"Situation or Problem" Immersion frying is a popular food preparation method. U.S. Consumers enjoy billions of pounds of low cost and taste appealing fried foods annually. Sensorial properties include golden color, crunchy crust, tender-moist core, and pleasing flavors. Unfortunately, immersion-fried foods have high caloric content due to their high oil content and are considered to have a negative impact upon consumer health through obesity and other related problems. Other issues include oil disposal, caustic equipment cleaning agents, and large number of accidents associated with immersion fryers. There are over 750,000 units in operation in the U.S. An alternative immersion frying process would be beneficial to consumers and producers alike. Recently a controlled, dynamic radiant frying process (CDR) using infrared energy was developed and a patent is pending. This process can: 1) finish fry several immersion fried foods (French fries, chicken nuggets, fish sticks, vegetables, etc.) with equal sensorial properties but 25-40% less calories; 2) produce unique food products, for example a hot center pastry, by adjusting the radiant energy profile; 3) lead to the development of a compact high-efficiency, non-oil fryer for convenience stores for on-the-go foods; and 4) stimulate the introduction of reduced fat low-caloric versions of existing snack foods. This technology lacks the research effort to match this process with an applicable oven design. The objective of this project is to continue CDR research by investigating oven technologies compatible with the CDR process. "Purpose" ATE anticipates being able to design and build a CDR compatible oven with testing to verify its suitability for fast food industry use. This oven will further demonstrate the CDR technology to potential client companies; many of which have expressed interest. ATE will utilize the knowledge from this project to enter into a phase II SBIR proposal for the development of prototype ovens for food industry clients. The benefits to society and the citizens of the United States are potentially great if this technology can bring lower fat and lower caloric food types assisting our general public with efforts to control obesity and obesity related health issues. Side benefits include similar investment cost by current immersion fryer users, lower energy usage, and safer systems for users and operators of the technology. OBJECTIVES: Recently a controlled, dynamic radiant frying process (CDR) using infrared energy was developed and a patent is pending. This technology lacks the research effort to match this process with an applicable oven design. The objective of this project is to continue CDR research by investigating oven technologies compatible with the CDR process. Anderson Tool & Engineering Co. (ATE) anticipates being able to design and build a CDR compatible oven with testing to verify its suitability for fast food industry use. Objectives include the development and design of an electrical emitter system compatible with the CDR process having necessary control and adjustability features. Secondly, ATE must develop and design a mechanical transport system for the intended food product types and then integrate this system with the electrical emitter system into a complete CDR oven unit design. Using State of Indiana matching funds, ATE will build and fabricate a CDR oven to the fore mentioned design effort and then transport the oven to Purdue University's food science department labs. ATE, along with consultants from Purdue's food science department will test and evaluate the results of the CDR prototype oven system. Significant project milestone dates include: Engineering design start 5/1/2008; completion 7/24/2008 Purchase of Materials/components start 6/2/2008; completion 6/10/2008 Oven parts fabrication start 6/16/2008; completion 8/15/2008 Oven assembly start 8/1/2008; completion 8/22/2008 Targeted transport date to Purdue 8/25/2008 Testing and evaluation 9/1/2008 to 11/3/2008 project contingency 11/3/2008 to 12/31/2008 Project outputs and deliverables will culminate in a detailed Phase I final report that substantiates the feasibility of this technology. The final report will be a written and illustrated document detailing the results of the research with descriptions of the design, development of the oven along with applicable testing results. Further findings in the report will suggest further changes and improvements to be considered during a Phase II effort. Although not considered a formal devliverable item, the prototype oven as a proof of concept of the CDR technology will be available for demonstration. APPROACH: Three technical objectives are included in our Phase I research. The first technical objective will develop and design a heating control system for the CDR process. This objective will involve Four tasks. The first task will determine the types of electrical emitters to be used. The second task will establish the mechanical layout of the chosen emitters. The third task will focus on adjustability and variable control of the emitters, and finally the fourth task will integrate these tasks into a completed control system design. The second technical objective will be to design a mechanical transport system for various food types for our oven. Then having completed this task, the transport system design must be integrated with the control system design to establish a total system design. Next a review of the design for system reliability, ease of cleaning, and adherence to food industry machinery standards will take place. The final step of this objective will be to fabricate and assemble the CDR prototype oven. The final technical objective is to test and evaluate the results of the CDR prototype oven to answer the following questions. First, what heat flux profile ranges can be generated in the oven? A Spectroradiometric Measurement System will be used to measure incident flux as a function of position emitter settings in the oven. This will establish oven heat flux profiles. A pyrofiber flux sensor with a data logger will be used to measure incident flux from each emitter. Emitter Temperatures will be measured using a fiber optic temperature probe. Results will be used to document the operating range of the oven. Second, what food types can be processed with the CDR oven? Comparisons will be performed between CDR and immersion oil frying for common fried foods. Both published and unpublished data on heat flux profiles of immersion-fried foods will be used to set CDR oven conditions to achieve the same profile as immersion frying. The foods evaluated may consist of French fries, chicken nuggets, fish fillets and chicken strips. An untrained sensory panel will be enlisted to compare CDR oven fried and immersion fried product. Third, what reduction in oil and calories are observed with the CDR oven? Calorie and Fat Measurements be will taken from samples processed. Nutritional information will be collected and compared on traditional and CDR fried foods. Product samples from both CDR fried and immersion fried will be evaluated for lipid, moisture, and protein content using AOAC Standard Methods of Food Analyses. Protein content will be determined by using a combustion process. Calorie content will be calculated based on weight change of lipid and protein content multiplied by energy density. Finally, can the oven be cleaned and sanitized to USDA and FDA requirements? Cleaning and sanitation procedures will be performed according to the ATE recommendations. A report will be generated documenting these findings and detailing any problems encountered during this assessment. The results of this assessment will be provided to ATE for use in improving future CDR ovens.
