Permeable Conveyor De-oiling for Low Oil Potato Chips
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Solution Overview
Problem
Current methods for producing low-fat potato chips fail to achieve consumer acceptance in terms of flavor and organoleptic properties while reducing oil content, as they often compromise on texture and taste, and existing de-oiling processes can lead to oxidation of potato lipids, affecting flavor and shelf life.
Innovation Solution
An apparatus and method using a permeable conveyor system with sequential water spray and air knife stations to de-oil potato slices, employing downward and upward water sprays and air blades to displace and remove surface oil, avoiding steam treatment to maintain flavor and shelf life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional frying is used to produce potato chips, then desirable organoleptic properties and texture are achieved, but high oil content (30-35 wt%) results which is unhealthy
Solution Approach 1:
The potato slices are preconditioned in warm oil before microwave cooking, which prepares the surface for subsequent de-oiling steps. This preliminary oil treatment ensures that the slices have the necessary surface characteristics for effective oil removal while maintaining the ability to achieve desirable texture and flavor in the final product
Solution Approach 2:
The patent employs multiple extraction steps to remove oil from the potato slices: first using a water spray to extract surface oil, then using air knives to extract remaining oil. This systematic extraction process reduces oil content while preserving the organoleptic properties that would otherwise require conventional frying
2Quantity of substance
If microwave cooking with lipophilic preconditioning is used, then low oil content is achieved, but oxidation of potato lipids occurs affecting flavor and shelf life
Solution Approach 1:
The patent converts the potential harm of oxidation into a benefit by using controlled water spray and air knife treatment. These steps remove excess surface oil that would otherwise be susceptible to oxidation, while the controlled environment prevents oxidative degradation of the remaining lipids, thereby extending shelf life and maintaining flavor
Solution Approach 2:
The use of air knives provides a controlled atmosphere that limits exposure to oxygen during the de-oiling process. This creates a protective environment that prevents oxidation of potato lipids while still effectively removing excess oil, thus preserving flavor and extending shelf life
3Quantity of substance
If water spray and air knife de-oiling is used, then oil content is reduced while maintaining flavor, but device complexity increases
Solution Approach 1:
The permeable conveyor system serves multiple functions: it transports the potato slices through the processing line, allows water spray to effectively contact and remove oil, and enables air knives to blow removed oil away. This multi-functional design achieves effective de-oiling while minimizing the number of separate components needed
Solution Approach 2:
The patent combines the water spray station and air knife stations into a integrated de-oiling system on a single permeable conveyor. This merging of functions reduces overall system complexity compared to using separate processing equipment, while still achieving effective oil removal and maintaining product quality
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 method effectively reduces oil content in potato chips to levels comparable to conventional fried chips while maintaining or exceeding their flavor and organoleptic properties, ensuring consumer acceptance and extended shelf life.
Implementation Method 1
spraying water downwardly and upwardly from respective upper and lower water spray units onto the plurality of potato slices on the conveyor
Implementation Method 2
cause the water to displace and lift surface oil on the potato slices
Implementation Method 3
directing upper and lower air blades downwardly and upwardly, respectively, onto the plurality of potato slices on the conveyor to cause the air blades to blow a mixture of oil and water from the potato slices
Implementation Method 4
an elongate longitudinal conveyor having an upstream end and a downstream end, the conveyor being permeable to oil, water and air and being adapted to convey potato slices on the conveyor
Data Source
AI summary
An apparatus for de-oiling potato slices, the apparatus comprising an elongate longitudinal conveyor having an upstream end and a downstream end, the conveyor being permeable to oil, water and air and being adapted to convey potato slices on the conveyor, a water spray station located towards the upstream end and a plurality of air-blower stations located in succession downstream of the water spray station, the water spray station comprising upper and lower water spray units adapted to spray water downwardly and upwardly, respectively, towards the conveyor, and each air-blower station comprising upper and lower air knife units adapted to direct an air blade downwardly and upwardly, respectively, towards the conveyor.