Compact in-Line Breading Machine

There has long been a need in the field of commissaries, large restaurants, industrial and institutional kitchens, food specialty producers and pilot production plants for a small machine to batter and bread food items. Desirable features of such a small machine are: (1) A moderate amount of automation to save hand labor and to produce uniform results; (2) compact construction for use in kitchen areas rather than in plant production areas; (3) relatively low production capacity compared with available production machines; (4) simplicity of operation and maintenance; (5) versatility to handle many types of coating materials and many types of food products; utilizing sanitary construction materials and providing ease of clean-up. The present invention provides such a small, compact machine.

Among the objects of the present invention are included -- (a) a liquid coating unit including a reservoir for the coating material, a submerger wheel having its lower periphery passing into the batter in the reservoir, a product carrying flexible wire mesh belt, tensioned by a counterweight and carrying the product beneath the submerger wheel and then up out of the batter where excess coating material is blown off, after which the product is passed to a breading unit; (b) to provide in a breading unit a single layer of dry breading material which is controlled so as to form both a receiving bread layer for the product and, in most forms a top cover for the product; (c) to maintain dry breading material levels for a period of time by means of a built-in hopper; (d) to pump the dry coating material from the hopper through a slot which provides sufficient pressure to force the dry material upwardly through an open wire mesh conveyor belt to the breading run; (e) to treat the dry coated product in a manner to remove most of the excess dry coating material; (f) to transfer the coated product out of the breading machine; and (g) to return the excess dry breading material back to the hopper.

Other objects and advantages of the invention will be apparent from the accompanying drawings and description and the essential features will be summarized in the claims.

In the drawings,

FIG. 1 is a side elevational view of the liquid-coating unit removably supported above the dry-coating unit in a preferred form of the invention;

FIG. 2 is a top plan view of FIG. 1;

FIG. 3 is an end view taken from the right-hand end of FIG. 1;

FIG. 4 is a side elevational view of one of two parallel vertical conveyor support plates positioned on opposite sides of the flexible wire mesh conveyor belt of the breading unit;

FIGS. 5 and 6 are respectively top plan and side elevational views of a tamper plate seen in broken lines at the upper mid-portion of FIG. 1;

FIGS. 7 and 8 are respectively top plan and side elevational views of the splitter seen at the left end of FIG. 2;

FIGS. 9 and 10 are respectively top plan and side elevational views of the conveyor belt frame used in the liquid-coating unit;

FIGS. 11 and 12 are respectively side elevational and top plan views of the batter reservoir of the liquid-coating unit;

FIGS. 13 and 14 are respectively side elevational and end views of the batter tank supports which hold the batter reservoir in position above the breading-coating unit;

FIG. 15 is an end view of a conveyor frame comprising two of the support plates shown in FIG. 4;

FIG. 16 is an enlarged view of the open mesh flexible wire belt described herein;

FIGS. 17 and 18 are respectively end and side elevational view of the belt reverser members;

FIG. 19 is a small perspective view showing the side frame support members 60 and attached parts tilted around pivots 62 for cleaning and inspection;

FIG. 20 is a side elevational view of a second embodiment of the invention showing the batter-coating unit removably supported at the in-feed end of the breading material coating unit;

FIG. 21 is a top plan view of FIG. 20;

FIG. 22 is an end view of the same taken from the right-hand side of FIG. 20;

FIG. 23 is a side elevational view of a third embodiment of the invention showing the liquid-coating unit removably supported at the in-feed end of a modified dry breading material coating unit;

FIG. 24 is a top plan view of FIG. 23;

FIG. 25 is an end view of the same taken from the right-hand side of FIG. 23;

FIG. 26 is a side elevational view of an alternate form of vertical conveyor support plates positioned on either side of the flexible wire mesh conveyor belt of the breading unit;

FIG. 27 is a side elevational view of the batter-coating unit conveyor frame extension used in the second and third embodiments of the invention

FIG. 28 is a top plan view of FIG. 27;

FIG. 29 is a side elevational view of an extension frame for the dry breading material conveyor belt for the third embodiment of the invention;

FIG. 30 is a top plan view of FIG. 29;

FIG. 31 is a perspective view of the breading blowoff housing as used in the third embodiment of the invention;

FIG. 32 is a perspective view of the in-feed bracket used to support the batter-coating unit in the second and third embodiments of the invention;

FIG. 33 is a side elevational diagrammatic view showing the product path through the preferred form of the invention as illustrated in FIG. 1;

FIG. 34 is a side elevational diagrammatic view showing the product path through the second embodiment of the invention as illustrated in FIG. 20; while

FIG. 35 is a side elevational diagrammatic view showing the product path through the third embodiment of the invention as illustrated in FIG. 23.

A preferred form of the open mesh flexible wire conveyor belt used in this invention, and shown in FIG. 16, is one made under the trade name "Flat-Flex" by the Wire Belt Company of America. Other similar conveyor belts may be suitable for use in this invention.

The conveyor belts shown in broken lines in FIG. 1 are omitted from FIGS. 2 and 3 for clarity.

Describing the first embodiment and referring to FIG. 1, the open mesh wire conveyor belt 20 is supported on a conveyor frame as shown in FIGS. 9 and 10 which in turn is supported in the batter reservoir 21 shown in greater detail in FIGS. 11 and 12. The drawings indicate that the belt 20 extends substantially from side to side of the reservoir when the conveyor is in its operating position.

The belt 20 is endless and passes over a pulley-equivalent or cross rod 22 at the product-inlet end of the liquid-coating unit, then beneath a submerger wheel 23, then over a cross rod 24, then over a drive pulley 25, then inwardly and downwardly over the curving plate 26 of the batter reservoir and beneath a counterweight 27 which is suspended by oscillatable arms 28 from pivot points 29 secured to the conveyor frame and the return rod of the conveyor then passes beneath cross rods 30 and 31 back to the first named pulley equivalent or cross rod 22. The cross rods 22, 24, 30 and 31, are fixed in conveyor side walls 32. The drive pulley 25 is rotatably supported in the conveyor side walls 32.

The submerger wheel 23 comprises two flat end disks 23a rigidly secured in spaced relation to a central shaft 33 and encased in a cylindrical covering of open mesh material, preferably the Flat-Flex open mesh material used in the conveyor belt 20. The shaft 33 is rotatably mounted in a pair of bearings 34 mounted respectively at 34a on the side frame members 32.

The batter tank or reservoir 21 is shown in FIGS. 1, 2, 11 and 12. It comprises a flat bottom 21a, parallel side walls 21b, a curved end wall 26 and an inclined end wall 21d. Each side wall has an outwardly turned flange 21e on which rests the conveyor frame members 32.

The batter tank is filled with the liquid batter coating to a desirable level indicated by the dot-dash line 35 in FIG. 1. The lower portion of the submerger wheel extends preferably about 1/2 inch below the level of line 35. It will be obvious that as the food product moves through the liquid batter, batter is continuously removed as a coating on the product. To reduce the frequency of manually replenishing the batter supply, a jug of batter indicated at 36 is provided with a downwardly turned neck 36a which is held at the level of line 35 while a curved tube 36b which communicates at one end with tank 21 and carries at its other end a bowl 37 in which the jug 36 may rest. Thus, as the level of batter in the tank 21 falls, the jug replenishes the liquid as necessary to maintain it to the level of the line 35.

It will be seen from the above description that the liquid coating belt 20 starts at cross member 22 above the level of the batter material in tank 21, then passes under the submerger wheel 23, and then returns to the original level at cross member 24. Due to the tension caused by counterweight 27, the top run of belt 20 will always be as close to the batter surface as permitted by the submerger wheel and any product carried under it. Thus, as soon as food product clears the submerger wheel, belt tension returns the belt to a minimum slope out of the liquid batter material, decreasing the possibility of product slip back down the slope. The tension caused by the counterweight 27 insures a positive nipping action between the belt and the wheel, to actually drag the food product under the liquid batter surface even against any flotation force.

As the top run of the liquid coating belt rises out of the liquid batter after passing beneath the submerger wheel, it passes under a slotted discharge of a small air blower 38, the slot being shown at 39, formed by the sloping walls 39a and extending transversely to the direction of travel of belt 20. The air blower is supported at 38a on the conveyor frame 32. Thus, a downwardly directed air curtain sweeps the excess liquid batter off the top of the product. Sweeping is assisted on most products by the fact that the product is on a sloping belt. The blower 38 is adjustable in height and in air volume. At the top of the slope, the belt 20 passes over the horizontal cross rod 24 and since this rod does not rotate, any liquid batter drops here for return to the liquid batter pool.

It should be noted that the structure described causes continuous agitation of the liquid batter in the reservoir or tank 21. The return run of conveyor belt 20 passes from the drive pulley 25 over the curved end wall 26, close to the wall, and then from counterweight 27 it travels close to the bottom wall 21a under cross rods 30 and 31 and then up the sloping wall 21d back to the cross rod 22. This gives a continuous wiping effect of the belt conveyor 20 on the bottom and end walls of the tank 21, and the continuous motion of the belt through the liquid has a stirring and turnover effect for continuous mixing. Also, the submerger wheel 23 is rotated by the passage of the product under it on belt 20 and this gives further agitation to the liquid batter.

It will be noted from this description that the liquid-coating unit might be used to coat a food product with batter whether or not it were combined with the dry-coating unit which will next be described.

The dry coating unit is best understood from FIGS. 1, 2 and 3. A stand 40 supports a base plate 41, on which rests all parts of the breading machine unit now to be described. Briefly, this structure includes a breading material storage hopper 42 having an inclined bottom 43 between two parallel vertical side walls 42a, a short end wall 44 and a partial top wall comprising a slider plate 45 which is generally flat and horizontal. A continuous open mesh wire conveyor belt 46 has a breading material elevating run traveling upwardly toward the left as viewed in FIG. 1 close to the inclined bottom wall 43, then passing over an idler pulley equivalent 47, then horizontally in a product-advancing run horizontal and close to the slider plate 45, then over drive pulley 48 and then downwardly on a transfer run around belr reverser 69 and over an idler pulley equivalent 49, near the product-take-away point, and then turning upwardly on the elevating run again.

One of the novel features of this invention is the "pumping" slot indicated at 50. This slot is enclosed by a roof 51 which is spaced above and parallel to the slanting bottom wall 43, and has as side walls the two side walls of the hopper 42. The opposite ends of the slot are open and the roof 51 is connected by side walls 51a to the slider plate 45 as seen in FIG. 4 and the right-hand end of the plates 51 and 51a, as seen in FIGS. 1 and 4, is closed by a plate 51b. The height of the slot 50 is preferably approximately one and one-half times the maximum thickness of breading material desired on the product receiving portion of the conveyor belt above the slider plate 45. Preferably also, means is provided for adjusting the effective height of the slot which in the drawings includes a rectangular plate 52, seen in FIG. 1, which is adjustably held by one or more screw connections 53. The suitable height and length of slot 50 will be discussed later.

The means for driving the belt 46 comprises an electrical motor 54 mounted on the base plate 41 and having a drive sprocket 55 which is connected by drive chain 56 with the drive sprocket 48d on stub shaft 48e. Take-up idlers 57 on spring loaded oscillatable arms 58 permit the main drive chain 56 to slip on the motor sprocket 55. In this particular installation, the motor sprocket teeth are cut down below the pitch diameter and in normal operation will drive the drive sprocket 48d. However, if excess load is introduced onto the main breader belt 46, such as a jam of some sort, the chain jumps the motor sprocket until the load is relieved. In normal operation, the idlers 57 take up slack in the drive chain 56. The motor 54 is reversible for a purpose which will appear later.

The level of the breading material in the hopper 42 is normally above the entrance to the slot 50. The belt conveyor 46 traveling upwardly through the slot pumps the breading material upwardly to the pulley equivalent 47. The spacing between the periphery of this pulley and the hopper walls 43 and 44 is approximately the thickness of belt conveyor 46. The movement of belt 46 piles up the breading material against the pulley equivalent 47 and forces it upwardly through a breading entrance at 46a which is between the pulley equivalent 47 and the upstream end 45a of the slider plate. The breading material at this point wells up through the mesh belt at 46a to a predetermined height as will presently appear.

Referring to FIGS. 1, 4 and 15, much of the operating structure of the breading machine is supported by a frame clearly shown in FIGS. 4 and 15. This includes as a unitary structure two parallel vertical conveyor support plates 60 which extend the full length of the product-advancing run of the belt conveyor 46. As clearly seen in FIG. 15, these support plates are connected rigidly by the slider plate 45, by a short vertical wall 61, by a short vertical wall at 45a and by the wall 51b. The openings 53a in the plate 51b are to receive the adjustment screws 53 which hold the slot height adjustment plate 52. Between the two support plates 60 are mounted the upstream pulley equivalent at the location 47a, the downstream drive pulley at the location 48a and a third pulley equivalent 49 at the location 49a. The support plates have parallel vertical downwardly extending ears 60a at the right-hand end thereof as seen in FIGS. 1 and 4 and these ears extend down to support the cross rod or pulley equivalent 49. Pivot pins 62a concentric with the pulley equivalent 49 oscillatably support the two ears 60 in the side walls of hopper 42, whereby the unitary structure thus disclosed may oscillate about the pivot pins for inspection and cleaning of the machine. The additional breading material control members are mounted along the upper edge of the two vertical conveyor support plates 60 as described in the next paragraph.

Means is provided for splitting the upper portion of the flow of breading material which is pushed upwardly through the breading entrance in the upstream space at 46a. This means is a V-shape, bent bar splitter 63, best seen in FIGS. 2, 7 and 8. This structure diverges from a nose 63a which is welded to two support rods 64 which are rigidly secured crosswise between the support plates 60. The splitter has parallel trailing legs 63b trailing in the direction of product travel from the respective ends of the V-shape member 63. The trailing legs of the splitter encompass a product travel path along the belt conveyor 46 which is wide enough to encompass the product intended to be coated and which is approximately half as long as the longest product intended to be coated. It will be noted in FIG. 8 that the lower edge of the splitter is planar and at the level of the desired thickness of breading material beneath the product on the product-advancing run of the conveyor belt 46.

It has been mentioned previously that the dry breading material wells up at 46a across the entire width of the conveyor belt 46. The splitter is in the central portion only of this path and diverts breading material laterally to each side above the level of the lower edge of the splitter. Means is provided for moving substantially all of the breading material on both sides of the product path including the material laterally diverted by the splitter 63, laterally inward from both sides onto the top of the product traveling along the conveyor belt 46. This means comprises two side plows 65, best seen in FIG. 2. One of these is on either side of the product path and each side plow has a converging portion extending from approximately a lateral edge of the slider plate 45 downstream and inwardly to approximately a colinear position with one of the splitter trailing legs 63b, and there is provided a trailer portion 65a extending downstream from the end of each plow parallel to the product path down to the product-discharge end of the slider plate 45b. Each trailer portion 65a is rigidly supported from a support member 60 by a stub tube 68. Each of these plows has a height extending from slightly above the slider plate 45 to a level above the breading material to be spread laterally inwardly over the food product and which is carried by the belt conveyor on the product-advancing run and between the side plow trailer portions.

The trailing legs 63b of the splitter are approximately one-half of the length of the longest product intended to be coated but may vary from twenty percent to thirty percent with various designs of the machine. The ends of the splitter trailing legs 63b are approximately in the same cross sectional plane where the side plows 65 start to leave the sides of the main conveyor frame 60. Side plow trailing legs are long enough to provide a predetermined product dwell time in breading at the predetermined belt speed. In one embodiment, the dwell time is approximately 6 seconds at a belt conveyor speed of 15 feet per minute.

To insure full coverage of the food product, preferably a tamper plate 66, best seen in FIGS. 1, 5 and 6, is floated on top of the dry breading material in the product path. This plate is pivoted horizontally on its upstream edge so that it is free to follow any fluctuations in the dry breading material thickness. It is nominally as wide as the product path, with clearance so that it will freely float between the side plow trailer portions 65a. It is long enough to reach the trailing edge of the slider plate 45 at 45b. Its side elevation as seen in FIGS. 1 and 6 is such that the main pressure line on the dry breading material is usually less than about one-half its length from its pivot. The plate is here shown as pivoted on two hooks 66a which are rigidly secured to the upstream edge of the plate 66. As shown in FIG. 6, the major portion of the plate 66 is concave upwardly so that it floats smoothly on the breading material. The hooks 66a hang on a cross bar 70, seen in FIGS. 1, 13 and 14, and which will be described later.

In the case of some flour coatings, which tend to bridge over the openings in the wire mesh conveyor 46, simple vibrators actuated by the passage of the conveyor belt 46 assist in its removal of excess dry breading material. As shown in FIGS. 1 and 2, two long flat vibrator blades 67 are provided, each with an integral bent portion on the upper end at 67a, which is hooked over cross bar 70. Each blade passes under a stub tube 68. This supports the vibrator blades in the inclined position shown in FIG. 1. The triangular block 67b rigidly fastened to the lower end of the blade 67 engages the cross wires of the conveyor belt 46 as they pass, and resultant vibration shakes the excess dry breading material through the belt 46 at breading exit 46b. Vibration effect may be increased or decreased by varying the shape of the blades before inserting them in the machine.

After passing over the drive pulley 48, the endless conveyor belt 46 turns downwardly approximately 120.degree. over the drive pulley shaft, in the transfer run 46c. The belt then bends approximately 120.degree. around a belt reverser shown in FIGS. 17 and 18, which, in this case, comprises three half-moon shape members 69 which are rigidly pinned to a rod 71 which is firmly held by bolts 72 at each end to the parallel side walls of the conveyor support members 60. The bolts 72 are horizontally adjustable in slots 72a. The belt 46 then has a short horizontal run 46d over to the pulley equivalent 49 where a 195.degree. turn brings the belt conveyor 46 back to the breading material elevating run along the bottom of the bread hopper 42.

The material dropping through the conveyor belt 46 at the breading material exit 46b drops downwardly into the breading material hopper 42. To spread this material fairly evenly over the elevating run of the conveyor belt 46, there is provided a plate inclined downwardly and inwardly as shown in FIG. 1 at 73. This is secured to the conveyor support members 60 by a pair of flanges 73a. In the center of the plate 73 there is rigidly secured an inverted V-shape roof 73b, seen in FIGS. 1 and 3, and the result of this structure is to cause the material dropping at 46b to be spread rather evenly across the elevating run of belt 46.

When the coated product reaches the drive pulley 48 it falls downwardly to a take-away point 75 indicated in FIG. 1, which is just above the pulley equivalent 49. This fall should be sufficient to permit the food product to flip over so that any excess material which is on the top of the product is dropped off. In the embodiment shown in the drawings, this distance is approximately six inches. At the take-away point, the product falls on a take-away conveyor 76 which comprises two parallel vertical side frame members 76a which are rigidly connected together by a flat slider bottom 76b which is fixed to the lower edges of the two side frame members 76a. The side frame members 76a at their outer ends rotatably support a drive pulley 77, whose shaft 77a is rotatably mounted in the side frame members. At their inner ends, the side frame members support a pulley equivalent 78 which serves as an idler for the endless open mesh wire conveyor belt 79 which passes over drive pulley 77 and the pulley equivalent idler 78. At the take-away point 75, a shallow tray 80 may be provided if desired. This tray catches loose breading material falling down the pulley 48 and from the food product falling downwardly therefrom and provides a relatively thin layer of dry breading material under the belt 79. Thus, when the food product falls onto the belt conveyor 79, it is cushioned by this layer of breading material and "printing" of the wire belt in the dry coating of the product is minimized. The tray 80 is below the upper run of belt 79 and above the return side of the belt which travels close to the slider bottom 76b. All dry breading material falling through the conveyor belt 79 is carried by the return run of the belt conveyor along the slider bottom 76b to the point 81 where it falls through the short horizontal run 46d shown in FIG. 1 of the conveyor belt of the breading machine and is thereafter carried into the hopper 42 and up the elevating run of the conveyor belt 46. If desired, one or more triangular shaped buttons 82 may be secured to the tray 80 in position to project above the top layer of the belt 79 and afford a small amount of vibration to assist flour type breading material in falling through the conveyor belt 79. The finished breaded product drops off the drive pulley 77 and is carried away for further processing.

For purposes of cleaning and inspection, the endless conveyor belt 46, its side frame support members 60, the drive pulley 48 and pulley equivalents 47 and 49, and all parts supported along the upper edges of the side frame support members 60 are preferably mounted so as to open upwardly about a pivot point 62 concentric with the pulley equivalent 49, when the batter coating unit is removed from the position shown in FIGS. 1 through 3. Such a rotated position of these parts is shown in FIG. 19 and this leaves exposed for cleaning the inclined bottom wall 43 of the hopper 42, and all of its side walls. The pivot connections for the ear portions 60a comprise frusto-conical members 62a clearly seen in FIGS. 4 and 15 which fit snugly with complementary members 62 fixed in the side walls of the hopper 42.

The inclined angle of the slider plate 45 in such open position, in this embodiment, is about 30.degree. short of the vertical.

The drive motor 54 has previously been mentioned as being a reversible electrical motor which drives the motor sprocket 55 as clearly seen in FIG. 1. A drive belt 83 runs vertical upwardly from a drive pulley 55a on the motor shaft and passes around the drive pulley 25b mounted on the stub shaft 25c of the liquid battering unit as shown. Another drive belt 84 runs horizontally from a suitable drive pulley on the motor shaft to a drive pulley on stub shaft 77e to run the take-away conveyor 76.

It should now be noted that the dry breading material coating belt 46 may be reversed so as to empty the breading hopper 42 at the end of a day's run. During such an operation, the normally product-advancing run of conveyor belt 46 moves nearly all of the breading material on plate 45 back to the area 46a where it falls through the belt onto the elevating run, which at this time is reversed and carries the material downwardly along the inclined bottom 43 and out of the hopper 42 beneath and over the pulley equivalent 49 as shown in FIG. 1. In the embodiments shown in the drawings, only about 30 cubic inches of dry breading material remain in the bread tank after this self-emptying operation.

Referring to FIGS. 1, 13 and 14, in the use of the combined liquid coating and dry coating units as shown in FIGS. 1, 2 and 3, the liquid coating unit is held by similar structures at opposite ends of the better reservoir tank 21. Each of these units comprises a pair of parallel vertical rigid struts 85 rigidly bolted or otherwise fastened to the side conveyor frame members 60 and connected across the tops thereof by the rods 70 previously mentioned. Pins 86 on the rods 70 fit relatively snugly on opposite sides of the batter reservoir 21 to hold it firmly in position. The rods 70 engage against pins 87 which extend outwardly from the front and rear end walls of the batter reservoir 21 as clearly seen in FIG. 1. It should be noted that at each drive shaft 25, 48 and 77a a stub shaft is used with an axially centered square socket, into which are plugged the square shouldered drive shafts for each of the conveyors.

To disconnect the batter coating unit so as to remove it from the position above the dry bread coating unit, it is only necessary to tilt the reservoir 21, containing the conveyor 32, free of the pins 86 in cross bars 70, and pull the axially centered square shouldered drive shaft 25 out of the axially centered square socket in the stub shaft at 25a, after which the batter coating unit can be lifted away.

To disconnect the take-away conveyor 76 so as to remove it from the dry coating unit, it is only necessary to rotate the take-away conveyor 76 upwardly about 90 degrees around shaft 77a, then lift the free end 77b of shaft 77a out of saddle bearing 77c, and then to pull the axially centered square shouldered drive end of shaft 77a out of the axially centered square socket at 77d, after which the take-away unit can be lifted away.

To disconnect the drive mechanism for belt 46, it is only necessary to pull knob 48b in the direction away from the back cover of the machine, which will pull the axially centered socket of the stub shaft 48e off of the axially centered square shoulder at the shaft 48 at 48c. The entire conveyor belt 46, its side frame support 60, the drive pulley 48 and pulley equivalents 47 and 49 may now be opened upwardly about a pivot point 62 as previously described.

It should now be clearly understood that the operation of the complete apparatus of this embodiment is. With the upper unit filled with batter to the level 35 and with the breading material hopper 42 filled with breading material beyond the point 52 at the entrance to slot 50, the motor 54 is actuated until breading material is spread along the slider plate 45 controlled by the splitter 63 and the side plows 65 as above described. Pieces of food product to be coated are then placed on the conveyor belt 20 inside of the batter reservoir 21 and the conveyor belt will then carry the food product to beneath the submerger wheel 23 and the air discharge slot 39 to fall over the pulley 25 onto the breading layer beneath the splitter 63. This fall is sufficient to cause the product to imprint itself somewhat into the uniform layer of breading material into which it falls. Then, as the product travels the path carried by the conveyor belt 46, the side plows 65 will spread the excess breading material laterally inwardly in both directions over the top of the product where the material will be flattened down and pressed into the product by the tamper plate 66. Then the excess breading material will fall through the conveyor belt at 46b, after which the product falls over the drive pulley 48 downwardly to the take-away conveyor 76 which carries it over the drive pulley 77 as a finished breaded product.

The liquid-batter coating unit will apply coatings varying from water thin to the thickness of heavy cream. The dry bread coating section will handle and apply finely divided dry materials including free flowing, granular and flour types, usually called "breading" by the trade. With slight modification, it will also handle granulated crystallized sugar, and other dry coatings.

Parts which may be coated by the described apparatus include fish portions and sticks and many fillets, most shrimp, cut-up chicken parts, meat patties, pork chops, veal cutlets, as well as such as oysters, clams, scallops, doughnuts and other bakery items, etc.

The path shown in the drawings of this embodiment might be varied without effectively changing any of the machine functions. For instance, as shown in the second and third embodiments, the battering unit could be reversed around the drive pulley 25 so that the product advanced from left to right as seen in FIG. 1 through the battering unit, thence falling downward or passing smoothly to the breading unit and continuing in the same straight line to the finish. Other rearrangements of the units are possible by those skilled in this art.

The size of the machine shown is not critical. The product path may be narrower or wider. The machine may be longer or shorter, faster or slower. The dry breading material elevating slope may be steeper or shallower. The parallel wire spacing of the Flat-Flex type of belt may be changed to suit the food product and the dry material being used. Flip distance may be increased or decreased or eliminated. Dimensions of the slot 50 may be varied considerably when other factors are also changed, or when induced results are acceptable.

As mentioned above, the height of the pumping slot 50 is preferably approximately one and one-half times as great as the maximum thickness of breading material desired on the product receiving portion of the conveyor belt above the slider plate 45. Obviously there will be some slippage in the breading material during pumping, so that the multiplier to obtain pump slot height must be greater than one. The figure of one and one-half is adequate for the described machine and is somewhat arbitrary. The length of the slot required to pump the desired amount of breading, once the slot height has been fixed, will vary according to the combination of several other factors. They are: the slope of the bottom wall 43 of hopper 42, the height of the end wall 45a at the inlet end of slider plate 45, the material and surface finish of the underside of slot roof plate 51, the spacing and diameter of the cross wires of the bread conveyor belt 46, and the constitution of the breading material itself. For each combination of the above, a slightly different slot length would be required. However, in constructing a simple machine as described, a variable slot length would be too costly. Therefore, the slot length is fixed at a length long enough to adequately pump most breading materials, which is ten inches in the machine described. Again obviously, this fixed length will be too long for some breading materials which pump easily due to their constitution of particles. In these cases, the slot as described will pump considerably more breading than is necessary or can be utilized on top of slider plate 45. The slot adjustment plate 52 provides a means for adjusting slot length by apparently adjusting slot height. When the slot adjustment plate 52 is lowered to reduce the opening at the inlet end of the slot, it restricts the amount of breading material entering the slot, and the upper surface of the bread layer does not touch the slot roof 51. If this condition remained throughout the slot length, there would be little pumping pressure at the outlet end of the slot to force breading upwardly through the belt 46 at 46a. However, the breading material then slips internally, backing up into the slot and filling the slot height. As the filling process continues down the slot length toward the inlet end of the slot, an increasing amount of breading is forced upward through the belt at 46a, until a steady state condition is reached, wherein the amount of breading being moved by the belt onto the slide plate 45 equals the amount entering the slot at 52. The slot length now in use is somewhat less than the original fixed length. This action could be seen through the transparent wall of a pilot model. In effect, the slot length has been shortened by reducing the slot height. When the use of a particular breading material is desired that will not pump adequately through the described slot, the slot length may be temporarily lengthened by bolting on a suitable slot extension plate, utilizing the bolt positions 53a.

The machine described will accept a regular or intermittent flow of food products at the inlet to the liquid batter coating section and will then completely liquid coat the product; remove excess liquid from most surfaces thereof; transfer the product to a dry breading coating section; completely coat the product with the dry breading material; tamp the dry material on the product; remove excess dry material from all parts of the product; and deliver the product to another conveyance for further action.

The machine described will continuously sift out large chunks of dry breading material which have been matted by contact with batter material.

It will have been noted that the machine dismantles for cleaning without tools. Removable parts are light enough to pose no lifting problems to anyone, and small enough to wash in a sink. The main breading hopper 42 and the dry coating conveyor 46 remain attached together with one end of the conveyor pivoted up to a safe stable point as shown in FIG. 19. This part could be washed on a counter so that the water drains into a sink, or if on a movable cart, could be washed in a large equipment washroom. High pressure hoses will not damage any components of the machine.

When compared to the smallest commercial machines presently available, the machine presented herewith utilizes about one-third of the conveyor belt area per minute, or about one-half the total conveyor belt length, and thus the capacity of the machine is about one-third to one-half that of the next smallest machine of comparable versatility.

This first embodiment described herein is only 17 inches wide by 43 inches long by 18 inches high, and weighs about 120 pounds complete. This may be compared with production type machines up to 5 feet wide by 15 feet long by 8 feet high and weighing 1800 pounds.

The machine presented herewith has very few adjustment points to regulate, and poor regulation is not usually a serious factor in use of the machine. Wear points are not critical and are easily replaced, rather than having to be adjusted. All replacement conveyor belts can be endless when received from the factory, so that special training is not necessary to lace them together. The machine dismantles for cleaning without the use of tools, and all surfaces are accessible for scrubbing. When open for cleaning, all belts are free wheeling for ease of cleaning, because the axial square socket connections and stub shafts on all of the driving pulleys permit all product driving pulleys to be disconnected from the power source.

The splitter and side plows might be eliminated for some products. The tamper plate is not always necessary, or could be replaced by a pressure roll or a spreader blade. The bread return deflector might be eliminated but this would require more frequent filling of the breading material hopper. The submerger wheel could be substituted by passing the conveyor 22 under a submerging bar.

As has been noted above, the product path shown in the drawings of the preferred first embodiment might be varied considerably without effectively changing the basic machine functions. In fact, some products require a different path due to adverse effects incurred if run through the preferred first embodiment. For istance, butterfly shrimp and perch have a tendency to close up when dropped from a high batter machine to a low breading layer as illustrated in FIG. 33, therefore they should be transferred with little or no drop. But once they are breaded, a dropping flip to remove excess breading is usually acceptable procedure. They can, therefore, be run on the second embodiment illustrated in FIGS. 20, 21, 22 and 34. In another instance, long fresh fish fillets may be so limp that they tend to fold crosswise when dropped any distance, even when breaded. Therefore, they must be gently transferred throughout the machine. Since no flips are acceptable, a blower must be used to remove excess breading on top of the product which in turn requires additional breading conveyor length. This is illustrated in the third embodiment, as in FIGS. 23, 24, 25 and 35. The machine is designed so that any of the three embodiments can be converted to another with the addition of proper parts, and with no cutting, drilling or welding procedures necessary.

In discussing the second and third embodiments, as shown in FIGS. 20 through 35, parts which are the same as shown and described in the first embodiment have been given the same reference characters, sometimes with a "prime", and are further described only when necessary for a clear understanding.

The chief change between FIG. 1 and FIG. 20 is that the liquid coating unit of FIG. 1 has been turned end for end in FIG. 20 with the discharge over drive pulley 25 nearer the level of conveyor run 46. New unit 95 (FIG. 32) supports the liquid coating unit, and unit 89 (FIGS. 27, 28) supports a short extension of conveyor belt 20.

In the drawings, FIGS. 20, 21, 22, 27, 28, 32 illustrate the parts additions necessary to convert from the preferred embodiment of FIG. 1 to the second embodiment in FIG. 20. FIGS. 27 and 28 show the batter conveyor extension 89 which consists of a bottom wall 89b and two parallel side walls 89a. Rigidly mounted between the side walls 89a is a cross rod 90, which serves as a pulley equivalent. One hole 25d with two satellite bearing bolt holes is punched in each side panel 89a. The conveyor extension 89 is bolted onto the conveyor frame 32' so that drive pulley shaft 25 passese through holes 25d in side walls 89a. Addition of a short length of wire mesh conveyoro belt to 20 provides sufficient length for the belt section 20a in FIG. 20 to extend from pulley 25 around cross rod 90 and back vie 20b to the underside of 25. The mounting holes in 89a are located so that the cross rod 90 is reasonably close to the breading layer carried by conveyor belt 46 on slider plate 45, thus insuring a gentle transfer of product from conveyor belt 20 to conveyor belt 46. The side walls 89a are enclosed on the outside by splitter plow trailing legs 63b. The bottom wall 89b of conveyor extension 89 serves the functions of keeping breading out of the path of batter belt 20, and retaining drip from the belt. The batter belt section 20 b continually wipes the top side of bottom wall 89b, thus returning any drip to the batter tank 21.

FIG. 32 shows the in-feed bracket 95, which consists of two side panels 95a separated by and rigidly connected by three cross rods 97a, 97b, 97c, so that the space between side panels is slightly more than the width of batter reservoir 21. The cutout 95b in one side wall 95a provides clearance for the batter jug support 36b on batter reservoir 21. The inverted channels 95c rigidly attached to each side panel 95a serve the two functions of: hooks to hang the bracket on the breading unit, and spacers to locate the batter coating unit substantially on the center line of the breading unit.

In the embodiment shown in FIG. 20, the batter reservoir 21 is supported by the in-feed bracket 95. The bracket 95 is mounted on the breading unit by hooking the inverted channels 95c over the back wall of the bread hopper at 44. The lower ends of the side plates 95a rest against the back of the machine and serve to support the bracket 95. The batter reservoir pins 87 at the inlet end of the reservoir 21 hook over cross rod 97c of infeed bracket 95, and the bottom wall 21a of reservoir 21 rests on cross rod 97b of bracket 95. Note in FIG. 20 the location 48f in the far hopper side wall 42a. This is the location used for the breading conveyor drive stub shaft 48e in the embodiment of FIGS. 23 and 24. It is covered by a seal plate in the embodiments of FIGS. 1 and 2, or 20 and 21. Note also in FIG. 20 the location 25e in the drive tower 99. This is the location used for the batter drive socket stub shaft 25c in the embodiment of FIGS. 1 and 2. It is covered with a seal plate 99a in the embodiments of FIGS. 20 and 21 or 23 and 24. Similarly, the location 25f for the socket stub shaft 25c in the embodiment of FIGS. 20 and 21, or 23 and 24, is covered by the seal plate 99a in the embodiment of FIGS. 1 and 2.

The shaft of drive pulley 25 is FIG. 20 has been reversed end for end from FIG. 1 in conveyor frame 32, and is driven at the new location 25f by stub shaft 25c. Drive belt 83 as shown in FIG. 20 does not have the belt crossed as shown in FIG. 1.

In the drawings, FIGS. 23, 24, 25, 27, 28, 29, 30, 31, 32 illustrate the parts additions necessary to convert from the preferred embodiment of FIG. 1 to the third embodiment in FIG. 23. Not shown in FIG. 23, 24, 25, are 76, 77, 78, 80, 81, 82. These are the assembly parts for the take-away conveyor used in FIG. 1 and FIG. 20 and are not used in the embodiment of FIG. 23.

In the embodiment of FIGS. 23, 24, 25, the arrangement of the batter unit is the same as in FIGS. 20, 21, 22. However, the breading unit is considerably modified in order to provide the straight-line discharge of the food product as illustrated in FIG. 35. FIGS. 29 and 30 show the bread conveyor extension frame 88. This consists of two side walls 88a, a sloping bottom wall 88b secured between them and a discharge chute 88c. Each side wall 88a has a punched shaft hole 48aa with satellite bearing bolt holes, which is the new position of drive pulley 48 in this embodiment. In addition, two holes 88d are furnished (FIG. 29) which match holes 88d in breading conveyor side panel 60' of FIG. 26. These holes may also be furnished in conveyor side panel 60 shown in FIG. 4. Four bolts through holes 88d in side panel 60' and extension side wall 88a serve to rigidly fasten bread conveyor extension frame 88 to bread conveyor side panels 60', so that one side wall 88a is outside of each side panel 60'. The discharge chute 88c now extends downwardly between side panels 60', to direct breading behind the shaft equivalent 49 and through belt section 46d, where it is returned to circulation.

As may be seen in FIG. 23, the flexible wire mesh breading belt 46 has been extended sufficiently to encompass the drive pulley 48 at its new location 48aa. Belt section 46c runs in close proximity to the top surface of the bottom wall 88b of the breading conveyor extension 88, thus serving to return excess bread to the chute 88c.

Excess breading on the top of the product as it moves on belt 46b toward drive pulley 48 must be removed without scraping or damaging the food product. This may be accomplished by blowing low pressure air downward from a point above the product. As shown in FIG. 31, a blower housing 92 may consist of a top wall 92b, two parallel side walls 92a and two parallel end walls 92c. The bottom of each side wall 92a is turned outwardly to form a flange 92e parallel to top wall 92b, and the edge is then turned downward to form a flange skirt 92d. One end wall is equipped with a thin and moderately stiff plastic curtain 96, to retain most blown-off breading yet permit free passage of breaded product. The blowoff housing 92 is mounted to straddle the conveyor side panels 60', with flanges 92e resting on the top of side panels 60', and with flange skirts 92d outside their respective panel 60'. The curtain 96 then hangs between side panels 60' almost to conveyor belt 46. The top wall 92b has an air manifold 91 attached thereto, with inlet end 91b facing the feed end of the breading unit and two drop tubes 91a passing through the top wall 92b. The clear surface of the top of the top wall 92b may be used as a mounting surface for the removable air blower 98, which discharges into air inlet 91b. Into each drop tube 91a, which is open at the bottom, a blower tube is inserted. Each blower tube consists of a vertical leg 93a or 94a, and two horizontal arms 93b or 94b. The bottom of each horizontal arm is drilled in a pattern of holes 101 to furnish a number of jets of air directed substantially downward toward the product. Ends of horizontal arms are closed by plastic stoppers. The primary blowoff tube 94 enters one drop tube at 91c and the secondary blowoff tube 93 enters the other drop tube at 91d. Both blowoff tubes are vertically adjustable for best effect. The shape of the blowoff tubes, the size and number of holes, and the hole arrangement may be extensively varied, consistent with good performance in removing breading, blower size and blower pressure. Blower pressure preferably should range from one-half to one and one-half PSIG, and air volume may be as low as 15 SCFM. Excess air pressure or volume introduces considerable dustiness outside the machine volume.

Note in FIG. 23, the location 48g in the far hopper side wall 42a. This is the location used for the breading conveyor drive stub shaft 48e in the embodiment of FIGS. 1 and 2, or FIG. 20 and 21. It is covered by a seal plate in the embodiment of FIGS. 23 and 24.

Note also in FIG. 23 the location 77f in both hopper side walls 42a. This is the location of the stub shaft 77e and drive pulley 77 of the take-away conveyor used in the embodiment of FIG. 1 or FIG. 20. In the embodiment of FIG. 23, these locations are covered with seal plates not shown.

FIG. 26 shows a second possible configuration for the vertical conveyor support plate 60' on either side of the breading unit conveyor 46. It is quite similar to that shown at 60 in FIG. 4. The main exception being that the bottom edge of plate 60' in FIG. 26 is a straight line between the areas 47a and 49a. This line matches the line of the bread hopper bottom wall 43. The plates 60' in FIG. 26 now become the side walls of the bread reserve volume 42, and also the side walls of pumping slot 50. FIG. 15 is substantially unchanged when the side panels of FIG. 26 are used in place of those from FIG. 4.

FIG. 33 serves to show how the product must flip from the batter section to the breading layer, and from the breading belt to the take-away conveyor, all as in the preferred embodiment of FIG. 1.

FIG. 34 serves to show how the product is gently transferred from the batter section to the breading layer, and then flipped from the breading belt to the take-away conveyor as in the second embodiment of FIG. 20. FIG. 35 serves to show how the product is gently transferred from the batter section to the breading layer, and then moves on a level path until it leaves the machine, thus avoiding all flips, in the third embodiment as shown in FIG. 23.

The embodiment in FIG. 20 is 17 inches wide by 63 inches long by 19 inches high and weighs 125 pounds. The embodiment of FIG. 23 is 17 inches high by 63 inches long by 25 inches high and weighs 150 pounds due to blower 98.

In addition to all of the above, there are numerous minor variations that can be made in the machine without changing its basic functions; coat with liquid, remove excess liquid, transfer to dry coating, dry coat, remove excess dry coating, transfer out of the machine. Several are listed below.

The submerger wheel 23 may be removed, and simple guides installed in its place to hold the belt 20 below the liquid level 35. This may be suitable for a few products which do not float, but there is no positive wheel effect to completely submerge the product.

The splitter plow 63 may be removed with the view of shortening the machine, or to obtain further lowering of the batter coating section. Removal of the splitter results in more bottom layer of breading and less top layer for less positive top coating. Also, when the splitter is removed, the trailing legs 63b no longer affect the top cover, so that bread is no longer rolled over the top of the leading edge of the product by the side plows 65. Product will then tend to climb the slope of breading plowed in by the side plows 65, thus further reducing top cover.

The bread return deflector 73 may be omitted, which will only result in a lower reserve volume in the breading hopper.

The tamper plate 66 could be removed, it could be weighted, or a pressure roll could be substituted. The effect would be to vary the packing of the breading onto and around the product when it is between the side plow trailing legs 65a.

The configuration of side plows 65 might be considerably changed, without altering their function. A more complex shape defeats one of the parameters of the machine, which is low cost. The side plows may be completely removed when only the bottom side of the product is to be dry coated.

The take-away conveyor location in FIG. 1 or FIG. 20 could be changed considerably without real effect except if it were raised to the level of the breading belt, thus eliminating the flip. This arrangement would be less satisfactory than that shown in FIG. 23.