Abstract: A food production system creating folded par-baked units (e.g. mini tacos) for frying, including a sheeter for continuously creating a succession of substantially flat raw dough units and an oven having a plurality of hanging conveyors (e.g. chains). The hanging conveyors are narrow so that the raw dough units raw fold down on either side thereof to form folded dough units. The oven includes a first plurality of cross-burners to pre-heat the hanging conveyor for transferring shape-setting heat directly from the hanging conveyor to the folded dough units. The oven further includes a second plurality of substantially longitudinal shape-setting burners that are substantially in parallel with and adjacent to the top dough carrying side of the hanging conveyor for providing further shape-setting heat to the folded dough units. The oven discharges par-baked units ready for frying.

Abstract: A food production system creating folded par-baked units (e.g. mini tacos) for frying, including a sheeter for continuously creating a succession of substantially flat raw dough units and an oven having a plurality of hanging conveyors (e.g. chains). The hanging conveyors are narrow so that the raw dough units raw fold down on either side thereof to form folded dough units. The oven includes a first plurality of cross-burners to pre-heat the hanging conveyor for transferring shape-setting heat directly from the hanging conveyor to the folded dough units. The oven further includes a second plurality of substantially longitudinal shape-setting burners that are substantially in parallel with and adjacent to the top dough carrying side of the hanging conveyor for providing further shape-setting heat to the folded dough units. The oven discharges par-baked units ready for frying.

Abstract: A compact, rounding machine, or rounder, for quickly rounding dough units discharged from a divider into substantially round dough balls used to make products like flour tortillas, buns, rolls, etc. The rounder includes a stationary shoe having a curved inner face that curves partially around an axis of rotation, and a stationary groove having a substantially semicircular profile and extending between an entry end and an exit end. A roller with an outer face and moving groove is positioned against the stationary shoe's inner face and stationary groove to define a rolling cavity, one half of the rolling cavity being formed by the stationary groove and another half of the rolling cavity is formed by the moving groove. A funnel assembly positioned adjacent to the roller, along with a beveled entry wall at the entry end of the stationary groove, guide dough units into the rolling cavity.

Abstract: A sheeter includes an internally grooveless front roller, a rear roller configured to rotate counter to the front roller, a partially spiraled stripper wire coupled across the front roller, and a conveyer belt connected to a proximal conveyer roller and a distal conveyer roller. The conveyer belt includes a landing zone configured to prevent damage to a received product. The conveyer belt includes a raised portion adjacent to the proximal end and flat portion towards the distal end.

Abstract: A compact, rounding machine, or rounder, for quickly rounding dough units discharged from a divider into substantially round dough balls used to make products like flour tortillas, buns, rolls, etc. The rounder includes a stationary shoe having a curved inner face that curves partially around an axis of rotation, and a stationary groove having a substantially semicircular profile and extending between an entry end and an exit end. A roller with an outer face and moving groove is positioned against the stationary shoe's inner face and stationary groove to define a rolling cavity, one half of the rolling cavity being formed by the stationary groove and another half of the rolling cavity is formed by the moving groove. A funnel assembly positioned adjacent to the roller, along with a beveled entry wall at the entry end of the stationary groove, guide dough units into the rolling cavity.

Abstract: A sheeter includes an internally grooveless front roller, a rear roller configured to rotate counter to the front roller, a partially spiraled stripper wire coupled across the front roller, and a conveyer belt connected to a proximal conveyer roller and a distal conveyer roller. The conveyer belt includes a landing zone configured to prevent damage to a received product. The conveyer belt includes a raised portion adjacent to the proximal end and flat portion towards the distal end.

Abstract: An improved dough sheeter having a pair of counterrotating sheeter rollers and a cutter roller rotating against a front one of the sheeter rollers to cut a pattern into a sheet of dough therebetween. The improvement is the cutter roller being formed from an oil-impregnated wear resistant plastic that results in a much longer cutter life. The dough sheeter's cutter roller may have axial shaft, a pair of cutter lift arms including a U-shaped end, and a pair of needle bearing assemblies, each needle bearing assembly located on a corresponding end of the axial shaft. Also disclosed is a method of manufacturing a cutter roller for a dough sheeter where the crown is formed before the cutting pattern is cut into the cutter roller.

Abstract: An improved dough sheeter having a pair of counterrotating sheeter rollers and a cutter roller rotating against a front one of the sheeter rollers to cut a pattern into a sheet of dough therebetween. The improvement is the cutter roller being formed from an oil-impregnated wear resistant plastic that results in a much longer cutter life. The dough sheeter's cutter roller may have axial shaft, a pair of cutter lift arms including a U-shaped end, and a pair of needle bearing assemblies, each needle bearing assembly located on a corresponding end of the axial shaft. Also disclosed is a method of manufacturing a cutter roller for a dough sheeter where the crown is formed before the cutting pattern is cut into the cutter roller.

Abstract: A saddle for a sheeting head includes a pair of semi-circular concave edges configured to seal a pair of rollers. The oppositely facing concave edges each include a tongue that fits in a corresponding groove in the roller and a retracted concave edge adapted to wrap around half the roller surface. The saddle includes a top portion wherein the concave edges downwardly converge, and a bottom portion wherein the concave edges downwardly diverge. A narrow waist is provided at the proximal-most position of the concave edges and adapted to fit in a pinch point between the rollers. A sheeting head assembly incorporating the saddle may include a sidewall to which the saddle need not be fastened. The self-locking characteristics of the saddle enable an assembly to omit sidewalls altogether.

Abstract: An oven conveyor alignment system for maintaining a conveyor belt centered on its supporting rollers is disclosed. The system comprises a camera that generates an image of alignment and stores it as a digital pixel representation. Thus, the system is able to take advantage of new improvements in digital camera resolution. The image information is used by interactive software that is able to transmit an electrical signal to a tension adjustment assembly.

Abstract: A saddle for a sheeting head includes a pair of semi-circular concave edges configured to seal a pair of rollers. The oppositely facing concave edges each include a tongue that fits in a corresponding groove in the roller and a retracted concave edge adapted to wrap around half the roller surface. The saddle includes a top portion wherein the concave edges downwardly converge, and a bottom portion wherein the concave edges downwardly diverge. A narrow waist is provided at the proximal-most position of the concave edges and adapted to fit in a pinch point between the rollers. A sheeting head assembly incorporating the saddle may include a sidewall to which the saddle need not be fastened. The self-locking characteristics of the saddle enable an assembly to omit sidewalls altogether.

Abstract: An oven conveyor alignment system for maintaining a conveyor belt centered on its supporting rollers is disclosed. The system comprises a camera that generates an image of alignment and stores it as a digital pixel representation. Thus, the system is able to take advantage of new improvements in digital camera resolution. The image information is used by interactive software that is able to transmit an electrical signal to a tension adjustment assembly.

Abstract: A tortilla press utilizing a single sensor provides improved efficiency and accuracy. The press has a belt driven by a motor and a platen driven by a hydraulic cylinder. The motor is controlled by an AC inverter. A programmable logic controller (PLC) controls the AC inverter and hydraulics associated with the hydraulic cylinder of the platen. The PLC coordinates the movement of the belt and the movement of the platen. A sensor detects detectible elements on the belt and sends a signal to the inverter to initiate stopping of the belt. The inverter detects the zero hertz from the motor once the motor and belt have stopped and sends a signal to the PLC indicating that the belt has stopped. The PLC in turn passes a command that sends a signal to bring the platen down.

Abstract: A conveyor system for transitioning articles between an external intermittent conveyor and an external continuous conveyor system includes an upper conveyor and lower conveyor. Each conveyor includes an infeed arm movable toward and away from the intermittent conveyor. Each infeed arm defines an infeed end that is movable along a common arc and rotatable about a common pivot point. With the infeed ends traveling along a common arc, each infeed end is easily moved to the same optimal receiving position for receiving articles from the intermittent conveyor. Each conveyor may switch between a continuous mode, wherein articles are continuously discharged onto the continuous conveyor, and an intermittent mode, wherein articles are intermittently received from the intermittent conveyor.

Abstract: A cutter carriage for moving a rotary cutter between a front side of the back roller and a back side of the back roller. The preferred system has a pair of guide rods located on the left and right side plates of the sheeting head. The rotary cutter is held at either end by pivot arms. Each arm, in turn is attached to a carriage side piece that slidingly engages one of the guide rods. The two side pieces are joined into a single cutter carriage by an elongate member parallel to the rotary cutter. Each carriage is equipped with a cutter engagement system that moves the pivot arms and attached rotary cutter into an operational position in relation to the sheeting head. When the rotary cutter is serviced, the engagement system is released allowing the pivot arm to move the rotary cutter away from the sheeting head roller, and the cutter carriage is slid along the guide rods making the rotary cutter readily accessible from the rear side of the sheeting head.

Abstract: An oven with slide-out transfer guides is provided for use in conjunction with multiple conveyor ovens to provide quick and convenient accessibility to an oven's interior in case of product transfer difficulties. A slidable rail assembly is mounted in the oven, which also has an access port for transfer guide egress and ingress, and a transfer guide with opposed lips forming a slot which mounts the transfer guide on the rail assembly. When access to the oven's interior is necessary to remedy a product transfer problem, the oven of the present invention allows the transfer guide to slide along the rail while still supported by same, and said transfer guide can be partially removed from said oven without the need to turn off the oven. In this way, obstructions can be cleared quickly without significant down time, thereby saving the user both time and expense.

Abstract: A sheeter head having a pair of counterrotating internally-driven sheeter rollers is disclosed. The sheeting rollers each include an independent internal drive motor and gear box affixed to a nonrotating shaft, along with a nonrotating idle shaft on an opposite end of the roller. The speeds of the drive motors are controlled by an external device such as an inverter speed control. The nonrotating shafts, in conjunction with the absence of any external drive mechanism, allow for sanitary operation, easy clean-up, and a simple and efficient adjustment mechanism for varying a pinch point between the rollers. The preferred adjustment mechanism includes a fixed front roller and horizontal slide plates connected to the axles of a back roller, the slide plate having pegs which slide in associated grooves. One of the grooves is preferably wider than the other to help prevent binding during an adjustment operation.

Abstract: Problems in counting and stacking fried food products such as tostadas are solved by an improved counter/stacker device in which tortilla food products ride a first moving belt through a photoelectric counting station. After being counted the product drops into a stack retainer shaped to hold the product. A series of stack retainers are arranged along the length of a flexible, intermittently moving, continuous belt. When the counting station signals that the required number of product have been counted and deposited into a stack, the flexible belt bearing the stack retainer is rapidly advanced to bring an empty stack retainer into position beneath the counting station. The stack retainers ensure that the product stacks do not shift and are stationary for a period of time, thereby facilitating manual or automatic packaging of the product.

Abstract: Masa handling methods for the continuous processing of masa type dough in conjunction with commonly available feed processing equipment, such as a masa extruder, an oven, or cooling apparatus. One masa handling method includes a masa separator having a pair of opposed, endless belt conveyors having facing surfaces spaced apart to receive a generally continuous masa stream output from a nozzle on the masa extruder. When the masa stream moves between the conveyors, it is gripped by their facing surfaces and moved away from the nozzle, causing the masa to be separated into individual pieces, or logs. The masa handling method can also include feeding the masa to masa hoppers fed by at least two endless belt conveyors arranged in upstream and downstream positions relative to each other.

Abstract: Mass handling methods for the continuous processing of masa type dough in conjunction with commonly available feed processing equipment, such as a masa extruder, an oven, or cooling apparatus. One masa handling method includes a masa separator having a pair of opposed, endless belt conveyors having facing surfaces spaced apart to receive a generally continuous masa stream output from a nozzle on the masa extruder. When the masa stream moves between the conveyors, it is gripped by their facing surfaces and moved away from the nozzle, causing the masa to be separated into individual pieces, or logs. The masa handling method can also include feeding the masa to masa hoppers fed by at least two endless belt conveyors arranged in upstream and downstream positions relative to each other.