Vibratory Coating Pan for Uniform Food Batter Application
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Solution Overview
Problem
Existing methods for coating food products with batter face challenges such as incomplete and uneven coating, excess batter loss, contamination risks, and high maintenance requirements due to the use of wire belts, which decrease productivity and increase shut-down times.
Innovation Solution
A batter applicator machine comprising a coating pan and drainage pan connected to a vibrating frame, where batter is applied through a constant flow mechanism, promoting even coating and tumbling of food products, with excess batter draining through perforations, and a design that allows for easy cleaning and reuse of batter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wire belts are used to convey and coat food products with batter, then food products can be transported through the coating process, but the coating becomes incomplete and uneven
Solution Approach 1:
The patent applies vibratory motion to the coating pan to facilitate complete and uniform batter coating. The vibration causes food products to tumble and move across the pan surface, ensuring all sides are evenly coated with batter while eliminating dead zones where coating might be incomplete.
2Loss of substance
If wire belts are used for conveying battered food products, then products can be transported to par-cooker, but excess batter is lost through belt openings
Solution Approach 1:
The patent extracts the conveying function from the coating mechanism by using a separate vibratory conveyor pan. This allows the coating pan to be a continuous, solid surface that retains batter, while the conveyor function is performed by vibration-driven motion rather than belt openings.
3Loss of time
If wire belts are used for conveying and coating, then food products can be processed continuously, but cleaning becomes time-consuming and complex
Solution Approach 1:
The patent segments the coating system into a removable vibratory pan that can be easily detached and cleaned separately from the main conveyor mechanism. This simplifies cleaning by isolating the batter-contact surface as a discrete, accessible component without complex crevices.
4Ease of repair
If wire belts with many moving components are used, then conveyance function is achieved, but maintenance requirements increase
Solution Approach 1:
The patent replaces the mechanical belt drive system with a vibratory mechanism that uses minimal moving parts. The vibratory pan is driven by a single vibration source rather than multiple belts, rollers, and tensioning mechanisms, dramatically reducing maintenance requirements and shutdown time.
5Object-affected harmful factors
If wire belts are used for conveying, then food products can be transported, but metal pieces can contaminate the food products
Solution Approach 1:
The patent uses a disposable or easily replaceable vibratory pan surface that contacts the food products, eliminating the risk of metal contamination from durable wire belts. The pan can be made of food-safe materials and replaced if worn or contaminated.
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 solution ensures complete and even batter coating, reduces waste, minimizes contamination, and decreases maintenance needs, thereby enhancing productivity and food product quality.
Implementation Method 1
a vibrator 110 on the chassis 108, with springs 112 coupling the frame 106 to the chassis 108. When the vibrator 110 on the chassis 108 is activated, its vibration is transferred to the frame 106 (and to the coating pan 102 and drainage pan 104 thereon)
Implementation Method 2
The drainage pan 104 has a perforated drainage pan surface 128 extending between a drainage pan input end 130 and a drainage pan output end 132
Data Source
AI summary
Batter is applied to food products by depositing the products atop a coating pan which vibrates such that the products are transported along the pan. As this occurs, batter is supplied atop the coating pan and the products. The coating pan is preferably configured such that the products tumble across the pan, thereby better ensuring that the products are coated on all sides with batter. The products are then received on a vibrating drainage pan having a perforated drainage pan surface, whereby excess batter drains from the batter-coated products through the perforations as the products are transported across the drainage pan. Batter-coated products leaving the drainage pan can then be received by a fryer, oven, conveyor, or other food processing equipment.