A method and system for manufacturing a frozen to thaw whipped textured pudding

Abstract

A method / system for manufacturing a frozen to thaw whipped textured pudding comprises mixing dry and liquid ingredients to create a dairy liquid mixture; pasteurizing the dairy liquid mixture; cooling the pasteurized dairy liquid mixture without freezing the pasteurized dairy liquid mixture; aerating the cooled pasteurized dairy liquid mixture including injecting air into the pasteurized dairy liquid mixture without freezing (and prior to freezing) the pasteurized dairy liquid mixture; and freezing the aerated pasteurized dairy liquid mixture such that the dairy liquid mixture is only frozen after the aerating is completed.

Description

A METHOD AND SYSTEM FOR MANUFACTURING A FROZEN TO THAWWHIPPED TEXTURED PUDDINGBACKGROUND

[0001] The present disclosure relates to the manufacture of a frozen to thaw whipped textured pudding.

[0002] People like desserts. There are many different types of desserts. One example of a well-liked dessert is pudding, which typically has a creamy consistency, or occasionally a whipped or mousse-like consistency. Freshly made pudding is very popular. However, there are times that a consumer desires fresh pudding but is not at a location that sells fresh pudding, or the consumer lacks the skills to prepare fresh pudding. Such a consumer is left with the option of purchasing a frozen or aseptic pudding product. However, some frozen puddings will thaw to a liquid rather than whipped or mousse-like consistency, which degrades the experience.SUMMARY

[0003] A method and / or system for manufacturing a frozen to thaw whipped textured pudding is proposed. That is, the result of the manufacturing process is a frozen product, that when thawed (e.g., moved from the freezer to a refrigerator or to another location to allow the temperature of the product to rise sufficiently), rises in temperature and changes in consistency from a solid to a pudding (e.g., which has a whipped or mousse-like consistency / texture).

[0004] One embodiment of the proposed method and / or system for manufacturing a frozen to thaw whipped textured pudding comprises mixing dry and liquid ingredients to create a dairy liquid mixture; pasteurizing the dairy liquid mixture; cooling the pasteurized dairy liquid mixture without freezing the pasteurized dairy liquid mixture; aerating the cooled pasteurized dairy liquid mixture including injecting air into the pasteurized dairy liquid mixture without freezing (and prior to freezing) the pasteurized dairy liquid mixture; and subsequentlyAttorney Docket No.: P-645523-PCP-645523-PC-APPfreezing the aerated pasteurized dairy liquid mixture such that the dairy liquid mixture is only frozen after the aerating is completed. A novel structure for adding mix-ins is also disclosed herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Like-numbered elements refer to common components in the different figures.

[0006] Figure 1 is a block diagram of a system for manufacturing a frozen to thaw whipped textured pudding.

[0007] Figure 2 is a side view of a multi-deck screener.

[0008] Figure 3 is a perspective view of a multi-deck screener.

[0009] Figure 4 is a top view of (looking down at) a multi-deck screener.

[0010] Figure 5 is a top view of (looking down at) a vibratory pan feeder.

[0011] Figure 6 is a first side view of a vibratory pan feeder.

[0012] Figure 7 is a second side view of a vibratory pan feeder.

[0013] Figure 8 depicts a multi-deck screener, a vibratory pan feeder and an Inclusion Feeder.

[0014] Figure 9 is a flow chart describing one embodiment of a process for manufacturing a frozen to thaw whipped textured pudding.DETAILED DESCRIPTION

[0015] Figure 1 is a block diagram of a system for manufacturing a frozen to thaw banana (or other flavor) pudding (e.g., which has a whipped or mousse-like consistency / texture). The components depicted in Figure 1 are positioned in a foodAtorney Docket No.: P-645523-PC P-645523-PC-APPmanufacturing facility; however, they can also be placed in other locations suitable for food preparation. Figure 1 shows Liquefier Mixer 102 receiving a batch of ingredients including banana puree 104, sweetened condensed milk 106, dry ingredients 108, water 110 and heavy whipping cream 112. In one embodiment, the dry ingredients include (but are not limited to) sugar, one or more starches and salt. Banana puree 104, stored in a stainless steel vat or another container, is transported to Liquefier Mixer 102 via diaphragm pump 114. Sweetened condensed milk 106, stored in a bag lined plastic container, is transported to Liquefier Mixer 102 via diaphragm pump 116. Water 110 is transported to Liquefier Mixer 102 via diaphragm pump 118. Heavy whipping cream 112, stored in a bag lined plastic container, is transported to Liquefier Mixer 102 via diaphragm pump 120. In an embodiment that is making a pudding other than banana pudding, the banana puree 104 and / or any of the other-described ingredients can be replaced with ingredients suitable for making the other pudding.

[0016] Liquefier Mixer 102 mixes the batch of ingredients it receives to create a dairy liquid mixture that is transported, via diaphragm pump 122, to VAT pasteurizers 124 and 126. In one embodiment, VAT pasteurizers 124 and 126 each hold 500 gallons of dairy liquid mixture. In other embodiments, VAT pasteurizers 124 and 126 can hold different volumes of the dairy liquid mixture (e.g., more or less than 500 gallons). In other embodiments, there can be more or less than two VAT pasteurizers. In one example implementation, Liquefier Mixer 102 has a volume of 250 gallons; therefore, Liquefier Mixer 102 will make four batches of the dairy liquid mixture (250 gallons per batch) to fill up VAT pasteurizers 124 and 126. In one example, VAT pasteurizers 124 and 126 perform a heat pasteurization process by heating the dairy liquid mixture to one hundred and sixty (160) degrees Fahrenheit and holding it at this temperature for thirty minutes.

[0017] After completing the heat pasteurization process, the pasteurized dairy liquid mixture is transported, via positive displacement pump 128, to Heat Exchanger 130 which crash cools the pasteurized dairy liquid mixture to a refrigeration temperature (which thickens the pasteurized dairy liquid mixture). In one embodiment, the pasteurized dairy liquid mixture enters Heat Exchanger 130 at approximately 160 degrees Fahrenheit and leaves Heat Exchanger 130 at approximately 38-40 degrees Fahrenheit. The cooled pasteurized dairy liquid mixture is then stored in one or more holding tanks; for example, Figure 1 shows the cooled pasteurized dairy liquid mixture being transferred from Heat Exchanger 130 to holding tankAttorney Docket No.: P-645523-PCP-645523-PC-APP132 and holding tank 134, each of which has a five hundred gallon capacity (other capacities can also be used). In some embodiments, only one holding tank is used. In one embodiment, the cooled pasteurized dairy liquid mixture is held / stored in chilled holding tanks 132 and 134 overnight (or at least eight hours) to ensure that the cooled pasteurized dairy liquid mixture is at ~38 degrees Fahrenheit (e.g., 35-42 degrees Fahrenheit).

[0018] From holding tanks 132 and 134, the cooled pasteurized dairy liquid mixture is transferred to chilled holding tanks 138 and 140 (capacity of 500 gallons each) via positive displacement pump 136. In one embodiment, the system includes two pairs of holding tanks 132 / 134 and 138 / 140 because one pair of holding tanks 132 / 134 is physically located adjacent components 102, 124, 126 and 130 while the other pair of holding tanks 138 / 140 is physically located adjacent components 146, 152, 154 and 156. In another embodiment, only one pair of holding tanks is used.

[0019] From holding tanks 138 and 140, the cooled pasteurized dairy liquid mixture is transferred through strainers 144, via positive displacement pump 142, to remove any large particles that should not be in the cooled pasteurized dairy liquid mixture (e.g., remove clumps of material). The strained cooled pasteurized dairy liquid mixture is then input to Aeration Mixer 146.

[0020] Aeration Mixer 146, which is a rotor stator mixer, inj ects air into the pasteurized dairy liquid mixture without freezing the pasteurized dairy liquid mixture. In one embodiment, Aeration Mixer 146 injects air to make cells (or pockets or voids) into the pasteurized dairy liquid mixture. For example, Aeration Mixer 146 causes a pressure drop that creates voids in the pasteurized dairy liquid mixture that enables air cells to be formed. The smaller air cells result in a creamier less dense texture for the final product.

[0021] In one embodiment, the aerating increases the viscosity of the pasteurized dairy liquid mixture. For example, prior to aerating in Aeration Mixer 146 the pasteurized dairy liquid mixture is at ~3-4 Bostwick, and after aerating in Aeration Mixer 146 the pasteurized dairy liquid mixture is at ~0 Bostwick. Other amounts of viscosity can also be implemented.

[0022] In one embodiment, Aeration Mixer 146 includes a stainless steel mixing head assembly consisting of front stator, rear stator, and rotor. The head assembly is mounted to theAtorney Docket No.: P-645523-PCP-645523-PC-APPmixer main frame by means of a machined, white epoxy, cast aluminum bearing housing which contains the rotor shaft. The rear stator hub is designed to accept a single rod assembly. Both front and rear stators are supplied with cooling jackets designed to remove most of the heat of mixing. The rear stator inlet and front stator outlet are supplied with 2" Tri-clamp sanitary fittings. The rotor is driven by a SEW 20 HP, TEFC inverter duty sanitary construction gear motor directly coupled to the rotor shaft. An Allen Bradley Powerflex 525 variable frequency inverter is used to power the rotor motor. The inverter is mounted in a single stainless steel NEMA4X power enclosure which includes a disconnect switch assembly, transformer, circuit breakers, terminal blocks, cabinet cooler and air filter. All piping is 2" sanitary tubing with Tri- clamp fittings. Inlet piping includes a Tri-clamp inline stainless steel side entry basket strainer and a special four way cross. Two of the cross ports are used to mount a stainless steel diaphragm isolated back pressure transducer and injection air check valve assembly. Outlet piping consists of a pneumatic restriction valve controlled by an external air pressure regulator. A special tee is supplied at the outlet of the mixing head for a digital thermometer. An injection air system mounted in a NEMA4X stainless steel pneumatic enclosure consists of a Matheson volumetric flowrator, pressure gauge, pressure regulator, air check valve injector, and tubing between the flowrator and the air check valve injector. A stainless steel diaphragm isolated back pressure transducer is mounted on top of the four way inlet cross. Aeration Mixer 146 features a programmable pressure cutout set point and digital display, which is used to stop the customer supplied product pump should the back pressure exceed the set point. Maximum pressure is typically set at 125 psi. The entire mixer is mounted on a stainless steel welded and polished tubular frame with castors. In one embodiment, Aeration Mixer 146 is a Continuous Automatic Mixer model 14MFH20IA from E. T. Oakes Corp.

[0023] The mixing of air into the pasteurized dairy liquid mixture does generate some heat; therefore, Aeration Mixer 146 has cooling water surrounding the mixing head to cool and maintain the temperature of the mixing head and the pasteurized dairy liquid mixture between 35 and 42 degrees Fahrenheit. As a result, the aerating comprises injecting air into the pasteurized dairy liquid mixture with minimal (non-significant) increase in temperature of the pasteurized dairy liquid mixture. In some alternative embodiments there can be a small (but not significant) change in temperature such that the aerating comprises injecting air into theAttorney Docket No.: P-645523-PC P-645523-PC-APPpasteurized dairy liquid mixture without changing temperature of the pasteurized dairy liquid mixture by more than five degrees Fahrenheit.

[0024] The output of Aeration Mixer 146, the aerated pasteurized dairy liquid mixture, passes a backpressure valve 148 and a sample valve 150 (used to sample the mix), and then is transported to Inclusion Feeder 152 that (optionally) adds mix-ins to the aerated pasteurized dairy liquid mixture. One example of Inclusion Feeder 152 is a Fruit Feeder used in commercial ice cream making. Examples of mix-ins include (but are not limited to) cookie pieces, chocolate pieces, chocolate ribbons, candy and fruit.

[0025] After leaving Inclusion Feeder 152, the aerated pasteurized dairy liquid mixture is transported to Container Filler 158 that fills empty pint containers (or other sized containers) with the aerated pasteurized dairy liquid mixture. In one embodiment, the filled pints will have a heat seal applied, a lid added, and a Best Buy date and lot code inked to the outer surface. In one embodiment, the filled pints will also be passed through a metal detector and then packed in cases.

[0026] The aerated pasteurized dairy liquid mixture, in the containers (e.g., pint contains packed in cases), is then moved into Freezer 160 to freeze the aerated pasteurized dairy liquid mixture. The freezing of the aerated pasteurized dairy liquid mixture in Freezer 160 is the first time that the dairy liquid mixture is frozen. That is, the dairy liquid mixture is not frozen at any time prior to aeration in Aeration Mixer 146 and the dairy liquid mixture is not frozen at any time during aeration in Aeration Mixer 146. The aerating is performed while the pasteurized dairy liquid mixture is not frozen. The dairy liquid mixture is only frozen after the aeration is completed.

[0027] Figure 1 also depicts Multi-Deck Screener 154 and Vibratory Pan Feeder 156. In general, mix-ins are placed in Multi -Deck Screener 154 to be screened such that the correct sized mix-ins are identified and provided to Inclusion Feeder 152 via Vibratory Pan Feeder 156. In one embodiment, Multi-Deck Screener 154 is configured to classify the mix-ins into at least three sizes (e.g., small, medium and large), discard mix-ins that are two of the sizes (e.g., discard mix-ins that are the small size and mix-ins that are the large size), and automatically route mix-ins of a third size (e.g., mix-in that are the medium size) to Vibratory Pan FeederAtorney Docket No.: P-645523-PCP-645523-PC-APP156. In this implementation, Vibratory Pan Feeder 156 is configured to transport the mix-ins of the third size to Inclusion Feeder 152.

[0028] One example of mix-ins includes cookie pieces. If the cookie pieces are too small, then they dissolve into the aerated pasteurized dairy liquid mixture and will not be enjoyed by a consumer. If the cookie pieces are too large then they may get stuck in Inclusion Feeder 152, be unable to fit properly in a container, too large for nozzles and / or be too large for the mouth of a consumer. Therefore, Multi-Deck Screener 154 is used to separate out the cookie pieces that are too small and the cookie pieces that are too large. In an alternate embodiment, Multi-Deck Screener 154 can classify mix-ins into more than three sizes or less than three sizes.

[0029] Figure 2 is a side view of one embodiment of Multi-Deck Screener 154. Figure 3 is a perspective view of Multi-Deck Screener 154. Figure 4 is a top view of (looking down at) Multi-Deck Screener 154. In one embodiment, Multi-Deck Screener 154 includes three pans 202, 204 and 206 stacked vertically. Pan 202 and pan 204 include mesh screens on a bottom surface of the respective pan. The mesh screen 210 at the bottom of pan 202 has different sized apertures than the mesh screen 212 at the bottom of pan 204. For example, the apertures of mesh screen 210 at the bottom of pan 202 are sized to allow the small and medium sized mix- ins to pass; therefore, holding the large mix-ins in pan 202. The apertures of mesh screen 212 at the bottom of pan 204 are sized to allow the small sized mix-ins to pass; therefore, holding the medium sized mix-ins in pan 204.

[0030] Each of the three pans 202, 204 and 206 includes a separate outlet. Pan 202 includes outlet 220. Pan 204 includes outlet 222. Pan 206 includes outlet 224. Pan 204 (the middle pan) has its outlet 222 aligned above an opening of Vibratory Pan Feeder 156 so that medium sized mix-ins are routed to Vibratory Pan Feeder 156. Outlets 220 and 224 can be aligned to portable bins such that small and large sized mix-ins can be collected and provided for another use (other than being mixed into the aerated pasteurized dairy liquid mixture).

[0031] At the bottom of Multi-Deck Screener 154 is a housing 228 that encloses a motor driven weight (not depicted) to create a flow pattern of mix-ins in each of the three pans 202, 204 and 206 toward a respective outlet. Springs 230 are connected between housing 228 and pan 206. In operation, mix-ins are poured into pan 202, as per arrow 232. The motor drivenAttorney Docket No.: P-645523-PCP-645523-PC-APPweight creates a flow pattern of mix-ins in each of the three pans 202 such that small and medium sized mix-ins pass to pan 204 (via screen 210) while large sized mix-ins flow toward and around the edge of pan 202 until they exit pan 202 via outlet 220. Due to the motor driven weight, those mix-ins that passed to pan 204 via screen 210 will experience a flow pattern toward and around the edge of pan 202 such that small sized mix-ins will fall through screen 212 and medium sized mix-ins (e.g., cookie pieces) will flow toward and around the edge of pan 204 until they exit pan 204 via outlet 222 into Vibratory Pan Feeder 156. Due to the motor driven weight, those mix-ins that passed to pan 206 via screen 212 will experience a flow pattern toward and around the edge of pan 206 until they exit pan 206 via outlet 224.

[0032] Figure 5 is a top view of (looking down at) Vibratory Pan Feeder 156. Figure 6 is a first side view of Vibratory Pan Feeder 156. Figure 7 is a second side view of Vibratory Pan Feeder 156. In one embodiment, Vibratory Pan Feeder 156 is configured to transport the medium sized mix-ins from Multi-Deck Screener 154 to Inclusion Feeder 152. Vibratory Pan Feeder 156 is also configured to adjustably control the rate of inclusion of mix-ins into the aerated pasteurized dairy liquid mixture via the Inclusion Feeder 152 by adjusting the rate that the mix-ins are transported from Multi-Deck Screener 154 to Inclusion Feeder 152. In one embodiment, Vibratory Pan Feeder 156 is also configured to adjustably control the rate of inclusion of mix-ins to accommodate (or based on) different speeds of the aerated pasteurized dairy liquid to the Container Filler 158.

[0033] Vibratory Pan Feeder 156 includes a hopper 502 for receiving and temporarily holding the screened mix-ins (e.g., the medium sized mix-ins) from Multi-Deck Screener 154. Hopper 502 empties the mix-ins on to tray 504. Adjustable output gate 506 can be vertically adjusted such that the higher the gate 506 is positioned the greater the height of the flow of mix-ins on to tray 504 and the lower gate 506 is positioned the lower the height of flow of mix- ins on to tray 504, thereby changing the amount of mix-ins per unit of time. Tray 504 is gently sloped down from hopper 502 toward the distal end of tray 504 (the end of tray 504 that is adjacent to Inclusion Feeder 152). Tray 504 is connected to a leaf spring (not depicted) that causes tray 504 to vibrate horizontally due to a piston (not depicted) connected to the leaf spring. The slope of tray 504 in combination with the vibration causes mix-ins to move from hopper 502 to Inclusion Feeder 152 (via the direction of arrow 508).Attorney Docket No.: P-645523-PCP-645523-PC-APP

[0034] Figure 8 shows the positioning of Multi-Deck Screener 154, Vibratory Pan Feeder 156 and Inclusion Feeder 152. As depicted, outlet 222 of pan 204 of Multi-Deck Screener 154 is aligned above hopper 502 (and the opening of hopper 502) of Vibratory Pan Feeder 156 so that medium sized mix-ins are routed from Multi-Deck Screener 154 to Vibratory Pan Feeder 156. The distal end of tray 504 of Vibratory Pan Feeder 156 is aligned above hopper 800 of Inclusion Feeder 152 so that medium sized mix-ins are routed from Vibratory Pan Feeder 156 to Inclusion Feeder 152 to be added to the aerated pasteurized dairy liquid mixture.

[0035] Figure 9 is a flow chart describing one embodiment of a process for manufacturing a frozen to thaw whipped textured pudding. In some embodiments, the process of Figure 9 is performed using the components described above with respect to Figures 1-8. In some embodiments, the process of Figure 9 is performed to manufacture frozen to thaw banana pudding.

[0036] Step 902 of Figure 9 includes mixing dry and liquid ingredients to create a dairy liquid mixture. One embodiment includes mixing banana puree, sweetened condensed milk, water, heavy whipping cream, one or more starches, sugar and salt in Liquefier Mixer 102. Step 904 includes heat pasteurizing the dairy liquid mixture in a pasteurizer, such as VAT pasteurizers 124 and 126. Step 906 includes cooling the pasteurized dairy liquid mixture in a heat exchanger (e.g., Heat Exchanger 130) without freezing the pasteurized dairy liquid mixture. Step 908 includes holding the cooled pasteurized dairy liquid mixture in one or more holding tanks overnight (e.g., for more than eight hours). For example, the cooled pasteurized dairy liquid mixture is held / stored in chilled holding tanks 132 and 134 overnight (or at least eight hours) to ensure that the cooled pasteurized dairy liquid mixture is at 38 degrees Fahrenheit (or between 35-42 degrees Fahrenheit).

[0037] Step 910 includes aerating the pasteurized dairy liquid mixture in an aeration mixer (e.g., Aeration Mixer 146, as discussed above) without freezing the pasteurized dairy liquid mixture. In one embodiment, the aerating comprises injecting air into the pasteurized dairy liquid mixture with minimal (or no) increase in temperature of the pasteurized dairy liquid mixture. In one embodiment, the aerating comprises injecting air into the pasteurized dairy liquid mixture without changing temperature of the pasteurized dairy liquid mixture by moreAtorney Docket No.: P-645523-PCP-645523-PC-APPthan five degrees Fahrenheit. The aerating is performed while the pasteurized dairy liquid mixture is not frozen and the aerating causes an increase in the viscosity of the pasteurized dairy liquid mixture.

[0038] Step 912 includes routing mix-ins through a multi-deck screener (e.g., MultiDeck Screener 154) that classifies the mix-ins into at least a small size, a medium size and a large size. Step 914 includes discarding mix-ins that are the small size and the large size. Step 916 includes automatically routing the mix-ins that are the medium size to a vibratory pan feeder, such as Vibratory Pan Feeder 156. Step 918 includes using the vibratory pan feeder to transport the mix-ins that are the medium size to Inclusion Feeder 152 (e.g., a mixer) so that the mix-ins will be added to the aerated pasteurized dairy liquid mixture. Step 920 includes adjusting the rate of inclusion of mix-ins that are the medium size into the Inclusion Feeder (which, in some alternative embodiments, can be optionally based on viscosity of the aerated pasteurized dairy liquid). Step 922 includes using the Inclusion Feeder to add the mix-ins that are the medium size to the aerated pasteurized dairy liquid mixture prior to freezing. Step 924 includes packaging the aerated pasteurized dairy liquid mixture (with the mix-ins). Step 924 can include filling pint (or other sized) containers.

[0039] Step 926 includes, after adding the mix-ins and packaging, freezing the aerated pasteurized dairy liquid mixture such that the dairy liquid mixture is only frozen after the aerating is completed. In one embodiment, the dairy liquid mixture is only frozen after the aerating is completed and mix-ins are added. For example, the dairy liquid mixture is not frozen prior to step 926. After freezing, the frozen product can be stored in a freezer until time for consumption. When the aerated pasteurized dairy liquid mixture is to be consumed (after it is frozen), the aerated pasteurized dairy liquid mixture is thawed to a whipped / mousse consistency (rather than a liquid) and then consumed (step 928) as banana pudding.

[0040] A method and system for manufacturing a frozen to thaw whipped textured pudding has been disclosed. This method can be used to manufacture frozen to thaw banana pudding, where the pudding (without mix-ins) has a consistency that is the same as a mousse (e.g., chocolate mousse).

[0041] One embodiment includes a method of manufacturing a frozen to thaw whipped textured pudding, the method comprising: mixing dry and liquid ingredients to create a dairyAtorney Docket No.: P-645523-PC P-645523-PC-APPliquid mixture; pasteurizing the dairy liquid mixture; cooling the pasteurized dairy liquid mixture; aerating the cooled pasteurized dairy liquid mixture including injecting air into the pasteurized dairy liquid mixture without freezing the pasteurized dairy liquid mixture; and after the aerating, freezing the aerated pasteurized dairy liquid mixture.

[0042] In one example implementation, the dairy liquid mixture is only frozen after the aerating is completed.

[0043] In one example implementation, the aerating comprises injecting air into the pasteurized dairy liquid mixture without changing the temperature of the pasteurized dairy liquid mixture by more than five degrees Fahrenheit.

[0044] In one example implementation, the aerating is performed while the pasteurized dairy liquid mixture is not frozen.

[0045] In one example implementation, the aerating includes increasing the viscosity of the pasteurized dairy liquid mixture.

[0046] One example implementation further comprises thawing the frozen aerated pasteurized dairy liquid mixture to a whipped consistency (after the freezing).

[0047] One example implementation further comprises thawing the frozen aerated pasteurized dairy liquid mixture to a mousse consistency (after the freezing).

[0048] One example implementation further comprises routing mix-ins through a multi-deck screener that classifies the mix-ins into at least a small size, a medium size and a large size; discarding mix-ins that are the small size and the large size; automatically routing the mix-ins that are the medium size to a vibratory pan feeder; using the vibratory pan feeder to transport the mix-ins that are the medium size to an Inclusion Feeder; and adding mix-ins that are the medium size to the aerated pasteurized dairy liquid mixture prior to freezing using the Inclusion Feeder. In one example implementation, the vibratory pan feeder is configured to adjustably control the rate of inclusion of mix-ins that are the medium size into the aerated pasteurized dairy liquid mixture via the Inclusion Feeder; and the method further comprises adjusting the rate of inclusion of mix-ins that are the medium size into the Inclusion Feeder. In one example implementation, the multi-deck screener includes three pans stack vertically, twoAttorney Docket No.: P-645523-PCP-645523-PC-APPof the three pans have mesh screens on a bottom surface with different aperture sizes, each of the three pans includes a separate outlet, a middle pan of the three pans has its outlet aligned above an opening of the vibratory pan feeder and the multi-deck screener includes a motor driven weight to create a flow pattern of mix-ins in each of the three pans toward a respective outlet as part of the routing particles through the multi-deck screener.

[0049] One embodiment includes a method of manufacturing a frozen to thaw whipped textured pudding, the method comprising: mixing dry and liquid ingredients in a liquefier mixer to create a dairy liquid mixture; pasteurizing the dairy liquid mixture in a pasteurizer; cooling the pasteurized dairy liquid mixture in a heat exchanger without freezing the pasteurized dairy liquid mixture; holding the cooled pasteurized dairy liquid mixture in one or more holding tanks for more than eight hours; aerating the pasteurized dairy liquid mixture in an aeration mixer without freezing the pasteurized dairy liquid mixture; routing mix-ins through a multideck screener that classifies the mix-ins into at least a three sizes, discarding mix-ins that are two of the sizes, and automatically routing the mix-ins of a third size to a vibratory pan feeder, adding the mix-ins of the third size to the aerated pasteurized dairy liquid mixture using an Inclusion Feeder that is fed the mix-ins of the third size from the vibratory pan feeder; and after adding the mix-ins of the third size, freezing the aerated pasteurized dairy liquid mixture such that the dairy liquid mixture is only frozen after the aerating is completed. In one example implementation, the dairy liquid mixture is only frozen after the aerating is completed and the aerating includes increasing the viscosity of the pasteurized dairy liquid mixture.

[0050] One embodiment includes a system for manufacturing a frozen milk-based dessert that thaws to banana pudding. The system comprises a liquefier mixer configured to create a dairy liquid mixture from mixing dry and liquid ingredients; a pasteurizer configured to heat pasteurize the dairy liquid mixture; a first pump connected between the liquefier mixer and the pasteurizer; a first holding tank configured to hold the pasteurized dairy liquid mixture; a second pump connected between the pasteurizer and the first holding tank; an aeration mixer; a third pump connected to the aeration mixer and configured to transfer the pasteurized dairy liquid to the aeration mixer after the pasteurized dairy liquid mixture has left the first holding tank; a container filler in fluid communication with the aeration mixer and configured to fill multiple containers with the aerated pasteurized dairy liquid mixture; and a freezer configured to freeze the aerated pasteurized dairy liquid mixture in the multiple containers.Atorney Docket No.: P-645523-PCP-645523-PC-APP

[0051] In one example implementation, the aeration mixer comprises a stainless steel pneumatic enclosure that includes a Matheson volumetric flowrator, a pressure gauge, a pressure regulator, an air check valve injector, and tubing between the flowrator and the air check valve injector.

[0052] One example implementation further comprises an Inclusion Feeder connected to the aeration mixer and the container filler, the Inclusion Feeder is configured to insert mix- ins into the aerated pasteurized dairy liquid mixture; a multi-deck screener; and a vibratory pan feeder connected to the mixer and the multi-deck screener. The multi-deck screener is configured to classify the mix-ins into at least three sizes, discard mix-ins that are two of the sizes, and automatically route mix-ins of a third size to the vibratory pan feeder. The vibratory pan feeder is configured to transport the mix-ins of the third size to the Inclusion Feeder.

[0053] In one example implementation, the vibratory pan feeder is configured to adjustably control the rate of inclusion of mix-ins of the third size into the aerated pasteurized dairy liquid mixture via the Inclusion Feeder.

[0054] In one example implementation, the multi-deck screener includes three pans stacked vertically, two of the three pans have mesh screens on a bottom surface with different aperture sizes, each of the three pans includes a separate outlet, a middle pan of the three pans has its outlet aligned above an opening of the vibratory pan feeder and the multi-deck screener includes a motor driven weight to create a flow pattern of mix-ins in each of the three pans toward a respective outlet.

[0055] For purposes of this document, reference in the specification to “an embodiment,” “one embodiment,” “some embodiments,” or “another embodiment” may be used to describe different embodiments or the same embodiment.

[0056] For purposes of this document, a connection may be a direct connection or an indirect connection (e.g., via one or more other parts). In some cases, when an element is referred to as being connected or coupled to another element, the element may be directly connected to the other element or indirectly connected to the other element via one or more intervening elements. When an element is referred to as being directly connected to another element, then there are no intervening elements between the element and the other element.Attorney Docket No.: P-645523-PCP-645523-PC-APPTwo devices are “in communication” if they are directly or indirectly connected so that they can communicate electronic signals between them.

[0057] For purposes of this document, the term “based on” may be read as “based at least in part on.”

[0058] For purposes of this document, without additional context, use of numerical terms such as a “first” object, a “second” object, and a “third” object may not imply an ordering of objects, but may instead be used for identification purposes to identify different objects.

[0059] For purposes of this document, the term “set” of objects may refer to a “set” of one or more of the objects.

[0060] The foregoing detailed description has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. The described embodiments were chosen in order to best explain the principles of the proposed technology and its practical application, to thereby enable others skilled in the art to best utilize it in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope be defined by the claims appended hereto.Attorney Docket No.: P-645523-PC P-645523-PC-APP

Claims

CLAIMSWhat is claimed is:

1. A method of manufacturing a frozen to thaw whipped textured pudding, the method comprising: mixing dry and liquid ingredients to create a dairy liquid mixture; pasteurizing the dairy liquid mixture; cooling the pasteurized dairy liquid mixture; aerating the cooled pasteurized dairy liquid mixture including injecting air into the pasteurized dairy liquid mixture without freezing the pasteurized dairy liquid mixture; and after the aerating, freezing the aerated pasteurized dairy liquid mixture.

2. The method of claim 1, further comprising: routing mix-ins through a multi-deck screener that classifies the mix-ins into at least a small size, a medium size and a large size; discarding mix-ins that are the small size and the large size; automatically routing the mix-ins that are the medium size to a vibratory pan feeder; using the vibratory pan feeder to transport the mix-ins that are the medium size to an inclusion feeder; and adding mix-ins that are the medium size to the aerated pasteurized dairy liquid mixture prior to freezing using the inclusion feeder.

3. The method of claim 2, wherein: the vibratory pan feeder is configured to adjustably control the rate of inclusion of mix-ins that are the medium size into the aerated pasteurized dairy liquid mixture via the inclusion feeder.

4. The method of claim 2, wherein: the multi-deck screener includes three pans stacked vertically, two of the three pans have mesh screens on a bottom surface with different aperture sizes, each of the three pans includes a separate outlet; a middle pan of the three pans has its outlet aligned above an opening of the vibratoryAtorney Docket No.: P-645523-PCP-645523-PC-APPpan feeder; and the multi-deck screener includes a motor driven weight to create a flow pattern of mix-ins in each of the three pans toward a respective outlet as part of the routing particles through the multi-deck screener.

5. The method of claim 1, further comprising: routing mix-ins through a multi-deck screener, the multi-deck screener includes three pans stacked vertically, two of the three pans have mesh screens on a bottom surface with different aperture sizes, each of the three pans includes a separate outlet, the routing the mix- ins through the multi-deck screener comprises classifying the mix-ins into at least a small size, a medium size and a large size; discarding mix-ins that are the small size and the large size; and adding the mix-ins that are the medium size to the aerated pasteurized dairy liquid mixture.

6. The method of claim 1, wherein: the dairy liquid mixture is only frozen after the aerating is completed.

7. The method of claim 1, wherein: the aerating comprises injecting air into the pasteurized dairy liquid mixture without changing temperature of the pasteurized dairy liquid mixture by more than five degrees Fahrenheit.

8. The method of claim 1, wherein: the aerating is performed while the pasteurized dairy liquid mixture is not frozen.

9. The method of claim 1, wherein: the aerating includes increasing the viscosity of the pasteurized dairy liquid mixture.

10. The method of claim 1, further comprising: after the freezing, thawing the frozen aerated pasteurized dairy liquid mixture to a whipped consistency.Atorney Docket No.: P-645523-PC P-645523-PC-APP11. The method of claim 1, further comprising: after the freezing, thawing the frozen aerated pasteurized dairy liquid mixture to a mousse consistency.

12. The method of claim 1 , wherein: the mixing dry and liquid ingredients comprises mixing a starch, banana puree, sweetened condensed milk, heavy whipping cream, salt and sugar; and the pasteurizing is performed after mixing in the dry and liquid ingredients.

13. The method of claim 1, further comprising: holding the cooled pasteurized dairy liquid mixture in one or more chilled holding tanks for more than eight hours prior to aerating.

14. A method of manufacturing a frozen to thaw whipped textured pudding, the method comprising: mixing dry and liquid ingredients in a liquefier mixer to create a dairy liquid mixture; pasteurizing the dairy liquid mixture in a pasteurizer; cooling the pasteurized dairy liquid mixture in a heat exchanger without freezing the pasteurized dairy liquid mixture; holding the cooled pasteurized dairy liquid mixture in one or more holding tanks for more than eight hours; aerating the pasteurized dairy liquid mixture in an aeration mixer without freezing the pasteurized dairy liquid mixture; routing mix-ins through a multi-deck screener that classifies the mix-ins into at least a three sizes, discarding mix-ins that are two of the sizes, and automatically routing the mix-ins of a third size to a vibratory pan feeder; adding the mix-ins of the third size to the aerated pasteurized dairy liquid mixture using an mixer that is fed the mix-ins of the third size from the vibratory pan feeder; and after adding the mix-ins of the third size, freezing the aerated pasteurized dairy liquid mixture such that the dairy liquid mixture is only frozen after the aerating is completed.Atorney Docket No.: P-645523-PCP-645523-PC-APP15. The method of claim 14, wherein: the aerating includes increasing the viscosity of the pasteurized dairy liquid mixture.

16. A system for manufacturing a frozen milk-based dessert that thaws to banana pudding, comprising: a liquefier mixer configured to create a dairy liquid mixture from mixing dry and liquid ingredients; a pasteurizer configured to pasteurize the dairy liquid mixture; a first pump connected between the liquefier mixer and the pasteurizer; a first holding tank configured to hold the pasteurized dairy liquid mixture; a second pump connected between the pasteurizer and the first holding tank; an aeration mixer; a third pump connected to the aeration mixer and configured to transfer the pasteurized dairy liquid to the aeration mixer after the pasteurized dairy liquid mixture has left the first holding tank; a container filler in fluid communication with the aeration mixer and configured to fill multiple containers with the aerated pasteurized dairy liquid mixture; and a freezer configured to freeze the aerated pasteurized dairy liquid mixture in the multiple containers.

17. The system of claim 16, further comprising: a mixer connected to the aeration mixer and the container filler, the mixer is configured to insert mix-ins into the aerated pasteurized dairy liquid mixture; a multi-deck screener; and a vibratory pan feeder connected to the mixer and the multi-deck screener; the multi-deck screener is configured to classify the mix-ins into at least three sizes, discard mix-ins that are two of the sizes, and automatically route mix-ins of a third size to the vibratory pan feeder; the vibratory pan feeder is configured to transport the mix-ins of the third size to the mixer.

18. The system of claim 17, wherein:Atorney Docket No.: P-645523-PC P-645523-PC-APPthe vibratory pan feeder is configured to adjustably control the rate of inclusion of mix-ins of the third size into the aerated pasteurized dairy liquid mixture via the mixer to accommodate different viscosities of the aerated pasteurized dairy liquid.

19. The system of claim 17, wherein: the multi-deck screener includes three pans stacked vertically, two of the three pans have mesh screens on a bottom surface with different aperture sizes, each of the three pans includes a separate outlet; a middle pan of the three pans has its outlet aligned above an opening of the vibratory pan feeder; and the multi-deck screener includes a motor driven weight to create a flow pattern of mix-ins in each of the three pans toward a respective outlet.

20. The system of claim 16, wherein: the aeration mixer comprises a stainless steel pneumatic enclosure that includes a Matheson volumetric flowrator, a pressure gauge, a pressure regulator, an air check valve injector, and tubing between the flowrator and the air check valve injector.Attorney Docket No.: P-645523-PC P-645523-PC-APP

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