AP93A

AP93A - Process to produce different kinds of pastries and machine therefor

Info

Publication number: AP93A
Application number: APAP/P/1989/000125A
Authority: AP
Inventors: Salim Kamrudin Rahim
Original assignee: Salim Kamrudin Rahim
Priority date: 1989-02-28
Filing date: 1989-04-21
Publication date: 1990-07-17
Also published as: GB2228708B; GB2228708A; GB9003993D0; ZA901433B; US5281427A; AP8900125A0

Abstract

A process to produce different kind of pastries in which an extruder forms regular discs of dough with a control led thickness and diameter, by extruding dough through a central opening of a lower circular plate which is heated and to which an upper plain descends to on adjustable distance. Samoosas are produced by forming thin discs of dough, which are partly cooked at one side, slacked and further pressurized and heated. Each disc is cut into four quarters. In each quarter a triangle is inscribed with its top on the middle of the circular side. Filling material is charged to the middle of each triangle whereupon the four quarters are simultaneously folded into triangles, firstly along the sides and then along the bottom by using hinged plates, one set for each quarter. Tortillas are produced by filling partly cooked dines and rolling them by a rolling machine. Chapatis and other flat pastries are produced by transferring the partly cooked disc in a station for finishing.

Description

Title; PROCESS TO PRODUCE DIFFERENT KINDS OF PASTRIES AND MACHINE THEREFOR

Abstract a process to produce different kinds of pastries in which an extruder fores regular discs of dough with a controlled thickness and diameter b> extruding dough through a central opening of a lower circular plate whiph is heated and to which.an upper plate descends to an adjustable distance.

For producing saaoosas thin discs of dough are foreed which are partly cooked at one side, stacked and further pressurized and heated. Each disc is cut into four quarters in which triangles are inscribed with their top on the aiddle of the circular side of each quarter- Filling aaterial is charged in the aiddle of each triangle whereupon the four quarters are siauitaneousiy folded into triangles, firstly along the sides and then along the bottoa by using three hinged plates, one set for each quarter ti be folded.

For producing filled tortillas the partly cooked disc of dough is filled and roiled by a rolling aachine.

For producing chapatll or other flat pastries the pertly cooked disc of dough Is transferred to a station for finishing the cooking.

BAD ORIGINAL

(56) Documents cited:

GB 2100179 DE 3511311

US 3669006 US 4574088

SU 1450800 SU 167793

1b

PASTRY PROCESSING MACHINE —iThe invention relates to a process and machine to produce different »

kinds of pastries. The processes for making samoosa, chapatis and tortillas are described but the principles for the invention can be used to produce other kinds of pastries.

A process to produce samoosas mechanically is described in GB patent 2146574. According to this process sheets of pastry are formed from which strips are cut out and the Strips are folded into samoosas.

c

However, the present invention can produce different kinds of pastries within the framework of the same process and machine.

According to the present invention the cooking device is fitted to the dough extruder and by forming discs of dough which are cut into quarters, no wastage of dough occurs.

Furthermore, the process of this invention provides moistening of the discs of dough, filling and sealing of the pastries.

The invention described a process to produce different kinds of pastries, comprising a dough extruder which forms regular discs of dough, having a controlled thickness and diameter, cooking means, and devices for cutting, filling and folding or rolling the discs of dough, depending on the kind of pastry.

AP000063

O <J

Figure 1 is an elevation and plan in schematic form of a pastrymaking assembly showing a cooking station, an extrusion station, a stacking/pressing station, a filling/folding station and a collection point. »

Figure 2 is an -elevation of an extrusion mechanism.

Figure 3 is an elevation of a stacking and pressing station.

Figure 4 is an elevation of a mechanism for producing and depositing uniform portions of filling.

Figure 5 is a diagram of a method for folding samoosas around a portion of filling.

Figure 6 is a plan of a folding station.

Figure 7 is an elevation of a mechanism for folding leaves of pastry around a filling.

Figure 8 is an elevation and plan of a mechanism for rolling a sheet of pastry around a filling.

SAMOOSA PROCESS (FIG 1)

The machine consists of an extrusion station 1 which produces regular discs of dough from a charge of mixed dough. The volume of these discs and their thickness can be controlled to produce different products. The discs may be pre-cooked at the extrusion station before

PATENT PENDING ---NO: 29/89 being transierred by a suction lifting pad running on rails 5 to .a stacking station 2 where up to fifty discs of pa.-·· try can be d':po:dte :.

Before depositing each layer the previous top surface is oiled by means of a spray 6 to enable later separation. The stacking station can be used to further reduce the thickness of the pastry discs by a pressing process together with the application of heat if desired.

The discs of pastry are then separated by means of the lifting pad and transferred to a filling and folding station 3. If the intermediate process of stacking and pressing is not required a single disc can be transferred directly from the extrusion station i to the filling and folding station 3· At this station a single circular disc is cut into four quarters by a descending blade 9 also running on the rails 5 an.:

then four charges of filling are delivered from a hopper 8 onto the pastry surface. A folding mechanism then seals the filling into the pastry with the help of a pasting spray 7 which can be applied during the folding process. The finished products are ejected from the filling station 3 into the collection point 4.

With reference to Figure 2 the extrusion station comprises a lower circular plate 21 with a central hole which can be heated by means of a heating element 23. An upper circular plate 22 can descend to within a small, adjustable distance of the lower plate 21. A close-fitting cylindrical piston 26 slides vertically In the central hole in the lower plate 21, A dough container· 23 carries a movii'g piston 25 which acts to extrude a small portion of do.:;?, into rh,·.

space above the piston 26 which at this point is in ire l.-.-wer position. The piston 26 then rises vindei’ the acti·.·:'. of a linear actuating- mechanism to seal off‘the exit from the container 23 And

AP000093

PATENT PENDING : NO: 29/89 lower pliito 21 and the piston 26 thus form tcgo ther a u-on'incus circular surface. The upper plate 22 is lowered by innans of a iinoa.· actuating mechanism and forms the dough into a circular disc, at the same time pre-cooking the dough by means of the heat from the heating element 23. The disc of pastry can be transferred from the extrusion station by means of a lifting pad 27 which carries a plurality of small holes 23 connected to an evacuator. By means of the suction produced the disc of pastry clings to the underside of the lifting pad and can be transferred to the other stations (2.2A.3 in Figure 1).

Discs of pastry of varying volumes can be obtained by varying the time ( for· which piston 25 moves before piston 26 rises and carries the portion of dough upwards. Discs of varying thickness are obtained by varying the final separation of the plates 21. 22. The diameter of the discs is determined by the volume and thickness.

With reference to Figure 3 the stacking/pressing station comprises a lower plate 31 which may be heated by means of a heating element 32.

Discs of pastry can be stacked 34 using the lifting pad 27 of Figure

2. Before adding a disc the top surface of the previous disc is oiled using the spray 6. The pressing plate 33 descends onto the stacked discs of dough 34 and presses them, reducing their thickness and increasing their diameter 35- The application of heat from the heating element 32 helps to enable separation of the thin discs fro:,:

the stack. 35- The suction lifting pad 27 can remove single discs from the stack 35 and transfer them to the filling folding station 3 of figure 1.

With reference to Figure 4 the filling mechanism comprises a he; per ·. :

containins a charge of filling 42 for example cooked meat cr

v e z e i % sp ices

The hopper terminates in :-1:1 ai vi-rnt·! wni coincides with an aperture In a slideway ii3 c -> r r.y i n g t slide .:.1.

<%· <%··

PATENT PENDING: -----NO: 29/89 slide is in the position shown. The slide is the moved ty means o:’ a linear actuating device to the position shown in dashed lines. Thia action seals the exit frcm the hopper 41 and ti-inrs the aperture i r.

the slide 44 over an aperture in the lower surface of the slideway % so that the amount of filling drops through a chute 45. The chute 4b is cranked and includes a rotating Joint 46 so that the amount of filling can be deposited in a range’ of positions about the arc of a circle in plan view.

With reference to Figure 5 the method of folding samoosas is shewn. A full circular disc of pastry (a) is first cut into quarters as shown.

Each quarter AOB will form one saraoosa. In each quarter (b) a triangle CDE may be inscribed with the angle DEC equal to 55 degrees.

The amount of filling is deposited within this triangle. The first folding stage (c) is to fold along a line DE so that the section ADE overlays the filling. Paste such as a fiour-and-water paste is then applied to the section ADE. The second folding stage (d) is to fold along a line CE so that the section BCE covers the preceding section and seals to it. Paste is then applied to the section BCE. The final folding stage (e) is to fold along a line DC so that the section DCC covers the preceding two sections and seals the filling completely within a pastry envelope.

With reference to Figure 6 the folding station is show:, in plan νΐο·.··.

A disc cf pastry is placed on the station t,v meant nf the lit'ing pu :

of Figure 2. The cutting blade 9 cf Figure 1 then uetcenIv and

ΔΡ 0 0 0 0 ft 3

Page 4 cuts the pastry into quarters.

PATENT PENDING -----NO: 29/89

The folding station has tour : de: 11 i ?a i parts each comprising· three hinged plates A. Q, C. The so plates hinge about the dashed lines shown and perform the folding operation described above (Figure 5)· In the first stage the four plates labelled A move simultaneously under the action of one or —.vo actuators mounted under the folding station and connected by pivots 54 to the lower surface cf the plates 61. The palates A rotate about a horizontal axis through approximately 180 degrees. In the second stage the four plates labelled D move similarly. In the final stage the four plates labelled C move under the action of a single linear actuator to complete the folding process. Before the second stage and before the final stage the pasting spray 7 of Figure 1 applies paste to the four pastries undergoing folding. When the samoosas are complete they may be ejected from the folding station by tilting it about an axis 65. Alternatively the cutter 9 of Figure 1 can descend onto the folding station and sweep the samoosas away by a lateral movement.

With reference to Figure 7 a detailed elevation of part of the folding mechanism is shown. The plate 71 represents the central, non-moving portion cf one of the quarters of the folding station. The plate 72 represents one cf the moving plates 61, 62, 63 of Figure 6. Plate 72 is hinged along its line of attachment to the fixed plate 71. Both the plates 71. 72 may be dished as shown so as to acoonrd&te the thickness of the pastry. Plate 72 performs the folding ·:; -,.r at i on t :

rotating about hinge ”3 under the action of an .1·: tuator ”a '·7.1<Ίι io connected t _o point on the plate 72 by a lir.ha 'hl. The linkn so arranged that linear motion of the tu.ator ^r'5 drive a 1 ·di a circular path to the position shown bi' dashed linos

BAD ORIGINAL

P'age achieved by means of a two-part linkage with moti.-.n rt.-’ru 76 whim prevent collapse of the linkage under the force from rr.,-> actuator.

The final position of the linkage is shown by dnslie·! linn:;. in ordei· to achieve the folding pattern of Figure 6 one actuator may be connected to one, two or four linkages so that a corresponding number of plates are simultaneously driven.

P.otl/Chapatl process

PATENT PENDING---NO: 29/89

With reference to Figure 1 the process for making ehapatis or other f~ . flat breads is as follows: the extrusion station produces a disc of dough which may be thicker than that used for samoosas. The lifting pad 27 then transfers the chapati, which may be partly cocked on the underside at station 1, to the cooking station 2A where a heating or grilling element 11 finishes the cooking process from above. Heat can also be applied from beneath at station 2A if desired by the provision of another element 12. The finished chapati may then be ejected from the cooking station by tilting the lower plate of the station or otherwise.

Tortilla process

With reference to Figures 1 and 8 the process for making filled tortillas (enchiladas) is as follows. A cooked disc of dough is produced at extrusion r’-iticn 1 and transferred m the filling- statior.

APO00093 h Figure 8 shows an alternative arrangement of the .-tattcn 3 where;.··.· the folding mechanism is replaced by a rolling ni-.rcr.an ism. This

PATENT PENDING ---NO: 29/89 disc of dough or tortilla 85 ideposited on the sneer 8.' and me filling mechanism of I'igure Z deposits one op mope port ion.; of 11 . i r, .36 onto the tortiJia in the approximate positions shown. The free edge 34 of the sheet 82 then moves along a curved path.S'ucli as that shown by a chain dotted line; for this purpose the edge 84 may be extended and fitted with rollers 87 which run ip. shaped grooves in a vertical plane (not shown). The result of the movement of sheet 32 is the rolling of the tortilla around the filling. The filled tortilla may then be ejected from the rolling station beyond the hinge 83 into the collection point 4 and the sheet returns to its initial flat position.

Claims

CLAIM 1

A process to produce different kinds of pastries comprising a dough extruder t which forms regular discs of dough, having a controlled thickness and diameter cooking means and devices for cutting, filling and folding or rolling of the discs of dough, depending on the kind of pastry.
CLAIM 2

A dough extruder according to claim 1 comprising a lower circular plate which can be heated, an upper circular plate which can descend within an adjustable distance of the lower plate, a dough container which carries moving pistons for extruding a portion of dough through a central hole in the lower plate.
CLAIM 3

A process to produce samoosas according to claim 1 in which the extruder forms k thin discs of dough partially cooked on one side and then cut into four quarters which are filled, folded and sealed.
CLAIM 4

A pastry machine to produce samoosas according to claims 1 to 3 in which the partially cooked discs of dough are transferred by means of a suction pad to a packing station where the top surfaces of the discs of dough are oiled and the discs are deposited upon stacks of several tenths of discs whereby the thickness of the discs can be further reduced by a press device which may be provided with heating means.
CLAIM 5

A process for filling and folding samoosas according to claim 3 whereby in each quarter of disc of dough is inscribed a triangle with the top on the middle of the circular side of the quarter, the filling material is charged to the disc in the middle of the triangle whereupon the quarter is folded, firstly along the sides and then along the bottom of the triangle.
CLAIM 6

A process for filling and folding samoosas according to claim 5 whereby the top angle of the triangle is 55' and the parts to be folded are sealed with a paste.
CLAIM 7

A filling and folding station according to claims 5 and 6 comprising of four identical parts, each of these parts having three hinged plates which move simultaneously under the action of actuators mounted under the folding station and connected by privots to the lower surface of the plates by a linkage which by a linear motion of the actuator drives the plate in a circular path and folds the quarter disc of pastry.
CLAIM 8

A process to produce chapatis or other flat pasty according to claim 1 in which the extruder forms a disc of dough, partially cooked on the underside, which is lifted and transferred to a cooking station where the cooking process is finished.

APO00093
CLAIM 9

A process to produce filled tortillas according to claim 1 in which dough extruder produces cooked discs of dough which are transferred to filling station, whereupon the disc is rolled by a rolling mechanism which comprises a thin, flexible sheet attached at one end to a plate on which the disc of dough is-deposited. By moving the free edge of the sheet along a curved path, the disc of dough is rolled around the filling to produce a tortilla.
CLAIM 10

Samoosas, chapatis, tortillas and other pastry produced according to one of the previous claims.