BE1028960A1 - METHOD FOR MAKING CIGARETTE COOKIES - Google Patents

Abstract

The present invention relates to a process for the continuous preparation of cylindrical biscuits on a steel conveyor belt, comprising the following steps: spraying fat onto the steel conveyor belt, applying biscuit dough onto the steel conveyor belt to form unbaked flat cookies, baking the unbaked flat cookies in an oven to form baked flat cookies, wherein the oven comprises four oven segments, wherein each oven segment is characterized by a respective oven temperature T1, T2, T3 , T4 and a respective residence time t1, t2, t3, t4, in which T1 is less than 150°C, T2 is less than 200°C, T3 is less than 220°C and T4 is less than 200°C, wherein the residence time in each oven segment t1, t2, t3 and t4 is less than 3 minutes, and rolling the baked flat biscuits into cylindrical biscuits. The invention further relates to these cylindrical biscuits or cigarette biscuits and to an assortment comprising such biscuits.

Description

METHOD FOR MANUFACTURING CIGARETTE COOKIES

TECHNICAL FIELD The invention relates to the production of cigarette biscuits. The invention relates in particular to a process for the continuous preparation of cigarette biscuits.

STATE OF THE ART Cigarette biscuits are rolled, cylindrical and baked biscuits. Known processes for the continuous preparation of cigarette cookies have several problems. The problems include obtaining a uniform cylindrical shape. Under-hardened dough is too sticky, does not release properly from the conveyor belt, and may sag during or after rolling. Dough that is too hardened breaks during rolling. The rolling process is therefore difficult to control.

There are also problems with getting a uniform color. The hardening of the paste can be controlled by the temperature of the oven. The thickness of the dough layer before rolling can also be controlled by the oven temperature. However, these also have a strong influence on the color of the biscuit obtained. Controlling the process by means of a recipe or variable temperature results in large color differences.

The known methods also present problems of accumulation of fat, sugar and dough residues on the conveyor belt. The accumulation of fat and sugar influences the composition of the dough. Differences are thus obtained in the flow of the dough, its color after baking and its rollability.

There is a need to improve the process and the recipe for the continuous preparation of cigarette cookies. In particular, it is necessary to obtain uniform paste flow properties at different points in the process. This is necessary to obtain uniformly shaped cigarette cookies. In addition, it is desirable to obtain a uniform and even final color.

It is also desirable to minimize the amount of food waste, in particular cigarette biscuits which do not meet high quality requirements. SUMMARY OF THE INVENTION The invention relates to a process for the continuous preparation of cylindrical biscuits according to claim 1. The preferred shapes are indicated in claims 2 to 13. In a second aspect, the invention relates to a cigarette biscuit according to claim 14 The present invention makes it possible to prepare cylindrical biscuits continuously. The present invention makes it possible to obtain cylindrical biscuits which are invariably the same size, of the same golden brown color and whose color, taste, consistency, fat content and water content are identical. Thus, few cylindrical biscuits are rejected, which reduces the amount of food waste and increases efficiency. The consumer always gets the desired cookies without any anomaly or problem.

In another aspect, the invention relates to an assortment of cookies according to claim 15.

DETAILED DESCRIPTION The invention relates to a process for the continuous preparation of cigarette biscuits. Unless otherwise defined, all terms used in the description of the invention, including technical and scientific terms, have the meaning generally understood by one skilled in the art competent in the technical field of the invention. For a better appreciation of the description of the invention, the following terms are explicitly explained. The terms "a", "an", "the" and "the" designate both the singular and the plural in this document, unless the context clearly indicates otherwise. For example, "a segment" means one or more segments.

When the terms "approximately" or "about" are used in this document to refer to a measurable quantity, parameter, duration or moment, and the like, we mean variations of +/-20% or less, from preferably +/-10% or less, more preferably +/-5% or less, even more preferably +/-1% or less, and even more preferably +/-0.1% or less relative to the value indicated, insofar as these variations are applicable to the invention described. However, it should be understood herein that the value of the magnitude when the term "approximately" or "about" is used is itself specifically disclosed.

The terms "comprise", "comprising", "composed of", "consisting of", "consisting of", "contain", "containing", "comprising", "comprising", "include" and "including" are synonyms and are inclusive or open ended terms indicating the presence of the following, and not excluding or precluding the presence of other components, features, elements, members, steps, known or described in the state of the art. The digital intervals expressed by the limits include all the integers, fractions and/or real numbers between the limits, these limits being included.

The present invention relates to a composition and a recipe for the continuous preparation of cylindrical biscuits or cigarette biscuits. "Cigarettes", "cigarette cookies" or "cylindrical cookies" are cookies formed by rolling a thin layer of baked cookie dough. After rolling this layer, the cookie dough hardens, leaving a relatively hard and brittle cylindrical cookie or cigarette cookie. These cookies are often eaten with coffee. The elongated cylindrical shape makes it easy to dip the biscuit in coffee or in sauces such as vanilla sauce.

The terms "continuous" and "continuous preparation" used herein particularly describe a continuous cooking process and, preferably, a continuous rolling process. A continuous process allows the efficient production of large quantities of biscuits. However, these continuous cooking and rolling processes are considerably more difficult to control than a batch process. Indeed, the desired properties depend strongly on the same process parameters. A small variation in the cookie dough recipe can of course be corrected by changing the baking and rolling settings as well. However, this will affect color, shelf life, rollability, fat content, among others. The inventors have succeeded in developing a continuous baking and rolling process which makes it possible to produce cigarette biscuits of uniform quality, with few anomalies and therefore little food waste. These cigarette cookies have, among other things, substantially the same size, uniform color, roll up well, do not break after being rolled, and after cooling have a fat and moisture content within a narrow range.

1. Process for preparing the cookie dough In a preferred embodiment of the present invention, the cookie dough relates to a composition comprising: - 25 - 35% by mass of sugar, - 25-30% by mass of flour, - 15-15% by mass fat, - 8-12% by mass protein, - 0.5 - 2.0% by mass milk powder, - 0.1 - 0.5% by mass of salt - 0.01 - 0.1% by mass of vanilla flavor, - supplemented with water. In a preferred embodiment, the sugar has a grain size of less than 700 micrometers, preferably less than 500 micrometers. The size of the sugar grains affects, among other things, the rate at which these sugar grains caramelize.

In a preferred embodiment, the flour has a grain size of less than 200 micrometers, preferably less than 100 micrometers. The size of flour grains has a strong influence on the flow of cookie dough. In a preferred embodiment, the proteins have a grain size of less than 200 micrometers, preferably less than 100 micrometers. In a preferred embodiment, the salt has a grain size of less than 700 micrometers, preferably less than 500 micrometers.

In a preferred embodiment, the powdered milk has a grain size of less than 500 micrometers, preferably less than 250 micrometers.

> BE2020/6001 These grain sizes can be ensured by sieving the granules.

Optimization of the grain size facilitates the mixing of the granules, the correct deposit of the cookie dough on the conveyor belt.

The size of the grains also influences the flow of the cookie dough and therefore the subsequent stages of the process, in particular the baking and rolling of the latter.

In a preferred embodiment, the sugar contains at least 50% by weight sucrose, more preferably still at least 70% by weight sucrose, even more preferably at least 80% by weight sucrose, even more preferably at least 90% by weight by mass of sucrose, more preferably still at least 95% by mass of sucrose, even more preferably at least 99% by mass of sucrose, most preferably all of the sugar is sucrose.

Vanilla flavor is a flavor usually obtained from the vanilla bean with vanillin as the main flavor component.

It is a well-known flavor in food and bakery products.

The aroma of vanilla is sweet and has the ability to enhance other flavors.

Powdered milk is milk from which the water has been removed, leaving a dry substance.

This powder is manufactured in two forms: skimmed milk powder and non-skimmed milk powder.

Skimmed milk powder is made by evaporating water from skimmed milk, whole milk powder is made by evaporating water from whole milk.

After mixing the powdered milk with water, milk is obtained again, but with a slightly modified taste.

In a preferred embodiment skimmed milk powder is used.

In another embodiment, a "coffee whitener" may also be added to the recipe.

"Coffee whitener" is a milk substitute often used in coffee or tea.

Coffee creamer consists mainly of vegetable fats, emulsifiers and maltodextrin.

Coffee whitener does not contain lactose and is not strictly speaking a dairy product.

In a preferred embodiment, the cookie dough is prepared continuously.

In another preferred embodiment, the cookie dough is prepared by: - mixing 25-35% by weight sugar and 15-15% by weight fat in a mixer until fully mixed , - sequential addition of 25 to 30% by mass of flour in the mixer until the flour is completely mixed, - sequential addition of 8 to 12% by mass of protein in the mixer until the proteins are completely mixed, 0.5 to 2.0% by mass milk powder, 0.1 to 0.5% by mass salt, 0.01 to 0.1% by mass flavoring vanilla and water and mixing them for at least 30 minutes, and - resting the mixture for at least one hour.

The sequential addition of ingredients according to the present method promotes mixing. It is important to let the cookie dough rest so that it can rise sufficiently. In a preferred embodiment, the agitator does not mix air into the cookie dough. In another preferred embodiment, the agitator blades are fully immersed in the cookie dough. Air bubbles are undesirable in cookie dough. When cookie dough is fed onto the steel conveyor belt, these air bubbles cause uneven distribution. It is not desirable.

In a preferred embodiment, the agitator comprises a primary shaft, wherein the primary shaft has at least one secondary shaft, wherein the secondary shaft has agitator blades, wherein the primary and secondary shaft are rotatably mounted. Such a stirrer is well suited for correct mixing at sufficiently low speeds. These low velocities are desirable so as not to mix the air.

In a preferred embodiment, the temperature is maintained between 10°C and 30°C during the preparation of the cookie dough, preferably between 15°C and 25°C, and preferably between 20°C and 24°C . The temperature has a strong influence on the viscosity of the fat, and an influence on the viscosity of the other components. This also promotes the mixing of the different components. In addition, this temperature is ideal for rising the dough during resting. By controlling the temperature throughout the process, problems with subsequent steps are avoided and a uniform end result is achieved.

2. Process for baking cigarette biscuits In a first aspect, the invention relates to a process for the continuous preparation of cylindrical biscuits on a steel conveyor belt, comprising the following steps: - the spraying of fat onto the steel conveyor belt - applying cookie dough to the steel conveyor belt to form unbaked flat cookies,

- baking the unbaked flat cookies in an oven until they become baked flat cookies, wherein the oven consists of four oven segments, each oven segment being characterized by a respective oven temperature T1, T2, T3, T4 and a respective residence time t1, t2, t3, t4, in which T1 is less than 150°C, T2 is less than 200°C, T3 is less than 220°C and T4 is less than 200 °C, wherein the residence time in each oven segment t1, t2, t3 and t4 is less than 3 minutes, and - rolling the baked flat biscuits into cylindrical biscuits.

According to a preferred embodiment, the temperature of the oven in the first segment T1 is between 120°C and 150°C. The first segment of the oven helps the cookie dough flow onto the conveyor belt. This results in unbaked flat biscuits of uniform thickness. This is advantageous for the subsequent rolling process. This flat shape also becomes uniformly circular. This is advantageous for obtaining cigarettes of constant dimensions and having fewer anomalies.

According to a preferred embodiment, the temperature of the oven in the second segment T2 is between 170°C and 200°C. In this segment of the oven, the excess water evaporates and the sugar begins to caramelize. This is advantageous for obtaining a well-defined water and fat content, which influences the flow during the rolling process as well as the consistency and taste of the final product.

According to a preferred embodiment, the temperature of the oven in the third segment T3 is between 200°C and 220°C. In this segment of the oven, the cookie dough changes from a light beige-white color to a warmer golden-brown color. The caramelization of the sugar also continues.

According to a preferred embodiment, the temperature of the oven in the fourth segment T4 is between 180°C and 200°C. The temperature in this segment of the oven is important for the rolling process that follows. The temperature in this segment of the oven determines the temperature and properties of the baked flat cookies for the rolling process.

According to a preferred embodiment, the residence time in each of the segments of the furnace is t1=t2=t3=t4. In another preferred embodiment, the residence time in each of the furnace segments t1, t2, t3 and t4 is between 1 and 2 minutes, and more preferably still, the residence time in each of the furnace segments is comprised between 80 and 100 seconds, and more preferably it is about 90 seconds.

According to a preferred embodiment, the fat is sprayed just before the application of the cookie dough. According to a preferred embodiment, the fat is only sprayed where the cookie dough is to be applied. Thus, the fat is not sprayed over the entire width of the conveyor belt. This has the advantage that no fat accumulates between the different rows of cookie dough on the conveyor belt. Fat buildup between rows of cookie dough results in a difference in fat content between the ends of the cookie and the inside of the cookie. This has adverse effects on color uniformity and the rolling process. According to a preferred embodiment, the method also comprises the step of: - polishing the steel conveyor belt, before spraying fat on the steel conveyor belt. This has the advantage of not leaving fat, caramelized sugar or cookie dough on the conveyor belt. It is particularly important that no small imperfections such as scratches remain on the steel conveyor belt. These form an anchor point for the accumulation of fat, sugar and dough. These buildups eventually stick to a flat baked cookie. They can here lead to an irregular rolling of a cigarette biscuit or remain in the final product. This increases the amount of food waste and/or decreases the quality of the final product.

3. Cigarette Cookie Rolling Method In a preferred embodiment, a flat baked cookie is rolled and transferred. The process for rolling and transferring a baked flat biscuit comprises the following steps: - transferring the baked flat biscuit onto a compressed band, - Winding the baked flat biscuit around a rotating winding bar, compressed band pressing the flat biscuit against the rolling bar until the flat biscuit is wrapped around the rolling bar, thus forming a cylindrical biscuit, and

- the withdrawal of said winding bar whereby said cylindrical biscuit is returned to the steel conveyor belt, in which the flat baked biscuit has a temperature of at least 50°C. In a preferred embodiment, the flat baked cookie has a temperature of at least 70°C.

In a preferred embodiment, a deflector plate is provided to release a baked flat cookie from the steel conveyor and guide it to the compressed belt. In another embodiment, a pressure roller is provided, which rotates freely and which is arranged above the steel conveyor belt and the deflector plate, so that the flat baked biscuit moves in the space between the deflector plate and the pressure roller. In a preferred embodiment, the minimum temperature of the flat-baked biscuit is ensured by rolling it up immediately after it comes out of the oven. According to a preferred embodiment, the baked flat cookies are rolled up within 2 minutes of leaving the last segment of the oven. According to a more preferred embodiment, the baked flat cookies are rolled up within one minute of leaving the last segment of the oven. Preferably, the baked flat cookies are rolled up within 30 seconds of leaving the last segment of the oven. It is advantageous to minimize the cooling time between the last segment of the furnace and the winding process. Thus, it is possible to better control the properties of the baked flat cookie dough in order to optimize the rolling process. In a preferred embodiment, the temperature at the outlet of the oven is 220° C. maximum, preferably 200° C. maximum. In a preferred embodiment, the temperature at the outlet of the oven is 220° C. maximum, preferably 200° C. maximum. In a preferred embodiment, the temperature at the outlet of the oven is between 180°C and 200°C. It is important that after this process, the baked flat biscuits are sufficiently fluid and shapeable so that they can be rolled up and not break during this process. However, they should not be too runny, so that the rolled cylindrical cookies do not sag or lose their shape. For this, good temperature control is important. In addition, reheating the baked biscuit after it has cooled does not achieve the desired consistency. It is therefore very advantageous to roll up the flat biscuit immediately after baking. It also saves energy in the form of heat.

It's also important that these cookies are sticky enough to stick to themselves, so that the cylindrical shape is retained after they are rolled up. However, too much adhesion is detrimental to their detachment from the conveyor belt and the proper functioning of the winding mechanism. After rolling the cookies, they should harden into a fairly hard and brittle cylinder. Consumers prefer these crispy cookies to soft cookies that end up being crumbly. Hardness is also beneficial for the shelf life of cookies.

In a preferred embodiment, the cylindrical biscuit is guided in a controlled manner to the steel conveyor belt after being removed from the roller bar.

In another preferred embodiment, the pressure belt is used to guide the cylindrical cookie in a controlled manner towards the steel conveyor belt.

Controlled guiding of the cylindrical biscuit to the conveyor belt can prevent the rolled biscuit from continuing to roll up, backing up, coming off the belt and/or breaking.

In a preferred embodiment, the baked flat biscuit is rolled according to an arrangement comprising: - A compressed belt, - A deflector plate suitable for transferring a baked flat biscuit supplied on the steel conveyor belt to said compressed belt, - A winding bar, on which the compressed strip slides at least partially and which is longitudinally detachable from the compressed strip. In a preferred embodiment, the arrangement further comprises: - a press roll, which can rotate freely, which is positioned above the steel conveyor belt and the deflector plate.

In another preferred embodiment, the compressed strip is driven by a shaft, which is driven by a variable speed electric motor. These electric motors are easily steerable, which is desirable for a delicate process such as rolling up heated cookies without breaking them.

4. Cigarette Cookies or Cylindrical Cookies In another aspect, the present invention relates to a cigarette cookie made by the process of the present invention. In another aspect, the invention also relates to an assortment of biscuits, namely a set of biscuits or other sweets, comprising the cigarette biscuits or the cylindrical biscuits according to the present invention. In a preferred embodiment, the cylindrical cookies can be cooled to a maximum of 30°C before being packaged.

Cylindrical cookies are packaged using a “pick and place” process. In another preferred embodiment, said "grip and place" method uses pliers or plungers to grip said cylindrical biscuits. The use of pistons is advantageous. However, for this purpose, it is very important that the cylindrical biscuits have a smooth surface and a constant fat and moisture content for correct suction.

Claims (15)

1. Process for the continuous preparation of cylindrical biscuits on a steel conveyor belt, comprising the following steps: - spraying fat onto the steel conveyor belt - applying the biscuit dough to the steel conveyor belt to form biscuits unbaked flat cookies, - baking the unbaked flat cookies in an oven until they become cooked flat cookies, wherein the oven comprises four oven segments, each oven segment being characterized by a respective oven temperature T1 , T2, T3, T4 and a respective residence time t1, t2, t3, t4, in which T1 is less than 150°C, T2 is less than 200°C, T3 is less than 220°C and T4 is less than 200°C, wherein the residence time in each oven segment t1, t2, t3 and t4 is less than 3 minutes, and - rolling the baked flat biscuits into cylindrical biscuits. 2. Process according to the preceding claim 1, in which the temperature of the oven in the first oven segment T1 is between 120°C and 150°C. 3. Method according to one of the preceding claims 1 or 2, in which the temperature of the furnace in the second segment T2 is between 170°C and 200°C. 4. Process according to one of the preceding claims 1-3, in which the temperature of the oven in the third segment T3 is between 200°C and 220°C. 5. Process according to one of the preceding claims 1-4, in which the temperature of the oven in the fourth segment T4 is between 180°C and 200°C. 6. Method according to one of the preceding claims 1-5, wherein the residence time in each of the furnace segments t1, t2, t3 and t4 is less than 2 minutes. 7. Method according to one of the preceding claims 1-6, wherein the residence times in each of the segments of the furnace are substantially equal t1 = t2 = t3 = t4. 8. Method according to one of the preceding claims 1-7, wherein the residence time in each of the oven segments t1, t2, t3 and t4 is between 1 and 2 minutes. 9. Process according to one of the preceding claims 1-8, in which the baked flat biscuits are rolled up less than 2 minutes after leaving the oven. 10. Method according to one of the preceding claims 1-9, in which the baked flat biscuits are rolled up less than 30 seconds after leaving the oven. 11.Procédé according to one of the preceding claims 1-10, comprising: - polishing the steel conveyor belt, before spraying fat on the steel conveyor belt. 12. A method according to the preceding of claims 1-11, wherein the baked flat biscuits have a cylindrical shape with an almost uniform thickness. 13. A method according to any of the preceding claims 1-12, wherein the oven temperature in the first oven segment T1 is between 120°C and 150°C, wherein the oven temperature in the second oven segment oven T2 is between 170°C and 200°C, wherein the oven temperature in the third oven segment T3 is between 200°C and 220°C, wherein the oven temperature in the fourth oven segment T4 is between 180°C and 200°C, and wherein the residence time in each of the furnace segments t1, t2, t3 and t4 is between 1 and 2 minutes. 14. Cylindrical biscuits or cigarette biscuits produced according to a process according to one of the preceding claims 1-13. 15. Assortment of biscuits comprising cylindrical biscuits or cigarette biscuits according to claim 14.