Apparatus and method for producing potato slices from potatoes, method and apparatus for producing, washing and fat-soluble pre-processing potato chips, and method and apparatus for producing potato chip bags, and potato chips

Abstract

An apparatus for producing potato slices from potatoes is provided. The apparatus includes a spaced-out array of containers, each container including its own inlet for receiving potatoes and its own outlet from which potatoes can protrude. The apparatus also includes a retainer for limiting the extent to which potatoes protrude from the container outlets and a cutting tool including a blade for cutting potatoes. Each container is movable in a reciprocating motion relative to the cutting tool, passing over the blade so that the portion of potato protruding from its respective outlet is sliced ​​by the blade to produce potato slices. The apparatus also includes a conveyor positioned to capture the potato slices.

Description

Technical Field

[0001] The present invention relates to a method and apparatus for manufacturing potato slices from potatoes, a method and apparatus for washing potato slices and performing fat-soluble pre-treatment of potato slices in the production of potato chips, a method for manufacturing potato chips, and a production line for manufacturing potato chips.

Background Art

[0002] Potato crisps (also known colloquially as "potato chips") have been manufactured for many years by frying slices of potatoes in oil. This provides potato crisps having approximately 35 wt% oil based on the total weight of the potato crisps. Health-conscious consumers are demanding potato crisps with lower oil content while maintaining desirable sensory properties such as texture, color, and taste. This presents a challenge to snack food manufacturers.

[0003] Recent developments include modifying the temperature at which fried potato crisps are fried or baking the potato crisps instead of frying. However, in some cases, these potato crisps have been found to lack the taste, texture, and / or color that consumers associate with fried potato crisps. Therefore, there is room for improvement in the manufacturing process of potato crisps with lower oil content in order to provide a healthier snack food without compromising on the perceptual attributes that consumers expect from such potato crisps.

Summary of the Invention

[0004] According to a first aspect of the present invention, an apparatus for producing potato slices from potatoes is provided, the apparatus comprising a spaced-apart array of containers, each container comprising a spaced-apart array including a respective inlet for receiving potatoes and a respective outlet from which potatoes can protrude, a retainer for limiting the extent to which potatoes protrude from the outlets of the containers, and a cutting tool including a blade for cutting potatoes, each container being movable in a reciprocating motion relative to the cutting tool, passing over the blade so that the portion of potato protruding from each outlet is sliced ​​by the blade to produce potato slices, and the apparatus comprising a conveyor positioned to capture the potato slices.

[0005] In this way, the potatoes are moved in a reciprocating motion relative to the cutting tool and blade during use, allowing a series of potato slices to be produced from each potato. The conveyor may be configured to keep the potato slices away from the cutting tool. In this way, the apparatus can provide a series of spaced-out potato slices on the conveyor.

[0006] Optionally, the cutting tool may include a continuous blade. The continuous blade may be configured to move in a continuous loop within the conveyor system. In this way, the same cutting tool may be used to slice potatoes protruding from each container. Providing a single cutting tool associated with each container may reduce the cost and / or complexity of the apparatus and / or improve the ease of maintenance of the apparatus.

[0007] Optionally, spaced-out arrangements extend in a direction perpendicular to the direction of motion of each container, forming a row of containers. Continuous blades may be configured so that, during use, the cutting edge is substantially perpendicular to the direction of motion of each container. In this way, potatoes protruding from the outlet of each container can pass laterally over the cutting edge during the cutting stroke of the container. This may improve the quality of the slices produced from the potatoes and / or reduce the stress on the cutting tool.

[0008] By providing spaced-out arrangements of containers, the production rate of potato slices by the apparatus can be improved, for example, compared to providing single containers. Furthermore, such spaced-out arrangements can provide improved distribution and / or separation of potato slices on the conveyor, for example, resulting in no overlap of potato slices on the conveyor. This can improve the efficiency of subsequent processes performed on the potato slices, such as washing, fat-soluble adjustment, and / or dewatering processes. In particular, by providing such spaced-out arrangements of containers, potato slices can be placed within corresponding spaced-out arrangements on the conveyor. For example, the spaced-out arrangements may include rows of containers, and the potato slices may be spaced apart in the corresponding rows on the conveyor, with the potatoes in each row spaced apart from each other in proportion to the spacing between containers.

[0009] Preferably, the potato slices in each row on the conveyor are evenly spaced from one another, and / or the rows of potato slices on the conveyor are evenly spaced from one another. This may be due to multiple containers being evenly spaced within a row of containers, or each container in a row of containers being moved back and forth at a constant frequency, or multiple containers being moved in a synchronized reciprocating motion so that the potatoes in each container can pass through the cutting tool simultaneously, and / or the conveyor being moved at a constant speed. Spaced and / or evenly spaced potatoes on the conveyor can improve the ease of further adjustment and / or handling of the potato slices downstream of the apparatus during the washing process, fat-soluble adjustment process, and / or dewatering process. Multiple containers may be moved at a constant frequency of up to 80, 90, 100, 110, 120, 130, or more than 140 reciprocations per minute.

[0010] Each container may be spaced apart from adjacent containers such that the potato slices in each row on the conveyor are spaced at least 3 mm, at least 5 mm, preferably at least 8 mm, or at least 10 mm apart. The rows of potato slices may be spaced apart from each other in accordance with the regular reciprocating motion of each container and / or the speed of the conveyor, as described above. The frequency of the reciprocating motion and / or the speed of the conveyor may be configured so that the rows of potatoes are spaced at least 3 mm, at least 5 mm, preferably at least 8 mm, or at least 10 mm apart.

[0011] Alternatively, the potatoes may be arranged on the conveyor in any other suitable arrangement. For example, the reciprocating motion of multiple containers may be such that the potatoes in two or more containers pass through the cutting tool when they are different. This could result in the potatoes being arranged alternately on the conveyor.

[0012] Optionally, each container is oriented such that, at least as the potatoes are passed across the cutting tool, gravity causes the potatoes to protrude from their respective exits.

[0013] In this way, the simplicity of the container can be improved, for example, by eliminating the need for a mechanism to push the potatoes toward and through the outlet. Each outlet may be located at the end of each container, and each container may include an inlet for receiving potatoes, the inlet being at the end of the container opposite the outlet. Each container may be oriented such that each inlet is above its respective outlet when the potatoes are passed across the slicer and / or throughout the container's entire range of motion. In this way, the potatoes may be received in the inlet during use, fall toward the outlet due to the action of gravity, and protrude through the outlet. In this way, the inlet may be easily accessible, for example, to allow personnel and / or a supply system to easily supply potatoes into the container.

[0014] Optionally, each container is configured to receive and hold multiple potatoes (using retainers), for example, up to two potatoes, up to three potatoes, up to five potatoes, or more than five potatoes. This may be due to each container containing a tube having heights and diameters such that potatoes received through the inlet can be stacked into a single stack of potatoes in the tube. Each tube may be configured to receive potatoes that, when elongated, have a major axis greater than the diameter of the tube and a minor axis smaller than the diameter of the tube or substantially equal to the diameter of the tube. This can ensure that the longitudinal dimensions (i.e., along the semi-major axis) of the potato in the tube are aligned with the axis of the tube. This can also ensure that, during use, the potato is held radially by the walls of each tube, reducing the radial movement of the potato within the tube as the potato is sliced ​​by the blade, thereby reducing the likelihood of the potato being ejected from the tube. Furthermore, this may allow potatoes to move more easily through each tube, and / or may provide potato slices with a more consistent shape and / or thickness than, for example, potatoes where each longitudinal axis is oriented in a different direction from the longitudinal axes of other potatoes in the tube.

[0015] Optionally, the tubes may have a diameter of 40mm to 90mm to receive potatoes of that size, for example. Optionally, the tubes may have a diameter outside the 40mm to 90mm range. Optionally, each tube may have the same diameter as the others, thereby providing a simpler arrangement. Optionally, two or more of the tubes may have different diameters. Alternatively, each tube may be interchangeable with another tube of a different size. By providing tubes of different sizes and / or interchangeable tubes, it may be possible to receive potatoes of various sizes in the tubes, thereby reducing the costs associated with using potatoes of a specific size.

[0016] Optionally, each tube may have a pattern on its inner surface. Optionally, the pattern may include equally spaced projections in the circumferential direction, extending along the length of each tube. This may form a star-shaped pattern when viewed axially along each tube. The star-shaped pattern may have any number of points, for example, up to 5, 7, 8, or 10 points. Alternatively, any other suitable pattern may be employed, for example, raised projections and / or rings on the inner surface of the tubes. In general, the pattern may include one or more projections on the inner surface of each tube. In any case, providing a pattern on the inner surface of each tube may reduce the surface area of ​​each tube that comes into contact with the potato within the tube. This may reduce the resistance to the movement of the potato through each tube, while similarly limiting the radial movement and / or reorientation of the potato within the tube during slicing. This can improve the consistency of the shape and / or thickness of potato slices produced using the slicer, for example, by improving the consistency of the range to which the potato protrudes from each outlet during each cutting stroke. Alternatively, one or more inner surfaces of the tubes may be smooth and without any such pattern.

[0017] Optionally, the apparatus includes a lubrication system that opens into each container to supply lubricant to each container. The lubricant may allow potatoes in the container to move more easily through the container toward the outlet. This may reduce the likelihood of potatoes getting stuck in the container and / or shorten the time that potatoes do not protrude from the outlet. This may, likewise, increase the yield of the apparatus by increasing the likelihood that potatoes are sliced ​​thinly in each cutting stroke of the container. Optionally, the lubrication system is configured to supply water into the container as a lubricant.

[0018] Optionally, the container may be movable in pendulum motion. The container may be pivotable about a pivot axis to provide pendulum motion. This may provide a simpler configuration with fewer moving parts than, for example, a container that is movable in linear reciprocating motion. By providing such a pivotably movable container, during use, the outlets and the potatoes protruding from each outlet may move in a substantially arc-shaped path during the reciprocating motion of the container. Alternatively, the container may be movable in substantially linear reciprocating motion, and as a result, the outlets and the portions of potatoes protruding from each outlet may move in a substantially linear path during use.

[0019] In any case, the cutting edge is positioned within the path through which the potato portion protruding from each exit passes, and the cutting edge can be used to thinly slice the potato portion protruding from each exit to produce potato slices.

[0020] Optionally, the device includes one or more actuators configured to move a container. Each actuator may include a piston and / or a motor.

[0021] Optionally, the containers are configured to move in synchronous reciprocating motion. That is, each container may be configured to reach the limits of its respective range of motion simultaneously with each other, and / or the potatoes protruding from each outlet simultaneously may be configured to traverse the path through which the cutting tool passes. This may be due to the containers being physically coupled to one another, resulting in them moving synchronously in their respective reciprocating motions, or in any other suitable manner. In this way, an orderly arrangement of potato slices can be captured by the conveyor, and the potatoes are aligned in horizontal and vertical rows on the conveyor. Any of these optional features may improve the ease of further adjustment and / or handling of the potato slices downstream of the apparatus, such as during washing, fat-soluble adjustment, and / or dehydration processes.

[0022] Optionally, the container array includes at least two containers containing tubes of different diameters. This may make it possible to provide potatoes of different sizes in each tube to ensure, for example, that the potatoes in each tube are longitudinally aligned with their respective tubes. As described above, by aligning the longitudinal axis of each potato with the longitudinal axis of each tube, it may be possible to ensure that the potatoes are held radially by the tube walls during use. This may make it possible to reduce the radial movement of the potatoes within the tubes when the potatoes are sliced ​​by the blade, thereby reducing the likelihood of the potatoes being ejected from each tube. This may also make it easier for the potatoes to move through each tube and / or may provide potato slices with a more consistent diameter than, for example, potatoes that are positioned with their longitudinal axes oriented differently from the longitudinal axes of other potatoes. Providing containers or tubes of different sizes allows for the use of potatoes of various sizes, which may reduce the cost of potato slices produced using a slicer and / or improve the variety of potato slice sizes, which may be more desirable for consumers.

[0023] Alternatively, one or more of the containers may be movable independently of one or more other containers. In other words, the movement of one or more containers may be physically isolated from the movement of one or more other containers. This may make it possible to provide an alternating arrangement of potato slices on the conveyor, for example, by ensuring that potatoes in adjacent containers are sliced ​​differently. This may improve the spacing between potato slices while providing or maintaining density, thereby maintaining or improving the yield of potato slices produced using the slicer.

[0024] Optionally, the retainer includes an upper surface arranged to abut against the end of the potato projecting from the outlet of each container and guide each potato towards the cutting edge of the cutting tool during the cutting stroke of the reciprocating movement.

[0025] Each container may be configured to move relative to the upper surface. In particular, the upper surface may be the upper surface of a fixed guide arranged adjacent to the cutting edge of the cutting tool. The upper surface may be a flat surface or a curved surface. The upper surface may be shaped such that the distance between the upper surface and the path taken by the outlet of each container during movement of the container is substantially constant. This can ensure that the potatoes project equally from each outlet along at least part of the range of movement of their respective containers, whereby the consistency of the shape and / or thickness of the potato slices produced using the slicer can be improved.

[0026] Providing a single such upper surface or guide for holding the potatoes within each container can provide a simpler structure than, for example, providing individual upper surfaces or guides, or other types of retainers, for each container.

[0027] Optionally, the apparatus includes a gap between the upper surface and the cutting edge of the cutting tool, and the thickness of the potato slices produced by the apparatus depends on the size of the gap.

[0028] Optionally, the retainer, or at least part of the retainer such as the upper surface, is adjustable to vary the size of the gap. The upper surface can be moved closer to or further away from the cutting edge to decrease or increase the size of the gap, respectively. The gap may represent the minimum distance between the upper surface and the cutting edge. By providing an adjustable retainer, a simpler method of adjusting the thickness of the potato slices can be provided compared to, for example, moving the cutting tool and / or the containers relative to each other.

[0029] The retainer may be positioned relative to the cutting edge such that the thickness of the potato slices obtained from potatoes in one container is the same as the thickness of the potato slices obtained from potatoes in each other container. This may be because, if provided, the gap between the retainer and the cutting edge is constant along at least a portion of the path the cutting tool takes, and this portion of the path is the part through which potatoes protruding from each container are passed during the reciprocating motion of each container. This can improve the consistency of the thickness of the potato slices obtained from each container. Optionally, the retainer may be adjustable as described above. In particular, the retainer may be adjustable to control the thickness of the potato slices obtained from potatoes in each container by adjusting the size of the gap, if provided. This may make it possible to simultaneously control the thickness of the potato slices from potatoes in each container by adjusting a single retainer relative to the cutting tool. This can improve the simplicity and ease of use of the device. The gaps may have a size, and / or the potato slices may have a thickness of up to 1.2 mm, up to 1.3 mm, up to 1.4 mm, up to 1.5 mm, up to 1.6 mm, up to 1.7 mm, up to 1.8 mm, or greater than 1.8 mm.

[0030] Optionally, the retainer is adjustable to adjust the distance between at least a portion of the retainer and at least a portion of the path taken by the outlet of each container during movement of the container. Optionally, the retainer is adjustable to vary the range that the potatoes project from their respective outlets during use. Optionally, the distance between the cutting edge and at least a portion of the path taken by each outlet during movement of each container may be fixed. In this way, by adjusting the retainer relative to the container while maintaining the distance between the cutting edge and the container, the thickness of the resulting potato slices can be varied. Stated another way, as described above, at least a portion of the retainer, if provided, may be adjustable to adjust the size of the gap between the upper surface and the cutting edge, thereby controlling the thickness of the potato slices. For example, it may be more convenient to adjust at least a portion of the retainer to adjust the thickness of the potato slices, as opposed to varying the distance of the cutting edge from at least a portion of the path taken by each outlet during movement of each container.

[0031] A second aspect of the invention provides a method of manufacturing potato slices from potatoes, the method comprising receiving a potato in each container of a spaced-apart array of containers, each container including an inlet and an outlet through which the respective potato can project, holding the potato in each container using a retainer such that the potato projects from the respective outlet, causing movement of each container in a reciprocating motion relative to a cutting tool, the cutting tool including a cutting edge for cutting the potato in each container, and causing movement of the container such that a portion of the potato projecting from each outlet is passed across the cutting edge so that the potato is sliced by the cutting edge to produce a potato slice.

[0032] In this way, a series of potato slices can be produced from potatoes, similar to the first aspect of the present invention described above. The potato slices can be aligned on a conveyor belt. In this way, the efficiency and / or effect of subsequent processes on the potato slices, such as a washing process, a fat-soluble adjustment process, and / or a dewatering process, can be improved.

[0033] Inducing the movement of a container in a reciprocating motion may include, for example, causing the movement of a container in a reciprocating motion at a constant frequency to produce a series of evenly spaced potato slices on a conveyor, which may further improve the efficiency and / or effectiveness of the subsequent process.

[0034] Optionally, the containers are spaced evenly to produce an evenly spaced array of potato slices on a conveyor belt. Optionally, the spaced array extends in a direction perpendicular to the reciprocating motion of each container, forming a row of containers. Optionally, the containers in the row are configured to move in a synchronized reciprocating motion, for example, by each container being physically coupled to each other in the row.

[0035] Optionally, the reciprocating motion has a constant frequency to create a series of evenly spaced rows of potato slices within the conveyor. Having spaced and / or evenly spaced potatoes on the conveyor can further improve the ease of handling and / or preparation of the potato slices during washing, fat-soluble preparation, and / or dehydration processes performed on them.

[0036] Optionally, causing the movement of the container includes causing the movement of the container by pendulum motion. This may provide a simpler configuration that requires fewer moving parts than, for example, moving the container by linear reciprocating motion. Optionally, causing the movement of the container includes, for example, causing the movement of one or more actuators configured to move the container, such as one or more pistons and / or motors, to pivot the container around a pivot axis in pendulum motion. The pivot axis may be a common pivot axis for each of the containers.

[0037] Optionally, the retainer is adjustable to adjust the size of the gap between the retainer and the cutting tool, and the method involves adjusting the retainer to adjust the size of the gap. Adjusting the size of the gap can adjust the thickness of the potato slices. Adjusting the retainer to adjust the thickness of the potato slices may be simpler and easier than, for example, adjusting the distance of the cutting edge from part of the path taken by the outlet during the movement of the container.

[0038] Optionally, two or more containers in an array of containers are tubular and have different diameters, and receiving a potato in each container includes receiving potatoes of different diameters in two or more containers.

[0039] Optionally, the method includes sorting potatoes by size and feeding them into appropriately sized containers. For example, smaller potatoes may be fed into a container having a smaller diameter than another, and / or received into a container having a smaller diameter than another. This may ensure better alignment and retention of the potatoes within each container, as described above, thereby reducing the likelihood of potatoes being ejected from each container when they are sliced ​​by the blade. Furthermore, sorting and receiving potatoes into appropriately sized containers may allow the potatoes to move more easily through each container, stack better within the containers, and / or improve the consistency of the thickness and / or diameter of the potato slices produced by the method.

[0040] Optionally, a container, retainer, cutting tool and / or conveyor are part of the apparatus. Optionally, the method is a method for producing potato slices from potatoes using the apparatus. Optionally, the apparatus is the apparatus of the first embodiment. It will be understood that the apparatus of the second embodiment, and therefore the method, may include any of the optional features and / or advantages of the first embodiment, and / or benefit from any of the optional features and / or advantages of the first embodiment.

[0041] A third aspect of the present invention provides a method for producing potato chips, comprising producing potato slices according to the method of the second aspect, and cooking the potato slices to produce potato chips.

[0042] Optionally, the method includes washing potatoes to produce washed potato slices, and cooking the potato slices includes cooking the washed potato slices. Optionally, the method includes performing a fat-soluble pre-treatment on the washed potato slices to produce prepared potato slices, and cooking the potato slices includes dehydrating the prepared potato slices. Optionally, performing a fat-soluble pre-treatment on the washed potatoes is part of the cooking process.

[0043] Optionally, cooking the prepared potato slices includes baking or frying them according to known methods. Alternatively, cooking the prepared potato slices includes dehydrating them, for example, by microwaving them in a microwave oven and / or drying them in an oven, according to the methods disclosed herein.

[0044] The method of the third embodiment may include any of the optional features and / or advantages of the first embodiment and / or the second embodiment, and / or may benefit from any of the optional features and / or advantages of the first embodiment and / or the second embodiment.

[0045] A fourth aspect of the present invention provides a production line for manufacturing potato chips, the production line comprising: an apparatus of the first aspect for manufacturing potato slices; a washer configured to wash potato slices to produce washed potato slices; a fat-soluble adjuster configured to adjust the fat-soluble properties of the washed potato slices to produce adjusted potato slices; and a dewaterer configured to dewater the adjusted potato slices to produce potato chips.

[0046] Optionally, the dehydrator includes an oven for drying or baking the prepared potato slices. Optionally, the dehydrator includes a microwave for microwaving the prepared potato slices to dehydrate them at least partially before drying. Optionally, the production line includes a packaging device configured to package potato chips into bags, for example.

[0047] It will be understood that the manufacturing line of the fourth embodiment may include any of the optional features and / or advantages of any of the first to third embodiments, and / or may benefit from any of the optional features and / or advantages of any of the first to third embodiments.

[0048] A fifth aspect of the present invention provides an apparatus for washing potato slices and pre-conditioning the fat-soluble potato slices in the production of potato chips, the apparatus comprising a water bath capable of receiving water for washing potato slices, and an oil bath capable of receiving oil for pre-conditioning the fat-soluble potato slices, and a belt assembly comprising an upper endless belt and a lower endless belt, the upper endless belt and the lower endless belt defining a product flow path between them, the product flow path passing through the water bath and / or oil bath, the product flow path having a height defined between the lower and upper surfaces of the respective upper and lower endless belts, which is less than or equal to the thickness of the potato slices.

[0049] In this way, the lower and upper surfaces of each upper and lower endless belt can simultaneously contact the upper and lower surfaces of each potato slice during use. Therefore, the potato slice can be firmly sandwiched between the upper and lower endless belts and held in place by the upper and lower endless belts during use. This can prevent or reduce the possibility of the potato slice being displaced as it passes through the water and / or oil baths. This may be particularly advantageous in maintaining spacing between multiple potato slices passing along the product flow path, thereby increasing the surface area of ​​each potato slice that comes into contact with the water and / or oil in each water and / or oil bath during use. This can improve the efficiency of the washing process and / or fat-soluble pre-conditioning performed by passing the potato slices through each water and / or oil bath.

[0050] Optionally, the height of the product channel is less than or equal to the maximum thickness of the potato slice. Optionally, the height of the product channel is less than or equal to the average, i.e., middle thickness of the potato slice. This may ensure that potato slices thinner than the maximum thickness are adequately held between the upper and lower endless belts. Optionally, the height of the product channel is less than or equal to the minimum thickness of the potato slice. This may ensure that even the thinnest potato slices are securely held between the upper and lower endless belts.

[0051] Optionally, the water bath is at ambient temperature, but alternatively, the water bath may be heated. Optionally, the belt assembly is a first belt assembly, the product flow path is a first product flow path passing through one of the water bath and the oil bath, and the apparatus includes a second belt assembly defining a second product flow path passing through the other of the water bath and the oil bath. Optionally, the first and second product flow paths each have a height less than or equal to the maximum or average thickness of a potato slice. Alternatively, a product flow path passing through both the water bath and the oil bath may be defined by the same belt assembly. In any case, the aforementioned advantages of the belt assembly, i.e., the upper endless belt and lower endless belt of each belt assembly, in firmly holding the potato slice can be applied to both the washing process and the fat-soluble preparation process.

[0052] Optionally, the upper endless belt and the lower endless belt are drive belts. Optionally, the upper endless belt and the lower endless belt are configured to be driven at the same speed. This can ensure that the position of the potato slices between the upper endless belt and the lower endless belt is maintained as the potato slices pass along the product flow path. Optionally, the upper endless belt and the lower endless belt of the belt assembly (or, if provided, one of each of the first and second belt assemblies) can be driven at a speed that requires a potato slice to pass through the water bath for a maximum of 25 seconds, 30 seconds, 40 seconds, 60 seconds, or more than 60 seconds. Optionally, the upper endless belt and lower endless belt of the belt assembly (or, if provided, one of each of the first and second belt assemblies) can be driven at a speed that requires a potato slice to pass through the oil bath for a maximum of 60 seconds, 70 seconds, 90 seconds, 100 seconds, or more than 100 seconds.

[0053] The apparatus may be configured such that potato slices pass through a water bath before passing through an oil bath. This ensures that the potato slices are washed, for example, to remove starch from them, before they are passed through the oil bath for fat-soluble pre-treatment. Potato slices that have passed through the water bath may be referred to herein as “washed potato slices.” Potato slices that have passed through the oil bath may be referred to herein as “pre-treated potato slices.”

[0054] Optionally, the apparatus is configured to heat the oil in the oil bath to a temperature of 85°C to 95°C, for example, 90°C, for example, 88°C to 92°C. Lowering the temperature of the oil in the oil bath may extend the shelf life of the resulting potato chips, but it may alter certain sensory properties of the potato chips, such as texture.

[0055] Optionally, the apparatus includes at least one air jet configured to apply at least one air jet to each potato slice in the product channel downstream of the water bath. At least one air jet can remove excess water from the surface of the potato slices in the product channel downstream of the water bath (i.e., the washed potato slices). This may be called a “dehydration” process and can reduce the total water content of the washed potato slices. This can, in turn, improve the quality of potato chips produced using the apparatus from washed and fat-soluble pre-processed potato slices.

[0056] Optionally, the apparatus includes at least one air jet configured to apply at least one air jet to each potato slice in the product flow path downstream of the oil bath. At least one air jet can remove excess oil from the surface of the potato slices in the product flow path downstream of the oil bath (i.e., pre-prepared potato slices). This may be called a “de-oiling” process and can reduce the total oil content of the pre-prepared potato slices. This can, in turn, improve the quality of potato chips produced using the apparatus from washed, fat-soluble pre-prepared potato slices.

[0057] The apparatus may include multiple air jets, each configured to deliver its own jet of air to potato slices in the product flow path downstream of the water bath and / or oil bath. The multiple air jets may be positioned above and / or below the product flow path, for example, above the upper endless belt and / or below the lower endless belt. This allows one air jet to strike the upper surface of the potato slices in the product flow path, and another air jet to strike the lower surface of the potato slices in the product flow path, thereby improving the amount of water and / or oil removed from the potato slices during use.

[0058] Optionally, the upper and lower endless belts are oil-permeable and water-permeable, respectively. This may allow potato slices in the product flow path to be exposed to the water and oil in the respective water and oil baths during use. This may also allow at least one air jet from at least one air jet, if provided, to collide with the potato slices in the product flow path downstream of the water and / or oil baths. This may improve the quality and / or efficiency of the washing, fat-solubility adjustment, dewatering, and / or de-oiling processes described above.

[0059] Optionally, the upper and lower endless belts include a mesh structure. Optionally, the upper and lower endless belts are wire mesh belts, including multiple connected wires, such as metal wires and / or polymer wires, that form the mesh structure. This may provide a robust yet flexible belt assembly for securely holding potato slices in the product flow path while reducing the risk of damage to the potato slices. Furthermore, the mesh structure may allow larger surface areas of the upper and lower surfaces of the potato slices to be exposed to water in a water bath, oil in an oil bath, and / or, if provided, at least one jet of air from at least one air jet each. Optionally, each of the upper and lower wire mesh belts has a total "open" area (i.e., the area between the connected wires) of up to 70%, up to 80%, up to 85%, or more than 85% of the total area of ​​the respective belts.

[0060] A sixth aspect of the present invention provides a method for washing potato slices and pre-conditioning the fat-soluble potato slices in the production of potato chips, the method comprising: washing potato slices by transporting potato slices through a water bath to produce washed potato slices; pre-conditioning the fat-soluble potato slices by transporting potato slices through an oil-containing phase at a temperature of 75°C to 90°C to produce pre-conditioned potato slices; and transporting potato slices through a water bath and / or an oil bath along a product channel defined between an upper endless belt and a lower endless belt, the product channel having a height defined between the lower and upper surfaces of the respective upper and lower endless belts, which is less than or equal to the thickness of the potato slices.

[0061] In this way, as described above, the lower and upper surfaces of the respective upper and lower endless belts can simultaneously contact the respective upper and lower surfaces of the potato slices to firmly hold them between the upper and lower endless belts. This can prevent or reduce the possibility of the potato slices shifting position as they pass through the water and / or oil baths. This can also help maintain spacing between multiple potato slices passing along the product flow path, thereby improving the efficiency of the washing process and / or fat-soluble pre-conditioning performed by passing the potato slices through the respective water and / or oil baths.

[0062] Optionally, the height of the product channel is less than or equal to the maximum thickness of the potato slice. Optionally, the height of the product channel is less than or equal to the average, i.e., middle thickness of the potato slice. This may ensure that potato slices thinner than the maximum thickness are adequately held between the upper and lower endless belts. Optionally, the height of the product channel is less than or equal to the minimum thickness of the potato slice. This may ensure that even the thinnest potato slices are securely held between the upper and lower endless belts.

[0063] Optionally, the method includes passing potato slices through one of a water bath and / or oil bath along a product flow path, where the product flow path is the first product flow path, and the upper endless belt and lower endless belt are the first upper endless belt and lower endless belt, respectively. Optionally, the method includes passing potato slices through the other of the water bath and / or oil bath along a second product flow path defined between the second upper endless belt and the second lower endless belt, respectively. Optionally, the first and second product flow paths each have a height that is no more than or equal to the maximum thickness of the potato slices. In either case, the aforementioned advantages of securely holding the potato slices between the belt assemblies, i.e., between the upper endless belt and the lower endless belt of each belt assembly, can be applied to both the washing process and the fat-soluble preparation process.

[0064] Optionally, the water in the water bath is at ambient temperature. Alternatively, the water in the water bath may be heated. Optionally, the method includes transporting potato slices through the water bath layer at a speed such that it takes a maximum of 25 seconds, 30 seconds, 40 seconds, 60 seconds, or more than 60 seconds for the potato slices to pass through the water bath. Optionally, this is done by the method including driving the belt assembly (or, if provided, each pair of the first and second lower endless belts and the first and second upper endless belts) at an appropriate speed. Optionally, the method includes transporting potato slices through the oil bath layer at a speed such that it takes a maximum of 60 seconds, 70 seconds, 90 seconds, 100 seconds, or more than 100 seconds for the potato slices to pass through the oil bath. Optionally, this is done by the method including driving the belt assembly (or, if provided, each pair of the first and second lower endless belts and the first and second upper endless belts) at an appropriate speed.

[0065] Optionally, the method includes applying at least one air jet to each of the potato slices in the product flow channels downstream of the water bath and / or the oil bath. The at least one air jet can remove excess water and / or oil from the surface of the potato slices in the product flow channels downstream of the water bath and / or the oil bath. This can reduce the total water and / or total oil content of the potato slices, thereby improving the quality of potato chips produced from washed and fat-soluble pre-treated potato slices produced using the method.

[0066] It will be understood that the method of the sixth embodiment may include, and / or benefit from, either the optional features of the apparatus of the fifth embodiment and / or any advantages deemed to belong to the apparatus of the fifth embodiment.

[0067] A seventh aspect of the present invention provides a production line for manufacturing potato chips from potatoes, the production line comprising a slicer for slicing potatoes thinly to produce potato slices, a fifth-aspect apparatus for washing the potato slices and adjusting their fat solubility to produce washed and pre-prepared potato slices, and a dewaterer for dewatering the washed and pre-prepared potato slices to produce dewatered potato slices.

[0068] Optionally, the dehydrator includes at least one microwave oven configured to reduce (i.e., dehydrate) the moisture content of washed and pre-prepared potato slices. Optionally, the dehydrator includes an oven for further dehydrating, drying, or baking the potato slices following the dehydration in the microwave oven.

[0069] Optionally, the slicer includes a slicer according to the first embodiment of the present invention. It will be understood that the production line may benefit from any of the optional features and / or advantages of the apparatus of the first embodiment, the production line of the fourth embodiment, and / or the apparatus of the fifth embodiment.

[0070] An eighth aspect of the present invention provides a method for producing potato chips from potatoes, the method comprising: slicing potatoes thinly to produce potato slices; washing the potato slices according to the method of the sixth aspect, adjusting the fat solubility of the potato slices to produce washed and pre-prepared potato slices; and dehydrating the pre-prepared potato slices to produce potato chips.

[0071] Optionally, dehydrating washed and pre-prepared potato slices involves microwaving the washed and pre-prepared potato slices in one or more microwave stages to reduce their moisture content. Optionally, microwaving the potato slices is performed before drying them. Optionally, microwaved potato slices may have a moisture content of up to 4%, up to 5%, up to 6%, up to 8%, up to 10%, or more than 10%.

[0072] Optionally, dehydrating washed and pre-prepared potato slices includes drying or baking them in an oven at temperatures up to 120°C, 130°C, 135°C, 140°C, or above 140°C. Optionally, the method includes drying the washed and pre-prepared potato slices for up to 7 minutes, 7.5 minutes, 8 minutes, or above 8 minutes. Optionally, drying the potato slices is done before microwaving them.

[0073] Optionally, the potato chips may have a moisture content of up to 1.4 wt%, up to 1.6 wt%, up to 1.8 wt%, up to 2 wt%, or more than 2 wt%, based on the total weight of the potato chips. Optionally, the potato chips may have an oil content of up to 18 wt%, up to 16 wt%, up to 15 wt%, up to 14 wt%, or up to 13 wt%, based on the total weight of the potato chips.

[0074] Optionally, slicing the potato slices thinly is performed according to the method of the second embodiment. It will be understood that the method of the eighth embodiment may include any of the optional features and / or advantages of the method of the second embodiment, the method of the third embodiment, and / or the method of the sixth embodiment, and / or may benefit from any of the optional features and / or advantages of the method of the second embodiment, the method of the third embodiment, and / or the method of the sixth embodiment.

[0075] A ninth aspect of the present invention provides a method for producing potato chips from potato slices, the method comprising: producing pre-treated potato slices by pre-treating the fat-soluble potato slices by transporting the potato slices along a product channel through an oil bath containing oil at a temperature of 75°C to 95°C; transporting the pre-treated potato slices along the product channel from the oil bath to at least one air jet; producing defatted potato slices by de-oiling the pre-treated potato slices by adding at least one air jet to the potato slices from each of the at least one air jets; and producing potato chips by de-watering the defatted potato slices, wherein adding at least one air jet from each of the at least one air jets is the only active de-oiling action performed between transporting the potato slices through the oil bath and de-watering the defatted potato slices, and the potato chips contain up to 18 wt% oil based on the total weight of the potato chips.

[0076] Adding at least one air jet as the sole active de-oiling action includes not adding water to the potato slices between transporting the potato slices through the oil bath and dehydrating the de-oiled potato slices. The method provides potato chips with up to 18 wt% oil content when the air jet is the sole de-oiling action performed before dehydrating the potato chips. This may provide a simpler and / or cheaper method for producing potato chips with up to 18 wt% oil content than, for example, spraying water onto pre-prepared potato slices before adding the air jet. The oil removed from the pre-prepared potato slices by the air jet may be recycled back into the oil bath.

[0077] The method may include providing a jet of air from an air jet nozzle at speeds of up to 50 ms⁻¹, up to 80 ms⁻¹, up to 100 ms⁻¹, up to 110 ms⁻¹, up to 130 ms⁻¹, or greater than 130 ms⁻¹. This may involve the method including setting the speed of a motor configured to drive a fan to supply airflow to the nozzle. The method may also include changing the speed of the air provided from the nozzle.

[0078] Optionally, the method includes measuring the oil content of potato slices downstream of the degreaser. This may be done, for example, by periodically taking and testing samples of potato slices downstream of the degreaser for a period of up to 15 minutes, up to 30 minutes, up to 60 minutes, or more than 60 minutes. Optionally, the method includes changing the velocity of the air supplied from the nozzle and / or changing the transport speed at which potato slices are transported through the air jet based on the determined oil content. This may be to achieve a desired setpoint oil content. For example, if the determined oil content is higher than the setpoint oil content, the method may include accelerating the velocity of the air jet and / or decelerating the transport speed. By accelerating the velocity of the air jet and / or increasing the duration for which the pre-conditioned potato slices are supplied by the air jet, the amount of oil removed from the pre-conditioned potato slices by the air jet may increase. Conversely, if the determined oil content is lower than the setpoint oil content, the method may include decelerating the velocity of the air jet and / or accelerating the transport speed. Changing the speed of the air jet may involve operating a motor, such as a motor that drives a fan to provide airflow to the nozzle at different speeds.

[0079] Optionally, the potato chips may have an oil content of up to 15 wt%, 13 wt%, 12 wt%, 11 wt%, or 10 wt%, based on the total weight of the potato chips. This may provide chips with less than 50% of the fat content of typical pure fried potato chips while providing improved sensory characteristics such as taste and texture. Optionally, the oil in the oil bath may be at a temperature of 85°C to 95°C, for example, 90°C, for example, 88°C to 92°C. Lowering the oil temperature may extend the shelf life of the resulting potato chips, but may alter certain sensory characteristics of the potato chips, such as texture. Optionally, the method may include applying at least one jet of air to the pre-prepared potato slices within 12 seconds of the pre-prepared potato slices last coming into contact with the oil in the oil bath.

[0080] Reducing the time it takes to pass pre-cooked potato slices from the oil bath to at least one air jet can increase the amount of oil that can be removed from the pre-cooked potato slices by the air jet, thereby potentially reducing the amount of oil contained in the potato chips produced by dehydrating the de-oiled potato slices. For example, the faster the air jet is applied to the pre-cooked potato slices, the higher the oil temperature on the pre-cooked potato slices may be when the air jet is applied. Oil has a lower viscosity at higher temperatures, so it can flow more easily and, when subjected to the shear force provided by the air jet, can be removed more easily from the pre-cooked potato slices.

[0081] Optionally, the method includes adding at least one jet of air within 10 seconds, 8 seconds, 5 seconds, 4 seconds, 3 seconds, or 2 seconds after the pre-prepared potato slices have last come into contact with the oil in the oil bath.

[0082] Optionally, the method includes adding a jet of air after the pre-cooked potato slices have made final contact with the oil in the oil bath, before the temperature of the pre-cooked potato slices drops by 10°C.

[0083] As described above, the higher the oil temperature on the potato slices when the air jet is applied to them, the lower the viscosity of the oil may be. Therefore, reducing the amount by which the temperature of the pre-cooked potato slices drops as they pass from the oil bath to the air jet may increase the amount of oil that can be removed from the pre-cooked potato slices by applying the air jet. Optionally, the method includes applying the air jet before the temperature of the pre-cooked potato slices drops by up to 10°C, up to 8°C, up to 6°C, preferably up to 5°C, up to 4°C, up to 3°C, up to 2°C, or up to 1°C.

[0084] Optionally, the product flow path is defined between the upper endless belt and the lower endless belt, and the product flow path has a height defined between the lower and upper surfaces of the respective upper and lower endless belts, which is less than or equal to the maximum thickness of a potato slice.

[0085] In this way, the potato slices can be firmly held between the upper and lower endless belts during use. This prevents or reduces the possibility of the potato slices moving relative to the upper and lower endless belts and / or relative to other potato slices in the product flow path when the potato slices are passed through the oil bath and / or when the air jet is applied to the pre-conditioned potato slices. This can favorably maintain the spacing between multiple potato slices in the flow path (for example, to limit or prevent overlapping of potato slices), thereby increasing the surface area of ​​each potato slice exposed to the oil in the oil bath and / or the air jet. This, in turn, can increase the amount of oil that can be removed from the pre-conditioned potato slices by the air jet.

[0086] Optionally, the method includes applying multiple air jets to pre-conditioned potato slices from each of multiple air jets. This may improve the amount of oil removed from the pre-conditioned potato slices during the de-oiling process. Optionally, multiple air jets are applied simultaneously to the pre-conditioned potato slices, for example, from above the upper belt and below the lower belt. This ensures that both the top and bottom surfaces of the potato slices are exposed to at least one air jet, thereby potentially increasing the amount of oil removed. Alternatively or further, multiple air jets are applied successively as the pre-conditioned potato slices pass along the product flow path. Optionally, the potato slices are transported in a row or each air jet is applied across the entire width.

[0087] A tenth aspect of the present invention provides a method for producing potato chips from potato slices, the method comprising: producing pre-prepared potato slices by transporting the potato slices along a product channel through an oil bath containing oil at a temperature of 75°C to 95°C to make the potato slices fat-soluble; and producing potato chips by dehydrating the pre-prepared potato slices, wherein no water is added to the potato slices between transporting the potato slices through the oil bath and dehydrating the pre-prepared potato slices, and the potato chips contain up to 18 wt% oil based on the total weight of the potato chips.

[0088] Optionally, the method includes degreasing pre-prepared potato slices by adding at least one air jet to each potato slice from at least one air jet to produce deflated potato slices. Optionally, adding at least one air jet from each at least one air jet is the only active degreasing action performed between transporting the potato slices through the oil bath and dewatering the deflated potato slices. It will be understood that the method of the tenth embodiment may include and / or benefit from any optional features of the apparatus of the ninth embodiment.

[0089] Optionally, the method of the ninth embodiment and / or the method of the tenth embodiment include slicing potato slices according to the method of the second embodiment. Optionally, the method of the ninth embodiment and / or the method of the tenth embodiment include washing the potato slices. Optionally, washing and fat-soluble pre-preparation (if provided) in the ninth embodiment and / or the tenth embodiment are performed according to the method of the sixth embodiment. It will be understood that the method of the ninth embodiment and / or the tenth embodiment may include any of the optional features and / or advantages of the method of the second embodiment, the third embodiment, the sixth embodiment, and / or the eighth embodiment, and / or may benefit from any of the optional features and / or advantages of the method of the second embodiment, the third embodiment, the sixth embodiment, and / or the eighth embodiment.

[0090] An eleventh aspect of the present invention provides a production line for manufacturing potato chips from potato slices, the production line comprising a product channel through which potato slices can pass through the production line, an oil bath through which the product channel passes, the oil bath being for fat-soluble pre-conditioning of potato slices to produce pre-conditioned potato slices, at least one air jet configured to add a jet of air to the pre-conditioned potato slices in the product channel downstream of the oil bath, and a dewaterer for dewatering the de-oiled potato slices to produce potato chips, the at least one air jet being the only device in the production line for actively de-oiling the pre-conditioned potato slices before dewatering, and the production line being configured to produce potato chips containing up to 18 wt% oil based on the total weight of the potato chips.

[0091] The fact that at least one air jet is the only device in the production line for actively de-oiling the pre-cooked potato slices includes the fact that the production line does not have any applicators for adding water to the potato slices between the oil bath and the dewaterer. Optionally, the dewaterer includes a microwave oven (i.e., by microwaving) for at least partially de-watering the de-oiled potato slices in the product flow path. Optionally, the dewaterer includes an oven for drying or baking the pre-cooked potato slices.

[0092] Optionally, the product channel is configured to accommodate multiple potato slices spaced apart across the width of the product channel, perpendicular to the direction of movement of the potato slices within the product channel. Optionally, at least one air jet includes an elongated nozzle extending across at least a portion of the width of the product channel, so that the air jet is applied to the multiple potato slices spaced apart across the width of the product channel during use. This may improve the capacity of the production line and / or increase the amount of oil removed from the potato slices by the air jet.

[0093] A twelfth aspect of the present invention provides a production line for manufacturing potato chips from potato slices, the production line comprising a product channel through which potato slices can pass through the production line, an oil bath through which the product channel passes, the oil bath being for pre-conditioning the fat-soluble potato slices to produce pre-conditioned potato slices, and a dewaterer for dewatering the de-oiled potato slices to produce potato chips, the production line having no applicators for adding water to the potato slices between the oil bath and the dewaterer, and the production line being configured to produce potato chips containing up to 18 wt% oil based on the total weight of the potato chips.

[0094] Optionally, the production line includes at least one air jet configured to produce de-oiled potato slices by applying an air jet to pre-cooked potato slices in a product channel downstream of the oil bath. Optionally, at least one air jet is the only device in the production line for actively de-oiling pre-cooked potato slices in a product channel upstream of the dewaterer. It will be understood that the production line of the twelfth embodiment may include any of the optional features and / or advantages of the production line of the eleventh embodiment, and / or benefit from any of the optional features and / or advantages of the production line of the eleventh embodiment.

[0095] Optionally, the production line of the 11th embodiment and / or the production line of the 12th embodiment includes a slicing device for producing potato slices. Optionally, the slicing device includes the device of the first embodiment. Optionally, the production line of the 11th embodiment and / or the production line of the 12th embodiment includes a water bath for washing potato slices in the product flow path upstream of the oil bath. Optionally, the production line of the 11th embodiment and / or the production line of the 12th embodiment includes the device of the fifth embodiment, the water bath of the 11th embodiment and / or the 12th embodiment is the water bath of the fifth embodiment, and the oil bath of the 11th embodiment and / or the 12th embodiment is the oil bath of the fifth embodiment.

[0096] It will be understood that the production line of the 11th embodiment and / or the production line of the 12th embodiment may include any feature and / or advantage of the apparatus of the first embodiment, the production line of the fourth embodiment, the apparatus of the fifth embodiment, the production line of the seventh embodiment, the method of the ninth embodiment, and / or the method of the tenth embodiment, and / or benefit from any feature and / or advantage of the apparatus of the first embodiment, the production line of the fourth embodiment, the apparatus of the fifth embodiment, the production line of the seventh embodiment, the method of the ninth embodiment, and / or the method of the tenth embodiment.

[0097] A thirteenth aspect of the present invention provides a method for manufacturing a bag of potato chips, comprising manufacturing potato chips according to the method of any one of the third, eighth, ninth, and tenth aspects, and packaging the potato chips into a bag. It will be understood that the method of the thirteenth aspect benefits from any optional feature of the third, eighth, and / or ninth aspects, and / or benefits from any advantage that is deemed to belong to any of the third, eighth, and / or ninth aspects.

[0098] A fourteenth aspect of the present invention provides potato chips manufactured according to the method of any one of the third, eighth, ninth, and tenth aspects, wherein the chips are optionally packaged in a bag according to the method of the thirteenth aspect. It will be understood that the potato chips of the fourteenth aspect benefit from any of the optional features of the third, eighth, ninth, tenth, and / or twelfth aspects, and / or benefit from any of the advantages that are deemed to belong to any of the optional features of the third, eighth, ninth, tenth, and / or twelfth aspects.

[0099] It will be understood that any optional feature of any of the above embodiments of the present invention may, where appropriate, be equally applicable to other embodiments of the present invention. In particular, the present disclosure provides three main embodiments for use in a method, apparatus and production line for manufacturing potato chips, these embodiments comprising slicing potatoes, washing and / or pre-treating the potato slices to make them fat-soluble, and de-oiling the potato slices. These embodiments may be combined in any suitable way to illustrate exemplary production lines and processes for manufacturing potato chips, as will be apparent from the description and drawings.

[0100] Herein, embodiments of the present invention will be described with reference to the accompanying drawings, merely as examples. [Brief explanation of the drawing]

[0101] [Figure 1] This is a schematic diagram of an exemplary production line for manufacturing potato chips. [Figure 2] Figure 1 is a schematic side view of an exemplary slicer used to produce potato slices from potatoes on the production line. [Figure 3] Figure 2 is a schematic front view of the slicer. [Figure 4] Figures 2 and 3 are schematic top views of a conveyor containing potato slices produced using the slicers shown. [Figure 5] Figures 2 and 3 are schematic cross-sectional views along the axes of the two containers of the slicer. [Figure 6] Figure 1 is a schematic side view of an exemplary washing machine for washing potato slices on the production line. [Figure 7] Figure 1 is a schematic side view of an exemplary regulator used for pre-adjusting the fat-soluble properties of potato slices on the production line. [Figure 8] Figure 1 is a schematic side view of an exemplary oil remover used to remove oil from potato slices in a manufacturing line. [Figure 9] This flowchart shows the process of making potato chips from potatoes. [Figure 10] This shows a flowchart of the manufacturing process for potato chip bags. [Modes for carrying out the invention]

[0102] The following description presents exemplary embodiments and, together with the drawings, serves to illustrate the principles of embodiments of the present invention. In particular, the following description describes a complete process for manufacturing potato chips, including embodiments disclosed in the previous summary section of the invention.

[0103] Figure 1 shows a schematic diagram of production line 1 for carrying out a method for manufacturing potato chips. Production line 1 includes a slicer 10, a washer 20, a regulator 30, a degreasing unit 40, a molding belt 50, a dewatering unit 60 including a microwave oven 61 and an oven 62, and a packaging machine 70. It should be noted that the following description shows only one embodiment of the production line and should not be construed as limiting with respect to a particular number, arrangement, and / or type of components or processes described herein. It will be apparent to those skilled in the art that one or more components or processes described herein may be omitted without departing from the scope of the invention as defined in the appended claims, and / or other components not described herein may be provided.

[0104] As will be described in more detail below with reference to further diagrams, the slicer 10 of production line 1 receives potatoes 100, slices the potatoes 100 into potato slices 110, and the potato slices 100 are then captured on a conveyor 190 which forms part of the product flow path 800 through production line 1. The potato slices 110 are transported to a washer 20 which includes a water bath 210. The potato slices 110 are immersed in and passed through the water bath 210 to remove starch from the potato slices 110. The potato slices 110 are then removed from the water bath 210 and dried using a blower (not shown in Figure 1) to produce washed potato slices 110 (for ease of understanding, the same reference number 110 is used here for potato slices 110 at any stage within production line 1).

[0105] The washed potato slices 110 are passed through a regulator 30 which includes a heated oil bath 310. The washed potato slices 110 are immersed in and passed through the heated oil bath 310 to perform a fat-soluble pre-conditioning of the washed potato slices 110 and to produce pre-conditioned potato slices 110. The fat-soluble pre-conditioning process alters the sensory properties of the potato slices 110 and changes the texture of the potato slices by inactivating enzymes that produce undesirable flavors and / or gelatinizing the natural starch in the potato slices 110 with natural water.

[0106] The pre-processed potato slices 110 are passed through a de-oiler 40. The de-oiler 40 applies at least one jet of air 371 to the pre-processed potato slices 110 to remove excess oil from the surfaces 111, 112 of the pre-processed potato slices 110, thereby producing de-oiled potato slices 110. The de-oiled potato slices 110 are then passed along the product flow path 800 to a molding belt 50 which includes polymer bands having a textured surface.

[0107] The potato slices are then passed through a dewaterer 60, which includes a primary microwave oven 61 and a deep microwave oven (not shown). The potato slices 110 are optionally dewatered quickly or dramatically by operating the primary microwave oven to reduce the moisture content of the potato slices 110. This improves the stiffness of the potato slices 110 by simulating the dewatering rate of the frying process. The potato slices are then carried into the primary microwave oven on a shaping belt 50. The shaping belt 50 changes the shape of the potato slices 110 within the primary microwave oven, for example, to match the shape of an uneven surface, at least partially. This can improve the visual and / or tactile appeal of the potato slices 110 and the resulting potato chips.

[0108] The potato slices 110 are then passed through a deep microwave oven for further, more gradual dehydration and / or drying. The deep microwave oven includes a tray for receiving the potato slices in stacks of potato slices 110. A stack is typically 2-3 potato slices high. The tray of potato slices 110 is then passed through an oven 62 for further dehydration, for example, to cook and / or bake the potato slices 110, to produce potato chips. The oven 62 gives the potato chips their final color and texture. Finally, the potato chips are passed through a packaging machine 70, which packages the chips into chip packets or other suitable containers.

[0109] The components of manufacturing line 1 are described in more detail below, in the order shown in Figure 1.

[0110] Figures 2 and 3 show a schematic front view and a schematic side view of the slicer 10, respectively. The slicer 10 includes a spaced array 105 of containers 120. The spaced array 105 includes first to fourth containers 120a, 120b, 120c, and 120d (collectively referred to herein using reference no. 120). The containers 120 are physically coupled to one another by a coupler 130 and are movable toward each other in reciprocating motion around a common axis of rotation 125. The reciprocating motion may be provided by a piston 150 coupled to the containers 120 via the coupler 130, but in other examples, it may be provided by any other suitable actuator. The containers 120 are coupled to each other by the coupler 130 such that the array 105 extends in a direction perpendicular to the direction of the reciprocating motion of the containers 120. It should be understood that any other suitable number of containers 120, such as up to three or more than four containers 120, may be provided in other examples.

[0111] Each container 120 includes a tube 140 having separate inlets 141a, 141b, 141c, 141d (collectively 141) for receiving potatoes 100, and separate outlets 142a, 412b, 142c, 142d (collectively 142) from which potatoes 100 can protrude. Each container 120 is configured to receive and hold multiple potatoes 100, such as up to four or more potatoes 100, within each tube 140 (using retainers as described below). Specifically, each tube 140 has a height 144 and a diameter 146 such that the potatoes received into the tube 140 can be stacked into a single stack of potatoes within the tube 140. Each tube 140 has a different diameter 146, and the tube 140 of the smaller diameter is configured to receive potatoes 100 smaller than those that the tube 140 of the larger diameter is configured to receive. In particular, the diameter 146 of adjacent tubes gradually increases from the first tube to the fourth tubes 140a, 140b, 140c, and 140d. During use, the potatoes 100 are distributed into tubes 140 that are made to an appropriate size such that the longitudinal diameter of each potato 100 (if the potatoes are elongated) is greater than the diameter 146 of the tube 140 into which the potatoes are inserted. This ensures that the longitudinal dimensions of each potato 100 in tube 140 are oriented mostly axially along the tube 140, thereby reducing radial movement and / or reorientation of the potatoes 100 in tube 140 during slicing.

[0112] The slicer 10 includes a cutting tool 160 which includes a cutting edge 161 for cutting the potatoes 100 protruding from each outlet 142. The cutting edge 161 is formed by a band blade 162 which moves in a continuous loop 163 around a set of pulleys 164a, 164b. The band blade 162 is positioned such that the cutting edge 161 extends along a direction perpendicular to the direction of motion of the container 120 and moves in that direction. In this way, as the container 120 moves in a reciprocating motion around the axis 125, the potatoes 100 protruding from each outlet 142 are passed across the cutting edge 161 substantially perpendicularly. This causes the potatoes 100 to be sliced ​​by the cutting edge 161 to produce potato slices 110, specifically unpeeled potato slices 110, which are then captured by a conveyor 190 located below the cutting tool 160.

[0113] The weight of the potatoes in each stack pushes the bottom potato toward its respective outlet 142. In this way, the potatoes are fed by gravity through the container 120, and as a result, the bottom potato 100 in each stack of potatoes 100 in each tube 140 is pushed out of its respective outlet 142 by the weight of the other potatoes in the stack. The slicer 10 includes a retainer 170 to limit the extent to which the potatoes 100 protrude from the outlet 142 of each container 120. As best illustrated in Figure 2, the retainer 170 includes an upper surface 171 that abuts against the end of the potato 100 protruding from each container outlet 142 and is positioned to guide the potato 100 toward the cutting edge 161 of the cutting tool 160 during the reciprocating cutting stroke of the container 120. A cutting stroke is defined herein as a portion of a reciprocating motion that moves the potato 100 in the container 120 from right to left in Figure 2, moving the potato toward the cutting edge 161 and across the cutting edge 161. A retraction stroke is defined herein as a portion of a reciprocating motion that moves the potato 100 in the container 120 from left to right in Figure 2, from the end of one cutting stroke to the beginning of the next cutting stroke.

[0114] The retainer 170 is shaped to match the path taken by the exits 142 during the cutting stroke. Specifically, the upper surface 171 of the retainer 170 is curved. This ensures that the potatoes 100 protrude substantially a certain amount from each exit 142 as they are passed towards the cutting edge 161. The upper surface 171 of the retainer 170 is spaced apart from the cutting edge 161 of the cutting tool 160 to form a gap 175 between the upper surface 171 and the cutting edge 161. In this way, during the cutting stroke, the potatoes 100 in each container 120 are guided along the upper surface 171 toward the cutting edge 161. The cutting edge 161 then contacts each potato 100 at a slight distance above the upper surface 171, corresponding to the size 176 of the gap 175. In this way, the thickness of the resulting potato slices 110 depends on the size of the gap 175.

[0115] As the potato 100 continues across the blade tip 161, the potato slice 110 passes through the gap 175, while the newly cut underside of the remaining potato passes along the support 180 above the cutting tool 160. The band blade 162 extends along the underside 181 of the support 180, and in some examples extends through an elongated hole (not shown) in the underside 181 of the support 180, so that the underside of the remaining potato can pass smoothly from the blade tip to the support 180. In this way, the support 180 acts as a guard to prevent the potato 100 from exerting a downward force along the surface of the band blade 162 following the cutting by the blade tip 161. In other words, the band blade 162 itself does not need to support the weight of the potatoes 100 stacked in the container 120. This can prevent bending of the band blade 162 and / or extend the life of the cutting tool 160. The support 180 shown in Figures 2 and 3 is flat. However, in other examples, the support 180, like the retainer 170, may coincide with the path taken by the outlet 142 in reciprocating motion.

[0116] The potato slices 110 produced by the slicer 10 pass through the gap 175 and onto the conveyor 190 located below the gap 175. The conveyor 190 is moved at a constant speed to move the potato slices 110 away from the slicer 10 along the product flow path 800 at a constant speed. A correspondingly spaced array 195 of potato slices 110 is provided on the conveyor 190 by arranging containers 120 in spaced arrays 105, moving the containers 120 in spaced arrays 105 in a reciprocating motion relative to the cutting tool 160, and moving the conveyor 190 at a constant speed. That is, as best shown in Figure 4, a view from above of the potato slices 110 on the conveyor 190, the potato slices 110 are spaced apart along the width of the conveyor by a width spacing of 191 minutes and along the length of the conveyor 190 by a length spacing of 192 minutes. The width spacing 191 can be increased or decreased by spacing the containers 120 in the array 105 of containers 120 further apart or closer together. The length spacing 192 can be increased by accelerating the conveyor speed and / or decreasing the frequency of the reciprocating motion of the containers 120. Alternatively, the length spacing 192 can be decreased by decelerating the conveyor speed and / or increasing the frequency of the reciprocating motion of the containers 120.

[0117] The width spacing 191 between each potato in each row (along the width of the conveyor 190) is shown here as constant for simplicity. Similarly, the length spacing 192 between each potato 100 in each column (along the length of the conveyor 190) is shown as constant. However, it will be understood that in practice the size of the potato slices 110 in each row and each column will depend on several factors, including which part of the potato was used to produce the potato slices, the actual size of the potato, and the specific orientation of the potato in the corresponding container. For example, the ends of the potato will produce potato slices 110 with a smaller diameter than the middle part of the potato. Furthermore, in some examples, the spacing between containers 120 may vary. Nevertheless, since the containers 120 are spaced apart and the conveyor speed and reciprocating frequency are set, the average spacing between each potato slice (i.e., the average width spacing 191 and the average length spacing 192) is at least 8 mm. The capacity of production line 1 can be increased by reducing the spacing between potato slices 110 on the conveyor 190. On the other hand, the efficiency of subsequent processes such as washing in the washing machine 20 and / or fat-soluble adjustment in the regulator 30 can be improved by increasing the width spacing and / or length spacing 191, 192 of the potato slices 110 on the conveyor 190.

[0118] As best shown in Figure 5, which shows a schematic view from above through the two containers 120b and 120c, each tube 140 has a pattern 145 on its inner surface 147. In the illustrated example, the pattern 145 includes equally spaced projections in the circumferential direction that extend along the length of each tube 140. This forms a star-shaped pattern 145 when viewed axially along the tube 140, as in Figure 5. This shape reduces the surface area of ​​each tube 140 that comes into contact with the potato within each tube 140. This reduces the resistance to the movement of the potato 100 through each tube 140, while similarly limiting the radial movement and / or reorientation of the potato 100 within the tube 140 during slicing. This can improve the consistency of the shape and / or thickness of the potato slices 110 produced using the slicer 10, for example, by improving the consistency of the extent to which the potato 100 protrudes from each outlet 142 during each cutting stroke. In other examples, it will be understood that any other suitable pattern 145 may be employed, for example, raised protrusions and / or rings on the inner surface 147 of the tube 140. In other examples, one or more inner surfaces 147 of the tube 140 are smooth and have no pattern 145.

[0119] Furthermore, as shown in Figures 2 to 4, the slicer 10 includes a lubrication system 175 to assist the movement of the potatoes through the tube 140. The lubrication system 175 includes a common channel 176 and first to fourth taps (both referenced by reference no. 177) that fluidly connect the common channel 176 to the tube 140 of each of the first to fourth containers 120. The common channel 176 is connected to a source of lubricant, which is water. The water flows through the common channel 176 into the tube 140 via each tap 177, lubricating the inner surface 147 of the tube 140. This further reduces the resistance to the movement of the potatoes 100 through the tube 140, thereby preventing blockages as described above and / or improving the consistency of the shape of the potato slices 110 produced using the slicer 10. In some examples, a manually operated tool (not shown), such as a mallet or pneumatic gun, is used to move the potatoes 100 along each tube 140.

[0120] In this example, both ends of each potato 100 in the longitudinal dimension are removed, for example, by hand using a knife, before inserting the potato 100 into each tube 140. In this way, both the top and bottom surfaces of each potato slice 110 produced from the potato by the slicer 10 may be free of potato peel, or may contain less potato peel than if the ends of the potato 100 had not been removed. This can improve the efficiency of downstream washing, fat-soluble pre-conditioning, and / or dewatering processes by ensuring that a larger proportion of the interior of each potato slice 110 is exposed to water, oil, and / or the atmosphere inside the microwave or oven. Also, pre-slicing the potato 100 in this way can ensure that the top and bottom surfaces of the potato slices 110 are substantially flat, providing improved retention and / or stability of the potato slices 110 on the conveyor 190.

[0121] The conveyor 190 is configured to move potato slices 110 along the product flow path 800 from the slicer 10 to the washing machine 20. Although not shown herein, intermediate conveyors or other components for moving the potato slices 110 may be provided in the product flow path 800 between the conveyor 190 and the washing machine 20, or in practice, between any other components of the production line 1 described herein.

[0122] The washer 20 includes a water bath 210, which contains a washing tank 211 that holds water 212 at a water level 213, as shown in Figure 6. The water 212 is at room temperature here, but may be heated in other examples. The washer includes a washer belt assembly 220, which includes an upper endless washer belt 221 and a lower endless washer belt 222, the upper endless washer belt 221 and the lower endless washer belt 222 defining a washer portion 810 of the product flow path 800 between them. The upper and lower endless washer belts are positioned such that the washer portion 810 of the product flow path has a height defined between the lower surface of the upper endless washer belt 221 and the upper surface of the lower endless washer belt 222, such that the thickness of a potato slice 110 is less than 115. This improves the retention of the potato slices 110 within the washing section 810 of the product flow path 800, thereby reducing the likelihood of the potato slices 110 being displaced as they pass through the water bath 210. Here, the thickness 115 of the potato slices 110 is the average thickness of the potato slices 110 within the product flow path 800. In other examples, this may be the maximum or minimum thickness of the potato slices 110 within the product flow path 800.

[0123] The potato slices 110 are received from the conveyor 190 at the first end 201 of the washing machine 20, on the upper surface of the lower endless washing machine belt 222. The potato slices 110 are then transported in the washing machine section 810 of the product flow path 800 and are gripped between the upper endless washing machine belt and the lower endless washing machine belts 221, 222 at the washing machine transport point 240 upstream of the water bath 210. The potato slices 110 are then passed through the water in the water bath 210 along the washing machine section 810 of the product flow path 800 to clean the potato slices 110 and reduce the amount of starch in the potato slices 110. Both the upper endless washing machine belt and the lower endless washing machine belts 221, 222, and therefore the washing machine section 810 of the product flow path 800, pass below the water level 213 in the washing machine 20, ensuring that the potato slices 110 are completely immersed in the water 212. The washing belt assembly 220 is configured to pass potato slices 110 through the water bath 210 for 30 seconds. In particular, the upper endless washing belt and the lower endless washing belts 221 and 222 are driven at the same constant speed so that the potato slices 110 being transported between them take approximately 30 seconds to pass through the water bath 210.

[0124] The potato slices 110 are then removed from the water in the water bath 210 by the washing belt assembly 220 and passed through the sprayer 260 to spray water onto the potato slices 110. The sprayer 260 further removes starch, such as starch, from the potato slices 110 that has been brought to the surfaces 211, 212 of each potato slice 110 by passing them through the water bath 210. The potato slices 110 are then passed between the upper washing air jet 271 and the lower washing air jet 272, which are configured to supply jets of air to the upper and lower surfaces of each potato slice 110, respectively. In this way, the upper air jet 271 and the lower air jet 272 remove excess water from the upper and lower surfaces of each potato slice 110. The removed water is then captured in the water bath 210. The upper endless washing belt and the lower endless washing belts 221 and 222 grip and hold the potato slices 110 as they are passed through the air jets from the upper washing air jet and the lower washing air jets 271 and 272.

[0125] The upper and lower cleaning belts 221, 222, and the upper and lower cleaning air jets 271, 272 are similar in structure and arrangement to the upper and lower regulator belts 321, 332 and regulator air jet 370 of the degreasing unit 40, which are shown in Figure 8 and described in more detail below. In particular, although not shown in the figure, the upper and lower cleaning jets 271, 272 each include elongated nozzles that extend across the width of the product flow path 800. This ensures that all potato slices 110 across the entire width of the product flow path 800 are exposed to the air jets.

[0126] The potato slices 100 are passed through the upper and lower washer air jets 271 and 272 to the washer discharge point 250, where they are discharged by the washer belt assembly 220. The lower endless washer belt 222 then carries the potato slices 110 toward the regulator 30, while the upper endless washer belt 221 returns to the washer transport point 250 upstream of the water bath 210. The potato slices 110 leave the washer 20 at the second end 202 of the washer 20, downstream from the first end 201 of the washer 20.

[0127] The regulator 30 (or “lipid-soluble regulator”) includes an oil bath 310 containing a tank 311 filled with oil 312 up to an oil level 313, as shown in Figure 7. The oil 312 is heated to a temperature of 90°C. This elevated temperature imparts the desired sensory properties to the potato slices, as described above, while ensuring that the potato slices 110 are not fried in the oil bath 310. The regulator 30 includes a regulator belt assembly 320, which includes an upper endless regulator belt 321 and a lower endless regulator belt 322, the upper endless regulator belt 321 and the lower endless regulator belt 322 defining the regulator portion 820 of the product flow path 800 between them. Similar to the washing section 810 of the product flow path 800, the upper endless regulator belt and the lower endless regulator belt 321, 321 are positioned such that the regulator section 820 of the product flow path 800 has a height 330 defined between the lower surface 321a of the upper endless regulator belt 321 and the upper surface 322a of the lower endless regulator belt 322, such that the thickness is less than the thickness of a potato slice 110. Again, the thickness is the average thickness, but alternatively, it may be the maximum or minimum thickness of a potato slice 110 in the product flow path 800.

[0128] The potato slices 110 are received from the washing machine 20 on the upper surface 322a of the lower endless regulator belt 322 at the first end 301 of the regulator 30. The potato slices 110 are then transported in the regulator section 32 of the product flow path 800 and gripped between the upper endless regulator belt and the lower endless regulator belts 321, 322 at the regulator transport point 340 upstream of the oil bath 310. The potato slices 110 are then passed through the oil 312 in the oil bath 310 along the regulator section 820 of the product flow path 800. Both the upper endless regulator belt and the lower endless regulator belts 321, 322, and therefore the regulator section 820 of the product flow path 800, pass below the oil level 313 in the regulator 30, ensuring that the potato slices 110 are fully immersed in the oil 312. The regulator belt assembly 320 is configured to pass potato slices 110 through the oil bath 310 for 90 seconds. In particular, both the upper endless regulator belt and the lower endless regulator belts 321, 322 are driven at the same constant speed so that the potato slices 110 being transported between them take approximately 90 seconds to pass through the oil bath 310.

[0129] The regulator belt assembly 320 is then configured to remove the potato slices 110 from the oil bath 310 and pass them through the degreasing unit 40 downstream of the oil bath 310. The degreasing unit 40 is shown in Figure 8, and for clarity only one is shown in Figure 8, but it includes two regulator air jets (both referred to using reference no. 370). Similar to the upper and lower washer air jets 271, 272 described above, the regulator air jet 370 is configured to provide a jet of air 371 to the potato slices 110 being transported between the upper endless regulator belt and the lower endless regulator belt 321, 322. In this way, the degreasing unit 40 removes oil from the surface (e.g., top and / or bottom surfaces 111, 112) of the potato slices 11 as they pass through the jets of air 371 from the regulator air jet 370. The regulator air jet 370 is positioned so that the oil removed from the potato slices 110 returns to the oil bath 310 under the influence of gravity.

[0130] The regulator air jet 370 together forms the only device in production line 1 for actively degreasing the potato slices 110 before dewatering them. In other words, production line 1 and regulator 30 do not have any other devices, such as water sprayers or brushes, for actively removing oil from the potato slices 110 before dewatering them. The term “actively degreasing” is understood to constitute “passive” degreasing, which does not include oil dripping from the potato slices under the action of gravity. The regulator air jet 370 is positioned to apply at least one air jet to the potato slices 110 within 5 seconds of the potato slices 110 last coming into contact with the oil 312 in the oil bath 310. This ensures that the temperature of the potato slices is not lowered by 5°C after the potato slices 110 last came into contact with the oil 312 in the oil bath 310 before the air jet is applied. The oil on the surface 111, 112 of the potato slices 110 is removed more easily by the regulator air jet 370 at a higher temperature because it has lower viscosity.

[0131] The regulator air jet 370 shown in Figure 8 is positioned to provide a jet of air to the upper surface 111 of the potato slices 110 within the regulator portion 820 of the product flow path 800. Specifically, the regulator air jet 370 is positioned above the upper endless regulator belt 321 within the regulator 30, and the nozzle 372 of the regulator air jet 370 is oriented toward the upper endless regulator belt 321. Further regulator air jets, not shown in Figure 8, are positioned to provide a jet of air corresponding to the lower surface 112 of the potato slices 110 within the regulator portion 820 of the product flow path 800. Specifically, further regulator air jets are positioned below the lower endless regulator belt 322 within the regulator 30 and include corresponding nozzles oriented toward the lower endless regulator belt 322. Also not shown in Figure 8, similar to the washer air jets 271 and 272, the nozzle 372 of the regulator air jet 370 is elongated and extends across the width of the product flow path. In other examples, it will be understood that the degreasing unit 40 may include any other suitable number of regulator air jets and / or nozzles 372, provided that any active degreasing process is carried out by air jets alone.

[0132] The regulator air jet 370 and the upper and lower washer air jets 271 and 272 are configured to supply their respective air jets from their respective nozzles 372 at a variable speed of 50 to 130 m / s. In particular, the regulator 30 includes a motor (not shown) for operating a fan (not shown) that provides airflow to each of the regulator air jets 370. The washer 20 includes a similar motor and fan to provide airflow to each of the washer air jets 371 and 372. In either case, the motor is capable of operating at a variable speed up to 80 Hz. In other examples, the motor(s) may be capable of operating at speeds up to 50 Hz, 60 Hz, 70 Hz, 80 Hz, or above 80 Hz. This may provide a variable flow rate from the fan and, similarly, a variable flow rate of air through each nozzle 372, and therefore a variable speed air jet from each nozzle 372.

[0133] Each of the belts in the washer belt assembly and regulator belt assembly 220, 320 is of the wire mesh type and includes multiple connected metal wires that form a mesh structure. This provides a robust yet flexible belt assembly for securely holding the potato slices 110 in the product flow path 800 while reducing the risk of damage to the potato slices 110. Furthermore, the mesh structure may allow a larger surface area of ​​the potato slices to be exposed to the water in the water bath, the oil in the oil bath, and the washer air jets and regulator air jets 271, 272, 370. In particular, each of the belts in both the washer 20 and regulator 30 has a total "open" area (i.e., the area between the connected wires) of approximately 85% of the total area of ​​each belt.

[0134] After degreasing, the potato slices 110 are passed through the regulator discharge point 350 located downstream of the degreasing unit 40, where they are discharged by the regulator belt assembly 320. The lower endless regulator belt 322 then carries the potato slices 110 toward the forming belt 50, while the upper endless regulator belt 321 returns to the regulator transport point 340 upstream of the oil bath 310. The potato slices 110 leave the regulator 30 at the second end 302 downstream of the first end 301 of the regulator 30.

[0135] It will be understood that the undulating surface of the polymer bands of the molding belt 50 can take on any suitable shape, which may vary depending on the shape to be imparted to the potato slices. The spacing of the potato slices on the molding belt 50 is maintained, but the spacing does not need to be regular, such as the spacing in the arrangement shown in Figure 4. Instead, the potato slices 110 may be irregularly spaced on the molding belt, such as in an alternating arrangement. In other examples, there may be slight overlap, but it is preferable that the spacing of the potato slices is maintained.

[0136] The molding belt 50 is configured to transport potato slices from the regulator 30 to the primary microwave 61. The potato slices 110 remain on the molding belt in the primary microwave 61 of the dewaterer 60. As the potato slices are heated in the microwave, they conform at least partially to the uneven surface of the molding belt 50. The primary microwave 61 reduces the moisture content of the potato slices to between 7% and 10%. The primary microwave 61 has an available output of up to 300 kW and is operated between 160 kW and 210 kW. The speed and output of the polymer belt can be varied to provide the desired moisture content and / or processing rate.

[0137] Next, the potato slices 110 are passed through a deep conveyor in a deep microwave oven (not shown), which includes trays for receiving the potato slices 110. The potato slices are not spaced apart in the tray, but instead are stacked in piles, or "floors," of potato slices 110, approximately 2-3 slices high. However, it will be understood that the "floor" can be deeper, for example, up to 5 or more potato slices 110 in height. The deep microwave oven microwaves the potato slices at an output between 16 and 20 kW. This provides potato slices with a moisture content between 4% and 6%.

[0138] An exemplary dewatering process, which includes transporting potato slices through a primary microwave on a conveyor having an uneven surface and then passing the potato slices through a deep conveyor, is shown and described in published international patent application no. WO2012104219.

[0139] The potato slices 110 are then passed from the deep microwave oven to the oven 62 for final drying or baking to produce potato chips. The temperature setting point of the oven 62 is 135°C, with a range of + / - 5°C. The potato slices remain in the oven for 7.5 minutes, with a range of + / - 30 seconds. The moisture content of the resulting potato chips is in the range of 1.4% to 1.8%. Finally, the potato chips are transported to the packaging machine 70, where they are packaged into chip packets, for example by combining the potatoes and placing them in chip packets, and then sealed. However, in other examples, the potato chips may be packaged in any other suitable container, such as a box, and / or transported or transferred to another facility or production line for packaging.

[0140] It will be understood that dehydration, and specifically, microwave heating in a primary microwave oven 61 and a deep microwave oven, and drying in an oven 62, may be carried out by any other suitable method. For example, other power, time, conveyor speed, and / or temperature ranges may be used according to specific embodiments of the present invention.

[0141] Potato chips produced on production line 1 typically have an oil content of approximately 10% to 11%, with a range of + / - 1%. This provides chips with reduced oil content (typically less than 50% of the oil content in fried chips) compared to purely fried chips, while maintaining the desired sensory characteristics such as taste and texture.

[0142] Referring now to Figure 9, an exemplary method 80 for manufacturing potato chips is shown. Method 80 corresponds to the process carried out by the manufacturing line 1 described above. Specifically, Method 80 includes producing an array of potato slices from potatoes 81, washing the potato slices 110 82 to produce washed potato slices 110, performing a fat-soluble pre-treatment of the washed potato slices 110 83 to produce prepared potato slices 110, de-oiling the prepared potato slices 110 without wetting the potato slices 84 to produce de-oiled potato slices 110, and dehydrating the potato slices 85 to produce potato chips.

[0143] The process of producing potato slices 110 from potatoes 100 81 corresponds to the process performed by the slicer 10 described above. In particular, the process of producing potato slices 110 81 includes receiving potatoes 100 in a container 120, holding potatoes 100 in the container 120 using a retainer 170 so that potatoes protrude from an outlet 142, and causing the container 120 to move in a reciprocating motion toward a cutting tool 160 so that the portion of potato 100 protruding from the outlet 142 passes across the blade 161 so that potatoes 100 produce thinly sliced ​​potato slices 110 by the blade. Method 80 also includes capturing the potato slices on a conveyor 190. In various examples, it will be understood that the process of producing potato slices 110 81 may include any of the processes described above in relation to the slicer 10.

[0144] Washing the potato slices 82 corresponds to the process performed by the washing machine 20 described above, which includes transporting the potato slices 110 through the water bath 210 between the upper endless washing machine belt and the lower endless washing machine belts 221, 222, spraying water onto the potato slices 110, and then adding a jet of air to the potato slices 110. Performing the fat-soluble pre-adjustment of the washed potato slices 83 corresponds to the process performed by the regulator 30 described above, which includes transporting the potato slices 110 along the regulator part 820 along the product flow path 800 through the oil bath 310 containing oil at a temperature of 85°C between the upper endless regulator belt and the lower endless regulator belts 321, 322. De-oiling the prepared potato slices 110 84 specifically involves applying a jet of air from the regulator air jet 370 to the potato slices 110 while the potato slices are held between the upper endless regulator belt 321 and the lower endless regulator belt 322. Finally, dehydrating the potato slices 85 includes a process carried out by the dehydrator 60, which includes microwaving the potato slices in a primary microwave oven 61 and / or a deep microwave oven and drying the potato slices in an oven 62 to produce potato chips.

[0145] Figure 10 shows an exemplary method 90 for manufacturing bags of potato chips. Method 90 includes manufacturing potato chips according to Method 80 described above 91 and packaging the potato chips into bags using a packaging machine 70 92.

[0146] However, while exemplary embodiments of the present invention have been described with reference to illustrated examples, it will be understood that modifications and alterations may be made without departing from the scope of the invention as defined by the appended claims.

Claims

1. An apparatus for producing potato slices from potatoes, An arrangement of containers spaced apart, where each container has an opening for receiving potatoes and an opening from which the potatoes can protrude, A retainer is provided to limit the extent to which the potatoes protrude from the outlet of the container. A cutting tool equipped with a blade for cutting the aforementioned potato, Equipped with, Each of the containers is movable in a reciprocating motion relative to the cutting tool, and the portion of the potato protruding from each of the outlets passes across the blade so that the potato is thinly sliced ​​by the blade to produce potato slices. The apparatus comprises a conveyor arranged to capture the potato slices. The aforementioned device.

2. The apparatus according to claim 1, wherein each container is oriented such that, at least when the potatoes are passed across the cutting tool, the potatoes are pushed out of their respective outlets by the action of gravity.

3. The apparatus according to claim 1 or 2, wherein each container comprises a tube having a height and diameter such that the potatoes received through the inlet can be stacked in a single pile of potatoes in the tube.

4. The apparatus according to claim 3, wherein each tube has a pattern on the inner surface of the tube.

5. The apparatus according to claim 4, wherein the pattern comprises projections that extend along the length of each tube and are equally spaced in the circumferential direction.

6. The retainer has an upper surface that contacts the end of the potato protruding from the outlet of each container and is positioned to guide each potato toward the cutting edge of the cutting tool during the reciprocating cutting stroke, The apparatus includes a gap between the upper surface and the cutting edge of the cutting tool, and the thickness of the potato slice produced by the apparatus depends on the size of the gap. The apparatus according to any one of claims 1 to 5.

7. A method for producing potato slices from potatoes, The method involves receiving potatoes into each container arranged at intervals, each container having an inlet and an outlet from which each potato can protrude, and the method of receiving, Using retainers, the potatoes are held in each container so that they protrude from their respective outlets, To cause the movement of each container in a reciprocating motion relative to a cutting tool, wherein the cutting tool is equipped with a cutting edge for cutting the potatoes in each container, Includes, The movement of the container is caused by passing the portion of the potato protruding from each outlet across the blade so that the potato is sliced ​​thinly by the blade to produce potato slices. The aforementioned method.

8. The method according to claim 7, wherein causing the movement of the container includes causing the movement of the container by pendulum motion.

9. The method according to claim 7 or 8, wherein the retainer is adjustable to adjust the size of the gap between the retainer and the cutting tool, and the method comprises adjusting the retainer to adjust the size of the gap.

10. The method according to any one of claims 7 to 9, wherein two or more of the containers in the array of containers are tubular and have different diameters, and receiving a potato in each of the containers includes receiving each potato of the different diameter in each of the two or more containers.

11. A method for manufacturing potato chips, To produce potato slices according to the method described in claim 10, Cooking the aforementioned potato slices to produce the aforementioned potato chips, The method, including the method described above.

12. A production line for manufacturing potato chips, An apparatus for producing potato slices according to any one of claims 1 to 6, A washing machine configured to wash the potato slices and produce washed potato slices, A fat-solubleness adjuster configured to adjust the fat-solubleness of the washed potato slices and produce adjusted potato slices, A dewaterer configured to dehydrate the prepared potato slices to produce potato chips, The manufacturing line comprising the above.

13. An apparatus for washing potato slices and pre-adjusting the fat-soluble properties of potato slices in the production of potato chips, A water bath capable of receiving water for washing the potato slices, and an oil bath capable of receiving oil for pre-conditioning the fat-soluble properties of the potato slices, A belt assembly comprising an upper endless belt and a lower endless belt, wherein the upper endless belt and the lower endless belt define a product flow path between them, and the product flow path passes through the water bath and / or oil bath, the belt assembly and Equipped with, The product flow path has a height defined between the lower and upper surfaces of the respective upper and lower endless belts, which is less than or equal to the thickness of the potato slices. The aforementioned device.

14. The apparatus according to claim 13, further comprising at least one air jet configured to apply at least one air jet to each of the potato slices in the product flow path downstream of the water bath.

15. The apparatus according to claim 13 or claim 14, further comprising at least one air jet configured to apply at least one air jet to each of the potato slices in the product flow path downstream of the oil bath.

16. The apparatus according to any one of claims 13 to 15, wherein the upper endless belt and the lower endless belt are oil-permeable and water-permeable.

17. A method for washing potato slices and pre-adjusting the fat-soluble properties of potato slices in the production of potato chips, Washing the potato slices by transporting them through a water bath to produce washed potato slices, The process involves transporting the potato slices through an oil bath containing oil at a temperature of 75°C to 90°C to perform a preliminary adjustment of the fat-soluble properties of the washed potato slices, thereby producing pre-adjusted potato slices. Transporting the potato slices through the water bath and / or the oil bath along a product flow path defined between the upper endless belt and the lower endless belt, Includes, The product flow path has a height defined between the lower and upper surfaces of the respective upper and lower endless belts, which is less than or equal to the thickness of the potato slices. The aforementioned method.

18. This is a production line for manufacturing potato chips from potatoes. A slicer for thinly slicing the aforementioned potato to produce potato slices, The apparatus according to any one of claims 13 to 16 for washing the potato slices, adjusting the fat solubility of the potato slices, and producing washed and pre-adjusted potato slices, A dewaterer for dewatering the washed and pre-prepared potato slices to produce dewatered potato slices, The manufacturing line comprising the above.

19. A method for making potato chips from potatoes, The process involves thinly slicing the aforementioned potatoes to produce potato slices, Washing the potato slices and adjusting the fat-soluble properties of the potato slices according to the method described in claim 17, thereby producing washed and pre-adjusted potato slices, The aforementioned pre-prepared potato slices are dehydrated to produce the potato chips, The method, including the method described above.

20. A method for making potato chips from potato slices, The process involves transporting the potato slices along a manufacturing channel that passes through an oil bath containing oil at a temperature of 75°C to 95°C to pre-adjust the fat-soluble properties of the potato slices, thereby producing pre-adjusted potato slices. Transporting the pre-adjusted potato slices from the oil bath to at least one air jet along the product path, Degreasing the pre-prepared potato slices by applying at least one air jet to each potato slice from at least one air jet, thereby producing degreasing potato slices. The process involves dehydrating the oil-removed potato slices to produce the potato chips, Includes, Adding the at least one air jet from each of the at least one air jets is the only active de-oiling action performed between transporting the potato slices through the oil bath and de-watering the de-oiled potato slices. The potato chips contain up to 18 wt% oil based on the total weight of the potato chips. The aforementioned method.

21. The method according to claim 20, comprising adding the at least one jet of air to the pre-prepared potato slices within 12 seconds after the pre-prepared potato slices last came into contact with the oil in the oil bath.

22. The method according to claim 20 or 21, further comprising adding the jet of air after the pre-prepared potato slices have last come into contact with the oil in the oil bath, and before the temperature of the pre-prepared potato slices drops by 10°C.

23. The method according to any one of claims 20 to 22, wherein the product flow path is defined between an upper endless belt and a lower endless belt, and the product flow path has a height defined between the lower and upper surfaces of the respective upper and lower endless belts, which is less than or equal to the maximum thickness of the potato slices.

24. A production line for manufacturing potato chips from potato slices, The potato slices are transported through a product channel that allows them to pass through the production line, An oil bath through which the product flow path passes, the oil bath for performing fat-soluble pre-adjustment of the potato slices and producing pre-adjusted potato slices, At least one air jet configured to produce de-oiled potato slices by applying an air jet to the pre-prepared potato slices in the product flow path downstream of the oil bath, A dewatering device for dehydrating the oil-dehydrated potato slices to produce potato chips, Equipped with, The at least one air jet is the only device in the production line for actively degreasing the pre-prepared potato slices before dewatering them. The production line is configured to produce potato chips containing up to 18 wt% oil, based on the total weight of the potato chips. The aforementioned manufacturing line.

25. A method for manufacturing a bag of potato chips, comprising manufacturing potato chips according to the method of any one of claims 11, 19, or 20 to 23, and packaging the potato chips into a bag.

26. Potato chips manufactured according to the method described in any one of claims 11, 19, or 20-24, wherein the chips are optionally packaged in a bag according to the method described in claim 25.

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