Method and apparatus for producing instant noodles

Abstract

A method for producing instant noodles starting from noodles divided into portions or blocks, the method comprising the steps of: conveying the noodle portions by a conveyor (2) along a conveying direction (D), the conveyor (2) comprising a number of cup-shaped trays (4) for receiving the noodle portions, each cup-shaped tray (4) having a perforated bottom (4a); exposing the noodle portions arranged in the number of cup-shaped trays (4) to an upper air flow having a temperature comprised between 100°C and 300°C, the upper air flow being directed from a first zone (3a) above the conveyor (2) to a second zone (3b) below the conveyor (2); and exposing the noodle portions arranged in the number of cup-shaped trays (4) to a lower air flow having a temperature comprised between 100°C and 300°C, the lower air flow being directed from the second zone (3b) to the first zone (3a).

Description

[Technical field]

[0001] The present invention relates to a method and apparatus for producing instant noodles.

[0002] Instant noodles (or instant ramen) are noodles prepared in precooked, dried portions or blocks and are intended to be cooked or immersed in boiling water before eating. [Background technology]

[0003] It is well known to prepare instant noodles by quick frying noodles that have been cooked in a continuous process.

[0004] For example, document US 4,254,696 describes an apparatus for deep-frying instant noodles. The noodles are divided into certain quantities (blocks or portions) and transported into the apparatus in a number of cup-shaped trays arranged in a row. The noodle portions are deep-fried in oil.

[0005] There is a felt need to produce instant noodles with lower fat content.

[0006] Moreover, instant noodles obtained by frying are not well appreciated by consumers because they tend to turn brown and become too soft.

[0007] Methods for "batch" production of instant noodles are also known, but these methods are not suitable for continuous production in the food industry. Summary of the Invention

[0008] In this context, the technical problem underlying the present invention is to propose a method and an apparatus for producing instant noodles, which overcomes the above-mentioned drawbacks of the prior art.

[0009] In particular, the object of the invention is to propose a method and an apparatus for producing instant noodles which have a lower fat content and which are generally healthier.

[0010] Another object of the present invention is to propose a method and an apparatus for producing instant noodles having a higher quality than the prior art, both in terms of texture and appearance.

[0011] The stated technical problem and the identified objectives are substantially achieved by a method for producing instant noodles starting from noodles divided into portions or blocks, the method comprising: conveying the noodle portions by a conveyor along a conveying direction, the conveyor comprising a plurality of cup-shaped trays for receiving the noodle portions, each cup-shaped tray having a perforated bottom; exposing the noodle portions arranged in a plurality of cup-shaped trays to an upper air flow having a temperature comprised between 100°C and 300°C, the upper air flow being directed from a first zone above the conveyor to a second zone below the conveyor; exposing the noodle portions arranged in a plurality of cup-shaped trays to an underside air flow having a temperature comprised between 100°C and 300°C, the underside air flow being directed from the second zone to the first zone.

[0012] According to one embodiment of the present invention, the noodle portions are first exposed to an upper air flow and then to a lower air flow.

[0013] According to another embodiment of the invention, the noodle portions are first exposed to a lower air flow and then to an upper air flow.

[0014] According to one aspect of the invention, the upper and lower air flows have a speed comprised between 20 m / s and 40 m / s.

[0015] According to one aspect of the invention, the time for which the noodle portion is exposed to the upper air flow and the time for which the noodle portion is exposed to the lower air flow are substantially the same.

[0016] According to one embodiment of the invention, the method further comprises the step of exposing the noodle portions disposed in the multiple cup-shaped trays alternately to a further upper air flow and a further lower air flow.

[0017] A further upper air flow has a temperature comprised between 100°C and 300°C and is directed from the first zone to the second zone, and a further lower air flow has a temperature comprised between 100°C and 300°C and is directed from the second zone to the first zone.

[0018] According to one embodiment of the present invention, the method further comprises moving the noodle portions disposed in the multiple cup-shaped trays by an air flow.

[0019] In particular, the moving step occurs prior to exposing the noodle portions to the upper and lower air flows.

[0020] The stated technical problem and the identified object are substantially achieved by an apparatus for producing instant noodles starting from noodles divided into portions or blocks, the apparatus comprising: a conveyor configured to convey noodle portions along a conveying direction, the conveyor comprising a plurality of cup-shaped trays for receiving the noodle portions, each cup-shaped tray having a perforated bottom; a toasting chamber, the conveyor being positioned so as to pass partially through the toasting chamber; a first air injection device configured to introduce an upper air flow toward the noodle portions arranged in the multiple cup-shaped trays into a first portion of the toasting chamber, the upper air flow having a temperature comprised between 100° C. and 300° C. and directed from a first zone above the conveyor to a second zone below the conveyor; a second air injection device configured to introduce an underside air flow toward the noodle portions arranged in the multiple cup-shaped trays into a second portion of the toasting chamber, the underside air flow having a temperature comprised between 100°C and 300°C and directed from the second zone to the first zone.

[0021] According to one aspect of the invention, the first and second portions of the toasting chamber are in fluid communication and have substantially the same volume.

[0022] According to one embodiment of the invention, the first part of the toasting chamber is arranged upstream of the second part of the toasting chamber with respect to the conveying direction.

[0023] According to another embodiment of the invention, the second part of the toasting chamber is arranged upstream of the first part of the toasting chamber with respect to the conveying direction.

[0024] According to one aspect of the invention, each air injection device comprises: at least one fan for directing a corresponding air flow toward the noodle portions; and a heating element that is adjustable to regulate the temperature of the corresponding airflow.

[0025] According to one aspect of the invention, the upper and lower air flows have a speed comprised between 20 m / s and 40 m / s.

[0026] According to one aspect of the invention, each air injection device comprises a number of tubes configured to generate focused air jets toward the noodle portions.

[0027] According to one aspect of the invention, the apparatus further comprises motorized means for operating the conveyor at a speed which can be set so that it takes a first predetermined time for a portion of noodles to move across a first portion of the toasting chamber and a second predetermined time for a portion of noodles to move across a second portion of the toasting chamber.

[0028] According to one aspect of the invention, the first predetermined time period is substantially equal to the second predetermined time period.

[0029] According to one aspect of the invention, the apparatus further comprises a plurality of rods disposed partially above the conveyor to maintain the noodle portions within the plurality of cup-shaped receptacles.

[0030] According to one aspect of the invention, each portion of the toasting chamber further comprises an exhaust conduit configured to extract a portion of the air to reduce the humidity level within the toasting chamber. [Brief description of the drawings]

[0031] Further features and advantages of the present invention will become more fully apparent from the non-limiting description of preferred but non-exclusive embodiments of a method and apparatus for producing instant noodles, as illustrated in the accompanying drawings. [Figure 1] FIG. 1 shows in a perspective view an apparatus for producing instant noodles according to the invention starting from noodles divided into portions or blocks. [Diagram 2] The device of FIG. 1 is shown in cross-section. [Diagram 3] 3 shows a part of the apparatus of FIG. 2. [Figure 4] 3 shows a part of the apparatus of FIG. 2 (particularly the first air injection device) in front cross section. [Diagram 5] 3 shows a part of the apparatus of FIG. 2 (particularly the second air injection device) in front cross section. [Figure 6] 2 shows a perspective view of a row of cup-shaped trays of the device of FIG. 1; [Figure 7] The column of FIG. 6 is shown in cross-sectional side view. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] With reference to the figure, the number 1 indicates an apparatus for producing instant noodles starting from noodles divided into portions or blocks. The noodle portions may be of any shape, i.e. cubic, parallelepipedal, spherical, conical, etc.

[0033] The device 1 comprises a conveyor 2 arranged to convey noodle portions in a conveying direction D.

[0034] According to a preferred embodiment, the conveyor 2 comprises a plurality of cup-shaped trays 4 for receiving the noodle portions. Preferably, the cup-shaped trays 4 are arranged in rows 5 aligned parallel to one another along a direction substantially perpendicular to the conveying direction D.

[0035] According to one embodiment, each cup-shaped tray 4 has a perforated bottom 4a.

[0036] For example, the bottom part 4a consists of a perforated sheet with a number of through holes, which serve to allow hot air flow through, as will be explained below.

[0037] The device 1 also comprises a toasting chamber 3 for toasting the noodle portions as they travel along a conveying direction D.

[0038] In fact, the conveyor 2 is arranged so as to pass partially through the toasting chamber 3 .

[0039] In particular, the toasting chamber 3 is bounded by a box-like case 6 having an entrance 6a for the conveyor 2.

[0040] The box-shaped case 6 is composed of a plurality of heat insulating panels 16 .

[0041] The conveyor 2 divides the toasting chamber 3 into a first zone 3 a located above the conveyor 2 and a second zone 3 b located below the conveyor 2 .

[0042] According to one aspect of the invention, the toasting chamber 3 comprises at least two parts, a first part 13 and a second part 23 in fluid communication.

[0043] In the embodiment described and illustrated here, the first part 13 of the toasting chamber 3 is arranged upstream of the second part 23 of the toasting chamber 3 with respect to the conveying direction D.

[0044] In an alternative embodiment (not shown), the second part 23 of the toasting chamber 3 is arranged upstream of the first part 13 of the toasting chamber 3 with respect to the conveying direction D.

[0045] Preferably, the first portion 13 and the second portion 23 have substantially the same volume.

[0046] According to an alternative embodiment, the first portion 13 and the second portion 23 have different volumes.

[0047] According to one aspect of the invention, each portion 13, 23 of the toasting chamber 23 further comprises an exhaust conduit 14, 24 configured to extract a portion of the air so as to reduce the humidity level within the toasting chamber 3.

[0048] Preferably, the apparatus 1 comprises a plurality of spaced rods 10 positioned partially above the conveyor 2 to maintain the portions of noodles in a plurality of cup-shaped receptacles 4 .

[0049] For example, the rods 10 are arranged above the conveyor 2, in a portion of the toasting chamber 3 arranged downstream. Considering the embodiment shown, the rods 10 are arranged in a second portion 23 of the toasting chamber 3.

[0050] The apparatus 1 also comprises a first air injection device 7 configured to introduce an upper air flow into the first portion 13 of the toasting chamber 3, and a second air injection device 8 configured to introduce a lower air flow into the second portion 23 of the toasting chamber 3.

[0051] In particular, the upper air flow is directed from a first zone 3 a above the conveyor 2 to a second zone 3 b below the conveyor 2 towards noodle portions disposed in a number of cup-shaped trays 4 .

[0052] The underside airflow is directed from the second zone 3b to the first zone 3a towards the noodle portions arranged in a number of cup-shaped trays 4.

[0053] In other words, the upper and lower air flows are in substantially opposite directions: the upper air flow is directed from above the toasting chamber 3 downwards across the conveyor 2, while the lower air flow is directed from below the toasting chamber 3 upwards across the conveyor 2.

[0054] Both the upper and lower air streams have a temperature comprised between 100°C and 300°C.

[0055] According to a preferred embodiment, the first air injection device 7 and the second air injection device 8 are independent of each other.

[0056] According to an alternative embodiment, the first air injection device 7 and the second air injection device 8 belong to a common system for introducing air into the toasting chamber 3 .

[0057] Preferably, each air injection device 7, 8 comprises: at least one fan for directing a corresponding air flow toward the noodle portions; and a heating element for heating the corresponding air flow.

[0058] In particular, the fans are configurable to adjust the speed of the corresponding airflow.

[0059] Preferably, the speed of the upper and lower air flows is comprised between 20 m / s and 40 m / s.

[0060] The heating elements are also preferably adjustable to regulate the temperature of the corresponding airflow.

[0061] The heating elements may be based on different types of technologies: electrical resistance, natural gas, LPG, etc.

[0062] According to the illustrated embodiment, each air injection device 7, 8 comprises a number of tubes 11 configured to generate focused air jets towards the noodle portions.

[0063] The number, size and location of the tubes 11 can be configured as needed.

[0064] According to one embodiment, the multiple tubes 11 are removably mounted within the infusion device 7, 8 so that they can be easily cleaned, maintained and replaced.

[0065] In the illustrated embodiment, in the first air injection device 7, multiple tubes 11 are positioned above the conveyor 2 such that an upper air flow is directed from the top to the bottom of the toasting chamber 3 towards the noodle portions 11.

[0066] In the illustrated embodiment, in the second air injection device 8, multiple tubes 11 are positioned below the conveyor 2 such that the lower air flow is directed from below to above the toasting chamber 3 towards the noodle portions 11.

[0067] According to a variant, the toasting chamber 3 comprises three or more parts in fluid communication, each exposed to an air stream having a temperature comprised between 100°C and 300°C.

[0068] Preferably, the air flow crosses the conveyor 2 with alternating directions, ie from the top to the bottom of the toasting chamber 3 or from the bottom to the top.

[0069] The device 1 further comprises motorized means 9 for operating the conveyor 2 at a speed that can be adjusted as required.

[0070] Preferably, the speed of the conveyor 2 is: so that the portion of noodles moves across the first portion 13 of the toasting chamber 3 at a first predetermined time. The noodle portion is adjusted to move across the second portion 23 of the toasting chamber 3 at a second predetermined time.

[0071] For example, the first predetermined time is substantially equal to the second predetermined time.

[0072] Alternatively, the first predetermined time period may be longer or shorter than the second predetermined time period.

[0073] A method for producing instant noodles according to the present invention starting from noodles divided into portions or blocks is described below.

[0074] The noodle portions are deposited into a number of cup-shaped trays 4 on a conveyor 2 moving along a conveying direction D.

[0075] It is envisaged that the noodle portions arranged in a number of cup-shaped trays 4 are moved by an air current before entering the toasting chamber 3.

[0076] The air flow for moving the noodle portions is generated by a fan (not shown). The air flow is focused towards the noodle portions by tubes similar to the tubes 11 of the toasting chamber 3. According to one embodiment, the air flow crosses the conveyor 2 from bottom to top.

[0077] For example, the air flow has a temperature comprised between 40°C and 60°C.

[0078] The airflow directed from bottom to top prevents the noodles from sticking to the multiple cup-shaped trays 4.

[0079] Indeed, the noodles arriving at the device 1 are initially wet (due to salt water residues) and have a tendency to stick to the walls of the multiple cup-shaped trays 4 .

[0080] The downward directed air flow also counteracts the compression of the noodle portions at the bottom 4a of the tray 4 due to gravity, and the noodle portions then enter the toasting chamber 3 through the inlet 6a.

[0081] In the embodiment shown, the conveyor 2 enters a first portion 13 and then a second portion 23 of the toasting chamber 3 .

[0082] In the first section 13, the noodle portions are exposed to an upper air stream having a temperature comprised between 100°C and 300°C.

[0083] The upper air flow is directed from a first zone 3 a above the conveyor 2 to a second zone 3 b below the conveyor 2 .

[0084] In the second section 23, the noodle portions are exposed to an underside air stream having a temperature comprised between 100°C and 300°C.

[0085] The underside air flow is directed across the conveyor 2 from the second zone 3b to the first zone 3a.

[0086] Thus, in the illustrated embodiment, the noodle portions are first exposed to the upper air flow and then to the lower air flow.

[0087] According to one embodiment, the temperatures of the upper and lower air flows may be different.

[0088] By setting the speed of the conveyor 2 it is possible to define the processing time of the noodle portions in the first portion 13 and the second portion 23.

[0089] According to one embodiment, the time for which the noodle portion is exposed to the upper air flow and the time for which the noodle portion is exposed to the lower air flow are substantially the same.

[0090] According to alternative embodiments, the exposure of the noodle portion to the upper air flow may last longer or shorter than the exposure of the noodle portion to the lower air flow.

[0091] In another embodiment (not shown), as the conveyor 2 enters the second section 23 and then the first section 13, the order of the air flows is reversed, i.e. the noodle portions are first exposed to the lower air flow and then the upper air flow.

[0092] The method may be carried out in one device 1 as described above.

[0093] In another embodiment, the method may also be carried out in a cascade of several devices 1. In effect, each device 1 acts as a module of a larger plant.

[0094] The number of devices or modules is selected depending on the production rate.

[0095] Depending on the specific needs of the method, each device / module of the cascade may be configured to produce a particular sequence of alternating air flows, each with a particular duration.

[0096] The features and advantages of the method and apparatus for producing instant noodles according to the present invention are apparent.

[0097] In particular, exposing the noodle portions to at least two different hot air streams leads to a healthier pre-cooking of the noodles than deep-frying. The temperature of the hot air streams is set to obtain a toasting of the noodles, which is not merely drying, but changes the chemical and physical properties of the noodles.

[0098] In particular, toasting involves rapid heat exchange, which leads to noodles that are more porous, less soft, and less likely to brown.

[0099] Furthermore, assuming that the hot air currents pass through the noodle portions in two opposite directions (from above the conveyor to below the conveyor and vice versa), it makes it possible to toast the noodles homogeneously.

[0100] Indeed, since the noodle portions arranged in multiple cup-shaped trays are substantially motionless, generating two or more oppositely directed hot air streams directed at them leads to homogeneous treatment.

[0101] The toasting conditions of the two parts of the toasting chamber may also be adjusted as needed.

[0102] The method and apparatus according to the present invention are intended for use in the continuous production of instant noodles.

[0103] Finally, the proposed invention avoids the use of oil, which creates disposal problems. [Prior art documents] [Patent documents]

[0104] [Patent Document 1] US4,254,696

Claims

1. 1. A method for producing instant noodles starting with noodles divided into portions or blocks, comprising the steps of: conveying noodle portions by a conveyor (2) along a conveying direction (D), said conveyor (2) comprising a number of cup-shaped trays (4) for receiving said noodle portions, each cup-shaped tray (4) having a perforated bottom (4a); exposing the noodle portions arranged in the cup-shaped trays (4) to an upper air flow having a temperature comprised between 100°C and 300°C, the upper air flow being directed from a first zone (3a) above the conveyor (2) to a second zone (3b) below the conveyor (2); exposing the noodle portions arranged in the cup-shaped trays (4) to an under-air flow having a temperature comprised between 100°C and 300°C, the under-air flow being directed from the second zone (3b) to the first zone (3a); and moving the noodle portions disposed in the plurality of cup-shaped trays (4) with an air flow, said moving step being performed prior to exposing the noodle portions to the upper air flow and the lower air flow.

2. The method of claim 1 , wherein the noodle portions are first exposed to the upper air flow and then exposed to the lower air flow.

3. The method of claim 1 , wherein the noodle portions are first exposed to the lower air flow and then exposed to the upper air flow.

4. 4. The method according to claim 1, wherein the upper and lower air flows have a speed comprised between 20 m / s and 40 m / s.

5. 4. The method of claim 1, wherein the time for which the noodle portions are exposed to the upper air flow and the time for which the noodle portions are exposed to the lower air flow are the same.

6. 4. The method according to any one of claims 1 to 3, further comprising the step of exposing the noodle portions arranged in the plurality of cup-shaped trays (4) alternately to a further upper air flow and a further lower air flow, the further upper air flow having a temperature comprised between 100°C and 300°C and directed from the first zone (3a) to the second zone (3b), and the further lower air flow having a temperature comprised between 100°C and 300°C and directed from the second zone (3b) to the first zone (3a).

7. An apparatus (1) for producing instant noodles starting from noodles divided into portions or blocks using the method according to any one of claims 1 to 3, comprising: a conveyor (2) configured to convey noodle portions along a conveying direction (D), the conveyor (2) comprising a plurality of cup-shaped trays (4) for receiving said noodle portions, each cup-shaped tray (4) having a perforated bottom (4a); a toasting chamber (3) arranged such that the conveyor (2) passes partially through the toasting chamber (3); a fan for generating an air flow to move the noodle portions placed in the cup-shaped trays (4); a first air injection device (7) configured to introduce an upper air flow into a first portion (13) of the toasting chamber (3) towards the noodle portions placed in the plurality of cup-shaped trays (4), the upper air flow having a temperature comprised between 100°C and 300°C and directed from a first zone (3a) above the conveyor (2) to a second zone (3b) below the conveyor (2); a second air injection device (8) configured to introduce an underside air flow towards the noodle portions arranged in the plurality of cup-shaped trays (4) into the second part (23) of the toasting chamber (3), the underside air flow having a temperature comprised between 100° C. and 300° C. and directed from the second zone (3b) to the first zone (3a); The device (1), wherein the first part (13) of the toasting chamber (3) is arranged upstream of the second part (23) of the toasting chamber (3) with respect to the conveying direction (D), or the second part (23) of the toasting chamber (3) is arranged upstream of the first part (13) of the toasting chamber (3) with respect to the conveying direction (D).

8. 8. The device (1) according to claim 7, wherein the first part (13) and the second part (23) of the toasting chamber (3) are in fluid communication and have the same volume.

9. Each air injection device (7, 8) at least one fan directing a corresponding air flow towards the noodle portions; 8. The device (1) according to claim 7, further comprising a heating element, adjustable to regulate the temperature of the corresponding air flow.

10. 8. Apparatus (1) according to claim 7, wherein each air injection device (7, 8) comprises a number of tubes (11) configured to generate focused air jets towards the noodle portions.

11. 8. The apparatus (1) according to claim 7, further comprising motorised means (9) for operating the conveyor (2) at a speed which can be set such that the noodle portion takes a first predetermined time to move across the first portion (13) of the toasting chamber (3) and such that the noodle portion takes a second predetermined time to move across the second portion (23) of the toasting chamber (3).

12. The device (1) according to claim 11, wherein the first predetermined time is equal to the second predetermined time.

13. 8. The apparatus (1) of claim 7, further comprising a plurality of rods (10) partially disposed above the conveyor (2) to maintain the noodle portions in the plurality of cup-shaped trays (4).

14. 8. The device (1) according to claim 7, wherein each part (13, 23) of the toasting chamber (3) further comprises an exhaust conduit (14, 24) configured to extract a portion of the air so as to reduce the humidity level within the toasting chamber (3).

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