Popcorn popping machines for different types of popcorn kernels and different popped popcorn types

Abstract

A method and popping machine for popping different types of popcorn kernels is provided, where the different types of popcorn kernels include at least mushroom type popcorn and butterfly type popcorn. The method includes determining a selected one of the different types of popcorn kernels to be popped in a first popping cycle based upon a selection made by an operator, and then retrieving and using a first set of predetermined cooking temperature set points associated with cooking the selected one of the different types of popcorn kernels during performance of the first popping cycle. The cooking temperature set points determine several items which may include when to heat a kettle of the popping machine, when to signal an operator to take action such as loading kernels or dumping popped popcorn, and when to add sugar if a sweetened popped popcorn type is desired.

What is claimed is: 
     
         1 . A popping machine configured to pop different types of popcorn kernels in different popping cycles, the popping machine comprising:
 a kettle associated with heating elements and configured to receive popcorn kernels for a popping cycle;   a heat sensor responsive to a temperature of the kettle;   a storage device which stores a plurality of stored sets of predetermined cooking temperature set points, which are associated with cooking different types of popcorn kernels in the kettle to produce different types of popped popcorn types;   a user interface which receives from an operator a selection of a current operating mode for the popping cycle, the current operating mode defined by a selected one of the different types of popcorn kernels and a desired popped popcorn type; and   a controller operatively connected to each of the heating elements, the heat sensor, the storage device, and the user interface, wherein the controller is programmed to operate the popping machine in the popping cycle by:
 retrieving from the storage device a first set of predetermined cooking temperature set points associated with the current operating mode selected for the popping cycle, which includes a load point temperature and a dump point temperature; 
 actuating heating of the kettle with the heating elements based on signals from the heat sensor indicating when the kettle reaches the load point temperature and the dump point temperature, to thereby cook kernels into popped popcorn; and 
 prompting for loading of the kernels into the kettle at a beginning of the popping cycle and for dumping of the popped popcorn from the kettle at an end of the popping cycle. 
   
     
     
         2 . The popping machine of  claim 1 , wherein the popping machine further comprises:
 at least one switch at the user interface which is configured to receive selections from the operator;   at least one indicator light which is configured to be illuminated by the controller to identify the current operating mode and to alert the operator when loading or dumping action is required; and   at least one audible alarm which is configured to be actuated by the controller to alert the operator when loading or dumping action is required.   
     
     
         3 . The popping machine of  claim 2 , wherein the user interface comprises at least one switch and/or at least one indicator light for each of the following:
 a mode selector for identifying the current operating mode;   an automated oil heating and dispensing system associated with the kettle;   the heating elements associated with the kettle;   a stir drive associated with the kettle; and   a heat element at a service platform for receiving the popped popcorn which is dumped from the kettle.   
     
     
         4 . The popping machine of  claim 1 , wherein the step of prompting for loading of the kernels into the kettle at a beginning of the popping cycle and for dumping of the popped popcorn from the kettle at an end of the popping cycle, which is performed by the controller, further comprises:
 prompting for loading of the kernels into the kettle when the kettle reaches the load point temperature, as measured by the heat sensor; and   prompting for dumping of the popped popcorn from the kettle when the kettle reaches the dump point temperature, as measured by the heat sensor.   
     
     
         5 . The popping machine of  claim 1 , wherein when the current operating mode selected by the operator is a sweet mode such that the desired popped popcorn type is to include a sweetened coating, the first set of predetermined cooking temperature set points retrieved from the storage device includes a sweet point temperature, and the controller is further programmed to operate the popping machine in the popping cycle by:
 detecting when the kettle falls below the sweet point temperature after the kernels are loaded into the kettle at the load point temperature; and   alerting the operator to load sugar into the kettle when the kettle falls below the sweet point temperature, so as to produce the sweetened coating for the desired popped popcorn type and so as to avoid burning the sugar in the kettle during the popping cycle.   
     
     
         6 . The popping machine of  claim 1 , wherein the different types of popcorn kernels include at least one of a mushroom type popcorn and a butterfly type popcorn. 
     
     
         7 . The popping machine of  claim 1 , wherein the step of retrieving from the storage device a first set of predetermined cooking temperature set points associated with the current operating mode selected for the popping cycle, which is performed by the controller, further comprises:
 retrieving a cold point temperature for a first batch of kernels, the cold point temperature defining a threshold for determining whether the kettle was cold at an initial power up of the popping machine;   retrieving a coast point temperature for the first batch of kernels, the coast point temperature defining a threshold for turning off heat energy to the kettle as the kettle approaches the load point temperature after starting from a cold kettle;   retrieving a set point temperature for the first batch of kernels, the set point temperature defining a temperature that is to be maintained at the kettle;   retrieving the load point temperature for the first batch of kernels, the load point temperature defining when to add the first batch of kernels to the kettle;   retrieving the dump point temperature for the first batch of kernels, the dump point temperature defining when to dump popped popcorn from the kettle; and   retrieving a sweet point temperature for the first batch of kernels, the sweet point temperature defining when to add sugar to the kettle when a sweet mode is active.   
     
     
         8 . The popping machine of  claim 7 , wherein the controller is further programmed to operate the popping machine in the popping cycle with the following steps:
 determining, based upon a selection made by the operator at the user interface during an initial power up of the popping machine, whether an offset calibration mode is activated;   detecting a current operating mode of the popping machine based on the selected one of the different types of popcorn kernels; and   when the offset calibration mode is activated:
 adjusting a dump offset added to the dump point temperature for the current operating mode based on input from the operator at the user interface; and 
 adjusting a sweet offset added to the sweet point temperature for the current operating mode based on input from the operator at the user interface, 
   wherein the dump offset and the sweet offset, respectively, enable operator adjustments to the dump point temperature and the sweet point temperature of the current operating mode based on operator preferences.   
     
     
         9 . The popping machine of  claim 1 , wherein the controller is further programmed to operate the popping machine in the popping cycle with the following steps:
 performing an alarm routine to determine whether any alarms for the operator should be activated or deactivated at about every 1 second following an initial power up of the popping machine.   
     
     
         10 . The popping machine of  claim 9 , wherein performing the alarm routine further comprises:
 determining whether the popping machine is in a load alarm mode or a dump alarm mode;   when the popping machine is in the load alarm mode, activating a load alarm to alert the operator to load a first batch of kernels into the kettle if the kettle is above the load point temperature, and then deactivating the load alarm when the kettle falls 15° F. below the load point temperature; and   when the popping machine is in the dump alarm mode, activating a dump alarm to alert the operator to dump popped popcorn from the kettle if the kettle is above the dump point temperature, and then deactivating the dump alarm after 10 seconds have passed following activation of the dump alarm,   wherein each of the load alarm and the dump alarm includes at least one of an audible alarm and illumination of an indicator light on the user interface.   
     
     
         11 . The popping machine of  claim 10 , wherein when the popping machine is in the load alarm mode, performing the alarm routine further comprises:
 starting a dump block timer when the load alarm is deactivated, the dump block timer defining a period of time in which the alarm routine remains in the load alarm mode before returning to the dump alarm mode, thereby allowing time for cooking the first batch of kernels in the kettle.   
     
     
         12 . The popping machine of  claim 11 , wherein the first set of predetermined cooking temperature set points also includes a sweet point temperature, and wherein when the dump block timer is running in the load alarm mode, performing the alarm routine further comprises:
 determining whether the kettle is below the sweet point temperature;   activating a sweet alarm to alert the operator to add sugar to the kettle when the kettle falls below the sweet point temperature; and   deactivating the sweet alarm after 10 seconds have passed following activation of the sweet alarm.   
     
     
         13 . A popping machine configured to pop sweet popcorn in a popping cycle, the popping machine comprising:
 a kettle associated with heating elements and configured to receive popcorn kernels and sugar during the popping cycle;   a heat sensor responsive to a temperature of the kettle;   a storage device which stores a set of predetermined cooking temperature set points associated with cooking the sweet popcorn;   a user interface which provides signals to an operator when actions are required at the popping machine; and   a controller operatively connected to each of the heating elements, the heat sensor, the storage device, and the user interface, wherein the controller is programmed to operate the popping machine in the popping cycle by:
 retrieving from the storage device the set of predetermined cooking temperature set points associated with cooking the sweet popcorn, which includes at least a load point temperature, a sweet point temperature, and a dump point temperature; 
 actuating heating of the kettle with the heating elements based on signals from the heat sensor, to thereby cook kernels and sugar into popped sweet popcorn; 
 alerting the operator to load the kernels into the kettle when the kettle reaches the load point temperature at a beginning of the popping cycle, and to load the sugar into the kettle when the kettle subsequently falls below the sweet point temperature, so as to avoid burning the sugar in the kettle during the popping cycle; and 
 prompting for dumping of the popped sweet popcorn from the kettle when the kettle reaches the dump point temperature at an end of the popping cycle. 
   
     
     
         14 . The popping machine of  claim 13 , wherein the step of alerting the operator, which is performed by the controller, further comprises:
 providing at least one of an audible alarm and an illumination of an indicator light to identify the loading or dumping action required by the operator.   
     
     
         15 . The popping machine of  claim 13 , wherein the controller is further programmed to operate the popping machine in the popping cycle with the following steps:
 performing an alarm routine to determine whether a sweet alarm for the operator should be activated or deactivated, wherein the alarm routine comprises:
 detecting that the kettle has fallen below the load point temperature by a predetermined temperature threshold, indicating that a batch of popcorn kernels has been loaded into the kettle and is reducing the temperature of the kettle accordingly; 
 after detecting that the kettle has fallen below the load point temperature by the predetermined temperature threshold, determining whether the kettle has fallen below the sweet point temperature; 
 activating a sweet alarm when the kettle falls below the sweet point temperature to complete the alerting of the operator in step (e); and 
 deactivating the sweet alarm after a predetermined time lapse has passed following activation of the sweet alarm. 
   
     
     
         16 . The popping machine of  claim 15 , wherein the predetermined temperature threshold is 15° F. below the load point temperature, and wherein the predetermined time lapse is 10 seconds. 
     
     
         17 . The popping machine of  claim 13 , wherein the controller is further programmed to operate the popping machine in the popping cycle with the following steps:
 determining, based upon a selection made by the operator at a user interface during an initial power up of the popping machine, whether an offset calibration mode is activated; and   when the offset calibration mode is activated, adjusting a sweet offset added to the sweet point temperature based on operator input at the user interface,   wherein the sweet offset enables operator adjustments to the sweet point temperature based on operator preferences.