The process of converting vibrated potatoes (factory waste) into fried potatoes with different ingredients

Abstract

The process of converting vibrated potatoes (factory waste) into fried potatoes with various compositions. This product includes various ingredients such as vibrated potatoes, batter, batter powder, wheat flour, starch, frying oil, carboxymethyl cellulose, salt, onion, and breadcrumbs, which are of significant nutritional value.

Description

The process of converting vibrated potatoes (factory waste) into fried potatoes with different ingredients

[0001] The process of converting vibrated potatoes (factory waste) into fried potatoes with various compositions. This product includes various ingredients such as vibrated potatoes, batter, batter powder, wheat flour, starch, frying oil, carboxymethyl cellulose, salt, onion, and breadcrumbs, which are of significant nutritional value.Technical field

[0002] A23L 5 / 00 - A23L 19 / 00Background Art

[0003] Method for producing potato products for finishing fries, processing line and potato products for finishing fries, JP6743127B2.

[0004] In the description of the patent JP6743127B2, it is recommended to use raw materials of a specific type or variety of potatoes to produce the product, which is not the case in my invention. In the invention of JP6743127B2, raw potatoes are used to produce a potato-based product, while in my invention, the product is not produced from raw, healthy and unpeeled potatoes, but from leftover French fries or small pieces,, which are a kind of waste in potato processing factories.

[0005] The steps of the JP6743127B2 patent are peeling - slicing - washing - sorting- washing- boiling or steaming - drying - creating a fried coating on the potato slices - quick freezing - storing at -20 °C- frying the product before serving (in fact, the above invention or the purpose of the above invention is to produce a low-calorie fried product or a food based on potatoes).

[0006] In my invention, firstly, there is no step of peeling-boiling or steaming-drying-washing, and secondly, the raw material of my invention is potato wedges of inappropriate size or leftover French fries or small pieces. In its current design (selection of optional product), like the main and current process of French fries, it recommends separating the appropriate sizes and does not have an idea for small pieces or leftover French fries, while the main subject of my invention and idea is to use the leftover French fries or small pieces to produce a product with an added value and to reduce the potato processing factory waste.

[0007] Appliance and method for cooking potato chips, CN109068891 B

[0008] In the description of the patent CN109068891 B, a kind of tool or household appliance for producing chips and the production method is described, which will reduce the amount of oilabsorption in potato chips by 80%, and in fact, it describes a device with a health-oriented method of producing chips. It is possible to produce low-oil chips by using hot, dry air and low oil, and on the other hand, with this method, the quality of the used oil is more preserved, and in fact, compared to the traditional method of making chips, where thin slices of potatoes are deep fried (frying by submerging food in a hot oil), has the advantage that the oil is not exposed to heat for a long time, and in fact, the food is not cooked with the old oil. The purpose of my invention is to reduce the waste of potato processing factories, not to produce chips or special chips appliances.

[0009] The invention of CN109068891 B is a method and a device or a household appliance for producing low-oil chips, while my invention is not a device, it is a method to reduce the waste by converting small pieces of potato into a higher value-added product.

[0010] A kind of sweet potato waste biscuit and production method thereof, CN103814996B

[0011] In the patent CN103814996B, a type of biscuit has been invented by using sweet potato waste, and the inventor has named the composition of his invention as follows: starchy sweet potato flour, a special type of wheat flour, cream, egg, xylitol, milk powder - nanometer calcium - polylysine, and with this invention, the inventor introduces a biscuit or a functional sweet product containing a lot of fiber and rich in various vitamins and minerals such as potassium and calcium, which is good for humans health. By referring to the fact that the invention is sugar-free, it is recommended for diabetics as well. In the detailed description of the invention, 3 kg of sweet potato flour is soaked with 3 L of 1 to 0.3% citric acid for 5 to 10 minutes, and then its moisture is removed using centrifugal force, and then it is microwave-dried for 30 to 60 minutes to drop its moisture content to below 5%. Then, the resulting is ground and force-passed through a 300 mesh sieve to result a powder with 48 microns’ particle size. The powder is, then, blended with wheat flour, cream, milk powder, and etc., which is followed by addition of other ingredients such as egg. Finally, using a pastry funnel, the resulting mixture is squeezed on a tray in the desired shape and transferred into the pre-heated oven (with a temperature of 135 to 155 °C) to bake. However, the temperature of oven should be adjusted to 185 to 195 °C during the baking, and after 10 to 30 minutes the tray or biscuit is removed from the oven to cool at room temperature before serving the biscuit.

[0012] In general, the raw materials and the main purpose of my invention is to reduce the waste of ordinary potatoes and not sweet potatoes, while sweet potatoes and ordinary potatoes are two different agricultural products, despite having almost the same name, and the amount of their production and cultivation in the whole world is quite different.

[0013] Use of potato waste in feeding livestock and poultry

[0014] Potato is a product whose energy is almost equal to corn and can be used as a source of energy. This research was conducted in order to review the possibility of using potato powder and potato tuber in broiler, livestock and poultry diets. The best food conversion factor was relatedto 30% potato tuber. Raw potatoes have a high nutritional value for fattening male lambs, and its price is related to the high starch content and digestibility of nutrients, as well as its palatability. Various researches have been conducted in the past years, which mostly discussed the use of 2nd grade potatoes for growth and performance characteristics and carcasses of broiler chickens. In general, the use of raw potato powder in the diet of broiler chickens caused a decrease in weight and food conversion ratio. There was no significant difference in carcass efficiency (p>0.05). There was no significant difference in the relative weight of breast, thigh and gizzard (p>0.05), but the percentage of carcass and liver had a significant difference (p<0.05). Also, the relative weight percentage of abdominal fat of broiler chickens increased under the effect of adding potato powder to the diet. Raw potato powder decreased the carcass percentage and increased the liver percentage. Also, the amount of feed consumption in broilers increased under the effect of adding potato powder to the diet. Raw potato powder reduces the yield at a level above 15% of corn replacement for poultry and above 30% of replacement in livestock.

[0015] Preparation of dry potato cubes with long shelf life

[0016] Potato is one of the most important agricultural products, which is consumed as a staple food in many countries due to its valuable protein. Unfortunately, in our country, a large percentage of the produced potatoes is wasted during storage. By turning this valuable product into products with higher added value and easier maintenance, it is possible to reduce waste, increase the variety of consumption methods and create high added value. Among these products, we can mention dried potato pieces. The drying method and the type of preparation steps before drying, including: removal of enzymes, immersion in different solutions, use of primary dehydration methods, use of microwave or water absorbent solutions, drying temperature, etc. have a great impact on the quality of the final product and it can affect important features such as the color of the product, the ease and amount of reabsorption of water, the taste of the product, the amount of oil absorption during frying, the disintegration of the product during cooking, and other features. In this article, the proper method of producing dry potato cubes is introduced. In the introduced process, in addition to thermal drying, different preparation methods are used, such as removing enzymes with hot calcium chloride solution and absorbent solutions. In this way, the produced product has the characteristics of absorbing water and maintaining the right color and taste, and its oil absorption during frying is also reduced. This instruction recommends calcium chloride concentration of 0.4%, moisture absorbent solution of 2% and drying temperature of 50°C for drying potato cubes.

[0017] Analysis of heat and mass transfer during the process of frying potato wedges

[0018] In this research, heat and mass transfer in the frying process was comprehensively investigated. For this purpose, potato slices were fried in a fryer equipped with a K-typethermocouple thermocouple system at three different oil temperatures of 145, 160, and 175 °C for 60, 120, 180, and 240 seconds. Changes in the central temperature of the product during frying were recorded using a T-type thermocouple connected to a data recording device in the computer. The moisture and oil content of the samples were also measured at any time and temperature of the process. Heat and mass transfer parameters were estimated using dimensionless temperature and concentration ratio diagrams and experimental equations with the aim of developing a realistic estimation method. The results showed that Biot number of mass transfer (Bim), mass transfer coefficient and effective penetration of moisture increased significantly with increasing oil temperature. In the regression models, with the increase in the temperature of the bed, the equilibrium content of the oil decreased in infinite time, and it can be said that the absorption of oil decreases with the increase in temperature. On the other hand, a linear relationship between the kinetic constants of water reduction and oil absorption was observed, which confirms the effect of partial drying pretreatment in reducing the kinetic constant of oil absorption. This effect can be due to the compression of the food matrix and as a result, the reduction of oil penetration after leaving the fryer during cooling. Finally, with the increase of the process temperature, the Biot number of heat transfer (Bih), displacement heat transfer coefficient and thermal conductivity of the product decreased significantly.

[0019] The difference between the mentioned articles and my product is very different in terms of the work process and the final product. By presenting this project, I tried to use potato waste optimally and at the same time, it is a product that has high nutritional value.Summary of invention

[0020] The present invention describes a process for converting vibrated potatoes into fried potatoes with various compositions to prevent potato waste in food production factories. For each kilogram of French fries produced, 2.5 kilograms of potatoes are required, with the remaining potato material, including peels, starch, and small pieces, becoming waste. In the production of every ton of French fries, 10 to 12 percent of small semi-fried potatoes are also produced, which are separated at the end of the production line and used for other purposes such as animal feed, falafel, and potato patties. However, the consumption of these by-products is less than their production, making it economically unviable. This waste is known as vibrated potatoes, which are sold at a lower price than raw potatoes. This invention aims to convert vibrated potato waste into fried potatoes with various compositions, maintaining similar nutritional value to French fries.

[0021] The product is first stored in cold storage and then processed using a food industry mixer with the help of a nugget former to shape the potatoes into various forms. Theformed potatoes are placed on a stainless steel conveyor belt and pass through several stages: initial breading, batter mixing, and finally, breading or frying. After these stages, the product goes through a quick-freezing machine and an output conveyor, where it is weighed using a scale. The final steps include packaging, date stamping, and transferring to cold storage (below zero) for the final product's preservation.Technical problem

[0022] Nowadays, people prefer to buy semi-prepared potatoes produced in factories at home. Because all they need to do is re-fry the potatoes in oil. As a result, it significantly saves their time. In addition, these potatoes have uniform shapes and a crispy texture. The demand for frozen semifried potatoes has increased in recent years, especially considering the high supply and popularity of fried potatoes in fast foods and restaurants.

[0023] Semi-prepared potatoes or French fries refer to a type of potato that, through a series of activities including washing, peeling, cutting, and frying, becomes semi-prepared. By placing it in a freezing chamber, the temperature of the potato is drastically reduced. This way, when this product reaches the customer, they can quickly prepare a ready and delicious meal and enjoy eating it.

[0024] The beginning of the production process in the semi-prepared potato production machine is related to the feeder or feeding belt. In this section, the potatoes in the warehouse enter the machine to separate stones and soil from them. After separation, the next part is cleaning or washing. In this section, the machine starts to remove soil and wash the potatoes so that the potatoes, without any contamination, move towards the peeling section. Now it's time for the peeling section, which works like centrifuges. The potatoes rotate like centrifuges, and the potato peel is removed by spraying water. At the end of the peeling process, the potatoes are evaluated in terms of appearance and lack of fungus or any defects on an inspection belt. After the potatoes are prepared for production, it's time to cut them. In this section, the potatoes pass through the blades installed in the machine under pressure to be cut evenly.

[0025] The thickness of the cuts is variable and can be different depending on your needs. To remove the starch in the potatoes, they go to the blancher where the starch is sterilized. To reach the frying stage, the water in the potatoes must first be removed. Therefore, the dehydration process is initially done by powerful fans, and then the remaining moisture in the potatoes is completely removed by placing them in a hot environment. Now, the potatoes are ready for frying. The potatoes are poured into a special container and fried for about 30 seconds. After frying, the oil in the potatoes is extracted. After this process and before packaging the potatoes, they must first be cooled and frozen. Therefore, in the first stage, the temperature of the potatoes is reduced to about 40 degrees, and then in another section, their temperature is reduced to below zero. After completing this process, we reach the final stage of the semi-prepared potato production process, which is the packaging process. The semi-prepared potatoes are poured into a special plastic andthen packaged. To store these products, semi-prepared and packaged potatoes are placed in cold storage at a temperature of about minus 20 degrees Celsius.

[0026] To produce each kilogram of French fries, 2.5 kilograms of potatoes are needed, and the remaining potatoes in the form of peels, starch, and small pieces of potatoes are wasted. In exchange for producing each ton of French fries, 10 to 12 percent of small semi-fried potatoes are also produced, which are separated at the end of the production line and used for other purposes such as animal feed, falafel production, and potato patties, but the consumption rate is less than the production rate of this item, and in fact, it does not have a profitable market or production. It is called vibrated potatoes, and its selling price is less than the price of raw potatoes. In my plan, I have tried to offer fried potatoes with various combinations from vibrated potato waste, which has a nutritional value similar to French fries.Solution of problem

[0027] By presenting this process, a new product from vibrated potatoes has been created. Based on this, necessary research on the chemical formula of this product has also been conducted. Additionally, various combinations such as vibrated potatoes, wheat flour, starch, frying oil, carboxymethyl cellulose, salt, onion, and breadcrumbs have been used in this product, which is of great nutritional value.

[0028] Vibrated Potatoes: In the French fries production process, some potato pieces, due to breakage or parts related to the potato edges that do not have a suitable size, are separated from the main product by the sorter device using vibration, which is referred to as vibrated potatoes.

[0029] Batter: Mix 2 kilograms of batter powder with 4 kilograms of potable water at a temperature of +2 to +5 degrees Celsius.

[0030] Batter Powder: Obtained from the complete mixture of 80.32% flour, 4.73% refined salt, 20.10% whey powder, 0.14% red pepper, 0.21% black pepper, 0.21% white pepper, 3.39% starch, and 0.58% sugar. Flavorings can be added to it as desired (Table 1 ).

[0031] CMC: Carboxymethyl cellulose is used in a wide range of food products such as ice cream, biscuits, cakes and pastries, macaroni, beverages, bread, and sauces.

[0032] The process of preparing the new product from vibrated potatoes is as follows:

[0033] Receiving vibrated potatoes and storing them in cold storage.

[0034] Transferring vibrated potatoes to the above-zero cold storage 15 to 24 hours before production to increase the temperature of the vibrated potatoes and soften them.

[0035] Grinding the whole peeled frozen onions needed for production.

[0036] Weighing and transferring the ingredients into the mixer and mixing for 180 seconds.

[0037] Removing the ingredients from the mixer and transferring them to the meat grinder.

[0038] Grinding the ingredients with a 6 mm mesh.

[0039] Transferring the ingredients into the former and shaping the ingredients.

[0040] Passing the ingredients through the conveyor belt and directing them to the fryer or initial breading machine.

[0041] At this stage, if we intend to produce the product without a breading coating, we directly guide it into the fryer. Otherwise, the following steps are performed:

[0042] Guiding the product into the initial breading machine and coating the product with a thin layer of wheat starch.

[0043] Passing the product through the battering machine and coating the product with a thin layer of batter.

[0044] Passing the product through the breading machine and coating the product with breadcrumbs.

[0045] Passing the product through the fryer for 35 to 40 seconds at 180 degrees Celsius (the oil inside the fryer should be palm or frying oil).

[0046] Removing the product from the fryer and directing it to the quick-freezing machine using a conveyor belt.

[0047] Removing the product from the quick-freezing machine and packaging it in desired weights.

[0048] In the production line, a series of machines (former, conveyor belt, initial breading machine, battering machine, breadcrumb machine, fryer, conveyor belt, quick-freezing machine, output conveyor belt) are arranged in a linear sequence, and the conveyor belt speed of all devices from the beginning to the end of the line is synchronized. The necessary amount of starch is placed inside the initial breading machine for proper operation; the batter is placed inside the battering machine; breadcrumbs are placed inside the breadcrumb machine; and special frying oil is poured into the fryer, which is then turned on to heat the oil to +180 degrees Celsius. The quick-freezing machine is turned on to reach -30 degrees Celsius, and now it is time to transfer the materials into the former and turn on all the production line machines to start production. If breading coverage is not required for the product, the initial breading machine, battering machine, and breadcrumb machine can be omitted from the line. Additionally, even when producing a breaded product, the initial breading stage can be optionally skipped.

[0049] For the breaded product, the following formulation is considered for the mixer (Table 2):

[0050] Vibrated potatoes, frozen onions, CMC, wheat starch, salt, white breadcrumbs, oil, water, butter flavoring, fresh garlic, powdered cheese flavoring, yellow mozzarella cheese

[0051] For the non-breaded product, the following formulation is considered for the mixer (Table 3):

[0052] Frozen semi-fried potato pieces (vibrated potatoes), drinking water, wheat or potato starch powder, granulated white breadcrumbs, soy or sunflower oil, frozen onions, CMC, saltAdvantage effects of invention

[0053] T ransforming Vibrate potato into a suitable value-added product

[0054] High nutritional value

[0055] Customer friendly

[0056] Its consumption demand is more than Vibrate potato production

[0057] Reducing the cost of producing French friesBrief description of drawings

[0058] [Fig. 1 ]: percentage of compounds

[0059] [Fig. 2]: Product with breadcrumb coating

[0060] [Fig. 3]: Product without breadcrumb coating

[0061] [Fig. 4]: The process of producing various products from Vibrate potatoesDescription of embodiments

[0062] [Fig. 1 ]: percentage of compounds

[0063] [Fig. 2]: Product with breadcrumb coating

[0064] [Fig. 3]: Product without breadcrumb coating

[0065] [Fig. 4]: The process of producing various products from Vibrate potatoesExamples

[0066] After placing the desired product in cold storage (sub-zero for raw materials), it is shaped using a food industry mixer (similar to meat industry mixers like nugget mixers) with the help of a former or nugget shaper into various shapes. It is then placed on a stainless steel conveyor belt. In the first stage, it passes through the initial breading machine, followed by the battering mixer, and finally the breadcrumb machine or fryer. The product then goes through the quick-freezing machine and the output conveyor belt, where it is weighed using a scale, and finally, it is packaged, date- stamped, and sent to the sub-zero cold storage for storing the final product.

[0067] Required machinery for the production line include:

[0068] Sub-zero cold storage for raw materials

[0069] Production hall and GMP for nugget-like products

[0070] Above-zero cold storage

[0071] Meat industry-specific trolley

[0072] Stainless steel food industry mixer (similar to meat industry mixers like nugget mixers)

[0073] Suitable meat grinder for frozen materials (similar to meat grinders used in meat and nugget factories)

[0074] Former or nugget shaper

[0075] Stainless steel conveyor belt

[0076] Initial breading machine

[0077] Batter mixer

[0078] Battering machine

[0079] Breadcrumb machine

[0080] Fryer

[0081] Stainless steel conveyor belt

[0082] Quick-freezing machine (IQF)

[0083] Output conveyor belt

[0084] Scale

[0085] Packaging machine

[0086] Date-stamping machine

[0087] Sub-zero cold storage for the final productIndustrial applicability

[0088] This potato product is available in various designs and shapes, that's why it is used in the attention of food manufacturing factories or companies that distribute packaged and frozen food.

Claims

Claims

1. The process of converting vibrated potatoes (factory waste) into fried potatoes with various compositions. This product includes various ingredients such as vibrated potatoes, batter, batter powder, wheat flour, starch, frying oil, carboxymethyl cellulose, salt, onion, and breadcrumbs, which are of significant nutritional value.

2. According to claim 1 , to prepare the batter, 2 kilograms of batter powder is mixed with 4 kilograms of potable water at a temperature of +2 to +5 degrees Celsius.

3. According to claim 2, to prepare the batter powder, a complete mixture of flour, refined salt, whey powder, red pepper, black pepper, white pepper, starch, and sugar is used, with flavorings added as desired.

4. According to claim 3, the process of preparing the new product from vibrated potatoes (with or without breading) is as follows:Receiving vibrated potatoes and storing them in cold storage.Transferring vibrated potatoes to above-zero cold storage 15 to 24 hours before production to increase the temperature of the vibrated potatoes and soften them.Grinding the whole peeled frozen onions needed for production.Weighing and transferring the ingredients into the mixer and mixing for 180 seconds. Removing the ingredients from the mixer and transferring them to the meat grinder.Grinding the ingredients with a 6 mm mesh.Transferring the ingredients into the former and shaping the ingredients.Passing the ingredients through the conveyor belt and directing them to the fryer or initial breading machine.Guiding the product into the initial breading machine and coating the product with a thin layer of wheat starch.Passing the product through the battering machine and coating the product with a thin layer of batter.Passing the product through the breadcrumb machine and coating the product with breadcrumbs.Passing the product through the fryer for 35 to 40 seconds at 180 degrees Celsius.Removing the product from the fryer and directing it to the quick-freezing machine using a conveyor belt.Removing the product from the quick-freezing machine and packaging it in desired weights.

5. According to claim 4, the following formulation is considered for the mixer for the breaded product: vibrated potatoes, frozen onions, CMC, wheat starch, salt, white breadcrumbs, liquid oil, water, butter flavor, fresh garlic, powdered cheese flavor, and yellow mozzarella cheese.

6. According to claim 5, the following formulation is considered for the mixer for the non-breaded product: frozen semi-fried potato pieces (vibrated potatoes), drinking water, wheat or potato starch powder, granulated white breadcrumbs, soy or sunflower oil, frozen onions, carboxymethyl cellulose, and salt.

Images