The conversion of vibrate potatoes (factory waste) into the original fried potatoes

Abstract

While producing French fries in factories, a number of potato pieces were broken or there were parts related to the edge of the potatoes, which did not meet the desired size. These are sorted out and are separated from the main product by the sorter machine due to vibration action. These are called Vibrate potatoes. In this invention, converting the Vibrate potatoes (factory waste) into fried potatoes using different ingredients. In general, the main purpose of my invention is to reduce the waste of potatoes in factories.

Description

[0001] Description

[0002] Title of invention:

[0003] The conversion of Vibrate potatoes (factory waste) into the original fried potatoes

[0004] Technical field

[0005] A23L5 / 10

[0006] Background Art

[0007] Method for producing potato products for finishing fries, processing line and potato products for finishing fries, JP6743127B2.

[0008] 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.

[0009] 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).

[0010] 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.

[0011] Appliance and method for cooking potato chips, CN109068891 B

[0012] 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 oil absorption 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.

[0013] 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.

[0014] A kind of sweet potato waste biscuit and production method thereof, CN103814996B

[0015] 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 - nanometre calcium - polystyrene, 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.

[0016] 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.

[0017] Use of potato waste in feeding livestock and poultry

[0018] 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 related to 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.

[0019] Preparation of dry potato cubes with long shelf life

[0020] 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.

[0021] Analysis of heat and mass transfer during the process of frying potato wedges

[0022] 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-type thermocouple 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.

[0023] 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.

[0024] Summary of invention

[0025] The present invention is the description of how to produce high quality fried potatoes using Vibrate potatoes with adding different ingredients. To produce each kilogram of French fries, 2.5 kg of potatoes are needed, and the rest of the potatoes are wasted in the form of skin, starch and small pieces of potatoes. Therefore, the purpose of this invention was to reduce this waste by converting them to a new value-added product. In my project, it has been tried to produce fried potatoes adding different ingredients to Vibrate potatoes, and to produce a new product with nutritional value comparable to the original French fries. All ingredients plus Vibrate potatoes are weighed based on recipe and transferred to the mixer to mix. Then, the mixture is molded in different shapes as desired. Then, the molded outcomes are pre-dusted, glazed, breaded, deep-fried, frozen, and finally packaged at desired weights. After printing the production and expiry dates on packaged products, they are stored at cold room (- 20°C).

[0026] Technical problem

[0027] Nowadays, people prefer to buy semi-prepared potatoes produced in the factories. Because all they need to do is simply to re-fry them partially in their home. Therefore, there would be a significant time-saving. In addition, the resulting fried potatoes will have a uniform shape and a crispy texture. The demand for frozen semi-fried potatoes has increased over recent years, especially considering the high supply capacity and popularity of fried potatoes in the fast food shops and restaurants.

[0028] Semi-prepared potatoes or French fries are a type of processed potatoes that gets semi-prepared after undergoing a series of processes including washing, peeling, slicing, frying, and finally freezing by using a freezing compartment. Now, they are ready to be used for preparing a delicious meal in a very short time and enjoying it.

[0029] The semi-prepared potato production machine begins with a feeder or feeding belt. In this part, the potatoes, which have been stored in the warehouse, are fed into the machine to separate off the stones and soil. Next step is cleaning and washing. In this section, the machine starts to dust and wash the potatoes so that the potatoes are sent to the peeling section without any contamination. The next section is the ling and steam peeler to peel the cleaned potatoes. In this machine, the peeling process is centrifuge-like. The potatoes are centrifuged, and their skins are removed by wetting them. At the end, the potatoes are evaluated on a strip called the inspection strip, in terms of appearance and the absence of fungus or any blackness. Now, they are ready to be sliced. In this part, the potatoes are forced through the installed blades in the machine to slice them all uniformly. The thickness of the slices is variable and can be different as desired.

[0030] In order to extract the potatoes starch, the potatoes undergo starch sterilization in the blancher. Before frying stage, the potatoes need to get dried. Hence, they are firstly exposed to the strong fans to dehydrate, and then are stored in a hot environment to remove all the remained moisture completely. Now, the potatoes are ready for frying. To fry the potatoes, they are transferred on a special dish and are fried for about 30 seconds. Then, their extra oil is dripped off. Now, they are ready for packaging, but they need first to be cooled and frozen. To do so, in the first stage, the potatoes temperature is brought to about 40 °C, and then, it is reduced to subzero temperature before packaging. The semi-prepared potatoes are packaged using special plastic bags. Finally, the resulting products are stored at -20 °C.

[0031] To produce each kilogram of French fries, 2.5 kg of potatoes are needed, and the rest are wasted in the form of skin, starch, and small pieces of potatoes. Also, 10-12% fine semi-fried potatoes are yielded per production of one ton French fries. These fines are separated at the end of the production line and used for other purposes such as animal feed, falafel and potato cutlet preparation, and etc. But, reworking them in these ways still lacks the economic interest. These fines are called Vibrate potatoes and their selling price is much lower than the price of purchased raw potatoes, if sold as they are. In my project, I have tried to produce the fried potatoes with the nutritional value similar to the original French fries using Vibrate potatoes in mixture with other different ingredients. Solution of problem

[0032] Applying this process, a new product has been prepared using Vibrate potatoes, on the basis of the necessary researches, which have been conducted on its chemical formula. In addition to Vibrate potatoes, different ingredients such as wheat flour, starch, frying oil, Carboxymethyl cellulose, salt, onion, and breadcrumbs have also been used to formulate the new product, which are very important in terms of adding nutritional value.

[0033] Vibrate potatoes: while producing the French fries, a number of potato pieces are separated from the original product by the sorting machine due to breakage or the potato edges that do not meet the desired size. These are so-called Vibrate potatoes.

[0034] Glaze or batter: result of mixing 2 kg of batter powder with 4 kg of drinking water at the temperature of 2 to 5 °C.

[0035] Glaze powder or batter powder: result of mixing the following ingredients: wheat flour with high bran extraction 80.32%, refined salt 4.73%, whey powder 10.20%, red pepper powder 0.14%, black pepper powder 0.21 %, white pepper powder 0.21 %, starch 3.39% and white sugar 0.58%, and a pinch of flavorings as desired (Table 1). CMC: Carboxymethyl cellulose is used in a wide range of foods such as ice cream, biscuits, cake, pasta, cookies, drinks, bread and sauce.

[0036] How to prepare a new product using Vibrate potatoes:

[0037] 1- Receiving the Vibrate potatoes and keeping them in the cold room (-18 °C).

[0038] 2- Transfer the Vibrate potatoes to the cold room (> 0 °C) for 15 to 24 hours prior to production, in order to raise the temperature of the Vibrate potatoes and soften them.

[0039] 3- All the peeled and frozen onions needed to produce the new product is ground.

[0040] 4- Weighing and transferring the ingredients into the mixer and mixing them for 180 seconds.

[0041] 5- Transferring the resulted mixture to a meat grinder.

[0042] 6- Grinding the mixture using a 6 mm mesh grinder.

[0043] 7- Molding the meat grinder outcome.

[0044] 8- Conveying the molded products directly to the deep fryer, if we intend to produce a fried product without coating, otherwise, the following steps are performed.

[0045] 9- The product is directed into the pre-dusting machine, where it is coated by a thin layer of wheat starch.

[0046] 10- The product is passed through a WetCoater machine or battering machine and coated by a thin layer of batter.

[0047] 11- The product is passed through a breading machine and coated by a layer of breadcrumbs.

[0048] 12- The product is passed through a deep fryer for 35 to 40 seconds at the temperature of 180 °C (the oil inside the deep fryer should be palm or frying type oil).

[0049] 13- Conveying the fried products to the quick freezing machine or IQF.

[0050] 14- Packaging the frozen products at desired weights. In the production line, the set of machines (former, wire belt conveyor, pre-dusting, battering, breading or Crumb Master, fryer, wire belt conveyor, quick freezing or IQF, and final conveyor belt) are arranged linearly in mentioned order, and their processing speeds are all adjusted. Before start, the pre-dusting machine is filled by starch, the Wet Coater machine or_battering machine is filled by batter, breading machine is filled by breadcrumbs, and fryer is filled by special frying oil and is set to get pre-heated to 180 °C. The quick freezing machine is set to reach -30 °C to -40 °C. Worth noting that, using pre-dusting machine is optional if breading is performed. Now, the production line is ready to produce the new product. But, if only simple fried products without coating are intended then the machines including pre-dusting, WetCoater machine or battering machine, and breading can be removed.

[0051] To produce a product coated by breadcrumbs, the following ingredients are needed (Table 2).

[0052] Vibrate potatoes or leftover French fries or small pieces, frozen onion, CMC, wheat starch, salt, white breadcrumbs, vegetable oil, drinking water, butter flavor, fresh garlic, cheese flavor, and yellow mozzarella cheese.

[0053] To produce a product without coating by breadcrumbs, the following ingredients are needed (Table 3). leftover French fries or small pieces (Vibrate potatoes), drinking water, wheat or potato starch, sunflower or soy oil, frozen onion, CMC, and salt.

[0054] Advantage effects of invention

[0055] 1. Transforming Vibrate potato into a suitable value-added product

[0056] 2. High nutritional value

[0057] 3. Customer friendly

[0058] 4. Its consumption demand is more than Vibrate potato production

[0059] 5. Reducing the cost of producing French fries

[0060] Brief description of drawings

[0061] Fig.01: percentage of compounds

[0062] Fig.02: Product with breadcrumb coating

[0063] Fig.03: Product without breadcrumb coating

[0064] Fig.04: The process of producing various products from Vibrate potatoes Description of embodiments

[0065] Fig.01: percentage of compounds

[0066] Fig.02: Product with breadcrumb coating

[0067] Fig.03: Product without breadcrumb coating

[0068] Fig.04: The process of producing various products from Vibrate potatoes

[0069] Examples

[0070] After being placed in a cold room (below zero for raw materials) by a food industry mixer (similar to a meat industry mixer such as nugget), the desired product is shaped into different shapes with the help of a nugget former, then it is placed on a steel conveyor belt. In the first stage, the primary flour machine, then the glaze mixer machine, and finally the bread machine or fryer go through the stages of product production one after the other. Then it is weighed on the fast freezing device and the output conveyor device with the help of a scale. Finally, it is packed, dated and referred to the cold room (below zero) to store the final product.

[0071] Machines required for the production line, including: cold storage below zero raw materials, hall and GMP production of products similar to nugget, cold storage above zero, trolley, mixer, Meat grinder suitable for frozen ingredients (similar to the meat grinder of meat and nugget factories) grinder, former, conveyor wire belt, pre-duster, batter mixer, wet coater, Crumb Breading Machine, Fryer, conveyor wire belt, IQF, conveyor, Weighing scale, packing machine, female date machine, sub-zero refrigerator for the final product.

[0072] Industrial applicability

[0073] 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 foods.

Claims

ClaimsWhat would be claimed:Claim 1 : converting the Vibrate potatoes (factory waste) into fried potatoes using different ingredients. In this product, various ingredients are used, such as or leftover French fries or small pieces (Vibrate potatoes), batter or batter powder, wheat flour, starch, frying oil, carboxymethyl cellulose, salt, onion and breadcrumbs, which contribute to the nutritional value of the final product.Claim 2: According to the claim 1 , while producing French fries in factories, a number of potato pieces were broken or there were parts related to the edge of the potatoes, which did not meet the desired size. These are sorted out and are separated from the main product by the sorter machine due to vibration action. These are called Vibrate potatoes. Claim 3: According to the claim 1 , in order to prepare batter, 2 kg of batter powder is mixed with 4 kg of drinking water (2-5 °C).Claim 4: According to the claim 1 , in order to prepare batter powder, the following ingredients are mixed: wheat zero flour, refined salt, whey powder, red pepper powder, black pepper powder, white pepper powder, starch, sugar and flavorings.Claim 5: How the new product using Vibrate potatoes (with or without coating) is produced: Receiving the Vibrate potatoes and storing them in a cold room. Transferring the Vibrate potatoes to the cold room (> 0 °C) for 15 to 24 hours before starting the production process, in order to raise the temperature of the Vibrate potatoes and soften them. Receiving the frozen peeled onions. Weighting and transferring all the ingredients to the mixer and mixing them for 180 seconds. Transferring the mixture to a meat grinder. Grinding the mixture using 6 mm mesh grinder. Molding the ground mixture by former. Conveying the former outcomes to the deep fryer or pre-dusting stage. Coating the fried outcomes by thin layer of wheat starch in pre-dusting step. Coating the pre-dusted outcomes by thin layer of batter in Wet Coater machine or battering machine. Breading the outcomes with breadcrumbs in breading machine. Frying the breaded outcomes in deep fryer for 35 to 40 seconds at temperature of 180 °C. Freezing the fried products in quick freezing machine. Packaging the frozen products in desired weights.Claim 6: According to the claim 5, for producing the product with breadcrumb coating, the following ingredients are considered to be mixed: Vibrate potatoes, frozen onions, CMC, wheat starch, salt, white breadcrumbs, vegetable oil, water, butter flavor, fresh garlic, cheese flavor and yellow mozzarella cheese.Claim 7: According to the claim 5, for producing the product without breadcrumb coating, the following ingredients are considered to be mixed: frozen semi-fried potato or the leftover French fries or small pieces (Vibrate potatoes), drinking water, wheat or potato starch, white breadcrumbs, soy oil or sunflower oil, frozen onion, carboxymethyl cellulose and salt.

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