A food product processing machine and methods of operation thereof

Abstract

A food product cooling and shaping machine (2) is able to receive, process and output a continuous flow of food products. The machine comprises a plurality of food product holders (4), each configured to receive a food product (18), and a transport mechanism (6) configured to circulate the holders along a flow path from an input location (4a) where a food product is received by each holder, via an output location (4g) where the food product is removed from each holder, back to the input location. Heat energy is extracted from each holder in a cooling region. Each holder is configured to change the size and / or shape of a food product within the holder.

Description

[0001] Title : A Food Product Processing Machine and Methods of Operation Thereof

[0002] Field of the disclosure

[0003] The present disclosure relates to a food product processing machine for cooling and shaping food products and a method for operating such a machine. More particularly, it concerns reshaping and crust freezing naturally formed meat products prior to slicing in order to minimise wastage.

[0004] Background to the disclosure

[0005] It is known to feed food products such as fresh meat incrementally towards a cutter in a food processing system, where slices or portions of a desired size are cut from a leading end of the food product.

[0006] In order to optimise the rate of throughput and to minimise the extent to which portions deviate from the desired weight, such systems operate at high speed, whilst at the same time providing close control of the weight of the slices or portions outputted by the system.

[0007] In addition, it is cost effective to optimise the amount of an incoming food product that is used to form slices or portions that meet weight requirements. These slices or portions can then be grouped together in packages ready to be sold to a consumer. This minimises the amount of the food product, if any, that remains and therefore may only be used for other, less valuable purposes.

[0008] Summary of the disclosure

[0009] The present disclosure provides a food product cooling and shaping machine, comprising: a plurality of food product holders, each configured to receive a food product; a transport mechanism configured to circulate the holders along a flow path from an input location where a food product is received by each holder, via an output location where the food product is removed from each holder, back to the input location; and a cooling region in which heat energy is extracted from each holder, wherein each holder is configured to change the size and / or shape of a food product within the holder.

[0010] The food product cooling and shaping machine is able to receive, process and output a continuous flow of food products, and therefore operate “in-line” in a food processing line, with the processing of one food product by the machine partly overlapping in time with the processing of the next food product. This is in contrast to existing systems for cooling food products one-by-one or in batches.

[0011] The machine is operable to cool the surface of a food product. This tends to enhance the ability of a food product to retain a desired outer profile imposed on the food product by the food product holders. In particular, the machine may be able to extract sufficient heat energy from areas of the surface of a food product to freeze at least an outer layer or crust of the food product. This serves to increase the rigidity of the food product as a whole, further improving the retention of a desired profile by the food product as it is processed downstream of the machine, by cutting into portions for example.

[0012] In some examples, the machine may be arranged to cool and shape a food product simultaneously to some extent. Initially, each product is likely to be relatively soft and more easily reshaped without damaging the product. As a result, less power may be consumed by the shaping process as there is less resistance from the product. The machine may extract heat energy from the product as it is being reshaped by the respective product holder. The reshaping may be completed before regions of the product are frozen by the machine.

[0013] The reshaping and / or cooling may take place as the food product moves along the flow path. The plurality of food product holders may be physically coupled (for example mechanically) to the transport mechanism. The transport mechanism may circulate the product holders around the flow path, so that the product holders circulate repeatedly around the flow path. The product holders may be continuously coupled to the transport mechanism as they travel around the flow path from the input location, to the output location and back to the input location.

[0014] As the machine includes a plurality of food product holders, multiple food products can be processed simultaneously. Food products may be loaded consecutively into the respective food product holders of the machine, and then unloaded one after the other. Simultaneous processing provides a high rate of product throughput by the machine, whilst allowing sufficient time for the shaping and cooling processes. For example, the machine may be able to output up to ten food products per minute or more.

[0015] The product holders may pass through the cooling region as they travel along the flow path from the input location to the output location. Alternatively, or in addition, the product holders may be cooled in the cooling region as they return to the input location from the output location.

[0016] Each food product holder may change the shape of a food product in the holder so as to press it into or towards a desired outer size and / or shape. For example, each food product may be elongate in a longitudinal direction and may be shaped by a food product holder so as to have a more uniform transverse cross-section profile in the longitudinal direction. This enables slices or portions to be cut from the food product of similar thickness with substantially the same weight, giving a high degree of consistency which is desired by food processor companies.

[0017] Food products may be fed to the machine along a product conveying direction, with the flow path of the machine extending transversely with respect to the product conveying direction. Food products may subsequently be outputted by the machine in the product conveying direction. Food products may be loaded into each food product holder along the product conveying direction. In other implementations, each food product may be moved transversely relative to the product conveying direction to transfer it to a product holder. Thereafter, each food product may be removed from the respective product holder along the product conveying direction.

[0018] The flow path of the machine may be circular. In other examples it may be oblong or oval for example, with a longer dimension of the flow path extending upwardly so that the shorter dimension extends laterally to minimise the lateral width of the footprint of the machine, and thereby avoid obstructing walkways for machine operators alongside the machine. In some implementations, the flow path may be a meandering path.

[0019] Each holder may include a plurality of dies, with each die having an inwardly facing product shaping surface. The product shaping surfaces may together define a transverse profile. The dies may be moveable between a larger transverse profile configuration and a smaller transverse profile configuration (and vice versa).

[0020] Each food product holder may be arranged to press a food product until a predetermined pressing force threshold is reached. For example, one or more dies may be configured to be driven towards the smaller transverse profile configuration until a predetermined pressing force threshold is reached.

[0021] Naturally formed meat products vary in size and shape and so this approach will accommodate greater variation in the dimensions of the food products, and avoid application of excessive forces to larger food products. This may result in the size and shape of the formed food products varying to some extent.

[0022] Alternatively, one or more dies may be configured to be driven towards the smaller transverse profile configuration until a predetermined position is reached. The food product holders may be arranged to press a food product until a predetermined cross- sectional area and / or profile shape is reached. Greater forces may therefore need to be applied to larger food products in order to achieve the required dimensions or profile. This control mode may be suitable for groups of products that are graded to be similar in size.

[0023] In some examples, each food product holder includes two dies, each of which defines two mutually perpendicular inwardly facing product shaping surfaces. The product shaping surfaces of the two dies may be substantially planar. Each die may have a longitudinally extending side which moves over a product shaping surface of an adjacent die when the dies move between the larger and smaller transverse profile configurations.

[0024] The dies may be moveable between a larger transverse profile configuration and a smaller transverse profile configuration by a die movement assembly.

[0025] Each holder may include a die mechanism which is operable to move the two dies towards and away from each other whilst maintaining each inwardly facing product shaping surface of one die perpendicular to an adjacent inwardly facing product shaping surface of the other die. The die mechanism may be provided by pivotable rigid support arms, push rods or supporting guideways, for example.

[0026] In further examples, each food product holder may include at least three dies, with each die having a longitudinally extending side which moves over the shaping surface of an adjacent die when the dies move between the larger and smaller transverse profile configurations. More particularly, each food product holder may include four such dies. The inwardly facing product shaping surface of each die may be perpendicular to the corresponding surfaces of the adjacent dies.

[0027] A die configuration of this form is described in co-pending UK patent application no. 2205486.0 (publication no. 2619265), and related PCT application no. PCT / GB2023 / 050977 (publication no. WO2023 / 199052), filed on 12th April 2023, and nationalised in the US as US patent application no. 18 / 842,747 (publication no. US2025 / 169529) on 29thAugust 2024, filed by the present applicant, the contents of which applications are fully incorporated by reference herein. In one implementation, each food product holder includes two dies, wherein one die defines a channel-shaped product shaping surface whilst the other die is insertable into the open side of the channel formed by the other die. The two dies are able to move towards each other in order to press a food product.

[0028] The dies may be moved by a die movement assembly of the machine. The die movement assembly may include drives in the form of electric motors (such as servo motors) or pneumatic or hydraulic drives. For example, electrically driven linear actuators may be used. In some implementations, one or more of the dies of each holder may be moved by mechanical means only, as each holder moves along the flow path. The circulating motion of the holders may lend itself to this approach rather than using drives requiring supply lines for power and control signals. For example, mechanisms using levers, cams and / or resilient components may be employed. Resilient components such as springs may be used to provide a degree of compliance to control the amount of pressure applied by the holder to a food product.

[0029] Each holder may include a die retention or latch mechanism which is configured to temporarily retain the dies of the holder in a transverse profile configuration which is smaller than the larger transverse profile configuration. The die retention mechanism may be in the form of a gear mechanism or other mechanical coupling with a sufficiently high mechanical advantage to retain a selected position. Alternatively, the die retention mechanism may include a ratchet for example or another device for temporarily locking the dies in position, such as a releasable gripping mechanism, a spring -biased latch or pressure plate, or a detent mechanism. The dies may be moved to a smaller transverse profile configuration by the die movement assembly and then retained in this configuration by the die retention mechanism.

[0030] For example, the die movement assembly may include drives which are configured to urge the dies towards a smaller transverse profile configuration. The die retention mechanism then locks the dies in this configuration and the forces exerted by the drives are removed. Thus, the dies may be held in the smaller transverse profile configuration without the need to supply power to the food product holder as it moves along the flow path. In some implementations, drives may push the dies towards a smaller transverse profile configuration and then withdraw, allowing the food product holders to continue along the flow path.

[0031] Once the food product resizing and / or reshaping process has been completed, the die retention mechanism is released, so that the dies can be returned to their larger transverse profile configuration.

[0032] Each food product holder may include an end stop configured to engage with one of the ends of a food product in the holder, and a movable end pressure plate configured to retractably move into engagement with an opposite end of a food product in the holder.

[0033] The end stop and end pressure plate may have substantially planar product engagement surfaces and therefore form flat faces on the ends of a food product as it is compressed by the food product holder, so that the end portions of the food product may then be used to form usable portions, rather than be discarded.

[0034] The movable end pressure plate may also be operable to eject a food product from the food product holder at the output location.

[0035] A retention mechanism may be coupled to the end pressure plate, wherein the retention mechanism is configured to temporarily retain the end pressure plate in contact with a food product in the holder as it moves along the product flow path. The retention mechanism may be in the form of a gear mechanism or other mechanical coupling with a sufficiently high mechanical advantage to retain a selected position. Alternatively, the retention mechanism may include a ratchet for example or another device for temporarily locking the end pressure plate in position, such as a releasable gripping mechanism, a spring-biased latch or plate, or a detent mechanism. Once the food product resizing and / or reshaping process has been completed, the end pressure plate retention mechanism can be released, so that the end pressure plate can return to its original, retracted location. In the cooling region of the machine, a cooling fluid may be directed onto external surface of dies in a food product holder and / or fed through conduits within dies.

[0036] Dies of each food product holder may define or include fluid conduits for receiving a cooling fluid in order to cool the dies in the cooling region. This may facilitate continuous cooling of the dies for an extended period. In order to supply cooling fluid to a food product holder as it circulates around the flow path of the machine, a supply of cooling fluid may be coupled to a central commutator or slip ring arrangement, from which couplings extend to and from each of the food product holders.

[0037] The machine may include one or more cooling fluid outlets configured to direct cooling fluid towards dies of a holder in the cooling region whilst the holder is empty. Several cooling fluid outlets may be provided in order to cool the die surfaces sufficiently quickly to the desired temperature. The dies may be rapidly cooled to a low temperature, as low as around -70°C or lower. It has been found that shaping a food product with dies at -40°C or less significantly reduces any adherence between the food product and the die surface, so that the food product can be reliably ejected.

[0038] The machine may include at least one drive configured to move the dies between the larger transverse profile configuration and the smaller transverse profile configuration, and a connector for selectively connecting the at least one drive to a holder. Accordingly, the machine may be implemented using fewer drives. The at least one drive may be connected to a product holder at the input location after a product has been loaded. The machine may control the at least one drive to move the dies and shape the food product. Once the movement of the dies has been completed, the at least one drive can then be disconnected from the holder. The retention mechanisms of the holder act to retain the dies in their smaller transverse profile configuration.

[0039] At least one drive and a respective connector may be provided to actuate a holder at the input location, with at least one drive and a respective connector provided to actuate a holder at the output location to release a product. Rather than provide one or more drives for each holder, drives may instead only be provided at the input and output locations to move the dies of an adjacent holder using their respective connectors. This reduces the cost and complexity of the machine.

[0040] The transport mechanism may form a carousel-type arrangement. The transport mechanism of the machine may include a rigid rotatable support structure mounted for rotation about a rotational axis, with the food product holders located around the rotational axis, for example around the outer periphery of the support structure. The rotatable support structure may rotate in use around a horizontal axis, or around a vertical axis in some examples. In other implementations, the transport mechanism may be configured to circulate the food product holders along a non-circular flow path. The transport mechanism may include linkages or couplings between adjacent holders so as to form a continuous, flexible chain or train of holders which extends along the flow path. In a further example, the food product holders may be coupled or attached to a conveyor, such as a flexible belt conveyor.

[0041] The present disclosure also provides a food processing system which comprises a food product cooling and shaping machine as described herein, a cutter configured to cut portions from a food product, and a transport system comprising one or more belt conveyors and / or toothed tracks for example to carry a food product from the food product cooling and shaping machine to the cutter.

[0042] The present disclosure additionally provides a method of cooling and shaping a food product with a food product cooling and shaping machine or food processing system as described herein, comprising the steps of: loading a food product into a food product holder at the input location; changing the shape of the food product with the holder; extracting heat energy from the food product into the holder; transporting the food product holder to the output location with the transport mechanism; and outputting the food product at the output location.

[0043] Heat energy may be extracted from the food product by the holder as the holder moves along the flow path. Heat energy may be extracted from areas of the surface of the food product by the holder to freeze those areas of the surface. For example, the surface may be frozen to a depth of around 5mm. Surface freezing may act to stabilise the shape of the food product as long as is required for subsequent processing, such as portioning.

[0044] The product holders may be transported by the transport mechanism to circulate around the flow path from the input location, to the output location and back to the input location. Thus, the transport mechanism may carry the product holders repeatedly around the closed loop of the flow path.

[0045] Brief description of the drawings

[0046] Examples of the present disclosure will now be described with reference to the accompanying schematic drawings, wherein:

[0047] Figure 1 is a front perspective view of a food product cooling and shaping machine according to an example of the present disclosure;

[0048] Figure 2 is an enlarged perspective view of a portion of the machine shown in Figure 1;

[0049] Figures 3 and 4 are end views of a food product holder of the machine shown in Figures 1 and 2, showing two different configurations of the holder;

[0050] Figure 5 is a side view of a food processing system in accordance with an example of the present disclosure;

[0051] Figure 6 is a front perspective view, and Figures 7 and 8 are rear perspective views, of a food product cooling and shaping machine similar to the example shown in Figure 1;

[0052] Figures 9 and 10 are upper front and lower rear perspective views of a food product holder of the machine shown in Figure 6;

[0053] Figures 11 to 13 are front cross-sectional views of a food product holder of the machine shown in Figure 6 at successive stages in its transition from a larger transverse profile configuration to a smaller transverse profile configuration;

[0054] Figures 14 to 16 are front views of a food product holder of the machine shown in Figure 6 at successive stages in its transition from a larger transverse profile configuration to a smaller transverse profile configuration; Figures 17 and 18 are front and upper front perspective views of a food product holder of the machine shown in Figure 6 during cooling using a cooling liquid; and

[0055] Figure 19 is a perspective view of a food product holder of the machine shown in Figure 6 which includes cooling fluid conduits in its dies.

[0056] Detailed description

[0057] The same reference signs are generally used to refer to corresponding or similar features in modified and different examples according to the present disclosure.

[0058] A food product cooling and shaping machine 2 according to an example of the present disclosure is shown in Figure 1. It includes a plurality of food product holders 4 mounted on a rotatable support structure 6. The rotatable support structure includes a central shaft 8 which lies on a central axis of rotation 10 of the rotatable support structure. The shaft 8 is rotatably mounted on a supporting framework 12. The supporting framework has height adjustable feet 14 for resting on a supporting surface and facilitating levelling of the machine.

[0059] In the example shown in Figure 1, eight identical food product holders 4 are provided around the outer circumferential periphery of the rotatable support structure 6 at equally spaced locations. An input conveyor 16 is shown for feeding food products 18 to the machine.

[0060] Following processing of food products by the machine, they are then carried away from the machine by output conveyor 20. The output conveyor 20 may pass through a tunnel 22, the interior of which is cooled in order to control the temperature of the food products passing along the output conveyor.

[0061] In the configuration shown in Figure 1, food product holder 4a is positioned at the input location of the machine, where it has received a food product 18 from input conveyor 16. The food product may be received at a chilled temperature of around -1 to 2°C, for example. At this temperature, a meat product may be reshaped using less force in comparison to a colder, possibly crust frozen, product. The input conveyor 16 is shown in a position above and laterally displaced from the input location. A pushing member may be provided to displace each food product in turn into the food product holder at the input location. Alternatively, the input conveyor may be pivotable about an axis parallel with the central axis 10 to tip each product into the food product holder. In other implementations, the input conveyor 16 may be in line with the input location to enable it to feed the food product into the product holder 4a.

[0062] Rotation of the rotatable support structure 6 (in an anti-clockwise direction as viewed in Figure 1) carries each food product holder in turn from the input location to the output location occupied by food product holder 4g in Figure 1. At this point, the food product is ejected from the food product holder onto the output conveyor 20.

[0063] The machine includes an electric drive motor 15 carried by framework 12 and a gear system 17 coupled between the motor and the shaft 8, so that the motor is operable to rotate the shaft and the rotatable support structure 6 relative to the supporting framework 12. In use, the motor may rotate the support structure 6 at a constant velocity. In some implementations, the motion of the support structure may be indexed, with a dwell time to allow sufficient time for each product to be loaded (and pressed in some implementations) at the input location and unloaded at the output location. For example, the gear system may include a “Geneva mechanism” to provide indexed motion driven by the motor operating at a constant speed.

[0064] The speed of rotation of the support structure may for example be selected to allow around 7.5s for loading and pressing a food product at the input location, together with simultaneous ejection of a food product from the output location, around 45s for the crust freezing stage, and around 7.5s for chilling of a product holder (for example by spraying with cooling fluid) before the next food product is loaded into it.

[0065] The food product holders will now be described in more detail with reference to Figures 2 to 4. Each food product holder includes two dies 30, 32 for engaging with a food product carried by the holder. The food product holders have a longitudinal axis 34 and are arranged to receive a food product which is elongated and orientated such that it is elongated in the direction of the longitudinal axis of the food product holder. The two dies each have two mutually perpendicular, inwardly facing product shaping surfaces 36, 38 and 40, 42, respectively, which extend parallel to the longitudinal axis 34. The product shaping surfaces together define a cross-sectional profile and the dies are movable between a configuration in which the product shaping surfaces define a larger transverse profile and a configuration in which the product shaping surfaces define a smaller transverse profile.

[0066] A food product holder is shown in Figure 3 with its upper and lower dies 30, 32 held in a configuration defining a larger transverse profile and shown in Figure 4 with its dies defining a smaller transverse profile. The product shaping surfaces of the dies are generally planar and extend parallel to the longitudinal axis 34 so as to define a uniform cross-sectional area along their length. In use of the machine, the dies of each food product holder are driven from a larger to a smaller transverse profile as the food product holder moves between the input and output locations of the machine, in order to resize and / or reshape the food product towards a more uniform cross-section along its length. The vertical product shaping surfaces 38 and 42 may be configured such that their height is variable, so that this dimension may reduce during the shaping process. For example, one section of a die may move over another. After the food product resizing and / or reshaping process has been completed, the dies revert to the larger transverse profile configuration, ready to be cooled and receive another food product.

[0067] Each food product holder shown in the drawings includes a die mechanism which forms part of a die movement assembly for moving the dies from one configuration to another. The die mechanism is illustrated by the end views of Figures 3 and 4. The die mechanism is operable to move the dies towards each other, without rotating the dies about the longitudinal axis 34 of the product holder. In the example shown in the drawings, each product holder has a rigid support 44. Each die 30, 32 is coupled to the rigid support 44 by a pair of rigid support arms 46. The rigid support arms are all of the same length and pivotably coupled at one end to the rigid support, and at the other end to one of the dies. The pivots 48 on the rigid support are spaced apart by the same distance as the pivots 50 on the die, such that the pivots 48 and 50 define a parallelogram in end view. Rotation of the arms around the pivots therefore moves the respective die laterally relative to the longitudinal axis 34, without rotation of the die.

[0068] The upper die 30 includes a horizontally extending portion 52 which is pivotably coupled to a vertically extending portion 54. This enables the portion 52 to be raised to enable a food product to be lowered into the product holder. This portion of food product holder 4a can be seen in a raised position in Figures 1 and 2, and is lowered in Figures 3 and 4.

[0069] Each product holder may include an end stop 100 configured to engage with one of the ends of a food product in the holder and a movable end pressure plate 102 configured to retractably move in the direction of longitudinal axis 34 into engagement with an opposite end of a food product in the holder (see Figure 9, for example). As the dies of the product holder are moved towards a smaller profile configuration, the end pressure plate may also be moved towards the end stop so as to shape the ends of the food product. The product engaging surfaces of the end stop and the end pressure plate may be largely planar so as to flatten the ends of the food product.

[0070] The end stop may be retractable so as to allow a food product to be ejected from the associated end of the food product holder. The ejection may be carried out by the end pressure plate moving through the food product holder or by another mechanism. The lateral dimensions of the end pressure plate may be variable to allow it to conform to the transverse cross-section of the product holder. An end pressure plate of this form is described in the co-pending UK patent application no. 2205486.0 (publication no. 2619265), and the related applications referred to above.

[0071] A signal from a force sensor may be used by a controller for an associated drive to govern the force exerted by a die or end pressure plate on the food product during a forming process. A force sensor may be provided in combination with each drive motor for sensing the magnitude of a force opposing movement of an associated die by the respective drive motor. Signals generated by the force sensors may be fed back to a controller and used to govern the amount of pressure exerted on a food product in the forming module by the dies.

[0072] As a food product holder is moved from the input location to the output location, heat energy is extracted from the food product within the holder. The surface of the dies (including in some examples the end stop and pressure plate) which engage with a food product may be cooled by circulating a cooling fluid through conduits within those components. Cooling fluid may be fed to each product holder via a loop which is coupled to a shared supply of cooling fluid, for example via a commutator arrangement. A refrigeration plant 56 for providing a supply of cooling fluid is shown in Figure 1.

[0073] In another implementation, each food product holder may be cooled immediately prior to receiving a food product by spraying cooling fluid over its product-engaging surfaces from a pair of cooling fluid outlets in the form of nozzles 58. The nozzles 58 are connected to the refrigeration plant 56 to receive cooling fluid therefrom. Cooling fluids for this purpose which are suitable for use in a food processing environment are liquid nitrogen or liquid carbon dioxide, for example. Figures 1 and 2 shows that product holder 4h is empty whilst it travels between the output location and the input location of the machine, allowing its surfaces to be cooled.

[0074] Figure 5 shows a food processing system 60 including a food product cooling and shaping machine 2 in accordance with the present disclosure. The system has a machine base in the form of a rigid base framework 62. The operation of the machine is governed by an electronic control system 64 which is communicatively coupled to components of the machine. The control system includes a user interface 66 to enable an operator to input control parameters and commands.

[0075] Food products to be processed by the machine are loaded consecutively onto a horizontal pre-feed conveyor 68. The food products are then passed by the pre-feed conveyor to the input conveyor 16 of the food product cooling and shaping machine 2. The food product holders of the machine may circulate within an enclosure, for safety purposes, and also to allow the holders to be within a cooled environment, maintained at a temperature between 2 to 4°C, for example.

[0076] The food products then move from the food product cooling and shaping machine 2 onto an inclined feed conveyor 70. The machine 2 may optionally include a pivotable section of conveyor in order to tilt outputted food products so as to be aligned with feed conveyor 70. A scanning region 72 is located between food product cooling and shaping machine 2 and the feed conveyor 70. The scanning region includes two or more scanning devices 74 which are configured to detect the transverse cross- sectional shape of the food product as it passes through the region. For example, each scanning device may include a light source for projecting a line of light across the product which is detectable by a camera of the scanning device.

[0077] An end gripper 76 may be provided for engaging a trailing end of a food product carried by the feed conveyor 70. The end gripper and feed conveyor cooperate to form a feeder for feeding each food product in a feed direction “D” towards a cutter 78. As the food product travels from the forming module towards the cutter, it is engaged by a product control assembly 80. The food product is constrained laterally by a pair of side guides 82 of the product control assembly, which exert forces on respective sides of the food product.

[0078] The cutter includes a blade 84. The blade 84 may be in the form of an orbitally mounted circular blade, an involute blade or a sickle-shaped knife blade, for example.

[0079] A portion thickness control assembly 86 is provided downstream of the cutter 78. It includes a product stop 88 which is operable to control the thickness of the slices or portions cut from a food product. The product stop is able to reciprocate between advanced and retracted positions. In operation of the machine, the advanced position of the product stop determines the extent to which the food product extends beyond the cutting plane and therefore the thickness of the next slice or portion to be cut from the food product. After cutting of the next slice or portion has started, the product stop is moved to its retracted position to allow the slice or portion to fall freely away from the end of the food product

[0080] A jump conveyor and stacker assembly 90 is located below the portion thickness control assembly. Slices or portions cut from a food product by the cutter fall onto the assembly 90 which is operable to arrange consecutive slices or portions in a desired configuration, such as groups, or vertical or shingled stacks, for example. The assembly 90 conveys the slices or portions towards a packaging station (not shown).

[0081] Figures 6 to 19 show a food product cooling and shaping machine similar to that depicted in Figures 1 to 4. The machine shown in the later Figures has a similar configuration and some aspects are shown in greater detail.

[0082] In the machine of Figure 1, the input conveyor is shown in a position above and laterally displaced from the input location. In Figures 6 to 8, an input conveyor 16’ is also shown to illustrate an alternative location for the input conveyor in line with the input location to enable it to feed the food product into a product holder 4.

[0083] In the machine of Figures 6 to 19, an end stop 100 and end pressure plate 102 are included in each product holder. The end stop is configured to engage with one of the ends of a food product in the holder and an end pressure plate 102 is retractably moveable into engagement with an opposite end of a food product in the holder. An individual product holder is shown in Figures 9 to 18.

[0084] The end stop 100 of the product holder is slidably mounted in a pair of guides 104 and 106 for reciprocal motion in a direction perpendicular to the longitudinal axis 34 of the holder. A drive in the form of a servo motor 108 is connected to the end stop of the product holder in Figures 9 and 10 via a connector 110. The connector couples the drive to the end stop via a gear mechanism 112 and a linear actuator 114. The mechanical ratio of the gear mechanism is configured such that it acts as a retention mechanism for the end plate. Thus, when the drive is disconnected from the product holder, the end plate is retained in a selected position. The connector 110 may be pneumatically, hydraulically or electromagnetically operated for example. In the implementation shown in Figure 9, a pair of pneumatic cylinders 116 and 118 are used to engage and disengage connector 110.

[0085] The connector 110 may be a curved-tooth gear coupling consisting of a male gear coupling and a female coupling sleeve (as marketed by BoWex for example). Alternatively, a jaw coupling, spur gears or friction couplings such as a cone clutch could be utilised.

[0086] Similarly, drive 120 is coupled to the end pressure plate 102 via a connector 122. The connector couples the drive to a gear mechanism 124 which is in turn coupled to a linear actuator 126 for the end pressure plate.

[0087] As best seen in Figure 10, a further drive 130 can be selectively coupled to the dies of the product holder via a respective connector 132. The connector 132 is in turn attached to a drive shaft 134. The drive shaft is connected to the gear mechanisms 136 and 138 associated with linear actuators 140 and 142.

[0088] In such an arrangement, the drives 108, 120 and 130 are arranged to be coupled to a product holder when it is the input location 4a in order to move the respective product engaging surfaces and apply pressure to a product in the holder. The drives are then decoupled from the holder using the respective connectors, with the product engaging surfaces being held in position by the respective gear mechanisms (acting as retention mechanisms). This enables the product engaging surfaces to cool the product in its reshaped state as the holder moves round to the output location 4g.

[0089] The product holder can then be moved by the rotatable support structure 6 (in direction R indicated in Figure 8). The rotation is indexed to bring the next product holder to the input location. When a product holder reaches the output location 4g, a second set of drives 150, 152 and 154 (see Figure 6) is provided to retract the end stop and product engaging surfaces and advanced the end pressure plate, respectively, in order to eject the reshaped product from the product holder. Figures 11 to 13 are cross-sectional views of a food product holder of the machine shown in Figure 6 at successive stages in its transition from a larger transverse profile configuration to a smaller transverse profile configuration. The action of the food product holder in moving the product engaging surfaces is similar to that described above with reference to Figures 3 and 4.

[0090] Figures 14 to 16 are front views of a food product holder of the machine shown in Figure 6 at successive stages in its transition from a larger transverse profile configuration to a smaller transverse profile configuration, which correspond to those shown in Figures 11 to 13. In Figures 14 to 16, the operation of drive 108 to move end stop 100 upwards as the die chamber closes is illustrated. The end stop is thereby aligned with the end face of the product as the product is pressed by the end of pressure plate 102.

[0091] Figures 17 and 18 illustrate injection of cooling fluid into a product holder by nozzles 58 in order to cool the product engaging surfaces when the holder is in an open configuration at position 4h. The angle of each nozzle may be independently adjustable to control the distribution of the cooling fluid over the product engaging surfaces.

[0092] Figure 19 shows dies 160, 162, 164 and 166 of a product holder which include a conduit circuit for receiving a cooling fluid. The surface of the dies, end stop and pressure plate which engage with a food product may be cooled by circulating a cooling fluid through conduits within those components. Each die includes a fluid inlet 168 and outlet 170. The outwardly facing surface of each die may include a backing formed of insulating material to reduce conduction of heat into the die from the surroundings of the holder. The cooling of each die by circulating cooling fluid within it may be used instead of, or in combination with, the spraying of cooling fluid onto external die surfaces.

[0093] It will be appreciated that references herein to perpendicular or parallel relative orientations and the like are to be interpreted as defining perpendicular or parallel relationships between components within practical tolerances. The term “substantially” may mean + or - 5%.

Claims

Claims1. A food product cooling and shaping machine, comprising: a plurality of food product holders, each configured to receive a food product; a transport mechanism configured to circulate the holders along a flow path from an input location where a food product is received by each holder, via an output location where the food product is removed from each holder, back to the input location; and a cooling region in which heat energy is extracted from each holder, wherein each holder is configured to change the size and / or shape of a food product within the holder.

2. A machine of claim 1, wherein each holder includes a plurality of dies, with each die defining an inwardly facing product shaping surface, and the dies are moveable between a larger transverse profile configuration and a smaller transverse profile configuration.

3. A machine of claim 2, wherein one or more dies are configured to be driven towards the smaller transverse profile configuration until a predetermined pressing force threshold is reached.

4. A machine of claim 2 or claim 3, wherein one or more dies are configured to be driven towards the smaller transverse profile configuration until a predetermined position is reached.

5. A machine of any of claims 2 to 4, wherein the plurality of dies comprises two dies, each of which defines two mutually perpendicular inwardly facing product shaping surfaces.

6. A machine of claim 5, wherein each holder includes a die mechanism which is operable to move the two dies towards and away from each other whilst maintaining each inwardly facing product shaping surface of one die perpendicular to an adjacent inwardly facing product shaping surface of the other die.

7. A machine of any of claims 2 to 6, wherein each holder includes a die retention mechanism which is configured to temporarily retain the dies of the holder in a transverse profile configuration which is smaller than the larger transverse profile configuration.

8. A machine of any preceding claim, wherein each holder includes an end stop configured to engage with one of the ends of a food product in the holder, and a movable end pressure plate configured to retractably move into engagement with an opposite end of a food product in the holder.

9. A machine of claim 8 including a retention mechanism coupled to the end pressure plate, wherein the retention mechanism is configured to temporarily retain the end pressure plate in contact with a food product in the holder.

10. A machine of any of claims 2 to 9, wherein dies of each holder include fluid conduits for receiving a cooling fluid in order to cool the dies in the cooling region of the machine.

11. A machine of any of claims 2 to 10 including a cooling fluid outlet configured to direct cooling fluid towards dies of a holder in the cooling region of the machine.

12. A machine of any of claims 2 to 11 including at least one drive configured to move the dies between the larger transverse profile configuration and the smaller transverse profile configuration, and a connector for selectively connecting the at least one drive to a holder.

13. A machine of claim 12, wherein at least one drive and a respective connector is provided to actuate a holder at the input location, and at least one drive and a respective connector is provided to actuate a holder at the output location.

14. A machine of any preceding claim, wherein the transport mechanism includes a rotatable support structure, with the holders mounted around the outer periphery of the support structure.

15. A machine of any of claims 1 to 13, wherein the transport mechanism includes linkages between adjacent holders so as to form a continuous chain of holders which extends along the flow path.

16. A food processing system, comprising a food product cooling and shaping machine of any preceding claim; a cutter configured to cut portions from a food product; and a transport system arranged to carry a food product from the food product cooling and shaping machine to the cutter.

17. A method of cooling and shaping a food product with a machine of any of claims 1 to 15 or a system of claim 16, comprising the steps of: loading a food product into a food product holder at the input location; changing the size and / or shape of the food product with the holder; extracting heat energy from the food product into the holder; transporting the food product holder to the output location with the transport mechanism; and outputting the food product at the output location.

18. A method of claim 17, wherein heat energy is extracted from the food product by the holder as the holder moves along the flow path.

19. A method of claim 17 or claim 18, wherein sufficient heat energy is extracted from areas of the surface of the food product by the holder to freeze those areas of the surface.

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