A production line for producing individual food products and a method for producing individual food products

Abstract

The present invention relates to a production line (1) for producing individual food products (2') from a pumpable food mass comprising a continuous forming device (5), in particular a shaping device,, a cutting device (7) and a food mass supply means, in particular a food mass pump (3), for conveying at least one food mass stream (2) through the continuous forming device (5) to the cutting device (7), wherein the cutting device (7) is arranged downstream of the continuous forming device (5) and configured for cutting the at least one food mass stream (2) leaving the continuous forming device (5) into individual food products (2'). The invention further relates to a method for producing individual food products (2') from a pumpable raw food mass, wherein a food mass supply means, in particular the pump (3), conveys, in particular pumps, a raw food mass stream (2), in particular a raw meat stream, through a downstream continuous forming device (5) to a cutting device (7), wherein the cutting device (7) cuts the food mass stream (2) into individual food products (2').

Description

[0001] A production line for producing individual food products and a method for producing individual food products

[0002] The present invention relates to a production line for producing individual food products and a method for producing individual food products.

[0003] Generally, food products containing meat, fish, the like or substitute products for these, petfood, pasta, potatoes may be forced into a desired shape or form and cut via specific forming machines comprising a reciprocating mould plate or a rotating mould drum or a rotating disc provided with mould cavities. In order for these machines to be industrially applicable, especially in terms of economic efficiency, they require much space and have a high degree of complexity. The high degree of complexity is mostly caused due to the different devices within the machines interacting with one another and which must be coordinated with each other. However, these different devices lead to an increased assembly time, possibly higher down times and an increased risk of cross contamination. It is the complexity of these machines and tooling that complicates the cleaning process of the machines and tooling. Additionally, these machines may also be suitable for handling raw food masses, especially meat, beef, veal, fish, chicken, pork or the like, wherein raw food necessaires good cleaning in order to meet the high hygiene standards, wherein any form of cross contamination may have severe consequences. However, an overcomplicated cleaning process, which not only costs more time but also requires a lot of water and cleaning agents, favours these consequences.

[0004] It is therefore the objective of the present invention to provide an apparatus for the production of individual food products with reduced operating expenses and efforts.

[0005] The problem is solved by a production line for producing individual food products from a pumpable food mass comprising a continuous forming device, in particular a shaping device, and a cutting device and a food mass supply means, in particular a food mass pump, for conveying at least one food mass stream through the continuous forming device, in particular the shaping device, to the cutting device, wherein the cutting device is arranged downstream of the continuous forming device, in particular the shaping device, and configured for cutting the at least one food mass stream leaving the continuous forming device, in particular the shaping device, into individual food products.

[0006] According to the invention, the production line for producing individual food products comprises at least one continuous forming device, in particular a shaping device, and at least one cutting device and at least one food mass supply means such as a food mass pump for conveying at least one food mass stream through the forming device, in particular the shaping device. The food mass supply means, particular the food mass pump, can provide a continuous or semi- continuous flow of the pumpable food mass, whereby the at least one food mass stream is conveyed, in particular pumped, through the continuous forming device, in particular the shaping device, to the cutting device. The food mass supply means, in particular the food mass pump, may comprise a grinder, a hopper, a feed screw system, a food mass pump system, a stuffer, etc. The cutting device is arranged downstream of the continuous forming device, in particular the shaping device, wherein the cutting device may cut the food mass stream into the desired sizes or portions of individual food products.

[0007] The inventive production line is advantageous as it requires less space than conventional production lines while simultaneously allowing for an easier cleaning and lower maintenance, due to the simple layout. Also, the amount of water and cleaning agents can be reduced. Even more so, the production line according to the invention faces lower risks of cross contamination.

[0008] Varying the speed of the food mass supply means, particular the pump, may allow for a variation of the residence time of the food mass stream within the continuous forming device, in particular the shaping device. Further, varying speed of the food mass supply means, in particular the food mass pump, may allow for the pressure with which the food mass is pumped through the forming device, in particular the shaping device, to be controlled and / or adjusted. The food mass supply means, particular the food mass pump, may be supplied with a food mass from a grinder, or a mixer, wherein for instance the food mass supply means, in particular the food mass pump, can then force the food mass stream through the continuous forming device, in particular the shaping device.

[0009] Within this application the terms “continuous forming device” and “shaping device” are synonymously used. According to a preferred embodiment of the invention, the production line comprises a food mass transport tube, which is configured to guide the food mass stream through the continuous forming device, in particular the shaping device, and / or from downstream the food mass supply means towards the cutting device. The food mass transport tube may be partially, in particular substantially, comprised by the continuous forming device, in particular the shaping device. The at least one food mass transport tube, which is preferably configured to guide a food mass stream from the food mass supply means, in particular the food mass pump, through the continuous forming device, in particular the shaping device, and towards the cutting device, may have a circular cross-sectional area. The food mass transport tube may extend from the food mass supply means, in particular the food mass pump, to downstream the continuous forming device, in particular the shaping device, wherein the food mass transport tube may extend further than a downstream end of the forming device, in particular the shaping device. The food mass supply means, in particular the food mass pump, may control the residence time of the food mass within the food mass transport tube.

[0010] According to a preferred embodiment of the invention, the at least one food mass transport tube and / or the shaping device is / are at least partially arranged within a temperature adjusting unit, in particular a cooling unit or a heating unit, or in direct contact with at least a part of a temperature adjusting unit, in particular a cooling unit or a heating unit, or arranged close to a temperature adjusting unit, in particular a cooling unit or a heating unit. Thus, advantageously allowing for the cooling of the food mass and / or food mass transport tubes. It may be desirable to cool the food mass transport tubes prior to or after any food mass being pumped through the food mass transport tube. As it is possible that during the conveyance of the food mass through the food mass transport tube, the food mass may be heated up due to the pressure exerted on the food mass via the food mass pump. Further, it may be preferred that the food mass transport tube is designed as short as possible in order to minimize any heat creation due to the acting forces, e.g. friction within the food mass stream or friction of the food mass stream with the wall of the food mass transport tube, within the food mass. Advantageously, these may be counteracted via the cooling unit. Even further, the at least one food mass transport tube may be made up of a metal or metal compound or the like with a thermal conductivity of at least 50 wherein this may allow for good thermal conductivity and a more efficient cooling.

[0011] According to a preferred embodiment of the invention, the production line comprises a mass flow divider arranged between the food mass supply means, in particular the food mass pump, and the continuous forming device, in particular the shaping device, for dividing the food mass stream delivered by the food mass supply means, in particular the food mass pump, into multiple food mass streams, wherein the continuous forming device, in particular the shaping device, is configured for the passage of said multiple food mass streams and the cutting device is configured for cutting said multiple food mass streams. The flow divider may split up the food mass stream leaving the food mass supply means, in particular the food mass pump, into multiple food mass streams. Preferably, each of these multiple food mass streams is arranged within a food mass transport tube, wherein the food mass transport tubes can lead the food mass streams through the continuous forming device, in particular the shaping device. More preferably, the flow divider may split the food mass stream into two, three, four, five or more multiple food mass streams within food mass transport tubes, which are arranged substantially parallel in the direction of conveyance of the food mass stream. The cutting device is favourably arranged downstream the continuous forming device, in particular the shaping device, wherein the cutting device may cut one or more of the multiple flow streams leaving the continuous forming device, in particular the shaping device, simultaneously. The flow divider may allow to process an increased amount of food mass in the continuous forming device, in particular the shaping device, and thus, results in a higher food product output of the product line.

[0012] In a further preferred embodiment of the invention, the food mass flow divider is at least partially or totally comprised by the continuous forming device, in particular the shaping device. The food mass flow divider may be made of the same material as the food mass transport tubes. It may be especially desirable to cool or heat the food mass flow divider. For this, the food mass flow divider may be cooled or heated by a further temperature adjusting unit, in particular a further cooling unit or further heating unit, in particular arranged between the food mass supply means, in particular the food mass pump, and the forming device, in particular the shaping device, or by the temperature adjusting unit, in particular cooling unit or heating unit, within the forming device, in particular the shaping device. Dividing the food mass stream into a plurality of food mass streams via the food mass flow divider may exert more forces onto the food mass, which may then create more heat within the food mass streams. Thus, it can be advantageous to cool the food mass within the food mass flow divider via cooling the food mass flow divider.

[0013] According to a preferred embodiment of the invention, the continuous forming device, in particular the shaping device, comprises at least one forming insert, in particular shaping insert, assigned to each of the at least one food mass streams, wherein the forming insert, in particular the shaping insert, is configured for forming, in particular shaping, the contour and internal structure of the food mass stream. The forming insert, in particular the shaping insert, is preferably arranged within the continuous forming device, in particular the shaping device, in particular in the food mass transport tube. Favourably, there may be more than one forming insert, in particular more than one shaping insert, for each food mass stream, allowing for more forming, in particular shaping, of the contour and internal structures or texture of the food mass stream. It is conceivable, that the forming inserts in particular shaping inserts, may vary for different food mass streams and / or food mass transport tubes. Advantageously allowing for different contoured and internally structured food products to be produced simultaneously. The food mass stream may be forced through the forming device, in particular shaping device, via the pressure exerted by the food mass supply means, in particular the food mass pump. Depending on the conveyance speed of the food mass supply means, in particular the food mass pump, the pressure, with which the food mass stream is forced through the forming insert in particular the shaping insert, may be controlled and thus, the contour and internal structure of the food mass stream downstream of the forming insert, in particular the shaping insert may be controlled to an extent. The internal structure of the food mass stream may influence the texture of the food product. The forming inserts, in particular the shaping inserts, are preferably arranged substantially perpendicular to the direction of conveyance of the food mass stream. A forming insert, in particular a shaping insert, may cover the entire cross-sectional area of the food mass transport tube, so that the food mass stream has to pass through the forming insert, in particular the shaping insert. Additionally or alternatively, a further forming insert, in particular a further shaping insert, may be placed between the food mass supply means, in particular the food mass pump, and the food mass flow divider. The further forming insert, in particular the further shaping insert, may be part of the forming device, in particular shaping device, if the food mass flow divider is comprised by the forming device, in particular shaping device, or may be part of the food mass supply means.

[0014] In a preferred embodiment of the invention, the forming insert(s), in particular the shaping insert(s), is / are removably attachable to the food mass transport tube. The forming insert, in particular the shaping insert, may easily be removed from the continuous forming device, in particular shaping device, in order to allow for easy cleaning of the apparatus. Preferably, the one or more food mass transport tube(s) comprises at least one opening, in particular slits, which are configured to receive at least one forming insert, in particular at least one shaping insert. The forming insert, in particular shaping insert, may comprise a removal lip or the like, wherein the removal lip extends out of the food mass transport tube, when the forming insert, in particular shaping insert, is positioned within the food mass transport tube. The removal lip may allow for easy removal of the forming insert, in particular shaping insert, and advantageously easier cleaning of the forming insert, in particular shaping insert, and the food mass transport tube. According to a preferred embodiment of the invention, the continuous forming device, in particular shaping device, comprises at least one forming insert, in particular shaping insert, that comprises multiple openings, in particular holes, for guiding the food mass in a structured manner. The food mass supply means, in particular the food mass pump, may force the food mass streams through the multiple openings, in particular holes, of the forming insert, in particular shaping insert. This may advantageously allow the food mass stream to be divided into smaller streams, which may be forced together again downstream of the forming insert, in particular shaping insert. Preferably, the multiple openings, in particular holes, within the forming inserts, in particular shaping inserts, are arranged substantially parallel to the direction of conveyance of the food mass stream. The food mass stream, downstream of the forming insert, in particular shaping insert, and upstream of the cutting device, may be pressed together by the walls of the food mass transport tube in combination with the pressure exerted by the food mass supply means, in particular the food mass supply pump. However, a structure or texture may advantageously remain within the food stream downstream of a forming insert, in particular shaping insert, which then after cutting, may still be present within the food product. Preferably, the multiple openings, in particular holes, are arranged in a concentric pattern. A concentric pattern in combination with a circular cross-section of the food mass transport tube may create a homogenous structure for a downstream cross-sectional area of the food mass stream. Favourably, a food mass transport tube may comprise two or more forming inserts, in particular shaping inserts, wherein these may be arranged substantially parallel to one another and more favourably contain different patterns and / or different numbers of the multiple openings, in particular holes. This may allow for more texture or inner structure to be brought into the food mass stream. Additionally or alternatively, if the forming device, in particular shaping device, comprises a plurality of different food mass transport tubes, it may be desirable to provide each of the food mass transport tubes with the same or different forming inserts and the same or different number of forming inserts, in particular shaping inserts.

[0015] In a preferred embodiment, the forming insert, in particular the shaping insert, is arranged inside the continuous forming device, in particular shaping device, preferably at a distance from an upstream inlet of the food mass transport tube of the continuous forming device, in particular shaping device. This allows the forming insert, in particular shaping insert, to be arranged closer to the cutting device than to the food mass supply means, in particular the food mass pump, and / or food mass flow divider. Advantageously, the structure or contoured or textured food mass downstream of the forming insert, in particular shaping insert, is not greatly pressed together again so that the food mass stream may keep the given structure or texture or contour created by the forming insert(s), in particular shaping insert(s). The greater the length of the food mass transport tube between the forming insert, in particular shaping insert, and the cutting device, the higher the chances are that the internal structure or texture of the food mass stream is affected by the walls of the food mass transport tube and / or the pressure exerted by the food mass pump. However, it may still be advantageous that the forming insert, in particular shaping insert, is placed at least at a small distance from the cutting device, so that the structured or contoured or textured food mass stream may be pressed together just enough to be holding together even after being cut by the cutting device.

[0016] According to a preferred embodiment of the invention, the production line comprises a strippermeans, preferably a strip per- pl ate, which is configured to cooperate with the forming insert, in particular the shaping insert, in order to prevent clogging of the forming insert, in particular clogging of holes of the forming insert. The stripper-means may be movable relative to the forming insert, in particular shaping insert. The stripper-means may comprise holes that are aligned with holes of the forming insert, in particular shaping insert. The holes in the forming insert, in particular shaping insert, preferably have an edge facing the stripper-means that is sharp in order to facilitate cutting of fibers by the stripper-means when the stripper-means is moving relative to the forming insert, in particular shaping insert.

[0017] Preferably the stripper means is a stripper plat. Alternatively, the stripper means can be a rotating knife which runs against the forming insert, in particular shaping insert at the entry side of the holes.

[0018] According to a preferred embodiment of the invention, a funnel-shaped compression element is arranged directly downstream the forming insert, in particular shaping insert. Thereby, the food mass exiting the insert may be compressed. Separate columns of food mass exiting the insert may be forced together. Thereby binding of the food mass downstream the insert may be supported.

[0019] According to a preferred embodiment of the invention, the cutting device comprises a cutting means, in particular one or more cutting blades or one or more cutting knives or a cutting wire. The cutting device may comprise one or more cutting blades or cutting wires to cut one food mass stream or multiple food mass streams, whereby preferably each cutting blade or cutting wire is controlled individually and configured for cutting a food mass stream leaving the forming device, in particular shaping device, into individual food products. This advantageously allows for different simultaneous portioning, e.g. thickness of the cut portion, for the multiple food mass streams. If multiple food mass streams are present, such embodiment allows for producing individual products with different thicknesses from a first food mass stream as compared to products from a second food mass stream. E.g., such embodiment allows for producing a diversity of product structures with different thickness in a convenient way. The cutting device is arranged downstream of the forming device, in particular shaping device, and the cutting means is, in particular the cutting blade or cutting wire, is preferably configured to cut the food mass stream(s) substantially perpendicular to the direction of conveyance of the food mass stream.

[0020] According to a preferred embodiment of the invention, the production line comprises a freezing apparatus for freezing the individual food products arranged downstream the cutting device. The freezing apparatus may freeze the individual food products, whereby the individual food products may pass through the freezing apparatus via a conveyor belt. The freezing apparatus can be arranged downstream of the cutting device. The finished individual product may thus be frozen in order to improve the shelf-life of the individual food products.

[0021] In another preferred embodiment of the invention, the freezing apparatus is configured for shock-freezing the individual food products. Advantageously allowing for the preservation of appearance, vitamins, minerals and taste of the individual food products.

[0022] According to a preferred embodiment of the invention, the production line comprises a packaging apparatus for packaging the individual food products arranged downstream of the cutting device. The individual food products may be portioned, counted or weighed prior to being filled into a package or within a package for the individual food products, wherein after the packaging apparatus air-tightly seals the portioned, counted or weighed individual food products. Preferably, the packaging apparatus is arranged downstream of the freezing apparatus.

[0023] In a further preferred embodiment of the invention, the food production line comprises an inline temperature measurement device configured to measure the outside temperature but more preferably the core temperature of at least one food mass stream. Preferably, the food production line comprises an infrared-camera, IR-camera, arranged to detect the core temperature and / or core temperature distribution at the end face of the food mass stream at the time an individual product has just been separated from the food mass stream by the cutting device. Alternatively, the inline temperature measurement device may include a temperature probe or an apparatus to determine dielectric properties of the food mass stream, e.g., the relative permittivity of the food mass stream.

[0024] Preferably, the food production line is configured to control the operation of the food mass supply means, in particular the food mass pump, and / or of the forming device, in particular shaping device, as a function of the determined core temperature and / or core temperature distribution. E.g., the conveyance speed of the food mass stream may be adapted to not exceed a predetermined target core temperature and / or predetermined target core distribution. It is conceivable that the pressure exerted onto the food mass streams via the food mass supply means, in particular the food mass pump, may have a direct effect on the core temperature of the food mass stream.

[0025] According to a preferred embodiment of the invention, the food mass supply means comprises or is a rotary vane pump. This embodiment comes with the advantage, that damage to the food mass can be reduced.

[0026] Another aspect of the invention is a method for producing individual food products from a pumpable raw food mass, wherein a food mass supply means, in particular a food mass pump, conveys, in particular pumps, a raw food mass stream, in particular a raw meat stream, through a downstream continuous forming device, in particular a shaping device, to a cutting device, wherein the cutting device cuts the food mass stream into individual food products. The raw food mass may be any of beef, veal, fish, chicken, pork or the like, whereby it is especially desired to avoid cross-contamination. Further, handling raw food masses necessaires high hygiene standards, wherein a simple cleaning process makes it easier to comply with these standards. Even further, cooling the raw food masses may be advantageous, especially in regard to the shelf-life.

[0027] The same advantages and technical effects that have been described in regard to the production line according to the invention may be achieved with the method for producing individual food products. The preferred embodiments and features described in connection with the production line according to the invention can also be applied individually or in combination to the method for producing individual food products according to the invention.

[0028] According to a preferred embodiment of the invention, the pumpable food mass comprises raw meat and the individual food products are hamburger patties. The structure or texture of the hamburger patties may be created via the continuous forming device, in particular the shaping device, and / or forming inserts, in particular shaping inserts.

[0029] According to a preferred embodiment of the invention, in a cleaning step following the production of the individual food products, the food mass supply means, in particular the food mass pump, and the continuous forming device, in particular shaping device, are rinsed by a cleaning fluid. The cleaning fluid is preferably a mixture of water and cleaning agents. If any forming inserts, in particular shaping inserts, were used in the production step, these may be taken out prior to the cleaning step and are cleaned in a separate cleaning step. In a cleaning step the food mass supply means, in particular food mass pump, may be switched on in order to allow for better cleaning. Any rotating parts within the food mass supply means, in particular food mass pump, may be cleaned more efficiently. If the production line comprises a flow divider and / or food mass transport tubes, these may also be rinsed by the cleaning fluid.

[0030] Another aspect of the invention is a combination of a forming insert, in particular a shaping insert, which is configured for forming, in particular shaping, the contour and internal structure of a food mass stream, wherein the insert comprises multiple hole; and a stripper-means, preferably a stripper-plate, which is configured to cooperate with the forming insert, in particular the shaping insert, in order to prevent clogging of the holes of the forming insert. The combination may prevent clogging of a forming device, in particular shaping device, of a production line.

[0031] These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.

[0032] Fig. 1 is a schematic representation of an embodiment of the production line according to the invention;

[0033] Fig. 2a is a schematic representation of an embodiment of a flow divider;

[0034] Fig. 2b is a schematic representation of another embodiment of a flow divider;

[0035] Fig. 3a a schematic representation of an embodiment of a forming insert, in particular shaping insert;

[0036] Fig. 3b a schematic representation of a production line dedicated to process whole muscle material comprising the insert shown in Fig. 3a;

[0037] Fig. 4a a schematic representation of an embodiment of a forming insert, in particular shaping insert;

[0038] Fig. 4b a schematic representation of an individual food product formed by an embodiment of the inventive method; Fig. 5 a schematic representation of a detail of a production line according to an embodiment of the invention dedicated to process material comprising fibrous components;

[0039] Fig 6a a schematic representation of a first embodiment of the inventive combination of a forming insert, in particular shaping insert, and a stripper-means;

[0040] Fig. 6b a schematic representation of a second embodiment of the inventive combination of a forming insert, in particular shaping insert, and a stripper-means;

[0041] Fig. 7a a schematic representation of a third embodiment of the inventive combination of a forming insert, in particular shaping insert, and a stripper-means in a state wherein the holes of the forming insert, in particular shaping insert, and the stripper-means are aligned;

[0042] Fig. 7b the embodiment of Fig. 7a in a state wherein the holes of the stripper-means are offset with respect to the holes of the forming insert, in particular shaping insert;

[0043] Fig. 8a / b schematic representations of a production line according to an embodiment of the invention;

[0044] Fig. 9a a schematic representation of cutting means according to a first embodiment of the invention;

[0045] Fig. 9b a schematic representation of cutting means according to a second embodiment of the invention;

[0046] Fig. 10a / b schematic representations of two embodiments production lines according to the invention including a temperature adjustment device to cool or heat the food mass stream;

[0047] Fig. 11a / b schematic representations of an embodiment of a forming insert, in particular shaping insert, comprising a supply of marinade or emulsion towards the food mass;

[0048] Fig. 12 a schematic representation of a production line comprising a freezing apparatus and packaging apparatus located after the cutting device. Fig. 1 illustrates a schematic representation of an embodiment of the production line 1 according to the invention. The production line 1 is used for producing individual food products 2’ from a pumpable food mass. For this, the production line 1 comprises a shaping device 5, in particular shaping device, and a cutting device 7and food mass supply means, in particular a food mass supply 3. The food mass supply means, in particular the food mass pump 3, can convey the pumpable raw food mass in the form of a raw meat stream 2 through the continuous forming device 5 to the cutting device 7. Further, the cutting device 7 is configured to cut the food mass stream 2 leaving the continuous forming device 5 into individual food products 2’. Preferably, the cutting device 7 has cutting means 15 such as a cutting blade or a cutting wire in order to cut the food mass stream 2, wherein the blade or the wire are arranged movable in a direction substantially perpendicular to the direction of conveyance of the food mass stream 2. Further, Fig. 1 also shows a forming insert 8, in particular shaping insert, which is comprised by the continuous forming device 5, in particular shaping device.

[0049] For transporting, in particular conveying, the food mass stream 2 through the continuous forming device 5, the production line 1 and / or the continuous forming device 5 comprises at least one food mass transport tube 6. In Fig. 1 the food mass transport tube 6 extends from upstream the continuous forming device 5 to downstream the continuous forming device 5, whereby the transport tube 6 originates at the food mass pump 3 and ends at the cutting device 7. The transport tube 6 shown comprises the forming insert 8, whereby the forming insert 8 is arranged preferably perpendicular to the food mass transport tube 6 and the conveyance direction of the food mass stream 2. The forming insert 8 is arranged inside the continuous forming device 5, at a distance from an upstream inlet of the food mass transport tube 6 of the continuous forming device 5. . The forming insert 8 is arranged close to the cutting device 7. A short length between the forming insert 8 and the cutting device 7 may allow to reduce the pressure on the food mass stream 2. Further, less heat is brought into the food mass stream 2 via inner friction.

[0050] The food mass supply means, in particular the food mass pump 3, as shown in Fig. 1 , may comprise a grinder, a hopper, a feed screw system, a pump system or stuffer in order to be supplied with a pumpable raw food mass’. The food mass supply means, in particular the food mass pump 3, can allow for a continuous or semi-continuous food mass stream 2, as the food mass supply means, in particular the food mass pump 3, exerts a pressure on the stream 2 in order for the mass to be conveyed, in particular pumped, through the continuous forming device 5, in particular the shaping device, and towards the cutting device 7. Prior to entering the food mass pump 3, a food product or food mass may be processed by a grinder into a pumpable raw food mass. Fig. 2a shows a schematic representation of an embodiment of a mass flow divider 4, wherein the mass flow divider 4 may be used to split up a single food mass stream 2 into multiple food mass streams 2. Preferably, the continuous forming device 5, in particular the shaping device, is configured for the passage of said multiple food mass streams 2 and even more preferably, the cutting device 7 is also configured to cut the multiple food mass streams 2. In Fig. 2 the flow divider 4 is illustrated, wherein the flow divider 4 has an inlet for the food mass stream 2, via a food mass transport tube 6, and a plurality of outlets for the food mass streams 2 via multiple food mass transport tubes 6, in this case five transport tubes 6. The food mass transport tubes 6 for the outlet of the flow divider 4 may be arranged substantially parallel. This is visualized in the front view of the cross-section of the mass flow divider 4. It is especially desired to arrange the flow divider 4 between the food mass pump 3 and the continuous forming device 5. Further, the front view of the multiple food mass transport tubes 6 shows that it may be desired to have a round cross-sectional area. It may lead to easier cleaning, as no remainders of the food mass stream 2 may get stuck at more difficult to clean edges or corners. However, additionally advantageous the form of the food product 2’ is mainly influenced by the form of the food mass transport tube 6, so that the cross-sectional area of the food mass transport tube 6 may be any desired form, e.g. polygonal, oval or any other desired shape, in order to influence the contour of the individual food product 2’. The continuous forming device 5 is preferably configured to comprise the multiple of food mass transport tubes 6, whereby the continuous forming device 5 may also partially or fully comprise the mass flow divider 4.

[0051] Fig. 2b shows another schematic representation of an embodiment of a mass flow divider 4, wherein the mass flow divider 4 may be used to split up a single food mass stream 2 into multiple food mass streams 2. Preferably, the continuous forming device 5 is configured for the passage of said multiple food mass streams 2 and even more preferably, the cutting device 7 is also configured to cut the multiple food mass streams 2. In Fig. 2b the flow divider 4 is illustrated, wherein the flow divider 4 has an inlet for the food mass stream 2, via a food mass transport tube 6, and a plurality of outlets for the food mass streams 2 via multiple food mass transport tubes 6, in this case five transport tubes 6.

[0052] Fig. 3a depicts a shaping-insert 8 that can be included in shaping device 5, in particular in a food mass transport tube 6, in order to influence or create a desired internal structure or texture of an individual food product 2’. In this depicted embodiment the shape is a nugget shape.

[0053] Fig. 3b depicting a production line 1 according to the invention which production line is dedicated to produce individual food products 2’ out of a food stream 2. Contrary to pre-grind meat used for shaping products, there is a demand, especially for certain chicken products, for whole muscle individual products 2’. This can be achieved by remaining the meat structure as much as possible during the shaping process. Consequently, this will result in individual food products 2’ comprising relatively large pieces of meat and preferably as less as possible different pieces of meat. From importance is that the food mass supply means 3 will not damage the meat structure and this can be achieved by using a pump system such as a rotary vane pump as depicted in Fig. 3b which pump will remain the meat structure as much as possible.

[0054] Fig. 4a depicts a forming insert 8, in particular shaping insert, that can be included in the continuous forming device 5, in particular the shaping device, in particular in a food mass transport tube 6, in order to influence or create a desired internal structure or texture of an individual food product 2’. The insert 8 is in particular suitable for processing material comprising fibrous components such as beef, turkey or the like. The forming insert 8 comprises multiple openings, in particular holes, whereby the food mass stream 2 is forced through the multiple openings, in particular holes, due to the pressure exerted onto the food mass stream 2 via the food mass supply means, in particular the food mass pump 3.

[0055] Fig. 4b depicts an individual food product 2’, which may be produced by the production line 1 according to an embodiment of the invention, wherein food mass stream 2 comprises preferably material comprising fibrous components such as beef, turkey or the like. In this case the individual food product 2’ is a hamburger patty, wherein this illustrates an internal structure that can be produced via the production line 1 . The internal structure may be influenced by the forming insert 8, in particular shaping insert, wherein the cross-sectional area of the hamburger patty is influenced by the cross-section of the food mass transport tube 6 or the shaping insert 8.

[0056] When producing a food product, for instance a round-shaped hamburger as depicted in Fig. 4b, the meat fibers within the food mass stream 2 tend to orient themselves in the direction of the food mass stream. Therefore it is preferable that the food mass transport tube 6 and consequently the flow of the food mass stream 2 will be perpendicular to the moving direction of cutting means 15 of the cutting device 7 and consequently perpendicular to a bottom 22 of the individual food product 2’. In that case, during cooking wherein the fibers will shrink in their length direction, an even shrinkage relative to the bottom 22 of the food product 2’ will take place resulting in no deformation of the outer shape, a round shaped burger will remain round after cooking. To support the orientation of the fibers perpendicular to the movement of the cutting means 15 of the cutting device 7 and the bottom 22 of the individual food product 2’, the food mass stream within introduction area 9 of shaping insert 8 will be split up and will be forced to flow through the holes 18 of the shaping insert 8. Consequently, small columns of the food mass will be discharged from the holes 18 and the food product will comprise, relative to its bottom, vertical columns of meat through its thickness and beside remaining the shape after cooking another advantage of this structure is that after cooking a reduced shrinkage of the outer shape will take place which will maintain the size of the burger. Further, when cooked, the structure results in an improved tender bite and enhanced juiciness of the burger. An advantage is also that the vertical columns of meat through its thickness also promote more effective heat transfer, leading to faster cooking and to a more consistent internal temperature.

[0057] Fig. 5 depicts an embodiment wherein the shaping device 8 and the cutting device 7 are located close to each other within one and the same apparatus. Goal is to reduce the conveying length of food mass stream 2 in order to reduce the pressure supplied by food mass supply means 3 in order to convey the food mass stream 2. This embodiment is advantageous when processing a food mass comprising fibrous components such as beef, turkey and the like and in particular advantageous when the food mass comprises a relatively high percentage of fat such as with beef. The shorter the distance between food mass supply means 3, shaping device 8 and cutting device 7, the less accumulation of fat against the inner walls will occur, such as against the inner walls of the food mass transport tube 6. This will prevent that accumulation of fat against the inner wall will result in blocking the conveying of food mass.

[0058] Fig. 6a and 6b depict two embodiments comprising a combination of stripper-means 17, shaping insert 8 and a to the shaping insert connected cylinder 10 / 11. In case of processing food material comprising fibrous components, it is common to use a food mass which is already pre-ground in order to ease the conveying of food mass through the holes in shaping insert 8. Preferably, the holes 18 in shaping insert 8 are distributed equidistantly over the surface area in order to prevent an individual food product 2’ with different density areas. The holes can have any cross-section for instance round holes or holes with a rectangular or square crosssection. Preferably the edge of each hole at the inlet is not rounded but sharp in order to facilitate cutting of fibers by the stripper-means 13. The holes can have a uniform cross-section over their entire length. The holes may have all the same length and / or the same cross-section. However, the holes can also vary in length and / or in their cross-section.

[0059] The food mass is conveyed via the food mass supply means 3 in the form of a food mass stream 2, in particular a raw food mass stream 2, towards the introduction area 9 of shaping insert 8 within shaping device 5. The food mass stream will be forced to flow through the holes 18. Consequently, columns of the food mass will be discharged from holes 18. While the columns of food mass 12 exiting holes 18 are at a distance from each other due to the pitch of the holes in the shaping insert there is no or minimum binding between the individual columns of food mass 12 and when directly cutting the columns of food mass when exiting the holes to create a food product, this food product will fall apart.

[0060] In the embodiment shown in Fig. 6a, a funnel-shaped compression element, here a compression cylinder 10, is arranged directly downstream the shaping insert 8. Due to the sloping inner wall in section 10’ the columns of food mass 12 are forced to move towards each other such that they come together and form a stable bundle of columns of food mass that does not fall apart as a whole. The length of section 10’ and the slope of section 10’ can be chosen depending on the food application. In section 10” over a certain length in the flow direction of the food mass the final outer dimension of the food mass will be shaped in the inner wall of compression cylinder 10. After passing section 10’ and section 10” a stable and coherent bundle of food mass columns with a defined outer dimension and outer shape is created.

[0061] In the embodiment shown in Fig. 6b, no funnel-shaped compression element is used. Columns of food mass 12 are created within the holes of stripper-plate 17 and / or within section 18’ (optional) of shaping insert 8. Section 18” comprises sloping and widening holes. During conveying of the food mass through these holes in shaping insert 8 the food mass will expand. The expansion should be such that the columns of food mass 12 exiting holes 18 will come together and form a stable bundle of columns of food mass that does not fall apart as a whole. The length of section 18” and the slope of section 18” can be chosen depending on the food application.

[0062] In retaining cylinder 11 over a certain length in the flow direction of the food mass the final outer dimension of the food mass will be shaped in the inner wall of retaining cylinder 11. After passing retaining cylinder 11 a stable and coherent bundle of food mass columns with a defined outer dimension and outer shape is created.

[0063] Fig. 7 depicts an embodiment comprising stripper-means 17. In case of production line 1 processing food material comprising fibrous components such as beef, turkey or the like it is common to use a food mass which is already pre-ground, this to prevent clogging of holes 18 in the shaping insert 8 and to be able to convey the food mass through these holes 18 in the shaping insert 8 with a reduced pressure. However, due to the fibers within the food mass it is hard to prevent that the holes 18 in the shaping insert 8 will be clogged during a production run. In an embodiment to prevent clogging, stripper-means 17 are introduced at the entry side of the holes 18 of the shaping insert 8. The stripper-means are implemented as a strip per- pl ate 13 driven by an actuator 14. The movement and frequency of movement of stripper-plate 13 is mainly depending on the clogging of the holes 18 by the fibers. In case the fibers will hardly tend to block the holes the stripper-means will be used in a certain time frequency. However, when a certain application and application speed results in rapid blocking of the holes 18 in the shaping insert 8 the stripper-means 13 need to strip the fibers much more frequently.

[0064] Alternatively, the stripper-means may be implemented as a rotating knife which runs against the shaping insert at the entry side of the holes. While a rotating knife will be located within shaping insert 8 and within the area wherein the food mass is flowing, it will block the food mass flow.

[0065] Fig. 7a depicts the stripper-plate 13 such that the holes in the stripper-plate correspond to the holes in the shaping insert 8. Food mass can pass the stripper-plate 13 as well as holes 18 within shaping inset 8.

[0066] Fig. 7b depicts the stripper plate 13 wherein holes 18 of shaping insert 8 are blocked, no food mass can enter. The strip per- pl ate has only made a short stroke. Depending on the food application and the application speed the stroke could even be shorter as long as there is no clogging of the holes 18. The movement of the actuator 14 driving the stripper-plate 13 can be controlled via a control unit which control unit receive signals from one or more sensors, preferably position sensors.

[0067] Preferably the strip per- pl ate 13 is relatively thin to prevent clogging of food mass. Preferably, the edge of the holes at the entry side of the strip per- pl ate 13 are rounded in order to ease the conveying of food mass through the stripper-plate. In another preferred embodiment the holes within the strip per- pl ate are slightly larger than the holes within shaping insert 8. The stripperplate 13 needs to be forced against the surface at the entry side of shaping insert 8 by pressure means 19 (not depicted in detail).

[0068] In another embodiment the stripper-means can also be used as a valve. Knowing the speed of movement of the food mass stream 2 and knowing the desired thickness of the final food product, the control unit can calculate when the stripper-means 13 should stop the entrance of food mass in holes 18. In such an arrangement a pre-determined amount of food mass will pass the holes 18 in the shaping insert 8 and a pre-determined amount of food mass will be within the final individual food product 2’. Fig. 8a and 8b show a schematic representation of a production line comprising a flow divider which line is dedicated to process material comprising fibrous components Fig. 8a depicts a production line 1 comprising a flow divider 4 resulting in multiple food mass streams 2. Fig 8b depicts a similar production line 1 comprising a flow divider 4 which production line 1 is dedicated to process material comprising fibrous components. After flow divider 4 the food mass stream 2 conveys through food mass transport tube 6, shaping device 5 and cutting device 7 in order to end up with individual food products 2’ on conveyor 25.

[0069] Fig. 5 depicts a cutting device 7 comprising a reciprocating cutting blade 15 in order to cut the food mass stream 2. This cutting blade is suitable for cutting a variety of food products. However, in an embodiment wherein the food mass stream comprising fibrous components such a blade and especially the reciprocating movement of the blade which will result in pressing the knife through the entire fiber structure is challenging and will, depending on the food mass properties, probably not cutting the fibers correctly.

[0070] Fig. 9a depicts an embodiment of a cutting blade 15 which is rotatably connected to an actuator 16 and will be moved around the axis of rotation. The cutting blade can be moved continuously with a certain rotational speed by means of actuator 16. During the cutting process the rotational speed can be increased to increase the cutting energy. During the continuous movement of conveying of the food mass stream 2 an almost vertical cut surface is produced. This embodiment is suitable in case the production line 1 comprises a single food mass stream 2 and processes a food mass comprising fibrous components. This embodiment is not suitable for a production line 1 that comprises multiple food mass streams 2 due to the complexity of multiple rotating cutting blades 15 and the lack of proper orientation of the individual food products 2’ on conveyor 25.

[0071] Fig. 9b depicts a preferred embodiment for a production line 1 that comprises multiple food mass streams 2 and which production line processes a food mass comprising fibrous components. This embodiment comprises two cutting blades 15 provided with holes which preferably have the same size as the final outer shape of the individual food product 2’ and which are driven via actuator 16. In case the food mass stream 2 needs to be cut, both cutting blades 15 making a reciprocating movement opposite to one another and thereby cutting the food mass stream 2. The speed wherewith the food mass stream is moving when leaving the shaping insert 8 together with the time difference between the food mass stream leaving the shaping insert and the moment of cutting the food mass stream will determine the thickness of the individual food products. Fig. 10a and Fig. 10b depict embodiments of the production line 1 according the invention, wherein a temperature adjusting unit 20 is arranged downstream food mass supply means 3 and upstream cutting device 7. Depending on the temperature of the food mass supplied to the hopper of the food mass supply means, temperature adjusting unit 20 can be a cooling device to cool the food mass stream. This can be advantageously in order to stabilize the food mass stream 2 to improve the quality of the formed food product and to improve cutting of the food mass stream into individual food products 2’. In practice it is common that the food mass 2 supplied to the hopper will be within the correct process temperature range to obtain stable individual food products.2’. In an embodiment wherein the food mass stream 2 comprises a relatively high percentage of fat such as beef and wherein the individual food product 2’ is for instance a hamburger patty it can be advantageously to provide heating means downstream of supply means 3 and upstream of cutting means 15. Heating means can for instance be in the form of liquid heating or trace heating and will maintain or raise the temperature of the food mass transport tube 6 and / or shaping insert 8. Preferably food mass transport tube 6 and / or shaping device 8 will be covered with thermal insulation to retain heat. The heat generated by the heating means will keep the fat within the food mass stream in a molten state such that it will not adhere against the inner wall(s) and that no blocking of food mass will occur. In case of food mass transport tube 6 it can be sufficient to heat the tube such that only fat in the food mass stream flowing closely to the inner wall of tube 6 will be in a molten state such that a relatively thin layer of molten fat at the outer circumference of food mass stream 2 occurs which prevents adhesion against the inner wall. The temperature adjusting unit 20 can be arranged over at least a part of the length of food mass tube 6. Alternatively, the heating device 20 may span over the whole length of the food mass tube 6.

[0072] Fig.10a depicts an embodiment of production line comprising a single food mass stream 2. Fig.10b depicts an embodiment of a production line comprising multiple food mass streams 2 wherein the heating device 20 surrounds at least a part of the length of mass flow divider 4, so that multiple food mass streams (2) are heated by the heating device 20.

[0073] Fig. 11a and 11 b depict an embodiment wherein marinade or emulsion will be supplied towards the food mass within the multiple holes 18 of shaping insert 8 via introduction area 26.

[0074] Fig. 11b is based on the cross section according to the arrows in Fig.11 a. Marinade, emulsion, etc. will flow towards food mass tubes 27 which tubes guide the food mass through holes 18 towards the discharge end of shaping insert 8. Holes 18 are provided with cross holes 28 which will supply marinade, emulsion, etc. towards the food mass. The number of cross holes 28 determines how much marinade, emulsion etc. will be picked- up by the food mass. The number of cross holes in the circumference of the tube 27 can be varied and further the length of the tubes can be varied such that additional cross holes can be provided. To further improve the pick-up of marinade, emulsion, etc. the entire inner space 29 can be put under pressure. Fig. 12 shows an embodiment of the production line 1 , whereby the production line 1 comprises at least a freezing apparatus 30 and a packaging apparatus 31 which are both arranged downstream of the cutting device 7. In an embodiment wherein the individual food product 2’ is a hamburger patty it is common to freeze the individual food products 2’ directly after the cutting device. Optionally but not preferable the food product can be flattened after the cutting device 7 and then frozen. Only after cutting the individual food products 2’ may be further processed to the freezing apparatus 30 and / or the packaging apparatus 31. The different apparatus 30, 31 may be connected via conveyor belts, allowing for the individual food products to be transported from one to the other apparatus.

[0075] List of reference signs:

[0076] 1 - production line

[0077] 2 - food mass stream

[0078] 2’ - individual food products

[0079] 3 - food mass supply means, food mass pump

[0080] 4 - flow divider

[0081] 5 - continuous forming device, shaping device

[0082] 6 - food mass transport tube

[0083] 7 - cutting device

[0084] 8 - forming insert, shaping insert

[0085] 9 - introduction area in shaping insert

[0086] 10 - compression cylinder

[0087] 11 - retaining cylinder

[0088] 12 - individual columns of food mass

[0089] 13 - stripper-means such as a strip per- pl ate, stripper-knife, etc.

[0090] 14 - actuator strip per- pl ate

[0091] 15 - cutting means.

[0092] 16 - actuator cutting means

[0093] 17 - holes in strip per- pl ate 13

[0094] 18 - holes in shaping insert 8

[0095] 19 - pressure means stripper means 13, strip per- pl ate

[0096] 20 - temperature adjusting unit

[0097] 22 - bottom of individual food product 2’

[0098] 25 - conveyor

[0099] 26 - Introduction area marinade, emulsion, etc.

[0100] 27 - Food mass tube shaping insert 8

[0101] 28 - supply openings for marinade, emulsion, etc.

[0102] 29 - inner space for marinade, emulsion, etc.

[0103] 30 - freezing apparatus

[0104] 31 - packaging apparatus

Claims

Patent claims:

1. A production line (1) for producing individual food products (2’) from a pumpable food mass comprising a continuous forming device (5), in particular a shaping device, and a cutting device (7) and a food mass supply means, in particular a food mass pump (3), for conveying at least one food mass stream (2) through the continuous forming device (5), in particular the shaping device, to the cutting device (7), wherein the cutting device (7) is arranged downstream of the continuous forming device (5), in particular the shaping device, and configured for cutting the at least one food mass stream (2) leaving the continuous forming device (5), in particular the shaping device, into individual food products (2’).

2. A production line (1) according to claim 1 , characterized in that the production line (1) comprises a food mass transport tube (6), which is configured to guide the food mass stream (2) through the continuous forming device (5), in particular the shaping device, and / or from downstream the food mass supply means (3) towards the cutting device (7).

3. A production line (1) according to claim 2, characterized in that the at least one food mass transport tube (6) and / or the continuous forming device, in particular the shaping device (5), is / are at least partially arranged within a temperature adjusting unit, in particular a cooling unit or a heating unit, or in direct contact with at least a part of a temperature adjusting unit, in particular a cooling unit or a heating unit, or arranged close to a temperature adjusting unit, in particular a cooling unit or a heating unit.

4. A production line (1) according to any of the preceding claims, characterized in that the production line (1) comprises a mass flow divider (4) arranged between the food mass supply means, in particular the food mass pump (3), and the continuous forming device (5), in particular the shaping device, for dividing the food mass stream (2) delivered by the food mass supply means, in particular the food mass pump (3), into multiple food mass streams (2), wherein the continuous forming device (5), in particular the shaping device, is configured for the passage of said multiple food mass streams (2) and the cutting device (7) is configured for cutting said multiple food mass streams (2).

5. A production line (1) according to any of the preceding claims, characterized in that the continuous forming device (5), in particular the shaping device, comprises at least one forming insert (8), in particular shaping insert, assigned to each of the at least one foodmass streams (2), wherein the forming insert (8), in particular the shaping insert, is configured for forming, in particular shaping, the contour and internal structure of the food mass stream (2).

6. A production line (1) according to claim 5, characterized in that the forming insert(s), in particular the shaping insert(s) (8), is / are removably attachable to a food mass transport tube (6).

7. A production line (1) according to any of the preceding claims, characterized in that the continuous forming device (5), in particular the shaping device, comprises at least one forming insert, in particular shaping insert, that comprises multiple openings, in particular holes, for guiding the food mass in a structured manner.

8. A production line (1) according to any of claims 5 to 7, characterized in that the forming insert (8), in particular the shaping insert, is arranged inside the continuous forming device (5), in particular shaping device, preferably at a distance from an upstream inlet of the food mass transport tube of the continuous forming device (5), in particular shaping device.

9. A production line (1) according to any of claims 5 to 8, characterized in that the production line (1) comprises a stripper-means (13), preferably a stripper-plate, which is configured to cooperate with the forming insert (8), in particular the shaping insert, in order to prevent clogging of the forming insert, in particular clogging of holes of the forming insert (8).

10. A production line (1) according to claim 9, characterized in that the stripper-means (13) is movable relative to the forming insert, in particular shaping insert.

11. A production line (1) according to any of claims 9 or 10, characterized in that the stripper-means (13) comprises holes that are aligned with holes of the forming insert (8), in particular shaping insert.

12. A production line (1) according to any of claims 5 to 11 , characterized in that a funnel- shaped compression element (10) is arranged directly downstream the forming insert, in particular shaping insert (8).

13. A production line (1) according to any of the preceding claims, characterized in that the cutting device (7) comprises a cutting means (15), in particular one or more cutting blades or one or more cutting knives or a cutting wire.

14. A production line (1) according to any of the preceding claims, characterized in that the production line (1) comprises a freezing apparatus (30) for freezing the individual food products (2’) arranged downstream the cutting device (7).

15. A production line (1) according to claim 14, characterized in that the freezing apparatus (30) is configured for shock-freezing the individual food products (2’).

16. A production line (1) according to any of the preceding claims, characterized in that the production line (1) comprises a packaging apparatus (31) for packaging the individual food products (2’) arranged downstream of the cutting device (7).

17. A production line (1) according to any of the preceding claims, characterized in that the food production line (1) comprises an inline temperature measurement device configured to measure the outside temperature but more preferably the core temperature of at least one food mass stream (2).

18. A production line (1) according to claim 17, characterized in that the food production line (1) is configured to control the operation of the food mass supply means, in particular the food mass pump (3), and / or of the forming device (5), in particular shaping device, as a function of the determined core temperature and / or core temperature distribution.

19. A method for producing individual food products (2’) from a pumpable raw food mass, wherein a food mass supply means, in particular a food mass pump (3), conveys, in particular pumps, a raw food mass stream (2), in particular a raw meat stream, through a downstream continuous forming device (5), in particular a shaping device, to a cutting device (7), wherein the cutting device (7) cuts the food mass stream (2) into individual food products (2’).

20. A method according to claim 19, characterized in that the pumpable food mass comprises raw meat and the individual food products are hamburger patties.

21. A method according to any of claims 19 to 20, characterized in that in a cleaning step following the production of the individual food products (2’), the food mass supply means, in particular the food mass pump, (3) and the continuous forming device (5), in particular the shaping device, are rinsed by a cleaning fluid.

22. A combination of a forming insert (8), in particular a shaping insert, which is configured for forming, in particular shaping, the contour and internal structure of a food mass stream (2), wherein the insert comprises multiple hole; and a stripper-means (13), preferably a stripper-plate, which is configured to cooperate with the forming insert (8), in particular the shaping insert, in order to prevent clogging of the holes of the forming insert (8).

Images