Frying method and apparatus
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Solution Overview
Problem
Industrial continuous fryers for snack food production have high capital and operating costs, product inconsistency, oil oxidation issues, and difficulty in controlling temperature profiles, leading to reduced product quality and increased manufacturing costs.
Innovation Solution
A tubular frying apparatus with a closed system that uses oil flow accelerators, such as venturi mechanisms, to convey snack food pieces through a series of controlled temperature zones without moving parts, ensuring consistent product quality and reduced oil exposure to oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional open tank continuous fryers with mechanical conveying components are used, then productivity is improved through continuous processing, but device complexity increases due to numerous moving parts requiring maintenance and sanitisation
Solution Approach 1:
The patent replaces mechanical conveying components (paddles, belts, screws) with a fluid dynamic system using oil flow to convey food pieces through the frying chamber. The oil circulation system driven by a pump and controlled by flow distributors eliminates the need for mechanical moving parts inside the frying tank, thereby reducing device complexity and maintenance requirements while maintaining continuous processing capability
Solution Approach 2:
The patent employs hydraulic principles by using the circulating oil flow as the conveying medium. The oil is pumped through the system and distributed across the food pieces to both convey them through the chamber and maintain frying conditions, replacing mechanical conveyance with a fluid-based system that reduces complexity
2Productivity
If large open tank fryers are used for continuous processing, then productivity increases, but manufacturing precision deteriorates due to uncontrolled variations in cooking conditions and difficulty in controlling temperature profile
Solution Approach 1:
The patent divides the continuous frying process into multiple discrete zones along the flow path, each with independent temperature control and oil flow distribution. This segmentation allows precise control of cooking conditions at different stages (initial frying, continued cooking, finishing) while maintaining continuous throughput, thereby improving product consistency without sacrificing productivity
Solution Approach 2:
The patent implements dynamic control of oil flow rates and temperature profiles through programmable flow distributors and heating zones. The system can adjust parameters along the flow path to optimize cooking conditions for different product requirements, enabling consistent quality control across continuous production runs
3Productivity
If conventional continuous fryers with long tanks are used, then productivity is improved, but manufacturing precision worsens due to difficulty in controlling temperature profile and oil static regions
Solution Approach 1:
The patent segments the frying chamber into multiple controlled zones with independent temperature and flow control. This prevents oil stagnation in any single region and ensures uniform temperature distribution throughout the process, maintaining manufacturing precision while enabling continuous high-volume production
Solution Approach 2:
The patent maintains continuous oil circulation and flow through the segmented zones, preventing static oil regions that would cause overheating and polymerisation. The continuous movement of oil and food pieces through controlled segments ensures consistent temperature profiles and improves both productivity and manufacturing precision
4Ease of manufacture
If conventional open tank fryers are used, then ease of manufacture is improved through simple open design, but object-affected harmful factors increase due to oil oxidation from atmospheric exposure
Solution Approach 1:
The patent employs a closed system design where oil circulates through enclosed piping and the frying chamber is sealed, limiting exposure to atmospheric oxygen. This prevents oil oxidation and polymerisation while maintaining ease of manufacture through a relatively simple closed-loop circulation system with pump, filters, and heating zones
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 tubular frying method and apparatus achieve energy and cost savings, improved product consistency, reduced oil content, and enhanced quality by controlling temperature and residence time, allowing for efficient production of high-quality snack foods while minimizing capital and operating expenses.
Implementation Method 1
an oil flow accelerator mechanism for accelerating oil flow from the inlet end to the outlet end in the downstream direction thereby conveying the snack food pieces
Implementation Method 2
Energy is required to heat the oil and maintain it at the desired cooking temperature
Implementation Method 3
the frying process dehydrates the pre-fried snack food precursor pieces and a volume of steam is generated
Data Source
AI summary
An apparatus for frying snack foods, the apparatus including a fryer having a tubular frying section with inlet and outlet ends, the outlet end downstream relative to the inlet end. An oil supply system for supplying oil to the inlet end. A food input at the inlet end adapted to introduce pre-fried snack food pieces into a flow of oil at the inlet end. A food output at, or downstream of, the outlet end adapted to separate fried snack food pieces from the flow of oil. An oil flow accelerator accelerating oil flow from the inlet end to the outlet end thereby conveying the snack food pieces, immersed in the oil, from the inlet end to the outlet end during a frying process. Also disclosed is a method of frying snack foods.