DEVICE FOR CONTINUOUS FRYING OF BAKERY PRODUCTS IN A DEEP FRYER

Abstract

This utility model relates to the food industry, specifically to equipment for deep-frying food products, and can be used in the industrial production of croutons, rusks, bread chips, and similar products. The technical result is increased frying performance.A device for continuously deep-frying bread products comprises a bath for frying oil, a transport device for moving the product through the bath, an oil heating system, and a bottom cleaning system, wherein the heating system is made in the form of flat tubular radiators configured to be connected to an external thermal oil boiler and located inside the bath above its bottom to form a gap, wherein the flat tubular radiators are divided into three heating zones, each of which is provided with an individual control valve and an automatic temperature control system, and the bottom cleaning system comprises a mechanical scraper mounted with the ability to move along the bottom of the bath and configured to move solid residues into a recess in the bottom of the bath, communicated with the suction branch of a pump connected to a system for filtering oil from crumbs. 6 c.p. phyl., 9 fig.

Description

[0001] The utility model relates to the food industry, namely to equipment for heat treatment of food products in deep frying, and can be used in the industrial production of croutons, rusks, bread chips and similar products.

[0002] The prior art discloses devices for deep-frying food products, including a bath of heated vegetable oil, heating elements, a conveyor for moving the product, and a crumb removal system.

[0003] The closest in technical essence are continuous frying devices with a conveyor feed of the product and oil filtration, as well as deep fryers in which the oil is heated by means of heat exchange elements or the circulation of a heated coolant.

[0004] A known solution is described in patent US2021321823A1, published on August 30, 2019. The application discloses oil circulation and the use of a heat exchanger for heating edible oil (thermal oil system, buffer tank, pumps).

[0005] A drawback of the described analogue is that it is essentially a batch fryer, cooking the product in batches rather than a continuous conveyor-fried line. Therefore, each batch of product must be loaded and unloaded after processing, which significantly reduces ease of use. Heating in US20210321823A1 is achieved through an external oil circulation system with a heat exchanger and pump, and the heating rate is increased only by a booster pump at the beginning and end of the process, which does not ensure uniform heat distribution throughout the oil. This analogue does not provide independent temperature control in different zones of the bath, which can lead to overheating or incomplete cooking in certain areas.Furthermore, patent US20210321823A1 uses a complex mixing device with rotating axes and radial blades to stir the product in the fryer vat, which increases the risk of damage to fragile products and complicates the design. The fryer in patent US20210321823A1 requires manual loading and unloading of each batch, along with pauses for cleaning the fryer. There is no automatic bottom cleaning mechanism (scraper), and sediment and crumbs are removed only by periodic draining of the oil or manually. The oil filtration system is a drum filter located outside the fryer. This roller filter, although located outside the fryer vat, is cumbersome and requires disassembly for cleaning. Furthermore, the booster pump is controlled only in short cycles (20-40 seconds at the beginning of a batch, 30-60 seconds at the end), with the oil circulating passively during these intervals. This complicates operation, as in normal operation, the user must wait for the temperature to recover after loading a new batch of product.

[0006] The analog, due to cyclic processing, requires more manual labor and downtime for maintenance, which increases costs. Energy consumption is also higher: the constant operation of the circulation and booster pumps, the agitator motor, and the auxiliary heater increases energy consumption. The drum filter requires regular maintenance (cleaning and replacement of the filter element). Overall, the design, with numerous moving parts (chains, gears, pumps) and the lack of a simple cleaning scraper, makes maintenance expensive and time-consuming.

[0007] Also known is patent CN102894018A, published October 17, 2012, describing a continuous frying line with heating pipes in the bottom and a mesh conveyor above the heating - the closest analogue in architecture to a continuous line with conveyor baskets.

[0008] A drawback of the described prototype is that it is a continuous oil fryer, but with a number of limitations. Heating is provided by built-in tubular heating elements attached to the bottom of the fryer. This method provides a smaller heat exchange surface and can create localized "hot spots" at the bottom. The patent does not specify multi-zone temperature control—only the overall heating is regulated (there is only a backup heating element in case of failure). This limits the accuracy of maintaining an optimal temperature profile as the product passes through the fryer.

[0009] The prototype, like its analogue, lacks a mechanical scraper for cleaning the bottom. Instead, it uses a sloped bottom (toward the outlet) and an oil filtration system: a pump at the bottom forces oil through a flat mesh on the surface of the tank. This design allows for the automatic removal of some suspended contaminants (cleaning the oily liquid without manual intervention), but the built-in filter screen still accumulates waste and requires periodic shutdown for cleaning. Controlling the operation of the auger and mesh conveyor at the inlet / outlet, timers, and valves adds to the complexity of operation. Furthermore, protection (railings, casing) and the complex kinematics of the design increase the demands on maintenance personnel.

[0010] Direct heating from tubular heating elements is typically less energy efficient than a heat transfer system with uniformly distributed radiators. Replacing or repairing tubular heating elements (and the backup switch that supports them) is more expensive than servicing an external radiator. The lack of three-zone control can lead to excessive oil consumption or frequent oil changes. The filter screen inside the bath also adds cost: when dirty, it must be removed and cleaned manually. Overall, the prototype design requires high energy costs and ongoing maintenance.

[0011] Thus, the disadvantages of known solutions include localized oil overheating (hot spots), accelerated oil degradation, the risk of fire when using immersion heaters, the accumulation of crumbs at the bottom of the bath, frequent downtime for cleaning and maintenance, labor-intensive filter maintenance, and the inability to maintain an optimal temperature map along the length of the bath.

[0012] The objective of the proposed technical solution is to develop a continuous frying device for bread products that ensures uniform and zone-controlled heating of oil, increased operational safety, reduced oil degradation, continuous removal of solid residues from the bottom of the bath, and simplified maintenance of the filtration system without stopping the line.

[0013] The technical result is to increase the productivity of the device for frying products.

[0014] The design allows for a stable temperature profile to be maintained and continuous cleaning of solid impurities to be carried out, which reduces oil degradation and reduces the frequency of oil changes and downtime for maintenance.

[0015] The technical result is achieved in that the device for continuously frying bread products in deep fat contains a bath for frying oil, a transport device for moving the product through the bath, an oil heating system and a bottom cleaning system, the heating system is made in the form of radiators made with the possibility of connection with an external thermal oil boiler and placed inside the bath above its bottom with the formation of a gap, wherein the radiators are divided into three heating zones, each of which is provided with an individual control valve and an automatic temperature control system, and the bottom cleaning system contains a mechanical scraper installed with the possibility of movement along the bottom of the bath and made with the possibility of moving solid residues into a recess in the bottom of the bath, communicated with the suction pipe of the pump connected to the oil filtration system from crumbs.

[0016] The essence of the utility model is explained by drawings, which depict:

[0017] Fig. 1 - general view of the device on the right,

[0018] Fig. 2 - general view of the device from the back,

[0019] Fig. 3 - general view of the device from the front,

[0020] Fig. 4 - general view of the device from above;

[0021] Fig. 5 - cross-section of the bathtub with the arrangement of flat tubular radiators;

[0022] in Fig. 6 - a bottom cleaning system with a mechanical scraper and a recess in the bottom;

[0023] Fig. 7 - diagram of the device and the arrangement of elements,

[0024] Fig. 8 - thermal oil circulation diagram (external boiler, pump),

[0025] Fig. 9 - general view of the basket,

[0026] where: 1 - frame,

[0027] 2 - bath,

[0028] 3 - heating elements (radiators),

[0029] 4 - conveying device (chain conveyor),

[0030] 5 - basket,

[0031] 6 - transport device drive,

[0032] 7 - woven stainless steel mesh,

[0033] 8 - chain,

[0034] 9 - scraper,

[0035] 10 - Crumb removal device drive,

[0036] 11 - recess,

[0037] 12 - pipe,

[0038] 13 - hot oil pump,

[0039] 14 - mesh filter,

[0040] 15 - weigh batcher,

[0041] 16 - unloading conveyor,

[0042] 17 - unloading device,

[0043] 18 - exhaust hood,

[0044] 19 - air duct,

[0045] 20 - radiator connection pipes to the thermal oil circuit,

[0046] 21 - three-way valve with electric drive,

[0047] 22 - electric crane,

[0048] 23 - expansion tank,

[0049] 24 - pump,

[0050] 25 - thermal oil boiler.

[0051] The device comprises a frame 1, which contains a bath 2 for deep-frying oil, a transport device (chain conveyor) 4 with mesh baskets 5, heating elements (radiators) 3, loading and unloading devices, and a bottom cleaning system.

[0052] Frame 1 is a rectangular structure welded from a stainless steel profile pipe, into which a bathtub with radiators is installed.

[0053] Bath 2 is made of food-grade stainless steel. Flat tubular radiators 3 are positioned above its bottom, creating a gap necessary for the free passage of the scrapers of the bottom cleaning system (crumb removal) and oil circulation. They are connected to an external thermal oil boiler 25 via thermally insulated pipes. Pump 24 circulates the thermal oil through the pipes. The thermal oil in the thermal oil boiler is heated to the required temperature, circulates through the pipes, and transfers heat to the oil in the bath via radiators 3. A three-way control valve 21 with an electric drive is installed at the inlet of each radiator. This valve is controlled by the automatic temperature control system, allowing the required temperature to be set in each zone along the length of the bath. The automatic control system consists of a controller, temperature sensors installed in the bath near each radiator, and valves with electric drives.Depending on the temperature set by the operator in each zone of the bath, the controller controls the opening degree of the valve in each zone, thereby regulating the temperature in each radiator, which in turn changes the heating rate of the oil in each zone. The bath is divided into three zones according to the location of the radiators: Radiator 1 - Zone 1, Radiator 2 - Zone 2, Radiator 3 - Zone 3. The bath is a rectangular container welded from stainless steel sheets and profile pipes. Three-way valves 21 with an electric drive are installed outside the device on the supply section of the thermal oil circuit of each radiator and serve to control the flow of heated oil into the radiator. Valve 22 serves for the rapid (emergency) discharge of hot oil from the supply to the return section of the circuit. Expansion tank 23 maintains the circuit filled with thermal oil and compensates for the thermal expansion of the thermal oil during heating.Pump 24 ensures constant circulation of thermal oil throughout the circuit.

[0054] Transport device 4 is designed as a chain conveyor with mesh baskets 5 mounted on it. These baskets can rotate and change their angle when immersed in and out of the oil. This is achieved by the design of axles and stops, which ensure smooth insertion and removal of the baskets from the oil. Drive 6 of the conveyor is attached to the frame and drives the chain with the baskets, which, moving counterclockwise, sequentially moves the baskets from one zone to another. A weigh batcher 15 is installed at the entrance to the working area. It is not part of the device and is attached to special supports in the loading zone above the mesh baskets. The weigh batcher ensures the dosing and uniform loading of the product into the baskets. At the exit, there is an unloading device 17, which tilts the baskets, and the product is unloaded onto an unloading conveyor 16, which delivers the finished product to the next process section.Unloading device 17 consists of a plastic rotating disc and a longitudinal plate, secured to the frame of the device in the unloading zone. As the chain with the baskets moves, the longitudinal end of the mesh basket encounters the freely rotating disc, and as the basket moves, the basket rotates around its axis. The basket inverts and rests on its edge on the longitudinal plastic plate. All product in the basket is discharged onto the unloading conveyor. The basket then moves along the plate, exits the unloading zone, and along the inclined portion of the plate, rotates, returning to its working position. The unloading conveyor is not part of the device and has its own supporting elements.

[0055] Basket 5 is a stainless steel mesh bent into a semicircle and secured to a frame with hangers that attach the basket to the conveyor chain. Axles are welded to both ends of the basket, inserted into the chain holes, allowing the basket to rotate freely.

[0056] To prevent food from floating during frying, the baskets are covered with a stainless steel mesh 7 at the right moment, immersed in a bath of hot oil, and kept covered until the baskets emerge from the oil, preventing any product from floating to the surface. The mesh size of the mesh is precisely designed to allow moisture to escape during frying while preventing the product from floating or leaving the perimeter of the basket. The mesh is a standard stainless steel mesh and is attached to the frame of the appliance with special hooks above the baskets in the frying zone.

[0057] The bottom cleaning system is a chain conveyor that includes a drive 10, a chain 8 with supports, and scrapers 9 installed along this chain at regular intervals. The conveyor has a horizontal and vertical section. A chain with scrapers is installed on the horizontal section; this section moves settled crumbs to the edge of the tank. The vertical section does not have scrapers and, via the chain, only transmits rotation from the drive, mounted outside the tank. The chain on the horizontal section is located parallel to the bottom of the tank; its upper part rests on support rollers, while the lower part does not have support rollers and moves along the bottom of the tank with the scrapers. As it moves along the bottom, a sufficient number of scrapers move to effectively remove crumbs. The scrapers are shaped to match the bottom of the tank and are of a size sufficient for effective crumb removal.During frying, a chain with scrapers moves settling crumbs along the bottom of the vat to a depression 11, connected by a suction pipe 12 to a hot oil pump 13. The pump draws in the oil and crumbs and delivers them to a mesh filter 14 located at the end of the vat. The crumbs remain on the mesh filter, and the oil drains back into the vat. As crumbs accumulate on the mesh filter, the operator removes the accumulated crumbs with a special scraper. If the mesh filter becomes clogged, it can be safely replaced with a clean one without interrupting the frying process.

[0058] The device operates as follows. The product to be fried is fed in portions into mesh baskets 5 using a weigh batcher 15. Chain conveyor 4 transports the filled baskets into a bath 2 with heated frying oil. The chain conveyor moves counterclockwise. As the baskets are immersed in the bath, they are covered with a woven mesh 7, which prevents the product from floating during frying. Heating elements are heated by thermal oil. The heating is turned on after the bath is filled with oil, and the temperature values ​​are set depending on the type of product being fried. As the baskets move in the bath, the product is fried. Then, the baskets exit the bath and are fed to the unloading zone, where unloading device 17 tilts the basket and unloads the fried product onto unloading conveyor 16. Empty baskets are fed back to the loading zone, and the cycle repeats.The exhaust hood 18 is connected to the external exhaust system via the air duct 19 and serves to remove moisture and combustion products formed during frying.

[0059] Thus, the technical result is achieved through the use of:

[0060] 1. A three-zone, closed-loop, automatically controlled oil heating system in a device's bath, using flat tubular radiators as heating elements, connected via insulated pipelines to an industrial gas-fired thermal oil boiler and a special liquid (technical oil) circulating in the heating system, certified for food safety. The heating system is explosion-proof, thermally insulated, and operates at atmospheric pressure.

[0061] 2. Oil bath bottom cleaning system for removing bread crumbs, consisting of a scraper driven by a chain drive connected to an electric motor, as well as a high-temperature oil pump with a mesh filter.

[0062] 3. Stainless steel mesh and mesh baskets prevent food from floating during frying. This reduces product loss and optimizes the frying process.

Claims

1. A device for continuously frying bread products in deep fat, comprising a bath for frying oil, a transport device for moving the product through the bath, an oil heating system and a bottom cleaning system, characterized in that the heating system is made in the form of flat tubular radiators made with the possibility of connection to an external thermal oil boiler and placed inside the bath above its bottom with the formation of a gap, wherein the flat tubular radiators are divided into three heating zones, each of which is provided with an individual control valve and an automatic temperature control system, and the bottom cleaning system contains a mechanical scraper installed with the possibility of movement along the bottom of the bath and made with the possibility of moving solid residues into a recess in the bottom of the bath, communicated with the suction pipe of a pump connected to a system for filtering oil from crumbs.

2. The device according to paragraph 1, characterized in that the flat tubular radiators are made of stainless steel.

3. The device according to paragraph 1, characterized in that each heating zone is equipped with a three-way control valve.

4. The device according to paragraph 1, characterized in that the scraper is driven by an electric motor via a chain transmission.

5. The device according to paragraph 1, characterized in that the transport device is made in the form of a chain conveyor with mesh baskets mounted on axles.

6. The device according to paragraph 5, characterized in that the mesh baskets are designed with the ability to rotate around their axis and change the angle of inclination when immersed in and exiting the frying oil.

7. The device according to claim 1, characterized in that the filtration system is designed with the possibility of removing mesh filters without draining the oil from the bath.

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