JP3364924B2 - Manufacturing method of freshly prepared food - Google Patents

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for producing freshly cooked food.

[0002]

2. Description of the Related Art Generally, when trying to provide freshly cooked food, kitchen work in a store is very labor-intensive work. In particular, in order to provide only the necessary amount when needed, small-quantity and frequent processing must be performed, and the work is complicated especially for breads and prepared foods that have many products and the processing process is complicated. It is very laborious and difficult for an amateur to do. In addition, these products are subject to considerable revision and a considerable amount of time and effort is required to master the cooking and processing conditions for them. Also, during the time when the product is sold,
For example, there are peaks such as during lunch and dinner, and the kitchen work peaks in those hours in conjunction with it, and kitchens cannot be simply cooked and processed in accordance with the time zone that the customer needs. Equipment and the like are required to have the ability to be adjusted at the peak time, and workers are also required to have the number to be adjusted at the peak time. Furthermore, since the types and quantities of products that can be sold differ depending on each store and business day, for example, the store manager decides the type and number of products to be manufactured by his own judgment based on his experience and feelings. There was a strong tendency to manufacture and process and display them in stores. On the other hand, kitchens are often away from stores, and it is very difficult to grasp in real time what kind of product a customer needs. As a result, there are few products lined up in the store by customers when they need them, and because the work in the kitchen is not leveled, there is a strong tendency for the number of workers to become excessive. . As a result, sales at each store have declined and personnel costs have increased, putting pressure on management.

For example, bakery products such as bread and donuts and foods such as prepared foods are many in variety, and various types of products are selected and enjoyed at a eating place. It is well known that foods such as bakery products and prepared foods containing wheat flour as a main component cause an aging phenomenon with aging immediately after they are cooked, but their quality deteriorates due to aging. Despite being approved, products that have not been freshly prepared and are considered as preserved foods have been accepted. On the other hand, for example, when trying to make freshly baked bread by a so-called scratch method in which bread is baked through all steps after mixing wheat flour, the process is short, and it takes 5 hours. You have to adjust the preparation so that they are close to each other.
In addition, in order to eat bread with a variety of different types and sizes by fresh baking, it was necessary to further complicatedly adjust the number and timing of each process such as preparation and baking.

Therefore, a method of using frozen dough has been proposed in recent years for the purpose of baking various kinds of bread more easily and labor-savingly. In this case, starting from frozen bread dough, thawing and proofing, and baking in an oven. However, even in such a case, in order to supply freshly baked bread in full scale for different types of bread, individual complicated manufacturing steps corresponding to the appropriate temperature and time are required. It was For example, with regard to the baking process, since bread has different baking temperature conditions depending on its tradition, it is usual to bake by changing the set temperature of the oven at that time, and the baking is delayed due to the time required for setting the temperature. . That is, in order to bake a good bread, it is necessary that the fermentation of the bread dough is completed and the setting of the oven is already set to a predetermined condition when it should be baked. On the other hand, in order to put the bread in the oven, it is necessary to prepare a fermentation degree and a dough bulge suitable for the type of the bread. That is, bread with good quality cannot be baked without sufficient proofing. However, the fermentation of bread dough is left to the yeast, and it is often not ready to put it in the oven to bake when needed. Therefore, if you finish the previous process with a little extra time than necessary and the proofer is fully ready for baking, it will be put in the oven and baked even if it is not necessarily during the bread selling time. Due to these process restrictions, it will be a bread that has been baked for a long time. Furthermore,
If the required quantity has been decided in advance, it is only necessary to calculate the quantity to be prepared from that quantity and prepare it, but when the estimated quantity and the actual necessary quantity differ due to the long pre-process of bread, fresh bread is supplied. Is even harder. Furthermore, the prospects often change due to the effects of weather and changes in the number of customers. As a result, the expected quantity is expected to be considerably higher, and loss will occur here as well. In view of the above circumstances, almost no studies have been made so far on a full-scale production method and supply system for freshly baked bread.

Incidentally, Japanese Patent Application Laid-Open No. 9-299017 discloses a mobile manufacturing and sales vehicle for breads, but the problem of fluctuations in sales and consumption has not been solved.
Although it is possible to reduce the time to transport to the consumption area,
It is necessary to burn a larger quantity than the sales forecast, and when the forecast is different from the forecast, the difference between the forecast and the actual result will be a loss. Further, Japanese Laid-Open Patent Publication No. 10-28563 proposes a freshly-baked hamburger supply system, but simplification from order receipt to supply is possible, but the problem concerning supply of bread dough has not been solved.

[0006]

The object of the present invention is to enable a minimum number of workers who are not professional craftsmen to meet the demands of customers or the demand for products, and to perform the work simply and as simply as possible. It is to prepare and supply the required type and amount of food at the required time in a fresh form. In particular, the present invention simplifies baking and / or frying treatment which was conventionally complicated in the production of freshly baked bread and donuts or prepared foods, and standardizes the work for many kinds of products. Are simultaneously processed to increase the baking frequency of bread dough or the frequency of frying of side dishes. It is another object of the present invention to provide a method of manufacturing a freshly cooked food, characterized by using a work instruction system using a computer.

[0007]

What is most needed in the method of constantly supplying fresh bread is how to supply sufficient bread dough that is ready to be put in an oven and immediately baked. Based on the above viewpoint, the present inventor provides a cycle system in which a unit of a constant time of, for example, 1 to 4 hours is used, and a frozen bread dough suitable for bread or donuts required within the unit time is provided. On the other hand, depending on the type of frozen bread dough, necessary thawing and fermentation, holding the dough dough and baking in an oven with fixed setting conditions are repeated for each unit time to constantly supply enough dough dough, We have found a way to supply fresh bread at all times.

That is, the present invention supplies within a predetermined unit time.
Frozen raw bread needed to produce the type and quantity of bread you plan to make
The ground is subjected to the thawing and proofing process at the same time, and the
Hold the dough on standby and then at least the dough
Part of it is baked in an oven with fixed baking conditions.
For making fresh bread using frozen bread dough
Pertain. Also, the present invention is planned to be supplied within a predetermined unit time.
Frozen bread dough needed to manufacture the bread type and quantity of
The bread dough is kept on standby under certain conditions
And then at least part of the bread dough is fixedly baked.
Frozen bread dough consisting of baking in a condition oven
The present invention relates to a method for producing freshly baked bread. Also, the present invention
Is the type and number of breads planned to be supplied within a given unit time
Defrosting and proofing the frozen bread dough necessary for manufacturing
In the process, hold the bread dough on standby under certain conditions,
Then, at least a part of the bread dough was subjected to fixed baking conditions.
Bake in oven and / or cook in oil fryer
Deep-fried dough with frozen bread dough
It relates to a method of manufacturing a tool. Furthermore, the present invention is based on a predetermined unit time
The cold needed to produce the type and quantity of bread that will be
The frozen bread dough is subjected to the thawing process at the same time, and the bread is baked under certain conditions.
Hold the dough on standby and then at least one of the doughs
Part is baked in an oven with fixed baking conditions and / or oil
Use frozen dough, which consists of cooking in a fryer
The present invention relates to a method for producing fried donuts for use . The unit time can be appropriately set by those skilled in the art according to the type of product, the scale of the store, the number of products to be supplied, the type, scale, and quantity of kitchen equipment, and is usually 1 to 4 hours. Furthermore, this unit time can be appropriately changed during the daily supply time zone in the store as needed. For example, the unit time can be determined on the basis of the standby holding period of the dough that has been discharged. In one day, there are usually a time zone in which the sales fluctuation is large and a time zone in which the sales fluctuation is little. Since the processing capacity of the equipment used for thawing and proofing is usually limited, the unit time should be shortened during times when sales fluctuate significantly.
In other time zones, it is preferable to set the unit time to be long so that the product is supplied at a firing rate according to the fluctuation in sales.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Materials for frozen bread dough used in the method of the present invention and their compounding ratios are not particularly limited. For example, those skilled in the art can appropriately select according to the type of various confectionery bread such as bean jam and the final product such as butter roll. A raw material obtained by appropriately mixing and preparing each material is subjected to each step well known to those skilled in the art, for example, pretreatment, kneading, fermentation, and the like, and then further divided, rounded, rounded, shaped, and molded. After finishing, etc., freeze using a plast freezer, etc., and freeze store in a freezer etc. at an appropriate temperature.
Furthermore, the frozen bread dough in the present invention is a bread dough that is frozen after being subjected to a proofing process (frozen bread dough after proofing), and a bread dough that is frozen after being baked and / or cooked with an oil fryer (frozen dough after baking).
It also includes. Therefore, when using these frozen bread dough after proofing or frozen bread dough after baking, the proofing step and / or the baking step etc. are not required in the above-mentioned manufacturing method, and the manufacturing lead time in the kitchen is shortened, so that more consumers It will be possible to supply freshly baked bread to meet the demand of. That is, in the method of the present invention, when using frozen bread dough after proofing, after thawing, if necessary, it can be immediately subjected to the baking step, while when using frozen bread dough after baking, thawing and After being heated in a microwave oven or an oven, it can be immediately supplied as a freshly baked bread. Hereinafter, the case where the frozen bread dough is used will be described in detail, but the frozen dough can be applied to a scratch dough or a refrigerated bread dough obtained through a mixing process. Even when the method of the present invention is carried out using scratch dough or refrigerated bread dough, the thawing / proofing process can be carried out under the conditions as described below. It is obvious to those skilled in the art that bread dough is fermented without being thawed. In addition, the production and sale per day in a small-scale store will be described as an example in consideration of more clearly and easily understandable, but it can be applied to the case of supplying and consuming other cooked food.

In the method of the present invention, the thawing and proofing process preferably uses an automatic thawing proofing chamber generally called "dough conditioner". As a suitable example of the dough conditioner that can be used in the method of the present invention, a dough conditioner having a capacity of a temperature rising rate of 0.5 ° C./min or more and a cooling rate of 0.5 ° C./min or more, for example, frozen bread dough charging amount For 20 kg,
A refrigerator having an output of more than 400 W, preferably 600 W or more, and an output of more than 600 W, preferably 1
An example is a dough conditioner equipped with a heater of 000 W or more. Within a predetermined unit time (for example, 3
Prepare a thaw proof storehouse with a capacity to store a quantity of frozen dough equivalent to consumption of 4 hours). It usually takes about 3 hours to unfreeze the frozen dough, so it is convenient to use a capacity equivalent to that, but if it changes due to the size of the dough being small or large, adjust it accordingly. It is also possible to use multiple thawing proof boxes at the same time. Those skilled in the art can appropriately select and determine the conditions for the thawing and proofing steps. Then, in order to hold the bread dough that has been sufficiently fermented and finished proofing under standby under certain conditions, it is placed in a standby state in a standby storage before firing. This standby holding needs to be performed under certain conditions in order to keep the state of the dough before baking constant and to allow it to be baked under the previously fixed baking conditions, if necessary. . The present inventor has revealed that humidity as well as temperature is important for the quality of baked product bread as such a condition. That is, the temperature is 5 to 15 ° C, preferably 8 to 13 ° C, and the humidity is 60 to 98%, preferably 65 to
By holding the bread dough on standby at 95%, various bread dough can be maintained in the same state for about 4 hours, preferably about 3 hours, and it is necessary from the standby storage depending on the degree of sale or consumption of bread. By taking out the amount and baking it in the oven, it becomes possible to supply the most freshly baked bread. The temperature range for the above standby holding is shown based on the case where normal yeast is used,
For example, when using a cold-sensitive yeast bacterium as described in JP-A-4-234939 (a type of yeast that has a large decrease in fermentation power or loses almost all fermentation power in a low temperature range), The temperature for standby holding can be raised according to the temperature sensitive area. By the way, as a method for pre-baking frozen bread dough in Japanese Patent Laid-Open No. 7-155100, 0-1 after thawing is done.
It has been proposed to maintain it at a temperature of 8 ° C, but no mention is made of humidity conditions. When a ball (plate) -shaped frozen bread dough is used, the forming and final fermentation steps can be further performed during the standby holding. As the standby storage, for example, an ordinary humidified cold storage can be used. Since the dough conditioner can also be used as a standby storage, in that case, it is not necessary to move the dough to the standby storage after the proofing is completed. In this way, when the dough thawing process, proofing process, and standby holding process of bread dough are performed in the same automatic thawing proofing chamber, these dough conditioners are used and the operation cycles are shifted by an appropriate time. This allows fresh bread to be supplied uninterrupted throughout the day's business hours. This state is shown in FIG.

As a specific example of the conditions of each step before the above firing, for example, the internal temperature is 17 ° C to 40 ° C, preferably 2
While maintaining at 2 ° C to 35 ° C and relative humidity in the oven 50% to 75%, preferably 60% to 65%, the thawing and proofing (fermentation) steps of frozen bread dough are continuously performed using a dough conditioner, After the completion of the proofing process, the temperature inside the chamber is kept at 0.2 ° C./min or more, preferably 0.degree. C. or less, while maintaining the difference between the dew point temperature of the air in the chamber and the dough surface temperature at 20 ° C. or less, preferably 15 ° C. 5 ℃ ~ at a cooling rate of 4 ℃ / min or more
There may be mentioned a method of cooling to 15 ° C. and then holding the bread dough on standby in the same dough conditioner under the above conditions. As another method relating to the thawing and proofing process of frozen bread dough, the temperature rising rate is 0 while maintaining the difference between the dew point temperature of the air in the refrigerator and the dough surface temperature at 20 ° C. or less, preferably 15 ° C. or less using a dough conditioner. It is also possible to raise the internal temperature to 17 ° C to 40 ° C at 1 ° C to 2 ° C / min. Both of these are methods of thawing and holding the dough on standby after the proofing process in the same chamber, but after the completion of the proofing process, the temperature is 5 to 15 ° C, preferably 8 to 13 ° C, and the humidity is 60 to 98. %, Preferably 65 to 95%, it is also possible to move the bread dough to a moisturizing refrigerating storage cabinet and maintain the state of the bread dough in the cabinet. Alternatively, while maintaining the difference between the dew point temperature of the inside air and the dough surface temperature at 20 ° C or lower, preferably 15 ° C or lower, the temperature inside the refrigerator is 0.2 ° C / min or higher, preferably 0.4 ° C / min. It is also possible to cool to 5 ° C to 15 ° C at a cooling rate of not less than minutes. Examples of such a pretreatment method for firing include Japanese Patent Application Nos. 11-258030 and 11-2.
The invention described in 58031 can also be applied. Here, the “in-compartment relative humidity (RH)” is the relative humidity of the in-compartment air, which is an average value that fluctuates within a range of about ± 10%. Further, the difference between the dew point temperature of the inside air and the dough surface temperature is an average value, which fluctuates within a range of about ± 10%. The dew point temperature of the air in the refrigerator and the dough surface temperature can be measured by methods known to those skilled in the art. For example, the dew point temperature of the air can be obtained from the "air diagram" which is a relationship diagram between temperature and humidity, and the fabric surface temperature can be obtained by actual measurement using a well-known temperature sensor. It is also possible to separately perform the thawing step and the proofing step using a thawing box or the like, and freshly baked bread can be supplied by appropriately holding the dough from the proofing machine on standby.

To provide various breads on order,
From the viewpoint of simplification of the work, it is preferable that the time required for thawing the frozen dough and the proofing process is substantially the same. However,
The composition of bread dough varies greatly depending on the type of bread, and even when the same yeast addition amount is different, especially when the addition amount of salt or sugar etc. is different, the degree of activity of yeast is greatly affected and the amount of carbon dioxide gas generated. (Generation speed) is very different. In addition, the optimum dough expansion rate at the time of final fermentation also differs depending on the type of bread, that is, the optimum amount of gas generation of yeast differs. Furthermore, the thawing speed also differs depending on the shape of the frozen dough and the amount of division. For example, frozen dough containing filling, bean jam, etc. generally tends to have a long thawing time. In such a case, the total required time can be made the same by adjusting the blending amount of yeast. Specifically, the yeast addition amount is changed for each dough, the carbon dioxide gas generation amount at each temperature from 10 ° C to 35 ° C is measured by a gas generation amount measuring device (fermograph), and the dough is inserted into the bread dough. Determining the specific yeast addition amount for each frozen bread dough according to the type, weight, shape, etc. of the bread dough, from the total amount of gas generation calculated based on the bread dough temperature measured by the temperature sensor This makes it possible to align the total time for thawing and fermenting several types of frozen bread dough.

[0013] Bread and large French bread, or even molded frozen bread dough having a complicated shape or good to be re-molded after thawing is processed in the process. For example, when making bread from frozen plate dough, thaw the frozen plate dough at 10 ° C to 35 ° C, roll the dough, and take bench time as necessary to match the pullman-shaped or mountain-shaped bread molding. It is molded, packed in a food mold of a predetermined size, and then taken. You can bake it as it is,
If desired, it can be fired after being held on standby.
In the case of baguette of French bread, the process is similar to the above process. Frozen plate dough is performed at 10 ° C to 35 ° C, the dough is rolled, bench time is taken if necessary, and it is formed according to the molding of a bucket type or a batar pan, and sandwiched in a campus of a predetermined size to take a proof. It may be baked as it is, but if desired, it may be baked after being held on standby. In the case of large-sized bread, it is relatively difficult to suppress the internal fermentation even at a low temperature, and thus the standby holding time is generally limited. In such a case, it may be a good idea to keep the hood out slightly. Further, it is preferable to make a firing plan such that the standby holding time is the minimum time. In order to match the thawing time of large bread with the thawing time of other types, the thickness of the dough can be adjusted at the stage of plate dough. Considering the time required for rolling and molding, the total time for thawing and proofing may be short. Therefore, when using the frozen plate dough, it is preferable to enhance the flavor such as medium or liquid at the dough stage. This makes it possible to prevent the fermentation time at the time of thawing from becoming short and the flavor from being insufficient. When remolding after thawing, it may be taken out from the thawing chamber at a predetermined time and molded. Even if it has the shape of the product at the stage of frozen dough called "molded frozen dough" and can be baked after thawing and proofing, it is called "kettle pretreatment" before baking, coated balls, sesame or You can also decorate toppings and squeeze mayonnaise. It is also possible to increase the variety of products by using a type of dough that does not undergo fermentation. For example, pies, muffins, caked nuts, and the like can be thawed appropriately or baked without thawing.

The thawing proof is performed by panning the frozen bread dough on the top plate, and the size of the top plate at this time can be adjusted according to the amount of the frozen dough. For example, if it is necessary to pan less than half of the frozen dough on a normal-sized top plate to meet the demand of a small amount and to defrost and thaw out, use a half-size top plate.
The time required for the thawing and proofing process can be aligned with other processes. In addition, if the baking conditions are the same, it is also possible to pan and bake two or more types of dough on one top plate. The frozen bread dough is appropriately stored in a freezer for storage.
The average daily usage rate is stored in the freezer, but it is preferable to arrange the dough so that the storage location and type of the dough can be easily discriminated from the viewpoint of efficiency and simplification of the work. For example, it is most convenient to store each type of frozen bread dough in a pull-out type and display the type according to the type. It is also possible to change the size of the pull-out type storage cabinet according to the amount of frozen dough used per day and the size of the dough to make several sizes.

Firing is performed using an oven set to fixed firing conditions. As a result, work efficiency and simplification can be achieved. The "fixed baking condition" means that the baking set temperature of the oven is constant, or the difference between the set temperature and the actual temperature is small, and the type and amount of bread dough, etc., at each baking process. It means that it is not necessary to adjust the setting temperature for baking each time, and the bread dough can be added as it is and baked immediately. Therefore, it does not mean that the baking conditions are always fixed throughout the work of the day, and the baking conditions of the oven can be changed several times if necessary. As an example of the fixed baking conditions, for example, the upper temperature of the oven is set to 170 ° C to 230 ° C and the lower temperature of the oven is set to a temperature selected from 180 ° C to 260 ° C. Normally, it is possible to provide a wider variety of breads by providing a plurality of ovens in a store and setting different baking conditions for each oven. In such a case, depending on the baking temperature and time conditions for each bread, the type of work before and after baking (before and after the kettle), the priority order of baking and the priority production priority in the leveling order, etc. It is convenient to divide each dough into groups beforehand. Furthermore, the baking time for each dough can be adjusted by shifting the time taken out from the oven for each type of bread dough or each group.

There are baking conditions suitable for the type of bread, and therefore, when baking different types of bread under fixed baking conditions, if there is a large difference in the appropriate conditions between the types, there will be some difference. Take measures. For example, the heat transfer from the lower heat can be suppressed by using a top plate with rivets, or the heat transfer from the lower heat can be strengthened by using a perforated top plate or a thin top plate. Furthermore, it is preferable to appropriately use a suitable baking aid. Examples of such baking aids include an upper shielding plate and a lower protective sheet, and the invention described in Japanese Patent Application No. 10-296449 or Japanese Patent Application No. 10-284066 can be referred to. The upper shielding plate is used for weakening the heat conduction of the upper part when baking bread such as melon bread, chocolate chip bread, and white bread that wants to suppress the coloring of baked bread, for example, stainless steel. Alternatively, there are a wire mesh and a porous metal plate made of aluminum, and a woven cloth made of a heat-resistant plastic fiber and a porous sheet made of a heat-resistant plastic such as Teflon. These shapes and structures can be designed at any time according to the desired heat shielding effect. For example, the diameter and density of the metal wire used for the wire mesh (the number of metal wires per unit area multiplied by the diameter) or the porosity (aperture ratio) of the porous metal plate can be appropriately adjusted. . Furthermore, the distance from the bread dough when these upper shielding plates are installed can be adjusted appropriately. The lower protective sheet is used to suppress the heat transfer rate of the lower part when you want to secure a sufficient moist feeling in the bread dough, such as bean jam, pumpkin bread, and uguisu bean bread, for example, aluminum foil, etc. Examples of the metal foil and heat-resistant plastic sheet such as Teflon. The thickness of the sheet can be appropriately selected in consideration of the thermal conductivity of the material used.

[Comparative Experiment] Comparison of short-term holding of proofing dough For selection of three typical frozen doughs, Kokura Anpan, Curry Bread, and French Pambourg, the waiting holding conditions for proofing dough The relationship between the quality of the baked product bread and the quality of the product bread was investigated. According to the results shown in Table 1, it was found that when the holding temperature was too low, the texture of bread became sticky, and when the humidity was low, the dough was peeled off and was not good. On the other hand, if the conditions for holding standby are appropriate for both temperature and humidity,
The quality of all breads was good. It was important for the humidity to be at least 60% or higher.

[0018]

[Table 1]

Further, according to the present invention, a work instruction in which the procedure of each process is described is displayed on the screen of the computer at regular intervals, and the work instruction is output by a document or a voice, and each work instruction is output based on the work instruction. The present invention relates to a method for producing a freshly cooked food, which is characterized by performing work associated with a process. This method
It can also be used to more effectively carry out the above-described method for producing freshly baked bread and fried donuts or prepared foods. In particular, for example, sales forecast data planned based on past sales performance data is corrected in real time by a computer based on the sales performance data of the day that is grasped in real time, and is created based on the corrected sales prediction data and production performance data. Prepare and display / output work instructions indicating the work content related to preparation of frozen bread dough and baking and / or frying treatment, or preparation of prepared foods and other cooking processing at regular time intervals (for example, 30 minutes). To do. As a simpler method, the sales forecast data planned based on the past sales performance data can be calculated without the computer from time to time correcting the sales forecast data, particularly based on the sales performance data of the day grasped in real time. It is also possible to use it as it is. In addition, it is desirable that the interval for creating / displaying / outputting the work contents is as short as possible in order to manufacture in accordance with demand, but if the interval is too short, it will be a burden on the operator. Therefore, the actual time interval is appropriately determined in consideration of the ability and skill of the worker. As an example of a system using such a computer, the following can be considered, for example. That is, first, in a LAN (Local Area Network) built in a store, the sales record data of the day that the customer bought when and what product by the input means in the POS (Point of Sales) system installed at the sales floor. Is input and the data is L
Sent to the store server in real time via AN,
It is recorded in the sales record recording means. The sales forecast system is connected to the store server via a LAN, and sales forecast values planned based on past sales results are recorded and managed in the sales forecast value recording means. In response to a command from the control program in the memory, the processor predicts the sales forecast value at regular time intervals based on the sales record data sent from the store server according to a certain law. The fixed rule is, for example, comparing the cumulative sales number of each product at each time point with the sales forecast value (number), calculating the progress rate for each product from the ratio, and calculating the sales forecast value from that point onwards. The sales forecast value is corrected at any time by multiplying it by a coefficient according to the progress rate. The coefficient can be appropriately determined in advance for each product. Furthermore, the sales record data is sent from the store server to the record management system connected by LAN. Here, data relating to the production (production) performance of the day, such as when and how many products were manufactured, are input from the input means. These data are totaled and stored in the recording means there. From the sales record data and the manufacturing record data, the difference of each number is calculated in real time according to the instruction of the control program in the memory, so that the number of each product displayed in the store can be grasped in real time. Furthermore, a work order (production order) system is connected to the sales forecasting system and the performance management system via a LAN, and from these systems, the revised sales forecasting data and information regarding the number of each product displayed in the store are displayed. It will be sent in real time. In the main memory (recording means) of the work instruction system, raw material conditions, processing / manufacturing conditions, and working time of all products, and manufacturing / cooking facilities (for example,
Information on the operation and capacity conditions of the dough conditioner, and / or the thaw cabinet, the proofer, the refrigerated storage cabinet, and the oven and / or the fryer) is recorded as master data. Also, in addition to those data,
Certain files that are referenced when deciding what to do (orders, rules for oven scheduling, rules to follow when panning, rules to determine products to work at the same time, rules to level out personnel, etc.) Is recorded as. The central processing unit of the work instruction system receives the command of the control program, and based on the information recorded as the master data, the corrected sales forecast data, and the information such as the number of each product displayed in the store, from the file. Applying the selected rules, for example, the work content concerning the preparation of frozen bread dough and the baking and / or frying treatment, or the preparation of prepared foods and other cooking processing is shown at regular intervals (for example, 30 minutes). A work instruction is created, which is displayed on the screen of the computer, and is output from the work instruction system by its document output means (printer) or voice output means. Furthermore, in the system of the present invention, based on the above information,
Various store management data necessary for store management can be displayed on the screen of the computer of the work instruction system, or can be output by a document output means (printer) or a voice output means. Such store management data includes, for example, data obtained by simulating the operating status of each facility and the personnel patterns required for work on and after the next day. This makes it easy to grasp the required number of workers for each time period on and after the next day, and to arrange necessary part workers. Furthermore, when opening a new store, it becomes easy to verify its ability and determine the necessary equipment. Furthermore, as store management data, the firing loss rate and unsold loss rate for each individual product that is manufactured can be listed.These data are automatically calculated by the central processing unit of the work instruction system, and the time for each individual product is calculated. Changes in the number of products sold and the number of products burned for each band can be automatically displayed in graphs and output as a daily report. An example of this is shown in FIG.
Similarly, sales and gross profit for each individual item and category can be automatically calculated and output. In addition, the amount of raw materials used in the store is automatically calculated as the store management data, so that the raw materials required for the store can be automatically ordered through the LAN system of the present invention. This makes it possible for a part-time worker or the like to perform a complicated work of ordering raw materials. Each of the control programs used in the above system can be recorded in any recording medium known in the art, such as magnetic or optical. FIG. 2 shows an example of a conceptual diagram of a sales forecast / work instruction / actual result management LAN system used in the manufacturing method of the present invention. The sales forecast / work instruction / actual result management LAN system of the present invention can be configured as a simple system that does not include POS as an element. In such a case, the sales performance data of the day from the POS is not sent to the store server in real time. Therefore, in the sales forecasting system, based on the sales performance data sent from the store server, according to a certain rule, The sales forecast value is not corrected at regular intervals.
However, it is possible to output the work means instruction and the store management data by the procedure as described above based on the sales forecast value planned based on the past sales record recorded and managed in the sales forecast value recording means. The effect of can be obtained. Note that, for example, the sales forecast value can be corrected / updated at any time by collectively inputting the sales performance data to the store server after the business is closed for one day or at an appropriate time during the business. The sales forecast value can be corrected / updated at any time by inputting a certain amount of sales result data into the store server at the end of the day of business or at an appropriate time during business. .
The above-mentioned LAN system in the store is connected to the host computer of the headquarters through, for example, an ISDN line or a dedicated line, and the host computer collectively collects and manages information from each store and It is also possible to use a manufacturing system in which the master data is transmitted to the system of the store.
3 and 4 show an example of the work instruction document output from the work instruction system.

The following can be listed as an example of an order used when creating the above work contents. A work instruction can be created by appropriately combining these. (1) Orders tailored to sales (made-to-order manufacturing) [Order occurrence conditions] -Products whose in-store inventory is below the standard value [Production volume] -It is expected that the products will be sold within one hour from the present time Quantity [Remarks] -Normally, if the product cannot be sold no matter how many schedules are set, the in-store inventory will not decrease, so no orders will occur. However, by setting a high standard of in-store inventory, it is possible to produce as planned. (2) Leveling of work / equipment capacity Order (minimum number of personnel) [Conditions for order generation] ・ Work volume and equipment at that time based on the predicted value every 2 hours ahead every 30 minutes When the load is calculated and the operation / equipment capacity is to be overflowed, the orders are generated at the present time sequentially from the products with the lowest production priority. It should be noted that the lower the holding time of the dough and the lower the priority order of baking, the lower the “advance production priority”. [Amount to be produced] -Amount planned to be produced in 2 hours (3) In-process production when the forecast is not correct [Order occurrence conditions] -Products with multiple process steps, Products that are maintained in the state of being processed midway and are approaching the limit of maintenance time. For example, when frozen dough or fried products are thawed and then processed in the process or in the facility. [Amount to be produced] -Amount that has been prepared in advance [Remarks] -A production instruction is issued based on the forecast even if the ordering order or the leveling order is not applied.・ A partially processed product will be lost if it is not processed to the end. Therefore, it waits until the last minute of the order and issues a production instruction within the range in which the quality can be maintained. FIG. 5 is a flow chart showing the flow of logic in a program used to determine the actual work instruction contents (after opening a store) for the formed frozen bread dough based on the above order using a computer.

Furthermore, the following can be cited as an example of rules for scheduling an oven. For example, the time taken out of the oven varies depending on the product, and it is substantially difficult to adjust the times so that they do not overlap. In addition, the occurrence of instantaneous peaks can be sufficiently dealt with by humans. Therefore, in the oven scheduling, pay attention only to the timing of the work in front of the kettle.
Therefore, a pattern in which the work load is distributed and a pattern in which the work load is concentrated
Adjust according to the number of patterns. Change the scheduling ring separately for bottom and peak. For example, since there are no visitors before the store opens, there is relatively room for work. Therefore, it is preferable to apply the following [bottom rule] and [peak rule 1]. After opening, it is preferable to mainly apply [peak rule 2] or [peak rule 3]. [Bottom rule] * The peak of personnel has been lowered, and the facility utilization rate has been lowered instead. ◆ The work before the kiln does not overlap with the work before the kiln and the work after the hook at all. [Rule 1 during peaking] * Some of the work overlaps before and after the kiln. ◆ You can start the next batch if you have a little time after the completion of the work after the hook. In that case, it is possible even if the back and front of the kettle overlap. [Peak rule 2] ◆ It does not matter if the front and back of the hook overlap at each stage, and immediately after the end of the hook, start the front of the hook. [Peak rule 3] * In order to purely set the facility operation rate to 100%, start the operation before and after the kettle is almost overlapped (allow extra time for the top plate to be taken in and out).

The following method may be mentioned as an example of the rule to be followed when panning the frozen bread dough in the dough conditioner. Check the condition of the proofer every 30 minutes. At that time, if the progress of baking the dough in the proof is poor, a baking order is issued for leveling. Therefore, the actual panning is determined at two points when the proof is empty or when it is necessary to prepare the dough according to the time schedule. The dough to be panned on the proof is based on the sales forecast value, so when the sales forecast is revised (reestimated) at any time as in the present invention,
It is necessary to reconfirm when the dough that was previously panned is proofing the dough at the current predicted value. If the sales forecast value has changed, it is necessary to change the target time for each proof, and adjust the target time for each proof, the product, and the number of tops. At that time, follow the following “concept”. "Concept" -Assign the pre-prepared dough within the range of the dough maintenance time (usable time). Therefore, the number of products, the number of top boards, and the usable time are the same. -During the maintenance time, we estimate the loss for the new material that has not been put into the proof, but is newly generated in the sales forecast. FIG. 6 is a flowchart showing the flow of logic in the program when the computer determines the panning work instruction content based on the rule for determining the panning timing described above.
In addition, the work before closing (baking up) is performed on the bread dough that is held in standby after the proofing, and the "when the proofing time is flattened baking order" of "when panning is not necessary" shown in FIG. Firing is performed according to the logic.

[0023]

[Example] Fresh bread 1000 pieces / day supply system (case of opening 10:30 and closing 8:00) [Equipment] The following equipment is prepared in the store. 1. Frozen storage: -20 ° C and -14 ° C even when defrosting
Those without the above temperature rise. Choose a storage capacity larger than the equivalent of 2000 loaves. With more than 40 drawers of frozen dough types. 2. Top plate and top plate display: 40 sets of 6-take top plates and 20 sets of 12-take top plates are prepared. Of the 6-piece top plates, 10 are rivet-top plates, and 10 are top plates with circular holes having a diameter of 2 mm (aperture ratio 20%). 3. Thaw proof dough conditioner: Prepare a commonly used programmed dough conditioner. The accommodating capacity is such that it can accommodate 40 6-acquisition top plates and 16 12-acquisition top plates. Temperature and humidity can be controlled, and different conditions can be set for each time. 4. Low temperature refrigerating storage for holding dough dough: One with two 6-capped tops and 24 steps. The accommodating capacity is such that it can accommodate 40 6-acquisition top plates and 16 12-acquisition top plates. Equipped with a refrigerator and a fan, which can constantly maintain 10 ° C., a temperature and humidity sensor can display the temperature and humidity inside the refrigerator, and a spray device at the front of the fan can prevent a decrease in humidity. . Assuming that the temperature in the store is room temperature 10 ° C or higher, no heating device is required. However, it does not matter if there is a fan. 5. Oven and fryer for frying: 6 ovens
Prepare two or more deck ovens with four trays. The temperature and heating intensity of the upper and lower fires can be changed independently, and a sensor is attached to enable automatic heating. Two
At least one side of the stage shall be equipped with a steam generator for French bread. The fryer is 170-200 for donuts
Prepare one at ℃. 6. Personal computer (hereinafter abbreviated as PC): A computer main body having a storage capacity of 16 megabits or more, a disk device combining a floppy disk and a hard disk, and a laser printer are prepared for each system. The display should have high resolution in color. Here, a PC (Windows NT) manufactured by Fujitsu Limited is used. [Frozen dough] 4 shown in Table 2 below as frozen bread dough
Prepare 0 kinds. The frozen bread dough may be prepared according to the usual method, but the yeast amount shown in Table 2 is used according to the kind of the dough and the divided weight of the dough. In addition, the amount of yeast is flour 10
It is indicated by the number of parts by weight (bakery%) relative to 0 parts by weight.

[0024]

[Table 2]

As a typical example, a method for producing a frozen dough for a baking pan is shown below. 1. Combined two baking pans with 60g frozen dough recipe (1)

[0026]

[Table 3]

(2) Medium seed production method: Strong flour, yeast, and water are mixed, and mixed by a hook for a low speed for 3 minutes and a high speed for 1 minute using a stirrer for bread making. The temperature on the kneader was 26 ° C. This is fermented at 27 ° C. for 3 hours to give a medium seed. (3) Hon kneading mixing: After mixing raw materials other than margarine and medium seeds in the same manner for 3 minutes at low speed, 2 minutes at medium speed, and 1 minute at high speed,
Add margarine and mix for 3 minutes at low speed and 2 minutes at high speed. The temperature was appropriately cooled and the temperature on the kneading was adjusted to 20 ° C. (4) Division, molding and freezing: The dough is divided into 30 g, rounded, left for 15 minutes, and molded in a roll by a moulder. After molding to have a length of 12 cm, two pieces were joined together, and both ends were firmly pinched and fixed, and then frozen in a freezer at -30 ° C for 35 minutes. [Operation and work] Store frozen dough in a freezer storage beforehand. Next, determine the number of units sold per day. Here, sales forecast data based on the results of the previous day is used. See Table 4. From this table, calculate the total number of units per unit time for each product within 3 hours (adjustable according to the capacity of the equipment and the maintenance time). From this, the quantity of frozen dough to be charged each time is determined. In bread groups under the same baking conditions, different types of bread can be panned on the same top plate. However, when it is desired to provide the most freshly baked products by increasing the number of firings, use a half-size top plate as much as possible. Table 5 shows an example of panning of frozen dough based on the sales forecast data shown in Table 4. As described above, the panning amount, the number of times, etc. are determined based on the sales forecast data, but this value is corrected based on the sales performance data at any time. Then, for the panned dough, a work instruction regarding baking is created in accordance with the rules described above. If you follow the instructions, you will get the desired type and quantity of freshly baked bread at a given time.

[0028]

[Table 4]

[0029]

[Table 5]

[Setting of operating conditions of each device] The operating conditions of the dough conditioner, the standby storage of the dough dough (refrigerated storage), the oven and the fryer were set as follows according to time. Table 6 shows an example of each firing group and top plate display. The firing group “L” in Table 6 is
Bake in a round bun for buns with a diameter of 10 cm on a baking sheet. Defrosting / proofing process: The temperature in the refrigerator is 10 when thawing.
C., humidity 50% RH, then the temperature was raised at a rate of 0.25.degree. C./min, and after 80 minutes it was set to 30.degree. During this time, the humidity is 50%
Set to RH. After that, temperature 30 ℃, humidity 80% RH
Was set for 100 minutes. The total time required for the thawing and proofing process was 3 hours. Storage (refrigerator): Temperature 10 ℃, Humidity 80% Oven 1: Top heat 190 ℃ / 220 ℃ Oven 2: Top heat 200 ℃ / 200 ℃ Fryer: 190 ℃

[0031]

[Table 6]

[0032]

EFFECTS OF THE INVENTION According to the method of the present invention, it is possible to simultaneously prepare a large number of freshly baked breads and fried donuts of stable quality, which is a labor-saving and simple operation and always saves fresh bread and space. Can supply fried donuts. Further, according to the system of the present invention, it is possible to control the quantity to be charged by automatically grasping the time change of the sales record by computer management. Loss can be reduced by increasing or decreasing the number of additional charges. In addition, depending on the type of bread, the oven temperature setting is fixed to a fixed value in advance assuming the time for the proofing, so there is no need to check the oven temperature and type of bread. Can be done.
Further, according to the system of the present invention, all the information regarding the work content and its timing can be immediately known and given to the worker as a work instruction. Therefore, if a basic manual is memorized, a part worker who is not a specialized craftsman, etc. However, it is possible to perform the work sufficiently, and it is possible to prepare food of excellent quality and supply it in a fresh form. Furthermore, by performing the work systematically based on the work instructions, it is possible to control the movement of the worker and the timing when the work occurs, so it is possible to easily realize the kitchen work that minimizes the number of personnel required for the work. It becomes possible to do.

[Brief description of drawings]

FIG. 1 shows the operation cycle in the method of the present invention when a plurality of dough conditioners are used.

FIG. 2 shows an example of a conceptual diagram of a sales forecast / work instruction / actual result management system.

FIG. 3 shows an example of a work instruction document output from the work instruction system.

FIG. 4 shows an example of a work instruction document output from the work instruction system.

FIG. 5 is a flow chart showing the flow of logic in a program used when determining the actual work instruction contents for the molded frozen bread dough by using a computer.

FIG. 6 is a flow chart showing a logic flow in a program when a work instruction content to be panned is decided by using a computer based on a rule for deciding a timing at the time of panning.

FIG. 7 is a graph showing changes in the number of sold and baked products for each individual freshly cooked food product for each time period.

─────────────────────────────────────────────────── ─── Continuation of the front page (72) Chifumi Kaga Inventor, 1177 Oyanagi, Shimada City, Shizuoka Prefecture Ajinomoto Frozen Bakery Co., Ltd. Technical Department (72) Takayuki Goto 1-1, Suzuki-cho, Kawasaki-ku, Kanagawa Prefecture (56) Reference JP-A-2000-157147 (JP, A) JP-A-62-262936 (JP, A) JP-A-3-27235 (JP, A) JP-A-2000-125747 (JP, A) (58) Fields surveyed (Int.Cl. ⁷ , DB name) A21D 13/00 A21D 6/00 A21D 8/02 G06F 17/60 CA / WPIDS (STN) FOODLINE / FOODS ADL IBRA / FOOD SCIENCE AND TECHNOLOGY ABS TRACTS (DIALOG) Food related literature information (food net)

Claims (7)

(57) [Claims] 1. Frozen bread dough required for production of the type and quantity of bread to be supplied within 1 to 4 hours is simultaneously thawed and subjected to a proofing process, and the temperature is 5 to 15 ° C. and the humidity is 60 to 98.
% Of the bread dough, and then baking at least a part of the bread dough in an oven under fixed baking conditions. 2. Frozen bread dough required for manufacturing the kind and quantity of bread to be supplied within 1 to 4 hours is simultaneously subjected to a thawing step, and the dough is waited at a temperature of 5 to 15 ° C. and a humidity of 60 to 98%. Holding and then baking at least a portion of the dough in an oven with fixed baking conditions,
A method for producing fresh bread using frozen bread dough. 3. Frozen bread dough required for manufacturing the type and quantity of bread to be supplied within 1 to 4 hours is simultaneously thawed and subjected to a proofing process, and the temperature is 5 to 15 ° C. and the humidity is 60 to 98.
% Of bread dough, and then baking at least a part of the bread dough in an oven under fixed baking conditions and / or cooking with an oil fryer to prepare fried donuts using frozen bread dough. . 4. A frozen bread dough required for manufacturing the type and quantity of bread to be supplied within 1 to 4 hours is simultaneously subjected to a thawing step, and the dough is waited at a temperature of 5 to 15 ° C. and a humidity of 60 to 98%. A method for producing fried donuts using frozen bread dough, which comprises holding and then baking at least a part of the dough in an oven under fixed baking conditions and / or cooking in an oil fryer. 5. The fixed firing conditions of the oven are as follows: the upper temperature of the oven is 170 ° C. to 230 ° C. and the lower temperature is 180 ° C.
° C. and setting the temperature selected from to 260 ° C., the production method according to any one of claims 1 to 4. 6. A dough conditioner is used to maintain the difference between the dew point temperature of the inside air and the dough surface temperature at 20 ° C. or lower, while increasing the temperature inside the chamber at a rate of 0.1 ° C. to 2 ° C./min to 17 ° C. ℃
By increasing the temperature to -40 ° C, the frozen bread dough is continuously thawed and the proofing step is performed, and after the proofing step is finished, the difference between the dew point temperature of the inside air and the dough surface temperature is 20 ° C or less,
The temperature in the chamber is 5 ° C to 15 ° C at a cooling rate of 0.2 ° C / min or more.
° C. until cooled, subsequently a temperature 5 to 15 ° C. in the same dough conditioners, and characterized by waiting holding the dough at a humidity 60 to 98%, according to claim 1, 3, or 5
The manufacturing method described in. 7. The total time for thawing and fermentation of several kinds of frozen bread dough is adjusted by adjusting the amount of yeast blended for each frozen bread dough.
7. The manufacturing method according to any one of 1 to 6 .