Continuous Food Coating Method with Recycled Stream
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Solution Overview
Problem
Current food coating methods produce homogenously coated products, lacking visual and textural interest, and do not allow for a range of coating layers on individual food pieces.
Innovation Solution
A continuous coating method involving a stream of uncoated food pieces being coated, split, and a portion redirected back through the enrober for additional coating, allowing for a range of coating layers on individual pieces, with the option to select the portion redirected based on size or weight, using a system with separate enrobers for liquid and dry components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single pass enrobing method is used, then the coating process is simple and efficient, but the product lacks visual and textural interest due to homogenous coating
Solution Approach 1:
The patent implements a nested structure where coated pieces are recycled back through the enrober multiple times. Each pass through the enrober adds another layer of coating, creating a nested sequence of coating applications (1st pass, 2nd pass, 3rd pass, etc.) that builds up variable coating thicknesses on different pieces, transforming the homogenous single-layer coating into a multi-layered structure with visual and textural variety.
2Ease of manufacture
If multiple coating passes are applied to all pieces, then visual and textural interest is improved, but the manufacturing complexity and processing time increase
Solution Approach 1:
The system uses the output of the enrober (coated pieces) to feed back into the same enrober input, creating a self-contained recycling loop. The coated pieces that receive additional coating passes are automatically separated and redirected back through the enrober, while single-coated pieces exit the system. This self-service mechanism achieves variable multi-layer coating without requiring complex external control systems or additional coating equipment.
Solution Approach 2:
The single enrober device performs multiple functions: it applies the first coating pass to all pieces, and subsequently applies additional coating passes to selected pieces that are recycled back through it. This multi-functional use of the same equipment eliminates the need for multiple separate enrobers or complex coating lines, maintaining manufacturing simplicity while achieving variable multi-layer coating results.
3Ease of manufacture
If coated pieces are recycled back through the enrober, then a range of coating layers is achieved, but the risk of over-coating and quality control difficulty increases
Solution Approach 1:
The system applies coating passes progressively and partially to different pieces. Not all pieces receive the same number of coating passes - some receive 1 pass, others receive 2, 3, or more passes. This partial action approach creates a deliberate distribution of coating thicknesses rather than uniform over-coating, achieving a range of coating layers while maintaining quality control through controlled recycling rates and enrober parameters.
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
This method produces food pieces with coatings distributed over a range of thicknesses and numbers of layers, enhancing visual and textural interest while utilizing waste products as coating components, maintaining product quality and reducing waste.
Implementation Method 1
directing the stream through an enrober to apply a first coating to at least a portion of a surface of each food piece
Data Source
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AI summary
Disclosed are methods and systems for continuously coating food pieces. The methods include a steps of directing and uncoated food stream through an enrober to apply a first coating to at least a portion of a surface of each food piece to form a coated stream and continuously redirecting a portion of the coated stream back through the enrober along with the stream of uncoated food pieces to apply at least one additional coating to the portion of the coated stream.