GB2586208A

GB2586208A - Manufacture of layered Foodstuffs

Info

Publication number: GB2586208A
Application number: GB1910445.4A
Authority: GB
Inventors: Dean Ledger Richard
Original assignee: Millitec Food Systems Ltd
Current assignee: Millitec Food Systems Ltd
Priority date: 2019-07-22
Filing date: 2019-07-22
Publication date: 2021-02-17
Anticipated expiration: 2039-07-22
Also published as: GB2586208B; GB201910445D0

Abstract

A food production system for depositing a flexible sheet 10 of foodstuff onto a food product comprises a backing sheet 12 having at least one flexible sheet of foodstuff along a length thereof. A driving means to conveys the flexible sheet 10 of foodstuff on the backing sheet 12 into proximity of a food product on a production line and at least one depositor is configured to deposit at least one flexible sheet 10 of foodstuff onto the food product by separation of the flexible sheet 10 from the backing sheet 12 by upwards pulling 28. Flexible sheet 10 is contained in cassettes 20, 30 respectively via dispenser 24 and placed in to position via roller 26. Conveyor belt 28 carries food product trays 40 beneath food dispensers 34, 36 and dispenser 24. Flexible food stuff 10 may be pasta sheets, with the food product 40 being a lasagne and dispensing cassettes 20, 30 may comprise a sensor and associated cutting mechanism so as to cut the flexible sheet 10 into a plurality of sheets whilst still attached to backing sheet 12. An associated method is also disclosed.

Description

Title -Manufacture of Layered Foodstuffs The present invention relates to the manufacture of foodstuffs, such as ready meals, and in particular the application of ingredients in sheets to layered foodstuffs.

A conventional lasagne ready-meal is illustrated in Figure 1. The lasagne ready-meal is packaged in a heat-proof tray 1, and has a combination of tomato-based non-pasta layers 2 (i.e. a sauce layer) and pasta sheet layers 3, with a cheese topping layer 4. The ready-meal may have a number of levels, ie the non-pasta layer and pasta layer sequence may be repeated multiple times.

When producing the conventional ready meal of Figure 1, first an open tray is provided, which is arranged beneath a depositing station for ejecting a predetermined amount of the sauce-based layer 2 into the tray 1. However, where the sauce-based layer can be handled in the manner of a viscous fluid, the pasta layer is more awkward to handle. Typically, it is desirable to use cooked (i.e. wet/compliant pasta sheets) and/or fresh egg pasta in the ready-meal and it is conventional for a human operator to manually apply the pasta sheet onto the sauce layer.

The process of dispensing the sauce layer and then manually applying the pasta sheet is repeated in order to build up the desired number of levels in the ready-meal product before applying a cover/lid, e.g. in the form of a sealed lid, over the tray 1.

The abovementioned layering process may need to be repeated at different stations of a production line.

There is an ongoing desire for automation in convenience food production in order to reduce cost, improve production efficiency/speed and/or ensure consistency of the resulting products. Despite such aims, the need for human operators to manually apply sheet pasta has conventionally remained because of the awkwardness of handling the compliant pasta sheets. For example, the individual pasta sheets are easily broken and difficult to machine-handle effectively at high production speeds.

It is an aim of the present invention to provide a method for applying sheet foodstuffs to layered ready meals that mitigates or resolves one or more of the above-discussed problems.

According to a first aspect of the invention, there is provided a food production system for depositing a flexible sheet of foodstuff onto a food product comprising: a backing sheet having at least one flexible sheet of foodstuff along a length thereof; a driving means to convey the flexible sheet of foodstuff on the backing sheet into proximity of a food product on a production line; and at least one depositor configured to deposit the at least one flexible sheet of foodstuff onto the food product by separation of the flexible sheet from the backing sheet.

The method of depositing flexible sheets of foodstuff is advantageous because it does not require a human operator and can achieve depositing of the sheet foodstuff with a low risk of damage/tearing the discrete sheets. Furthermore it can accommodate continuous production of food products having multiple layers at high speeds.

The system may comprise a linear actuator configured to move the food product into proximity of the depositor. The linear actuator may comprise a conveyor belt.

The flexible sheet may be peeled from the backing sheet. The system may comprise a roller and the backing sheet is driven over the roller to provide a change of direction in order to peel the flexible sheet from the backing sheet.

The at least one depositor may comprise, or be fed by, a cassette comprising the sheet foodstuff. The cassette may comprise the sheet foodstuff laying on the length of backing sheet, which may be wound onto a support. The support may comprise a rotating support arranged to allow dispensing of the backing sheet and sheet foodstuff from the cassette, e.g. in a direction tangential to an axis of rotation of the cassette/support.

The cassette may comprise a sensor configured to detect the presence and/or position of the food product.

The at least one flexible sheet of foodstuff may comprise a length of foodstuff substantially longer than the length of one of the discrete portions of foodstuff deposited onto the food products. The flexible sheet may comprise a plurality of discrete flexible sheets. The flexible sheet may extend substantially the length of the backing sheet and a cutting mechanism may be configured to cut the at least one flexible sheet into a plurality of discrete flexible sheets whilst still attached to the backing sheet.

The flexible sheet foodstuff may conform to the backing sheet and/or lie flat on the backing sheet.

The flexible sheet foodstuff may be less than lOmm, 5mm or 3mm in height/thickness.

The system may comprise a controller configured to control the driving means or linear actuator to synchronise the position/speed of the backing sheet and the food product.

The food product may comprise a receptacle, for example, an open tray, and each flexible sheet is deposited into a respective receptacle.

The system may comprise a plurality of depositors e.g. at spaced locations along the conveyor.

The flexible sheets of foodstuff may be at least partially cooked. The flexible sheets of foodstuff may be wet. and/or floppy (e.g. incapable of maintaining its form under the force of gravity without support). The flexible sheets of foodstuff may comprise pasta. The food product may comprise lasagne.

According to a second aspect of the invention, there is provided a method of depositing a flexible sheet of foodstuff onto a food product, the method comprising: providing at least one flexible sheet of foodstuff along a length of backing sheet; driving the backing sheet in order to convey the flexible sheet of foodstuff on the backing sheet into proximity of a food product on a production line; and depositing the at least one flexible sheet of foodstuff onto a food product by separation of the flexible sheet from the backing sheet.

According to a third aspect of the invention, there is provided a dispensing cassette configured to deposit flexible sheets of foodstuff onto a food product comprising: a backing sheet wound around an axis, e.g. an axle, a drum or a pin; and the backing sheet having at least one flexible sheet of foodstuff thereon.

The cassette may comprise a sensor configured to detect the presence and/or position of a food product proximal to an outlet of the dispensing cassette.

The dispensing cassette may comprise a cutting mechanism configured to cut the at least one flexible sheet into a plurality of discrete flexible sheets whilst still attached to the back sheet.

The cassette and/or drum may comprise one or more side wall, e.g. wherein the backing sheet and the flexible sheet foodstuff is supported on the drum adjacent a 25 side wall or between opposing side walls. Side walls may be spaced by the drum.

The side wall(s) may comprise a housing for the wound backing sheet.

The drum may be rotatable in use to allow dispensing of the flexible sheet of foodstuff by unwinding the backing sheet from the drum.

Practicable embodiments of the invention will now be described in further detail, with reference to the accompanying drawings, of which: Figure 1 is schematic cross-sectional view through a conventional lasagne ready meal; Figure 2a is an aerial view of discrete sheet portions of flexible foodstuff placed on a backing sheet; Figure 2b is an aerial view of a continuous sheet portion of flexible foodstuff placed on a backing sheet; Figure 3 is a side view of a dispensing cassette comprising the backing sheet of Figure 2a or Figure 2b; Figure 4 is a close up view of the cutting mechanism of a dispensing cassette Figure 5 is a side view of a food production system comprising the pasta-dispensing cassette of Figure 3.

Figures 2a and 2b show a backing sheet comprising flexible foodstuff located thereon. The flexible foodstuff may comprise a foodstuff for a food item comprising a plurality of layers, for example, a lasagne, a hamburger, a sandwich, a cake, a ready meal, or other baked/cooked goods.

The flexible foodstuff may comprise inter alia: lasagne sheets, cheese, icing. The flexible sheet may be floppy (i.e. incapable of maintaining its form under the force of gravity without support).

Figure 2a illustrates a length of backing sheet 12 having a plurality of pre-cut flexible sheets 10 thereon. The flexible sheets 10 may be cooked or partially cooked prior to being placed on the backing sheet 12. The flexible sheet foodstuff conforms to the backing sheet 12 and/or lies flat on the backing sheet 12.

The flexible sheets 10 are loosely bonded to the backing sheet 12 (i.e. the flexible sheets are sticky/tacky). The flexible sheets 10 may be wet either prior to being placed on the backing sheet 12, or whilst on the backing sheet 12.

Each of the flexible sheets 10 on the backing sheet 12 are of a uniform width and length, the uniform width and length configured to be slightly smaller than the width and length of the ready-meal food trays the flexible sheets 10 are intended to be placed into. The width and/or length of the flexible sheets may be greater than 5cm, 10cm or 15cm. The width and/or length of the flexible sheets may be less than 50cm, 40cm, 30cm or 20cm. The width of the flexible sheets 10 may be 10-25cm, or 12-20cm, or 14-18cm. The length of the flexible sheets 10 may be 15-40cm, or 20-30cm, or 22-26cm.

The thickness of the flexible sheets 10 may be less than lOmm, 5mm, 4mm or 3mm. The thickness of the flexible sheets may be at least 0.1, 0.5 or 1.0mm.

However thinner sheets could be accommodated, if desired. A typical range of thickness might be 0.5-3mm.

The length of the backing sheet 12 is substantially longer than the length of the flexible sheets 10, such that multiple flexible sheets 10 may be provided on a single backing sheet 12. The length of the backing sheet 12, and/or the flexible foodstuff sheet thereon may be at least 10m, 20m, 30m, 50m, 70m or more.

The width of the backing sheet 12 may be wider than the width of the lasagne sheets 10, e.g. slightly wider, such as less than 10% or 5% wider. The width of the backing sheet 12 may be 12-27 cm, or 14-22cm, or 16-20cm. The thickness of the backing sheet 12 may be 20-150gsm, or 30-90gsm, or 35-55gsm.

Figure 2b illustrates a length of backing sheet 12 having an uncut flexible sheet 14 thereon. The uncut flexible sheet 14 is intended to be cut at predetermined lengths along its length, as indicated by dashed lines 16 to provide a plurality of individual flexible sheets substantially identical to the pre-cut flexible sheets 10. The uncut flexible sheet 14 may be partially cooked prior to being placed on the backing sheet 18. The uncut flexible sheet 14 may be wet either prior to being placed on the backing sheet 18, or whilst on the backing sheet 18.

The uncut flexible sheet 14 is of a uniform width over the whole of the backing sheet 18. The uniform width may be configured to be slightly smaller than the width of the ready-meal food trays the cut lasagne sheets are intended to be placed into. The width of the uncut lasagne sheet may be 10-25cm, or 12-20cm, or 14-18cm.

The length of the uncut flexible sheet 14 is substantially longer than the predetermined length at which the flexible sheet 14 is intended to be cut. The length of the uncut flexible sheet 14 may be 1-100m, or 3-80m, or 10-50m. The predetermined length at which the flexible sheet 14 is intended to be cut is uniform across the whole of the flexible sheet 14, and is configured to be slightly smaller than the length of the ready-meal food trays the cut flexible sheets are intended to be placed into. The length of the cut flexible sheets may be 15-40cm, or 20-30cm, or 22-26cm. The thickness of the flexible sheet 14 may be 0.01-3mm, or 0.02-1.5mm, or 0.5-1 mm.

The length of the backing sheet 12 is at least the length of the flexible sheet 14 (e.g. the flexible sheet 14 extends substantially the full length of the backing sheet). The length of the backing sheet 12 may be 1-100m, or 3-80m, or 10-50m. The width of the backing sheet 12 is wider than the width of the flexible sheet 14. The width of the backing sheet 12 may be 12-27 cm, or 14-22cm, or 16-20cm. The thickness of the backing sheet 18 may be 20-150gsm, or 30-90gsm, or 35-55gsm.

Figure 3 illustrates a dispensing cassette 20 for storing a backing sheet 12 with flexible sheets 10 thereon. The backing sheet 12 is wound into a roll 22 and stored within a housing of the dispensing cassette 20. The backing sheet 12 may be rolled around itself, or around a pin or rotatable drum located at the centre of the dispensing cassette 20. The cassette may have a plurality of side walls either side of the pin/drum to prevent the roll 22 from falling from the dispensing cassette 20.

The dispensing cassette 20 comprises a depositor 24, through which a first end 18 of the backing sheet 12 and the flexible sheet 10 can pass through. The flexible sheet 10 is arranged on the outer surface of the baking sheet such that the flexible sheets 10 are on a downward side of the backing sheet 18 at the depositor 24.

Where the flexible sheet 14 is not already pre-cut into discrete portions 10 before being placed on the backing sheet 12, the dispensing cassette 20 may also comprise a cutting mechanism 42 configured to cut the flexible sheet 14 into discrete portions 10.

Figure 4 shows a close up of the cutting mechanism located within the dispenser 24 of the cassette 20. The cutting mechanism 42 comprises a first roller 44 and a second roller 46 arranged on opposing sides of the uncut flexible sheet 14 (shown in dashed lines) and the backing sheet 12. The first roller 44 comprises one or more blades 45 disposed circumferentially about the first roller 44 and extending along the axial length of the first roller 44. The second roller 46 comprises a resiliently deformable body/surface.

In operation, the first roller 44 rotates at a predetermined speed so that the blades 45 contact the uncut flexible sheet 14 at predetermined intervals and thereby providing cut sheets 10 of a predetermined size. The second roller 46 provides a mandrel to prevent movement of the backing sheet 12 in a radial direction with respect to the first roller. The deformable body/surface of the second roller 46 reduces the contact pressure of the blade 45 against the backing sheet 12, thereby allowing cutting of the flexible sheet 10 without cutting the backing sheet 12.

The spacing of the cuts 16 may be varied by changing the rotational speed and/or of the number of blades 45 provided on the first roller 44.

Figure 5 illustrates a production line for depositing the flexible sheet onto a food product, particularly for depositing a pasta layer, e.g. into a ready meal lasagne.

The first end 18 of the backing sheet 12 is connected to a driving means (not shown) configured to pull the backing sheet 12 out of the cassette 20. The backing sheet 12 is driven over a roller 26 located adjacent the dispenser 24, and the backing sheet 12 and is pulled in an upwards direction (as indicated by arrow 28).

The roller 26 locates the backing sheet 12 at a height suitable for deposition of the lasagne sheet onto a food product and provides an upwards change of direction of the backing sheet 12.

The production line comprises a linear actuator, such as a conveyor belt 38, configured to move a food product relative to the dispensing cassette 20. The food product may comprise a partially completed foodstuff, for example, a lasagne layer, a hamburger patty, a sandwich filling, a cake etc. The food product may further comprise a container for the foodstuff, for example, a ready meal container, an open tray, a rigid base, or a bowl.

The production may comprise a dispenser 34 for dispensing a further foodstuff onto the food product. The further foodstuff may comprise a liquid/fluid food stuff, for example, a tomato sauce, a relish, mince, or a cheese sauce.

A controller/sensor may provide synchronisation between the movement of the food product 40 and the dispensing cassette 20 and/or the dispenser 34, such that foodstuff is deposited onto the food product at the correct time/location.

In an embodiment, the linear actuator 38 and the driving means are operated continuously in a synchronised fashion by the controller, such that each flexible sheet 10 is deposited onto the food product 40 in a continuous fashion.

In other embodiments, the dispensing cassette 20/roller 26 comprises a sensor configured to detect the presence and/or position of a food product and control the driving means accordingly. Therefore, the driving means is only actuated when the food product 40 is present, for example, to accommodate uneven spacing of the food products 40. The sensor may be any of, or any combination of a light sensor, a proximity sensor, a pressure sensor and a temperature sensor.

Operation of the invention The conveyor belt 38 moves the tray 40 into a position beneath the dispensing cassette 20. In response to the sensor detecting the presence and/or position of the food product 40, the driving means pulls the backing sheet 12 such the flexible sheet 10 is in a correct position over the food product 40. The driving means then moves the backing sheet 12 at the same speed as the food product 40, such there is little or no relative movement between the flexible sheet 10 and the food product 40.

The roller 26 and/or the dispensing cassette 20 contact the food product 40 such that the flexible sheet 10 sticks to the food product 40. The movement of the conveyor and the backing sheet 18 are synchronised, such that the flexible sheet 10 is laid evenly onto the food product 40. As the food product passes the roller 26, the upwards movement of the backing sheet causes the flexible sheet 10 to peel away from the backing sheet 12. The food product 40 is moved out of contact with the roller and/or dispensing cassette 20, having a flexible sheet deposited thereon.

In other embodiments, the roller 26 and/or the dispensing cassette 20 do not contact the food product 40, and the upwards change of direction of the backing sheet 12 at the roller 26 causes the flexible sheet 10 to gradually peel from the backing sheet 12 due to gravity. The flexible sheet then gradually falls onto the food product 40.

Alternatively, the flexible sheet 10 may be separated from the backing sheet 12 using mechanical means, for example, a blade located adjacent the roller 26.

Once of the flexible sheet 10 has been deposited, the sensor will indicate a food product is no longer present and the driving means will no longer be active, preventing further withdrawal of further flexible sheet 10 from the depositor 24 of the dispensing cassette 20.

Having received the pasta sheets 36, the food product 40 is transported by the conveyor belt 38 to the next station of the production line. Here, a food dispenser 34 deposits a further food stuff.

The food product is moved by the conveyor to a second dispensing cassette 30 located downstream from the first food dispenser 34. The second dispensing cassette 30 provides a further layer of flexible sheet 10 onto the partially prepared food product 40 in substantially the same way as the first dispensing cassette 20.

A second food dispenser 36 provides a further layer of foodstuff on top of the second lasagne layer. The second food dispenser 36 may provide a different foodstuff to the first food dispenser 34.

Further dispensing cassettes and/or food dispensers may be provided along the food production line to create a multi-layered foodstuff.

Once the food product 40 reaches the end of the production line, it is sealed and packaged for delivery. This process may be an automated process, or a human-20 operated process.

The implementation of a long length of sheet material (e.g. using a cassette) for dispensing lasagne, or other foodstuff, sheets is particularly beneficial to productivity. For example, cassettes need replacing only periodically, in contrast to numerous workers being required to manually placed the sheets into foodstuff containers on an assembly line. Multiple cassettes may be loaded such that a continuous food production line can continue whilst an individual cassette is being replaced.

Claims

Claims 1. A food production system for depositing a flexible sheet of foodstuff onto a food product comprising: a backing sheet having at least one flexible sheet of foodstuff along a length thereof; a driving means to convey the flexible sheet of foodstuff on the backing sheet into proximity of a food product on a production line; and at least one depositor configured to deposit the at least one flexible sheet of foodstuff onto the food product by separation of the flexible sheet from the backing sheet.
2. A food production system according to claim 1 comprising a linear actuator, the linear actuator configured to move the food product into proximity of the 15 depositor.
3. A food production system according to claim 2, wherein the linear actuator comprises a conveyor belt.
4. A food production system according to any preceding claim, where the flexible sheet is peeled from the backing sheet.
5. A food production system according to claim 4 comprising a roller, the backing sheet driven over the roller to provide a change of direction in order to peel the flexible sheet from the backing sheet.
6. A food production system according to any preceding claim, where the depositor comprises a cassette, the flexible sheet and backing sheet contained within the cassette and dispensable therefrom.
7. A food production system according to claim 6, where the flexible sheet and backing sheet are rolled up inside the cassette.
8. A food production system according to claim 6 or 7, where the cassette comprises a sensor configured to detect the presence and/or position of the food product.
9. A food production system according to any preceding claim, where the flexible sheet comprises a plurality of discrete flexible sheets
10. A food production system according to any of claims 1-8, where the flexible sheet extends substantially the length of the backing sheet.
11. A food production system according to claim 10, comprising a cutting mechanism, the cutting mechanism configured to cut the at least one flexible sheet into a plurality of discrete flexible sheets.
12. A food production system according to claim 11, where the cutting is performed whilst the at least one flexible sheet is still attached to the backing sheet.
13. A food production system according to any preceding claim comprising a controller, the controller configured to control the driving means or linear actuator to synchronise the position/speed of the backing sheet and the food product.
14. A food production system according to any preceding claim, where the food product comprises a receptacle and each flexible sheet is deposited into a respective receptacle.
15. A food production system according to any preceding claim, where the system comprises a plurality of depositors.
16. A food production system according to claim any preceding claim, wherein the flexible sheets of foodstuff are at least partially cooked.
17. A food production system according to any preceding claim, wherein the flexible sheets of foodstuff are wet.
18. A food production system according to any preceding claim, wherein the flexible sheets of foodstuff comprise pasta.
19. A food production system according to any preceding claim, where the food product comprises lasagne.
20. A method of depositing a flexible sheet of foodstuff onto a food product, the method comprising: providing at least one flexible sheet of foodstuff along a length of backing sheet; driving the backing sheet in order to convey the flexible sheet of foodstuff on the backing sheet into proximity of a food product on a production line; and depositing the at least one flexible sheet of foodstuff onto a food product by separation of the flexible sheet from the backing sheet.
21. A dispensing cassette configured to deposit flexible sheets of foodstuff onto a food product comprising: a backing sheet wound around an axis comprising a drum or pin, the backing sheet having at least one flexible sheet of foodstuff thereon.
22. A dispensing cassette according to claim 21, the dispensing cassette further comprising a sensor configured to detect the presence and/or position of a food product proximal to an outlet of the dispensing cassette.
23. A dispensing cassette according to claim 21 or 22, the dispensing cassette comprising a cutting mechanism, the cutting mechanism configured to cut the at least one flexible sheet into a plurality of discrete flexible sheets whilst still attached to the backing sheet.