Methods for production of food batter materials

Abstract

A batter mixing apparatus and process is disclosed for mixing a dry batter mix with a predetermined amount of water is adapted to continuously measure the temperature and the viscosity, in centipoises, with an inline viscometer. The controls of the apparatus are fully automated using a programmable logic controller in conjunction with a touchscreen display that provides real-time data, process control parameters, and a choice of batter recipes. Once the batter has reached a desired viscosity, a variable speed feed pump is used to pump the batter to a batter applicator where a food product is coated. Excess batter from the applicator is collected and returned to the mixing apparatus via a pump. The viscosity and temperature of the returned batter is measured and adjusted automatically with dry batter mix or water in order to satisfy the set parameters.

1 . A process for preparing a food batter material and controlling viscosity of the batter material, comprising the steps of: 
 (a) supplying at least first and second batter components to a mix tank;    (b) mixing at least said first and said second components in said mix tank into a batter product during a mix cycle;    (c) directing an amount of the batter product through an independent supply conduit to a viscosity control system, the viscosity control system comprising an in-line viscometer coupled to the conduit to receive the batter product and substantially continuously monitor the viscosity of the batter product, and returning the product to the mix tank; and    (d) control the supply of the at least first and second components, and said mix cycle, to substantially maintain the batter product at a predetermined viscosity.    
   
   
       2 . The process according to  claim 1 , wherein the in-line viscometer is an ultrasonic viscometer which measures the viscosity of the batter product continuously.  
   
   
       3 . The process according to  claim 1 , further comprising the step of filtering the batter product supplied to the in-line viscometer.  
   
   
       4 . The process according to  claim 3 , wherein the filtering of the batter product is performed after being supplied to the independent supply conduit.  
   
   
       5 . The process according to  claim 1 , further comprising the step of providing an independent pump for supplying the batter product to the in-line viscometer in a substantially uniform volume.  
   
   
       6 . The process according to  claim 1 , wherein the batter product is supplied to a housing in which the in-line viscometer is positioned to allow the batter product to flow around the viscometer.  
   
   
       7 . The process according to  claim 6 , wherein an independent pump supplies the batter product to the housing such that the batter product flows through the housing without substantial pressure loss.  
   
   
       8 . The process according to  claim 1 , wherein the step of substantially maintaining a predetermined viscosity is performed as the batter product is supplied to a batter applicator for application to food products, by controlling the amounts of the first and second batter components introduced into the mix tank to maintain a volume of batter product in the mix tank, and controlling the temperature of the batter product within the mix tank, with the viscosity controlled relative to a predetermined viscosity in centipoise.  
   
   
       9 . The process according to  claim 1 , further comprising the step of monitoring the temperature of the batter product in the mix tank and controlling the temperature so as to be substantially maintained about a predetermined temperature.  
   
   
       10 . The process according to  claim 1 , wherein the in-line viscometer produces a signal relating to the measurement of viscosity which is coupled to a programmable control system, wherein the control system is programmed to control the mixing cycle and addition of the at least first and second components, and the temperature of the batter product to substantially maintain the batter product at a predetermined viscosity.  
   
   
       11 . The process according to  claim 10 , wherein the programmable control system may include a plurality of batter recipes stored therein, whereby an operator may select a recipe and the control system will automatically provide and maintain a batter product according to the selected recipe.  
   
   
       12 . The process according to  claim 10 , wherein the control system is interfaced with other equipment in a food processing line, and wherein parameters of operation of the other equipment or characteristics of food products being processed in such other equipment are monitored and facilitate production of the batter product.  
   
   
       13 . A process for preparing a food batter material and substantially maintaining a predetermined viscosity of the batter material, comprising the steps of: 
 (e) supplying at least first and second batter components to a mix tank;    (f) mixing at least said first and said second components in said mix tank into a batter product during a mix cycle;    (g) directing an amount of the batter product to a viscosity control system, wherein the amount of batter product is filtered prior to being introduced into an in-line viscometer for measurement of the viscosity of the batter product; and    (h) continuously controlling the supply of the at least first and second components, and said mix cycle, based on the measured viscosity, to substantially maintain the batter product at a predetermined viscosity.    
   
   
       14 . The process according to  claim 13 , wherein the filtering of the batter product provides a substantially homogenous product to the in-line viscometer for measurement of the viscosity in centipoise.  
   
   
       15 . The process according to  claim 13 , wherein the batter product is independently pumped to the in-line viscometer to substantially continuously provide a substantially uniform volume of the batter product to the in-line viscometer.  
   
   
       16 . The process according to  claim 13 , wherein the in-line viscometer comprises an ultrasonic probe within a housing, configured such that the amount of batter product supplied thereto substantially completely contacts the probe within the housing.  
   
   
       17 . The process according to  claim 16 , wherein the ultrasonic probe is disposed in the housing in a manner which allows the material to flow around the probe.  
   
   
       18 . The process according to  claim 13 , wherein the in-line viscometer is continuously supplied with the amount of batter product for viscosity measurement.  
   
   
       19 . The process according to  claim 13 , wherein the in-line viscometer is intermittently supplied with the amount of batter product for viscosity measurement.  
   
   
       20 . A process for preparing a food batter and controlling viscosity of the batter comprising the steps of: 
 supplying at least a first and a second component to a mix tank;    mixing at least said first and said second component in said mix tank during a mix cycle; and    programming a controller for controlling the supply of the at least first and said second components, and said mix cycle to substantially maintain a predetermined viscosity through a closed loop feedback from an in-line viscometer, and a cooling system used in conjunction with a probe for measuring a temperature of said batter in said mix tank to substantially maintain said temperature of batter in said mix tank.