Combisteamer Tray-Level Control to Prevent Cross-Contamination
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Solution Overview
Problem
The 'rolling' cooking process in combisteamers often leads to cross-contamination of food products due to condensates dripping from upper trays to lower trays, where the lower trays may not have sufficient cooking time to kill pathogens, posing a risk of food contamination.
Innovation Solution
A system using a distance sensor and camera to identify the level and type of food products, determining the 'hygienic safe control time' (HSCT) for each product, and blocking unsafe levels to prevent cross-contamination by ensuring that food products are not placed on levels with insufficient cooking time remaining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rolling cooking process is used to increase productivity and flexibility, then the cooking device can handle multiple food products with different cooking times, but cross-contamination risk increases due to condensates dripping from upper trays to lower trays
Solution Approach 1:
The system performs preliminary actions by detecting food products and calculating HSCT values before the cooking process begins. It proactively identifies unsafe tray configurations and prevents cross-contamination before it occurs, rather than reacting after contamination has happened. The camera and sensor system scans and analyzes the cooking chamber state before allowing the rolling cooking process to proceed.
Solution Approach 2:
The system implements continuous feedback by monitoring the cooking chamber, calculating HSCT values in real-time, and providing visual feedback through the display interface. The system adjusts tray availability based on feedback from the cooking process state, dynamically updating which trays are safe for loading. This closed-loop control ensures productivity is maintained while preventing cross-contamination.
2Object-affected harmful factors
If sheet metal barriers are added between cooking levels to prevent cross-contamination, then food safety is improved, but device complexity and space utilization deteriorate
Solution Approach 1:
The patent replaces the mechanical barrier system (sheet metal barriers) with an intelligent control system using cameras, sensors, and software algorithms. Instead of physically blocking condensate flow, the system uses optical detection and computational logic to identify and prevent unsafe configurations. This substitution reduces mechanical complexity while maintaining cross-contamination prevention effectiveness.
Solution Approach 2:
The system changes the approach from physical modification (adding barriers) to parameter-based control (HSCT calculations). By monitoring and controlling the time parameter (cooking duration) and tray position parameters, the system dynamically determines safety without adding physical barriers. This parameter-based approach maintains simplicity while achieving the same safety outcome.
3Object-affected harmful factors
If sheet metal barriers or additional trays are used to prevent cross-contamination, then food safety is improved, but the space available for cooking trays is reduced
Solution Approach 1:
The system replaces physical space-consuming barriers with a software-based detection and control system. The camera and sensor array requires minimal space compared to sheet metal barriers that would physically block the cooking chamber. This substitution preserves maximum cooking space while achieving cross-contamination prevention through intelligent monitoring and tray availability control.
4Object-affected harmful factors
If the cooking device monitors and controls tray safety in real-time, then cross-contamination is prevented, but the system complexity increases
Solution Approach 1:
The system performs self-service by automatically detecting food products, calculating HSCT values, and determining tray safety without requiring external intervention. The camera system autonomously identifies products, the processor automatically computes safety parameters, and the display interface self-updates tray availability status. This automation reduces the need for complex manual monitoring systems while achieving effective cross-contamination control.
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
Effectively reduces or eliminates cross-contamination by ensuring that food products are placed on levels with sufficient cooking time, providing a safer cooking environment without requiring additional hardware or handling.
Implementation Method 1
a camera (10) for capturing an image of the food product (P)
Implementation Method 2
a distance sensor (9) for detecting a position of a carrier tray (7) holding the food product (P)
Implementation Method 3
combisteamers are generally designed to cook food products using heat, steam or a combination of heat and steam
Implementation Method 4
cook food products using heat, steam or a combination of heat and steam
Implementation Method 5
cook food products using heat, steam or a combination of heat and steam
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Disclosed are methods and system for reducing or eliminating the possibility of cross-contamination between food to be cooked in a cooking device and food cooking in the cooking device. The methods and systems determine the placement into a cooking device of food product to be cooked by the distance sensor, determine a hygienic safe cooking time (HSCT) for that product based on the identification of food product to be cooked, and compare the HSCT to one or more remaining cooking times of food product cooking in the cooking device on levels below and/or above the desired placement of the food product to be cooked. Various methods of identifying the food to be cooked may be employed, both manual and automatic. As a result of the comparison, the methods and systems of the disclosure can identify safe carrier/tray level(s) for accepting placement of the food to be cooked.