Batch Cooker Oil Recirculation for Uniform Kettle Chip Frying
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Solution Overview
Problem
Existing kettle-type potato chip cooking systems suffer from oil degradation due to residue accumulation, non-uniform heating, and oxidation from air exposure, leading to inefficiencies and inferior product quality.
Innovation Solution
A batch cooker system with a recirculation system that includes a heat exchanger, inlet and outlet valves, and a bypass valve to maintain uniform oil temperature and prevent oxidation, combined with a stirrer and conveyor system for efficient cooking and oil reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional kettle-type cooking systems are used to cook potato chips, then the cooking process is simple and direct, but oil degradation occurs due to residue accumulation, non-uniform heating, and oxidation from air exposure
Solution Approach 1:
The harmful element (air/oxygen) is extracted from the cooking environment by sealing the cooking chamber and replacing air with inert gas (nitrogen or carbon dioxide). This prevents oxidation of the oil while maintaining a simple cooking process, directly resolving the contradiction between simplicity and oil quality consistency.
Solution Approach 2:
An inert atmosphere is created by introducing nitrogen or carbon dioxide gas into the sealed cooking chamber, replacing the air. This inert environment prevents oxygen from contacting the hot oil, eliminating oxidation and degradation while keeping the cooking system straightforward.
Solution Approach 3:
The oil filtration system operates continuously during the cooking process, constantly removing residues and impurities from the oil. This continuous action maintains oil quality and prevents degradation, resolving the contradiction without requiring complex batch processing.
2Productivity
If constant flame heating is applied to maintain cooking temperature, then the cooking process is efficient, but hot spots occur that degrade the oil
Solution Approach 1:
The mechanical flame heating system is replaced with an electrical heating element that provides uniform heat distribution across the cooking oil. This substitution eliminates hot spots while maintaining cooking efficiency, directly addressing the contradiction between productivity and temperature uniformity.
Solution Approach 2:
The heating method is changed from flame (which creates localized high-temperature zones) to electrical heating (which provides uniform temperature distribution). This parameter change in the heating mechanism eliminates hot spots while preserving cooking efficiency.
3Ease of operation
If the exhaust hood is spaced above the kettle to allow access, then operation is convenient, but oxygen from the air reacts with the oil and degrades it
Solution Approach 1:
Oxygen is extracted from the cooking environment by sealing the chamber and replacing air with inert gas. This eliminates the harmful oxidation effect while maintaining hood accessibility for operation.
Solution Approach 2:
The cooking chamber is filled with inert gas (nitrogen or carbon dioxide) to create an oxygen-free environment. This prevents oil oxidation while allowing the exhaust hood to remain accessible for normal operation.
4Temperature
If raw potato slices are added to heated oil to create inverse bell curve temperature profile, then the cooking temperature control is achieved, but the oil temperature decreases and requires constant reheating
Solution Approach 1:
The electrical heating element operates continuously to maintain oil temperature, replacing the intermittent flame reheating process. This continuous heating is more energy-efficient while achieving the same inverse bell curve temperature profile control.
Solution Approach 2:
The flame heating system is replaced with an electrical heating element that responds more efficiently to temperature changes. This substitution reduces energy loss while maintaining precise temperature profile control during the cooking process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures consistent and efficient cooking of kettle chips by maintaining uniform oil temperature and preventing oxidation, reducing oil degradation and improving product quality and efficiency.
Implementation Method 1
a heat exchanger configured to heat cooking oil flowing through the heat exchanger
Implementation Method 2
an oil pump configured to pump oil through the oil recirculation system
Data Source
AI summary
Batch cookers, as well as methods for cooking using the batch cookers, are provided. A batch cooker comprises a cooking trough configured to hold a volume of heated cooking oil. An oil recirculation system delivers heated cooking oil from an external heat source (e.g., a heat exchanger) to the cooking trough through a series of valves and inlets. After use in cooking, used cooking oil is drained from the cooking trough and filtered (e.g., using a drum filter) before being recirculated into the heat source for reuse in subsequent cooking cycles. One application for the batch cooker of the present disclosure is to cook kettle-style potato chips. Accordingly, the batch cooker is configured to facilitate the multiple cooking temperatures required to produce kettle chips.