RU2729109C1 - Method for production of beaten bakery products - Google Patents

Abstract

FIELD: food industry.SUBSTANCE: invention relates to bakery industry. Method for production of beaten bakery products involves dosing of recipe components, dough kneading, beating, molding, baking of dough pieces and cooling of bakery products. Kneading and beating processes are performed simultaneously in one chamber or sequentially in different chambers. Kneading process is carried out until obtaining a homogeneous viscous-plastic structure by a loop type device installed horizontally or vertically in the working chamber under atmospheric or excess gas pressure (pure air, oxygen O, nitrogen N, carbon dioxide CO). Dough is beaten to achieve bulk density of 0.2–0.7 g/cm. Recipe components used are freshly ground or ripe flour or dispersed sprouted grains of cereals or legumes with particle size of 10–150 mcm, edible organic acids, fruit, vegetable, berry, milk and oil semi-products, sugar and sugar substitutes, edible oils and fats, extracts of cereals and herbs, dry gluten, food fibers, vitamins, macro- and microelements. Dough pieces are formed after the dough beating process is completed by dividing beaten dough pieces with string cutting or knife without destroying their structure. Baking of dough pieces is carried out at temperature of 196–260 °C using either convective heating or infrared radiation-convective heating, UHF radiation-convective heating or UHF-IR radiation-convective heating with subsequent cooling of hot bakery products during 1–3 minutes. Full cycle of production of beaten bakery products is performed during 10–36 minutes.EFFECT: invention allows to simplify the technological process and increase unit capacity of the plant and production, enhance the quality and stabilize the dough and bakery products structure, expand their range, simplify and increase accuracy of the dough division into portions of the specified weight.1 cl, 2 dwg, 14 ex

Description

The invention relates to bakery production, and can be used for the production of bakery products, including yeast-free, gluten-free or gluten-free.

A known method of producing bread from whipped dough (IPC A21D 8/02, A21C 1/00, A21D 10/04, RU No. 2475028C1,0208.2011, Bul. No. 5. 20.02.2013. Author: Evseev N.V., (analogue) , in which, at the beginning, the recipe components are mixed in a separate chamber, and then the dough pieces are formed by dividing them into portions of a given weight in a volumetric manner into baking molds. The churning process is carried out separately for each portion of dough in a baking form under a pressure of at least 0.3 MPa followed by a decrease in pressure to atmospheric at a controlled rate, while the pressure is reduced to atmospheric before the knocking device is removed from the dough or after the knocking device is removed from the dough.

The churning process can be carried out in intermediate glasses with the subsequent transfer of the dough into baking molds or in baking molds.

The disadvantage of this method is the low unit performance of one churning unit, since one portion of dough of a given weight is prepared in a separate chamber, then one portion of the dough is formed into a separate baking mold and churned. Therefore, there is no need for a high performance industrial dividing head to increase productivity. In addition, industrial dividers do not work with high-moisture dough, as the dough sticks to the divider head. In addition, another disadvantage of this method is that in a kneaded dough with a visco-plastic structure in a separate chamber, the elastic-elastic structure is quickly restored when mixing is stopped. The bakery dough is characterized by thixotropy properties, i.e. restore the original structure upon removal of the load (stop mixing) and increase the viscosity.

This phenomenon creates difficulties for the process of churning the kneaded dough. At the same time, the volume of the churned dough decreases, or the volume of the dough does not rise at all when churned. Therefore, it is possible to cook only one portion of a given weight of the kneaded dough by molding for churning in one baking mold.

In the proposed method of preparing the dough and churning the dough is carried out in one installation for a given number of portions of churned dough pieces.

Another disadvantage of this method is the complexity of organizing the process of churning one portion of dough in a baking form in a churning machine:

- setting and fixing the bakery mold in the churning chamber;

- sealing the chamber by closing;

- supply of compressed air to a given pressure;

- introduction of a finger stirrer into a baking dish with dough;

- enabling the process of churning the dough;

- withdrawal of the finger stirrer from the knocked-down dough in a baking form;

- release of excess air pressure to atmospheric with an adjustable speed;

- opening of the whipping chamber;

- withdrawal of the bakery form with whipped dough from the whipping chamber.

At the same time, “tails” of the whipped dough that have fallen from the fingers of the mixer accumulate in the whipping chamber, thereby contaminating the whipping chamber. Therefore, it is necessary to additionally clean the mixer fingers from the adhered whipped dough every time after churning.

In the proposed method, the process of churning the dough is carried out by intensively churning it to a predetermined volumetric mass in a working chamber with a whisk mixer when the excess gas pressure is set to a predetermined value.

Then, dough pieces of a given weight are formed into baking molds of various designs installed on a strain gauge balance by extruding the whipped dough with a stabilized structure in the form of a rope from the whipping chamber through the unloading crane, followed by string cutting of the rope into portions of the whipped dough of a given weight without destroying the original foam-like structure.

Another disadvantage of this method is the lack of an objective tool for prompt and high-quality determination of the readiness of the kneaded dough for beating from the whipped dough with a stably constant structure.

Another disadvantage of this method is the use of a less accurate volumetric method for dividing dough pieces when forming their bakery form, compared to the weight method for dividing dough pieces, which is used in the proposed method.

In the proposed method, the readiness of the kneaded dough for churning, - churning dough for molding is determined objectively by three parameters: 1. temperature at the end of kneading and churning of the dough; 2. specific power of kneading and churning of dough; 3. video tracking the process of structure formation at the end of kneading and churning of the dough.

In the proposed method, the kneaded prepared dough for the estimated number of batches of dough pieces is immediately knocked down and then the structure of the whipped dough is stabilized and molded without destroying the foam structure of the molded dough pieces.

The next disadvantage of the method is the complexity and instability of the process of churning dough in intermediate glasses and overloading the churned dough into baking molds.

Firstly, a separate unit portion of the dough must be prepared for each beater; secondly, when the whipped dough is overloaded into baking molds, uneven unloading from each glass occurs due to the adhesion of the dough to the surface of the intermediate glasses; thirdly, during overloading, part of the whipped dough in the form of flat "tails" hangs on the walls of the glasses, which contaminates the whipping chamber and, in general, makes it impossible to qualitatively overload from intermediate cylindrical glasses into baking molds, especially of a rectangular configuration.

In addition, the remaining whipped dough on the walls of the intermediate glasses dries out over time, thereby the next batch of whipped dough still sticks to the walls of the glasses

The significant dimensions of the installation and the large "idle" gas consumption for filling the non-working part of the installation chamber increases energy consumption.

In the proposed method, the choice of the design of the horizontal whisk mixer in the working chamber is determined by the rheological properties of the dough, i.e. viscosity - a slightly strong liquid-like structure with a high moisture content of more than 52%. For such rheological systems, a whisk mixer is chosen, which, at low energy consumption, provides maximum uniformity of the distribution of recipe components in the volume of the dough of the working chamber and provides, with intensive churning of the dough and an excess gas pressure of a given value, a fast and maximum process of gas dissolution in the volume of the dough.

The disadvantage of this method is the use of a vertical finger stirrer, which does not provide a high coefficient of uniformity, the distribution of recipe ingredients in the volume of the dough and, therefore, the low quality of the whipped dough. In addition, the complication of the design of the installation when using a vertical mixer with "fingers", operating under excess gas pressure when using an additional magnetic stirrer to seal the gap of the mixer shaft from excess gas pressure in the working chamber.

In the proposed method, the gap sealing of the horizontal shaft of the whisk mixer is achieved by the high-viscosity dough structure by blocking the gap of the rotating shaft from excessive gas pressure in the working chamber.

A known method for the production of bread from whipped dough (RU N 2549108 C1, 01.22.2014, Bul. No. 11, 04.22.2015, authors: Evseev N.V., Kuznetsov V.K., Timofeev D.M., (analog), in which the process of dosing ingredients is carried out in separate portions into baking forms, and the subsequent processes of mixing the ingredients with the formation of a homogeneous dough, churning the dough and baking bread are carried out in these baking forms.The process of churning the dough is carried out under increased pressure, and the process of mixing the ingredients with the formation of a homogeneous dough is carried out either under atmospheric pressure, or under increased pressure equal to or different from the pressure at which the dough beating process is carried out.

The disadvantage of this method is the low unit performance of the whipping installation when preparing the whipped dough. In this case, in one baking form, one portion of the dough is kneaded and churned. This method increases the duration of preparation of one portion of the whipped dough (more than 10 minutes).

Another significant disadvantage of the method is the heterogeneity of the distribution of ingredients when mixing with a vertical finger stirrer, i.e., the upper layers of ingredients in the baking form are not sufficiently involved in the process of uniform distribution in the chamber volume. Consequently, the coefficient of uniformity of distribution of ingredients is no more than 70% in the volume of the baking form. This leads to a decrease in the quality of the whipped dough, and sometimes, with certain ingredients for kneading, leads to the impossibility of the whipping process.

Another disadvantage of this method is the absence of an objective tool for determining the readiness of the kneaded dough to switch the installation to the churning process, as well as the readiness of the churned test to turn off the facility upon completion of the churning process. This leads to instability of the quality of the whipped dough and, consequently, of the finished bakery products.

In the proposed method, there is a high unit productivity of one whisk unit, since at the same time a large batch of whipped dough is prepared for dividing into a given number of single portions of whipped dough, by intensively whipping it to a given volumetric mass while increasing the excess gas pressure to a given value in a chamber with a horizontal whisk mixer ...

This achieves maximum homogeneity and a stable foam structure with a given bulk density.

The disadvantage of this method is the sticking of the dough to the fingers of the mixer and the surface of the bakery mold, and then baked bakery products to the surface of the bakery molds, which reduces the quality of the finished products.

This is due to the fact that the adhesion of the dough to the surface of the baking mold increases. During the operation of the finger stirrers, centrifugal force occurs, which increases the pressing force of the dough to the surface of the baking form and, accordingly, the interaction of the dough with the walls of the baking form increases.

In addition, by combining the processes of dosing ingredients, mixing them until a homogeneous dough structure is obtained and dough churning, the duration of the whipped dough preparation dramatically increases, which means that the duration of contact of the dough with the surface of the baking form increases and the adhesion of the dough to the surface of the baking form increases.

In the proposed method, the minimum contact time of the dough with the walls of the bakery mold, there is no centrifugal force for pressing the dough against the wall of the baking mold, which prevents adhesion to the surface of the bakery mold after baking the bakery products. After baking, baked goods do not stick to the surface of the baking pan.

The disadvantage of this method is a decrease in the quality of the whipped dough during the process of mixing the recipe ingredients of the dough under excessive gas pressure, thus slowing down or even stopping the process of transition of soluble protein substances (albumin) from flour to solution, which are responsible for the whipping process.

In the proposed method, the supply of excess gas pressure into the chamber when knocking down the dough is carried out after the completion of the transition of water-soluble protein substances from flour to solution.

The closest of the known inventions in terms of technical essence is a method for the production of whipped yeast-free bread from whole-grain wheat flour (RU No. 2364087 C1, 08/20/2009), in which the dough ingredients are mixed at the beginning to obtain a given amount of dough, then the whipping process is carried out of the obtained dough under high pressure, after which the process of dividing the dough is carried out to obtain portions of whipped dough of a given weight, followed by their baking in baking tins.

The disadvantage of this method is the long process of mixing the recipe ingredients for the preparation of the dough, before the process of churning with a homogeneous structure.

Another disadvantage of this method is the lack of objective tools for determining the readiness of the kneaded dough for feeding for churning, as well as the readiness of the churned dough for molding.

In the proposed method, an intensive process of churning the dough is carried out until a homogeneous viscous-plastic stable structure is obtained. In this case, the optimal value of the specific work of churning the dough and the swelling temperature of the protein substances of the flour are achieved. Then continue the process of churning the dough under excess gas pressure of a given value until the volumetric mass of the churned dough is 0.2-0.7 g / cm ³ . The readiness of the whipped dough for molding is determined by the optimal value of the specific work of whipping and the temperature of the whipped dough.

Then the structure of the whipped dough is stabilized by releasing the excess gas pressure in the whipping chamber and the dough pieces of a given weight are formed into baking molds installed on a strain gauge balance. The weighing accuracy is 50% higher than that of the prototype.

During molding, the foamy structure of the whipped dough is preserved as much as possible.

The disadvantage of this method is the long process of baking dough pieces with convective heating, as well as cooling the baked bakery products.

In the proposed method, baking of dough pieces and cooling after baking of bakery products is carried out quickly. Baking is carried out at a temperature of 196-260 ºС using convective, or IR-radiation-convective, or microwave-radiation-convective, or microwave-IR-radiation-convective heating for 5-30 minutes.

Cooling of bakery products is carried out by vacuum cooling to room temperature for 1-3 minutes. At the same time, the full cycle of obtaining bakery products is carried out within 10-36 minutes.

In the proposed method, not only clean air is used as a gas, but also nitrogen N ₂ , carbon dioxide CO ₂ , oxygen O ₂ , which accelerate the process of gas dissolution in the dough and increase the stability of their foam structure.

In the proposed method, to obtain whipped bakery products, freshly ground or ripened flour of different types and varieties, or dispersed germinated grains of cereals or legumes with a dispersion of solid particles of 10-150 microns is used.

In the proposed method, the following are used as fortifiers in the preparation of whipped bakery products: food organic acids, fruit, vegetable, berry, dairy and oil semi-finished products, sugars and sweeteners, edible oils and fats, extracts of cereals and medicinal plants, dry gluten, dietary fiber, vitamins, macro and microelements.

The known method has the disadvantage that the processes of dosing prescription ingredients, mixing them until a homogeneous, viscous-plastic structure of the dough is obtained and knocking it down to obtain a given volumetric mass is carried out in one working chamber, which reduces the unit productivity of the installation.

In the proposed method, prescription ingredients dosing and their intensive mixing at 800-1000 rpm until a homogeneous viscous-plastic structure of the dough is obtained is carried out in a separate working chamber for 90-105 seconds, and then pumped into another chamber for churning for 15-30 sec under excess gas pressure. Consequently, the duration of the preparation of the whipped dough is reduced and, accordingly, the possibility of increasing the unit productivity of the whipping installation increases.

Another variant of the proposed method is the implementation of the processes of dosing and mixing of recipe components and churning in one working chamber, and the processes of mixing and churning are carried out intensively, and churning is carried out under an excess gas pressure of a given value.

In the proposed method, an intensive process of mixing the prescription components is carried out with a whisk mixer located horizontally in the working chamber.

An important law of physicochemical mechanics says: when creating highly concentrated disperse systems, it is necessary to disaggregate and disperse the initial recipe components as much as possible before the process begins, and to achieve maximum homogeneity of the dispersed system.

Consequently, having reached the maximum intensity of stirring and churning without destroying the continuous structure of the dough, the duration of the whipped dough preparation cycle was reduced to 90-120 seconds when using a whisk mixer located horizontally in the working chamber with a rotational speed of 800-1000 rpm.

As a result, the homogeneity of the 100% foam structure and the quality of the whipped dough increase, the unit productivity (5-10 times) and energy consumption are reduced.

The technical problem of the invention is to obtain competitive bakery products, to reduce the production area, the duration of the production process of bakery products.

To solve the technical problem posed, a method is proposed for producing whipped bakery products, including dosing prescription components, kneading dough, churning, molding, baking dough pieces and cooling bakery products, characterized in that the processes of kneading and churning dough are carried out simultaneously in one chamber or sequentially in different cameras; the kneading process is carried out until a homogeneous viscous-plastic structure is obtained; a beater-type device installed horizontally or vertically in the working chamber under atmospheric or excess gas pressure (clean air, oxygen O ₂ , nitrogen N ₂ , carbon dioxide CO ₂ ) knock down the dough until a bulk density of 0.2-0.7 g / cm3 ³ ; freshly ground or ripened flour of different types and varieties or dispersed germinated grains of cereals or legumes with a dispersion of solid particles of 10-150 microns, food organic acids, fruit, vegetable, berry, dairy and oilseed semi-finished products, sugars and sweeteners, food oils and fats, extracts of cereals and medicinal plants, dry gluten, dietary fiber, vitamins, macro- and microelements, and the dough pieces are formed after the process of churning the dough is completed by dividing the churned dough pieces with string cutting or with a knife without destroying their structure; baking of dough pieces is carried out at a temperature of 196-260 ºС using either convective heating, or IR-radiation-convective heating, microwave-radiation-convective heating, or microwave-IR radiation-convective heating with subsequent cooling of hot bakery products for 1- 3 minutes, while the full cycle of obtaining whipped bakery products is carried out within 10-36 minutes.

The technical result of the proposed invention is to simplify the technological process and increase the unit productivity of the installation and production, improve the quality and stabilize the structure of dough and bakery products and expand their range, simplify and improve the accuracy of the process of dividing the dough into portions of a given weight.

The technical result is realized by means of a method for the production of whipped bakery products from whipped, including yeast-free dough, including the processes of dosing recipe components, kneading dough, whipping dough, molding, baking dough pieces and cooling baked goods.

In this case, the processes of kneading and churning are carried out simultaneously in one working chamber, and the dough pieces are formed after the process of churning the dough is completed. Or the process of kneading the dough is carried out in a separate chamber until a homogeneous viscous-plastic structure is obtained. Periodic processes of kneading and churning the dough are carried out with a whisk-type device installed horizontally in the working chamber, and churning the dough under excessive gas pressure until the volumetric mass of the churned dough reaches 0.2-0.7 g / cm ³ . Clean air, oxygen O ₂ , carbon dioxide CO ₂ and nitrogen N ₂ are used as gas for churning the dough.

To obtain whipped bakery products, freshly ground or ripened flour of various types and varieties, or dispersed germinated grains of cereals or legumes with a dispersion of solid particles of 10-150 microns are used, and edible organic acids, fruit, vegetable, berry, dairy and oilseeds are used as fortifiers. semi-finished products, sugars and sweeteners, edible oils and fats, extracts of cereals and medicinal plants, dry gluten, dietary fiber, vitamins and macro- and microelements.

The process of forming dough pieces is carried out without destroying the structure.

Baking of dough pieces is carried out at a temperature of 196-260 ºС using convective, or IR-radiation-convective, or microwave-radiation-convective, or microwave-IR-radiation-convective heating.

Hot baked goods are cooled to room temperature within 1-3 minutes. The full cooking cycle of bakery products is 10-36 minutes.

Simplification of the technological process and an increase in the unit productivity of the installation and production is achieved through the use of a whisk mixer installed horizontally in the working chamber with a rotation speed of 800-1000 rpm and the simultaneous preparation (3-20 kg) of a large batch of whipped dough with a bulk density of 0.2 -0.7 g / cm ³ both in different chambers and in one chamber for a minimum cooking time of 105-120 sec. In this case, the shaping of the whipped dough pieces is carried out with preliminary stabilization of the foam-like structure of the whipped dough in the working chamber and the subsequent division by string cutting of the formed bundle of the whipped dough into equal parts by weight in agreement with the tensometric weighing of the bakery mold with the formed dough piece.

The forming speed is adjustable: one portion by weight (50-2000 g) is 1-5 sec. The productivity of production increases when baking dough pieces by convective or radiation-convective (IR, microwave, microwave-IR) heating at a temperature of 196-260 ˚С for 5-30 minutes, and cooling of hot bakery products within 1-3 minutes. Thus, for an installation with a one-time preparation of a large portion of whipped dough (3-20 kg) in 120 seconds, the productivity is 8-12 times higher in comparison with the known methods.

The entire production cycle for the production of whipped bakery products is 10-36 minutes.

An increase in the quality and stabilization of the structure of dough and bakery products is achieved through the use of a whisk mixer installed horizontally in the working chamber with a rotation frequency of 800-1000 rpm for preparing whipped dough with a bulk density of 0.2-0.7 g / cm ³ for a minimum time 105-120 sec. At the same time, after the completion of the process, the prepared dough, by intensive churning without stopping, is subjected to further intensive churning under excess gas pressure of a given value until the volumetric mass of the churned dough reaches 0.2-0.7 g / cm ³ . As a result, there is no possible restoration of the original dough structure when the dough is stopped. Consequently, the volumetric mass of the whipped dough of 0.2-0.7 g / cm ^{3 is} stably achieved.

For each whipped dough recipe, a consistently constant bulk density corresponds. Improving the quality and stable structure of dough and bakery products is achieved through the use of objective instruments to determine the readiness of the kneaded dough with a viscous-plastic structure for the further process of churning the dough, as well as the readiness of the churned dough for the molding process, regardless of the properties of the raw materials. Objective tools for analyzing the processes of dough structure formation are: optimal specific work, kneading temperature and dough churning, as well as video monitoring of the structure formation process during dough kneading and churning.

An increase in the quality and stability of the structure of the dough and bakery products is also achieved by stabilizing the structure of the whipped dough before molding by releasing the excess gas pressure in the chamber and subsequent molding with a small amount of excess gas pressure in the chamber in the form of a tow of whipped dough and dividing it into equal fractions of a given weight string cutting combined with tensometric scales, on which a baking form is installed with a knocked down dough piece of a given weight.

At the same time, the foam-like structure of the whipped dough piece of a given weight in a baking mold is not destroyed.

An increase in the quality and stability of the structure of the dough and bakery products is also achieved through intensive mixing of the recipe ingredients and achieving maximum uniformity of their distribution in the dough volume until the dough structure is formed and then the simultaneous structure formation of the dough throughout the entire volume without the formation of a local dough structure. When the dough is churned under excess gas pressure, a homogeneous fine-porous foam-like structure of the churned dough is formed with stabilized foam films of gas bubbles with surfactants, i.e., water-soluble proteins-albumin flour, and then gluten proteins. Thus, the gas bubbles of the whipped dough acquire a stabilized structure due to the acquisition of elastic-elastic properties by the foam films of gas bubbles.

In addition, the whipped dough after the pressure release significantly increases the volume of the dough and the elastic-elastic properties of their foam films of gas bubbles. Therefore, when forming a rope of whipped dough with subsequent string cutting into dough pieces of a given weight, the foam structure of the dough is preserved without destruction.

And during baking, in the process of heating, the foam films of gas bubbles are stabilized due to the denaturation of the proteins of the foam films, and then due to the gelatinization of starch in the interbubble space.

The result is a high quality of bakery products and a stabilized fine-pored crumb structure of bakery products with a significant specific volume.

Thus, when the foam structure of the whipped dough is stabilized, the quality of dough with a minimum bulk density of 0.2-0.7 g / cm ³ and bakery products with a maximum specific volume of 180-310 cm ³ / g increases.

Simplification and increasing the accuracy of the process of dividing the whipped dough into portions of a given weight is achieved through the use of intensive kneading and whipping processes at an excess gas pressure of a given value and the use of a whisk mixer installed horizontally in the working chamber with a rotation frequency of 800-1000 rpm as a result of the formation a homogeneous foam structure throughout the entire dough without a local structure, which makes the whipped dough resistant to destruction. Then, after the excess gas pressure in the chamber is released, the dough structure is additionally stabilized, which does not lead to destruction of the structure during molding and dividing into portions of a given weight by string cutting.

As mentioned above, foam films of gas bubbles acquire stable elastic-elastic properties, due to which a stable structure of molded dough pieces in baking molds is maintained.

With the continuous forming of the whipped dough from the working chamber in the form of a bundle of a certain configuration, the string cutting with a pneumatic cylinder is divided into dough pieces according to a given weight.

Pieces of dough of a given weight fall into baking molds, which are mounted on a strain-gauge balance. If the weight of the dough pieces deviates beyond the permissible limits, the weight of the dough is regulated by the speed of the string cutting. At the end of the forming process, the working chamber discharge valve is closed. Thus, as a dough divider, a string cutting with a pneumatic cylinder of a simple design, in which the cutting speed is easily adjusted, and, accordingly, the weight of the dough piece of any mass, works.

Improving the quality and stabilization of the structure of dough, bakery products and expanding their range is achieved through the use of carbon dioxide CO ₂ , nitrogen N ₂ , oxygen O ₂ as a gas when churning dough, in addition to clean air, and when preparing dough - as fortifiers: organic acids, fruit, vegetable, berry, dairy and oil semi-finished products, sugars and sweeteners, edible oils and fats, extracts of cereals and medicinal plants, dry gluten, dietary fiber, vitamins, macro and microelements.

When using inert gases CO ₂ and N _2, oxidative processes in dough and bakery products are slowed down in the presence of oilseeds, and oxygen, due to oxidative processes, increases the whiteness of the crumb of bakery products.

In addition, the gases CO ₂ , O ₂ , N ₂ accelerate the foaming processes and significantly reduce the bulk mass of the whipped dough and increase the specific volume of bakery products.

Improving the quality and expanding the range of whipped bakery products is achieved through the use of freshly ground or ripened flour of different types and varieties, or dispersed germinated cereal grains, or legumes with a dispersion of solid particles of 10-150 microns., As well as through fortifiers: food organic acids, fruit, vegetable, berry, dairy and oil semi-finished products, sugars and sweeteners, edible oils and fats, extracts of cereals and medicinal plants, dry gluten, dietary fiber, vitamins, macro and microelements.

The method is illustrated by the following examples:

Example 1 (fig. 1)

The recipe components (a) of the dough are dosed manually and hermetically closed chamber 2 with a horizontal whisk mixer 3 and with an electric motor 1 and intensively stirred at a stirrer speed of 14 s ^-1 at atmospheric pressure until a viscous-plastic homogeneous dough structure is formed for 90-105 s ... The objective readiness of the dough is recorded by the optimal value of the specific work of the kneading 11 (A ₃ , W * h / kg) and the maximum temperature 8 (Tg, ºС) of flour protein swelling, as well as by video surveillance 9 of the dough structuring process.

Then an excess (b) gas pressure of 0.5 MPa is fed into the working chamber, and the intensive mixing process is continued for 15-30 seconds until a homogeneous foam-like structure of whipped dough with a bulk density of 0.6 g / cm ^{3 is formed} .

The objective readiness of the whipped dough for molding is determined by the optimal value of the specific work of whipping dough 11 (A _sat , W * h / kg), and the temperature (T _sat , ºС) of the whipped dough, as well as by video surveillance 9 of structuring the whipped dough.

Then the excess gas pressure is released, the valve (a1) is opened and the whipped dough is unloaded in the form of a bundle under a slight excess gas pressure in the working chamber. In this case, the structure of the whipped dough is stabilized and formed without destroying the foamy structure.

The division of the whipped dough rope is carried out by string cutting with a pneumatic cylinder 10 by adjusting the speed of the string cutting. The dough piece 4 with a predetermined weight is fed into the baking mold 6, installed on a strain gauge balance 5. According to the readings of the dough piece weight on a strain gauge balance, the speed of the string cutting is adjusted to achieve a constant specified weight of the dough pieces.

Baking forms are continuously fed under molding, and then they are sent with dough pieces for baking at 260 ºС by microwave-IR-radiation-convective heating for 10 minutes. The hot baked goods are then cooled for 3 minutes in a vacuum cooling chamber to room temperature. The weight of the whipped dough simultaneously prepared in the working chamber is 10 kg. The speed of dividing a rope of whipped dough with a weight of 0.5 kg by string cutting is 2 seconds. Thus, the technological process is simplified and the unit productivity of the installation is increased by 4 times when molding a dough piece with a weight of 0.5 kg. The duration of the whipped dough preparation is reduced by 3 times for 10 kg of whipped dough compared to the prototype - 2.5 kg.

As a result, the quality increases and the structure of whipped dough with 0.6 g / cm ³ and bakery products with a specific bread volume of 200 cm ³ / g is stabilized.

Example 2 (figure 1).

The recipe components (a) of the dough are dosed and hermetically closed the working chamber 2 with a horizontal whisk mixer 3 and with an electric motor 1 and intensively stirred at a stirrer rotation frequency of 16.6 s ^-1 at atmospheric pressure until a viscous-plastic homogeneous dough structure is formed for up to 90 -105 sec. The objective readiness of the dough is recorded by the optimal value of the specific work of the dough kneading 11 (А ₃ , W * h / kg) and the maximum temperature 8 ( _Тz , ºС) of flour protein swelling, as well as by video surveillance in the process of dough structuring. Then, a predetermined amount of excess gas pressure (b) of 0.6 MPa is collected in the working chamber and the intensive mixing process is continued for 15-30 seconds until a homogeneous foam-like structure of the whipped dough with a bulk density of 0.2 g / cm ^{3 is formed} . The objective readiness of the churned dough for molding is determined by the optimal value of the specific work of churning 11 (A _sat , W * h / kg), and the temperature 8 (T _sat , ºС) of the churned dough, as well as by video surveillance of the process of structure formation of the churned dough. Then the excess gas pressure (b1) is released, the unloading valve (a1) is opened, and the whipped dough is unloaded in the form of a bundle under a slight excess gas pressure in the working chamber, while the structure of the whipped dough is stabilized and formed without destroying the foamy structure.

The division of the whipped dough rope is carried out by string cutting with a pneumatic cylinder 10 by adjusting the speed of the string cutting. The dough piece 4 with a predetermined weight falls into a baking mold 6 installed on a strain gauge balance 5. According to the weight of the dough pieces on a tensometric balance, the speed of the string cutting is adjusted to achieve a constant preset weight of the dough pieces.

Baking molds are continuously fed under molding and then sent with dough pieces for baking at a temperature of 260 ° C convective heating for 20 minutes. The hot baked goods are then sent to be cooled to room temperature for 3 minutes in a vacuum cooling chamber. The weight of the whipped dough simultaneously prepared in the working chamber is 20 kg. The speed of dividing a string of whipped dough weighing 0.5 kg by string cutting is 2 seconds. Thus, the technological process is simplified and the unit productivity of the installation is increased by 8 times with the molded mass of the dough piece of 0.5 kg. The duration of the whipped dough preparation is reduced by 3 times for 20 kg of whipped dough compared to the prototype - 2.5 kg.

Example 3 (figure 2).

The recipe components (a) of the dough are dosed and hermetically closed the working chamber 2 with a horizontal whisk mixer 3 and with an electric motor 1 and intensively stirred at a stirrer speed of 16.6 sec ^-1 at atmospheric pressure until a viscous-plastic homogeneous structure of the dough is formed within 90- 105 sec. The objective readiness of the dough for unloading from the working chamber is determined by the optimal value of the specific work of the kneading 11 (A ₃ , W * h / kg) and the maximum swelling temperature of flour proteins 8 (T _z , ºС), as well as by video surveillance 9 of the process of dough structure formation. Then, a predetermined amount of overpressure (b) of gas is collected in the working chamber 2 for unloading the dough from the whisker (I) into the working chamber 2 of the whisker (II) and the chamber is hermetically closed, a predetermined value of the overpressure (b) of the gas is collected 0.6 MPa and vigorously stirred for 15-30 seconds until a homogeneous foamy dough structure with a bulk density of 0.2 g / cm ^{3 is formed} . The objective readiness of the whipped dough for molding is determined by the optimal value of the specific work of whipping (A _sat , W * h / kg) 11 and temperature 8 (T _sat , ºС), as well as by video surveillance 9 of the process of structure formation of the whipped dough. Then the excess gas pressure (b ₁ ) is released, the tap (a ₂ ) is opened and the whipped dough is unloaded in the form of a bundle under a slight excess gas pressure in the working chamber 2 of the whipping installation (II), while the structure of the whipped dough is stabilized and formed without destroying the foamy structure.

The division of the rope, whipped dough is carried out by string cutting 10 with a pneumatic cylinder by adjusting the speed of the string cutting.

The dough piece 4 with a given weight falls into a baking mold (6) installed on a strain gauge balance (5). According to the indications of the weight of the dough pieces on a strain gauge balance, the speed of the wire cutting is adjusted to achieve a constant weight of the dough pieces. Baking forms 6 are continuously fed under molding, then they are sent with dough pieces for baking at a temperature of 260 ºС by convection heating for 20 minutes. The hot baked goods are then cooled for 3 minutes to room temperature in a vacuum cooling chamber. At the same time, whipped dough is prepared in a working chamber with a total weight of 20 kg. The speed of dividing the whipped dough rope weighing 0.5 kg is 1 sec. Thus, the technological process is simplified and the unit productivity of the installation is increased by a factor of 12 with the molded mass of the dough piece of 0.5 kg. The duration of the preparation of the whipped dough in the working chamber II is reduced to 15 - 30 seconds. instead of 120 sec. Consequently, when using two working chambers I and II, it is possible to provide a continuous process for the preparation of the whipped dough and its shaping.

Example 4.

Whipped dough is prepared for 120 seconds and 20 kg of whipped dough is formed within 120 seconds. Baking molds with dough pieces weighing 0.5 kg are served for baking at a temperature of 196 ºС in an oven with convection heating for 30 minutes. The hot baked goods are then cooled for 2 minutes to room temperature in a vacuum cooling chamber. The duration of the full cycle of production of whipped bakery products is 36 minutes.

Example 5.

Whipped dough with a weight of 20 kg is prepared for 120 seconds and formed with a weight of 0.5 kg of dough pieces for 120 seconds, then bakery molds with dough pieces with a weight of 0.5 kg are served on baked goods at a temperature of 260 ºС in an oven with IR radiation-convective heating for 15 min. Then the hot bakery products are cooled for 3 minutes in a vacuum cooling chamber. The duration of the full production cycle of whipped bakery products is 22 minutes.

Example 6.

Whipped dough with a weight of 20 kg is cooked for 120 seconds and formed within 120 seconds. Then bakery molds with dough pieces weighing 0.5 kg are served on baked goods at a temperature of 260 ºС in an oven with microwave radiation-convective heating for 10 minutes. Then the hot bakery products are cooled for 3 minutes in a vacuum cooling chamber. The duration of the full production cycle of whipped products is 17 minutes.

Example 7.

Whipped dough with a weight of 20 kg is cooked for 120 seconds and formed within 120 seconds. Then bakery molds with dough pieces weighing 0.5 kg are served on baked goods at a temperature of 260 ºС in an oven with microwave-IR radiation-convective heating for 5 minutes. Then the hot bakery products are cooled for 1 min in a vacuum cooling chamber. The duration of the full production cycle of whipped bakery products is 10 minutes.

Thus, the entire production cycle of whipped bakery products according to pp. 1-7 is 10-36 minutes. Therefore, it indicates a high productivity of the production of whipped bakery products with a relatively low production cycle time.

Example 8.

The process of churning the dough is carried out at a mixer rotation frequency of 16.6 s ^-1 and an excess pressure of carbon dioxide (CO ₂ ) of 0.5 MPa is supplied to the working chamber for 10-15 seconds until a homogeneous foamy fine-pored structure of the churned dough with a bulk density of 0 is formed, 2-0.3 g / cm ³ . At the same time, an acceleration of the process of foaming and foam resistance of the whipped dough was noted, the specific volume of bakery products was 180-210 cm ³ / g.

Example 9.

The process of churning the dough is carried out at a mixer rotation frequency of 16.6 s ^-1 and an excess pressure of nitrogen gas (N ₂ ) of 0.5 MPa is fed into the working chamber for 10-15 sec until a homogeneous foamy fine-pored structure of the churned dough with a bulk density of 0 is formed, 2-0.3 g / cm ³ . At the same time, an acceleration of the process of foaming and foam resistance of the whipped dough was noted, the specific volume of bakery products was 210-280 cm ³ / g.

Example 10.

The process of churning the dough is carried out at a mixer rotation frequency of 16.6 s ^-1 and an excess pressure of oxygen (O ₂ ) of 0.5 MPa is fed into the working chamber for 5-10 sec until a homogeneous foamy fine-pored structure of the churned dough with a bulk density of 0.2 is formed. -0.3 g / cm ³ . At the same time, a significant acceleration of the process of foaming and foam resistance of the whipped dough was noted, the specific volume of bakery products was 280-310 cm ³ / g, and the whiteness of the crumb of bread also increased.

Example 11 (Fig. 1).

Recipe components (a), including food organic acids as fortifiers, fruit and vegetable and berry semi-finished products, sugars and sweeteners, extracts of cereal crops and medicinal plants, semi-finished oil crops are dosed and hermetically closed the working chamber 2 with a horizontal whisk mixer 3 and with electric motor 1 and vigorously stirred at a stirrer speed of 14 s ^-1 at atmospheric pressure.

Then an excess gas pressure of 0.5 MPa is fed into the working chamber and the intensive mixing process is continued at a mixer rotation frequency of 16.6 s ^-1 for 15-30 seconds until a homogeneous foam-like structure of whipped dough with a bulk density of 0.5 g / cm ^{3 is formed} ... Dough pieces with a weight of 0.5 kg are formed into bakery molds and baked in an oven at a temperature of 260 ºС with microwave-IR radiation-convective heating for 10 minutes. Hot baked goods were cooled for 3 minutes. in a vacuum cooling chamber to room temperature.

As a result, the assortment is expanded, the quality is increased by increasing the nutritional value of bakery products due to the enrichment of functional macro and micro nutrients contained in natural fortifiers.

Example 12 (figure 1).

Prescription components (a) of the dough, including food organic acids, semi-finished dairy products, sweeteners, edible oils and fats, dry gluten, dietary fiber, vitamins, macro and microelements as a fortifier, dose and hermetically close chamber 2 with a horizontal mixer 3 and an electric motor 1 and vigorously stirred at a stirrer speed of 16.6 s ^-1 until a viscous-plastic homogeneous structure of the dough is formed for 90-105 seconds. Then, a predetermined amount of excess gas pressure (b) of 0.6 MPa is collected in the working chamber and the intensive mixing process is continued for 15-30 seconds until a homogeneous foam-like structure of the whipped dough with a bulk density of 0.2 g / cm ^{3 is formed} . Dough pieces with a weight of 0.5 kg are formed into baking molds and fed to baked goods at a temperature of 260 ºС in a convective heating oven for 30 minutes. The hot baked goods are then cooled for 3 minutes in a vacuum cooling unit.

As a result, the assortment expands, the quality increases due to an increase in the nutritional value of baked goods due to the enrichment with functional macro and micro nutrients.

Example 13 (figure 2).

The recipe components (a) of the dough, including freshly ground or ripened flour of different types and varieties with a dispersion of solid flour particles of 10-150 microns, are dosed and hermetically closed chamber 2 with a horizontal whisk mixer 3 and with an electric motor 1 and intensively stirred at a stirrer speed 16 , 6 sec ^-1 at atmospheric pressure until the formation of a viscous-plastic homogeneous structure of the dough for 90-105 sec. Then, a predetermined amount of overpressure (b) of gas is collected in the working chamber 2 for unloading the dough from the whisker (I) into the working chamber 2 of the whisker (II) and the chamber is hermetically closed, a predetermined value of the overpressure (b) of the gas is collected 0.6 MPa and vigorously stirred at a mixer rotation frequency of 16.6 sec ^-1 for 15-30 sec until a homogeneous foamy dough structure with a bulk density of 0.2 g / cm ^{3 is formed} . Dough pieces with a weight of 0.5 kg are formed into baking molds and served on baked goods with a temperature of 260 ºС in an oven with convection heating for 30 minutes. The hot baked goods are then cooled for 3 minutes in a vacuum cooling unit.

Due to the use of freshly ground flour without ripening for 7 days, it allows organizing the production of high quality whipped bakery products.

Example 14

The recipe components (a) of the dough, including dispersed grains of cereals or legumes with a dispersion of solid particles of 10-150 microns are dosed and hermetically closed chamber 2 with a horizontal whisk mixer 3 and with an electric motor 1 and intensively stirred at a stirrer speed of 16.6 sec ^-1 at atmospheric pressure until the formation of a viscous-plastic homogeneous structure of the dough for 90-105 sec. Then, a predetermined amount of overpressure (b) of gas is collected in the working chamber 2 for unloading the dough from the whisker (I) into the working chamber 2 of the whisker (II) and the chamber is hermetically closed, a predetermined value of the overpressure (b) of the gas is collected 0.6 MPa and vigorously stirred at a mixer rotation frequency of 16.6 sec ^-1 for 15-30 sec until a homogeneous foamy dough structure with a bulk density of 0.2 g / cm ^{3 is formed} . Dough pieces with a weight of 0.5 kg are formed into baking molds and served on baked goods with a temperature of 260 ºС in an oven with convection heating for 30 minutes. The hot baked goods are then cooled for 3 minutes in a vacuum cooling unit.

The assortment is expanding, the quality of bakery products is increasing by increasing the nutritional and biological value.

In both of the proposed options, the implementation of the method for simplifying the technological process and increasing the unit productivity of the installation and production, improving the quality and stability of the structure of whipped dough, bakery products and expanding their range, simplifying and increasing the accuracy of the process of dividing into specified portions of whipped dough is achieved by using a horizontal whisk mixer in working chamber; the intensity of mixing the recipe components and achieving 100% homogeneity before the beginning of structure formation and churning under excess gas pressure; objective instruments for determining the readiness of the kneaded dough for churning; as well as the readiness of the whipped dough for molding; stabilizing the structure of the whipped dough before molding; various prescription components, including as fortifiers; various gases for churning (clean air, carbon dioxide CO ₂ , nitrogen N ₂ , oxygen O ₂ ); various types of energy supply for baking (convective, IR-radiation-convective, microwave-radiation-convective, microwave-IR-radiation-convective), string cutting for precise division by weight of dough pieces during molding. The first option (figure 1) of obtaining a whipped dough can be recommended for a batch production method, the second option (figure 2) can be recommended for a continuous method of producing a whipped dough.

Legend:

1-electric motor;

2-working chamber;

3-whisk stirrer;

4-dough piece;

5-strain gauge balance;

6-bakery form;

7-conveyor;

8-temperature sensor;

9-camcorder;

10-string cutting with pneumatic cylinder;

a-supply of recipe components;

a ₁ - dough unloading;

b-supply of overpressure;

b _{1 -} discharge of excess gas pressure;

B-video camera monitor;

VK-top tap;

NK-bottom tap;

I-first installation figure 2;

II-second installation of Fig. 2.

Claims (2)

1. A method of producing whipped bakery products, including dosing of recipe components, kneading dough, whipping, molding, baking dough pieces and cooling bakery products, characterized in that the processes of kneading and whipping dough are carried out simultaneously in one chamber or sequentially in different chambers, the kneading process carried out until a homogeneous viscous-plastic structure is obtained with a corolla-type device installed horizontally or vertically in the working chamber under atmospheric or excess gas pressure (clean air, oxygen O ₂ , nitrogen N ₂ , carbon dioxide CO ₂ ), knock down the dough until a bulk density of 0 , 2-0.7 g / cm ³ , freshly ground or ripe flour or dispersed germinated grains of cereals or legumes with a dispersion of solid particles of 10-150 microns, food organic acids, fruit, vegetable, berry, dairy and oilseeds are used as recipe components semi-finished products, sugars and sweeteners, edible oils and ore, extracts of cereals and medicinal plants, dry gluten, dietary fiber, vitamins, macro- and microelements, and the dough pieces are formed after the process of churning the dough is completed by dividing the churned dough pieces with string cutting or with a knife without destroying their structure, baking the dough pieces is carried out at a temperature of 196-260 ºС using either convective heating, or IR-radiation-convective heating, microwave-radiation-convective heating, or microwave-IR radiation-convective heating with subsequent cooling of hot bakery products for 1-3 minutes, with the full cycle of obtaining whipped bakery products is carried out within 10-36 minutes. 2. A method of producing whipped bakery products according to claim 1, characterized in that the dough kneading process is carried out in a separate chamber, and then the dough is pumped into another chamber for whipping.

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