WO1995031905A1

WO1995031905A1 - Fillable muffin and process for manufacture

Info

Publication number: WO1995031905A1
Application number: PCT/AU1995/000299
Authority: WO
Inventors: Nelson Beatty
Original assignee: Quality Bakers Australia Limited
Priority date: 1994-05-23
Filing date: 1995-05-23
Publication date: 1995-11-30

Abstract

An improved muffin product, process for forming the product and apparatus for manufacture are disclosed. The product (40) incorporates a depression (43) in its upper surface to allow a filling to be inserted. The process uses a stamping apparatus (35) to form depressions in the surface, after the lidding process is completed.

Description

FILLABLE MUFFIN AND PROCESS FOR MANUFACTURE Technical Field

The present invention relates to english muffin type products, and to a process for manufacture of such products. Background Art

In recent years various forms of hand-held products have been provided, which can incorporate a savoury or sweet filling, such as mini pizzas, and the like. English muffins conventionally require splitting, and the application of a filling to the interior. US patent No. 4653392 to Gerber discloses a baking pan assembly for forming a cavity in the base of a conventional muffin, using a shaped insert. Other disclosures show the use of a mould to shape a baked product, for example US patent No. 3518091 to Turner.

It is an object of the present invention to provide a readily tillable muffin product, and to provide a process for the manufacture of such products. Summary of invention

According to one aspect, the present invention provides an improved muffin, characterised in that a depression is formed in an upper surface thereof which is adapted to contain a filling. Preferably the muffin is not pre-split.

Preferably the depression is substantially disc shaped and substantially concentric with the periphery of the muffin.

According to another aspect the present invention provides a process for forming a shaped depression in a surface of an english muffin product, said process including baking said product in a baking means, including lidding said product at an intermediate point of baking to form a flat upper surface, characterised in that a stamping process forming a shaped depression is applied between the lidding process and the end of said baking step.

Preferably said baking process utilises a pan cavity associated with each muffin.

Preferably the stamping process continues for a predefined period of time. Preferably the stamping process incorporates a gradual removal of the stamping tool.

Preferably the product stamped substantially retains its shape after stamping. According to another aspect the present invention provides an apparatus for forming an english muffin product having a shaped depression in the surface thereof, said apparatus being used in conjunction with a baking means, said baking means having a pan cavity for each muffin product, and including a lidding process, said apparatus being adapted for use after the lidding process and comprising means for making a depression in the surface of said muffin products in said pan cavities, using stamping means travelling synchronously with each pan.

It has been determined that it is possible to bake a muffin product with a preferred cavity. It is noted that moulding per se will not produce a satisfactory muffin product.

It has further been discovered that stamping the dough in the pan distorts the dough so that an unsatisfactory irregular product tends to result and that stamping during the lidding process tends to similarly distort the muffin. Accordingly, the process described is the only approach found by the inventors which results in a satisfactory product. Description of Drawings

The invention will be described in more detail with reference to the accompanying figures, in which:

Figure 1 illustrates schematically the inventive stamping process; Figure 2 illustrates partly in section an apparatus for performing the shaping process according to the present invention;

Figures 3 and 4 illustrate in section, the stamping unit in disengaged and engaged positions respectively;

Figure 5 is an illustration of an inventive muffin product in plan view; Figure 6 is a sectional view of the muffin of Figure 5;

Figure 7 is a side view of the muffin of Figure 5; and

Figure 8 is a perspective view of the muffin of Figure 5. Description

The inventive process is an addition to a conventional english muffin manufacturing process. Conventional dough, temperatures and baking times are used, and these are well understood in the industry. English muffins are widely manufactured in Australia and throughout the world. The skilled worker in the art will be well aware of alternative processes and variations in manufacture. Typically, ingredients (in no particular order) will include: flour gluten yeast vinegar salt soya flour ground corn emulsifiers (472-e, 471, 481) animal or vegetable oils or fats food acid (262) preservatives (282, 200) enzymes (e.g. amylase) sugar water

As is well understood, muffin dough is generally prepared to a wet, sticky, pourable consistency, with considerably more water content than bread dough. A typical manufacturing process would include the following steps:

1. Ingredient weigh off

2. Mixing

3. transfer to scaling/dividing equipment

4. Dough poured into hopper; small dough pieces of specified weight dispensed

5. Proof

6. Bake in cups in gas travel oven or griddle (electric, oil or other) 7. Cooling after baking

8. scoring and forking

9. Packaging.

The present inventive process utilises additional means operating during the last part of the baking process, after lidding has been completed but still within the travel oven.

Referring to Figure 1, a partly baked product is within pan 10, which is part of a griddle plate generally welded or attached thereto. Stamping device 12 descends, forms baked product 11 into a depressed surface, and is removed. It is important that the movement is in synchronism with the pan, so that the product 11 is not deformed in undesired directions. It is highly desirable that the depression be relatively concentric with the product, so as to provide relatively even walls around the depression for filling.

Referring to Figure 2, pans 10 carrying partly baked product enter on the conveyor of the baking means which is a travel griddle 34 (not shown in detail) at end 32 and travel to end 33. Stamping apparatus 35 according to a preferred embodiment comprises a series of stamping units 30, conveyed in a loop, so as to engage pans 10 and more particularly the contents thereof. The stamping apparatus 35 travels by chain drive 31 or the like so as to have the same speed as travel griddle conveyor 34 when adjacent thereto. In other words, within the frame of reference of pans 10, the corresponding stamping unit 30 is laterally stationary, and the stamping unit 25 only moves vertically. The apparatus is so sized that the period for which the stamping unit 25 is engaged is sufficient to substantially permanently form a depression in the partly baked surface. After exiting travel griddle shortly after end 33, the product is further subjected to a baking process known as "browning" and shortly there after the products are cooled and packaged as for conventional muffins. Because of the nature of use of the novel product, scoring and forking is generally not required. It will be understood that the unit in use will have many, say 10 muffins in one line, and correspondingly 10 stamping units 25. Figures 3 and 4 illustrate an individual stamping unit 25. In the disengaged position of Figure 3, bias spring 21 extends engaging part 20 fully downwards, within sleeve 26, and lever 23 is maintained in a retracted position.

In Figure 4, as engaging part 20 engages a surface adjacent the pan (e.g. the travel griddle), it gradually extends lever 23, and stamping part 22 engages the surface of bakery article 11 (this engagement can be seen in Figure 1). Stamping part 22 rests partly on the pan surface, so as to ensure consistent depth of engagement. At release, near end 33 (see Figure 2) the bias spring 21 ensures gradual release, so that the surface of the muffins is not damaged. A preferred product is shown in Figures 5, 6, 7 and 8, where there is illustrated a muffin 40 having a base 41 and a circumferential side 42. Any other shape that is suitable for the baking process of an english muffin described above, could also be used.

By means of the inventive process described above, a cavity or depression 43 is made. In cross section, as illustrated in Figure 6, the circumferential wall 42 has angled sides 44, with the depth of the cavity 43 being as desired, but is depicted in Figure 6 as being approximately half the depth of the muffin 40. Where suitable for the baking process described above, other cavities of differing shapes, depths and location within the muffin can also be used.

It will be appreciated that variations and additions are possible within the spirit and scope of the invention.

Claims

CLAIM S

1. An improved english muffin product, characterised in that a depression is integrally formed in an upper surface thereof during a baking process, said depression being adapted to contain a filling.

2. A product according to claim 1 the depression is substantially disc shaped and substantially concentric with the periphery of the muffin.

3. A product according to claim 1 or claim 2, wherein said product is formed by a process including baking said product in a baking means, and including lidding said product at an intermediate point of baking to form a flat upper surface, characterised in that a stamping process forming a shaped depression is applied between the lidding process and the end of said baking step.

4. A product according to claim 3 , wherein said baking process utilises a pan cavity associated with each muffin.

5. A product according to any one of the preceding claims, wherein the stamping process continues for a predefined period of time.

6. A process for forming a shaped depression in an english muffin product, said process including baking said product in a baking means, and including lidding said product at an intermediate point of baking to form a flat upper surface, characterised in that a stamping process forming a shaped depression is applied between the lidding process and the end of said baking step.

7. A process according to claim 7 , wherein said baking process utilises a pan cavity associated with each muffin.

8. A process according to any one of claims 7 to 9, wherein the stamping process continues for a predefined period of time.

9. A process according to any one of claims 7 to 10, wherein after stamping the product retains substantially the shape of the depression.

10. Apparatus for forming an english muffin product having a shaped depression in the surface thereof, said apparatus being used in conjunction with a baking means, said baking means having a pan cavity for each muffin product, and including a lidding process, said apparatus being adapted for use after the lidding process and comprising means for making a depression in the surface of said muffin products in said pan cavities, using stamping means travelling synchronously with each pan.

11. Apparatus according to claim 12, wherein said stamping means include means for limiting the depth of penetration into said products.

12. Apparatus according to claim 12 or claim 13, wherein said stamping means are arranged to travel on a continuous loop.