Automatic Fryer Oil Circulation and Gating for Continuous Cooking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fryers face inefficiencies in cooking and filtering processes, including temperature uniformity issues, manual filtration complexities, and operational interruptions, leading to increased costs and reduced productivity.
Innovation Solution
A system with a flume-style cooking chamber that continuously circulates and filters cooking medium using a pump, featuring a false bottom for easy cleaning and actuable gates to manage food product flow, eliminating the need for baskets and allowing for continuous filtration during cooking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple frozen food products are placed into hot oil at the same time, then productivity increases, but temperature uniformity deteriorates and cooking time increases
Solution Approach 1:
The cooking chamber is divided into multiple zones with independent heating elements and temperature controls, allowing different temperature zones to handle different cooking stages simultaneously. This enables maintaining temperature uniformity even when multiple batches are being cooked at different rates.
Solution Approach 2:
The system implements continuous circulation of cooking oil through pumping mechanisms that constantly move oil between different zones and through filtration systems. This continuous movement ensures uniform heat distribution throughout the oil, maintaining temperature consistency during high-volume cooking operations.
2Reliability
If manual filtration systems are used, then filtering can be performed, but operational complexity increases and operator errors occur
Solution Approach 1:
The filtration system is designed to operate automatically without operator intervention. Sensors detect oil quality parameters and trigger filtration cycles automatically. The system self-regulates flow rates, activates pumps and filters based on real-time conditions, and alerts operators only when maintenance is needed, eliminating manual valve operations while maintaining reliable filtration.
Solution Approach 2:
Manual mechanical valve operations are replaced with automated control systems using sensors, microprocessors, and electronic actuators. The system uses electrical and electronic controls rather than manual mechanical manipulation, reducing human error and operational complexity while improving reliability through consistent automated execution.
3Ease of operation
If baskets are used to transport food products, then food handling is simplified, but device complexity increases due to control mechanisms
Solution Approach 1:
The system removes baskets and their complex control mechanisms entirely from the cooking process. Food products are placed directly into the cooking oil through simple drop-in mechanisms at the chamber entrance. The extraction of baskets eliminates the need for rails, motors, sensors, and control systems while maintaining ease of operation through direct product placement.
Solution Approach 2:
Instead of using baskets to actively transport food through the system, the system inverts the approach by allowing food to be passively introduced at fixed points and relying on oil circulation and convection currents to move and cook the products. This eliminates mechanical transport while simplifying the overall system.
4Reliability
If conventional filtration systems are used, then filtering can be performed, but operational interruptions occur and downtime increases
Solution Approach 1:
The filtration system is designed to operate continuously in parallel with cooking operations. Multiple filtration units are configured so that while one filter is processing oil, another is being cleaned or serviced. The system maintains continuous oil circulation and filtration without stopping cooking, eliminating downtime while ensuring reliable filtration through redundant filtering capacity.
Solution Approach 2:
The system performs preliminary filtration actions by continuously removing food particles and contaminants from the oil during cooking operations. Pre-filtration screens and continuous fine filtration prevent buildup that would require shutdowns for maintenance, allowing filters to be serviced during normal operations without interrupting cooking.
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 solution achieves improved temperature uniformity, increased throughput, reduced downtime, and extended oil life by continuously circulating and filtering the cooking medium, while simplifying the cooking process and reducing operational interruptions.
Implementation Method 1
a pump is disposed at a first end of the cooking chamber to continuously circulate the cooking medium through the system, in a flow direction along the length of the flume style cooking chamber
Implementation Method 2
A heating mechanism is disposed in the cooking chamber and is configured to heat the cooking medium
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
An automatic fryer apparatus and method of frying food products includes a cooking chamber, a heating mechanism disposed in the cooking chamber, and a pump disposed at an end of the cooking chamber to circulate cooking medium within the cooking chamber. Food product is added to the cooking chamber and flows along with the cooking medium in a flow direction. A controller controls a plurality of gates by individually actuating each gate. The controller stores data regarding predetermined time periods, which regulate when to raise and lower each gate. Food product moves downstream of each gate along a flow direction when each respective gate is raised. Food product is automatically transferred to a holding station when it reaches an outlet end of the cooking chamber.