JP2015149922A - Method of preparing dough ball for manufacturing square-shaped bread - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a dough ball for a square-shaped bread containing relatively large bubbles in a relatively simple manner, through gradual contraction of bubbles in a dough which initially contains relatively large bubbles by primary fermentation.SOLUTION: A method of preparing a dough ball for manufacturing a square-shaped bread includes the steps of: forming a primarily fermented bread dough D1 into a continuous belt-shaped dough D3 on a belt conveyor 20 through a belt-shaped dough forming device 10; dividing the continuous belt-shaped dough D3 into bread dough pieces D4 each having a specified weight; rounding the divided bread dough piece D4 into a dough ball on the belt conveyor through a rounding device; and automatically disposing a plurality of dough balls in one rectangular mold. Relatively large bubbles generated in the primary fermentation are gradually contracted to relatively small bubbles by the belt-shaped dough forming device and the rounding device.

Description

  The present invention relates to a method of manufacturing a square bread, and more particularly to a method of preparing dough balls for manufacturing a square bread.

  Conventionally, various methods for producing a square bread have been proposed. One method is a method in which a plurality of dough balls formed in a round shape are placed in a single rectangular parallelepiped mold, and the dough balls are fermented and fired. In Japan, square bread is generally called Yamagata bread or bread. After putting the dough ball into a rectangular parallelepiped mold, if the mold is not covered, a mountain-shaped bread (see FIG. 4A) whose upper part is rounded is formed, and if the mold is covered, the rectangular parallelepiped A shaped bread is formed (see FIG. 4B).

  When producing a square bread, it is important to make the dough balls have a uniform weight and shape. For example, if the weights and shapes of a plurality of dough balls placed in one mold are different, the shape and size of the mountain portions are not uniform in the case of a mountain-shaped bread (see (c) in FIG. 4). In the case of bread, the product may not have a rectangular parallelepiped shape (see (d) of FIG. 4).

  Square bread is in demand for lunch, home breakfast, and the like, and is produced continuously and in large quantities at a bread factory of a bakery company. The square bread manufacturing system installed in a bread company has not changed for more than 30 years, and is common to each bread company. Hereinafter, such a manufacturing system will be schematically described.

  A conventional manufacturing system includes (1) a step of sucking bread dough mixed with a mixer into a predetermined volume using a divider and dividing the dough into pieces of a predetermined weight (see, for example, Patent Document 1), (2) using a first rounding machine to round the shape of the divided dough pieces (see, for example, Patent Document 2); (3) using a conveyor puller and leaving the round dough pieces for a while. And (4) using a second rounding machine or by human work, the surface of the fermented and swollen dough is stretched downward to form a round dough ball. And (5) a step of disposing a plurality of round dough balls in a single rectangular parallelepiped mold.

  The kneaded bread dough undergoes fermentation over time, and expands as the gas confined in the dough expands. Therefore, when a fabric having the same volume is divided into fabric pieces, the divided fabric pieces tend to become lighter as time passes. Therefore, in the manufacturing system described above, in the step (1), a method of dividing the dough forcibly sucked into a space of a predetermined volume using a divider is used, and the weight of the dough pieces to be divided is used. In order to make uniform, the dough that has hardly been fermented immediately after being kneaded (bread dough with small bubbles) is put into a dividing machine.

  However, when divided in this way, the surface of the fabric is broken and the function of trapping gas is impaired. Therefore, in the step (2), the shape of the dough piece is rounded to recover the surface state of the dough.

  Next, in the step (3), the dough piece is allowed to stand for a while, thereby performing primary fermentation and expanding bubbles in the dough piece.

  However, the size of the bubbles swelled in the dough piece becomes uneven. Therefore, in the step (4), it is again formed into a round shape to make the size of the bubbles uniform.

JP 2004-065044 A (FIGS. 1 and 2) Japanese Utility Model Publication No. 63-037832 (FIG. 3) JP 2008-199996 A (FIG. 1) Japanese Patent Laying-Open No. 2004-248574 (FIG. 2) JP 2000-69899 A (FIG. 1) International Publication No. 2013/180115 International Publication No. 2013/183423 Japanese Patent No. 35007064 (FIG. 1)

  As described above, a conventional square bread manufacturing system starts by dividing a dough that has hardly been fermented immediately after being mixed (a dough with small bubbles, a so-called young dough). The dough pieces are then left for a suitable time to ferment the dough pieces. Thereby, small bubbles grow into large bubbles. In the case of continuous production, providing the time for leaving (fermenting time) means providing a conveyor, and increases the installation space for the manufacturing machine. When relatively large bubbles are obtained, the length of the conveyor becomes longer and the manufacturing time becomes longer than when relatively small bubbles are sufficient. In general, a conveyor puller employed in the step (3) in an existing square bread manufacturing system is a considerably larger apparatus than other apparatuses (see, for example, Patent Document 3).

  Moreover, since the size of the bubbles after fermentation is mixed with large and small bubbles, the second rounding device is used to align extremely large bubbles with the sizes of other bubbles. Also, a tight skin is formed on the surface of the dough to confine the gas in the dough during the final fermentation.

  Therefore, the present invention provides a method that makes it possible to prepare a dough ball for producing a square bread containing relatively large bubbles in a relatively short time and in a simple manner, and such a dough The object is to provide a method which makes it possible to produce a square bread containing relatively large bubbles using balls.

  The inventor of the present application does not start by dividing the dough with small bubbles, but first ferments the dough supplied to the manufacturing system, starts with dough containing relatively large bubbles, and gradually reduces the bubbles. By making it possible to produce a square bread containing relatively large bubbles in a relatively short time and in a simple manner, and to prepare dough balls for it. Researched and came up with the present invention.

  In order to achieve the above object, a method according to the present invention for preparing dough balls for producing square bread is a continuous belt-like continuous dough on a belt conveyor by using a dough forming apparatus. A dough forming step for forming dough, a dividing step for dividing the dough into a predetermined weight using a weighing device and a dividing device while conveying a continuous belt-like dough by a belt conveyor, and divided dough By using a rounding device, a piece is formed into a round shape on a belt conveyor, and the surface of the dough is stretched downward to form a dough ball in which the gathered portion of the dough gathered downward is positioned directly below. A dough layout that automatically places multiple dough balls from the belt conveyor into a single cuboid mold while the dough gathering section is located directly below Has a degree, and is characterized in that relatively large bubbles generated by the primary fermentation is reduced gradually in a relatively small bubbles by strip dough forming apparatus and rounder.

  In the method according to the present invention configured as described above, relatively large bubbles generated in the dough by primary fermentation pass the dough before dividing through the belt-shaped dough forming apparatus and the dough pieces after dividing pass through the rounding apparatus. Sometimes, the balls are gradually reduced to relatively small bubbles, and a dough ball having a desired bubble size is obtained. That is, relatively uniform bubbles larger than the desired bubble size are always retained in the dough. For this reason, it is possible to omit the step (3) used in the conventional manufacturing system to grow small bubbles into large bubbles. Thereby, it is possible to reduce the time spent for the process (3) and the space for the equipment therefor. Thus, it becomes possible to prepare a dough ball for manufacturing a square bread containing relatively large bubbles in a relatively short time and in a simple manner. Moreover, the square bread | pan containing a comparatively big bubble can be manufactured using this dough ball.

  In an embodiment of the present invention, preferably, after the dividing step, further comprising a step of degassing using a degassing device, that is, a step of crushing dough pieces to reduce bubbles, and the dough ball forming step is The dough pieces that have been divided and degassed are formed into dough balls.

  In the method constructed in this way, not only a square bread dough ball containing relatively large bubbles, but also a dough ball for producing a square bread containing small bubbles similar to existing products is easily prepared. be able to.

  In addition, the method of the present invention for producing a square bread is characterized by having a step of fermenting and baking dough balls arranged in a rectangular parallelepiped mold by the above-described method.

  According to the method of the present invention, it is possible to prepare a dough ball for manufacturing a square bread containing relatively large bubbles in a relatively short time and in a simple manner, and using such a dough ball A square bread containing relatively large bubbles can be produced.

1 is a schematic front view of an exemplary belt-shaped dough forming apparatus used in a method according to the present invention. 1 is a schematic right side view of an exemplary strip-shaped dough forming apparatus used in a method according to the present invention. 1 is a schematic perspective view of an exemplary rounding device used in the method according to the invention. It is a figure which shows various square bread | pans.

  In the following, exemplary embodiments of the method according to the invention for preparing dough balls for producing square bread and the method according to the invention for producing square bread using such dough balls are described.

  First, prepare the primary fermented dough.

  For example, the bread dough formed by the mixer is subjected to primary fermentation. The mixer is, for example, a horizontal mixer usually used in a bakery factory (see, for example, Patent Document 5), and 10 to 400 kg of dough is mixed in one batch. The mixed dough is transferred to a lifter box (see, for example, Patent Document 5). The lifter box is, for example, 80 cm long and 120 cm wide. The dough is left for 5 to 180 minutes after mixing is completed, primary fermentation is performed, and bubbles in the dough swell. Thereby, the 300 kg dough in the lifter box swells to a height of 60 cm, for example.

  Subsequently, the dough forming process which shape | molds the bread dough subjected to primary fermentation into the strip | belt-shaped continuous dough on a belt conveyor by using a strip | belt-shaped dough forming apparatus is performed.

  The belt-shaped dough forming apparatus is an apparatus described in Patent Document 6, for example, and is shown in FIGS. 1 and 2. The dough D1 subjected to primary fermentation is put into the hopper 12 of the apparatus 10 by lifting and rotating the lifter box with the lifter. By operating the cutter 14 provided at the lower part of the hopper 12, it is divided into 2 to 20 kg of elongated dough D <b> 2 and placed on the conveyor 16. While operating the transport conveyor 16, the cutter 14 is operated so that the rear end portion of the divided elongated fabric D2 overlaps the front end portion of the elongated fabric D2 to be divided next. Thereby, a strip-shaped continuous dough is formed.

  The width and thickness of the belt-like fabric and the internal bubbles are not uniform. Therefore, for example, it is preferable to pass the elongated fabric D2 between the plurality of opposed rollers 18 arranged in a V shape and the opposed diaphragm 19. The thickness of the fabric is increased by passing the elongated fabric D2 through a passage defined by the opposed diaphragm 19 and the opposed roller 18 while increasing or decreasing the distance between the opposed rollers 18 and vibrating the opposed diaphragm 19. Reduce thickness and width to make uniform. Thereby, the comparatively large bubble which exists in the inside of cloth D2 is made small, and a bubble is made uniform in the whole. Since the minimum spacing of the opposing rollers 18 is 1.0-5.0 cm, the bubble size remains larger than the desired bubble size. Finally, a belt-like continuous fabric D3 having a width of 3 to 40 cm and a thickness of 1 to 6 cm is formed on the belt conveyor 20.

  Next, a dividing step is performed in which a continuous dough in a belt shape is conveyed by a belt conveyor, and is divided into bread dough pieces having a predetermined weight one by one using a weighing device and a dividing device.

  The weighing device and the dividing device are devices described in Patent Document 6, for example, and are shown in FIG. The weighing device 30 shown in FIG. 1 is a weighing conveyor 30 separated from the conveyor belt 20, and the dividing device 32 is a blade cutter 32 that is provided at the downstream end of the conveyor belt 20 and moves up and down. When the amount of the dough D3 transferred from the conveyor belt 20 to the weighing conveyor 30 reaches a predetermined amount, the blade cutter 32 is operated to divide the dough into pieces D4. For example, the predetermined amount is 25 to 1200 g, and the length of the divided fabric piece D4 is 3 to 30 cm. In one example, the predetermined amount is 300 g, the width of the divided fabric piece D4 is 10 cm, the thickness is 3 cm, and the length is 12 cm.

  Next, the divided dough pieces are rounded on a belt conveyor by using a rounding device, and the dough surface is stretched downward, and the dough gathering portion gathered downward is located directly below the dough. A dough ball forming process for forming balls is performed.

  The rounding device is a device described in Patent Document 7, for example, and is shown in FIG. The rounding device 40 shown in FIG. 3 generally includes a belt conveyor 42 that conveys the dough pieces intermittently and a pair of forming plates 44 that are arranged on the belt conveyor. The pair of molded plates 44 has a V-shaped inclined surface 44a sandwiching the fabric piece D4, and the angle between the inclined surfaces 44a increases toward the traveling direction A, that is, spreads upward. Is getting bigger. Preferably, a protruding portion 44b that sandwiches the bottom portion of the fabric piece D4 is provided at the bottom portion of the pair of molding plates 44, and the interval between the protruding portions 44b decreases toward the traveling direction A. The pair of molded plates 44 are configured to be movable so as to approach and separate from each other and to be movable in opposite directions in the traveling direction A.

  The dough piece D4 is advanced in the traveling direction A by the belt conveyor 42 and stopped at an appropriate position. Next, the pair of molded plates 44 are moved closer to each other and moved in the traveling direction A in opposite directions. On the upstream side where the angle between the inclined surfaces 44a is small and the protrusion 44b is absent or small, the dough piece is mainly rolled into a cylindrical shape between the pair of forming plates 44. The action of rounding works. On the downstream side where the angle between the inclined surfaces 44a is large and the protrusion 44b is large, the surface of the fabric piece D4 is mainly stretched downward and the fabric pieces gathered downward are positioned directly below. D4 is rounded. In order to prevent the dough piece D4 from rolling when the pair of forming plates 44 are separated from each other, it is preferable to press the dough piece D4 from above. Thus, the dough ball D5 in which the gathering portion of the dough is located directly below is formed.

  Next, a dough arranging step of automatically arranging a plurality of dough balls from a belt conveyor into a single rectangular parallelepiped mold while the dough gathering portion is positioned directly below is performed. Thereby, the dough ball for manufacturing square bread is prepared.

  An existing panner (not shown) is preferably used to perform the dough arranging step (see Patent Document 8). For example, when four dough balls are arranged in one rectangular parallelepiped mold, roughly, dough balls flowing in a row on a first belt conveyor (not shown) are By retracting the retractable tip of the belt conveyor, four laterally arranged on a second belt conveyor (not shown) perpendicular to the first belt conveyor and repeating it, the dough The balls are arranged in four rows on the second belt conveyor. Next, the four dough balls in the lateral direction are brought close to each other by a movable guide plate (not shown) so that they can be placed in a rectangular parallelepiped mold. The second belt conveyor includes two belt conveyor portions and can be opened and closed between the two belt conveyor portions. When the four dough balls reach between the two belt conveyor parts, the two belt conveyor parts are opened and the four dough balls are placed in a rectangular parallelepiped mold located below. When the four dough balls are placed in a rectangular parallelepiped mold, the gathering portion of the dough remains positioned directly below.

  Next, a process of fermenting and baking the dough balls arranged in a rectangular parallelepiped mold is performed. Thereby, a mountain-shaped bread is manufactured.

  Specifically, for example, the dough balls in a rectangular parallelepiped mold are fermented while being moved on a conveyor for a predetermined time, and are passed through a tunnel oven and baked. As a modification, the dough balls in each mold may be individually fermented and baked individually in an oven.

  The relatively large bubbles generated in the dough D1 by the primary fermentation become relatively small bubbles when the dough D1 before division passes through the belt-like dough forming apparatus 10 and the dough piece D4 after division passes through the rounding device 40. The dough ball D5 which is gradually reduced and includes a desired bubble size is obtained. That is, relatively uniform bubbles larger than the desired bubble size are always retained in the dough. Since the size of the bubbles is gradually reduced, it is possible to make relatively large bubbles uniform, and a dough ball for producing a square bread containing relatively large bubbles in a relatively simple manner. Be prepared.

  When the method according to the present invention is compared with the steps of the conventional manufacturing system, the step of primary fermentation is performed before the step of dividing the dough into dough pieces, so that (2) the first rounding described above results. The process of rounding the shape of the divided dough pieces using a machine (see, for example, Patent Document 2) (3) The process of leaving the rounded dough pieces for a while using a conveyor puller (for example, patents) (Refer to Document 3) is unnecessary, and installation space when a new manufacturing system is introduced is saved. Further, in the method according to the present invention, a dough forming step using a belt-like dough forming device, a dividing step using a weighing device and a dividing device, a dough ball forming step for forming dough balls, and a dough arrangement for arranging dough balls in a rectangular parallelepiped mold It is possible to reduce the time required for the entire process and the space occupied by the equipment compared to the time taken by the conventional manufacturing system and the space occupied by the equipment.

  In a conventional mountain bread manufacturing system, (4) a step of forming a round dough ball by stretching the surface of the dough that has been fermented and expanded using a second rounding machine or by human work (downward) ( For example, it was previously described that there is a patent document 4). For example, when the apparatus described in Patent Document 4 is used, the surface of the dough is stretched downward, but the dough ball rolls so that the position of the gathering portion of the dough gathered downward is the dough ball. May not be stable. For this reason, the dough balls are often placed in the mold by the work of the person with the position of the gathering portion directly below. In addition, when a round dough ball is formed by a person's work, the bubbles may become smaller depending on individual differences. Therefore, the probability that a mountain-shaped bread whose shape of the mountain portion is not uniform is manufactured is relatively high. On the other hand, using the method according to the present invention and using the apparatus described in Patent Document 7, the size of the dough ball and the size of the bubbles contained in the dough ball are stable, and the shape of the mountain portion The probability of producing a uniform mountain-shaped bread is higher than before.

  Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications are possible within the scope of the invention described in the claims. Needless to say, these are also included within the scope of the present invention.

  In the above embodiment, a method of preparing a dough ball for producing a square bread having relatively large bubbles has been described. However, a smaller bubble, for example, a square having a relatively small bubble similar to the conventional one. A dough ball for making bread may be prepared. In this case, after the dividing step, there is a step of degassing using a degassing device, and the dough ball forming step forms the divided and degassed dough pieces into dough balls. The degassing device is, for example, a counter roller 34 disposed between the weighing conveyor 30 and the rounding device 40 (see FIG. 1).

  In addition, a plurality of dough balls formed in the dough ball forming step are placed in a single rectangular parallelepiped mold, the mold is covered, and the dough balls are fermented and fired to produce a rectangular parallelepiped bread. Also good.

10 belt-shaped dough forming device 20 belt conveyor 30 weighing conveyor (weighing device)
32 Blade cutter
34 Degassing roller 40 Rounding device 42 Belt conveyor D3 Belt-like continuous fabric D4 Fabric piece D5 Fabric ball

Claims (3)

A method of preparing dough balls for producing square bread,
A dough forming step of forming the primary fermented bread dough into a continuous continuous dough on a belt conveyor by using a dough forming apparatus;
A dividing step of dividing a continuous dough of a belt shape into a dough piece of a predetermined weight one by one using a weighing device and a dividing device while being conveyed by a belt conveyor,
By using a rounding device, the divided bread dough pieces are formed into a round shape on a belt conveyor and the dough surface is stretched downward, and a dough ball in which the gathering portion of the dough gathered downward is located directly below is formed. Dough ball forming process to be molded,
A dough arrangement step of automatically arranging a plurality of dough balls from a belt conveyor into a single rectangular parallelepiped mold while the dough gathering portion is positioned directly below,
A method in which relatively large bubbles generated by primary fermentation are gradually reduced to relatively small bubbles by a belt-shaped dough forming apparatus and a rounding apparatus. Furthermore, it has the process of degassing using a degassing apparatus after the said division | segmentation process,
The method according to claim 1, wherein the dough ball forming step forms dough pieces that are divided and degassed into dough balls. A method for producing a square bread,
A method comprising fermenting and baking the dough balls arranged in a rectangular parallelepiped mold by the method according to claim 1 or 2.

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