CA2184520C - Method & apparatus for preparation & packaging of commercial unfrozen baked waffles - Google Patents
Method & apparatus for preparation & packaging of commercial unfrozen baked waffles Download PDFInfo
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- CA2184520C CA2184520C CA 2184520 CA2184520A CA2184520C CA 2184520 C CA2184520 C CA 2184520C CA 2184520 CA2184520 CA 2184520 CA 2184520 A CA2184520 A CA 2184520A CA 2184520 C CA2184520 C CA 2184520C
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Abstract
Baked waffles, especially breakfast waffles, are brought to the market for commercial sale in unfrozen condition, being packaged in sealed aseptic packages. The waffles are prepared by being baked to an extent less than 100% and greater than about 80% baked, and at least until the temperature of the interior of the waffle being baked has reached at least 72°C. The waffles are removed from their waffle form and transferred to a packaging station while still hot, and are placed into heat stable package that is sealed while each baked waffle remains at an elevated temperature, thereby rendering the package aseptic. The sealed aseptic packages are cooled and stored so that the baked waffles arrive for commercial sale in unfrozen condition. The baked waffles, in their sealed aseptic packages, may have a shelf-life of up to three months. Conveniently, the baked waffles are prepared in an apparatus which comprises two chains of opposed waffle iron forms which pass through an oven for baking. The chain runs formed by a plurality of opposed waffle irons are positioned so that the waffle irons are closed and opened due to the geometry of the chain runs, whereby loading and unloading each respective waffle iron is easily effected. Generally, a heated discharge conveyor zone is located at the exit end of the oven so that the temperature of the baked waffles remains at an elevated temperature throughout the period of time following its baking and until it is placed into the packaging. This renders the package aseptic; and after sealing the aseptic package, it is taken for subsequent cooling and handling into the commercial market. Thus, the baked waffles are brought to the market unfrozen, in sealed aseptic packages.
Description
218~520 METHOD & APPARATUS FOR PREPARATION & PACKAGING
OF COMMERCIAL UNFROZEN BAKED WAFFLES
FIELD OF THE INVENTION:
This invention relates to methods and apparatus for the production of commercialbaked waffles, especially breakfast waffles, which are to be sold in an unfrozen condition in the commercial market. More particularly, the present invention is directed to methods 5 and preparation of waffles which are sold unfrozen in sealed aseptic packages, and which may have exceptional shelf-life.
BACKGROUND OF THE INVENTION:
There are numerous baked waffles that are sold primarily in the commercial retail 10 markets for breakfast consumption. However, without exception, those waffles are sold in frozen condition. That means that, after the waffles have been baked in a commercial waffle bakery, they must be significantly cooled until they are frozen, they must shipped in frozen condition, they must be displayed for retail sale in frozen condition, they must be conveyed by the purchasing consumers to their homes in frozen condition, and they 15 must be stored in frozen condition until such time as they are removed from their packaging for consumption. This requires, therefore, very considerable commitments of capital equipment, beyond the baking and packaging equipment, for freezing, storing, transporting, commercial warehousing, and commercial retail sale, of frozen waffles.
What the waffles of the present invention have in common with commercial 20 breakfast waffles that are currently available is that they are pre-baked, they are packaged for retail sale, and they are prepared for consumption by the customer by being placed in an oven or toaster for re-heating. What the baked waffles of the present invention do not have in common with ~;ullelllly commercial available waffles is, therefore, that they are not frozen, and there is no necessity for additional significant capital expenditures.
218~20 Of course, in order for baked waffles to be brought to the market in unfrozen condition, and still enjoy significant shelf-life, requires that the packaging shall be rendered aseptic. The present invention provides for that, as will be described hereafter, by ensuring that each waffle remains heated when it is placed into its packaging and while the 5 packaging is sealed so as to render the package aseptic.
In general, that means that the interior temperature of the waffle, as it is being baked, must be elevated to a temperature of at least 72C. Thereafter, the interior temperature of the waffle should not be permitted to become depressed significantly; and this generally means that efforts and steps should be taken to m~int~in the temperature of 10 the interior of the waffle at least at or above about 72C. In that manner, there is sufficient retained heat in the baked waffle that the heat will transfer to the interior of the package;
and, if the package is sealed shortly thereafter, it will be rendered aseptic. In the event that the interior temperature of the waffle shall have fallen below 72C or so, after the package has been sealed it may be re-heated, usually at a temperature of up to about 90C so as to 15 re-heat the interior of the waffle back up to at least about 72C. Microbiological activity is unlikely to occur if a product such as a baked waffle has been sealed into an aseptic environment at about 72C, so that airborne mold spores or other cont~min~nl~ will not gain access to the product within the aseptic package. Therefore, products such as baked waffles can enjoy a substantial shelf-life without deterioration, since no cont:~min~nt within 20 the waffle will have survived 72C, and because it cannot become re-cont~min~ted. Of course, after a package cor~ il-g a plurality of waffles in keeping with the present invention has been opened, if several baked waffles remain unconsumed, they must be refrigerated.
There is, moreover, a further advantage of the present invention, beyond precluding 25 the necessity for capital expenditures for freezing and frozen storage, transport, warehousing, and retail sale equipment; and that there is no necessity for the use of chemical additives to waffle batter for use as preservatives. The waffle batters utilized by the present invention may be considered to be so-called "all natural", comprising at least water, flour, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent such as baking powder or baking soda. Waffles that are manufactured in keeping with the present invention may further comprise a dairy product such as whole milk, skim or partially skimmed milk, or whey, as well as lecithin, salt, or other flavoring ingredients such as vanilla or fruit additives.
Another factor that needs to be stressed, in respect of the manufacture of bakedwaffles, is that waffles are prepared from a waffle batter, as opposed to the pl~al~lion of breads which are prepared from dough. Further, the differences between waffles and wafers must be distinguished; waffles are relatively thick without any significant crust being developed thereon during their baked and will still have a retained moisture content.
Wafers, on the other hand, are relatively thin, they may have a crust due to a higher sugar content, and in any event they are baked until there is substantially zero moisture content retained.
Returning to the differences between dough, from which breads are baked, and batter, from which waffles are baked, it is necessary for the dough to be sheeted and proofed because they are generally leavened using yeast. Waffle batters are leavened using a chemical leavening system such as baking powder or baking soda and are pourable whereby, after preparation, the batter may be poured into a waffle form. Moreover, waffles are baked in an enclosed form whereas breads are generally permitted to rise during their baked process in open-topped baking pans or tins.
Still further, the baking process by which waffles are baked is more or less concluded, at least to the extent that is desired, while the waffle is still in its waffle form or waffle iron and while it is still in an oven which is m~int~ined at an elevated temperature. Thus, waffles can be partially baked, at least up to 80% baked but less than 100% baked, and the baking process can be suspended at that time to be concluded at a later time when the waffle is about to be consumed by its purchaser. With few exceptions, such as with french bread which comprises only flour, water, yeast, and salt, it is not possible to partially bake breads, and then suspend the baking process until a later time.
These factors are important when it comes to understanding certain prior art patents, which are discussed below.
~184~20 The energy savings which may be accomplished in keeping with the present invention may be very significant. Comparing traditional frozen waffles for commercial sale--which are baked and then frozen, and which must therefore be maintained in frozen condition during storage, shipping, and retail sale, and even in the home of the consumer 5 until they are to be consumed--with unfrozen waffles sold in sealed aseptic packages, the savings for the manufacturer, the distributor, the retailer, and ultimately to the consumer, may be profound, as discussed hereafter. Those savings are in terms of both invested and operating capital, and energy expended. For the moment, it is merely necessary to note that until such steps are taken as to m~int~in the temperature of baked waffles at an elevated 10 temperature prior to their packaging, the costs in keeping with the present invention and of traditional frozen waffle production may be essentially identical; as may the costs of packaging materials, as well as boxes, promotion and advertising, cost of sale, in order to bring the products to the market. All other costs ~;ullelllly required for the production, storage, shipping, and sale, of frozen waffles, are not at all necessary in keeping with the 15 present invention.
Moreover, the present invention provides significantly new apparatus within which waffles may be baked. In order for efficient pr~lalion and baking of waffles forcommercial market purposes to be accomplished, there must be significant automation applied to the process. This means that the apparatus that is used for the preparation of 20 waffles for commercial sale, once designed and installed, should be capable of being operated over extended periods of time with minim~l shut-down and/or maintenance except as may be required for purposes of cleanliness and hygiene, and for such preventative m~int~n:~nce of equipment as may be necessarily required. Often, the design and provision of machinery having as few moving parts as possible is desirable, and is accomplished by 25 baking equipment and especially waffle forms in keeping with the present invention. As will be described in greater detail hereafter, the waffle forms that are provided in keeping with these teachings are such that they have no necessity for hinge-mounted upper and lower waffle forms in the sense of tradition waffle irons. What is provided, as will be 2184~
described hereafter, are articulated chains which are physically mounted in such a manner that the opening and closing of the waffle iron forms, and removing of the baked waffles from the waffle forms, is accomplished merely as a consequence of the geometry of the apparatus.
DESCRIPTION OF THE PRIOR ART:
In keeping with the above discussions, there is no known prior art that specifically teaches several of the key features of the methods and apparatus according to the present invention. However, the following prior art is referenced for purposes of expressing and demonstrating differences between the prior art and features of the present invention.
As to prior art which is particularly directed to methods by which baked products are prepared in substantially automated processes, and placed into packaging for shipment to the retail market, the following patents are noted:
KOMATSU et al United States patent No. 3,892,058 is concerned with short-time high temperature sterilization of packaged articles such as soups or meat products. The food product is filled into a flexible container, and non-condensible gasses which are left in the voids of the container are excluded, after which the packaging is heat sealed.
Thereafter, the packaged food is sterilized within its own sealed package by being heated to elevated temperatures for as short a time as may be possible.
PLEMONS et al United States patent No. 3,979,525 is directed to a method of producing pizza crusts, which are essentially breads. Here, the pizza crusts may be stored unsealed at room temperature, because they have been treated with ethyl alcohol. This may create significant marketing problems, since it is essentially unknown and unacceptable to add chemical compounds to a finished food product.
United States patent No. 4,120,984 to RICHARDSON et al is directed to an apparatus for placing baked goods into a sterile package and for preventing damage to the product as it is being cooled. The plastic sheet that is used is usually perforated; the invention is directed in any event to baked bread products; and there is a requirement to draw sterile air into the package.
~18gi5~0 ..
JOULIN United States patent No. 4,357,356 teaches a method of producing a bread product which is baked, packaged into hermetically sealed packages under partial vacuum, and then sterilized. The specific bread product discussed is french bread which comprises only flour, water, salt, and yeast; and, while french bread may, indeed, be partially baked, 5 it will nonetheless have a short shelf life before it becomes almost completely unpalatable.
It must also be remarked that the bread products specifically discussed by Joulin have much smaller surface areas per unit mass or per unit volume than do waffles. Moreover, waffles will at least contain eggs and perhaps milk ingredients, which may enhance microbial activity, and thus the necessity to freeze waffles has heretofore been recognized as the only 10 way to inhibit microbial activity.
OTTOW et al United States patent No. 4,426,401 discusses the packaging of perishable goods that contain water, in aseptic packages. However, the package must include vents through which vapour can escape during heat treating of the goods after they have been placed into the package. Thereafter, once the product has been cooled down, 15 the vents may then be sealed.
United States patent No. 4,457,702 to MARCHETTI teaches the packaging of foodstuffs into polyethlyne bags, which are then dropped into a bath of hot water for subsequent re-heating.
DURST United States patent No. 4,582,711 teaches the preparation of baked goods 20 that can have very long shelf life. However, those baked goods are effectively anhydrous, being such as canned cake products, cookies, or brownies, and the like.
United States patent No. 4,734,291 to RAFFENSPERGER concerns itself with the preparation with al dente pasta products which may have good shelf storage life. Here, the partially cooked pasta is extruded into a pouch pack; however, it is necessary that sufficient 25 water be used so as to reduce the pH to 4.6 or less.
SUGISAWA et al United States patent No. 4,777,057 concerns itself with a semi-prepared dough that has a specific hardness and which is charged into a heat resistant packaging container. After the package is sealed, it is then heat treated. The dough system, in any event, is packaged at its dough stage, after which it is steamed.
~18~2~3 United States patent No. 4,911,939 to LOU et al is directed to a cookie dough which is partially pre-baked and then packaged and sealed. However, this cookie dough should have high fructose content, and is specifically intended for microwave baking prior to its consumption.
SCHIRMER United States patent No. 4,928,474 teaches a retort container which may be filled with food that is sensitive to spoilage from oxygen contact. The filled container is closed by being heat sealed, then retorted, and then enclosed with an oxygen barrier material.
The following prior art patents relate particularly to various apparatus for theproduction of waffles, wafers, or baked bread:
United States patent No. 4,058,039 to SCHMID teaches a waffle transfer machine in which baked waffles are removed from a conventional waffle iron, trimmed, andtransferred onto a transfer conveyor. In the embodiments illustrated, each waffle iron comprises a clamshell hinged structure in which six waffles at a time are baked, and which thereafter require trimming, transfer, etc., for commercial packaging purposes.
WESTOVER United States patent No. 4,208,441 teaches a pair of endless mated cooking irons, one above the other, each of which comprises a pocketed cooking iron that resembles a waffle iron. However, what is prepared is pizza shells and the like, which are yeast leavened dough products. The dough requires mixing, sheeting, cutting, and proofing before it is baked. The sheets of dough are placed between hot irons which are closed by bringing their edges into contact. The dough requires to be trimmed, because it is essentially a bread dough. After the pizza dough has been baked, it may then be covered with pizza toppings, and then frozen.
Two patents to HAAS et al are United States patent No. 4,417,508 and No.
4,438,685. Each of those patents, however, is concerned with the preparation of wafers, which are prepared in a conventional hinged shell; and which, when baked, are essentially anhydrous.
~18452~
United States patent No. 4,769,245 to FARAR et al is directed to the pfepal~ion of bread products which may be removed from their packaging for browning and serving.
Special containers for the french bread are provided, into which the product is placed while it is hot enough to inactivate microbial org~ni~m~ that may be within the product.
5 However, a filter hole or aperture is required, which is small enough to allow the package to "breath" so as to equalize the pressure within and without the package. Care is taken that air does not impinge directly on the packaged food product.
HERTING United States patent No. 5,079,015 is directed to a method for at least partially cooking multi-colored waffles in more or less conventional cooking forms, from 10 which the waffles are then removed and passed to an oven for fini.~hing. The waffles are particularly intended for use as ice cream cones, and are thus very thin and essentially anhydrous.
SUMMARY OF THE INVENTION:
In accordance with one aspect of the present invention, there is provided a method for the production of baked waffles for commercial sale in unfrozen condition in sealed aseptic packages. The method comprises the steps of:
(a) Preparing a waffle batter, which has at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent which may be baking powder or baking soda.
(b) Dispensing a measured amount of waffle batter into a waffle form.
(c) Closing the waffle form.
(d) Placing the closed waffle form and the waffle batter enclosed therein into a baking oven.
(e) Maintaining the closed waffle form with the waffle batter therein in the oven at least until the waffle is baked to an extent less than 100% baked and greater than about 80% baked. The temperature of the interior of the waffle being baked must have reached at least 72C.
(f) Removing the waffle form and the baked waffle therewithin from the baking oven.
(g) Removing the hot baked waffle from the waffle form.
(h) Transferring the still hot baked waffle to a packaging station.
(i) Placing the still hot baked waffle into a heat stable package that is heat sealable. This step is taken while the baked waffle remains at an elevated temperature.
Thus, the package is rendered aseptic.
(j) The package is then sealed.
(k) The sealed aseptic package is then permitted to cool to ambient temperature.(l) Finally, the cooled sealed package is placed into storage and handling facilities. Thus, commercial sale of the unfrozen baked waffles in sealed aseptic packages may then be achieved.
In keeping with another aspect of the present invention, there is provided an apparatus for the production of baked waffles for commercial sale in unfrozen condition in sealed aseptic packages. As noted above, the baked waffles are prepared from a waffle batter having at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent which may be baking powder or baking soda, as constituents thereof. The apparatus comprises a mixer in which the waffle batter is prepared, and conveying means for conveying the mixed waffle batter to a batter depositor. The batter depositor has control means to select a specific amount of waffle batter to be deposited into a waffle form; the waffle form comprises lower and upper waffle iron shells that are arranged so as to be closed together as a waffle iron within the interior of which a waffle will be baked.
An oven is provided and will operate at a specified temperature into which the waffle iron and the waffle batter enclosed therein will be placed for sufficient time so as to bake the waffle to an extent less than 100% baked and greater than about 80% baked. The baking process will continue, in any event, until the temperature of the interior of the waffle being baked has reached at least 72C.
218~20 Means are provided for opening and unloading the waffle iron and removing the hot baked waffle therefrom to a conveyor, which conveys the hot baked waffle away from the oven and towards a packaging station. At the packaging station, the still hot baked waffle is placed into a heat stable package while the baked waffle remains at an elevated temperature, so as to render the package aseptic. Means are provided for sealing the heat stable package, cooling it to ambient temperature, and storing and h~n~ling the products for commercial sale of the baked waffles in unfrozen condition.
The lower and upper waffle iron shells, in keeping with a further aspect of thisinvention, comprise links in continuous runs of lower and upper chains of a plurality of similar waffle iron shells. The lower and upper chains are arranged to pass through a tunnel oven, and are spaced so as to be sufficiently close to one another that each respective waffle iron is at first open and then closed as the respective upper and lower chains approach and depart from each other as they wrap around respective drive and idler pinions for the respective chains.
BRIEF DESCRIPTION OF THE DRAWINGS:
The novel features which are believed to be characteristic of the present invention, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in which a presently preferred embodiment of the invention will now be illustrated by way of example. It is expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. Embodiments of this invention will now be described by way of example in association with the accompanying drawings in which:
Figure 1 is a schematic drawing showing the principal operating units which comprise the apparatus of the present invention, and showing the flow of product through the apparatus;
218~20 Figure 2 is a schematic side elevation of a baking oven in keeping with the present invention;
Figure 3 is a plan view of a typical link forming a chain of waffle iron shells in keeping with the present invention; and Figure 4 is a cross-sectional view of a closed waffle iron in keeping with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS:
Reference will no be made to Figures 1 through 4.
First, with reference to Figure 1, a commercial apparatus 10 for the production of baked waffles, in keeping with the present invention, will have the following principal components or operating units:
A mixer 12 is provided, in which waffle batter will be prepared. The waffle batter generally will comprise at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent which is usually either baking powder or baking soda. As noted above, the waffle batter may further or may optionally further include a dairy product which may be whole milk, skimmed or partially skimmed milk, or whey. Moreover, yet a further optional constituent of the waffle batter may be any one or more of lecithin, salt, and flavoring ingredients such as vanilla or fruit additives.
Throughout the apparatus, there will be a variety of conveying means such as themeans 13 or 15 which are suitably sized piping through which the mixed waffle batter may be pumped. A holding tank 14 may be provided, as necessary.
The waffle batter is conveyed as at 15 to a batter depositor 16, which is arranged so as to deposit waffle batter into a waffle form, as described hereafter. So as to ensure that each waffle to be prepared in keeping with the present invention has the same volume and mass, conkol means 18 are associated with the batter depositor 16 so as to select a specific amount of waffle batter to be deposited into the waffle form.
~18~520 An oven 20 is provided, more details of which are described below, with respect to Figure 2. The oven 20 has appropliate controls so that it operates at a specified temperature, and it may be either gas fired or electrically heated. The length of time for which waffles are baked to an extent less than 100% baked but greater than about 80%
5 baked, and in any event until the temperature of the interior of the waffle has reached at least 72C, are discussed below. Again, the specifics of the waffle irons in keeping with present invention are discussed below, but it is clear that means must be provided for opening and unloading the waffle irons after the waffles have been baked. Individual baked waffles exit the oven 20, in keeping with the usual provisions of the present 10 invention where the waffles are passed through the oven on a conveyor, and are passed at 21 to a further conveyor 22 which is arranged to convey the hot baked waffles away from the oven 20 and towards a packaging unit 26.
There may be interposed between the conveyor 22 and the packaging unit 26 a sorter 24, so that selected numbers of waffles may be collected together for placing into 15 packages for commercial sale. Intermediate conveyors 23 and 25 may also be provided.
Within the packaging unit 26, there is a sealer 28 which is arranged to seal heat stable packages after the still hot baked waffles have been placed into them. Finally, following further conveyors 29, there are provided means generally identified at 30 where the sealed heat stable packages with the baked waffles therein may be cooled, stored, 20 palletized for shipping, and shipped.
To the extent so far described, none of the operating components and units, with the exception of the heated conveyor 22, might be significantly different than is found in any commercial waffle bakery.
However, the presence of the conveyor 22 is important, because it assures that the 25 waffles as they exit the oven 20 remain at elevated temperatures, so as to inhibit microbial activity.
Turning to Figures 2, 3, and 4, further details of the oven and the waffle forms in keeping with the present invention are now discussed:
218~520 -In general, the oven 20 comprises an insulated shell 40, within which are two chain runs 42 and 44. The upper chain 42 is contained within the oven 20, the lower chain 44 extends beyond the entrance end 45 and the exit end 47 of the oven 20. Each chain run 42 and 44 is wrapped around drive and idler pinions 46 and 48, which may be arranged at either end of each chain as necessary and appropliate.
The output from the batter depositor 16 is shown at 51, being deposited on the upper reach of the lower chain 44; the output of baked discrete waffles is taken away from the lower chain 44 at 53.
Turning to Figures 3 and 4, some details of the respective upper and lower chains 42 and 44 are discussed. Each chain is essentially identical to the other chain, except for the number of links that comprise the respective chains, due to the differences of their lengths.
A typical link 60 is shown in Figure 3. This link provides, in this case, a pair of waffle iron shells 62, each of which is identical to the other and is configured in typical waffle fashion. Thus, each of the waffle iron shells may comprise a plurality of elevations 63 and indentations 65, as shown in Figure 4. Figure 4 also shows the manner in which respective links from the upper and lower chain runs 42 and 44 will mate together.
Each of the links 60 is articulated to the links on either side of it by connecting links (not shown) passed through respective openings 66 and 68 at the left and right sides thereof, as shown. Each link 60 moves in the direction of either of arrows 67 or 69. Thus, each of the upper and lower chains 42 and 44 passes through, or is contained in, the oven 20, which is arranged in the form of a tunnel oven. The respective upper and lower chain runs 42 and 44 are, as noted and demonstrated by Figure 4, sufficiently closely spaced to one another so as to form the waffle iron. As each of the lower and upper chain runs 42 and 44 approach each other as the upper chain 42 wraps around pinion 46 as shown in Figure 2, each respective waffle iron will be closed. Then, as the upper chain 42 wraps around pinion 48, each respective waffle iron will open. Moreover, as the baked waffle in each respective waffle iron shell exits the oven 20 at exit end 47, it is at least 80% baked and is therefore firmly formed so that it will generally fall from the waffle iron shell as the lower chain wraps around its respective pinion 48. Thus, the unloading means for the lower chain 44 is located beyond the exit end of the oven 20. If necessary, a selectively operated air jet may also be provided either to blow the at least 80% baked waffle from each respective waffle iron shell, or to lift it from the shell by vacuum.
Once any baked waffle has been removed from its respective waffle iron shell 62 at the unloading station indicated generally by the reference 53, it passes to the conveyor 22. Here, as noted, the conveyor is such that it will ensure that the waffles as they exit the oven 20 will remain at elevated temperatures. This is typically accomplished by providing the conveyor 22 in the shape of a further heated tunnel, where the temperature inside the tunnel is maintained sufficiently high so that the interior temperature of the waffles will not fall below anything less than 72C.
If the sorter 24 is present, its ambient temperature is also m~int~ined at an elevated temperature, once again so as to preclude cooling of the interior temperature of the freshly baked waffles below no less than 72C. The purpose of the sorter is, particularly in an automated baked waffle manufacturing facility, to permit a selected number of waffles to be collected so that they may be packaged together in a single package of, say, usually six or eight waffles, for commercial sale purposes. The waffles, or groups of waffles, are then conveyed to the packaging unit 26 by the supplementary conveyor 25.
At the packaging unit 26, the waffles or selected numbers of waffles are placed into their packages, while still hot--preferably, while their internal temperature remains at least at 72C, so as to preclude or inhibit microbial activity after the waffle has been cooled down. Each package is generally formed of a heat stable polypropylene film, having a heat sealable film l~min~tç~l thereto. It is evident that any such package may then be, appropriately, heat sealed, using conventional heat sealing apparatus. Alternatively, the package may comprise a heat stable formed plastic fill cup, usually one which has been pre-formed using vacuum forming equipment, which may then be heat sealable or hermetically sealable by placing a heat sealable or hermetically sealable cover film thereover. It is evident that, no matter which variety of package may be used, if the packaging material per se is a~plo~iately stored and conveyed into the packaging unit 26, c~l84520 and filled and sealed at the sealer 28 while at all times the interior temperature of the waffles being placed into each heat sealed package remains above at least 72C, then the retained heat within each waffle will be sufficient to heat whatever air may be captured in the package, and thereby render the package aseptic. It should be noted that, in general, 5 the interiors of the packaging unit 26 and sealer 28 are also m~int~ined at elevated temperatures.
In the event that the interior temperature of the waffles has cooled below about72C, or, in any event, for greater surety of the aseptic nature of the heat sealed package, provided the material of the package will withstand temperatures of at least 90C, it is 10 possible to re-heat the sealed aseptic packages up to a temperature of about 90C so as to re-heat the baked waffles that are sealed therein. If the appropriate dwell time is chosen, then the interior temperature of each of the baked waffles will, once again, be elevated at least up to 72C.
The importance of the temperature of about 72C is, of course, that, at that 15 temperature and above, microbial activity is substantially precluded or the aseptic quality of the package is assured inhibited; and if the sealed package is rendered aseptic at the time that it is sealed, or by subsequent or supplemental heating thereafter, then the aseptic quality of the package will be certain.
Referring now to the batter depositor 16, it has associated with it a control means 20 18 whose purpose is to select and assure that a specified amount of waffle batter will be deposited into the waffle form. Typically, each waffle will have a weight of 30 to 75 grams. In any event, the volume of the waffle to be baked in each waffle iron form is known and, since the density of the waffle batter is known or can easily be determined, a precise amount of batter may therefore be deposited into each waffle iron form. This 25 assures that there will be no flash or spillover on the one hand, and that each waffle will be fully developed and baked. It is evident, of course, that any shape and particular volume of waffle can be prepared in keeping with the present invention, merely by appropriate design of the waffle iron shells 62 and the links 60 in which they are formed.
~ls~s2a The material from which the links 60 is formed may conveniently be cast aluminumor other appropriate materials such as cast iron, and it may be appropriately coated with a non-stick material such as PTFE. Moreover, a suitable vegetable oil spray may be utilized by being sprayed into each respective waffle iron shell at an applopliate station at or near 5 the entrance end 45 of the oven 20.
It is a simple matter, of course, having determined the shape, volume, and weight of each waffle to be baked to calculate and establish the appropriate temperatures within the oven 20 and the dwell time for each respective waffle iron form to pass through the oven 20, in order that each waffle may be at least 80% baked but less than 100% baked.
Typically, the interior of the oven in maintained at about 170C or 225C, depending on the formulation. A typical dwell time for each waffle as it passes through the oven 20 is approximately 95 seconds. Thus, the speed of driving the upper and lower chains 42 and 44 may easily be adjusted ~plopliately.
Likewise, the interior of the conveyor 22, the sorter 24, and the packaging unit 26, 15 are normally m~int~ined at least at about 75C, usually about 90C. This assures that, once the interior of each waffle as it has been baked has reached the temperature of about 72C, it will not cool below that temperature. Moreover, there is little incremental baking activity that continues after the waffles have been removed from their respective waffle irons, because there is no significant heat differential between the temperature of the waffle and 20 the ambient within which it is being m~int~ined.
From all of the above, it follows that the steps taken for the production of baked waffles for commercial sale in unfrozen condition in sealed aseptic packages, in keeping with the present invention, will be essentially as follows:
(a) First, the waffle batter is prepared. As noted, the waffle batter will have at 25 least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent which is generally baking powder or baking soda. As noted, the waffle batter may further comprise a dairy product such as whole milk, skimmed or partially skimmed milk, and whey; and it may have a further optional constituent such as lecithin, salt, and flavoring ingredients such as vanilla, or a fruit additive.
218~520 (b) A specific measured amount of waffle batter is dispensed into a waffle form.(c) The waffle form is then closed.
(d) Then, the closed waffle form, with the waffle batter therewithin, is placed into a baking oven. Typically, as discussed, this entails passage of a waffle form as a link 5 or a portion of a link of a chain passing through a tunnel oven, but other baking oven facilities and/or waffle irons may also be employed.
(e) Each closed waffle form and the waffle batter therewithin is maintained in the oven for a sufficient dwell time so that the waffle will bake to an extent less than 100%
baked but greater than about 80% baked. Moreover, the temperature of the oven and the 10 dwell time of each waffle form within it will be chosen, in any event, so that the interior temperature of the waffle being baked will reach at least 72C.
(f) Then, the baked waffle form and the baked waffle therewithin will be removed from the oven.
(g) The hot baked waffle will be removed from the waffle form.
(h) The still hot baked waffle will be transferred to a packaging station. This usually requires, as noted above, that the hot baked waffle will be passed through a heated zone on a conveyor, where the temperature thereof will be m~inl:~ined sufficiently high so that the interior temperature of the baked waffle remains above at least 72C.
(i) Moreover, while m~int:~ining the interior of the waffle above at least about20 72C, the waffle is placed into a heat stable package which is sealable while the baked waffle still remains at an elevated temperature. This will render the package aseptic, as discussed above.
(j) The package is then sealed, usually by heat sealing.
(k) Thereafter, the sealed aseptic package is permitted to cool to ambient 25 temperature. It is not necessary, in keeping with the provisions of this invention, to lower the temperature of the sealed aseptic packages with baked waffles therewith to below ambient temperature; specifically, it is not necessary to freeze the baked waffles.
~18~20 ,.
(l) Finally, the cooled (to ambient temperature) sealed aseptic packages of baked waffles are placed into storage or handling facilities from whence they may be delivered into commercial distribution streams for commercial sale of the unfrozen waffles in their sealed aseptic packages.
As noted above, in general, each package will contain a selected number of sealed waffles; it is possible, however, for such industries as the hospitality industry, hotels, hospitals, and the like, that individual baked waffles in their own respective sealed aseptic packages may be distributed.
When the waffles are removed from their sealed aseptic packages, it is generallyintended that they shall be re-heated by being placed into a toaster or conventional or toaster oven for consumption. By re-heating in a toaster or oven, which is heated by radiant heat which transfers to the waffle, the discontinued baking procedure for the waffle will be fin~li7ed. This is because there still remains a significant moisture content within the waffle, and because there is no significant crust that has been formed on the exterior surface of the waffle. Moreover, because of the nature of the formation of the waffles, they have a very high ratio of surface area to volume or mass, as compared with bread or pizza doughs, and the like, and heat transfer to the waffle is accomplished quite quickly.
It is evident that there may be significant savings in terms of expenditures of capital money to build plants and equipment, operating costs to store and ship baked waffles prepared by the present invention, and energy expended, when compared to frozen waffles that are currently available in the market. There is no need for the construction of freezers, frozen storage facilities, frozen delivery facilities, and frozen retail sale cabinets; neither is there any necessity for energy to be expended in removing heat from baked waffles so as to freeze them and then m~int~ining them in a frozen condition.
As stated above, the cost of materials and the amount of materials used in keeping with the present invention, as compared with presently commercially available frozen waffles, will be essentially the same. The waffles will be the same, the packaging will be essentially the same by way of the wrapping material, the retail boxes will be essentially the same, and even the shipping cartons will be essentially the same except that they do not need to be specially prepared for handling at extremely low temperatures.
~18~S2~
The waffles prepared in keeping with the present invention are delivered to the consumer in unfrozen condition, which means that the consumer does not need to provide special storage facilities such as home freezers or the like to store them prior to consumption. However, once removed from their aseptic packaging, any waffles that are 5 not consumed should be refrigerated because microbial activity could be re-initiated at that time. Otherwise, the baked waffles provided by the present invention to the market in unfrozen condition in aseptic packages may have a shelf life of three or four months.
It follows, therefore, that the baked waffles in keeping with the present invention may be delivered to the consumer for a lower cost, and may therefore be acquired by the 10 consumer for a lower price. There are further environmental concerns, since there is no wasted energy required to freeze the waffles or to m~int~in them in a frozen condition.
All of the above is achieved, as noted, without the requirement for any additional chemical additives or preservatives in the waffle batter, without the necessity for injecting inert gasses such as carbon dioxide into the packages, nor without the necessity to utilize 15 vacuum technology to remove entrapped air from the packaging. Still further, and in any event, the packaging that is provided in keeping with the present invention will permit the sealed aseptic package to be re-heated, if necessary and appropriate. This does not require, however, irradiation or other sterilization or pasteurization techniques, since the waffles have been sealed into packages that are rendered aseptic due to the incipient or specific 20 heat which remains present within the waffles as they were placed into the packaging, thus inhibiting or precluding microbial activity.
Other modifications and alterations may be used in the design and manufacture ofthe apparatus of the present invention without departing from the spirit and scope of the 25 accompanymg clalms.
OF COMMERCIAL UNFROZEN BAKED WAFFLES
FIELD OF THE INVENTION:
This invention relates to methods and apparatus for the production of commercialbaked waffles, especially breakfast waffles, which are to be sold in an unfrozen condition in the commercial market. More particularly, the present invention is directed to methods 5 and preparation of waffles which are sold unfrozen in sealed aseptic packages, and which may have exceptional shelf-life.
BACKGROUND OF THE INVENTION:
There are numerous baked waffles that are sold primarily in the commercial retail 10 markets for breakfast consumption. However, without exception, those waffles are sold in frozen condition. That means that, after the waffles have been baked in a commercial waffle bakery, they must be significantly cooled until they are frozen, they must shipped in frozen condition, they must be displayed for retail sale in frozen condition, they must be conveyed by the purchasing consumers to their homes in frozen condition, and they 15 must be stored in frozen condition until such time as they are removed from their packaging for consumption. This requires, therefore, very considerable commitments of capital equipment, beyond the baking and packaging equipment, for freezing, storing, transporting, commercial warehousing, and commercial retail sale, of frozen waffles.
What the waffles of the present invention have in common with commercial 20 breakfast waffles that are currently available is that they are pre-baked, they are packaged for retail sale, and they are prepared for consumption by the customer by being placed in an oven or toaster for re-heating. What the baked waffles of the present invention do not have in common with ~;ullelllly commercial available waffles is, therefore, that they are not frozen, and there is no necessity for additional significant capital expenditures.
218~20 Of course, in order for baked waffles to be brought to the market in unfrozen condition, and still enjoy significant shelf-life, requires that the packaging shall be rendered aseptic. The present invention provides for that, as will be described hereafter, by ensuring that each waffle remains heated when it is placed into its packaging and while the 5 packaging is sealed so as to render the package aseptic.
In general, that means that the interior temperature of the waffle, as it is being baked, must be elevated to a temperature of at least 72C. Thereafter, the interior temperature of the waffle should not be permitted to become depressed significantly; and this generally means that efforts and steps should be taken to m~int~in the temperature of 10 the interior of the waffle at least at or above about 72C. In that manner, there is sufficient retained heat in the baked waffle that the heat will transfer to the interior of the package;
and, if the package is sealed shortly thereafter, it will be rendered aseptic. In the event that the interior temperature of the waffle shall have fallen below 72C or so, after the package has been sealed it may be re-heated, usually at a temperature of up to about 90C so as to 15 re-heat the interior of the waffle back up to at least about 72C. Microbiological activity is unlikely to occur if a product such as a baked waffle has been sealed into an aseptic environment at about 72C, so that airborne mold spores or other cont~min~nl~ will not gain access to the product within the aseptic package. Therefore, products such as baked waffles can enjoy a substantial shelf-life without deterioration, since no cont:~min~nt within 20 the waffle will have survived 72C, and because it cannot become re-cont~min~ted. Of course, after a package cor~ il-g a plurality of waffles in keeping with the present invention has been opened, if several baked waffles remain unconsumed, they must be refrigerated.
There is, moreover, a further advantage of the present invention, beyond precluding 25 the necessity for capital expenditures for freezing and frozen storage, transport, warehousing, and retail sale equipment; and that there is no necessity for the use of chemical additives to waffle batter for use as preservatives. The waffle batters utilized by the present invention may be considered to be so-called "all natural", comprising at least water, flour, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent such as baking powder or baking soda. Waffles that are manufactured in keeping with the present invention may further comprise a dairy product such as whole milk, skim or partially skimmed milk, or whey, as well as lecithin, salt, or other flavoring ingredients such as vanilla or fruit additives.
Another factor that needs to be stressed, in respect of the manufacture of bakedwaffles, is that waffles are prepared from a waffle batter, as opposed to the pl~al~lion of breads which are prepared from dough. Further, the differences between waffles and wafers must be distinguished; waffles are relatively thick without any significant crust being developed thereon during their baked and will still have a retained moisture content.
Wafers, on the other hand, are relatively thin, they may have a crust due to a higher sugar content, and in any event they are baked until there is substantially zero moisture content retained.
Returning to the differences between dough, from which breads are baked, and batter, from which waffles are baked, it is necessary for the dough to be sheeted and proofed because they are generally leavened using yeast. Waffle batters are leavened using a chemical leavening system such as baking powder or baking soda and are pourable whereby, after preparation, the batter may be poured into a waffle form. Moreover, waffles are baked in an enclosed form whereas breads are generally permitted to rise during their baked process in open-topped baking pans or tins.
Still further, the baking process by which waffles are baked is more or less concluded, at least to the extent that is desired, while the waffle is still in its waffle form or waffle iron and while it is still in an oven which is m~int~ined at an elevated temperature. Thus, waffles can be partially baked, at least up to 80% baked but less than 100% baked, and the baking process can be suspended at that time to be concluded at a later time when the waffle is about to be consumed by its purchaser. With few exceptions, such as with french bread which comprises only flour, water, yeast, and salt, it is not possible to partially bake breads, and then suspend the baking process until a later time.
These factors are important when it comes to understanding certain prior art patents, which are discussed below.
~184~20 The energy savings which may be accomplished in keeping with the present invention may be very significant. Comparing traditional frozen waffles for commercial sale--which are baked and then frozen, and which must therefore be maintained in frozen condition during storage, shipping, and retail sale, and even in the home of the consumer 5 until they are to be consumed--with unfrozen waffles sold in sealed aseptic packages, the savings for the manufacturer, the distributor, the retailer, and ultimately to the consumer, may be profound, as discussed hereafter. Those savings are in terms of both invested and operating capital, and energy expended. For the moment, it is merely necessary to note that until such steps are taken as to m~int~in the temperature of baked waffles at an elevated 10 temperature prior to their packaging, the costs in keeping with the present invention and of traditional frozen waffle production may be essentially identical; as may the costs of packaging materials, as well as boxes, promotion and advertising, cost of sale, in order to bring the products to the market. All other costs ~;ullelllly required for the production, storage, shipping, and sale, of frozen waffles, are not at all necessary in keeping with the 15 present invention.
Moreover, the present invention provides significantly new apparatus within which waffles may be baked. In order for efficient pr~lalion and baking of waffles forcommercial market purposes to be accomplished, there must be significant automation applied to the process. This means that the apparatus that is used for the preparation of 20 waffles for commercial sale, once designed and installed, should be capable of being operated over extended periods of time with minim~l shut-down and/or maintenance except as may be required for purposes of cleanliness and hygiene, and for such preventative m~int~n:~nce of equipment as may be necessarily required. Often, the design and provision of machinery having as few moving parts as possible is desirable, and is accomplished by 25 baking equipment and especially waffle forms in keeping with the present invention. As will be described in greater detail hereafter, the waffle forms that are provided in keeping with these teachings are such that they have no necessity for hinge-mounted upper and lower waffle forms in the sense of tradition waffle irons. What is provided, as will be 2184~
described hereafter, are articulated chains which are physically mounted in such a manner that the opening and closing of the waffle iron forms, and removing of the baked waffles from the waffle forms, is accomplished merely as a consequence of the geometry of the apparatus.
DESCRIPTION OF THE PRIOR ART:
In keeping with the above discussions, there is no known prior art that specifically teaches several of the key features of the methods and apparatus according to the present invention. However, the following prior art is referenced for purposes of expressing and demonstrating differences between the prior art and features of the present invention.
As to prior art which is particularly directed to methods by which baked products are prepared in substantially automated processes, and placed into packaging for shipment to the retail market, the following patents are noted:
KOMATSU et al United States patent No. 3,892,058 is concerned with short-time high temperature sterilization of packaged articles such as soups or meat products. The food product is filled into a flexible container, and non-condensible gasses which are left in the voids of the container are excluded, after which the packaging is heat sealed.
Thereafter, the packaged food is sterilized within its own sealed package by being heated to elevated temperatures for as short a time as may be possible.
PLEMONS et al United States patent No. 3,979,525 is directed to a method of producing pizza crusts, which are essentially breads. Here, the pizza crusts may be stored unsealed at room temperature, because they have been treated with ethyl alcohol. This may create significant marketing problems, since it is essentially unknown and unacceptable to add chemical compounds to a finished food product.
United States patent No. 4,120,984 to RICHARDSON et al is directed to an apparatus for placing baked goods into a sterile package and for preventing damage to the product as it is being cooled. The plastic sheet that is used is usually perforated; the invention is directed in any event to baked bread products; and there is a requirement to draw sterile air into the package.
~18gi5~0 ..
JOULIN United States patent No. 4,357,356 teaches a method of producing a bread product which is baked, packaged into hermetically sealed packages under partial vacuum, and then sterilized. The specific bread product discussed is french bread which comprises only flour, water, salt, and yeast; and, while french bread may, indeed, be partially baked, 5 it will nonetheless have a short shelf life before it becomes almost completely unpalatable.
It must also be remarked that the bread products specifically discussed by Joulin have much smaller surface areas per unit mass or per unit volume than do waffles. Moreover, waffles will at least contain eggs and perhaps milk ingredients, which may enhance microbial activity, and thus the necessity to freeze waffles has heretofore been recognized as the only 10 way to inhibit microbial activity.
OTTOW et al United States patent No. 4,426,401 discusses the packaging of perishable goods that contain water, in aseptic packages. However, the package must include vents through which vapour can escape during heat treating of the goods after they have been placed into the package. Thereafter, once the product has been cooled down, 15 the vents may then be sealed.
United States patent No. 4,457,702 to MARCHETTI teaches the packaging of foodstuffs into polyethlyne bags, which are then dropped into a bath of hot water for subsequent re-heating.
DURST United States patent No. 4,582,711 teaches the preparation of baked goods 20 that can have very long shelf life. However, those baked goods are effectively anhydrous, being such as canned cake products, cookies, or brownies, and the like.
United States patent No. 4,734,291 to RAFFENSPERGER concerns itself with the preparation with al dente pasta products which may have good shelf storage life. Here, the partially cooked pasta is extruded into a pouch pack; however, it is necessary that sufficient 25 water be used so as to reduce the pH to 4.6 or less.
SUGISAWA et al United States patent No. 4,777,057 concerns itself with a semi-prepared dough that has a specific hardness and which is charged into a heat resistant packaging container. After the package is sealed, it is then heat treated. The dough system, in any event, is packaged at its dough stage, after which it is steamed.
~18~2~3 United States patent No. 4,911,939 to LOU et al is directed to a cookie dough which is partially pre-baked and then packaged and sealed. However, this cookie dough should have high fructose content, and is specifically intended for microwave baking prior to its consumption.
SCHIRMER United States patent No. 4,928,474 teaches a retort container which may be filled with food that is sensitive to spoilage from oxygen contact. The filled container is closed by being heat sealed, then retorted, and then enclosed with an oxygen barrier material.
The following prior art patents relate particularly to various apparatus for theproduction of waffles, wafers, or baked bread:
United States patent No. 4,058,039 to SCHMID teaches a waffle transfer machine in which baked waffles are removed from a conventional waffle iron, trimmed, andtransferred onto a transfer conveyor. In the embodiments illustrated, each waffle iron comprises a clamshell hinged structure in which six waffles at a time are baked, and which thereafter require trimming, transfer, etc., for commercial packaging purposes.
WESTOVER United States patent No. 4,208,441 teaches a pair of endless mated cooking irons, one above the other, each of which comprises a pocketed cooking iron that resembles a waffle iron. However, what is prepared is pizza shells and the like, which are yeast leavened dough products. The dough requires mixing, sheeting, cutting, and proofing before it is baked. The sheets of dough are placed between hot irons which are closed by bringing their edges into contact. The dough requires to be trimmed, because it is essentially a bread dough. After the pizza dough has been baked, it may then be covered with pizza toppings, and then frozen.
Two patents to HAAS et al are United States patent No. 4,417,508 and No.
4,438,685. Each of those patents, however, is concerned with the preparation of wafers, which are prepared in a conventional hinged shell; and which, when baked, are essentially anhydrous.
~18452~
United States patent No. 4,769,245 to FARAR et al is directed to the pfepal~ion of bread products which may be removed from their packaging for browning and serving.
Special containers for the french bread are provided, into which the product is placed while it is hot enough to inactivate microbial org~ni~m~ that may be within the product.
5 However, a filter hole or aperture is required, which is small enough to allow the package to "breath" so as to equalize the pressure within and without the package. Care is taken that air does not impinge directly on the packaged food product.
HERTING United States patent No. 5,079,015 is directed to a method for at least partially cooking multi-colored waffles in more or less conventional cooking forms, from 10 which the waffles are then removed and passed to an oven for fini.~hing. The waffles are particularly intended for use as ice cream cones, and are thus very thin and essentially anhydrous.
SUMMARY OF THE INVENTION:
In accordance with one aspect of the present invention, there is provided a method for the production of baked waffles for commercial sale in unfrozen condition in sealed aseptic packages. The method comprises the steps of:
(a) Preparing a waffle batter, which has at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent which may be baking powder or baking soda.
(b) Dispensing a measured amount of waffle batter into a waffle form.
(c) Closing the waffle form.
(d) Placing the closed waffle form and the waffle batter enclosed therein into a baking oven.
(e) Maintaining the closed waffle form with the waffle batter therein in the oven at least until the waffle is baked to an extent less than 100% baked and greater than about 80% baked. The temperature of the interior of the waffle being baked must have reached at least 72C.
(f) Removing the waffle form and the baked waffle therewithin from the baking oven.
(g) Removing the hot baked waffle from the waffle form.
(h) Transferring the still hot baked waffle to a packaging station.
(i) Placing the still hot baked waffle into a heat stable package that is heat sealable. This step is taken while the baked waffle remains at an elevated temperature.
Thus, the package is rendered aseptic.
(j) The package is then sealed.
(k) The sealed aseptic package is then permitted to cool to ambient temperature.(l) Finally, the cooled sealed package is placed into storage and handling facilities. Thus, commercial sale of the unfrozen baked waffles in sealed aseptic packages may then be achieved.
In keeping with another aspect of the present invention, there is provided an apparatus for the production of baked waffles for commercial sale in unfrozen condition in sealed aseptic packages. As noted above, the baked waffles are prepared from a waffle batter having at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent which may be baking powder or baking soda, as constituents thereof. The apparatus comprises a mixer in which the waffle batter is prepared, and conveying means for conveying the mixed waffle batter to a batter depositor. The batter depositor has control means to select a specific amount of waffle batter to be deposited into a waffle form; the waffle form comprises lower and upper waffle iron shells that are arranged so as to be closed together as a waffle iron within the interior of which a waffle will be baked.
An oven is provided and will operate at a specified temperature into which the waffle iron and the waffle batter enclosed therein will be placed for sufficient time so as to bake the waffle to an extent less than 100% baked and greater than about 80% baked. The baking process will continue, in any event, until the temperature of the interior of the waffle being baked has reached at least 72C.
218~20 Means are provided for opening and unloading the waffle iron and removing the hot baked waffle therefrom to a conveyor, which conveys the hot baked waffle away from the oven and towards a packaging station. At the packaging station, the still hot baked waffle is placed into a heat stable package while the baked waffle remains at an elevated temperature, so as to render the package aseptic. Means are provided for sealing the heat stable package, cooling it to ambient temperature, and storing and h~n~ling the products for commercial sale of the baked waffles in unfrozen condition.
The lower and upper waffle iron shells, in keeping with a further aspect of thisinvention, comprise links in continuous runs of lower and upper chains of a plurality of similar waffle iron shells. The lower and upper chains are arranged to pass through a tunnel oven, and are spaced so as to be sufficiently close to one another that each respective waffle iron is at first open and then closed as the respective upper and lower chains approach and depart from each other as they wrap around respective drive and idler pinions for the respective chains.
BRIEF DESCRIPTION OF THE DRAWINGS:
The novel features which are believed to be characteristic of the present invention, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in which a presently preferred embodiment of the invention will now be illustrated by way of example. It is expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. Embodiments of this invention will now be described by way of example in association with the accompanying drawings in which:
Figure 1 is a schematic drawing showing the principal operating units which comprise the apparatus of the present invention, and showing the flow of product through the apparatus;
218~20 Figure 2 is a schematic side elevation of a baking oven in keeping with the present invention;
Figure 3 is a plan view of a typical link forming a chain of waffle iron shells in keeping with the present invention; and Figure 4 is a cross-sectional view of a closed waffle iron in keeping with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS:
Reference will no be made to Figures 1 through 4.
First, with reference to Figure 1, a commercial apparatus 10 for the production of baked waffles, in keeping with the present invention, will have the following principal components or operating units:
A mixer 12 is provided, in which waffle batter will be prepared. The waffle batter generally will comprise at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent which is usually either baking powder or baking soda. As noted above, the waffle batter may further or may optionally further include a dairy product which may be whole milk, skimmed or partially skimmed milk, or whey. Moreover, yet a further optional constituent of the waffle batter may be any one or more of lecithin, salt, and flavoring ingredients such as vanilla or fruit additives.
Throughout the apparatus, there will be a variety of conveying means such as themeans 13 or 15 which are suitably sized piping through which the mixed waffle batter may be pumped. A holding tank 14 may be provided, as necessary.
The waffle batter is conveyed as at 15 to a batter depositor 16, which is arranged so as to deposit waffle batter into a waffle form, as described hereafter. So as to ensure that each waffle to be prepared in keeping with the present invention has the same volume and mass, conkol means 18 are associated with the batter depositor 16 so as to select a specific amount of waffle batter to be deposited into the waffle form.
~18~520 An oven 20 is provided, more details of which are described below, with respect to Figure 2. The oven 20 has appropliate controls so that it operates at a specified temperature, and it may be either gas fired or electrically heated. The length of time for which waffles are baked to an extent less than 100% baked but greater than about 80%
5 baked, and in any event until the temperature of the interior of the waffle has reached at least 72C, are discussed below. Again, the specifics of the waffle irons in keeping with present invention are discussed below, but it is clear that means must be provided for opening and unloading the waffle irons after the waffles have been baked. Individual baked waffles exit the oven 20, in keeping with the usual provisions of the present 10 invention where the waffles are passed through the oven on a conveyor, and are passed at 21 to a further conveyor 22 which is arranged to convey the hot baked waffles away from the oven 20 and towards a packaging unit 26.
There may be interposed between the conveyor 22 and the packaging unit 26 a sorter 24, so that selected numbers of waffles may be collected together for placing into 15 packages for commercial sale. Intermediate conveyors 23 and 25 may also be provided.
Within the packaging unit 26, there is a sealer 28 which is arranged to seal heat stable packages after the still hot baked waffles have been placed into them. Finally, following further conveyors 29, there are provided means generally identified at 30 where the sealed heat stable packages with the baked waffles therein may be cooled, stored, 20 palletized for shipping, and shipped.
To the extent so far described, none of the operating components and units, with the exception of the heated conveyor 22, might be significantly different than is found in any commercial waffle bakery.
However, the presence of the conveyor 22 is important, because it assures that the 25 waffles as they exit the oven 20 remain at elevated temperatures, so as to inhibit microbial activity.
Turning to Figures 2, 3, and 4, further details of the oven and the waffle forms in keeping with the present invention are now discussed:
218~520 -In general, the oven 20 comprises an insulated shell 40, within which are two chain runs 42 and 44. The upper chain 42 is contained within the oven 20, the lower chain 44 extends beyond the entrance end 45 and the exit end 47 of the oven 20. Each chain run 42 and 44 is wrapped around drive and idler pinions 46 and 48, which may be arranged at either end of each chain as necessary and appropliate.
The output from the batter depositor 16 is shown at 51, being deposited on the upper reach of the lower chain 44; the output of baked discrete waffles is taken away from the lower chain 44 at 53.
Turning to Figures 3 and 4, some details of the respective upper and lower chains 42 and 44 are discussed. Each chain is essentially identical to the other chain, except for the number of links that comprise the respective chains, due to the differences of their lengths.
A typical link 60 is shown in Figure 3. This link provides, in this case, a pair of waffle iron shells 62, each of which is identical to the other and is configured in typical waffle fashion. Thus, each of the waffle iron shells may comprise a plurality of elevations 63 and indentations 65, as shown in Figure 4. Figure 4 also shows the manner in which respective links from the upper and lower chain runs 42 and 44 will mate together.
Each of the links 60 is articulated to the links on either side of it by connecting links (not shown) passed through respective openings 66 and 68 at the left and right sides thereof, as shown. Each link 60 moves in the direction of either of arrows 67 or 69. Thus, each of the upper and lower chains 42 and 44 passes through, or is contained in, the oven 20, which is arranged in the form of a tunnel oven. The respective upper and lower chain runs 42 and 44 are, as noted and demonstrated by Figure 4, sufficiently closely spaced to one another so as to form the waffle iron. As each of the lower and upper chain runs 42 and 44 approach each other as the upper chain 42 wraps around pinion 46 as shown in Figure 2, each respective waffle iron will be closed. Then, as the upper chain 42 wraps around pinion 48, each respective waffle iron will open. Moreover, as the baked waffle in each respective waffle iron shell exits the oven 20 at exit end 47, it is at least 80% baked and is therefore firmly formed so that it will generally fall from the waffle iron shell as the lower chain wraps around its respective pinion 48. Thus, the unloading means for the lower chain 44 is located beyond the exit end of the oven 20. If necessary, a selectively operated air jet may also be provided either to blow the at least 80% baked waffle from each respective waffle iron shell, or to lift it from the shell by vacuum.
Once any baked waffle has been removed from its respective waffle iron shell 62 at the unloading station indicated generally by the reference 53, it passes to the conveyor 22. Here, as noted, the conveyor is such that it will ensure that the waffles as they exit the oven 20 will remain at elevated temperatures. This is typically accomplished by providing the conveyor 22 in the shape of a further heated tunnel, where the temperature inside the tunnel is maintained sufficiently high so that the interior temperature of the waffles will not fall below anything less than 72C.
If the sorter 24 is present, its ambient temperature is also m~int~ined at an elevated temperature, once again so as to preclude cooling of the interior temperature of the freshly baked waffles below no less than 72C. The purpose of the sorter is, particularly in an automated baked waffle manufacturing facility, to permit a selected number of waffles to be collected so that they may be packaged together in a single package of, say, usually six or eight waffles, for commercial sale purposes. The waffles, or groups of waffles, are then conveyed to the packaging unit 26 by the supplementary conveyor 25.
At the packaging unit 26, the waffles or selected numbers of waffles are placed into their packages, while still hot--preferably, while their internal temperature remains at least at 72C, so as to preclude or inhibit microbial activity after the waffle has been cooled down. Each package is generally formed of a heat stable polypropylene film, having a heat sealable film l~min~tç~l thereto. It is evident that any such package may then be, appropriately, heat sealed, using conventional heat sealing apparatus. Alternatively, the package may comprise a heat stable formed plastic fill cup, usually one which has been pre-formed using vacuum forming equipment, which may then be heat sealable or hermetically sealable by placing a heat sealable or hermetically sealable cover film thereover. It is evident that, no matter which variety of package may be used, if the packaging material per se is a~plo~iately stored and conveyed into the packaging unit 26, c~l84520 and filled and sealed at the sealer 28 while at all times the interior temperature of the waffles being placed into each heat sealed package remains above at least 72C, then the retained heat within each waffle will be sufficient to heat whatever air may be captured in the package, and thereby render the package aseptic. It should be noted that, in general, 5 the interiors of the packaging unit 26 and sealer 28 are also m~int~ined at elevated temperatures.
In the event that the interior temperature of the waffles has cooled below about72C, or, in any event, for greater surety of the aseptic nature of the heat sealed package, provided the material of the package will withstand temperatures of at least 90C, it is 10 possible to re-heat the sealed aseptic packages up to a temperature of about 90C so as to re-heat the baked waffles that are sealed therein. If the appropriate dwell time is chosen, then the interior temperature of each of the baked waffles will, once again, be elevated at least up to 72C.
The importance of the temperature of about 72C is, of course, that, at that 15 temperature and above, microbial activity is substantially precluded or the aseptic quality of the package is assured inhibited; and if the sealed package is rendered aseptic at the time that it is sealed, or by subsequent or supplemental heating thereafter, then the aseptic quality of the package will be certain.
Referring now to the batter depositor 16, it has associated with it a control means 20 18 whose purpose is to select and assure that a specified amount of waffle batter will be deposited into the waffle form. Typically, each waffle will have a weight of 30 to 75 grams. In any event, the volume of the waffle to be baked in each waffle iron form is known and, since the density of the waffle batter is known or can easily be determined, a precise amount of batter may therefore be deposited into each waffle iron form. This 25 assures that there will be no flash or spillover on the one hand, and that each waffle will be fully developed and baked. It is evident, of course, that any shape and particular volume of waffle can be prepared in keeping with the present invention, merely by appropriate design of the waffle iron shells 62 and the links 60 in which they are formed.
~ls~s2a The material from which the links 60 is formed may conveniently be cast aluminumor other appropriate materials such as cast iron, and it may be appropriately coated with a non-stick material such as PTFE. Moreover, a suitable vegetable oil spray may be utilized by being sprayed into each respective waffle iron shell at an applopliate station at or near 5 the entrance end 45 of the oven 20.
It is a simple matter, of course, having determined the shape, volume, and weight of each waffle to be baked to calculate and establish the appropriate temperatures within the oven 20 and the dwell time for each respective waffle iron form to pass through the oven 20, in order that each waffle may be at least 80% baked but less than 100% baked.
Typically, the interior of the oven in maintained at about 170C or 225C, depending on the formulation. A typical dwell time for each waffle as it passes through the oven 20 is approximately 95 seconds. Thus, the speed of driving the upper and lower chains 42 and 44 may easily be adjusted ~plopliately.
Likewise, the interior of the conveyor 22, the sorter 24, and the packaging unit 26, 15 are normally m~int~ined at least at about 75C, usually about 90C. This assures that, once the interior of each waffle as it has been baked has reached the temperature of about 72C, it will not cool below that temperature. Moreover, there is little incremental baking activity that continues after the waffles have been removed from their respective waffle irons, because there is no significant heat differential between the temperature of the waffle and 20 the ambient within which it is being m~int~ined.
From all of the above, it follows that the steps taken for the production of baked waffles for commercial sale in unfrozen condition in sealed aseptic packages, in keeping with the present invention, will be essentially as follows:
(a) First, the waffle batter is prepared. As noted, the waffle batter will have at 25 least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent which is generally baking powder or baking soda. As noted, the waffle batter may further comprise a dairy product such as whole milk, skimmed or partially skimmed milk, and whey; and it may have a further optional constituent such as lecithin, salt, and flavoring ingredients such as vanilla, or a fruit additive.
218~520 (b) A specific measured amount of waffle batter is dispensed into a waffle form.(c) The waffle form is then closed.
(d) Then, the closed waffle form, with the waffle batter therewithin, is placed into a baking oven. Typically, as discussed, this entails passage of a waffle form as a link 5 or a portion of a link of a chain passing through a tunnel oven, but other baking oven facilities and/or waffle irons may also be employed.
(e) Each closed waffle form and the waffle batter therewithin is maintained in the oven for a sufficient dwell time so that the waffle will bake to an extent less than 100%
baked but greater than about 80% baked. Moreover, the temperature of the oven and the 10 dwell time of each waffle form within it will be chosen, in any event, so that the interior temperature of the waffle being baked will reach at least 72C.
(f) Then, the baked waffle form and the baked waffle therewithin will be removed from the oven.
(g) The hot baked waffle will be removed from the waffle form.
(h) The still hot baked waffle will be transferred to a packaging station. This usually requires, as noted above, that the hot baked waffle will be passed through a heated zone on a conveyor, where the temperature thereof will be m~inl:~ined sufficiently high so that the interior temperature of the baked waffle remains above at least 72C.
(i) Moreover, while m~int:~ining the interior of the waffle above at least about20 72C, the waffle is placed into a heat stable package which is sealable while the baked waffle still remains at an elevated temperature. This will render the package aseptic, as discussed above.
(j) The package is then sealed, usually by heat sealing.
(k) Thereafter, the sealed aseptic package is permitted to cool to ambient 25 temperature. It is not necessary, in keeping with the provisions of this invention, to lower the temperature of the sealed aseptic packages with baked waffles therewith to below ambient temperature; specifically, it is not necessary to freeze the baked waffles.
~18~20 ,.
(l) Finally, the cooled (to ambient temperature) sealed aseptic packages of baked waffles are placed into storage or handling facilities from whence they may be delivered into commercial distribution streams for commercial sale of the unfrozen waffles in their sealed aseptic packages.
As noted above, in general, each package will contain a selected number of sealed waffles; it is possible, however, for such industries as the hospitality industry, hotels, hospitals, and the like, that individual baked waffles in their own respective sealed aseptic packages may be distributed.
When the waffles are removed from their sealed aseptic packages, it is generallyintended that they shall be re-heated by being placed into a toaster or conventional or toaster oven for consumption. By re-heating in a toaster or oven, which is heated by radiant heat which transfers to the waffle, the discontinued baking procedure for the waffle will be fin~li7ed. This is because there still remains a significant moisture content within the waffle, and because there is no significant crust that has been formed on the exterior surface of the waffle. Moreover, because of the nature of the formation of the waffles, they have a very high ratio of surface area to volume or mass, as compared with bread or pizza doughs, and the like, and heat transfer to the waffle is accomplished quite quickly.
It is evident that there may be significant savings in terms of expenditures of capital money to build plants and equipment, operating costs to store and ship baked waffles prepared by the present invention, and energy expended, when compared to frozen waffles that are currently available in the market. There is no need for the construction of freezers, frozen storage facilities, frozen delivery facilities, and frozen retail sale cabinets; neither is there any necessity for energy to be expended in removing heat from baked waffles so as to freeze them and then m~int~ining them in a frozen condition.
As stated above, the cost of materials and the amount of materials used in keeping with the present invention, as compared with presently commercially available frozen waffles, will be essentially the same. The waffles will be the same, the packaging will be essentially the same by way of the wrapping material, the retail boxes will be essentially the same, and even the shipping cartons will be essentially the same except that they do not need to be specially prepared for handling at extremely low temperatures.
~18~S2~
The waffles prepared in keeping with the present invention are delivered to the consumer in unfrozen condition, which means that the consumer does not need to provide special storage facilities such as home freezers or the like to store them prior to consumption. However, once removed from their aseptic packaging, any waffles that are 5 not consumed should be refrigerated because microbial activity could be re-initiated at that time. Otherwise, the baked waffles provided by the present invention to the market in unfrozen condition in aseptic packages may have a shelf life of three or four months.
It follows, therefore, that the baked waffles in keeping with the present invention may be delivered to the consumer for a lower cost, and may therefore be acquired by the 10 consumer for a lower price. There are further environmental concerns, since there is no wasted energy required to freeze the waffles or to m~int~in them in a frozen condition.
All of the above is achieved, as noted, without the requirement for any additional chemical additives or preservatives in the waffle batter, without the necessity for injecting inert gasses such as carbon dioxide into the packages, nor without the necessity to utilize 15 vacuum technology to remove entrapped air from the packaging. Still further, and in any event, the packaging that is provided in keeping with the present invention will permit the sealed aseptic package to be re-heated, if necessary and appropriate. This does not require, however, irradiation or other sterilization or pasteurization techniques, since the waffles have been sealed into packages that are rendered aseptic due to the incipient or specific 20 heat which remains present within the waffles as they were placed into the packaging, thus inhibiting or precluding microbial activity.
Other modifications and alterations may be used in the design and manufacture ofthe apparatus of the present invention without departing from the spirit and scope of the 25 accompanymg clalms.
Claims (20)
1. A method for production of baked waffles for commercial sale in unfrozen condition in sealed aseptic packages, comprising the steps of:
(a) preparing a waffle batter having at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent chosen from the group consisting of baking powder and baking soda, as constituents thereof;
(b) dispensing a measured amount of waffle batter into a waffle form;
(c) closing the waffle form;
(d) placing the closed waffle form and enclosed waffle batter therewithin into a baking oven;
(e) maintaining the closed waffle form and waffle batter in the oven at least until a waffle is baked to an extent less than 100% baked and greater than about 80%
baked, and until at least the temperature of the interior of the waffle being baked has reached at least 72°C;
(f) removing the baked waffle form and baked waffle therewithin from the oven;
(g) removing the hot baked waffle from the waffle form;
(h) transferring the still hot baked waffle to a packaging station;
(i) placing the still hot baked waffle into a heat stable package that is sealable while said baked waffle remains at an elevated temperature, whereby said package is rendered aseptic;
(j) sealing the package;
(k) permitting the sealed aseptic package to cool to ambient temperature;
and (l) placing the cooled sealed package into storage and handling facilities for commercial sale thereof in unfrozen condition in said sealed aseptic package.
(a) preparing a waffle batter having at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent chosen from the group consisting of baking powder and baking soda, as constituents thereof;
(b) dispensing a measured amount of waffle batter into a waffle form;
(c) closing the waffle form;
(d) placing the closed waffle form and enclosed waffle batter therewithin into a baking oven;
(e) maintaining the closed waffle form and waffle batter in the oven at least until a waffle is baked to an extent less than 100% baked and greater than about 80%
baked, and until at least the temperature of the interior of the waffle being baked has reached at least 72°C;
(f) removing the baked waffle form and baked waffle therewithin from the oven;
(g) removing the hot baked waffle from the waffle form;
(h) transferring the still hot baked waffle to a packaging station;
(i) placing the still hot baked waffle into a heat stable package that is sealable while said baked waffle remains at an elevated temperature, whereby said package is rendered aseptic;
(j) sealing the package;
(k) permitting the sealed aseptic package to cool to ambient temperature;
and (l) placing the cooled sealed package into storage and handling facilities for commercial sale thereof in unfrozen condition in said sealed aseptic package.
2. The method of claim 1, wherein the waffle batter may optionally further comprise a dairy product chosen from the group consisting of whole milk, skimmed or partially skimmed mills, and whey;
and a further optional constituent chosen from any one or more of the group consisting of lecithin, salt, and flavoring ingredients.
and a further optional constituent chosen from any one or more of the group consisting of lecithin, salt, and flavoring ingredients.
3. The method of claim 1, wherein step (h) is carried out by passing the baked waffle through a heated zone having a temperature sufficiently high so as to maintain the interior temperature of said baked waffle at least at 72°C until step (i) is concluded.
4. The method of claim 1, wherein said aseptic package comprises a heat stable polypropylene film having a heat sealable film laminated thereto so as to permit heat sealing thereof.
5. The method of claim 1, wherein said aseptic package comprises a heat stable formed plastic fill cup and a heat sealable or hermetically sealable cover film.
6. The method of claim 1, wherein said heat stable aseptic package will withstand temperatures of at least 90°C.
7. The method of claim 6, wherein after step (j), said sealed aseptic package is reheated at a temperature of up to 90°C so as to reheat the baked waffle sealed therewithin at least until the interior temperature of said baked waffle is elevated at least up to 72°C.
8. The method of claim 1, wherein step (i) is repeated until a selected number of still hot baked waffles are placed in said heat stable package, followed thereafter by steps (j), (k), and (l).
9. Apparatus for the production of baked waffles for commercial sale in unfrozen condition in sealed aseptic packages, where said baked waffles are prepared from a waffle batter having at least flour, water, sweeteners, whole eggs, vegetable oil or butter, and a leavening agent chosen from the group consisting of baking powder and baking soda, as constituents thereof, said apparatus comprising:
a mixer for preparation of said waffle batter;
conveying means for conveying mixed waffle batter to a batter depositor;
said batter depositor having control means to select a specific amount of waffle batter to be deposited into a waffle form;
said waffle form comprising lower and upper waffle iron shells arranged so as to be closed together as a waffle iron within the interior of which a waffle will be baked;
an oven operating at a specified temperature into which said waffle iron is placed for sufficient time as to bake said waffle to an extent less than 100% baked and greater than about 80% baked, and until the temperature of the interior of the waffle being baked has reached at least 72°C;
opening and unloading means for opening and unloading the hot baked waffle from said waffle iron;
conveyor means for conveying the hot baked waffle away from said oven and towards a packaging station at which the still hot baked waffle is placed into a heat stable package while said baked waffle remains at an elevated temperature, whereby said package is rendered aseptic;
sealing means for sealing said heat stable package;
cooling means for cooling said sealed heat stable package and baked waffle therein to ambient temperature; and storage and handling means for placing a plurality of said cooled sealed and aseptic packages into channels for commercial sale thereof in unfrozen condition.
a mixer for preparation of said waffle batter;
conveying means for conveying mixed waffle batter to a batter depositor;
said batter depositor having control means to select a specific amount of waffle batter to be deposited into a waffle form;
said waffle form comprising lower and upper waffle iron shells arranged so as to be closed together as a waffle iron within the interior of which a waffle will be baked;
an oven operating at a specified temperature into which said waffle iron is placed for sufficient time as to bake said waffle to an extent less than 100% baked and greater than about 80% baked, and until the temperature of the interior of the waffle being baked has reached at least 72°C;
opening and unloading means for opening and unloading the hot baked waffle from said waffle iron;
conveyor means for conveying the hot baked waffle away from said oven and towards a packaging station at which the still hot baked waffle is placed into a heat stable package while said baked waffle remains at an elevated temperature, whereby said package is rendered aseptic;
sealing means for sealing said heat stable package;
cooling means for cooling said sealed heat stable package and baked waffle therein to ambient temperature; and storage and handling means for placing a plurality of said cooled sealed and aseptic packages into channels for commercial sale thereof in unfrozen condition.
10. The apparatus of claim 9, wherein a holding tank for said mixed waffle batter is interposed between said mixer and said batter depositor.
11. The apparatus of claim 9, wherein said lower and upper waffle iron shells of said waffle iron each comprises a link in a continuous respective lower and upper chain of a plurality of similar waffle iron shells, where each chain is wrapped around respective drive and idler pinions at each end of the chain run formed thereby;
wherein each of said lower and upper chains is arranged to pass through a tunnel oven in such a manner that respective ones of said lower and upper waffle iron shells face each other so as to form said waffle iron, and said respective lower and upper chain runs are sufficiently closely spaced to one another and arranged so that each respective waffle iron is at first open and is then closed as each said upper shell approaches a respective lower shell; and wherein said opening means for said waffle iron is formed by said upper chain moving away from said lower chain as it wraps around a respective one of said drive and idler of said upper chain, pinions its respective end, and said unloading means is formed at least in part by said lower chain as it wraps around a respective one of said drive and idler pinions at its respective end of said lower chain.
wherein each of said lower and upper chains is arranged to pass through a tunnel oven in such a manner that respective ones of said lower and upper waffle iron shells face each other so as to form said waffle iron, and said respective lower and upper chain runs are sufficiently closely spaced to one another and arranged so that each respective waffle iron is at first open and is then closed as each said upper shell approaches a respective lower shell; and wherein said opening means for said waffle iron is formed by said upper chain moving away from said lower chain as it wraps around a respective one of said drive and idler of said upper chain, pinions its respective end, and said unloading means is formed at least in part by said lower chain as it wraps around a respective one of said drive and idler pinions at its respective end of said lower chain.
12. The apparatus of claim 11, wherein each link of said lower and upper chains of waffle iron shells comprises at least two similar waffle iron shells in juxtaposed relation to one another in crosswise orientation with respect to the length of each said chain.
13. The apparatus of claim 11, wherein said lower chain of waffle iron shells extends beyond an entrance and exit end of said tunnel oven, wherein said batter depositor is located at said entrance end for depositing a specific amount of waffle batter onto each respective lower waffle iron shell, and wherein said unloading means is located beyond an exit end of said tunnel oven.
14. The apparatus of claim 11, wherein said packaging station is arranged to form aseptic packages for said baked waffles, where each package comprises a heat stable polypropylene film having a heat sealable film laminated thereto so as to permit heat sealing thereof.
15. The apparatus of claim 11, wherein said packaging station is arranged to form aseptic packages for said baked waffles, where each package comprises a heat stable formed plastic fill cup and a heat sealable or hermetically sealable cover film.
16. The apparatus of claim 11, further comprising a heated discharge conveyor zone located at said exit end of said tunnel oven, wherein the temperature is maintained sufficiently high in said heated discharge conveyor zone so as to maintain the interior temperature of each said baked waffle at least at 72°C while each baked waffle is conveyed therethrough.
17. The apparatus of claim 11, wherein each heat stable aseptic package into which said baked waffles are placed will withstand temperatures of at least 90°C.
18. The apparatus of claim 17, further comprising package reheating means wherein sealed aseptic packages of baked waffles may be reheated at a temperature of up to 90°C so as to reheat the baked waffles sealed therein at least until the interior temperature thereof is elevated at least up to 72°C.
19. The apparatus of claim 11, wherein said packaging station is arranged so that a selected number of said still hot baked waffles are placed into each said heat stable aseptic package prior to each said package being sealed.
20. The apparatus of claim 13, wherein said unloading means further comprises a selectively operated air jet to assist separation of a baked waffle from its respective lower waffle iron shell.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US53711895A | 1995-09-29 | 1995-09-29 | |
| US08/537,118 | 1995-09-29 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2184520A1 CA2184520A1 (en) | 1997-03-30 |
| CA2184520C true CA2184520C (en) | 2000-02-22 |
Family
ID=24141291
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2184520 Expired - Fee Related CA2184520C (en) | 1995-09-29 | 1996-08-30 | Method & apparatus for preparation & packaging of commercial unfrozen baked waffles |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2184520C (en) |
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1996
- 1996-08-30 CA CA 2184520 patent/CA2184520C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2184520A1 (en) | 1997-03-30 |
| MX9604410A (en) | 1997-09-30 |
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