IE914578A1 - Bread Processing - Google Patents

Abstract

Tins 20 loaded with bread dough for proving are delivered from a first conveyor 30 through a transition zone 35 to a second conveyor 31 at right angles to the first. A first 5 photoelectric emitter/sensor 39, 40 detects if a loaded tin is present at the end of the first conveyor 30. A second photoelectric emitter/sensor 41, 42 detects if space is available on the second conveyor 31 to receive a tin from the transition zone 35. A proximity switch 49 detects when a full 10 batch of tins is present at the prover inlet station and sends a signal to over-ride all other sensor/emitters to prevent further tins entering the prover inlet station as a batch of tins are being loaded into the prover. A stop bar 45 is activated to prevent a tray entering the transition zone 35 15 from the first conveyor 30. The arrangement allows a batch of tins to be delivered into the prover substantially on demand and a high level of efficiency and throughput is thereby achieved.

Description

>ABSTRACT Tins 20 loaded with bread dough for proving are delivered from a first conveyor 30 through a transition zone 35 to a second conveyor 31 at right angles to the first. A first photoelectric emitter/sensor 39, 40 detects if a loaded tin is present at the end of the first conveyor 30. A second photoelectric emitter/sensor 41, 42 detects if space is available on the second conveyor 31 to receive a tin from the transition zone 35. A proximity switch 49 detects when a full batch of tins is present at the prover inlet station and sends a signal to over-ride all other sensor/emitters to prevent further tins entering the prover inlet station as a batch of tins are being loaded into the prover. A stop bar 45 is activated to prevent a tray entering the transition zone 35 from the first conveyor 30. The arrangement allows a batch of tins to be delivered into the prover substantially on demand and a high level of efficiency and throughput is thereby achieved.

IRELAND PATENTS ACT, 1964 (OPEN TO PUBLIC INSPECTION UNCT'P SECT ION 23 AND PULE 23 JNL. ..........OF/fo t- 7 3 COMPLETE SPECIFICATION Bread Processing APPLICATION No.. SPECIFICATION FILED Patent Application by unicrest INTERNATIONAL LIMITED, an Irish Company Of 39 Fitzwilliam Place, Dublin 2, Ireland. - 2 The invention relates to a process for mixing and processing dough to form loaves of bread. More specifically, the invention relates to a method and apparatus for handling baking tins loaded with bread dough for introduction into a prover.

The production of loaves of bread on a large scale requires that a large number of steps are preformed in an interlinking and matched manner so that all processing steps and apparatus are being utilised to their maximum capacity.

One particular area where this presents difficulties is in presenting baking tins loaded with bread dough to a prover. The prover generally operates on a batch of trays of bread and it is important that these be presented to the prover on demand so that the prover is operating to it's maximum capacity at all times to ensure maximum throughput. Heretofore, this has been extremely difficult to achieve without the intervention of a large number of manual handling operations. - 3 This invention is directed therefore towards providing an improved method of handling baking tins loaded with bread dough for presentation to a prover on demand.

According to the invention, there is provided a method of 5 handling baking tins loaded with bread dough comprising the steps of:leading baking tins loaded with bread dough along a first conveyor, detecting by means of a first detector means the presence 10 of a loaded baking tin at the end of the first conveyor, detecting by means of a second detector means if space is available in a transition area between the first conveyor and a second conveyor, delivering the first baking tin into the transition area 15 in response to a signal from the second switching means indicating that the transition area is clear, preventing the delivery of a following baking tin into the transition area until the first tin has cleared the transition area by operating a stop means, delivering the baking tin from the transition area onto the second conveyor, disabling the stop means when the first tin clears the transition area, and assembling a batch of tins in line on the second conveyor and delivering the batch of tins into a prover, on demand.

In one embodiment of the invention, the method comprises the additional steps of:10 detecting by means of a third detector means if space is available on the second conveyor for receiving a baking tin from the transition area, and delivering the baking tin from the transition area onto the second conveyor in response to a signal from the third detector means indicating that space is available on the second conveyor.

In one arrangement, the presence of a baking tin is detected by means of photoelectric sensors/emitters.

Preferably, the second conveyor extends substantially at right angles to the first conveyor. - 5 In a preferred arrangement, the second conveyor operates at a faster speed than that of the first conveyor.

In one embodiment of the invention, after proving and cooking hot loaves are removed from their respective tins by a de5 lidding apparatus and delivered to a conveyor for transfer to a cooler, the process including the steps of detecting by means of a tin detector, the presence of a lid over the loaves.

Preferably during de-lidding the presence of blockages caused 10 by broken or misplaced loaves is detected. In one arrangement the method includes the step of providing an alarm signal in response to activation of one or more of the detectors.

Preferably the method includes the step of disabling the delidding apparatus in response to activation of one or more of the detectors.

The invention also provides an apparatus for handling baking tins loaded with bread dough by the method of the invention, the apparatus comprising:a first conveyor, a second conveyor for delivery of a batch of baking tins into a prover, •Ε 914578 - 6 a transition zone between the first and second conveyors, first detector means for detecting the presence of a baking tin at the end of a first conveyor, second detector means for detecting if space is available 5 in the transition area, and stop means for preventing the delivery of baking tins from the first conveyor into the transition area when the first baking tin is occupying the transition area.

In a preferred arrangement, the apparatus includes third 10 switch means for detecting if space is available on the second conveyor for receiving a baking tin from the transition area.

Preferably, the switch means are photoelectrically operated.

In one arrangement the second conveyor extends substantially at right angles to the first conveyor. Usually, the second conveyor operates at a faster speed than that of the first conveyor.

In one arrangement, the first switch means comprises a photoelectric sensor and emitter arranged to emit a signal at right angles to the first conveyor adjacent the end thereof.

Preferably, the second switch means comprises a photoelectric sensor and emitter arranged to emit a signal which substantially diagonally traverses the transition area. In one arrangement, a third switch means comprises a photoelectric sensor and emitter arranged to emit a signal which substantially diagonally traverses the second conveyor adjacent the start thereof.

In addition, the invention provides a process for mixing and processing dough to form loaves of bread utilising the method and apparatus of the invention, the process comprising the steps of:mixing flour, water and dry ingredients in a batch mixer to form a dough, dividing the dough, handing up the dough, intermediate proving of the dough, moulding the dough into a desired shape, loading the shaped dough into a baking tin, - 8 leading baking tins loaded with bread dough along the first conveyor, detecting by means of the first detector means the presence of a loaded baking tin at the end of the first conveyor, detecting by means of a second switch means if space is available in the transition area between the first conveyor and the second conveyor, delivering the first baking tin into the transition area 10 in response to a signal from the second switching means indicating that the transition area is clear, preventing the delivery of a following baking tin into the transition area until the first tin is clear of the transition area by operating a stop means, delivering the baking tin from the transition area onto the second conveyor, disabling the stop means when the first tin clears the transition area, - 9 assembling a batch of tins in line on the second conveyor and delivering the batch of tins into a prover, on demand, final proving of the dough, cooking the dough to form loaves of bread, removing the loaves from the tins, and cooling the loaves.

The invention also provides bread whenever prepared by the method or apparatus of the invention.

The invention will be more clearly understood from the following description thereof given by way of example only with reference to the accompanying drawings in which:Fig. 1 is a schematic view of a process for mixing and processing dough to form loaves of bread according to the invention, Fig. 2 is a top plan view of an apparatus for handling baking tins loaded with bread dough according to the invention, - 10 Fig. 3 is a perspective view on an enlarged scale of part of the apparatus of Fig. 2, Fig. 4 is a plan view of the part of the apparatus illustrated in Fig. 3, Fig. 5 is a perspective view of a baking tin utilised in the method and apparatus of the invention, and Fig. 6 is a side elevational view of a improved delidding apparatus also according to the invention.

The process for mixing and processing dough to form loaves of bread is schematically illustrated in Fig. 1. Flour, water and additional conventional dry ingredients are loaded into a batch mixer 2 as will be described in more detail below. The mixer is then operated to form a dough which is divided in a divider apparatus 3. The divided dough is then handed up in step 4. The dough then goes through an intermediate proving stage 5 and a moulding stage 6 from which units of dough moulded into a desired shape are loaded into tins for final proving in a stage 7 prior to cooking in an oven 8. The hot bread loaves thus made are removed from their tins in a de20 tinning step 9 and are subsequently passed to a cooler 10 and from there to a slicing step 11 prior to packaging 12‘. - 11 Referring particularly to Figs. 2 to 5, there is illustrated an apparatus according to the invention for handling baking tins such as the tin 20 illustrated in Fig. 5 loaded with bread dough. Typically, the tin 20 has a capacity of four loaves. The apparatus which is illustrated in Figs. 2 to 4 comprises a first conveyor 30, a second conveyor 31 for delivery of a batch of baking tins into a prover only a part 32 of which is shown. A transition zone 35 is provided between the first and second conveyors 30, 31. The transition zone is shown particularly in Figs. 3 and 4.

In this case, the second conveyor 31 extends substantially at right angles to the end of the first conveyor 30 and travels, when operated, at a faster speed than that of the first conveyor 30 because the tins are arranged lengthways on the first conveyor 30 and widthways on the second conveyor 31.

First detector and switch means for detecting if a loaded tin is present at the end of the first conveyor 30 comprises a photoelectric sensor 39 and emitter 40 which are arranged to emit a signal substantially at right angles to the first conveyor 30 adjacent the end thereof.

Second detector and switch means for detecting if space is available in the transition area 35 is in this case provided by a photoelectric sensor 41 and emitter 42 which are arranged to emit a signal which substantially diagonally traverses the /E 914578 transition area 35 as will be apparent particularly from Fig. 4.

Third detector and switch means for detecting if space is available on the second conveyor 31 to receive a baking tin from the transition area 35 is provided by a photoelectric sensor 43 and emitter 44 which are arranged to emit a signal which substantially diagonally traverses the second conveyor 31 adjacent the start thereof, again as will be particularly apparent from Fig. 4.

Stop means for preventing the delivery of a following baking tin into the transition area 35 until the first tin has cleared the transition area is provided by a stop bar 45 which is movable from a retracted position in which the baking tin is free to pass from the first conveyor 30 into the transition zone 35 to an extended or stop position in which the movement of a baking tray from the first conveyor 30 into the transition zone 35 is prevented.

A proximity switch 49 is used to detect when a full batch of tins is present at the prover inlet station for loading into the prover. As tins are introduced from the conveyor 31 they are moved along until the first tin activates the switch 49 indicating that a full batch of tins is ready for loading into the prover. When the switch 49 is activated a signal is sent to over-ride all emitter/sensors to prevent further tins - 13 entering the prover inlet station as a batch of tins is being loaded into the prover.

In use, baking tins are loaded with bread dough in a loading station in a substantially continuous manner and delivered along the first conveyor 30. When the presence of a loaded baking tin is detected by the first sensor/emitter 39, 40 at the end of the first conveyor 30, the stop bar 45 is either raised or lowered depending on whether or not space is available in the transition zone 35 as detected by the second sensor/emitter 41, 42. If space is available in the transition area 35, the first baking tin is delivered into the transition area 35 in response to a signal from the second emitter sensor 41, 42 which disables the stop means 45. Once the first baking tin is delivered into the transition area 35, the second sensor/emitter 41, 42 are activated to engage the stop means 45 and prevent a further baking tin from entering the transition area. Provided the emitter/sensor 41, 42 is not blocked, a tin may be accepted into the transition area .

The first baking tin is delivered from the transition area 35 onto the second conveyor 31 in response to a free space being available on the second conveyor 31 as detected by the third emitter sensor 43, 44. When a baking tin is delivered from the transition area 35 onto the second conveyor 31, the second emitter sensor 41, 42 is activated to release the stop 45 and - 14 allow a following tin to enter the transition zone 35. When the emitter sensor 43, 44 is blocked by a tin, the conveyor 31 is activated unless an over-ride signal is received from the switch 49 when a batch of tins is ready for loading into the prover. The baking tins are automatically handled in this way until a batch of tins in line are assembled for loading into a prover 32 as detected by operation of the proximity switch 49. During the loading step the second conveyor 31 is disabled. When the batch of baking tins loaded with dough for proving is loaded into the prover the cycle continues.

The method and apparatus of the invention allows baking tins loaded with dough to be delivered into a prover substantially on demand so that the prover operates at a high level of efficiency and throughput.

Referring to Fig. 6, there is illustrated an improved delidding apparatus 50 also used in the process and apparatus according to the invention. The de-lidding apparatus 50 is used to remove hot bread from the baking tins and place them onto a conveyor for delivery to a cooler. The apparatus 50 comprises an air jet arrangement 51 which shoots a blast of air onto the loaves as the tins pass under the air jet to assist in dislodging the loaves from the tins. A series suckers 52 arranged on a continuous belt then engage the top of the loaves of bread and deliver them as illustrated onto a E914578 - 15 conveyor 54. The de-lidding apparatus 50 is extremely sensitive to blockages and damage to the suckers 52.

Photoelectric sensor and emitter combinations 61, 62, 63 are provided respectively at the inlet end of the apparatus 50 upstream of the air jet 51 to detect the presence of a lid over the loaves and the tins. If such a lid is detected, the machine stops and an alarm sounds. The emitter sensor combinations 62, 63 detect any blockage in the critical area of the delivery of the loaves onto the conveyor by a partially broken loaf or the like. In this way the de-lidding apparatus is effectively protected against damage by lids or dislodged and/or broken loaves of bread. Not only is down-time significantly reduced but also the useful life of the suckers 52 is significantly extended.

The invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail.

Claims (22)

1. A method of handling baking tins loaded with bread dough comprising the steps of:leading baking tins loaded with bread dough along a 5 first conveyor, detecting by means of a first detector means the presence of a loaded baking tin at the end of the first conveyor, detecting by means of a second detector means if 10 space is available in a transition area between the first conveyor and a second conveyor, delivering the first baking tin into the transition area in response to a signal from the second switching means indicating that the transition area 15 is clear, preventing the delivery of a following baking tin into the transition area until the first tin has cleared the transition area by operating a stop means, - 17 delivering the baking tin from the transition area onto the second conveyor, disabling the stop means when the first tin clears the transition area, and 5 assembling a batch of tins in line on the second conveyor and delivering the batch of tins into a prover, on demand.

2. A method as claimed in claim 1 comprising the additional steps of:10 detecting by means of a third detector means if space is available on the second conveyor for receiving a baking tin from the transition area, and delivering the baking tin from the transition area onto the second conveyor in response to a signal 15 from the third detector means indicating that space is available on the second conveyor.

3. A method as claimed in claim 1 or 2 wherein the presence of a baking tin is detected by means of photoelectric sensors/emitters. - 18

4. A method as claimed in any preceding claim wherein the second conveyor extends substantially at right angles to the first conveyor.

5. A method as claimed in any preceding claim wherein the 5 second conveyor operates at a faster speed than that of the first conveyor.

6. A method as claimed in any preceding claim wherein after proving and cooking hot loaves are removed from their respective tins by a de-lidding apparatus and delivered 10 to a conveyor for transfer to a cooler, the process including the steps of detecting by means of a tin detector, the presence of a lid over the loaves.

7. A method as claimed in claim 6 wherein, during de-lidding the presence of blockages caused by broken or misplaced 15 loaves is detected.

8. A method as claimed in claim 6 or 7 including the step of providing an alarm signal in response to activation of one or more of the detectors.

9. A method as claimed in any of claims 6 to 8 including the 20 step of disabling the de-lidding apparatus in response to activation of one or more of the detectors. - 19 10. A method substantially as hereinbefore described with reference to the accompanying drawings. 11. Apparatus for handling baking tins loaded with bread dough by a method as claimed in any of claims 1 to 6, the 5 apparatus comprising:a first conveyor, a second conveyor for delivery of a batch of baking tins into a prover, a transition zone between the first and second

10. Conveyors, first detector means for detecting the presence of a baking tin at the end of a first conveyor, second detector means for detecting if space is available in the transition area, and 15 stop means for preventing the delivery of baking tins from the first conveyor into the transition area when the first baking tin is occupying the transition area. - 20 12. Apparatus as claimed in claim 11 including third detector means for detecting if space is available on the second conveyor for receiving a baking tin from the transition area. 5 13. Apparatus as claimed in claim 11 or 12 wherein the switch means are photoelectrically operated.

11. 14. Apparatus as claimed in any of claims 11 to 13 wherein the second conveyor extends substantially at right angles to the first conveyor. 10 15. Apparatus as claimed in any of claims 11 to 14 wherein the second conveyor operates at a faster speed than that of the first conveyor. 16. Apparatus as claimed in claim 13 wherein the first detector means comprises a photoelectric sensor and

12. 15 emitter arranged to emit a signal at right angles to the first conveyor adjacent the end thereof.

13. 17. Apparatus as claimed in claim 13 or 16 wherein the second detector means comprises a photoelectric sensor and emitter arranged to emit a signal which substantially diagonally traverses the transition area. - 21

14. 18. Apparatus as claimed in claim 14, 16 or 17 wherein the third detector means comprises a photoelectric sensor and emitter arranged to emit a signal which substantially diagonally traverses the second conveyor adjacent the 5 start thereof.

15. 19. Apparatus substantially as hereinbefore described with reference to the accompanying drawings.

16. 20. A process for mixing and processing dough to form loaves of bread utilising a method as claimed in any of claims 10 1 to 10 or an apparatus as claimed in any of claims 11 to 19, the process comprising the steps of:mixing flour, water and dry ingredients in a batch mixer to form a dough, dividing the dough, 15 handing up the dough, intermediate proving of the dough, moulding the dough into a desired shape, loading the shaped dough into a baking tin, - 22 leading baking tins loaded with bread dough along the first conveyor, detecting by means of the first detector means the presence of a loaded baking tin at the end of the 5 first conveyor, detecting by means of a second switch means if space is available in the transition area between the first conveyor and the second conveyor, delivering the first baking tin into the transition 10 area in response to a signal from the second switching means indicating that the transition area is clear, preventing the delivery of a following baking tin into the transition area until the first tin is 15 clear of the transition area by operating a stop means, delivering the baking tin from the transition area onto the second conveyor, disabling the stop means when the first tin clears 20 the transition area, - 23 assembling a batch of tins in line on the second conveyor and delivering the batch of tins into a prover, on demand, final proving of the dough, 5 cooking the dough to form loaves of bread, removing the loaves from the tins, and cooling the loaves.

17. 21. A method as claimed in claim 20 comprising the additional steps of:10 detecting by means of a third detector means if space is available on the second conveyor for receiving a baking tin from the transition area, and delivering the baking tin from the transition area onto the second conveyor in response to a signal 15 from the third switching means indicating that space is available on the second conveyor.

18. 22. A method as claimed in claim 20 or 21 wherein the presence of a baking tin is photoelectric sensors. detected by means of

19. 23. A method as claimed in any of claims 20 to 22 wherein the second conveyor extends substantially at right angles to the first conveyor.

20. 24. A method as claimed in any of claims 20 to 23 wherein the second conveyor operates at a faster speed than that of the first conveyor.

21. 25. A method for mixing and processing doughs substantially as hereinbefore described with reference to the accompanying drawings.

22. 26. Bread whenever prepared by a process as claimed in any of claims 20 to 25 by using a method as claimed in any of claims 1 to 10 or an apparatus as claimed in any of claims 11 to 19. Dated this 31st day of December 1991