Method of making stuffed burger patties

Abstract

This disclosure provides a method for making stuffed patties, e.g., stuffed burger patties, and a patty preform suited for use in the process. The patty preform can include a patty formulation formed into a first lobe, a second lobe, and a flexible hinge that connects the first and second lobes.

Description

METHOD OF MAKING STUFFED BURGER PATTIESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 652,429, filed May 28, 2024, which is incorporated by reference herein in its entirety.FIELD OF THE INVENTION

[0002] The present disclosure relates to meat products in general. More particularly, it relates to stuffed meat products and to stuffed patties such as stuffed burger patties.BACKGROUND OF THE INVENTION

[0003] Stuffed burgers have been enjoyed for decades. Stuffed burger patties can be stuffed with a wide variety of ingredients to add flavor and / or texture. Examples of known burger stuffings include avocados, Thanksgiving stuffing, olives, and caramelized figs, among many others. Perhaps the most common stuffing is cheese, creating a cheeseburger with the cheese inside the burger patty instead of on top. The generic term for a cheese-stuffed burger is “juicy lucy” or “jucy lucy.”

[0004] Stuffed burgers are complex to form. One must form smaller patties, add the stuffing to one, carefully position the other smaller patty atop the stuffing, and manually squeeze the edges of the two patties together around the entire circumference to seal the stuffing inside. Many recipes require one to manually fold up the rim of one of the smaller patties to receive the stuffing then seal the edge to the other smaller patty; see, e.g., https: / / www.thespruceeats.com / bacon- double-cheese-stuffed-burgers-recipe-335131. Some commercially available burger presses, e.g., the Cuisinart CSBP-200 Stuffed, 4-in-l Burger Press, use a mold to form a lower patty with upturned edges to receive the stuffing so that need not be done by hand. Others suggest making the bottom of the two smaller patties a little larger than the other one then folding the edges of the bottom one around the edge of the upper one; see, e.g., https: / / www.reddit.eom / r / Cooking / comments / 199exp / first_post_on_rcooking_cheese_filled_bur gers / . Particularly in light of increasing labor costs, those labor-intensive recipes are likely to be too time-consuming and expensive for many casual dining and quick-service restaurants to offer stuffed burgers on their menus.SUMMARY OF THE INVENTION

[0005] This disclosure provides an ingenious method for making stuffed patties, e.g., stuffed burger patties, and a patty preform suited for use in the process. The patty preform includes a patty formulation formed into a first lobe, a second lobe, and a flexible hinge that connects the first and second lobes. The hinge may have a length that is between 0.5 and 3 times a thickness of the second lobe adjacent the hinge.

[0006] In one method of making a stuffed patty, a patty preform and a stuffing are conveyed on a first conveyor. The patty preform has a first lobe, a second lobe, and a flexible hinge that connects the first and second lobes. The stuffing is carried by an upper surface of the first lobe. A leading portion of the first lobe is lowered from the first conveyor to a second conveyor such that a weight of the first lobe pulls downwardly on the hinge. A surface of the second lobe is juxtaposed with the stuffing and the upper surface of the first lobe. The first and second lobes are compressed against one another such that a portion of the juxtaposed surface of the second lobe adheres to a portion of the upper surface of the first lobe to enclose the stuffing in a pocket of the stuffed patty.

[0007] In another method of making a stuffed patty, a patty preform and a stuffing are conveyed on a first conveyor. The patty preform has a first lobe, a second lobe, and a flexible hinge that connects the first and second lobes, the hinge having a length that is between 0.5 and 3 times a thickness of the first lobe adjacent the hinge. The stuffing is carried by an upper surface of the first lobe. The patty preform comprises ground beef and salt and the stuffing comprises cheese. A leading portion of the first lobe is allowed to descend under gravity from the first conveyor to a second conveyor with a trailing portion of the second lobe still on the first conveyor such that a weight of the first lobe and the stuffing pulls downwardly on the hinge and on a leading portion of the second lobe. A surface of the second lobe is juxtaposed with the stuffing and the upper surface of the first lobe by folding the hinge to flip the second lobe. A periphery of the upper surface of the first lobe and a periphery of the juxtaposed surface of the second lobe are compressed against one another such that the peripheries adhere to enclose the stuffing in a pocket of the stuffed patty.BRIEF DESCRIPTION OF THE FIGURES

[0008] The present invention will now be described in detail with reference to the following figures, in which like numbers among the figures indicate like elements:

[0009] Figure l is a top view of a patty preform in accordance with the disclosure.

[0010] Figure 2 is a side view of the patty preform of Figure 1.

[0011] Figure 3 is a schematic overview of a manufacturing system that may be used to manufacture stuffed patties.

[0012] Figure 4 is a perspective view an interface between first and second conveyors in the manufacturing system of Figure 3.

[0013] Figures 5-7 provide a series of schematic side views illustrating how a patty preform may be folded to create a stuffed patty.

[0014] Figure 8 is a schematic side view of an assembled, unpressed patty.

[0015] Figure 9 is a top view of a finished stuffed patty.

[0016] Figure 10 is a cross-sectional view of the stuffed patty of Figure 9.DETAILED DESCRIPTION

[0017] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one skilled in the art to which this invention belongs.

[0018] As used herein, the term “patty” refers to a quantity of a patty formulation, e.g., meat or meat analogue, in a shape that has a thickness that is less than the shape’s diameter, if circular, or both the length and width of the shape. A “patty preform” is a quantity of meat or meat analogue that is formed into an initial shape that can be manipulated to form the shape of the burger patty. A “stuffed patty” refers to a patty that has a stuffing at least partially enclosed in the meat or meat analogue. The terms “burger patty,” “burger patty preform,” and “stuffed burger patty” refer to a patty, patty preform, or stuffed patty, respectively, having a size and shape suitable for eating in sandwich form, e.g., a hamburger.

[0019] As used herein, the term “meat analogue” refers to compositions that mimic the general appearance, flavor, texture, mouthfeel, and / or nutritional content of natural animal meat but contain less than 50 percent by weight (wt%) of tissues or cells from a whole animal or an in vitro culture of such tissues or cells. Some desirable meat analogues are animal-free, i.e., are free of animal tissues or cells. The rest or all of the meat analogue can include non-meat proteins such as plant-based proteins (e.g., pea protein, soy protein), fungal-based proteins (e.g., mycoproteins), insect proteins, or combinations thereof. Meat analogues typically also include other ingredients, such as fats, texturizers, colors, and flavors, to better mimic the intended meat. A variety of such meat analogue products are widely commercially available.Burger Patty Preforms

[0020] Figure 1 shows a top view of a patty preform 10 in accordance with an aspect of the invention. Figure 2 shows a side view of the patty preform 10 of Figure 1. The patty preform 10 includes a first lobe 20, a second lobe 40, and a flexible hinge 60. The first lobe 20 has a leading edge 22, a trailing edge 24, and lateral edges 26 extending between the leading and trailing edges 22, 24. The first lobe 20 has an upper surface 30 and an external surface 36 spaced from one another by a thickness Tl. The upper and external surfaces 30, 36 are shown as being parallel so the thickness Tl is substantially constant, but the thickness may vary from one location to another if so desired. The first lobe 20 has a length LI at the maximum distance between its leading edge 22 and its trailing edge 24 and a width W1 at the maximum distance between the lateral edges 26, 26.

[0021] The first lobe’s upper surface 30 includes a peripheral region 32 that extends around a central region 34. As explained below, the central region 34 is adapted to carry a portion of stuffing or “stuffing mass” 80. The peripheral region 32 should provide sufficient surface area to adequately adhere to a peripheral region 52 of a second lobe’s confronting surface 50, mentioned below. In stuffed patties having a stuffing that melts or otherwise becomes flowable, the width of the peripheral region 32 is desirably sufficient to form a seal that provides an enclosure for the stuffing that limits leaking of the stuffing through the seal. The peripheral region 32 may have a width, i.e., a distance between the outer periphery of the first lobe 20 and the central region 34, that is between 5% and 40%, e.g., 7-33%, of the greater of the length LI and the width Wl. Desirably, the width of the peripheral region 32 is 8-20%, preferably 10-15%, of the greater of the length LI and the width W 1. For stuffed patties (90 in Figures 9 and 10) that are generally circular, for example, the peripheral region 32 of the first lobe 20 may be 0.25-1.5 inches, 0.3-1.25 inches, 0.5-1.5 inches, 0.6 inches-1 inch, or 0.4-0.6 inches. For a stuffed burger patty having a diameter of 3-5 inches, the peripheral region 32 may be 0.5-1.5 inches or 0.6 inches-1 inch. A peripheral region having a width of about 0.75 inches has worked well for a 5-inch-diameter stuffed 0.75 inches burger.

[0022] The second lobe 40 has a leading edge 42, a trailing edge 44, and lateral edges 46 extending between the leading and trailing edges 42, 44. The second lobe 40 has an upper or confronting surface 50 and an external surface 56 spaced from one another by a thickness T2. The upper and external surfaces 50, 56 are shown as being parallel so the thickness T2 is substantially constant, but the thickness may vary from one location to another if so desired. The second lobe40 has a length L2 at the maximum distance between its leading edge 42 and its trailing edge 44 and a width W2 at the maximum distance between the lateral edges 46, 46.

[0023] The second lobe’s confronting surface 50 includes a peripheral region 52 that extends around a central region 54. As explained below, the peripheral region 52 should provide sufficient surface area to adequately adhere to the peripheral region 32 of the first lobe’s upper surface 30. In stuffed patties having a stuffing that melts or otherwise becomes flowable, the width of the peripheral region 52 is desirably sufficient to form a seal that provides an enclosure for the stuffing that limits leaking of the stuffing through the seal. The peripheral region 52 may have a width, i.e., a distance between the outer periphery of the second lobe 40 and the central region 54, that is between 5% and 40%, e.g.,7-33%, of the greater of the length L2 and the width W2. Desirably, the width of the peripheral region 52 is 8-20%, preferably 10-15%, of the greater of the length L2 and the width W2. For stuffed patties that are generally circular, for example, the peripheral region 52 of the second lobe 40 may be 0.25-1 inch, 0.3-1.25 inches, 0.5-1.5 inches, 0.6 inches-1 inch, or 0.4-0.6 inches. For a stuffed burger patty having a diameter of 3-5 inches, the peripheral region 52 may be 0.5-1.5 inches or 0.6 inches-1 inch. A peripheral region having a width of about 0.75 inches has worked well for a 5-inch-diameter stuffed ground beefburger.

[0024] The width of the peripheral region 32 of the first lobe’s upper surface 30 and the peripheral region 52 of the second lobe’s upper surface 50 may be the same. This can be useful if the first lobe 20 and second lobe 40 have generally the same shape and dimensions as in the patty preform 10 shown in Figures 1 and 2. If the lobes 20, 40 have different shapes or dimensions, the widths of the lobes’ peripheral regions 32, 52 can differ. Preferably, the peripheral region of the larger lobe is wider than the peripheral region of the smaller lobe to ensure the peripheral regions 32, 52 overlap sufficiently to adequately adhere together when the stuffed burger patty is formed.

[0025] The weight of the first lobe 20 and the stuffing mass (80 below) should be greater than the weight of the second lobe 30. If so desired, the weight of the first lobe 20, without the stuffing mass 80, can be greater than the weight of the second lobe 40. This may be accomplished by making a first lobe 20 that has an upper surface 30 larger than the confronting surface 50 of the second lobe 40 and / or a thickness T1 that is greater than the thickness T2 of the second lobe 40.

[0026] The flexible hinge 60 is joined to the first lobe 20 at a leading end 62 and is joined to the second lobe 40 at a trailing end 64. It has lateral edges 66 extending between the first and second lobes 20, 40. The flexible hinge 60 also includes an inner surface 70 spaced from an external surface 72 by a thickness TH. The width WH between the lateral edges 66 may berelatively consistent along the length LH of the flexible hinge 60, but it may be tapered along its length LH, e.g., with a minimum width near the midpoint between the leading and trailing ends 62, 64. The junction between the lateral edges 66 and the trailing edge 24 of the first lobe 20 and the leading edge 42 of the second lobe 40 are shown in Figure 1 as a right angle. If so desired, that junction may include a chamfer or fillet.

[0027] As explained below, the hinge 60 should be long enough to allow the second lobe 40 to flip forward so its confronting surface 50 is juxtaposed with the upper surface 30 of the first lobe. The hinge 60 should be long enough to accommodate the flipping without undue hindrance by the leading edge 42 of the second lobe 40 contacting the trailing edge 24 or upper surface 30 of the first lobe 20.

[0028] The length LH of the hinge 60 may be 0.5-3, 0.5-2, or 0.5-1.5 times the thickness T1 of the first lobe 20 adjacent the hinge 60, e.g., along the width of the leading end 62 of the hinge . One useful patty preform has a hinge with a length LH at least 0.75 times and no more than twice, preferably no more than 1.5 times, the thickness T1 of the first lobe 20. Thus, the length LH of the hinge 60 may be 0.75-1.8, 0.75-1.5, 0.75-1.25, 1-1.5, or 1-1.25 times the thickness T1 of the first lobe 20. If the thickness T1 of the first lobe 20 is not uniform, those relative measurements of the length LH of the hinge 60 and the thickness T1 of the first lobe would apply to the thickness of the first lobe 20 adjacent the hinge.

[0029] The first lobe 20, second lobe 40, and hinge 60 of the patty preform 10 could be formed separately and joined together, e.g., by pressing them together. Preferably, though, the patty preform 10 is integrally formed from a patty formulation, e.g., a meat or meat analogue. In one commercially useful process described below, the patty preform 10 is formed by extruding a mass of the patty formulation through a die having the desired shape. Integrally forming the patty preform is preferred as it promotes structural integrity of the connection of the flexible hinge 60 to the first and second lobes 20, 40.

[0030] As outlined below, the patty preform 10 maybe be formed using a die having a uniform thickness that provides a patty preform of uniform thickness, i.e., Tl, T2, and TH are the same. The thicknesses Tl, T2, and TH may differ from one another, though, e.g., by having a hinge thickness TH less than that of the thicknesses Tl and T2 of the first and second lobes 20, 40. The hinge should remain strong enough, though, to tug the leading edge of the second lobe down with sufficient force to aid flipping the second lobe as described below.

[0031] The thicknesses Tl, T2, TH should be selected to yield a stuffed burger patty of a desired thickness after it is pressed, as described below. Depending on the type of product beingmade and how much thinner it gets when pressed, each of the thicknesses Tl, T2, TH may range from 0.1 to 1.5 inches. Desirably, each of those thicknesses is 0.15-1 inch, 0.2-0.75 inches, preferably 0.2-0.5 inches or 0.25-0.45 inches. For thinner patty preforms 10, it may be helpful to adjust the patty formulation, e.g., by adding functional starch, to ensure the patty preform 10 can withstand the mechanical rigors of the manufacturing process. One useful ground beef patty preform 10 has a uniform thickness of 0.36-0.41 inches.

[0032] The shapes and sizes of the first and second lobes 20, 40 can be varied as desired to form a stuffed burger patty with the intended dimensions. In Figure 1, the shape of each lobe is oblong with the leading edge 22 or 42 parallel to the trailing edge 24 or 44 along much of their lengths; those leading and trailing edges adjoin curved or semicircular lateral edges 26 or 46. The lobes 20, 40 may can have a variety of other shapes, though, e.g., oval, rectangular, or square. If a circular or square stuffed burger patty is desired, each lobe 10, 20 may have a width Wl, W2 greater than its length LI, L2. As explained below, the final stuffed burger patty may be compressed by passing it between two rollers in a direction from the leading edge 22 to the trailing edge 24 of the first lobe 20. This will elongate the stuffed burger patty lengthwise more than widthwise, bringing the lengths LI, L2 closer to the widths Wl, W2.

[0033] The patty preform is formed from a patty formulation. The patty formulation may comprise ground meat from a vertebrate animal or animals, e.g., ground beef, ground pork, ground lamb, ground turkey, or ground chicken. If ground beef is used, for example, its fat content may be 30 wt% or less, e.g., 3-30 wt%, 7-30 wt%, desirably 10-27 wt%, preferably 15-25 wt% fat. Alternatively, the patty formulation may comprise a meat analogue, which may be an animal-free meat analogue, that mimics a ground meat, e.g., a ground beef analogue. Suitable ground meat analogues are commercially available, such as Beyond Beef from Beyond Meat, Inc. and Impossible Beef from Impossible Foods Inc.

[0034] The patty formulation may include ingredients in addition to meat or a meat analogue, such as salt, spices, and other seasonings or flavors. The patty formulation for a ground beef analogue, for example, may include a beef flavor. If the stuffed patty is a breakfast sausage patty, the patty formulation may include seasonings commonly used in such sausage patties. If so desired, the patty formulation can also include one or more functional ingredients that modify an attribute of the raw or cooked stuffed patty, e.g., taste, texture, nutrition profile, shelf life, or freeze / thaw stability. Examples of such functional ingredient(s) include antioxidants, antimicrobials, plant protein, fungal protein (e.g. mycoprotein), egg albumen, starches, hydrocolloids, oils, flavors, and colors. One exemplary patty formulation includes only salt and ground beef.

[0035] The patty formulation should be selected to provide the patty preform 10 sufficient structural integrity to allow it to be formed into the stuffed patty. Preferably, that includes a strong enough connection between the first and second lobes 20, 40 via the flexible hinge 60 to allow the first lobe 20 to tug the leading edge 42 of the second lobe 40 downwardly to flip the second lobe as outlined below.

[0036] The patty formulation should also have sufficient cohesion to allow the peripheral portion 52 of the second lobe’s confronting surface 50 to adhere to the peripheral portion 32 of the first lobe’s upper surface 30 when the two lobes are compressed together as described below. In one exemplary ground beef stuffed burger patty, the patty formulation includes ground beef and an edible chloride salt, e.g., sodium chloride. By a combination of longer mixing and / or more salt, the ground beef patty formulation can have an “overworked” consistency that is sufficiently tacky to provide the patty preform 10 with the desired cohesion to enclose and substantially seal the stuffing in the stuffed burger patty.

[0037] Stuffed patties (90 in Figures 9 and 10) in accordance with this disclosure can vary significantly in size, such as from a smaller breakfast sausage patty or “slider” patty to a large hamburger size. Prior to cooking, the stuffed patties may be circular and have a diameter of 1.5- 7 inches (desirably 1.5-5 inches, 2-4.5 inches, or 2.5-4 inches) and a thickness of 0.3-1 inch (desirably 0.5-1 inch, or 0.5-0.8 inches). The weight of the stuffed patties prior to cooking may range between 20 grams and 8 ounces, and is desirably 1.5-8 ounces or 2-6 ounces.Methods of Making Stuffed Burgers

[0038] As noted above, this disclosure provides a process to make stuffed burger patties. This process can be completely automated, making production much more cost-effective and efficient. Making the stuffed burger patties at a central location and shipping them to restaurants for preparation can allow casual dining and quick-service restaurants to offer stuffed burgers at an acceptable price point.

[0039] Figure 3 is a high-level schematic diagram of one manufacturing system 100 that may be used to manufacture stuffed burger patties. The following discussion describes a method of manufacture with reference to the patty preform 10 shown in Figures 1 and 2 to facilitate understanding. This method is not limited to that particular patty preform, however.

[0040] The manufacturing system 100 includes a patty preform station 110 adapted to make patty preforms and deposit them on a first conveyance system 200. The patty preform station 110 includes a patty formulation supply 112, a fill station 114 and an ejector 116. The fill station 114 receives the patty formulation the supply 112 and fills a mold (not shown) that has at least oneopening in the shape of the patty preform 10. If the patty preform 10 has a uniform thickness, the mold may comprise a flat plate with a uniform thickness. The mold may be filled via high-pressure plate forming, in which the patty formulation is fed into the mold opening(s) from one side and a back plate (not shown) is positioned against the other side to define a predetermined thickness and volume for the patty preforms 10. The mold can be formed of any food-safe material, such as stainless steel or a food-safe plastic resin like polyoxymethylene (acetal). Once the mold is filled, it may be positioned over a conveyor surface of the first conveyance system 200 and an ejector 116 may push the patty preform out of the mold plate.

[0041] If so desired, the fill station 114 can use an extrusion die instead of the mold. The die would include at least one opening in the shape of the patty preform 10. A blade can cut the patty formulation exiting the die at the desired patty preform thickness.

[0042] A stuffing depositor 150 deposits a predetermined quantity of a stuffing composition from a stuffing supply 152 onto the central portion 32 of the upper surface 30 of the first lobe 20. The stuffing depositor 150 desirably deposits the stuffing mass (80 in Figure 6) on the central portion 34 in a manner that causes the stuffing mass 80 to adhere to the upper surface 30. If the stuffing mass is sufficiently tacky to adhere to the upper surface 30, the stuffing mass might be lightly deposited on the upper surface. Preferably, though, the stuffing depositor 150 presses the stuffing mass 80 against the central portion 32 of the upper surface 30 with enough force to cause it to adhere thereto when the first lobe 20 is inclined during a subsequent stage of the process described below in connection with Figure 6.

[0043] The stuffing mass 80 may be a preformed mass, such as a slice of cheese, that is deposited atop the upper surface 30 of the first lobe 20. Alternatively, the stuffing composition may be pumpable and pumped onto the upper surface 30.

[0044] The stuffing composition should be sufficiently cohesive to hold together while the first lobe 20 is inclined, as described below. Hence if the stuffing composition comprises separate pieces, e.g., blue cheese crumbles or diced vegetables, it may include a viscous binder that holds the stuffing composition together so the pieces don’t drop off.

[0045] The stuffing composition may be varied to make any desired stuffed burger patty - peanut butter, jam, pate, etc. If the stuffed burger patty is a juicy lucy, the stuffing composition comprises cheese, e.g., a cheddar cheese composition or a slice of cheese. If so desired, such a juicy lucy stuffing composition may include other seasonings, flavors, or inclusions (e.g., bacon crumbles or diced jalapenos).

[0046] In some stuffed burger patties, such as a juicy lucy, the stuffing composition may melt somewhat as the stuffed burger patty is cooked. Preferably, the stuffing composition does not turn into a lower- viscosity liquid that can leak out during cooking. Keeping the stuffing composition relatively viscous even when heated will also reduce the amount of the stuffing that may leak out of the cooked patty when it is cut or during eating. If the stuffed burger patties are to be frozen prior to being cooked, the stuffing composition may be selected to stabilize it during the freeze / thaw cycle.

[0047] If so desired, texturizers such as thickeners or hydrocolloids can be added to achieve these and other properties. These texturizers can affect viscosity, so appropriate selection can yield desired properties during formation (e.g., a pumpable stuffing) as well as in cooked patties. Suitable texturizers include native corn, wheat, or tapioca starches, including waxy com starches; modified food starches such as com, wheat, tapioca, potato, or sago starches that have been chemically treated, e.g., monostarch phosphate (E1410), distarch phosphate (E1412), phosphated distarch phosphate (E1413), acetylated distarch phosphate (E1414), acetylated starch (E1420), acetylated distarch adipate (E1422), hydroxypropyl starch (E1440), hydroxy propyl distarch phosphate (E1442), and n-octenyl succinic anhydride-treated (nOSA) starches (E1450); or hydrocolloids or emulsifiers derived from sources other than grains or cereals, e.g., pectin, carrageenan, seaweed powder, xanthan gum, alginates such as sodium alginate, or lecithin. One stuffing composition suitable for juicy lucies comprise cheese, a modified food starch, and sodium alginate.

[0048] As explained in more detail in connection with Figures 4-7, the first conveyance system 200 moves patty preforms 10 toward a second conveyance system 300. As the patty preforms 10 are transferred from the first conveyance system 200 to the second conveyance system 300, the second lobe 40 of the patty preform is flipped forward to form an unpressed stuffed patty (85 in Figure 8). The second conveyance system 300 delivers the unpressed stuffed patty 85 to a press 400 that compresses the unpressed stuffed patty 85 to form the stuffed patty 90 shown in Figures 9 and 10.

[0049] Figures 4-7 illustrate an interface between the first conveyance system 200 and the second conveyance system 300. Figures 5-7 are schematic side views that illustrate how the patty preform 10 may be manipulated to assemble the unsealed patty 85. Figure 4 is a schematic side perspective view of this interface that roughly corresponds to the position of the patty preform 10 in the schematic view of Figure 6.

[0050] The first conveyance system 200 includes a frame 205 that supports a movable first conveyor 210. The first conveyor 210 is adapted to move patty preforms 10 toward the second conveyance system 300, i.e., to the right in Figures 4-7. The first conveyor 210 is typified in Figures 5-7 as a continuous loop, such as a conveyor belt, supported by a series of rollers 220. The first conveyor 210 should bear the weight of the patty preforms 10 and allow clean release of the patty preform 10 in assembling the unsealed patty. The first conveyor 210 may be a conventional conveyor belt having a flat surface. Preferably, though, the first conveyor has a textured surface or the like that creates friction between the patty preform 10 and the first conveyor 210. Such support surfaces are conventional in food handling and should be formed of a material that is safe for food contact. This friction limits sliding of a trailing portion of the second lobe 40 of the patty preform 10 off the first conveyor 210 when the hinge 60 pulls downwardly on the second lobe, as explained below. The enhanced friction can also impart more momentum to the second lobe to help it flip forwardly as described below. A first conveyor 210 with a wire belt has proven effective to achieve sufficient friction. A wire belt also has openings that reduce adhesion of the patty preform 10 to the support surface, making it easier to flip the second lobe 40.

[0051] The first conveyor 210 includes a rearward segment 212 and a forward segment 214 adjacent to, and desirably partially overlapping, a second conveyor 310 of the second conveyance system 300. The first conveyor 210 may be flat and horizontal along its length. The first conveyor 210 shown in Figures 4-7, however, is generally horizontal along its rearward segment 212 but its forward segment 214 is disposed at an angle A to the rearward segment 212. The forward segment214 may itself be relatively flat along its length. The angle A may be fixed, but the angle A may be adjusted in the conveyor system 200 of Figures 5-7 by means of an actuator 230 carried by the frame 205 that can be adjusted about a pivot point 232. Although angle A may be acute, 90°, or obtuse, an obtuse angle less than 180° is preferred; an incline adjacent the forward end 215 of the forward segment 214 can facilitate flipping of the second lobe 40 of the patty preform 10 as explained below. The angle A may be 150-180°, 160-180°, 165-180°, or 170-177°. Thus, if the rearward segment 212 is horizontal, the forward segment 314 is inclined at an angle of 0-30°, 0- 20°, 0-15°, or 3-10° to horizontal. If the first conveyor 210 is flat along its length, i.e., the angle A is 180°, a similar benefit can be achieved by inclining the first conveyor 210 so its forward end215 is higher. In that instance, the length of the conveyor may be at an angle with respect to horizontal of 0-30°, 0-20°, 0-15°, or 3-10°.

[0052] The second conveyance system 300 includes a frame 305 that supports a movable second conveyor 310. The second conveyor 310 is adapted to move patty preforms 10 from the first conveyance system 200 to the press (400 in Figure 3), i.e., to the right in Figures 5-7. The second conveyor 310 is, like the first conveyor 210, typified in Figures 5-7 as a continuous loop, such as a conveyor belt, supported by a series of rollers 320. The considerations in selecting materials for the conveyor 310 are similar those mentioned above for the first conveyor 210, though the second conveyor 310 does not need to impart as much momentum as it carries the semi-finished unpressed stuffed patties 85. Both conveyors 210, 310 may be formed of the same material if so desired.

[0053] The second conveyor 310 includes a rearward segment 314 adjacent to the first conveyor 210 and a forward segment 312 extending away from the first conveyance system 210. The rearward segment 314 desirably extends rearwardly beneath a portion of the forward segment 214 of the first conveyor 210, with the upper surface of the rearward segment 314 separated from an upper surface of the first conveyor adjacent its forward end 215 by a height H. The height H may be varied. In one suitable manufacturing system 100, the height H is at least 0.75 times or at least 0.9 times, e.g., 0.75-1.5 or 0.9-1.3 times, the length LI of the first lobe 20 of the patty preforms 10 used in the system 100. Preferably, the height H is no less than, and is preferably greater than, the length LI of the first lobe 20. The height H may be 1-1.5 times, preferably 1-1.4 time or 1.1-1.35 times the length LI. In another adaptation, the height H is no less than, and is preferably greater than, the combined length LI of the first lobe 20 and length LH of the hinge 60 of the patty preform. The height H in Figure 5 may be 1-1.3 times, preferably 1-1.2 times, that combined length Ll+LH.

[0054] Like the first system's conveyor 210, the second conveyor 310 may be flat and horizontal along its length. The second conveyor 310 shown in Figures 4-7, however, is generally horizontal along its forward segment 312 but its rearward segment 314 is disposed at an angle B to the forward segment 314. The rearward segment 314 may itself be relatively flat along its length. The angle B may be fixed, but the angle B may be adjusted in the second conveyor system 300 of Figures 5-7 by means of an actuator 330 that can be adjusted about a pivot point 332. Although angle B may be acute, 90°, or obtuse, an obtuse angle less than 180° is preferred; an incline beneath the forward end 215 of the forward segment 214 can facilitate flipping of the second lobe 40 of the patty preform 10 as explained below. The angle B may be 150-180°, 160- 180°, 165-180°, or 170-177°. Thus, if the rearward segment 312 is horizontal, the forward segment 314 is inclined at an angle of 0-30°, 0-20°, 0-15°, or 3-10° to horizontal. If the first conveyor 210is flat along its length, i.e., the angle B is 180°, a similar benefit can be achieved by inclining the second conveyor 310 upwardly in the direction of the press 400.

[0055] Figure 6 shows the same interface between the first and second conveyance systems 200, 300 shown in Figure 5, but later in time. The patty preform 10 and unpressed stuffed patty 85 shown in Figure 6 are moved to the right relative to their positions in Figure 5. The next patty preform 10' for the next stuffed patty is seen at the left of Figure 6. The first lobe 20 and the hinge 60 of the patty preform 10 are no longer supported by the first conveyor. In Figure 6, the height H between the forward end 215 of the first conveyor 210 and the upper surface of the second conveyor 310 beneath it is approximately equal to the combined lengths LI, LH of the patty preform’s first lobe 20 and hinge 60. The leading edge (22 in Figure 1) of the first lobe 20 is just touching the second conveyor 310 and the leading edge (42 in Figure 1) of the second lobe 40 is adjacent the leading edge (215 in Figure 6) of the first conveyor 210.

[0056] The stuffing mass 80 adheres to the upper surface (30 in Figure 1) of the first lobe 20 sufficiently to keep the stuffing mass 80 in place on the first lobe despite the virtually vertical orientation of the first lobe. As noted above, this can be achieved by selecting compositions for the patty formulation and the stuffing formulation that readily adhere to each other and / or by pressing the stuffing mass against the upper surface 30 of the first lobe as it is deposited.

[0057] The combined weight of the first lobe 20 and stuffing mass 80 is at least as great as, and preferably is greater than, the weight of the second lobe 40. In the position shown in Figure 6, almost all of that combined weight and the weight of the hinge 60 is pulling down on the second lobe at the trailing edge (64 in Figure 1) of the hinge 60 that is attached to the second lobe 40 adjacent its leading edge (44 in Figure 1). In the position illustrated in Figure 6, this downward force at the forward edge 215 of the first conveyor has started to lift a trailing portion of the second lobe’s external surface (56 in Figure 1) off the first conveyor 210. Just prior to the position shown in Figure 6, the trailing portion of the second lobe 40 will still be on and carried by the first conveyor 210.

[0058] Figure 7 shows the same interface between the first and second conveyance systems 200, 300 that is shown in Figures 5 and 6, but later in time than Figure 6. In Figure 7, a leading portion of the first lobe 20 rests against the second conveyor 310. The external surface (56 in Figure 1) of the second lobe 40 is now free of the first conveyor 210 and leans forwardly.

[0059] The weight of the unsupported portion of the first lobe 20, the weight of the hinge 60, and a weight of a leading portion of the second lobe 40 pull downwardly on the rest of the second lobe 40. This combined weight causes the patty preform 10 to bend, preferably with some of thepatty preform bowing toward the left in Figure 7 so it extends beneath a short length of the first conveyor 210. This will help pivot the patty preform’s second lobe 40 with the forward edge 215 of the first conveyor acting in a manner similar to a fulcrum. That will lend some momentum to the second lobe, causing it to flip forwardly such that the confronting face 50 of the second lobe 40 is facing generally toward the upper surface 30 of the first lobe.

[0060] The hinge 60 should be strong enough to pull downwardly on the second lobe 40 without tearing or breaking. If the hinge 60 breaks, the second lobe 40 may not flip as intended.

[0061] The two conveyors 210, 310 can move at the same speed. Further forward momentum can be imparted to the second lobe, relative to that of the first lobe, by the first conveyor 210. This can be greatly enhanced by moving the first conveyor 210 at a faster speed than the second conveyor 310. Because the first conveyor 210 is moving faster than the second conveyor on which part of the first lobe 20 rests, momentum imparted by the first conveyor 20 will carry the trailing portion of the second lobe 40 forward relative to the first lobe 20. Keeping the leading edge of the first lobe 20 closer to the first conveyor’s forward edge 215 also reduces the distance the second lobe 40 must travel to flip such so its confronting surface 50 is juxtaposed with the upper surface 30 of the first lobe 20. Moving the second conveyor more slowly than the first one can also encourage the leftward bowing of the patty preform 10 mentioned above, more effectively using the first conveyor’s leading edge 215 as a fulcrum. For example, the ratio of the speed of the first conveyor 210 to that of the second conveyor 310 can be between 1.1 and 4, e.g., between 1.25 and 3.5, or preferably between 1.5 and 3.

[0062] Figure 8 is a schematic side view of an unpressed stuffed patty 85 resting on the second conveyor 310 of the second conveyance system 300. The second lobe 40 of the patty preform 10 is shown as generally straight for purposes of illustration and understanding. Desirably, though, the second lobe 40 is flexible and would bend such that it would partially obscure certain features, including some or all of the stuffing mass 80, in such a side view. This is reflected in the shape of the unpressed stuffed patty 85 shown in Figures 4-7.

[0063] The stuffing mass 80 is positioned between the first lobe 20 and the second lobe 40. More particularly, the stuffing mass 80 is resting on a central portion (34 in Figure 1) of the first lobe’s upper surface 30. The confronting surface 50 of the second lobe 40 is juxtaposed with the upper surface 30 of the first lobe 20 and the stuffing mass 80. Commonly, the confronting surface 50 of the second lobe 40 will be in contact with, and may rest upon, the stuffing mass 80. A peripheral portion 32 of the first lobe’s upper surface 30 is juxtaposed with the peripheral portion 52 of the second lobe’s confronting surface. This positions the peripheral portions 32, 52 of therespective surfaces 30, 50 adjacent one another so they can be compressed against one another by the press 400.

[0064] The flexible hinge 60 is curved and is still joined to the first and second lobes 20, 40. Although that is desirable, it is acceptable if the hinge 60 breaks as the second lobe 40 is flipped into the position shown in Figure 8 so long as it remained intact long enough to pull downwardly on the second lobe to facilitate the flip.

[0065] The second conveyance system 300 will convey the unpressed stuffed patty 85 to the press 400. The press compresses the second lobe and the first lobe such that the peripheral portion 52 of the confronting surface 50 of the second lobe 40 is compressed against and adheres to the peripheral portion 32 of the upper surface 30 of the first lobe 20. As shown in Figures 9 and 10, this forms a generally sealed periphery 92 of the stuffed burger patty 90 and encloses the stuffing mass 80 in interior pocket 94 of the stuffed burger patty 90.

[0066] Using a compression roller as the press 400 has proven useful in making the stuffed burger patties 90. The space between the rollers of the press will determine the thickness of the stuffed burger patty. As the unsealed stuffed burger patty is advanced toward the rollers, the rollers will first engage the leading edge 22 of the first lobe 20 and / or the trailing edge 44 of the second lobe. This will depend on the relative positions of the first and second lobes 20, 40. Preferably, the surfaces of the press rollers will move at a slightly faster linear speed than the speed at which the unsealed (then partially unsealed) stuffed burger patty advances, resulting in a stuffed burger patty that has a length between the leading edge 22 of the first lobe 20 and the external surface 72 of the now-folded hinge 60 that is longer than the length of the length LI of the first lobe 20 of the patty preform 10.EXAMPLES

[0067] The invention is further described in detail by reference to the following experimental examples. These examples are provided for purposes of illustration only and are not intended to be limiting unless otherwise specified.Example 1

[0068] Lean beef and fat were separately ground to a coarse grind of 3 / 8" (0.375 inches or 9.5 mm). Samples were removed from each of the lean and fat coarse-ground materials and the samples’ fat content was measured using a FOSS FoodScan. A total of 60 pounds of coarse- ground material was added to a KFM 110 Fatosa mixer, with the relative amounts of fat and lean selected to produce a coarse grind that was 76 wt% lean and 24 wt% fat. Salt (sodium chloride)was added to the KFM 110 Fatosa mixer at 1 part per 200 parts of meat, producing a patty formulation having approximately 0.5 wt% salt. This was mixed in the KFM 110 Fatosa mixer for 10 minutes at a temperature of 29-31° F. This mixed composition was then ground to a final grind of 3 / 32” (0.094 inches or 2.4 mm).

[0069] The stuffed burger patties made in this experiment used a pasteurized process cheese sauce as the stuffing composition. The stuffing composition comprised cheddar cheese, modified food starch, and sodium alginate. The stuffing composition had a consistency and texture similar to cream cheese. It was pumpable under pressure but didn’t flow freely only under gravity. The stuffing composition was tacky enough to cling to the patty preform 10 when forming the unpressed stuffed patty 85 as described below. When heated to a temperature of 165° F, the stuffing composition maintained its integrity and light chewing resistance without freely flowing under gravity or greasing out.

[0070] One hundred stuffed burger patties were then made using a system similar to the manufacturing system 100 shown in the drawings. For ease of understanding, reference numbers used in the drawings are used in the ensuing discussion. This final-ground meat composition was then formed into patty preforms 10 at a fill station 114 via high-pressure plate forming using a Formax F6. The patty preforms were generally the same shape shown in Figures 1 and 2, with a first lobe 20 having a length LI of 2.75 inches and a width W1 of 3.95 inches; a second lobe 40 having a length L2 of 2.75 inches and a width W2 of 3.95 inches; a hinge 60 having a length LH of 0.313 inches and a width WH of 1.125 inches; and a uniform thickness of 0.382 inches. Each patty preform weighed 4.5 ounces.

[0071] The patty preforms 10 were deposited on the first conveyor 210 of the first conveyance system 200 by the ejector 116. The first conveyor 210, a wire belt, conveyed the patty preforms 10 toward the forward end 215 of the first conveyor. During this travel, about 0.5 ounces of the stuffing composition was deposited in the middle of the upper surface 30 of the first lobe of each patty preform using a piping bag, pressing the stuffing composition lightly against the upper surface to improve adhesion. The height difference H between the upper surface of the first conveyor adjacent that forward end 215 and the upper surface of the rearward segment 314 of the second conveyor 310 was 9 mm. Both conveyors were flat and horizontal, i.e., the angles A and B in Figure 5 were 180°. The first conveyor was advanced at a speed of 66 feet / min and the second conveyor 310, which was also a wire belt, was advanced at a speed of 26 feet / min.

[0072] The patty preform was transferred from the first conveyor 210 to the second conveyor 310 to form an unpressed stuffed patty 85 generally as outlined above. The second lobe 40 wasflexible enough to drape slightly around the stuffing in a manner similar to the unpressed stuffed patty 85 shown in Figures 4-6. The unpressed patty was then passed through a compression roller to a thickness of 0.48-0.52 inches, making a stuffed burger patty 90 having a diameter of about 5 inches.

[0073] The patty preforms 10 consistently folded to form unpressed stuffed patties 85 without inadvertently damaging the patty preform. Exiting the press 400, sealed periphery 92 of the stuffed burger patties formed a good seal between the periphery 32 of the first lobe’ s upper surface 30 and the periphery 52 of the second lobe’ s confronting surface 52. The patties were then stored in a freezer at a temperature of -20° F.

[0074] Ten of the frozen stuffed burger patties 90 were removed from the freezer and allowed to thaw in a refrigerator set at a temperature of about 36° F. The thawed patties were then cooked on a charbroiler to a temperature of about 165° F. The cheese stuffing did not leak out of the patties during cooking. When the cooked stuffed patties were cut in half, the stuffing was warm but had sufficient viscosity to keep most of the stuffing inside the pocket 94 instead of oozing out. Example 2

[0075] A patty formulation was made substantially as in Example 1, but without the salt and with less mixing. In Example 1, salt was added to the coarse-grind ground beef and mixed for 10 minutes at 29-31° F. In this Example 2, the coarse-grind ground beef and mixed for 10 minutes at 29-31° F without added salt. The patty preforms were too stiff and did not fold well to make unpressed stuffed burger patties. In many of the patties, the hinge broke. In others, the second lobe 40 partially broke up atop the stuffing 80 instead of draping over it as in Example 1. When the stuffed burger patties exited the press 400, many of them were malformed. Much of the stuffing showed through gaps in the second lobe of some patties, failing to form a continuous pocket 94 that can keep the stuffing from leaking out during cooking. Others did not form a good peripheral seal. This demonstrates that including salt in a patty formulation that is ground beef improves yield and performance. Those in the field will recognize that ingredients other than salt, e.g., hydrocolloids, can be used in a variety of patty formulations, including those that are plantbased meat alternatives, to promote a suitable peripheral seal 92 in stuffed patties 90.

Claims

CLAIMSWe claim:

1. A patty preform comprising a patty formulation formed into a first lobe, a second lobe, and a flexible hinge that connects the first and second lobes, the hinge having a length that is between 0.5 and 3 times (desirably between 0.75 and 1.5 times, preferably between 0.75 and 1.25 times or between 1 and 1.25 times) a thickness of the first lobe adjacent the hinge.

2. The patty preform of claim 1, wherein the first lobe, second lobe, and hinge are integrally formed from the patty formulation.

3. The patty preform of claim 1 or claim 2, wherein the patty formulation comprises meat or an animal-free meat analogue.

4. The patty preform of any preceding claim, wherein the first lobe weighs more than the second lobe.

5. The patty preform of any preceding claim, further comprising a stuffing carried by an upper surface of the first lobe.

6. The patty preform of any one of claims 1-4, further comprising a stuffing carried by an upper surface of the first lobe, wherein the first lobe and the stuffing together weigh more than the second lobe.

7. The patty preform of claim 5 or claim 6, wherein the upper surface of the first lobe has an inner segment in contact with the stuffing and a periphery surrounding the inner segment that is not in contact with the stuffing.

8. The patty preform of any preceding claim, wherein the patty formulation comprises ground meat, preferably ground beef, ground turkey, or ground chicken, and the stuffing comprises cheese.

9. The patty preform of any one of claims 1-7, wherein the patty formulation comprises a meat analogue.

10. A method of making a stuffed patty comprising the steps of:a) conveying a patty preform and a stuffing on a first conveyor, the patty preform having a first lobe, a second lobe, and a flexible hinge that connects the first and second lobes, and the stuffing being carried by an upper surface of the first lobe; b) lowering a leading portion of the first lobe from the first conveyor to a second conveyor such that a weight of the first lobe pulls downwardly on the hinge; c) juxtaposing a surface of the second lobe with the stuffing and the upper surface of the first lobe; and d) compressing the first and second lobes against one another such that a portion of the juxtaposed surface of the second lobe adheres to a portion of the upper surface of the first lobe to enclose the stuffing in a pocket of the stuffed patty.

11. The method of claim 10, wherein the first lobe and the stuffing together weigh more than the second lobe.

12. The method of claim 10 or claim 11, wherein each of the first conveyor and the second conveyor moves along a conveying direction, the first conveyor moving along the conveying direction faster than the second conveyor does.

13. The method of any one of claims 10-12, wherein the first lobe has a length between its leading edge and the hinge, and an upper surface of the first conveyor adjacent a forward end thereof is spaced above an upper surface of the second conveyor by a height that is at least 0.75 times, e.g., between 0.9 and 1.3 times, the length of the first lobe.

14. The method of claim 10, wherein the stuffing adheres to the upper surface of the first lobe and is retained thereon while the first lobe is inclined between the first and second conveyors.

15. The method of any one of claims 10-14, further comprising depositing the stuffing on the upper surface of the first lobe such that the stuffing adheres to the upper surface of the first lobe.

16. The method of any one of claims 10-15, wherein the stuffing does not cover the portion of the upper surface of the first lobe, allowing the portion of the upper surface to adhere directly to the portion of the face of the second lobe.

17. The method of any one of claims 10-16, wherein the portion of the upper surface of the first lobe is a periphery of the upper surface and the portion of the face of the second lobe is a periphery of that face.

18. A method of making a stuffed patty comprising the steps of: a) conveying a patty preform and a stuffing on a first conveyor, wherein: i. the patty preform has a first lobe, a second lobe, and a flexible hinge that connects the first and second lobes, the hinge having a length that is between 0.5 and 3 times a thickness of the first lobe adjacent the hinge; ii. the stuffing is carried by an upper surface of the first lobe; iii. the patty preform comprises ground beef and salt; and iv. the stuffing comprises cheese; b) allowing a leading portion of the first lobe to descend under gravity from the first conveyor to a second conveyor with a trailing portion of the second lobe still on the first conveyor such that a weight of the first lobe and the stuffing pulls downwardly on the hinge and on a leading portion of the second lobe; c) juxtaposing a surface of the second lobe with the stuffing and the upper surface of the first lobe by folding the hinge to flip the second lobe; d) compressing a periphery of the upper surface of the first lobe and a periphery of the juxtaposed surface of the second lobe against one another such that the peripheries adhere to enclose the stuffing in a pocket of the stuffed patty.

19. The method of any one of claims 10-18, further comprising cooking the stuffed patty.

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