ULTRASONIC CLEANING METHOD AND SYSTEM

FIELD OF THE INVENTION

[0001] The present invention relates to methods and systems for ultrasonic cleaning of food processing equipment.

BACKGROUND OF THE INVENTION

[0002] The co-extrusion process for manufacturing hot dogs creates a hot dog with a meat center e.g ., pork, chicken, turkey, or beef) and a thin outer skin, which typically comprises collagen. This outer layer of collagen when dried creates a skin or casing for the hot dog. Once formed, the hot dogs are placed into long baskets. These baskets are conveyed on a chain system that takes the hot dogs through an oven to be dried. The outer collagen layer is partially dried in this oven. This oven is referred to as the“pre-dry oven.” Once through this pre-dry oven, the hot dogs are exposed to liquid smoke that adds smoke flavor to the hot dog. The liquid smoke process partially rehydrates the collagen skin. The hot dogs then go through a post-dry oven system (similar to the pre-dry oven) which has its own set of baskets. The post-dry oven dries the outer layer for a second time. Products are then ejected from the oven for packaging and further processing. There is a long-felt need in the food service industry for a method of efficiently cleaning the food processing equipment that is exposed to collagen and liquid smoke.

SUMMARY OF THE INVENTION

[0003] The invention relates to a method for ultrasonic cleaning of baskets.

[0004] In many embodiments of the invention, the method for in-line cleaning food-processing equipment may comprise ultrasonic cleaning, rinsing, and drying of the equipment.

[0005] In many embodiments, the method for cleaning food-processing equipment may comprise: (a) conveying the equipment through an ultrasonic bath and subjecting the equipment to ultrasonic cleaning; and (b) drying the equipment after ultrasonic cleaning.

[0006] In other embodiments, a method for cleaning food-processing equipment may comprise: (a) placing the equipment in an ultrasonic bath; (b) subjecting the equipment to ultrasonic cleaning; and (c) drying the equipment after ultrasonic cleaning.

[0007] In many embodiments, the food-processing equipment may comprise one or more baskets. The baskets may be coupled in a series, preferably on a chain or belt. The baskets may be adapted to hold food products with partially dried collagen coating. The food products may be hot dogs. [0008] In many embodiments, the ultrasonic bath may comprise water, preferably degassed fresh water. The water may be substantially free of detergents or other cleaning products.

[0009] In any embodiment, the ultrasonic cleaning may use an ultrasound frequency between 20 kHz to 400 kHz. The ultrasound frequency may be about 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, or 400 kHz. The ultrasound frequency may be 20- 50 kHz, 60-120 kHz, 130-170 kHz, 180-200 kHz, 210-250 kHz, 260-280 kHz, 290-310 kHz, 320-350 kHz, 360-380 kHz, 390-400 kHz, 20-400 kHz, 100-400 kHz, 300-400 kHz, 50-300 kHz, 50-300 kHz, or 200-400 kHz. The ultrasound frequency may be about 45 kHz.

[0010] In many embodiments, the ultrasonic cleaning may be at a temperature of l30°F to l70°F. The temperature may be about l40°F, l4l°F, l42°F, l43°F, l44°F, l45°F, l46°F, l47°F, l48°F, l49°F, l50°F, l5l°F, l52°F, l53°F, l54°F, l55°F, l56°F, l57°F, l58°F, l59°F, l60°F, l6l°F, l62°F, l63°F, l64°F, l65°F, l66°F, l67°F, l68°F, l69°F, or l70°F. The ultrasonic cleaning may be conducted at a temperature of l40°F to l60°F.

[0011] In many embodiments, the ultrasonic cleaning may be for 1-25 seconds. The ultrasonic cleaning may be for about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 seconds. The ultrasonic cleaning may be for 1-5 seconds, 1-10 seconds, 5-15 seconds, 10-15 seconds, 8-15 seconds, 11-15 seconds, 15-20 seconds, 10-20 seconds, 7-15 seconds, 1-20 seconds, 1-15 seconds, 3-12 seconds, 9-18 seconds, or 4-16 seconds. The ultrasonic cleaning may be for about 12 seconds.

[0012] In several embodiments, the ultrasonic bath may have a volume of about 200 gallons to about 400 gallons. The ultrasonic bath may have a volume of 200-400 gallons, 250-350 gallons, 250-300 gallons, 300-400 gallons, or 225-375 gallons. The ultrasonic bath may have a volume of about 250 gallons to 300 gallons.

[0013] In several embodiments, the ultrasonic cleaning may be at a power setting of about 4,000 Watts to 10,000 Watts. The power setting may be about 4,000 Watt, 5,000 Watts, 6,000 Watts, 7,000 Watts, 8,000 Watts, or 9000 Watts. The power setting may be 4,000 Watts to 9,000 Watts; 6,000 Watts to 10,000 Watts, 7,000 Watts to 8,500 Watts, or 6,500 Watts to 9,500 Watts. The power setting may be about 8,000 Watts.

[0014] In several embodiments, the ultrasonic cleaning may be at a ratio of 15-40 Watts/gallon of water. The ultrasonic cleaning power may be at a ratio of 15-35 Watts/gallon of water, 20-40 Watts/gallon of water, 25-35 Watts/gallon of water, or 30-40 Watts/gallon of water. The ultrasonic cleaning power may be at a ratio of 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40 Watts/gallon of water. The ultrasonic cleaning power may be at a ratio of about 32 Watts/gallon of water.

[0015] In many embodiments, the method may further comprise rinsing the ultrasonic cleaning equipment with water. The rinsing may comprise spraying, misting, dipping, or hosing off the ultrasonic cleaning equipment with water. The water may be at a temperature of l30°F to l70°F, preferably l40°F to l60°F. The rinsing may comprise using water under pressure, preferably a pressure of 60 pounds per square inch (PSI). In several embodiments, the ultrasonic cleaning equipment may be rinsed with water for 1-5 seconds, preferably 2-3 seconds.

[0016] In any of the foregoing embodiments, the method may further comprise drying the baskets, preferably after ultrasonic cleaning, more preferably after rinsing with water after ultrasonic cleaning. The drying may comprise air blasting the baskets, preferably with an air knife system. The drying may be for 1-25 seconds. The drying may be for about 1, 2, 3, 4, 5, 6,

7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 seconds. The drying may be for 1-5 seconds, 1-10 seconds, 5-15 seconds, 10-15 seconds, 8-15 seconds, 11-15 seconds, 15-20 seconds, 10- 20 seconds, 7-15 seconds, 1-20 seconds, 1-15 seconds, 3-12 seconds, 9-18 seconds, or 4-16 seconds. The drying may be for about 12 seconds. The drying may comprise air blasting at a pressure of 1,000 cubic feet per minute (CFM) to 1,500 CFM. The pressure may be about 1,200 CFM.

[0017] A method for cleaning hot dog manufacturing equipment may comprise: (a) co-extrusion to produce at least one hot dog with a coating; (b) loading the hot dog into an empty basket; (c) passing the hot dog in the basket through a pre-dry oven; (d) transferring the hot dog to a liquid smoke basket; (e) passing the hot dog through a liquid smoke applicator; (f) transferring the hot dog to a post-dry oven basket; (g) running the hot dog in the basket through a post-dry oven; (h) transferring the hot dog in the basket for further processing; (i) placing an empty basket in an ultrasonic bath; (j) subjecting the empty basket to ultrasonic cleaning; (k) subjecting the empty basket to a clean water rinse; and (1) drying the empty basket after ultrasonic cleaning. In many embodiments, the coating may be collagen, alginate, or cellulose. In several embodiments, the coating may be collagen.

[0018] In a particular embodiment, a series of parallel ultrasonic cleaning assemblages may be arranged. [0019] In many embodiments, the method may further comprise transferring the hot dogs to a packaging machine, typically after the post-dry oven.

[0020] In many embodiments, the method may further comprise casing, taping, and palletizing packages.

[0021] In any of the foregoing embodiments, the ultrasonic cleaning may remove collagen buildup from the equipment.

[0022] In any of the foregoing embodiments, the method may be a continuous method.

[0023] In any of the foregoing embodiments, the method may be a batch method.

BRIEF DESCRIPTION OF THE FIGURES

[0024] Figure l is a flow chart of exemplary method for cleaning baskets used in hot dog manufacture.

[0025] Figure 2A depicts an exemplary configuration of the ultrasonic cleaning system equipment.

[0026] Figure 2B depicts another exemplary configuration of the ultrasonic cleaning system equipment.

[0027] Figure 3 is a flow chart of exemplary method for cleaning baskets used in hot dog manufacture in a batch method.

[0028] Figure 4A depicts a perspective of an embodiment of exterior portions of uncleaned basket (top) and cleaned basket (bottom).

[0029] Figure 4B depicts another perspective of an embodiment of exterior portions of uncleaned basket (top) and cleaned basket (bottom).

[0030] Figure 5A depicts a perspective of an embodiment of interior portions of uncleaned basket (top) and cleaned basket (bottom).

[0031] Figure 5B depicts another perspective of an embodiment of interior portions of uncleaned basket (left) and cleaned basket (right).

[0032] Figure 5C depicts a perspective of an embodiment of exterior and interior portions of uncleaned basket (right) and cleaned basket (left).

[0033] Figure 6A depicts a perspective of an embodiment of exterior portions of cleaned basket.

[0034] Figure 6B depicts a perspective of an embodiment of exterior portions of uncleaned basket (upper right) and cleaned basket (lower left).

[0035] Figure 6C depicts another perspective of an embodiment of exterior portions of uncleaned basket (upper left) and cleaned basket (lower left). [0036] Figure 7 A depicts a perspective of an embodiment of exterior portions of an uncleaned basket.

[0037] Figure 7B depicts a perspective of an embodiment of exterior portions of a cleaned basket.

[0038] Figure 8 depicts a side-view of an embodiment of a series of baskets filled with sausages in process.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0039] In order that the invention herein described may be fully understood, the following detailed description is set forth. Various embodiments of the invention are described in detail and may be further illustrated by the provided examples. Additional viable variations of the embodiments can easily be envisioned.

Definitions

[0040] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as those commonly understood by one of ordinary skill in the art to which this invention belongs.

[0041] As used in the description herein and throughout the claims that follow, the meaning of “a,”“an,” and“the” includes plural reference unless the context clearly dictates otherwise.

[0042]“Hotdogs,” or“Hot dogs” as used herein, refers broadly to Frankfurters, franks, furters, hot-dogs, wieners, Vienna sausage, bologna, garlic bologna, knockwurst, and similar cooked sausages that are comminuted, semisolid sausages prepared from one or more kinds of raw skeletal muscle meat or raw skeletal muscle meat and raw or cooked poultry meat, seasoned and cured, using one or more curing agents. Hot dogs comprise sausages that comprise a meat center comprising beef, pork, veal, lamb, goat, duck, turkey, chicken, or a combination, with a casing, e.g ., collagen or alginate casing. They may be comminuted, semisolid products made from one or more kinds of raw skeletal muscle from livestock (e.g, beef or pork), and may contain poultry meat. Smoking and curing ingredients contribute to flavor, color, and preservation of the product. Hot dogs are link-shaped and come in all sizes— short, long, thin, and chubby.

[0043] Although the description refers to hot dogs it understood that this is not intended to limit the scope or applicability of the invention.“Hot dogs” may be made from red meat (e.g, beef, buffalo, and lamb or mutton) and/or poultry meat (e.g, chicken, turkey, ostrich, grouse, goose, guinea, and duck). The meat used in the present invention can be“organic,”“natural,”“Kosher,” and/or“Halal.” The hot dog can be pork, preferably cured pork. The meat can be certified “organic” and/or“natural” by the appropriate state or Federal authorities ( e.g ., FDA and USDA) and/or by meeting the appropriate standards set forth by said authorities.

[0044]“Casing,” as used herein refers to the coatings used in the preparation of sausages or hot dogs. The coating may be alginate, collagen, or cellulose.

[0045]“Ultrasonic cleaning” and“Ultrasound cleaning,” as used herein, refer to a process that uses ultrasound (e.g., 20-400 kHz) in a cleaning solvent (e.g, fresh water, pure degassed water).

Ultrasonic Cleaning of Food-Processing Equipment

[0046] The invention provides methods and systems for ultrasonic cleaning of baskets used in food processing.

[0047] Hot dogs with a meat center (e.g, pork, chicken, turkey, or beef) and a thin outer skin (e.g, collagen) are placed into long baskets conveyed on a chain system that takes the hot dogs through a pre-dry oven; then the hot dogs are placed into another set of baskets conveyed on a chain system through a compartment where liquid smoke is applied; followed by the placement of the hot dogs into another set of baskets that takes the hot dogs through a post-dry oven.

[0048] As collagen is dried, it becomes sticky, and the baskets are rotated as the hot dogs are dried in an attempt to prevent collagen from sticking to the baskets and to help form a round hot dog. Small amounts of collagen get stuck on the baskets, and these small amounts of collagen build up on the baskets after only a few hours of operation. Once the collagen build-up gets to a certain level, small pieces of built-up collagen start to come off of the baskets and attach to the hot dogs. Collagen buildup that attaches to the hot dog in the pre-dry oven does not present a quality problem, since collagen is of a neutral color and does not change the appearance of the final product. However, the collagen which builds up on the baskets in the post-dry oven does present a quality problem. Collagen buildup on the basket in the post-dry oven is repeatedly exposed to liquid smoke which turns the collagen on the baskets to a dark, almost black color. As the collagen and liquid smoke residue builds up, the collagen and liquid smoke residue starts to come off the baskets and attach to the hot dogs. This collagen-liquid smoke material creates a dark spot on the hot dog product that does not meet quality requirements. The hot dog production operation must be stopped and all baskets cleaned before operations can resume. This interruption in the operation is costly and disruptive.

[0049] The current manual cleaning method requires two workers about an hour, using hoses with 400 PSI water at l40°F to clean the equipment used in sausage production. This manual cleaning method also uses about 7,000 gallons of water. Further, the current manual cleaning method requires that the manufacturing line be shut down and the equipment at least partially dismantled. This, in total, requires almost 2 hours of worker labor to perform the cleaning task.

[0050] The inventors surprisingly discovered that the use of ultrasonic cleaning bath resulted in a rapid method for removing collagen that accumulated on baskets used in sausage production. In contrast, the method of this invention takes only about 12 seconds to remove 2 days of collagen build-up without disruption to the manufacturing process. As a consequence, the efficiency of the cleaning task is improved, which reduces associated labor and costs. This was unexpected because it was unclear how the ultrasonic energy would affect the collagen build-up, how long the ultrasonic cleaning should last for, and it was believed that the ultrasonic energy would damage the equipment. Further, there was no known method of cleaning the equipment save for manual disassembly and cleaning of the equipment. Indeed, the inventors worked for over 6 years to find a suitable solution to the problem of collagen build-up on the baskets used in sausage production without success. The inventors used an approach for which the art provided no guidance. The ultrasonic energy created from the ultrasonic cleaning bath blasts the collagen off of the baskets. When used in continuous operation, the ultrasonic cleaning prevents the over saturation of repeated exposure to liquid smoke. Surprisingly, ultrasonic cleaning according to this invention can be accomplished in clear water, without the addition of cleaning agents, such as surfactants. Avoiding cleaning products in contact with food contacted surfaces is beneficial in the processing industry.

[0051] The method and system of this invention for ultrasonic cleaning of the equipment may comprise an assemblage of equipment comprising: (a) an ultrasonic cleaner ( e.g ., ultrasonic rods submerged in a water bath) with a power of as much as 8000 Watts, coupled to (b) a rinsing station (e.g., a jet spray rinse; when the baskets come out of the water, they may be subjected to a spray rinse, for example, a spray rinse preferably at a pressure of 60 pounds per square inch (PSI)) where water is applied at a temperature of l40-l60°F for 2-3 seconds coupled to (c) a drying station (e.g, air dry blower) where warm dry air at an ambient air temperature (e.g, about 68°F to about 77°F) is applied at a velocity of, e.g, about 1200 CFM (cubic feet per minute). These elements may be integrated into a production line for making sausages. Each oven has its own set of baskets. Hot dogs from the pre-dry oven are transferred into other baskets for the liquid smoke application. The product is then transferred from the liquid smoke baskets to the post-dry oven baskets. Hot dogs from the post dry oven are ejected onto a discharge conveyor to be taken to another machine for packaging and further processing. The baskets from each of the pre-dry oven and post-dry oven can be taken through an ultrasonic cleaning machine.

[0052] Using the methods and systems described herein, each hot dog is placed into a clean basket, free of collagen build-up. The inventor surprisingly discovered that the use of ultrasonic cleaning allowed for the rapid in-line cleaning of baskets used in sausage manufacture. The methods described herein also use less water, require less time, and require less disruption to the production line to clean the baskets.

[0053] The baskets may travel along a chain conveyor where they are loaded with hot dogs from a co-extruder and passed through a pre-dry oven ( e.g ., MAREL® drying oven). Once the hot dogs are done drying in the pre-dry oven, the hot dogs may be placed onto a roller conveyor or other type of conveyor, which takes the hot dogs to baskets for the liquid smoke station (e.g., MAREL® liquid smoke applicator). After that, the hot dogs are again moved on a conveyor to another set of baskets which are part of a post-dry oven (e.g, MAREL® drying oven). The baskets for each of the pre-dry oven, liquid smoke application, and post-dry oven can be coupled to a system for ultrasonic cleaning comprising an ultrasonic cleaning tank, rinsing station, drying station. The baskets may then be rerouted to the start of the pre-dry oven, liquid smoke applicator, or post-dry oven, respectively.

[0054] A number of different types of equipment may be cleaned with the present invention, including product carriers transiting drying ovens, liquid smoke applicators, rinsing stations, and packaging machines. Multiple pieces of equipment and combinations of different equipment types also may be cleaned with the present invention. In order to provide rapid control of product quality (as described herein) and to eliminate unnecessary handling steps, it is preferred that the process is a continuous process rather than being a batch process. A continuous process produces a substantially continuous supply of hot dogs without interruption of the process, and typically comprises continuously removing the hot dogs from the process chain, allowing the empty baskets to be cleaned and reused.

[0055] Alternatively, the equipment, including product carriers transiting drying ovens, liquid smoke applicators, rinsing stations, and packaging machines, may be cleaned in a batch method. In a batch method, the carrier equipment is removed from production line and cleaned and then returned to the production line. For example, individual pieces of equipment which have a build- up of collagen/liquid smoke may be removed and replaced with clean equipment. The equipment which have a build-up of collagen/liquid smoke is then subjected to ultrasonic cleaning. In turn, this now clean equipment may be returned to the production line.

[0056] In many embodiments, a system for ultrasonic cleaning of food-processing equipment may comprise a conveyor system comprising a liquid smoke applicator coupled to a drying oven coupled to an ultrasonic bath coupled to a rinse station coupled to a dryer.

[0057] In many embodiments, a system for ultrasonic cleaning of food-processing equipment may comprise: a tank; at least one vibratory rod within the tank; a plurality of baskets coupled to a chain conveyor that passes the plurality of baskets into the ultrasonic cleaning system; a first pulley gear to pull the basket chain into the tank; a second pulley gear to pull the basket chain out of the tank; a third pulley gear to pull the basket chain upward and out of the tank; a fourth pulley gear to pull the basket chain into a chamber within the ultrasonic cleaning system; an air knife positioned above the fourth pulley gear; and a fifth pulley gear to pull the basket chain down from the chamber and out of the ultrasonic cleaning system. The basket chain may comprise a series of baskets adapted to hold collagen-cased sausage products during the drying of the collagen casing. The baskets may comprise pre-dry oven baskets, liquid smoke applicator baskets, post-dry oven baskets, or other food processing equipment baskets. The baskets may include one or more stainless steel parts, and one or more plastic wires at least partially disposed thereon, such as an arc-like shape. For example, the one or more plastic wires of the basket may be at least partially disposed in an arrangement on a portion of the one or more stainless steel parts of the basket, such as a web-like concave arrangement or plastic-coated fiber screen having ultra-high molecular weight (“UHMW”) polyethylene material or polypropylene material. For example, the plastic fibers may be spaced 1/8” apart. The tank may comprise an overflow drain. The second pulley gear may comprise an idler gear. The third pulley gear may comprise an idler gear. The fourth pulley gear may comprise an idler gear. The fifth pulley gear may comprise an idler gear. The system may further comprise one or more sprayers located near the third pulley gear. The sprayers may spray water on the plurality of baskets, preferably at a pressure of 60 pounds per square inch, for 1-5 seconds, preferably 2-3 seconds. The air knife may blow air to dry the plurality of baskets, preferably for 1-25 seconds. The at least one vibratory rod may be mounted in the tank. The at least one vibratory rod may be hung inside the tank. The at least one vibratory rod may vibrate at a frequency of about 20 kHz to 400 kHz, and preferably at about 45 kHz. The plurality of baskets may be exposed to the at least one vibratory rod for 1-25 seconds, preferably 7 seconds. The at least one vibratory rod may be positioned at a height lower than a top of the overflow drain. The system may further comprise a plurality of vibratory rods. The tank may comprise water, preferably degassed fresh water. The water may be substantially free of detergents or other cleaning products. The tank may comprise a volume of about 200 gallons to about 400 gallons.

[0058] A method for cleaning hot dog manufacturing equipment may comprise: (a) co-extrusion to produce at least one hot dog with a collagen coating; (b) loading the hot dog into an empty basket; (c) passing the hot dog in the basket through a pre-dry oven; (d) transferring the hot dog to a liquid smoke basket; (e) passing the hot dog through a liquid smoke applicator; (f) transferring the hot dog to a post dry oven basket; (g) running the hot dog in the basket through a post-dry oven; (h) transferring the hot dog from the basket for further processing; (i) placing an empty basket from step (c), (e), or (g) in an ultrasonic bath; (j) subjecting the empty basket to ultrasonic cleaning; (k) subjecting the empty basket to a clean water rinse; and (1) drying the empty basket after ultrasonic cleaning.

[0059] A method for in-line cleaning food-processing equipment may comprise: ultrasonic cleaning, rinsing, and drying of the equipment.

[0060] A method for cleaning food-processing equipment may comprise: (a) conveying the equipment through an ultrasonic bath and subjecting the equipment to ultrasonic cleaning; and (b) drying the equipment after ultrasonic cleaning.

Ultrasonic Cleaning System

[0061] An ultrasonic cleaning system comprises a tank for holding a fluid and ultrasonic transducers, an overflow drain output and steam heat input for the tank. It is typically further comprised of a region with sprayers where high pressure fluid can remove particles from food processing equipment such as baskets after the particles are loosened by ultrasound. It may further include an air knife for drying the food processing equipment and removing remaining food particles, and/or a dryer to dry the food processing equipment. The food processing equipment may be moved throughout the ultrasonic cleaning system by a belt or a chain pulley system with gears.

[0062] The ultrasonic cleaner is a water-containing tank that has at least one ultrasonic transducer.

[0063] The ultrasonic transducer may be rod shaped and may be immersed in a fluid or attached to the inside of the tank wall. Although conventional transducers are mounted to the outside of the tank, the ultrasonic transducer of this invention is preferably disposed internal to the tank and suspended in the water column by one or more support brackets. Generally, the submerged transducers are more efficient, and the external transducer tend to damage the ultrasonic tank over time. The transducer may be a rod made of titanium or other metal, or metal alloy. The transducer may have a length of one to four feet long. The transducer may be similar in design to the rod shaped resonators found in the ultrasonic cleaners provided by Crest Ultrasonics (NJ). The tank may be filled with water ( e.g ., degassed fresh water). The water is preferably substantially free of cleaning products (e.g., comprising less than 0.001% cleaning agents). The water may be fresh water, preferably degassed fresh water. Baskets are directly exposed to food products— accordingly chemicals, such as surfactants or solvents, are typically not used. The fluid may be water, preferably potable water. The potable water may be substantially free of detergents, or the potable water may be free of detergents.

[0064] The ultrasonic energy created by the transducer produces sufficient intensity of ultrasonic energy to dislodge contaminants including collagen build-up and liquid smoke residue from baskets. An electrical signal from a generator feeds into the transducers, creating sound in the fluid strong enough to create cavitation of the water and remove the collagen/liquid smoke build- up from the baskets. The electrical signal may come from a generator located external to the tank, and it may be connected to the transducers located within the tank by a lead.

[0065] The baskets may flow through the ultrasonic cleaning system in a continuous manner such that they move from the food product drying equipment to the ultrasonic cleaning system and then back to the food product equipment again. In a continuous cleaning system, baskets flow through the ultrasonic cleaning system while connected by a chain. The baskets may be welded to the chain. The baskets may be clipped to the chain in such a way that they are removable from the chain. The baskets may be positioned on a belt that runs through the ultrasonic cleaning system. The baskets may be from the pre-dry oven, the post-dry oven, the liquid smoke application, or any other food processing equipment used to make the hot dogs.

The baskets that flow through the ultrasonic cleaning system in a continuous manner may have the collagen accumulation removed by ultrasonic cleaning. This allows for the baskets to have the collaged accumulation removed during the operation of the system.

[0066] The baskets may be processed in the ultrasonic cleaning system in a batch configuration. The baskets may be removable from the chain or belt and placed into the ultrasonic cleaning system for cleaning while another set of baskets continues to be used with the food processing equipment. The baskets may be processed in the ultrasonic cleaning system in a batch manner to have the collagen accumulation removed by ultrasonic cleaning. The newly cleaned baskets may then replace the used baskets so that the used baskets can be cleaned while the clean baskets are used in the food processing equipment.

[0067] In another embodiment, an entire belt or chain with baskets may be run through the ultrasonic cleaning system while another chain or belt with baskets is used in the food processing equipment. There may be 2, 3, 4, or 5, or more batches that rotate through the food processing equipment and the ultrasonic cleaning system. In this batch method of cleaning the baskets, each batch of baskets may be used with the food processing equipment for one day, two days, or even a full week, before they are swapped out with a freshly cleaned batch of baskets.

Conditions for Ultrasonic Cleaning

Temperature

[0068] The baskets may undergo ultrasonic cleaning at a temperature of l20°F to l80°F, preferably l40°F to l60°F. The baskets may be rinsed at a temperature of l20°F to l80°F, preferably l40°F to l60°F. The baskets may be dried at an ambient temperature (e.g, about 68°F to about 77°F). For example, air at a temperature of about 68°F to about 77°F may be blasted over the baskets to dry them. The tank water may be used to rinse the baskets. Use of a tank of water to rinse the baskets will further reduce water consumption.

Time

[0069] The baskets may undergo ultrasonic cleaning for about 1-20 seconds, optionally about 8- 15 seconds, and preferably, the baskets may be undergo ultrasonic cleaning for about 12 seconds. The baskets may undergo ultrasonic cleaning for about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 seconds. The baskets may be exposed to ultrasonic energy for 1-5 seconds, 1-10 seconds, 5-15 seconds, 11-15 seconds, 15-20 seconds, 10-20 seconds, 7-15 seconds, 1-20 seconds, 1-15 seconds, 3-12 seconds, 9-18 seconds, or 4-16 seconds.

[0070] The baskets may be dried for a time ranging from 1 to 20 seconds. For example, the baskets may be dried for 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 seconds. The baskets may be dried for 1-5 seconds, 1-10 seconds, 5-15 seconds, 11-15 seconds, 15-20 seconds, 10-20 seconds, 7-15 seconds, 1-20 seconds, 1-15 seconds, 3-12 seconds, 9-18 seconds, or 4-16 seconds. The baskets may be dried for 8-15 seconds, and preferably, the baskets may be dried for about 12 seconds. Power

[0071] Any high power ultrasonic cleaning unit may be used in the methods and systems described herein. For example, the ultrasonic cleaning unit may have an 8,000 Watts power capacity. Power requirements are a function of the volume of water to be energized, accordingly a smaller tank would require less wattage. The power generated may be, for example, the power setting may be 4,000; 5,000; 6,000; 7,000; 8,000; 9,000; 10,000; 11,000; or 12,000 Watts. For example, the ultrasonic cleaning power may be set at a ratio of about 32 Watts/gallon of water. The ultrasonic cleaning power may be set at a ratio of 15-40 Watts/gallon of water. For example, the ultrasonic cleaning power may be set at a ratio of 15-35 Watts/gallon of water, 20-40 Watts/gallon of water, 25-35 Watts/gallon of water, or 30-40 Watts/gallon of water. The ultrasonic cleaning power may be set at a ratio of 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26,

27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40 Watts/gallon of water.

Frequency

[0072] The ultrasonic cleaning unit may use ultrasonic energy at about 20 to 250 kHz.

Preferably, the ultrasonic system may use a frequency of 45 kHz. The generator must produce enough power to generate a transducer frequency 20 to 400 kHz. For example, the ultrasonic cleaning may be performed at a frequency of 20 kHz, 25 kHz, 30 kHz, 35 kHz, 40 kHz, 45 kHz, 50 kHz, 55 kHz, 60 kHz, 65 kHz, 70 kHz, 75 kHz, 80 kHz, 85 kHz, 90 kHz, 95 kHz, 100 kHz, 105 kHz, 110 kHz, 115 kHz, 120 kHz, 125 kHz, 130 kHz, 135 kHz, 140 kHz, 145 kHz, 150 kHz,

155 kHz, 160 kHz, 165 kHz, 170 kHz, 175 kHz, 180 kHz, 185 kHz, 190 kHz, 195 kHz, 200 kHz,

205 kHz, 210 kHz, 215 kHz, 220 kHz, 225 kHz, 230 kHz, 235 kHz, 240 kHz, 245 kHz, 250 kHz,

255 kHz, 260 kHz, 265 kHz, 270 kHz, 280 kHz, 285 kHz, 290 kHz, 295 kHz, 300 kHz, 305 kHz,

310 kHz, 315 kHz, 320 kHz, 325 kHz, 330 kHz, 335 kHz, 340 kHz, 345 kHz, 350 kHz, 355 kHz,

360 kHz, 365 kHz, 370 kHz, 375 kHz, 380 kHz, 385 kHz, 390 kHz, 395 kHz, or 400 kHz. The ultrasonic cleaning may be at a frequency of 20-50 kHz, 60-120 kHz, 130-170 kHz, 180-200 kHz, 210-250 kHz, 260-280 kHz, 290-310 kHz, 320-350 kHz, 360-380 kHz, 390-400 kHz, 20-400 kHz, 100-400 kHz, 300-400 kHz, 50-300 kHz, 50-300 kHz, or 200-400 kHz. The ultrasonic cleaning may be at a frequency of 45 kHz. The ultrasonic cleaning may be performed at a frequency of 45 kHz, at 8000 Watts of power, for 12 seconds in a 250 gallon tank of water. Tank

[0073] The tank may have a volume of about 200 gallons to about 400 gallons. The tank may have a volume of about 300 gallons to about 350 gallons. The tank may have a volume of 200- 400 gallons, 250-350 gallons, 250-300 gallons, 300-400 gallons, or 225-375 gallons. The tank may have a volume of about 250 gallons to 300 gallons.

[0074] Proceeding now to a description of the drawings, FIG. 1 shows an exemplary flow-chart for carrying out steps of the process of the present invention. Sausage production— which may be provided upstream of the shown equipment— is not shown, as such equipment and methods for making a sausage with a meat core and a collagen coating are known in the art, such as co- extruders. In FIG. 1, co-extrusion produces hot dogs with collagen coating 101 which are placed in baskets 100 which travel along a chain system that conveys the hot dogs through an oven system to dry the hot dogs 102. A chain system 100 is depicted, but other systems may be used for passing the hot dogs through a drying oven. The chain system 100 passes the hot dogs in baskets 102 through a pre-dry oven 103 where the outer collagen layer is partially dried. The chain system 100 passes the hot dogs in baskets 102 through liquid smoke 104 that adds smoke flavor to the hot dogs. This process partially rehydrates the collagen coating. The chain system then passes the hot dogs in baskets through a post-dry oven 105 where the post-dry oven dries the outer layer for a second time.

[0075] The hot dogs are ejected from the oven for packaging and further processing 106. The packaging machine may be a vertical or horizontal packaging machine including but not limited to a vertical Form/Fill/Seal (VFFS) packaging machine, horizontal Form/Fill/Seal (HFFS) packaging machine, or a premade pouch packaging machine. Further, the packaging may be modified atmosphere (MAP) or vacuum packed. The cooking area is illustrated in schematic form only, as that equipment, in and of itself, is conventional. Additionally, thermal imaging, sensors, or vision systems may be coupled with the system for quality and process control.

[0076] After the hot dogs leave the baskets for packaging, the chain system then passes the empty baskets through an ultrasonic cleaning bath 107. The chain system then passes the baskets through an optional fresh water rinse 108 and an air dry blower 109. For example, the optional fresh water rinse 108 may be a spray rinse, preferably at a pressure of 60 pounds per square inch (PSI). After the baskets pass through the optional fresh water rinse 108 and air dry blower 109, the chain system then returns the cleaned baskets to the beginning of the process. [0077] The equipment assemblages may be arranged such that they are vertically tiered ( e.g ., stacked on top of each other in different levels) to allow for a maximization of the use of plant space.

[0078] FIG. 2A shows a side view of the width of an exemplary equipment assemblage 200 for carrying out steps of the process of the present invention, and it does not depict the progression of the basket chain 201 along the belt/pulley system gears. In contrast, FIG. 2B shows a side view of the width of an exemplary equipment assemblage 200 for carrying out steps of the process of the present invention, and it depicts the progression of the basket chain 201 along the belt/pulley system gears. FIG. 2A depicts the starting point of the basket chain. Accordingly, and for purposes of brevity, references to FIG. 2A will be understood to correspond to references of FIG. 2B. Thus, explanation of the progression of the basket chain (or baskets) 201 will now be made with respect to FIG. 2B, as depicted by the direction of the various arrows illustrated therein. The production of the hot dog— which may be provided upstream of the shown equipment— is not shown, as such equipment and methods for making a hot dog are well known in the art.

[0079] In FIG. 2B, the chain system passes the empty baskets 201 into the ultrasonic cleaning system 200. The ultrasonic cleaning system 200 may have dimensions of a height of 18 inches, a width of 26 inches, and a length of 88 inches. Upon entering the ultrasonic cleaning system 200, the chain system 216 moves the baskets 201 inward and downward into a tank 202 with an ultrasonic cleaning bath 203 via a first pulley gear 204. The baskets 201 may be from a pre-dry oven, liquid smoke applicator, post-dry oven, or other food processing equipment. Tank 202 may have a volume of about 250 gallons to 300 gallons. The ultrasonic cleaning bath may be water, e.g., fresh water, pure degassed water. The water temperature is from l40°F to l60°F. The basket chain 201 path moves downward into tank 202. The basket chain 201 then wraps around a second pulley gear 205, and moves upward and out of the ultrasonic cleaning bath 203. The second pulley gear 205 may be an idler gear.

[0080] The tank 202 contains an overflow drain 206. Positioned in the tank 202 are one or more high frequency vibratory rods 207. For example, there may be three or four or more high frequency vibratory rods 207. The rods 207 may be anywhere from 12 inches to 4 feet long. The rods 207 may be mounted in the tank 202, or hung inside the tank 202. The high frequency vibratory rods 207 may be positioned at a height lower than that of the top of the overflow drain 206, so that they remain covered with the ultrasonic cleaning bath 203. [0081] There is a generator (not shown) located in a room above the production area. Power leads (not shown) extend from the ultrasonic rods 207 upwards through the ceiling where they are attached to the generator. The ultrasonic cleaning system 200 also contains an input for temperature controlled steam heat (not shown), which is applied to the ultrasonic cleaning bath 203. Steam is used to preheat and maintain the water temperature. The steam is generated externally from the ultrasonic cleaning system 200, in a steam generating system (not shown).

[0082] When the baskets 201 of the basket chain are in the ultrasonic cleaning bath 203, the high frequency vibratory rods 207 are powered by a generator which causes the rods 207 to vibrate. The generator provides 8000 Watts of power. The rods 207 vibrate at a frequency of about 45 kHz. The vibrations from the high frequency vibratory rods 207 translate into vibrations in the water of the ultrasonic cleaning bath 203. These vibrations create cavitation in the water that dislodges the collagen and liquid smoke build-up on the baskets 201. The baskets 201 are in the ultrasonic cleaning bath 203, exposed to the vibratory rods 207, for approximately 7 seconds. For example, the time in the tank 202 for which the baskets 201 are exposed to the vibratory rods 207 may be greater or less than 7 seconds depending on the speed and length of the basket chain. The speed of the belt controls the submerge time of the baskets 201 in the tank 202.

[0083] The use of vibratory rods 207 (rather than a traditional resonator that is a transducer attached to the bottom of a tank) provides benefits, such as increased efficiency, and less wear and tear on the equipment. A traditional transducer, over time, erodes through a stainless steel tank and thus incurs damage to the tank. Further, with the vibratory rods 207, the vibrations do not have to pass through the wall of the tank 202 to reach the baskets 201, so there is an improved transfer of energy with this system. The vibratory rods 207 may be vibratory rods such as those found in the ultrasonic cleaning equipment sold by Crest Ultrasonics (NJ).

[0084] Once the baskets 201 move upward and out of the ultrasonic cleaning bath 203, they move upward on the basket chain path towards a third pulley gear 210. The third pulley gear 210 may be an idler gear. One or more optional sprayers 211 are located near the third pulley gear 210. For example, as shown in FIG. 2B, the baskets 201 may travel between the third pulley gear 210 and one or more optional sprayers 211. The sprayers 211 may spray high pressure water on the baskets 201 to clean any remaining collagen in the baskets 201 that have not been dislodged from the baskets 201 in the ultrasonic cleaning bath 203, as the baskets 201 are pulled through this region of the ultrasonic cleaning system 200. The baskets 201 may be subjected to a spray rinse by the sprayers 211, for example, a spray rinse preferably at a pressure of 60 pounds per square inch (PSI).

[0085] The baskets 201 are then pulled up and over a fourth pulley gear 212. The fourth pulley gear 212 pulls the basket chain out of the area with the sprayers 211 and into another chamber 213. An air knife 214 is positioned above the fourth pulley gear 212. As the basket chain is being pulled over the fourth pulley gear 212, air knife 214 blows air over the baskets 201 to dry the baskets. The fourth pulley gear 212 may be an idler gear. For example, as shown in FIG. 2B, the baskets 201 may travel between the fourth pulley gear 212 and the air knife 214. The air from the air knife 214 may also remove any remaining collagen or liquid smoke particles remaining in the baskets 201 after they have been pulled through the ultrasonic cleaning bath 203.

[0086] After passing over fourth pulley gear 212, a fifth pulley gear 215 pulls the basket chain 201 down through chamber 213. The fifth pulley gear 215 may be an idler gear. The basket chain is wrapped under the fifth pulley gear 215 and then exits the ultrasonic cleaning system 200. Upon exiting the ultrasonic cleaning system 200, the baskets 201 are ready to reenter the pre-dry oven, post-dry oven, liquid smoke applicator, or other food processing equipment (not shown).

[0087] FIG. 3 shows a flow chart for carrying out steps of the process of the present invention as a bath method. The production of the hot dog— which may be provided upstream of the shown equipment— is not shown, as such equipment and methods for making a hot dog are well known in the art.

[0088] Empty baskets are run through an ultrasonic cleaning bath 307. The chain system then passes the baskets through an optional fresh water rinse 308 and an air dry blower 309. The chain system then returns the cleaned baskets to the pre-dry oven, post-dry oven, liquid smoke applicator, or other food processing equipment to be loaded with hot dogs.

[0089] Now that the equipment and the processes have been described in sufficient detail to enable one skilled in the art to practice the preferred form of the invention, it will be even more apparent how variations of time, temperature and humidity may be made by those skilled in the art to take into account a particular processing environment. Although certain manufacturers, model names and numbers are given for machinery used in the invention, other machinery may be substituted, as would be appreciated by those skilled in the art.

[0090] Further embodiments of the present invention will now be described with reference to the following examples. The examples contained herein are offered by way of illustration and not by any way of limitation. EXAMPLES

EXAMPLE 1

ULTRASONIC CLEANING METHOD

[0091] Sample sections of baskets were used for testing. These baskets were used in production for 2 days in the post-dry oven before being removed from the system for testing. Baskets, which had 2 full days of build-up, were heavily coated with dried collagen and super-saturated with liquid smoke residue. For example, the build-up on the baskets was concentrated to the point that subsequent hot dogs placed in the basket would pull some of the dried collagen off of the basket, and it would become attached to those hot dogs. Basket segments were exposed to a variety of ultrasonic conditions for 15 seconds each. The basket segments cleaned in pure degassed water at l50°F with a frequency of 45 kHz at 1000 Watts power showed the most thorough cleaning. Observations showed that immediately after submerging a basket segment, the collagen became fully rehydrated and the concentration of smoke diluted to a neutral state. After 15 seconds of exposure, the baskets were removed from the water. Any collagen left attached to the basket could be readily removed ( e.g ., by spray rinse). Baskets cleaned after every pass through in this manner will have a minimum amount of build-up, making cleaning easier the next time the baskets are run through the ultrasonic cleaning system. The cleaning of the basket is total and complete such that no residual foreign matter, including collagen and liquid smoke residue, remains on the basket. In one example, the chain is continuous with baskets disposed or otherwise positioned along its length and the speed of the chain is about 30 feet per minute. Spacing between the baskets is about 5 inches. This results in a submerged time of the baskets of about 7 seconds, depending on the level of water in the tank, which is sufficient to clean the basket.

[0092] By way of example, and as shown in FIG. 4A, the uncleaned basket (top) illustrates a exterior portion of build-up on the basket of about 2 days and has not undergone the cleaning method described above. The cleaned basket (bottom) illustrates a basket that has undergone the cleaning method described above. As shown in FIG. 4B, another perspective of exterior portions of the uncleaned basket (top) illustrates a build-up on the basket of about 2 days. Another perspective is shown in which the cleaned basket (bottom) illustrates a basket that has undergone the cleaning method described herein. As can be observed from exterior or outside portions of the baskets of FIG. 4A and FIG. 4B, although the cleaned basket (bottom) exhibits a bit of residual collagen on the basket, a cleaning after every pass of the basket will keep them virtually spotless. It is further noted that these baskets had a 2 day build-up. Moreover, as illustrated in FIG. 4A and FIG. 4B, stainless steel parts of the cleaned basket (bottom) are completely clean from collagen and smoke build-up. Additionally, as illustrated in FIG. 4A and FIG. 4B, plastic wires of the cleaned basket (where they enter into a rubber portion of the basket) are clean on the exterior or outside of the transition points, and even on the interior or inside of the transition points (as will be illustrated in other Figures). This level of cleaning cannot be achieved by, and is superior to, conventional methods, such as high pressure spray or rinsing.

[0093] FIG. 5A illustrates a perspective of interior portions of uncleaned (top) and cleaned (bottom) baskets. As with FIG. 4A, the uncleaned basket (top) illustrates and includes 2 days of build-up. The cleaned basket (bottom) illustrates a basket that has undergone the cleaning method described herein. Notably, these baskets depict the interior or inside portions of the basket. FIG. 5B illustrates another perspective of interior portions of uncleaned (left) and cleaned (right) baskets, also depicting the interior or inside portions of the basket. FIG. 5C illustrates a close up of a side view of the interior and exterior portions of the uncleaned (right) and cleaned (left) baskets.

[0094] FIG. 6A illustrates a perspective of an exterior portion of a cleaned basket that has undergone the cleaning method described herein after a 2 day build up. FIG. 6B illustrates a perspective of exterior portions of uncleaned (right) and cleaned (left) baskets. The uncleaned basket (right) includes a 2 day build up. The cleaned basket (left) has undergone the cleaning method described herein after the 2 day build up. FIG. 6C illustrates another perspective of exterior portions of uncleaned (right) and cleaned (left) baskets. The uncleaned basket (right) includes a 2 day build up. The cleaned basket has undergone the cleaning method described herein after the 2 day build up. For example, it can be observed from FIG. 6A, FIG. 6B, and FIG. 6C that the plastic wires of the basket are clean.

[0095] FIG. 7A illustrates a perspective of an exterior portion of an uncleaned basket including a 2 day build up. FIG. 7B illustrates a perspective of an exterior portion of a cleaned basket, which previously had included a 2 day build up but now has undergone the cleaning method described herein to produce the cleaned basket. For example, it can be observed from FIG. 7B that the stainless steel parts of the basket are substantially free of collagen and smoke build-up.

[0096] Although the invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it should be understood that certain changes and modifications may be practiced within the scope of the appended claims. Modifications of the above-described modes for carrying out the invention that would be understood in view of the foregoing disclosure or made apparent with routine practice or implementation of the invention to persons of skill in food chemistry, food processing, mechanical engineering, and/or related fields are intended to be within the scope of the following claims.

[0097] All publications ( e.g ., Non-Patent Literature), patents, patent application publications, and patent applications mentioned in this specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All such publications (e.g., Non-Patent Literature), patents, patent application publications, and patent applications are herein incorporated by reference to the same extent as if each individual publication, patent, patent application publication, or patent application was specifically and individually indicated to be incorporated by reference.

[0098] While the foregoing invention has been described in connection with this preferred embodiment, it is not to be limited thereby but is to be limited solely by the scope of the claims which follow.