Product portion enrobing machines and methods

1. An apparatus for enrobing a product portion comprising:

a) at least one polymer spray head adapted to create at least one flow of polymeric fibers to produce at least one polymer enrobing zone; and

b) a conveyor system adapted to move at least one product portion from at least one position below at least one polymer enrobing zone to at least one position above at least one polymer enrobing zone to drop each product portion through one or more polymer enrobing zones a plurality of times at different orientations to enrobe each product portion with polymeric fibers,

wherein said conveyor system is adapted to move at least one product portion from at least one position below a first polymer enrobing zone to at least one position above the first polymer enrobing zone to drop each product portion through the first polymer enrobing zone a plurality of times.

2. The apparatus of claim 1 , wherein said conveyor system is adapted to drop each product portion through one or more polymer enrobing zones a predetermined number of times.

3. The apparatus of claim 1 wherein said conveyor system is adapted to move each product portion laterally with each drop.

4. The apparatus of claim 3 , further comprising baffles above or below said first polymer enrobing zone to move each product portion laterally between each drop.

5. The apparatus of claim 1 wherein said conveyor system comprises a conveyor belt adapted to move between a position below said first polymer enrobing zone and a position above said first polymer enrobing zone.

6. The apparatus of claim 5 , wherein said conveyor belt comprises a plurality of ridges adapted to inhibit product portions from sliding or rolling backwards on said conveyor belt.

7. The apparatus of claim 1 , further comprising a molding device to mold at least one product portion.

8. The apparatus of claim 1 , further comprising at least one polymer collection roller opposite from at least one polymer spray head and adapted to collect polymeric fibers that are not wrapped around product portions dropped through a polymer enrobing zone.

9. An apparatus for enrobing a product portion comprising:

a) at least one polymer spray head adapted to create at least one flow of polymeric fibers to produce at least one polymer enrobing zone; and

b) a conveyor system adapted to move at least one product portion from at least one position below at least one polymer enrobing zone to at least one position above at least one polymer enrobing zone to drop each product portion through one or more polymer enrobing zones a plurality of times at different orientations to enrobe each product portion with polymeric fibers,

wherein said conveyor system comprises one or more pneumatic conveying tubes.

10. An apparatus for enrobing a product portion comprising:

a) at least one polymer spray head adapted to create at least one flow of polymeric fibers to produce at least one polymer enrobing zone; and

b) a conveyor system adapted to move at least one product portion from at least one position below at least one polymer enrobing zone to at least one position above at least one polymer enrobing zone to drop each product portion through one or more polymer enrobing zones a plurality of times at different orientations to enrobe each product portion with polymeric fibers,

wherein said conveyor system comprises a rotary drum positioned around said at least one polymer spray head, said rotary drum being adapted to move at least one product portion from at least one position below at least one polymer enrobing zone and to at least one position above at least one polymer enrobing zone to drop each product portion through one or more polymer enrobing zones a plurality of times.

11. The apparatus of claim 10 , wherein said conveyor system further comprises a spray guard positioned between said rotary drum and said polymer spray head.

12. The apparatus of claim 11 , wherein said spray guard comprises a collection conveyor adapted to collect polymer fibers from said polymer spray head.

13. The apparatus of claim 10 , further comprising a portion guide in said rotary drum adapted to ensure that product portions travel around the perimeter of said rotary drum and back into said one or more polymer enrobing zones.

14. The apparatus of claim 10 , wherein said rotary drum is tilted.

15. An apparatus for enrobing a product portion comprising:

a) at least two polymer spray heads, each polymer spray head being adapted to create at least one flow of polymeric fibers to produce at least one polymer enrobing zone, the at least two polymer spray heads including a first polymer spray head which is adapted to create at least one flow of polymeric fibers to produce a first polymer enrobing zone and a second polymer spray head which is adapted to create at least one flow of polymeric fibers to produce a second polymer enrobing zone, and

b) a conveyor system adapted to convey one or more product portions dropped through said first polymer enrobing zone from a position below said first polymer enrobing zone to a position above said second polymer enrobing zone to drop each product portion through said second polymer enrobing zone at a different orientation than the orientation at which each product portion was dropped through said first polymer enrobing zone.

16. The apparatus of claim 15 , comprising at least three polymer spray heads, the at least three polymer spray heads including a third polymer spray head which is adapted to create at least one flow of polymeric fibers to produce a third polymer enrobing zone, wherein said conveyor system is adapted to convey each product portion dropped through said second polymer enrobing zone from a position below said second polymer enrobing zone to a position above said third polymer enrobing zone to drop each product portion through said third polymer enrobing zone.

17. An apparatus for enrobing a product portion comprising

a. a polymer spray head adapted to create a flow of polymeric fibers to produce a polymer enrobing zone; and

b. means for transporting at least one product portion from a position below said polymer enrobing zone to a position above said polymer enrobing zone to repeatedly drop said at least one product portion through said polymer enrobing zone.