Automated food processing system and method

• US 20080166461A1
• Filed: 03/14/2008
• Published: 07/10/2008
• Est. Priority Date: 04/22/2002
• Status: Active Grant

• Current Assignee: Andrew Courier, Benny Nunley, Charles E. Rose, Christopher Juneau, Curtis Clarence Pinnow, David Bone, Doug Jones, Douglas Christian Greening, Eddie Mann, Gerald A. Sus, Glenn Schackmuth, Henry T. Ewald, James Lozouski, Jenny Hong, Jerry Sank, John A.J. Wedel, John M. Corliss, John Meisner, Joseph Gerstmann, Keith Stanger, Kevin Keough, Ly Nguyen, Mario G Ceste, Mitchell Strew, Richard Montafi, Richard Terrazzano, Roberto Nevarez, Ron Dorsten, Steven Konold, Tiffany Curry, William Day
• Original Assignee: Andrew Courier, Benny Nunley, Charles E. Rose, Christopher Juneau, Curtis Clarence Pinnow, David Bone, Doug Jones, Douglas Christian Greening, Eddie Mann, Gerald A. Sus, Glenn Schackmuth, Henry T. Ewald, James Lozouski, Jenny Hong, Jerry Sank, John A.J. Wedel, John M. Corliss, John Meisner, Joseph Gerstmann, Keith Stanger, Kevin Keough, Ly Nguyen, Mario G Ceste, Mitchell Strew, Richard Montafi, Richard Terrazzano, Roberto Nevarez, Ron Dorsten, Steven Konold, Tiffany Curry, William Day
• Inventors: Wedel, John A.J., Corliss, John M., Jones, Doug, Lozouski, James, Sank, Jerry, Ceste, Mario G., Gerstmann, Joseph, Nevarez, Roberto, Schackmuth, Glenn, Hong, Jenny, Dorsten, Ron, Ewald, Henry T., Stanger, Keith, Day, William, Pinnow, Curtis Clarence, Sus, Gerald A., Keough, Kevin, Rose, Charles E., Juneau, Christopher, Konold, Steven, Nunley, Benny, Terrazzano, Richard, Curry, Tiffany, Bone, David, Montafi, Richard, Courier, Andrew, Nguyen, Ly, Greening, Douglas Christian, Meisner, John, Strew, Mitchell, Mann, Eddie
• Granted Patent: US 8,034,390 B2
• Time in Patent Office: Days
• US Class Current: 426/438
• CPC Class Codes: A47J 37/1228 Automatic machines for frying and dispensing metered amounts of food
• CPC Class Codes: B65B 43/305 specially adapted for boxes, cartons or carton blanks

Abstract

An automated food processing system and method is provided that allows food to be dispensed, fried and packaged in a suitable container, which may be an individual portion-sized container. In one embodiment, the system includes separate automated modules for dispensing, frying and packaging the food.

In one embodiment, an automated dispensing device dispenser a predetermined portion of food from a bulk storage container or food dispensing magazine. Food is dispensed from the automated dispensing device to an automated fry device that can include at least one circular fry wheel having a plurality of food containing compartments. After the food is fried it is dispensed from the fry device to an automated packaging device. The automated packaging device dispenses food to a container that may be an individual portion-sized container that is retrieved, erected and held into position for filling by an automated container handling system. After a food container is filled, a conveyor system transports the filled container to a suitable pick-up location.

Claims

1. An automated method of dispensing, frying and discharging food comprising:

dispensing a desired quantity portion of food to be fried from an automated dispensing module by gravity into an automated fry module located adjacent the dispensing module;

frying the portion of food dispensed from the dispensing module in the automated fry module adjacent the dispensing module to produce a quantity of fried food; and

discharging the quantity of fried food from the fry module.

2. The automated method of claim 1 wherein said dispensing comprises automatically dispensing food from a storage container located in a freezer and onto a ramp that permits the food to enter the fry module.

3. The automated method of claim 2 wherein said dispensing comprises:

dispensing a predetermined quantity of food from the storage container into a secondary container located in the freezer and dispensing the quantity of food from the secondary container to a location outside of the freezer.

4. The automated method of claim 1 wherein said frying comprises:

rotating a fry wheel having at least a generally circular perimeter and a plurality of compartments, each compartment having an opening towards the perimeter, the food being contained in one of said compartments during said frying, and the fry wheel being mounted for rotational movement relative to the radial axis of the fry wheel in a fry vat, which radial axis is disposed above a normal operating level of the cooking oil in the fry vat.

5. The automated method of claim 4 further comprising controlling a drive mechanism to periodically rotate the fry wheel back and forth through a relatively small amount of angular rotation to simulate shaking of a fry basket during said frying.

6. The automated method of claim 3 wherein the dispensing of the desired quantity portion of food from the automatic dispensing module includes conveying the food to the secondary container;

automatically sensing when the food present in the secondary container is the desired quantity portion of food;

stopping the conveying of food to the secondary container when the desired quantity portion is sensed to be contained in the secondary container; and

thereafter dispensing the desired quantity portion of food from the secondary container onto the ramp and into the opening of one of the compartments of the fry wheel.

7. The automated method of claim 4 wherein the fry wheel is rotated to a first position whereat one of the open compartments is proximate to the dispensing module and the open end of the compartment is facing generally upwards for receiving dispensed food;

dispensing the desired portion of food into the compartment through the open end of the compartment when the fry wheel is in the first position;

thereafter rotating the fry wheel so that the compartment travels through heated cooking oil contained in the fry vat over a period of time to cause the food to be fried; and

thereafter rotating the fry wheel to a second position where the compartment is above the level of the fry vat oil and the opening of the compartment is facing generally downward for discharging food; and

thereafter discharging the fried food from the compartment through the downward facing opening.

8. The automated method of claim 1 further comprising electronically coordinating the operation of said two modules with an electronic control system.

9. The automated method of claim 1 wherein the dispensing of the desired quantity portion of food from the automatic dispensing module comprises dispensing food from a storage container located in a freezer into a secondary container located in the freezer by conveying the food from the storage container to the secondary container;

automatically sensing when the food present in the secondary container is the desired quantity portion of food; and

thereafter dispensing the desired quantity portion of food from the secondary container to the fry module.

10. The automated method of claim 6 wherein the storage container comprises a magazine for storage of a plurality of individual pieces of food portions that are released from the magazine and conveyed to the secondary container;

and

automatically packaging the discharged fried food into individual food containers after the quantity of fried food is discharged from the fry module.

11. An automated method for dispensing, frying and discharging French fries comprising:

containing French fries to be dispensed in a storage container located in an environment that is below 32°

F.;

dispensing a predetermined quantity of French fries from the storage container into a secondary container located in an environment that is below 32°

F.;

dispensing the quantity of French fries from the secondary container to a location outside of the environment that is below 32°

F. and into a frying module;

frying with the frying device the French fries dispensed from the dispensing module to produce a quantity of fried French fries; and

discharging the French fries from the frying module.

12. The automated method of claim 11 wherein said dispensing further comprises:

controlling the amount of French fries dispensed to the secondary container by using a vibratory conveyor.

13. The automated method of claim 11 further comprising automatically controlling and coordinating the operation of said dispensing device and frying device with an electronic control system.

14. The automated method of claim 12 further comprising automatically packaging the discharged French fries wherein said automatic packaging comprises:

rotating a rotatable French fry dispensing member having an inlet location to receive a quantity of cooked French fries to discharge cooked French fries into a French fry dispensing chute positioned to receive the cooked French fries from the rotatable French fry dispenser; and

dispensing the French fries from the dispensing chute into an individual portion-sized French fry container.

15. An automated method of dispensing, frying and discharging food comprising:

providing an automated dispensing device contained in a first housing, and comprising a freezer, a storage container located in the freezer for containing the food to be dispensed, means for dispensing a predetermined quantity of food from the storage container into a secondary container, said means and said secondary container located in the freezer, and means for dispensing the quantity of food from the secondary container to a location outside the freezer;

providing an automated fry device contained in a second housing and comprising a fry vat for containing and heating cooking oil, at least one circular fry wheel having at least a generally circular perimeter and a plurality of compartments, each compartment having an opening towards the perimeter, the fry wheel mounted for rotational movement relative to the radial axis of the fry wheel, which radial axis is disposed above the normal operating level of the frying oil in the fry vat and a drive mechanism for rotating the fry wheel;

dispensing a predetermined quantity of food from the storage container to the secondary container;

dispensing the quantity of food from the secondary container from the dispensing device into one of the compartments of the circular fry wheel;

rotating the fry wheel to move the quantity of food dispensed into the compartment into the cooking oil in the fry vat to fry the quantity of food;

thereafter rotating the fry wheel to move the fried quantity of food out of the frying oil; and

thereafter discharging the quantity of fried food from the compartment and the fry device.

16. The automated method of claim 15 further comprising providing a control system, the control system automatically controlling the means for dispensing a predetermined quantity of food from the storage container into a secondary container, automatically controlling said means for dispensing the quantity of food from the secondary container to a location outside the freezer, and automatically controlling the movement of the fry wheel.

17. The automated method of claim 16 further comprising:

providing the dispensing device with a weighing device for sensing the weight of the quantity of food in the secondary container;

providing the dispensing device with a conveyor means for conveying the food from the storage container to the secondary container;

operating the conveyor means to convey food from the storage container to the secondary container;

sensing the weight of the food conveyed to and present in the secondary container;

stopping the operation of the conveyor means when the sensed weigh of food in the secondary container is a predetermined weight or greater; and

thereafter dispensing the food from the secondary container.

18. The automated method of claim 15 further characterized by:

rotating the open end of one of the compartments to a first position for receiving the quantity of food dispensed from the secondary container;

dispensing the quantity of food into the compartment when the compartment is in the first position;

rotating the fry wheel compartment with the dispensed quantity of food therein into the heated oil to fry the quantity of food in the compartment;

thereafter rotating the fry wheel compartment to a second position above the level of the fry oil; and

thereafter discharging the quantity of fried food from the compartment.

19. The automated method of claim 15 further comprising:

providing an opening in the first housing for dispensing the quantity of food from the dispensing device;

providing a door automatically movable from a closed position sealing the opening in the first housing and to an open position;

automatically moving the door to the open position to allow the dispensing of the quantity of food from the secondary container to outside of the first housing; and

automatically moving the door to the closed position after the dispensing of the quantity of food.

20. The automatic method of claim 15 further comprising:

providing an automatic packaging device;

providing a ramp for receiving the quantity of fried food discharged from the fry wheel compartment;

discharging the quantity of food onto the ramp and into the automatic packaging device; and

thereafter automatically packaging the discharged fried food into individual food containers.