Coating of food products with a particulate coating material

Abstract

The invention relates to a coating machine (10) adapted to coat food products with a particulate coating material. The machine comprises a wire mesh belt (11), a belt drive (12) and multiple rollers (13r, 11a, 11b, 12a, 60a) along which the belt is guided, the wire mesh belt comprising a food products run (F) adapted to receive food products to be coated at an inlet (8) of the machine and to convey the food products towards an outlet (9) of the machine. A return run (T) extends below the food products run, and a central belt drive (12) provided along the return run is adapted to drive the wire mesh belt.

Description

[0001] Title: COATING OF FOOD PRODUCTS WITH A PARTICULATE COATING MATERIAL

[0002] The present invention relates to a coating machine and method for coating food products with a particulate coating material, for example in an in-line arrangement with other food processing equipment, e.g. allowing for large scale food products preparation wherein large volumes of food pieces are coated, e.g. allowing subsequent cooking, e.g. by frying.

[0003] In-line food product coating machines for coating with a particulate coating material are well-known from the prior art and widely available in the field. The particulate coating material might range in composition from a flour mixture to a coarse bread-crumb mixture, e.g. comprising crumbs, e.g. a mixture of coarse and fine particles. The coating material may be composed of a mixture of vastly different particulate materials, not only with respect to particle size, but also, or alternatively, with respect to their structure, basis, etc. The various kinds of coating material allow inclusion of spices or flavourings within the mixture, e.g. adding flavour and / or texture to the product. The coating material may also be referred to as breading.

[0004] Coating machines of this type are commercially available by the applicant and have been described in patent applications and WO2019125157.

[0005] A recovery system is provided to receive coating material for re-use. This can be coating material not being picked up by the products and falling through the wire mesh belt in or after the food products run to the bottom of the machine. It is also conceivable, as described in WO2023217846 of the same applicant, that an excess coating material separation station is provided which is configured to cause excess coating material to be separated from said coated food products.

[0006] The aim of the present invention is to provide an alternative and more versatile coating machine and method.

[0007] The present invention provides a food products coating machine according to claim 1 and a method according to claim 9.

[0008] The coating machine has a single, long wire mesh belt having a food products run, a recovery run and a return run. A belt drive provided along a run of the belt is adapted to drive the wire mesh belt. Commonly, a central belt drive provided along the return run is adapted to drive thewire mesh belt. Alternatively, an inlet belt drive provided at the inlet end of the machine is adapted to drive the wire mesh belt.

[0009] According to the present invention, both a central belt drive and an inlet belt drive are provided to drive the wire mesh belt at the same time.

[0010] The advantage of providing multiple drives for the wire mesh belt is the reduction of load on the belt. The wire mesh belt is installed with a desired tension, adequate to convey the food products and the coating material bed. However, due to the length of the belt and these multiple functions allocated to it, the accumulative forces are high. The overall length of the belt can be 10.000 mm. The accumulation of tension is stopped when passing a drive. Hence, by providing multiple drives high accumulative tension is prevented. In embodiments, the drives split the overall length of the belt, e.g. in 4000-5000 mm.

[0011] Load or tension peaks in the wire mesh belt are e.g. caused by the accumulation of coating material (lumps), e.g. when lumps get stuck between the wire mesh belt and other machine parts. In particular when food products are subjected to a moisturized coating, the coating material tends to form unfavourable doughy lumps. If such a lump of coating material, e.g. a large dough part, comes loose at once, this may cause peak loads on the conveyor. Other causes of tension peaks are e.g. deformed wire belt wires, bone particles being crushed between the wire belt and guide plates. The tension peaks build up over the entire belt loop and can result in high forces on the belt and will eventually result in undesired breaking and reduced belt-life, and breakdowns in the convenience line. As a precautionary measure, the wire mesh belt is replaced on a regular basis to prevent breakdowns. In occasions, preventive replacement takes place every 1 to 2 weeks.

[0012] The implementation of multiple drives for a single belt conveyor is not common and usually not desired because the belt may suffer from uneven driving power allocation, i.e. a dual drive problem of unequal load sharing between primary and secondary drives, also referred to as an ‘overdetermined system.’ A more common solution is to provide two shorter conveyors, each having an associated drive.

[0013] According to the invention, a central belt drive is provided along the return run to drive the wire mesh belt. This location is advantageous as in this return run the belt does not convey food products or coating. Furthermore, the location assures sufficient tension on the belt in the products run. The return run adjoins the food products run at the release roller and extends below the food products run. The central belt drive is provided along the return run to drive thewire mesh belt. It is conceivable that the central belt drive drives the release roller or another roller along the return run.

[0014] Without additional inlet belt drive, tension is built up cumulatively over the entire belt loop from the central belt drive, over the recovery run and the food products run until tension in the belt is at a maximum just prior to arriving back at the central belt drive. This provides a desired minimum tension in the food products run of the belt. On the other hand, without additional central belt drive, tension is built up cumulatively over the entire belt loop from the inlet belt drive, over the food products run, the return run and the recovery run until tension in the belt is at a maximum just prior to arriving back at the inlet belt drive.

[0015] By providing both the inlet belt drive and the central belt drive, tension is built up cumulatively over the belt starting from the inlet belt drive, over the food products run and part of the return run until the central belt drive, where the belt tension is brought back to a desired starting tension. After the central belt drive, tension is built up again in the remaining part of the return run and the recovery run, until the inlet belt drive where the belt tension drops back again to a desired tension level. As a result, the maximum belt force can be kept much lower compared to the belt loop driven by a single drive. In other words, the provision of two drives for the belt reduces the overall belt load in operation.

[0016] Advantageously, the coating material bed is used to supply the coating device of the coating machine. This re-used coating material can e.g. attribute to or provide a bottom coating material bed below the food products run onto which products to be coated are received. In addition, or alternatively, the re-used coating can attribute to be provided to a top coating unit, e.g. via a coating wheel into which the re-used coating is ploughed, positioned above the food products run, allowing the discharge of particulate coating material onto the food products.

[0017] In embodiments, the coating machine comprises a bottom coating material bed support, wherein the bottom coating material bed support is adapted to support thereon a bottom coating material bed of particulate coating material, wherein the coating machine is configured so that food products to be coated are received on said bottom coating material bed, and wherein at least part of the food products run passes through said bottom coating material bed support and is configured to convey said bottom coating material bed over said bottom coating material bed support.

[0018] Preferably, the recovered coating material bed is conveyed to attribute to or form the bottom coating material bed support. At the inlet of the machine, the recovered coating bed material istransported upwards to the product infeed for creating or attributing to a bottom bed. Coating material is pushed through the wire belt from the inside to the outside of the wire mesh belt. Above the bottom coating material bed support, excessive coating material tends to accumulate under the wire belt and may even lift up the wire belt. Therefore, a minimum belt tension is desired in this section of the food products run at the inlet. Such a minimum belt tension is e.g. in the order of 400-800N.

[0019] It is noted that at the inlet, occasionally the belt tension can be excessively high due to meat pieces in the recovery run that are being forced through a narrow passage, in particular between the wire belt and a curved plate provided in the proximity of and extending around part of the periphery an inlet guide roller of the food products run. It is advantageous to have an inlet belt drive at the relatively heavily loaded infeed shaft.

[0020] The provision of both a central belt drive and an inlet belt drive advantageously allows for active control of the belt tension, in particular in the food products run, without overloading the wire belt.

[0021] The provision of an inlet belt drive at the inlet of the machine is advantageous in order to provide adequate belt tension in the food products run. This is in particular advantageous in such embodiments having a bottom coating material bed, requiring sufficient belt tension. Another advantage is that the location of the inlet belt drive is approximately halfway the belt loop.

[0022] In embodiments, a belt tensioner is provided to tension the belt at a certain pre-tension.

[0023] Commonly, such a belt tensioner is pneumatically driven. Alternative methods to actively tension the belt include using gravity and spring loading. Embodiments without an active tensioner are also conceivable. Such a belt tensioner advantageously engages the belt at the return run.

[0024] Advantageously, the central belt drive is provided in the vicinity of a belt tensioner.

[0025] Preferably, the inlet belt drive and the central belt drive are embodied as a master-slave arrangement. In this concept, one drive is the master drive and dictates the belt speed. This is preferably the inlet belt drive. The other drive is the slave drive, preferably the central belt drive.

[0026] In embodiments, the central belt drive and inlet belt drive can be controlled by load sharing. For example, the slave drives the belt with a speed or torque or other parameter relative to the master drive.

[0027] Alternatively, the central belt drive and inlet belt drive can be controlled by active tension control.In embodiments with active tension control, a loadcell is provided, preferably at the inlet of the machine, actively measuring the load on the belt at the inlet, and wherein these measurement data are used as input for an upwards belt drive. In embodiments, the tension of the belt section preceding the central belt drive acting as a slave, i.e. the food products run, can be controlled on the basis of loadcell data obtained at the beginning of the food products run, where the inlet belt drive acts as a master.

[0028] In this concept, also one drive is the master drive and dictates the belt speed. This is preferably the inlet belt drive. The other drive is the slave drive, preferably the central belt drive, and applies a pre-set tension at the belt, advantageously at the position where the coating material is pushed through the wire belt. So with “active tension control”, the actual belt tension is measured by a loadcell. And the pre-set belt tension is obtained by regulating the speed of the central drive.

[0029] In embodiments wherein the central belt drive and inlet belt drive are controlled by load sharing, a loadcell can be dispensed with.

[0030] In embodiments, a rotary tumbling drum is applied for tumbling food products and particulate coating material together, such that a fraction of the particulate coating material adheres to the food product. It is desired to obtain adequately coated food products, in particular combinations of food products, e.g. chicken, and coating material, such as crumbs.

[0031] In embodiments, as explained in detail in WO2019125157, the food products run is configured to extend via the intake opening into a rotary tumbling drum, wherein a release end adjusting mechanism is provided for adjusting the longitudinal position of a release end of the food products run relative to the rotary tumbling drum.

[0032] It is conceivable that in a ‘retracted’ position of the release end the coating machine is in the drum-mode, allowing the dropping of the products to be coated onto the drum wall of the rotary tumbling drum. Possibly, the release end is at the intake opening of the drum wall. It is also possible that the release end of the food products run is at a distance from the intake opening of the rotary tumbling drum, while still allowing products to be dropped onto the drum wall, e.g. via a chute. Such a fully retracted position beyond the intake opening of the drum wall can also be beneficial for other purposes, such as for cleaning or exchange of the rotary tumbling drum.

[0033] In embodiments, the release end in a fully ‘extended’ position adjoins a discharge conveyor assembly, i.e. the conveyor-mode. Alternatively, one or more temporary bridging conveyorsare provided between the release end and the discharge conveyor assembly to arrive at the conveyor-mode of the coating machine.

[0034] In embodiments, distinct modes of the coating machine are also conceivable by distinct positions of the release end, along a length of the drum wall. These modes differ in that products are allowed to tumble less with the release end extending more into the rotary tumbling drum, and tumble more with the release end closer to the intake of the rotary tumbling drum. Hence, the amount of tumbling can be set, adding versatility to the coating machine.

[0035] The invention will now be explained with reference to the drawings. In the drawings:

[0036] Fig. 1a shows a schematic cross-section of an embodiment of a multi-mode coating machine of the invention in the drum-mode;

[0037] Fig. 1b shows a schematic cross-section of the multi-mode coating machine of the invention in the conveyor-mode;

[0038] Fig. 1c shows in a perspective view the wire mesh belt of the coating machine of fig. 1b; Fig. 2a shows in cross section the wire mesh belt of the coating machine of fig. 1b;

[0039] Fig. 2b illustrates the force build up on the belt 11 of the machine of fig. 2a over the entire belt loop in operation;

[0040] Fig. 3a shows in cross section the wire mesh belt of a prior art coating machine similar to that of fig. 1b, with only drive 12;

[0041] Fig. 3b illustrates the force build up on the belt 11 of the machine of fig. 3a over the entire belt loop in operation;

[0042] Figs. 4a-4c show in cross-section and perspective view an alternative configuration of a wire mesh belt of the invention;

[0043] Figs. 5a-5f show in cross-section and perspective view part of the recovery system 60 in detail;

[0044] Figs. 6a-6j show in cross-section and perspective view part of an alternative recovery system 560 in detail;

[0045] Figs. 7a-7b show in cross-section and perspective view part of an alternative recovery system 760 in detail;

[0046] Figs. 8a-8b show in cross-section and perspective view part of an alternative recovery system 860 in detail;

[0047] Figs. 9a-9d show in cross-section and perspective view part of an alternative recovery system 960 in detail.

[0048] With reference to the figures an exemplary embodiment of a coating machine 1 according to the invention will be discussed. The coating machine 1 is adapted to coat food products witha particulate coating material, such as breading crumb material. The coating machine 1 is here embodied as an in-line multi-rotary tumbling drum. Further details of the in-line multirotary tumbling drum coating machine 1 are elucidated in WO2019125157.

[0049] The in-line multi-mode coating machine 1 comprises in-line with each other and in succession, seen in a direction of conveyance C: a coating device 50, a rotary tumbling drum 20 and an elevator device 30. Furthermore, a recovery system 60 is provided. In this embodiment, food products are received by a conveyor assembly 10 at an inlet 8 of the machine and discharged by a discharge conveyor assembly 40 at an outlet 9 of the machine.

[0050] Conveyor assembly 10 comprises a wire mesh belt 11, belt drives 12, 13 and multiple rollers 13r; 11a; 11b; 12a; 60a along which the belt is guided. These rollers can be passive or actively driven. The rollers are e.g. embodied as shafts or guides.

[0051] In the depicted embodiment the wire mesh belt 11 is an endless belt, e.g. a (stainless steel) wire mesh belt as is rather common in the art.

[0052] The wire mesh belt 11 comprises a food products run F adapted to receive food products to be coated at an inlet 8 of the machine. For example, the food products have already passed a batter machine and / or a pre-dusting machine. In embodiments, the food products are fed to the food products run F by a further conveyor, e.g. of such other machine. The food products run F is adapted to convey the food products towards an outlet 9 of the machine, in the shown embodiment to the discharge conveyor assembly 40.

[0053] In the shown embodiment, the food products run F extends between an inlet guide roller 13r, in the shown embodiment driven by an inlet belt drive 13, and a release roller 11a.

[0054] The wire mesh belt 11 further comprises a recovery run R, which will be explained in relation to the recovery system 60. In the shown embodiment, the recovery run extends between a reception roller 60a and the inlet guide roller 13r.

[0055] The wire mesh belt further comprises a return run T, in the shown embodiment extending between the food products run F, in particular starting from the release roller 11a, and the recovery run R, in particular to the reception roller 60a.

[0056] The wire mesh belt 11 in the shown embodiment and according to an aspect of the disclosure is also driven in the return run T by a drive 12 which drives shaft 12a. This drive 12 alsoattributes in control of the belt tension in the food products run. In the shown embodiment the return run T comprises a positioning roller 11b and a tensioning roller 11c.

[0057] It is also conceivable that the wire mesh belt according to an aspect of the disclosure is driven in the return run T by a drive driving the release roller 11a.

[0058] In the shown embodiment a belt tensioning system is provided, comprising a tensioning roller 11c. The wire mesh belt 11 is guided in the return run T along tensioning roller 11c. A tensioning roller 11c is provided for tensioning the belt, in particular the food products run F of the belt.

[0059] The belt drives are preferably motor drives, e.g. of variable speed, and provided to move the belt 11. For example, the motor drive drives a shaft or roller over / along which the belt is guided.

[0060] Preferably, the inlet belt drive 13 acts as a master and the central belt drive 12 as a slave.

[0061] In embodiments, a loadcell is provided at the inlet 8 of the machine, actively measuring the load on the belt 11 at the inlet, and wherein these measurement data are used as input for the central belt drive 12. This is in particular advantageous in cases requiring active tension control.

[0062] In the shown embodiment, discharge conveyor assembly 40 comprises a discharge mesh belt 41, here an endless belt, e.g. a (stainless steel) wire mesh belt as is common in the art. A discharge drive 42, preferably a motor drive, e.g. of variable speed is provided to move the discharge mesh belt 41, here by driving a discharge shaft 42a. Multiple rollers are provided along which the discharge mesh belt 41 is guided. A discharge tensioning roller 411 is provided which is part of a discharge tensioning system, adapted to adjust the tension of the discharge mesh belt 41.

[0063] The discharge mesh belt 41 comprises a discharge food products run FD adapted to receive coated food products and to convey the coated food products in the direction of conveyance C towards the outlet 9 of the machine. The discharge food products run FD extends between a discharge inlet roller 41m and a discharge outlet roller 41 n at the outlet 9 of the machine.

[0064] In the drum-mode shown in fig. 1a, the release roller 11a of the food products run F is in the proximity of the rotary tumbling drum 20, allowing in a drum-mode of the coating machine thedropping of the products to be coated onto the drum wall 22 of the rotary tumbling drum 20. It is also conceivable that the release roller 11a of the food products run extends into the rotary tumbling drum 20.

[0065] In the drum-mode shown in fig. 1a, the discharge food products run FD receives coated food which are gravity fed from the elevator device 30 onto a receiving part 43 of the discharge food products run FD and conveys the coated food products to an outlet 9 of the machine 1. Here, the discharge food products run FD extends between a discharge inlet roller 41m, in the shown embodiment in the proximity of discharge opening 26 of the rotary tumbling drum 20 to take over the food products, and discharge outlet roller 41 n at the outlet 9 of the machine.

[0066] In fig. 1b the in-line multi-mode coating machine is shown in the conveyor-mode, wherein the position of the release end 11a of the conveyor assembly 10 and the discharge food products run FD of the discharge conveyor assembly 40 are arranged to adjoin each other whilst extending through the rotary tumbling drum 20, so that food products bypass the rotary tumbling drum 20 and the rotary elevator wheel 30. The discharge food products run FD receives coated food products directly from the food products run F of the conveyor assembly 10. The discharge food products run FD extends between discharge inlet roller 41m, here in the proximity of roller 11a of the conveyor assembly 10 to take over the food products, and discharge outlet roller 41 n at the outlet 9 of the machine.

[0067] In practical embodiments the belt width of the conveyor assemblies 10, 40 of the machine may be between 40 and 100 centimetres. As will be appreciated the diameter of the rotary tumbling drum and the elevator device is greater than said width, e.g. in the range between 60 and 120 centimetres. For example, the diameter of the drum and elevator device is at least 20 centimetres greater than the width of the section of the conveyor assembly extending through the drum in the conveyor mode. Preferably the width of the conveyor assemblies of the machine is the same, e.g. when formed by one and the same conveyor belt, e.g. wire mesh belt. e.g. exceeds 60 cm, preferably 90 cm, allowing the passage of a conveyor having a conveyor width of 50-80 cm in the conveyor-mode.

[0068] In the shown configuration, the food products run F, and the discharge food products run FD both extend at a slight obtuse angle with the horizontal, essentially horizontally, and at generally the same first horizontal level.In the shown coating machine 1, the position of the positioning roller 11b and the release roller 11a is adjustable to alter the conveyor assembly 10 between the drum-mode, as shown in fig. 1a, and conveyor-mode coating, as shown in fig. 1b.

[0069] In particular, the release roller 11a of the conveyor assembly 10 is allowed to extend via intake opening 25 into the rotary tumbling drum 20 - as shown in fig. 1b.

[0070] To this end, the infeed conveyor assembly 10 is provided with a release end adjusting mechanism for adjusting the longitudinal position of the release roller 11a and the positioning roller 11 b of the conveyor assembly 10 relative to the rotary tumbling drum 20. This mechanism for example comprises a telescopic support for the release roller 11 a of the assembly 10 at said release end.

[0071] For example, the release end adjusting mechanism comprises a spindle drive, e.g. manually operable, to adjust the position of the release roller 11a, e.g. to extend and retract a telescopic support for the release roller 11a.

[0072] As shown, the release end adjusting mechanism is, as preferred, with a belt length compensation mechanism that is adapted for compensating the length of the belt of the conveyor upon adjusting the position of the release roller 11a. Here this compensation mechanism comprises a positioning roller 11b that has adjustable positions relative to the frame of the machine, e.g. displaceable over a guide. For example, the positioning roller 11b is mechanically linked to the release roller 11a and / or a telescopic support thereof.

[0073] In fig. 1 a top coating unit 50 is shown, positioned above the conveyor assembly 10, upstream of the rotary tumbling drum 20, allowing the discharge of particulate coating material onto the food products. The shown coating unit resembles the commercially available RotoCrumb. A skilled person is familiar with multiple alternative coating units, which are all suitable to be combined with the in-line multi-mode coating machine of the invention.

[0074] The top coating device 50 that is supplied with particulate coating material discharges particulate coating material from above onto the food products on the food products run F.

[0075] In the shown embodiment, the top coating unit 50 comprises a top coating conveyor 51 driven by a top coating conveyor drive 52 to spread the top coating over the food products run F and over the bottom coating material bed support 15.The coating machine 1 further comprises a bottom coating material bed support 15, adapted to receive thereon a bottom coating material bed of particulate coating material. The bottom coating material bed receives food products to be coated in proximity of the inlet 8 of the machine 1. The coating machine 1 is configured so that food products to be coated are received on said bottom coating material bed. At least part of the food products run F passes over said bottom coating material bed support. The advancing conveyor run F conveys this bottom coating material bed over the bottom coating material bed support 15.

[0076] In the shown configuration, the bottom coating material bed will also receive coating material from above from the top coating unit 50.

[0077] Here, as preferred, the support bed 15 also is telescopic with bed plates 15a, 15b, wherein bed plate 15b slides relative to stationary bed plate 15a when the release end adjusting mechanism is operated, altering the coating machine between the drum-mode and the conveyor-mode.

[0078] The rotary tumbling drum 20 is adapted to be supplied with particulate coating material and to tumble the food products and particulate coating material together about a longitudinal axis, here a horizontal longitudinal axis, to subject the food products to a coating treatment wherein some of the particulate coating material adheres to the food products while the remainder is excess coating material. The rotary tumbling drum comprises a drum wall 22 between an intake opening 25 and a discharge opening 26. In the drum mode shown in fig. 1a, the release roller 11a of the food products run F is positioned adjacent, but not into the intake opening 25 of the rotary tumbling drum 20.

[0079] In the shown embodiment, the drum wall 22 is provided on the inside thereof with a helical structure 23 configured to advance or assist in advancing the mixture of coating material and coated food products in the direction towards the discharge opening 26. Alternative structures for achieving this advancing effect are also conceivable. It is also conceivable that the mixture and products are advanced without the presence of such a structure.

[0080] In embodiments it is envisaged that a substantial amount of coating material is deposited in the drum 20 via the food products run F, e.g. falling off the release roller 11a, and piles up in the drum 20.

[0081] In the embodiment of fig. 1 , further internal agitator members 24 are provided at the inside of the drum wall 22 to repeatedly lift and drop the mixture of food products and particulatecoating material, thereby tumbling and mixing the food products and particulate coating material. It is conceivable that the configuration of the internal agitator members 24 at the same time form a structure for advancing the mixture of coating material and food products in the direction of the discharge opening.

[0082] The in-line multi-mode coating machine 1 further comprises an elevator device 30, which is adapted to receive the mixture of a portion of coating material and coated food products from the discharge opening 26 of the rotary tumbling drum and to supply said coated food products to the discharge conveyor assembly 40. The elevator device 30 is positioned adjacent and downstream in the direction of conveyance of the rotary tumbling drum 20.

[0083] In the shown embodiments, the elevator device 30 here comprises a food product elevator wheel with an annular wheel body 32 adapted to revolve about an axis of rotation, here coinciding with the longitudinal axis of the rotary tumbling drum 20, by an elevator wheel drive. The elevator wheel 30 is for example rotatably supported in a frame of the machine 1, e.g. on rollers, to revolve about a substantially horizontal axis of revolution. A motor drive, e.g. of variable speed, is provided to drive the wheel 30, e.g. a wheel having a circular toothed rack and the drive having a mating pinion. In preferred embodiments, the elevator wheel drive is independent from the rotary tumbling drum drive, allowing distinct drive speeds.

[0084] Here, the elevator wheel 30 has a circumferential array of pockets 31 in said annular wheel body 32, the pockets being open towards a central opening of the elevator wheel and adapted to receive therein the coated food products, said elevator device being adapted to move said mobile array of pockets along an endless path that passes said discharge opening 26 of the rotary tumbling drum 20 in order to fill coated food products and possibly also excess coating material from the rotary tumbling drum into said pockets. The coated food products are discharged from said pockets and the discharged coated food products are supplied onto the discharge food products run FD, in particular the receiving part 43 of the discharge food products run FD.

[0085] In the drum-mode, the discharge food products run FD is positioned downstream of the elevator device 30 and may be positioned adjacent the elevator device 30 or extend partly into the elevator device. It is conceivable that in the conveyor-mode, the discharge food products run FD extends through the elevator device 30, and possibly even (partly) through the rotary tumbling drum 20.In figs. 1a and 1b a chute 35 is visible, provided in a central opening of the elevator wheel, for guiding products dropping out of the pockets of the elevator device onto the receiving part 43 of the discharge food products run FD. Such a chute 35 allows a configuration wherein the discharge food products run FD is positioned at a (small) distance from the elevator device 30. The chute advantageously attributes to remaining the integrity of delicate products.

[0086] The provision of a chute could also attribute to a distribution of products onto the receiving part of the discharge food products run FD. For example, a chute could align products in the direction of conveyance. In addition or alternatively, products could be distributed over the width of the receiving part of the discharge food products run FD. In embodiments, the chute is provided with alignment means such as grooves.

[0087] It is also conceivable that the chute is provided with openings acting as sieve for excess coating material. Optionally, the chute is provided with a vibration motor, assisting in the sieving of excess coating material.

[0088] The coating machine further comprises a recovery system 60 adapted to receive coating material for re-use.

[0089] In the coating machine shown in figs. 1a and 1b, downstream of the coating devices 50, 20, and adjacent the discharge food products run FD an excess coating material separation station 48 is provided which is configured to cause excess coating material to be separated from the coated food products in order to recover the excess coating material for re-use.

[0090] In the very simple and practical embodiment depicted, the station 48 is no more than the trailing end of a discharge support bed 45 extending below the discharge food products return run, which causes excess material to drop through the mesh belt of the discharge food products return run FD whilst the coated products remain on the belt 41. In another embodiment, e.g. in addition to the trailing end of discharge support bed 45, one or more blowers, air-knives 49, etc. may be provided to cause or enhance removal of excess coating particles, e.g. blowing said excess down through the mesh belt 41. In embodiments separation of excess material is enhanced by having a belt agitator device at station 48, so that excess material is dislodged from the belt and / or the food products.

[0091] The recovery system comprises a bed support 65 adapted to receive thereon said coating material to form a recovered coating material bed on said bed support.A recovery run R, here of the wire mesh belt 11 , extends above said bed support 65 and is movable relative to said bed support and configured to convey said coating material bed over said bed support towards the inlet 8 of the machine. In the shown embodiment, the recovery run extends between a reception roller 60a and the inlet guide roller 13r.

[0092] The recovery system 60 further comprises a guide 61 adapted to guide coating material to the reception roller 60a. A curved guide plate 62 is provided in the proximity of and extending about a sector of the reception roller 60a, here between the guide 61 and the bed support 65, to form a slit 63 between the guide plate and the reception roller. The guide plate 62 extends around part of the periphery of the reception roller 60a. Preceding the recovery run R, the wire mesh belt 11 is movable over the reception roller 60a relative to the guide plate 62 and configured to draw (convey) coating material for re-use through the slit 63 between the guide plate 62 and the wire mesh belt 11 towards the bed support. This is shown in further detail in figs. 5a-5f.

[0093] The shown coating machine 1 comprises a particulate coating material elevator wheel 55 that is adapted to supply a portion of the recovered coating material to the top coating device 50 for reuse. Details of such a particulate coating material elevator wheel 55 are further described in WO2023217846.

[0094] An elevator wheel fill assembly is arranged along the recovery run R configured to fill pockets of the revolving particulate coating material elevator wheel with recovered excess coating material.

[0095] As can be seen the coating machine 1 is embodied to transfer recovered excess coating material remaining in the recovered coating material bed downstream of the elevator wheel fill assembly to the bottom coating material bed support 15.

[0096] In this embodiment inlet guide roller 13r, guiding the wire mesh belt 11 is partly surrounded by a curved deflector 14 that forms an extension of bed support 65 so that excess coating material is moved around the inlet guide roller 13r onto an inclined ascending portion of the bottom coating material bed support 15.

[0097] The elevator wheel 55 comprises an annular wheel body adapted to revolve about an axis of rotation and having a central opening, and a circumferential array of pockets in said annular wheel body, the pockets being open towards the central opening of the elevator wheel.The elevator wheel 55 is rotatably supported in a frame of the machine 1, e.g. on rollers, to revolve about a substantially horizontal axis of revolution. A motor drive, e.g. of variable speed, is provided to drive the elevator wheel 55, e.g. a wheel having a circular toothed rack and the drive having a mating pinion.

[0098] As depicted the food products run F, return run T and the recovery run R each extend through the central opening of the annular wheel body, the recovery run R below the return run T and the return run T below the food products run F. Also depicted is that the elevator wheel 55 passes over the top coating device 50 such that particulate coating material is gravity fed from pockets into the top coating device 50.

[0099] Advantageously, the elevator wheel fill assembly comprises one or more adjustable discharge opening devices adapted to control one or more discharge openings across the recovered coating material bed support, in the recovered coating material bed allowing to discharge at an adjustable rate a portion of the recovered coating material bed passing over the one or more discharge openings into pockets of the particulate coating material elevator wheel.

[0100] In the shown embodiment, the elevator wheel fill assembly further comprises an adjustable upper layer diverter device 58 that is configured to engage an upper layer of the recovered coating material bed passing over the recovered coating material bed support 65, with a lower layer passing underneath the diverter device 58, and to divert at least a portion of said upper layer at an adjustable rate into (pockets of) the particulate coating material elevator wheel 55.

[0101] The upper layer diverter device 58 e.g. comprises at least one diverter blade engaging the upper layer and diverting at least a portion thereof over one of the lateral sides and into the particulate coating material elevator device 55. The blades are e.g. arranged in a V with point counter to the direction of conveyance of the recovered coating material bed when seen in top view.

[0102] The effect of the dual drive follows from figures 2a, 2b, 3a, 3b. Figs. 2a and 3a show in cross section the wire mesh belt 11 of a coating machine. In fig. 2a the coating machine of figs, laic is shown, having two belt drives 12, 13. The wire mesh belt 111 of fig. 3a is driven by a single drive 112. Similar parts have been given same reference numerals, to which ‘100’ has been added.

[0103] On the belt the location of load measurements is indicated in roman reference numerals i-xi. In figs. 2b and 3b on the y-axis the force build up in the wire belt over the entire loop isshown, in gentle circumstances (solid line) and hard circumstances (dashed line). The roman reference numerals i-xi indicated in the x-direction in the graphs correspond with the belt sections as indicated in figs. 2a and 3a.

[0104] In fig. 3b the force build up in coating machines having a single drive 112 is shown. The belt 111 is tensioned at a certain pre-tension and from directly after the drive 112, tension starts to be built up cumulatively all the way over the entire belt loop 111 from start i to end xi. Only at the drive 112 the belt load in the belt drops back until pre-tension level.

[0105] In fig. 2b a similar force build up in two different circumstances is shown, in a machine having two drives 12 and 13. Instead of further increasing the belt force in section vi-vii, the belt force drops until a certain level. From the drive 13 onwards, the belt force starts increasing again until the next drive 12, similar to drive 112 of fig. 3a. As a result the maximum belt force can be kept much lower compared to the belt 111 driven by one drive 112.

[0106] In figs. 4a-4c in cross-section and perspective view an alternative configuration of a wire mesh belt 211 of a coating machine adapted to coat food products with a particulate coating material, according to an aspect of the invention is shown. The coating machine comprises a wire mesh belt 211, and belt drives 212, 213 and multiple rollers 213r; 211a; 212a; 211c along which the belt is guided. The wire mesh belt comprises a food products run F adapted to receive food products to be coated at an inlet 208 of the machine and to convey the food products towards an outlet 209 of the machine. A coating device, not shown, is provided, and adapted to be supplied with particulate coating material and to subject the food products on the food products run F to a coating treatment wherein coating material adheres to the food products. A return run T extends below the food products run F.

[0107] A central belt drive 212 provided along the return run T is adapted to drive the wire mesh belt, in particular shaft 212a. In addition, an inlet belt drive 213 is provided at the inlet end 208 of the machine and is adapted to drive the wire mesh belt at the same time by driving inlet shaft 213r.

[0108] Part of the recovery system 60 is shown in detail in figs. 5a-5f. Guide plate 62 is provided in the proximity of and extending about a sector of the reception roller 60a to form a slit 63 between the guide plate and the reception roller, extending towards the bed support 65. The guide plate 62 extends around part of the periphery of the reception roller 60a. Preceding the recovery run R, the wire mesh belt 11 is movable over the reception roller 60a relative to theguide plate 62 and configured to convey said coating material in a slit 63 between the guide plate 62 and the wire mesh belt 11 towards the bed support.

[0109] In figs. 5d-5f said coating material M is shown. Upon clockwise rotation of the reception roller 60a coating material on the wire mesh belt is conveyed around the reception roller 60a in the slit 63 between the guide plate 62 and the wire mesh belt 11. It is noted that smaller parts of coating material are allowed to pass through the wire mesh belt directly and are not conveyed by the wire mesh belt. In fig. 5e, a start of an accumulation of coating material M is visible, resulting in a lump of coating material M* in fig. 5f. This lump of coating material M* will cause extensive tension forces on the wire mesh belt 11.

[0110] According to an aspect of the invention, the width of the slit 63 is periodically variable during said conveying of the coating material in the slit. An example is shown in figs. 6a-6j. Here part of recovery system 560 is shown in detail. Similar parts have been indicated with the same reference numeral to which 500 has been added. Guide plate 562 is provided in the proximity of reception roller 560a between a guide (not shown) and the bed support 565. The guide plate 562 extends around part of the periphery of the reception roller 560a. Preceding the recovery run R, wire mesh belt 511 is movable over the reception roller 560a relative to the guide plate 562 and configured to convey said coating material in a slit 563 between the guide plate 562 and the wire mesh belt 511 towards the bed support 565.

[0111] In figs. 6c-6j said coating material M is shown. Upon clockwise rotation of the reception roller 560a coating material on the wire mesh belt 511 is conveyed around the reception roller 560a in the slit 563 between the guide plate 562 and the wire mesh belt 511. In fig. 6c, a lump of coating material M* at the entrance of the slit 563 is visible, similar to the situation of fig. 5f.

[0112] In the alternative embodiment of figs. 6a-6j, the reception roller 560a has an oval shape, distinct from the round reception roller 60a of figs. 1a-1c and 5a-5f. The advantage of an oval reception roller 560a is visible in figs. 6c-6j: the lump of coating material M* the lump is scraped off in small bits than can be conveyed to the bed support 565. The oval shape attributes to pulverization of the coating material and / or prevents the formation of unfavourable doughy breading lumps, clogs, or nuggets. Visible is that a propulsive displacement effect is created between the guide plate 562 and the mesh belt 511, towards the bed support. This creates a flow and avoids a stagnant mass from sticking to the guide or guide plate.In figs. 7a-7b an alternative recovery system 760 in detail; and in figs. 8a-8b an alternative recovery system 860. Similar parts have been indicated with the same reference numeral to which 700 respectively 800 has been added. Guide plate 762, 862 is provided in the proximity of reception roller 760a, 860a between a guide (not shown) and the bed support 765, 865. The guide plate 762, 862 extends around part of the periphery of the reception roller 760a, 860a. Preceding the recovery run R, wire mesh belt 711, 811 is movable over the reception roller 760a, 860a relative to the guide plate 762, 862 and configured to convey said coating material in a slit 763, 863 between the guide plate 762, 863 and the wire mesh belt 711, 811 towards the bed support 765, 865.

[0113] The reception roller 760a has a triangular shape, while the reception roller 860a is mounted eccentrically. Both configurations create a periodically variable slit, similar to the oval reception roller 560a and thereby cause any lump of coating material to be scraped off in small bits, attributing to pulverization of the coating material and / or prevents the formation of unfavourable doughy breading lumps, clogs, or nuggets.

[0114] In figs. 9a-9d yet an alternative recovery system 960 is shown in detail. Similar parts have been indicated with the same reference numeral to which 900 has been added. Guide plate 962 is provided in the proximity of reception roller 960a between a guide (not shown) and the bed support 965. The guide plate 962 extends around part of the periphery of the reception roller 960a. Preceding the recovery run R, wire mesh belt 911 is movable over the reception roller 960a relative to the guide plate 962 and configured to convey said coating material in a slit 963 between the guide plate 962 and the wire mesh belt 911 towards the bed support 965. In the shown embodiment, a guide plate drive 964 is provided to dynamically position the curved guide plate to create the periodically variable slit 963. In fig. 9c a smaller slit 963’ is shown than the slit 963 in fig. 9a.

Claims

CLAIMS1. Coating machine (1) adapted to coat food products with a particulate coating material, the machine comprising:a wire mesh belt (11) and multiple rollers (13r; 11a; 11b;12a; 60a) along which the belt is guided, the wire mesh belt comprising a food products run (F) between an inlet guide roller (13r) provided at the inlet of the machine and a release roller (11a), which food products run (F) is adapted to receive food products to be coated at an inlet (8) of the machine and to convey the food products towards an outlet (9) of the machine; wherein a return run (T) adjoins the food products run (F) at the release roller (11a) and extends below the food products run (F), and wherein a central belt drive (12) is provided along the return run to drive the wire mesh belt;a coating device (50, 20) adapted to be supplied with particulate coating material and to subject the food products on the food products run to a coating treatment wherein coating material adheres to the food products;a recovery system (60) adapted to receive coating material for re-use; characterized in that in addition, an inlet belt drive (13) is provided to drive the inlet guide roller (13r).

2. Coating machine according to claim 1, wherein the recovery system (60) comprises: o a bed support (65) adapted to receive thereon said coating material to form a recovered coating material bed on said bed support,o a recovery run (R) of the wire mesh belt (11) above said bed support and movable relative to said bed support and configured to convey said coating material bed over said bed support towards the inlet of the machine; wherein the return run (T) extends between the food products run (F) and the recovery run (R).

3. Coating machine according to any of the preceding claims, wherein the inlet belt drive and the central belt drive are embodied as a master-slave arrangement.

4. Coating machine according to any of the preceding claims, wherein a loadcell is provided at the inlet of the machine, actively measuring the load on the belt at the inlet, and wherein these measurement data are used as input for the central belt drive.

5. Coating machine according to any of the preceding claims, wherein a belt tensioning system is provided, comprising a tensioning roller 11c having an adjustable position, wherein the wire mesh belt 11 is guided in the return run T along the tensioning roller 11c.

6. Coating machine according to any of the preceding claims, wherein the coating machine comprises a bottom coating material bed support (15), wherein the bottom coating material bed support is adapted to support thereon a bottom coating material bed of particulate coating material, wherein the coating machine is configured so that food products to be coated are received on said bottom coating material bed, and wherein at least part of the food products run passes over said bottom coating material bed support and is configured to convey said bottom coating material bed over said bottom coating material bed support.

7. Coating machine according to any of the preceding claims, further comprising an excess coating material separation station (48) configured to cause excess coating material to be separated from said coated food products in order to be recovered by the recovery station.

8. Coating machine according to any of the preceding claims, wherein the recovered coating material bed is used to supply the coating device (50, 20) of the coating machine, preferably attribute to or provide a bottom coating material bed below the food products run onto which products to be coated are received, and / or attribute to a top coating unit (50), positioned above the food products run, allowing the discharge of particulate coating material onto the food products.

9. Method for coating of food products, wherein use is made of a coating machine according to any of the preceding claims, preferably comprising the step of conveying of the coating material in the slit, during which the width of the slit periodically varies.

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