Multiple-Pass Toaster Conveyor Layout for Compact High-Throughput Cooking
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Solution Overview
Problem
Traditional food service equipment for preparing and cooking tortillas or similar food products requires individual input and processing, which is inefficient and time-consuming, especially in fast-food settings where quick turnaround is essential.
Innovation Solution
The equipment employs synchronized upper and lower endless conveyor belts with a semi-circular self-return product feeder to convey multiple food products simultaneously, allowing them to pass through a heated zone for cooking or toasting, and features inclined ramps for efficient infeed and discharge, with additional conveyor sets to extend cooking time without increasing footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional individual feeding method is used, then equipment structure is simple, but processing efficiency is low and preparation time is long
Solution Approach 1:
The equipment divides the processing system into multiple independent conveyor belts (first upper conveyor, first lower conveyor, second upper conveyor, second lower conveyor) that can operate simultaneously. Each conveyor belt handles specific tasks in the processing sequence, allowing multiple tortillas to be processed at different stages at the same time, thereby improving productivity without requiring a complete redesign of the equipment structure
Solution Approach 2:
The patent implements a nested conveyor configuration where the first lower conveyor and second upper conveyor are positioned within the space between the first upper conveyor and second lower conveyor. This nesting arrangement allows multiple conveyor systems to occupy overlapping spatial zones, enabling simultaneous multi-stage processing while maintaining a compact overall equipment footprint and avoiding excessive structural complexity
2Loss of time
If multiple food products are processed simultaneously, then preparation time is reduced, but workspace area increases
Solution Approach 1:
The patent transitions from a single-plane conveyor arrangement to a multi-dimensional stacked configuration. Conveyor belts are arranged in vertical layers (upper and lower runs) and horizontal sequences (first and second conveyors), utilizing three-dimensional space to accommodate multiple processing stages. This dimensional expansion allows simultaneous processing of multiple products without proportionally increasing the horizontal workspace footprint
Solution Approach 2:
The patent combines multiple conveyor functions into an integrated processing system where the first upper conveyor feeds to the first lower conveyor, which then feeds to the second upper conveyor, and finally to the second lower conveyor. These merged conveyor systems share common structural supports, heating elements, and control mechanisms, enabling simultaneous multi-stage processing while minimizing the overall equipment footprint through functional integration
3Duration of action of moving object
If cooking time is extended for proper toasting, then food quality improves, but equipment footprint increases
Solution Approach 1:
The patent implements continuous cooking action through the multi-conveyor system where tortillas pass through multiple heated zones in sequence. The first lower conveyor and second upper conveyor provide continuous heating surfaces that maintain consistent cooking temperature throughout the extended processing path. This continuous useful action allows proper cooking time to be achieved without requiring additional horizontal space, as the cooking process occurs along the continuous path of the nested conveyors
Solution Approach 2:
The nested conveyor arrangement allows the cooking path to fold back on itself vertically, with the first lower conveyor positioned beneath the first upper conveyor and the second upper conveyor positioned beneath the second lower conveyor. This nesting creates an extended cooking trajectory within a compact vertical footprint, enabling prolonged cooking time without proportionally increasing the horizontal equipment area
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 enables simultaneous processing of multiple food items, reducing preparation time, minimizing workspace, and allowing efficient operation with a minimal number of personnel, while maintaining compactness and quick service capabilities.
Implementation Method 1
A first heated platen is disposed above the lower run of the first upper endless conveyor belt, while a second heated platen is disposed beneath the upper run of the second lower endless conveyor belt so as to effectively impart heat to their respectively associated first and second conveyor belts
Data Source
AI summary
Food service equipment comprises a multiple-pass feeder conveyor and toaster which comprises an upper inclined food product infeed conveyor ramp for causing the food products to proceed in a first direction extending from the rear of the appliance toward the front of the appliance and onto the upper run of a first upper endless conveyor. The upper run of the first upper endless conveyor conveys the food products into a semi-circular return product feeder which causes the food products to be conveyed in a second opposite direction extending from the front of the appliance toward the rear of the appliance and into an entry space defined by means of the lower run of the first upper endless conveyor and the upper run of a second lower endless conveyor, the two conveyors being synchronized together. The pair of conveyors convey the food products between heated platens respectively associated with the two conveyors whereby the food products are cooked or toasted. The cooked or toasted food products are discharged onto a lower inclined food product discharge ramp which is disposed substantially parallel to the first inclined food product infeed ramp such that the finished food products are conveyed in a third direction, parallel to the first direction, toward a finished food product platform from which the finished food products may be removed for serving to diners. Additional pairs of conveyors can also be incorporated within the system, in a vertically stacked array, so as to effectively increase the length of travel experienced by the multiple food products without increasing the footprint of the equipment.