IES20090716A2

IES20090716A2 - A cutting device

Info

Publication number: IES20090716A2
Authority: IE
Inventors: Donal Cronin
Original assignee: Iaws Technology & Global Services Ltd
Priority date: 2009-09-18
Filing date: 2009-09-18
Publication date: 2011-01-19
Also published as: WO2011033087A3; WO2011033087A2; EP2477500A2; CA2774209A1

Abstract

A device for scoring a dough article prior to baking is provided. Score lines are imparted to the dough piece which act to pre-portion the dough. The dough pieces are scored so that sections are easily torn off into indicidual pre-determined portion sizes at the point of consumption, with the scoring being insufficiently weak so that the protions seperate during production steps. The cutter device (1,2) has a frame (10,20) from which depends a supporting member (18,28) with a base (15,25). Also depending from the frame (10,20) are cutting blades (12,22,13,23) with scoring edges (14,24), which edges are optionally notched. At least a portion of the edges of the blades are located closer to the frame than the base of the supporting member to limit the depth to which the edges can penetrate a dough piece, thereby providing a score on the dough piece when the cutting device is lowered over it, with the supporting member base resting on a board which carries the dough piece. <Figure 2>

Description

The present invention relates to a cutting device, in particular to a cutting device suitable for portioning a piece of dough.

The concept of “tearing and sharing bread has existed for some time. This relates to a bread product which comprises individual portions which are baked together as a single loaf with deep score lines provided in it. At the point of consumption individual portions are torn away from the loaf causing the individual portion to separate from the loaf along 10 the deep score lines. The loaf can thus easily be shared amongst the persons present.

However it is normally difficult to provide tear and share bread that provides consistent torn portion sizes on a mass scale.

Previously ‘tear and share’ bread was only available from smaller bakeries where the 15 process for making this type of bread was a manual driven process. The primary reason for this is the tool used to cut the dough but not to separate it is a straight metal scraper device. This tool requires at least seven strokes to portion a standard sized dough piece. Furthermore use of the scraper device is highly dependent on the skill of the person using it. Care is required to ensure that the user correctly positions the scraper device on the 20 dough piece to ensure even portioning of the dough piece. This tool is cumbersome to use. It is not suitable for use in automated lines where up to 5,500 pieces of bread per hour gets baked.

It is therefore an object of the present invention to provide a cutting device that is 25 designed to portion a piece of dough prior to final cooking that provides a consistent portion size, yet prevents the loaf from falling into pieces before reaching the consumer.

It is acknowledged that the term ‘comprise’ may, under varying jurisdictions be provided with either an exclusive or inclusive meaning. For the purpose of this specification, and 30 unless otherwise noted explicitly, the term comprise shall have an inclusive meaning that it may be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components. Accordingly, the term ‘comprise’ is to be attributed with as broad an interpretation as possible within any given jurisdiction and this rationale should also be used when the terms ‘comprised’ and/or ‘comprising’ are 35 used.

IE 0907 16 Further aspects of the present invention will become apparent from the ensuing description which is given by way of example only.

According to a first aspect of the invention there is provided a cutting device suitable for portioning a dough piece, comprising; a frame having an upper side and an under side, the under side of the frame having depending therefrom a supporting member having a base remote from the under side of the frame and at least two adjoining cutting blades spaced apart from the supporting member on the under side of the frame, each cutting blade having a scoring edge remote from the under side of the frame, wherein the base of the supporting member extends beyond the scoring edge of the cutting blades.

The gap so formed between the bases of the supporting member and the scoring edges allows the scoring edges of the cutting blades to score the upper surface of a dough piece without fully cutting through the piece when the frame is placed about the dough piece.

The advantage of the cutting device is that it is easy to use in a bakery production line prior to dough being baked or partially baked. Specifically the spacing between the supporting member and the scoring edge of the cutting blades on the under side of the frame prevent the cutting device from fully cutting the dough, thus enough dough is left to hold the bread together while still allowing a consumer to easily tear off portions of bread once the bread is fully cooked.

In a further aspect of the invention, at least one of the adjoining cutting blades comprises a plurality of notches on the cutting edge. Conveniently the notches serve to provide a perforated score line on the dough piece along their length, thus forming areas of weakness in the dough which easily tear when the final baked product is pulled apart into individual portions while at the same time providing unscored or less shallowly scored areas along the line which serve to hold the bread potions together during production. Optionally the notches may take any shape which provides the function that some parts of the cutting edge score less deeply into the dough than other parts.

IE 09 07 In a further aspect of the invention, the supporting member comprises a skirt or leg positioned on the under side of the frame. Conveniently, the scoring edges of the adjoining cutting blades lie in a common plane. In this way, when the cutting device is placed over a dough piece, the supporting member contacts a board on which a dough piece is resting while the scoring edges of the cutting blades do not contact the board. Instead the scoring edges of the cutting blades score the upper side of the dough piece but do not cut wholly through it.

In a further aspect of the invention, the base of the supporting member include feet, which further prevent the user from pushing the scoring edges of the cutting blades too far into the dough. Advantageously, in yet a further aspect of the invention, the feet are adjustable to enable a user to adjust the depth of the score into the dough. Conveniently this enables a user to use the cutting device on a wide range of products that may require cuts of a different depth due to the type of dough and or the recipe being used. In this aspect of the invention it is the combination of the adjustable feet and the gaps in the blades that ensure that the piece of bread does not fali apart before the consumer gets the opportunity to break off the pieces.

In a further aspect of the invention the adjoining cutting blades are positioned such that one of the cutting blades extends through another cutting blade. In this aspect of the invention the cutting blades are positioned at an angle to each other. Ideally the cutting blades are positioned at an angle of approximately 90° relative to each other. It is of course understood that position of the cutting blades relative to each other is not limited to this angle and that any suitable angle determined by a person skilled in the art can be used. Conveniently the cutting device is not limited to two cutting blades; it is possible to use any number of cutting blades as determined by a person skilled in the art. Advantageously the number and arrangement of the cutting blades in the cutting device of the invention enables the dough to be portioned into consistent piece sizes with scores that are deep enough for easy separation of the dough into individual portions at the point of consumption yet with sufficient unnotched dough to resist the loaf falling into pieces before reaching the consumer. It is understood that the dough piece can be of any desired shape for example rectangular, square, circular or irregular shape. The cutting blades can be positioned at any required angle to produce a portion of any desired shape or size, for example, wedge shaped.

In a further aspect of the invention the cutting device is a handheld portable device. Conveniently in this aspect of the invention the cutting device is provided with a handle attached to the frame. Optionally the handle of the cutting device is positioned centrally on the upper side of the frame. In an alternative aspect the cutting device is provided with one or more handles on side members of the frame intermediate upper and under sides of the side members. Conveniently in a further aspect at least two handles are provided on opposing side members of the frame. It is of course understood that in this further aspect the cutting device could also be provided with a handle positioned centrally on the upper side of the frame. The advantage of having more than one handle on the cutting device of the invention is that any adverse ergonomics are minimized by having more than one holding position.

In a further aspect of the invention the cutting device is readily modified for use with a robotic arm. Optionally the robotic arm is aligned with a vision system.

In a further aspect the frame of the cutting device has a cover. Optionally the cover comprises a mesh or perforated cover which allows a user to correctly position the cutting device over a dough piece to ensure even pieces when the bread is pulled apart by a consumer. In use the cutting device is positioned over the piece of dough and pressed into the dough to form the scores. Conveniently the cutting device is easily used by bakery personnel requiring minimum human force to form the scores within the piece of dough.

Conveniently the cutting device of the invention enables an operator to insert cuts into a dough piece at a rate that matches the capability of the line without adding an excessive amount of labour, thus producing a new product with significant customer appeal.

Ideally the cutting device of the present invention is formed from a suitable metal known to a person skilled in the art. In addition the cutting device is designed without moving parts, thus it is safe to use and easy to clean.

Conveniently the cutting device of the present invention is easy to use after a minimum amount of training time.

IE 0 9 07 16 The invention will now be described more particularly with reference to the accompanying drawings, which show by way of example only two embodiments of a cutting device of the invention.

In the drawings, Figure 1 is a plan view of a first embodiment of a cutting device according to the invention; Figure 2 is an end elevation view of the cutting device of Figure 1; Figure 3 is an elevation view of the cutting device of Figure 1; Figure 4 is an elevation view of a second embodiment of the cutting device of the invention; Figure 5 is a plan view of the cutting device of Figure 4; and Figures 6a to 6c show a sequence of the operation of the cutting device partially cutting down through the dough prior to baking, the dough once baked and the bread being 20 pulled apart into the consistent sized portions.

Referring now to the drawings and specifically to Figures 1 to 5 there are shown two embodiments of the cutting device of the invention referred to as 1 and 2 respectively.

Each embodiment of the cutting device 1, 2 comprises a frame 10, 20 having an upper 25 side and an under side. Depending from the frame 10 is a supporting member 18,28 with a base or feet 15, 25. Hereinafter the supporting member will be referred to as a skirt or leg 18, 28. It is understood that the supporting member is not limited to this type of support and that any suitable support mechanism known to a person skilled in the art can be used to achieve this purpose, Referring specifically to Figures 1, 2, 5 and 6a, there is shown a plurality of adjoining cutting blades also attached to the under side of the frame 10, 20 comprising a central cutting blade 12, 22 and a plurality of cross blades 13, 23. Each cutting blade 12,13,22, 23 has a scoring edge 14, 24 remote from the under side of the frame 10, 20. The cross 35 blades 13, 33 have a plurality of notches 14a, 24a on the scoring edge 14, 24 to avoid a full cut through the dough occurring when the cutting device 1, 2 is pressed into a dough IE Ο 9 Ο 7 16 piece. In effect, notches 14a, 24a serve to provide a perforated score line on the dough piece along their length. The central cutting blade 12, 22 and cross blades 13, 23 are slotted at the top and bottoms of the blades respectively to allow cross blades 13, 23 to extend through the central cutting blade 12, 22. In this arrangement the cross blades 13, 5 23 extend through the central cutting blade 12,22 at an angle of 90”.

In use, the cutting edges of the blades are pressed down into a dough piece so as to score it deeply without cutting wholly through the dough. The so produced score lines form areas of weakness in the dough which easily tear when the final baked product is 10 pulled apart into individual portions for consumption.

Scoring edges 14, 24 lie in a common plane and are spaced closer to the frame 10 than the base or feet 15, 25 of the skirt or legs 18, 28. In this way, when the cutting device is placed over a dough piece, the base of the skirt or legs 15, 25 are in contact with a board 15 on which the dough piece is resting, the scoring edge 14, 24 of cutting blades 12, 13, 22 and 23 score the dough piece but do not cut wholly through it.

As shown in the drawings, the base of the skirt or feet 15, 25 are adjustable on the under side of the frame 10,20. Adjustable feet 15, 25 prevent the user from pushing the scoring 20 edge 14, 24 of blades 13,23 so far into the dough piece that the portions are completely separated from one another but instead allow the user to penetrate the dough enough to score it. They also prevent the blades from reaching the surface of the boards that carry the dough. The adjustable feet 15,25 also allow various depths to be achieved to suit any one of numerous dough recipes available. Thus, adjustment of the feet can be used to 25 achieve any desired score depth in the dough piece.

In an alternative arrangement not shown in the drawings, the legs may be non adjustable or may be provided as a continuous or discontinuous skirt depending from the frame about the outer periphery of the cutting device.

Each device 1, 2 further comprise at least one handle 11,21 attached to the frame 10, 20. In both embodiments of the cutting device 1,2 handles 11 and 21 are positioned centrally on the upper side of the respective frames 10, 20. Handle 21 can be held and operated with two hands adjacent to one another on the handle. In the second embodiment, cutting 35 device 2 is provided with additional handles 21a, 21b on side members of the frame 20 IE 0 9 0 7 16 intermediate the upper and under sides at opposing ends of the device 2, thus providing a further option for holding cutting device 2, The purpose of this is to minimize any adverse ergonomics that might exist by having only one position in which the device could be held.

In these specific embodiments of the cutting device, each device 1, 2 is approximately 30.5cm (12”) long. Conveniently the central cutting blades 12, 22 of cutting device 1 and 2 are approximately 29.2 cm (11.5’’) long and cross blades 13, 23 are approximately 15.2cm (6”) long. Cross blade 13, 23 are shown to have seven notches 14a, 24a cut into the scoring edge 14, 24. It is of course understood that neither the device nor the cutting blades of the device are limited to this length or number of notches, any suitable size or length determined by a person skilled in the art can be used.

Frame 10,20 of cutting device 1,2 further comprises a cover 16,26. Conveniently cutting device 2 includes a mesh or perforated cover 26 which allows a user to position device 2 correctly over a dough piece to portion the dough piece accurately and ensure even portion sizes when the bread is pulled apart by a consumer.

Referring now specifically to Figures 6a, 6b and 6c, the process of making bread which can be easily pulled apart into consistently sized portions will now be described.

Dough pieces 30 are automatically placed on a peel board 31. For example, six pieces of dough are placed on a peel board advancing on a conveyor at a rate of twelve peel boards per minute. The dough pieces are rectangular in shape and are approximately 26.7cm to 29.2cm (10.5” to 11.5”) long and 11.4cm to 14.0cm (4.5 to 5.5”) wide. The peel boards are advanced into a retarder and held there for two hours in a controlled temperature and humidity environment. There is no major change in the footprint of the dough during this time with the exception of a minor dip in the height of each piece as the dough relaxes.

The boards 31 exit the retarder and travel on a conveyor to an oven via a docking table. At the docking table the boards pause for approximately 15 to 20 seconds. During this time a team of operators use the cutting devices 1,2 of the invention (Figure 6a in which cutting device 2 is shown) to partially cut down through each dough piece 30. This is achieved by centring device 2 over the dough piece 30 and then pressing down until the feet 25 come in contact with the peel board 31, Each operator has to work at a pace to ensure that every dough piece 30 is worked on before it moves from the docking table. Output is determined by aligning the cutter headcount with the dough piece rate through the docking area of the line.

The dough pieces 30 are then peeled from the boards 31 and loaded onto the oven hearth for an initial bake time. Following this, the bread is cooled, optionally frozen, passed through a metal detector and packed prior to distribution. At domestic, retail store or restaurant level, the bread 30a (Figure 6b) receives its final bake and is then passed to the consumer. The consumer can then break the bread 30a into portions 30b (Figure 6c). Alternatively, the bread may be fully baked in the production plant ready for immediate consumption at table.

In this particular example shown in Figures 6b and 6c, the bread 30a is scored and broken into twelve individual portions 30b, which are generally square. By varying the relative orientation between the central cutting blade and the cross blades and/or by adjusting the separation between the cross blades, other shaped portions may be formed, for example non-square rectangles, lozenge shape and the like.

It will of course be understood that the invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible within the scope of the invention.

MACLACHLAN & DONALDSON Applicants’ Agents 47 Merrion Square Dublin 2 f£ Ο 9 Ο 7 16 CT Ll_ IE Ο 9 Ο 7 16 Fig. 2 IE 0 907 16 IE 0 9 07 16 4/8 CM 000000 KO 0 0 0 0 0000 0 0 0 ooooooc ooooooo ooooooc )000000 ooooooc ooooooo ooooooc ooooooo ooooooc 3000000 ooooooc 3000000 0 0 0 0 o c 300000 ooooooc 3000000 ooooooc 3000000 ooooooc 3000000 ooooooc 3000000 ooooooc 0 0 0 00 0 0 00000 0 0 0 0 0000 0 0 0 0000000 )000000 ooooooo )000000 0 0 0 0 0 0 c )000000 ooooooo )000000 ooooooc )000000 ooooooc )000000 ooooooc )000000 ooooooc )000000 ooooooc )000000 ooooooo )000000 ooooooc )000000 ooooooc 0 0 0 oooooL 00000000000 000000000000 CM /8 0 0 0 0 0000 0 0 0 0 00000 00000( oooooo Ο 00 Ο 0 c oooooo 0 0 D Ο LH oooooo )00000 oooooo I ο ο ο ο 0 0 0 0 oooq 0 0 0 0 oooooc )00 oooooq ο IOOOOOC ο 1 000000 ο pooooq 3 φοοοοό ¢00000 ι ι1 Γι Ί 00000 QO ) ¢00000 ) ¢00000 ) |o ο 00000( ι_η ό LL IB 0 9 07 16 ft0 9 07 16 IE 09 07 16 8/8 Fig. 6c The following amended page 8 of the Specification was filed on 17th September 2010 IE 0 9 0716 ensure that every dough piece 30 is worked on before it moves from the docking table. Output is determined by aligning the cutter headcount with the dough piece rate through the docking area of the line.

It will of course be understood that the present invention is not limited to the specific details herein described which are given by way of example only, and that various alternations and modifications may be made without departing from the scope of the invention as defined by the appended claims.

Claims

CLAIMS:

1. A dough cutting device suitable for scoring a dough piece to pre-portion it, comprising; a frame having an upper side and an under side, the under side of the frame having depending therefrom a supporting member having a base with a free end distal from the under side of the frame and at least two adjoining cutting blades spaced apart from the supporting member on the under side of the frame, each cutting blade having a scoring edge distal from the under side of the frame, the base of the supporting member extending distally beyond at least a portion of the scoring edge of the cutting blades.

2. A dough cutting device as claimed in Claim 1, in which the full length of the scoring edge is spaced distally apart from the free end of the base of the supporting member and in which at least one of the adjoining cutting blades optionally includes a plurality of notches in the scoring edge.

3. A dough cutting device as claimed in Claim 1, in which one or more sections of the scoring edges of the cutting blades lie in the same plane as the free end of the base of the supporting member and the remaining section or sections are spaced closer to the underside of the frame, at least one of the adjoining cutting blades including a plurality of notches on the scoring edge, and in which the or each section of the notched scoring edge which is co-planar with the free end of the base is sized, positioned and/or shaped to cut wholly through dough in use, resulting in a perforated score line in the dough.

4. A dough cutting device as claimed in any preceding claim, in which the supporting member comprises a skirt or leg positioned on the under side of the frame and extends generally perpendicularly therefrom toward the free end, which defines the base of the supporting member, in which the base of the supporting member includes at least two feet, and in which the feet are adjustable to enable the distance of the base of the supporting member relative to the under side of the frame to be altered; the device further including at least one handle attached to the frame.

5. , A dough cutting device substantially in accordance with any of the embodiments herein described with reference to and/or as shown in Figures 1 to 3 or 4 to 5 and 6 or the accompanying drawings.