IE84131B1 - Food processing - Google Patents

Description

Introduction The invention relates to a method for preparing filled bread rolls on a large manufacturing scale. In particular, the invention relates to the manufacture of bread rolls containing a sauce and a filling, typically a meat filling which is frozen for subsequent reheating by a consumer such as by microwaving. ._The manufacture of filled bread rolls efficiently on a large scale is difficult because of the very many steps required which must all run at at least similar speeds for optimum processing efficiency.

This invention is directed towards providing a continuous production method for the manufacture of such filled rolls.

Statements of Invention According to the invention there is provided a method for preparing a filled bread roll comprising the steps of:— preparing a bread dough mixture; extruding the bread dough mixture into a ribbon; slitting the ribbon longitudinally to form a number of lanes of dough; cutting the dough in each lane transversely to form a dough portion; rolling the dough portion into a roll; partially flattening an upper face of the rolled dough portion; baking the rolled dough portion; forming a longitudinal extending slit in the upper partially flattened face of the roll; opening the slit to receive a filling; and packaging the filled roll.

In a preferred embodiment the upper face of the rolled dough portion is partially flattened by applying a pressing force to the upper face of the dough portion.

Preferably the height of each flattened dough portion is substantially the same.

In one embodiment the method comprises the step of separating the dough portions prior to rolling.

In one embodiment the method comprises laminating the ribbon of bread dough mixture prior to slitting of the ribbon.

Preferably the rolled dough portion is loaded into a pan for baking. In this case the method comprises de-panning of the roll after baking and cooling the baked roll prior to sauce injection.

In one embodiment the slit in the upper partially flattened face of the roll is formed by slicing through an upper section of the roll. The slit may be opened by applying a guide plough to the side walls defining the slit.

In one embodiment a sauce is injected into the roll prior to filling. A sauce may be applied to a filling in the roll.

Typically the method comprises applying a topping to the filling in the roll. The method typically also comprises freezing the filled roll and packaging the filled roll.

Detailed Description To manufacture filled bread rolls on a large scale in accordance with the invention the first step is to prepare a bread dough mixture comprising flour, yeast, salt, Water and standard flour treating agents. The bread dough mixture thus formed is then presented to a pastry line on which the dough is extruded into a ribbon which is subsequently laminated. The ribbon thus formed is then slit longitudinally into typically four lanes which are gradually separated forming four longitudinally extending lanes. The longitudinal lanes are then cut transversely to fonn four dough portions. The dough portions in the lanes are separated to provide gaps between adjacent dough portions in a lane sufficient to allow for rolling of the dough portion in a spiral fonn to form a substantially cylindrical bread dough shape.

The generally cylindrical bread dough portions are then led underneath a press head which applies a pressing face to partially flatten the uppermost face of the roll. The partially flattened roll shapes are then loaded into a baking pan and cooked in an oven, typically at 200 to 220°C air temperature for 15 to 20 minutes. The baked rolls are de-panned and cooled, typically in an air temperature of about 8°C for about one hour at 0% humidity.

A plurality of the cooled baked bread rolls with their partially flattened face uppermost are then presented to a filling line. Each roll is partially slit longitudinally centrally from the upper face downwards. A sauce is typically injected into the roll and the slit is opened, for example by a guide plough to present an open filling mouth to receive a filling, typically a meat filling from ‘a multihead weigher. The guide plough is released and the mouth partially closes.

Optionally a sauce is applied over the filling and a topping such as shredded cheese may be applied.

The filled bread roll is then flow wrapped, frozen and packaged for palletisation and delivery to a point of sale.

The invention provides an integrated process for the manufacture of filled bread rolls on a large scale in a highly efficient and reproducible manner.

The invention is not limited to the embodiments hereinbefore described which may be varied in detail without departing from the scope of the appended claims.

Claims (12)

1. A method for preparing a filled bread roll comprising the steps of:— preparing a bread dough mixture; extruding the bread dough mixture into a ribbon; slitting the ribbon longitudinally to form a number of lanes of dough; cutting the dough in each lane transversely to form a dough portion; rolling the dough portion into a roll; partially flattening an upper face of the rolled dough portion; baking the rolled dough portion; forming a longitudinal extending slit in the upper partially flattened face of the roll; opening the slit to receive a filling; and packaging the filled roll.

2. A method as claimed in claim 1 wherein the upper face of the rolled dough portion is partially flattened by applying a pressing force to the upper face of the dough portion.

3. A method as claimed in claim 1 or 2 wherein the height of each flattened dough portion is substantially the same.

4. A method as claimed in any preceding claim comprising the step of separating the dough portions prior to rolling.

5. A method as claimed in any preceding claim comprising laminating the ribbon of bread dough mixture prior to slitting of the ribbon.

6. A method as claimed in any preceding claim wherein the rolled dough portion is loaded into a pan for baking.

7. A method as claimed in any preceding claim wherein the slit in the upper partially flattened face of the roll is formed by slicing through an upper section of the roll.

8. A method as claimed in any preceding claim wherein the slit is opened by applying a guide plough to the side walls defining the slit.

9. A method as claimed in any preceding claim comprising injecting a sauce into the roll prior to the filling.

10. A method as claimed in claim 9 comprising de-panning of the roll afier baking and cooling the baked roll prior to sauce injection.

1 1. A method as claimed in any preceding claim comprising applying a sauce to a filling in the roll.

12. A method as claimed in any preceding claim comprising applying a topping to the filling in the roll. A method as claimed in any preceding claim comprising freezing the filled roll and packaging the filled roll. A method for preparing a filled bread roll substantially as hereinbefore described. A filled bread roll whenever manufactured by a method as claimed in any preceding claim. F. R. KELLY & CO., AGENTS FOR THE APPLICANTS