper position, as opposed to the main drawing.
  • Figure 2 is a top view schematic representation of the industrial plant for manufacturing popcorn nougat from Everta corn, which includes the apparatus of figure 1, the cooking apparatus, the mobile dumping receptacle and the granulometric screening device.
  • the insert shows a detail in cross-section corresponding to the compression and ejection stations.
  • Figure 3 is a top view schematic representation of the present apparatus in another embodiment in which the conveyor is a linear-type conveyor.
  • the insert shows a detail in cross- section corresponding to the compression and ejection stations .
  • Figure 4 is a longitudinal section view of a vibrating device arranged at the loading inlet of the loading station, interposed between the feeding receptacle and the mobile compartment of the intermittent conveyor.
  • Figure 5 is a schematic representation of the heating means in the machine of fig. 1 and the control system thereof.
  • Figure 6A is a cross-section view of the compression and ejection stations of the insert in figure 1, showing the arms thereof in their inactive position.
  • the sketch shows that the stationary base in the compression station comprises the bottom wall of the mobile receptacle, whereas in the ejection station, the discharge opening replaces the bottom wall of the mobile receptacle.
  • Figure 6B is another cross-section view of the compression and ejection stations, the mobile compartment in the compression station being full of popcorn.
  • Figure 6C is another cross-section view of the compression and ejection stations, in which the compression for obtaining the compressed unit is observed.
  • Figure 6D is another cross- section view of the compression and ejection stations, showing the compression and ejection actions.
  • Figures 7A and 7B are perspective magnified views of the machine of figure 1 looking towards the compression and compartment stations, respectively, showing the respective arrangements of sprayers devices.
  • FIGS 8A and 8B are respectively front elevation and top plan views in schematic representation, of a cooking station with three pans corresponding to one embodiment of the present invention.
  • each drawing represents, on the left: a closed pan in operation, in the middle: another pan tilted for dumping its contents after cooking and, on the right: a third pane depicted without its bridge and half-lids to illustrate the stirring blades.
  • Figure 9A is a magnified perspective view showing the assembly of the bridge and the half-lids on a pan of figures 8A-8B.
  • Figures 9B and 9C are, respectively, a schematic inside section and a cross-section of the bottom of a pan of figures 8A-8B showing the arrangement of electrical heating resistance wiring therein and temperature feedback control means.
  • Figures 10A, 10B, and IOC are schematic views illustrating the expansion process and the addition of a sweetener into a corn kernel at the cooking station of figures 8A and 8B.
  • Figures 11A, 11B, and 11C are perspective views of, respectively, a refining rotating cylinder, a vibrator sieve and a retro-wave-driven sieve forming the granulometric screening devices of figure 2.
  • the apparatus represented in figure 1 manufactures nougat from popcorn using a series of sequentially arranged means and stations for a continuous production, in which portions of popcorn 52 are compressed until a food product of compressed units 53 of said popcorn 52 is obtained.
  • Intermittent conveyor unit with mobile compartments The apparatus comprises an intermittent conveyor 11 moving in a set direction through a series of stations.
  • the intermittent conveyor 11 operates rotatably either because it has a circular or annular form, or because it is deformable and it may adapt itself to a rotatory operating configuration.
  • the intermittent conveyor 11 may be linear, rectilinear, mixed linear —with linear sections of different angular orientations— or it may be deformable to adopt polygonal tracks of any shape, enabling the conveyor to go through preset stations.
  • the intermittent conveyor 11 comprises multiple mobile compartments 12. Such mobile compartments 12 are receptacles in which popcorn 52 is transported, heated and compressed along stations. The upper portions of the mobile compartments 12 are open, while their side walls are closed and their bottom portions are closed by the stationary base 13 on which said intermittent conveyor 11 travels.
  • one or more mobile compartments 12 may stop simultaneously at each station.
  • the conveyor unit 11 includes eight pairs of compartments 12.
  • the conveyor unit comprises a horizontal rotating table 11; the compartments 12 are partially formed in the rotating table 11 in combination with a stationary horizontal base 13 providing the bottom portion for the compartments 12, with the exception of the ejection station 14, in which there is a discharge opening 16 provided in the stationary base 13 instead of a bottom, where ejecting means 17 of the compressed units are located.
  • the rotating table 11 comprises a stainless steel sheet with square openings 12 of 6 cm x 6 cm. Lateral walls 18 of the compartments 12 extend from the rotating table 11, which are made of the same steel sheet as the table 11 and welded at the borders of the opening 12. The height of the plate of the rotating table 11 above the stationary base 13 which provides the bottom portion of compartments 12 is 18cm.
  • the rotating table 11 may consist of a synthetic material moulded with a thickness equal to the height of compartment 12 formed therein by means of square through openings; the rotating table 11 slides on the stationary base 13 which provides the bottom portion of compartments 12.
  • the loading station 19 includes a loading inlet 29 which is fed from the feeding receptacle - which in this embodiment is a top-loading hopper 21 - and loads popcorn 52 in the required amount for filling the mobile compartment 12 which has stopped at said loading station 19.
  • the top-loading hopper 21 has a double jacket so as to form an air chamber 22 which isolates the internal wall 23 from the heat to which the external wall 24 is subjected by the hot air from the metal walls of the tunnel oven 26 (described below), so that the internal wall 23 is kept at room temperature thus preventing cooked popcorn from sticking to the hopper walls.
  • Ambient humidity is controlled to about 40%.
  • the top-loading hopper 21 discharges into mobile compartments 12 arrested at loading station 19 using means such as dispensers for charge control or vibrators 27 i.a., which assist gravitational discharge, as shown in figure 4.
  • the dispenser 27 operates based on load volume and comprises a lower hopper 28 in the base of which there is a fixed discharge opening 29 flush with the horizontal plane defined by the upper surface 31 of the rotating table 13, thereby closing the discharge opening when the filled compartments 12 leave the loading station 19.
  • the lower hopper or receptacle 28 is elastically articulated on its upper part by means of supports 32 with springs 33 so that it is intermittently shaken near its base a preset amount of times at every stop of the conveyor unit by a vibrating actuator 34.
  • a vibrating actuator 34 In the present embodiment an odd number of jerks (31 ⁇ 2 cycles in 2 seconds) are applied by means of a pneumatic piston 34, so that the lower hopper 28 changes sides in each loading cycle.
  • the vibrating device 34 also prevents agglomeration of the load in the lower hopper due to stickiness of the caramelized popcorn.
  • the present embodiment comprises a tunnel oven 37 through which mobile compartments 12 with their contents of caramelized popcorn travel through three of the eight stations of the conveyor 11. Heating is effected by blowing warm air heated by means of four electrical resistances inside the duct 38 connecting the tunnel oven with a blower 39.
  • there is a resistance in the upward vertical section 38V of duct 38 and three additional resistances 41 distributed throughout horizontal section 38H, where each resistance comprises windings of electrical wire calculated to provide 2 kW, so that the forced air reaches a temperature Th 90°C at the entrance of tunnel oven 37.
  • the air temperature may be controlled by a thermostat (not shown) which turns off one of the resistances in case the temperature exceeds the preset value T h by ⁇ .
  • An air filter (no shown) is provided at the entrance of blower 39 to prevent contamination by ambient dust .
  • the four electrical heating 2-kW resistances 41 are powered from a three-phase 3x380VAC power mains via individual solid-state relays 42 controlled from a PLC - programmable logic controller (not shown) .
  • Three such resistances 41' are connected between one separate phase-line R, S, T and neutral N; the fourth resistance 41" is connected in parallel to one of the other resistances 41' and may be disconnected or reconnected for controlling working temperature.
  • a single-phase shunt 43 powers the motors of different conveyor belts and a second single-phase shunt 44 supplies electric power for the PLC, the blower 39 and other attendant electrical means.
  • a compression station 46 wherein one or more compacting means 47 actuate.
  • these compacting means 47 comprise a mobile arm 48 ending in a piston-like operational end 49, which in this case is intended for compression.
  • at least surface 51 which contacts popcorn 52 may include a non-stick material which facilitates its operation.
  • popcorn 52 is pressed until compressed units of food 53 are obtained, as shown in sequence in figures 6B and 6C.
  • the degree of compression is critical for the invention. Compression must be sufficient for the self-agglomeration of popcorn exiting tunnel oven 37, thereby forming the final nougat product 53, although it should not be too high so as to avoid the destruction of nougat structure.
  • the product is moulded to a size of 6cm x 6cm as determined by the dimensions of the mobile compartment 12 and with an initial thickness of 75mm at the heating station 36, as determined by the amount of popcorn falling through the hopper 28 of loading station 19 in each batch.
  • Each compression block 47 presses the mass of popcorn 52 in a mobile compartment 12 until a height of 18mm is reached, thus reducing product volume 53 to about 25% of its initial volume 52 and increasing four times its density. Experimental assays show that volume reductions in the range of 20 to 25% are advisable.
  • the pressure exerted by compression block 47 is of about 20kg. Pressures lower that the recommended value will result in nougat not forming as such, but a crumbly nougat will be obtained instead, which is edible as a conventional popcorn product however without the particular taste of the product obtained using the apparatus of the present invention. On the other hand, higher pressures, for example of 400kg, which compress the product in the mobile compartment to a thickness of only 10mm, would transform the product into a hard disintegrated powder, uneatable in practice .
  • the compression station 46 is followed by an ejection station 14, where compartments containing compressed popcorn arrive after three stops inside the tunnel oven; at the ejection station 14 one or more ejection means comprising ejectors 56 operate.
  • said ejectors 56 comprise a mobile arm 48 ending in an ejecting piston-like operational end 49.
  • the stationary base 13 comprises one or more ejection openings 16 which leave the mobile compartments 12 passing through that position without a bottom.
  • progression of ejectors 56 ejects the compressed units 53 out of the intermittent conveyor 11, for example, into an ejection duct 57 and a first output conveyor 58.
  • FIG. 6A After ejecting the nougats 53, the ejectors return to their upper position (figure 6A) while the mobile compartments 12 are returned to the loading station 19, where they are sprayed with a short burst of a release agent, conveniently corn oil, which is essential to prevent sugar from sticking.
  • a spraying device 61 is used, located between the ejection station 14 and the loading station 19.
  • Figure 1 includes a partially cut-out view of the actuator 59 showing the sprayer 61 with its nozzle 62 aimed downwards to passing compartments 12.
  • An additional spraying device 63 for a similar purpose is provided at compression station 46 which nozzle 64 is arranged so as to provide short bursts of corn oil spray upwards against the bases 51 of the pair of compacting means 47.
  • Figures 7A and 7B are perspective magnified views of the compression station 46 and the ejection station 14 of figure 1, showing the arrangement of sprayers 61 and 63 of the compacting means 47 and compartments 12, respectively.
  • a second output conveyor 66 carries the compressed food units 53 from the outlet conveyor 58 to the packing station 67, where food units 53 are packed and then arrive to the product dispatch station.
  • the present apparatus is capable of receiving popcorn 52 manufactured previously at any other location, it is preferred that the cooking station 68 is comprised in or is a part as the first station of the apparatus of the present invention, so that the sugar-cooked popcorn would not undergo a significant cooling which might cause the expanded kernels to shrink, thus affecting the quality of the final product. Therefore, an embodiment is envisioned in which this apparatus includes other stations 68; 69 to produce popcorn 52 for supplying the feeding receptacle or hopper 21. Stations 68, 69 act as an auxiliary apparatus for producing fat-free popcorn (40) to feed the feeding receptacle or hopper 21. In such CcL S ⁇ cL Cooking station is included in the first place, comprising a cooking apparatus 68 described below, followed by a disaggregation apparatus 69 as de-scribed below. Cooking station
  • the cooking apparatus 68 is provided with a number of mobile receptacles (herein, three of them are illustrated) consisting of tiltable pans 71 with thermally conductive cooking walls 72 actuating on the corn and fluidizing one or more sweeteners and/or flavouring additives.
  • Each pan 71 has a mixer comprising a vertical axle 73 of pan 71 to the lower end of which a horizontal stainless steel rod 74 is attached, raising a few millimeters above the bottom 76. Above each pan rotates a drive shaft 77 which is connected to the axle 73 of pan 71 through a pair of conical gears 78 at a 1:1 ratio, so as to transform the horizontal rotation into a vertical rotation and thus actuate the mixer 74 inside the pan 71.
  • the rotation speed of the axle is 50 rpm.
  • Each pan consists in a flat container 71 with circular bottom 76 and tapered wall 72 made of cast steel, above which a bridge 81 is fastened by means of two nuts 79, so that the driving axle 73 of mixer 74 of pan 71 passes through a bearing located in the bridge central point.
  • the lid of the pan is formed by two halves 82 of a disk made of stainless steel with a pair of openings 83, to which two L-shaped hooks 84 are connected, linked to the bridge 81 from which they project. This, as well as the bridge 81 and both lid halves 82, facilitate the disassembling the pan 71 for readily washing it with a hot water bath.
  • the floor or bottom 76 of the pan is supported by a rotation axle 86 around which it pivots for tilting pan and dumping the cooked popcorn onto a conveyor belt 87.
  • the tilting of pan 71 takes place at the end of each cooking cycle by manually lowering a lever 88 which is firmly fixed to a side of pan 71, from which it extends forward, co-planarly to the pan 71 (that is, horizontally while the pan is in its normal cooking position) .
  • mechanical means may be implemented for tilting the pan 71, with one or more pistons located behind the pan to hit it and thus help in discharging the popped popcorn 52.
  • the bridge 81 is parallel to the driving axle 77; the rotation directions of axle 77 and pan 73 are such that a net attraction torque is created between the gears 78, which keeps them stably engaged so that some force must be exerted to disengage the gears 78 when lowering the lever for tilting pan 71. This is achieved by rotating the driving shaft 77 downward and forward, so that the axle 73 of the pan rotates backwards on the engaging side, thus tilting the pan 71 forwardly.
  • Figures 9B and 9C schematically show a preferred heating arrangement comprising three concentrically-arranged heating wires 89, each dimensioned as a 2-kW electrical resistance, embedded in the bottom wall 76 of each pan 71.
  • FIG. 9C further schematically shows a sensor 90 centrally located on the underside of each pan 71 and connected to a pyrometer reader P which, in turn, controls contactor means C for keeping the pan temperature at around 210°C.
  • the rotation axle 86 is hollow, so as to house the electrical wiring conducting power to the resistances 89.
  • Cooking time is of generally several minutes, depending on actual temperature inside the pan 71 and volume of the contents, after which the pan 71 is tilted to dump its contents onto a conveyor belt 87. That is, the cooking station 68 operates batch-wise so that the number of pans 71 operating at this station depends on the production capacity of the main section of the nougat manufacturing machine.
  • FIG 10A shows the typical internal structure of an Everta corn kernel 91, with a hard hull 92 mostly containing starch 93, an important moisture content 94 which is specific for this type of corn and which makes it suitable for producing popcorn 52, and an embryo 96.
  • refined sugar 97 is added which is then melted together with the hull 92 by the cooking heat, thereby integrating both of them.
  • the moisture inside the kernel 91 is vapourized thereby expanding it (as shown in figure 10B) and, subsequently, a burst will form the popcorn 52 (as shown in figure IOC) .
  • the resulting popcorn acquires crispiness during cooking due to the incorporation of dextrose 97 inside the kernel 91 by impregnating it, besides it has no added fats and has a sweet and pleasant flavour.
  • the material entering this station includes some kernels of intermediate size, which have not finished popping, either because of insufficient internal moisture or for other reasons.
  • the purpose of refining is to perform a rigorous selection, by size and density, separating dust, unpopped kernels and small kernels. These components are potentially capable of turning the final product crumbly.
  • the above-described cooking apparatus 68 discharges its contents into a refining station 69 comprising three serially arranged apparatuses 98; 99 and 101, each having different characteristics for discharging cooking waste and further, for supplying a feeding receptacle 21.
  • the cooking pans 68 pour cooked and expanded popcorn onto a conveyor belt 87 which, in the first place, exits into a cylindrical mobile cooling container 98 with open gridded walls 102 and paddles 103, subsequently followed by two sieve-shakers 99 and 101.
  • Mesh opening sizes range from 8 mm to 10 mm or 8 mm x 10 mm, which is sufficient for dropping unpopped corn kernels while retaining the expanded kernels 52.
  • This is followed by a conveyor belt 104 connecting the refining station 69 with the loading station 19 which is also used for performing a visual inspection and manually remove un-suitable, unpopped or partially expanded kernels, which may have passed through the sieves .
  • the side wall 102 comprises a backbone formed by four stainless steel strips 107, the ends of which are welded to rings 108 made of the same metal.
  • Four sieve screens 109 each of them formed into a quarter of a cylinder, have their corresponding edges fixed to two successive strips 107 and to end rings, thus collectively forming the side screen wall of the refining cylinder 98 with a mesh opening size of 10 mm x 10 mm.
  • the cylinder 98 rotates at a speed of 20 rpm, thus stirring the popcorn such that the unpopped kernels drop through the screen 109 of side wall 102, and out of the cylinder 98 onto a waste tray 111.
  • the paddles 103 of a size of 40 cm x 15 cm, raise part of the product to a certain height so that it falls behind the paddle
  • the cylindrical unit 98 is provided with a 25 cm-high step 112 at the outlet to prevent the progression of the heaviest kernels such as those that did not pop at the cooking station 68 or which popped deficiently, which therefore tend to remain at the bottom, thus favouring the progression to the next sieve 99 of the most expanded popcorn kernels 52, which are the most suitable for nougat manufacturing because they are lighter or less dense.
  • a circular vibratory sieve 99 follows, within which the preceding cylinder 98 directly pours its contents, followed by a linear vibrating sieve 101 which linearly continues on the mentioned conveyor belt 104.
  • the circular sieve 99 vibrates by effect of an excentrically loaded motor 113 and has a sieve-like bottom 114 which splits the kernel stream between a waste output 116 and an output 117 containing mostly useful kernels which are poured onto the linear vibrating sieve 101 continuing linearly into the above-mentioned conveyor belt 104.
  • the linear sieve 101 has a motor-driven mechanism 118 which causes it to perform a circular movement represented by the arrow 119 and thus pushing the good kernels 52 towards the conveyor belt 104 in transit towards the hopper 21. Operation
  • popcorn 52 passes through the loading inlet 21, where means such as vibrating means, weight dispensing means, etc may be arranged for controlling or facilitating the popcorn stream motion.
  • means such as vibrating means, weight dispensing means, etc may be arranged for controlling or facilitating the popcorn stream motion.
  • the mobile compartments 12 are loaded, they are moved by the intermittent conveyor 11 to the heating station 36 where, under the combined action of heating means 41 and the forced air device 39, a succession of short and intense heating cycles are applied. This type of heating allows for heating popcorn 52 below its toasting point, which otherwise would be undesirable .
  • the mobile compartments 12 move to the compression station 46 where compacting means 47 operate by compressing the popcorn 52 inside the mobile compartment 12, which acts as a compression receptacle.
  • the ejection opening 16 allows for ejecting the compressed units 53 by means of the ejectors 56; afterwards the compressed units 53 pass through the output conveyors 58; 66, to the packing station 67 for further dispatch .
  • the procedure which is applicable with the present apparatus comprises a series of stages through which popcorn 52 is transformed into compressed units 53 of a food product.
  • portions of popcorn 52 are dispensed and introduced into mobile compartments 12 which are parked at said station.
  • popcorn 52 is then subjected to short and intense heating cycles, so that popcorn will not reach its toasting temperature. Subsequently, at the compression station 46, portions of heated popcorn 52 are compressed, until its volume is substantially reduced and compressed units 53 of a food product are obtained.
  • the compressed units 53 are ejected out of the mobile compartments 12. They are then transported to a packing station 67 where compressed units 53 are packed and finally exit to dispatch.
  • the apparatus includes a cooking station 68, first the corn kernels are subjected to cooking by contact-heating until popcorn 52 is obtained, which is carried out without using fats and with the addition of additives such as sweeteners. Then, popcorn 52 passes to the disaggregation device 72, where kernels are substantially separated from each other, and also subjected to slight cooling to avoid a substantial reduction of kernel size.

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Nutrition Science (AREA)
  • Botany (AREA)
  • Inorganic Chemistry (AREA)
  • Grain Derivatives (AREA)

Abstract

La présente invention concerne un appareil de production de pop-corn (52) comprenant un transporteur intermittent (11) avec des compartiments mobiles (12) se déplaçant à travers une station de chargement (19), une station de chauffage (36), une station de compression (46), une station d'éjection (14) et une station d'emballage (67). Il peut comprendre en outre une station de cuisson (68) et une station de raffinage (69) desservant la station de chargement (19). Le procédé de fabrication comprend une série d'étapes comprenant la distribution de pop-corn (52), le chauffage de celui-ci à une température inférieure à la température de toastage, la compression de celui-ci, la décharge des produits pressés de maïs et leur emballage.
PCT/EP2014/079462 2014-12-30 2014-12-30 Appareil de fabrication de nougat à base de pop-corn WO2016107652A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/EP2014/079462 WO2016107652A1 (fr) 2014-12-30 2014-12-30 Appareil de fabrication de nougat à base de pop-corn

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2014/079462 WO2016107652A1 (fr) 2014-12-30 2014-12-30 Appareil de fabrication de nougat à base de pop-corn

Publications (1)

Publication Number Publication Date
WO2016107652A1 true WO2016107652A1 (fr) 2016-07-07

Family

ID=52302214

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2014/079462 WO2016107652A1 (fr) 2014-12-30 2014-12-30 Appareil de fabrication de nougat à base de pop-corn

Country Status (1)

Country Link
WO (1) WO2016107652A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110150707A (zh) * 2017-12-28 2019-08-23 浙江东来天然生物制品有限公司 条状食品成型设备
CN110809938A (zh) * 2019-11-18 2020-02-21 湖南省中医药研究院 黄精种子快速萌发的装置及方法
WO2020131028A1 (fr) * 2018-12-18 2020-06-25 Xinova, LLC Systèmes pour fabriquer un agrégat alimentaire à partir d'éléments alimentaires et procédés associés
CN111504505A (zh) * 2020-05-09 2020-08-07 安徽春辉仪表线缆集团有限公司 一种弹性耐振温度计
US11998037B2 (en) 2019-04-17 2024-06-04 Ppm Technologies Holdings, Llc Bulk material processing system and method

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3912433A (en) * 1973-10-26 1975-10-14 Kwok Chuen Ma Automatic egg roll making machine
US4394395A (en) * 1980-10-31 1983-07-19 Societe D'assistance Technique Pour Produits Nestle S.A. Process for the production of a molded food product by sintering
CA2164280A1 (fr) * 1994-12-05 1996-06-06 Ganesh S. Ganesan Appareil et methodes pour le formage de tablettes de mais eclate enrobe
WO2013076644A1 (fr) * 2011-11-22 2013-05-30 San Lucio S.r.l. Aliment basé sur du pop-corn et du fromage et procédé de production respectif

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3912433A (en) * 1973-10-26 1975-10-14 Kwok Chuen Ma Automatic egg roll making machine
US4394395A (en) * 1980-10-31 1983-07-19 Societe D'assistance Technique Pour Produits Nestle S.A. Process for the production of a molded food product by sintering
CA2164280A1 (fr) * 1994-12-05 1996-06-06 Ganesh S. Ganesan Appareil et methodes pour le formage de tablettes de mais eclate enrobe
WO2013076644A1 (fr) * 2011-11-22 2013-05-30 San Lucio S.r.l. Aliment basé sur du pop-corn et du fromage et procédé de production respectif

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110150707A (zh) * 2017-12-28 2019-08-23 浙江东来天然生物制品有限公司 条状食品成型设备
WO2020131028A1 (fr) * 2018-12-18 2020-06-25 Xinova, LLC Systèmes pour fabriquer un agrégat alimentaire à partir d'éléments alimentaires et procédés associés
US11998037B2 (en) 2019-04-17 2024-06-04 Ppm Technologies Holdings, Llc Bulk material processing system and method
CN110809938A (zh) * 2019-11-18 2020-02-21 湖南省中医药研究院 黄精种子快速萌发的装置及方法
CN111504505A (zh) * 2020-05-09 2020-08-07 安徽春辉仪表线缆集团有限公司 一种弹性耐振温度计

Similar Documents

Publication Publication Date Title
WO2016107652A1 (fr) Appareil de fabrication de nougat à base de pop-corn
US5846584A (en) Apparatus and method for forming cereal food products
JP2001505064A (ja) ピザの製造方法及び装置
JP2000515764A (ja) ピザを製造するための装置および方法
JP2008539702A (ja) 複合冷凍糖菓
JP5015791B2 (ja) 温かい食料製品のディストリビュータ
EP0715826B1 (fr) Méthode et dispositif pour rÔtir en continu des produits alimentaires
CN108471772B (zh) 用于输送包括颗粒材料的冷冻甜食的设备
KR20090043519A (ko) 팝콘류 과자의 제조방법 및 이 방법의 이용장치
EP0561513B1 (fr) Méthode de production d'une barre de confiserie
JPH11514267A (ja) 食品分与機械
JP2005218389A (ja) 麺類製造方法及び麺類製造装置
JPH02135041A (ja) パンケーキ等の自動製造・供給装置
CA2206425A1 (fr) Dispositif permettant de griller des aliments aptes a etre grilles
US5600964A (en) Apparatus for freezing or deep-freezing food products
WO2020175979A1 (fr) Appareil de formation de produits alimentaires
US20020127310A1 (en) Cereal food product and method
RU2093033C1 (ru) Способ производства мучных кондитерских изделий вида печенья сахарного, вафель и изделий на вафельной основе, тортов и пирожных, кексов, бисквитных рулетов и ромовых баб
CN114557462B (zh) 制作蛋白棒的设备、系统、方法及存储介质
CN114557588B (zh) 食物制作设备、方法、系统及计算机可读存储介质
CN215533803U (zh) 可制作多种食物的设备
CN215124043U (zh) 可制作多种食物的设备以及食物制作设备
CN114532560B (zh) 食物制作方法、系统、设备、装置及计算机可读存储介质
CN215341247U (zh) 无人售卖雪糕站
CN215075239U (zh) 制作食物的设备及食物成型装置

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 14824855

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 14824855

Country of ref document: EP

Kind code of ref document: A1