WO2002039837A1

WO2002039837A1 - Method and device for using freely bakeable dough to make a shell-shaped foodstuff and foodstuff produced therewith

Info

Publication number: WO2002039837A1
Application number: PCT/EP2001/012916
Authority: WO
Inventors: Peter MÖHLENBROCK; Michael Jansen; Bernard Sedgwick
Original assignee: Mars Incorporated
Priority date: 2000-11-14
Filing date: 2001-11-08
Publication date: 2002-05-23
Also published as: DE10056348C2; DE10056348A1; AU2002221823A1

Abstract

The invention relates to a method for producing a shell-shaped foodstuff out freely bakeable dough as described in the following steps: a) introducing a defined quantity of freely bakeable dough into or onto a first or a second mould, b) bringing the first mould into contact with the second mould, c) pressing the first and second moulds together in such a way that the amount of dough formed has a shape which is predetermined by the surfaces of the said moulds, and by their positions relative to each other, is of a uniform nature. The invention is characterised by the following steps: d) preparing a defined space between the two moulds in order that the dough, when introduced into the first mould, will be pushed onto the second mould; e) separating the first mould from the second mould in such a way that the moulded dough sticks to the second mould, and f) baking the moulded dough thus maintained in the second mould. The invention also relates to a device with which the method can be carried out, as well as a food product produced according to said inventive method.

Description

Method and device for producing a bowl-shaped food product from a dough to be baked freely, and food product produced thereafter

The invention relates to a method for producing a bowl-shaped food product from a dough to be baked freely, in which, first of all, in the case of biscuit, pretzel, cracker or whole grain dough, the method steps of introducing a defined amount of dough into or onto a first or a first second shape, the merging of a second shape with the first shape and the pressing of the second shape and the first shape relative to one another such that the amount of dough is given a natural shape predetermined by the contours of the second shape and first shape and their position relative to one another, which then is fixed in the baking process.

"Shell-shaped" is intended to mean that filling materials can be introduced into the finished food product and held therein. WO 98/41105 may be mentioned in this connection, in which two such bowl-shaped food products are combined to form a bakery product or confectionery product. However, the term "bowl-shaped" is not limited to these configurations as hemispheres or hemispherical structures, as will be explained in more detail later. Various basic forms are also described in connection with confectionery products in EP 0 054229 B1.

The first and the second form are, for example, an upper form and a lower form, as are used in automated baking processes.

In the production of waffle half-shells, the dough is baked with the lower and upper molds closed, with continuous half-shells, usually arranged in a regular pattern, being formed via dough webs. These dough webs must be removed before further processing, for example by the procedure according to EP 0 054 229 B1, which means waste and dust nuisance and last but not least an additional process step. In order to increase the sensory experience when eating filled food products, it is desirable to be able to use other types of dough. Biscuit, pretzel, cracker and wholemeal doughs, however, generally have to be baked freely so that their taste characteristics can fully develop.

It is therefore the object of the invention to design the method mentioned at the beginning in such a way that it enables the production of bowl-shaped food products from a dough which is free to be baked. This object is achieved by a method according to claim 1 and an apparatus according to claim 4. A product produced by the method is the subject of claim 9. Advantageous refinements are the subject of the respective back-related claims.

According to the invention, in a method of the type mentioned at the outset, it is provided that a defined area of the first form is disengaged from the second form, so that the shaped amount of dough is forced onto the second form, and then the second form is separated from the first form, whereby the molded dough adheres to the second mold, and the molded dough on the second mold is baked. The invention takes advantage of the fact that the adhesion ratios for the dough can be adjusted when the first mold is divided, and in such a ratio that the adherence shifts in favor of the second mold. The dough therefore only has to detach from the first mold from a relatively small area and only in a second step from a second surface which is small relative to the mold surface of the second mold.

According to the invention, the first form is one which is flexible in its function in that it changes its effective surface during the course of the process. The second form, however, remains rigid throughout the process.

The ratio of the molding area of the defined area to be disengaged in the first mold to the molding area of the second rigid mold is approximately 60 to 90%, preferably approximately 70%, the ratio of the molding area of the defined part to be disengaged to the molding area of the remaining part of the first flexible mold is about 80 to 95%, preferably about 90%. It can advantageously be provided that the second mold is rotated before baking in such a way that the shaped amount of dough rests on the surface of the second mold under the influence of gravity.

In principle, the method according to the invention is not restricted to any sizes in the bowl-shaped food products. If confectionery-sized food products are to be produced, a large number of first forms and a large number of associated second forms become a "large first form" or. combine "large second form". In contrast to the prior art, however, a coherent dough surface is never produced over its entire surface; rather, as will be explained later, a dough piece is inserted into each individual first mold or a dough piece is placed on every second mold.

In the device according to the invention, the inventive idea is realized in that the first mold is provided with a releaser which comprises part of the mold surface of the first mold and can be moved against the second mold independently of the first mold.

The ratio of the mold surface of the releaser to the mold surface of the remaining first mold is furthermore advantageously greater than 1.

In general, one mold plate will be provided with a multiplicity of first molds, another holding plate with a multiplicity of second molds. The advantage of the invention is that, for example, a defined amount of dough is introduced into each first mold, which is further shaped and baked without removing any excess.

A product produced by the method according to the invention can be produced from biscuit dough, pretzel dough, cracker dough, whole grain dough or the like. There are hardly any limits to the shape of the shells, but rounding is always necessary and sharp edges should be avoided. The first form and the second form do not necessarily have to have corresponding mold surfaces, within baking technology limits, for example, different wall thicknesses, different inside and outside forms, etc. can also be produced for the nalir agent product. Another advantage of the invention is that the food product is also provided with temperature-sensitive fillings can, since the product is already baked when the filling step takes place. Two bowls can also be put together to form a closed product, for example a ball.

The invention is suitable for endless operation, since a multiplicity of second forms remove the dough from first forms according to the present invention and transport them further in a continuous product line, they only interacting with one fixed set of first forms during the forming process. Such an automated baking line is known per se and can also be used for the first time for processing the dough mentioned.

The invention will be explained in more detail below with reference to the accompanying drawing. It shows:

1 shows a partial section through a device for producing a bowl-shaped

Food product made from a free-to-bake dough according to the invention;

Figure 2 is a schematic representation of the procedure.

In the device according to the invention shown in FIG. 1, a plurality of releasers 14 protrude from a base plate 10. Each releaser 14 opens into an opening 26 in a mold plate 18 lying on a support plate 12. The support plate 12 and mold plates 18 can also be in one piece. The carrier plate 12 is preloaded relative to the base plate 10 by generally a plurality of springs 20, only one of which is shown here. The second molds 32 are fixed on a carrier plate 30, preferably fixed interchangeably, each second mold 32 being fastened, for example, by a screw, not shown in the drawing, which is guided through the carrier plate 30 into the respective second mold. Every second shape 32 is hemispherical and has an extension 34 with which it is let into a respective recess 36 of the carrier plate 30. The carrier plate 30 is placed here on a base 40 which is firmly connected to the base plate 10, for example screwed. A frame 22, which is also attached to the base plate 10 and runs around the circumference, forms the guide for the carrier plate 30 and for the carrier plate 12. The exact The engagement of the carrier plate 30 is additionally ensured in that the base 40 is provided with an end plate 42 around which an annular recess 24 provided in the carrier plate 12 can grip.

FIG. 1 shows the situation in the device according to the invention before the separating step, in which the carrier plate 30 together with the dough pieces 50 located on the second molds 32 are lifted off the rest of the device and fed to the baking step.

Not shown in the drawing is a tensioning mechanism which ensures that the carrier plate 12 with the mold plate 18 is pressed against the action of the springs 20 on the base plate 10. The operation and mode of operation of this tensioning mechanism is explained in more detail in connection with FIG. 2.

FIG. 2 shows with partial images a) to g) the procedure for producing a food product from dough to be baked freely.

Figure 2a) shows a highly schematic arrangement of the base plate 10, support plate 12 and mold plate 18, the relaxed springs 20 lifting the support plate 12 with the mold plate 18 so far that the mold surfaces 16 together with the exposed mold surfaces of the releasers 14 first forms. The ring recess 24 in the carrier plate 12 now engages around the end plate 42 of the base 40, between the base plate 10 and the arrangement of carrier plate 12 and mold plate 18 there is a gap. A so-called pick-and-place unit 100, shown only very schematically in the drawing, has placed a piece of dough 50 in each first form.

Figure 2b) shows the approach of the carrier plate 30 with the second molds 32 for closing the device.

Figure 2c) shows the molding process in which the carrier plate 30 is lowered so far that it rests on the bases 40. The dough pieces 50 are deformed and exactly fill the cavity formed between the respective second mold 32 and the first mold. 2d) shows how the arrangement of the carrier plate 12 and the mold plate 18 is pressed onto the base plate 10. This is achieved by a tensioning device, not shown. The springs 20 are compressed. The mold surfaces 16 are thus withdrawn, so that the dough pieces 50 are still between the mold surfaces of the releasers 14 and the mold surfaces of the second molds 32. Between these, the area ratios and thus the adhesive forces are so favorable that, as shown in FIG. 2e), it is possible to lift off the carrier plate 30 together with the dough pieces 50 without substantial dough remnants remaining in the first forms.

The illustration in FIG. 2d) corresponds to the partial section of FIG. 1.

As shown in FIG. 2f), the carrier plate 30 with the dough pieces 50 can now be guided to the baking process. It can be advantageous to rotate the carrier plate by 180 °, with the result, as shown in FIG. 2g), that the dough pieces 50 rest on the second molds 32 and can be baked in this way.

The device according to the invention is suitable for setting up a production line, wherein a plurality of carrier plates 30 with second molds 32 are used in combination with an arrangement with the first molds which contains the entire mechanical, pneumatic or electrical system. After the carrier plate 30 with the second molds and dough pieces has been removed, the tensioning mechanism is released, the springs 20 relax, so that the state of the device shown in FIG. 2a) is again reached, a new batch of dough pieces to be baked then being inserted can. It is conceivable to arrange the carrier plates carrying the second forms in the manner of an endless belt.

The materials used to construct the device must be food-safe and to a certain extent resistant to abrasion, since the sugar often contained in the dough is mechanically aggressive.

The features of the invention disclosed in the above description, in the drawing and in the claims can be essential for realizing the invention both individually and in any combination.

Claims

claims

1. A method for producing a bowl-shaped food product from a free-to-bake dough, comprising the following steps:

a) Introducing a defined amount of dough into or onto a first mold or into or onto a second mold b) Bringing together the first mold with a second mold c) Pressing the second mold and the first mold relative to one another such that the amount of dough is reduced by the mold Surfaces of the second form and the first form and their position relative to one another are given a specific shape, characterized by d) disengaging a defined area of the divided first form against the second form, so that the shaped amount of dough is forced to the second form, e) separating the second mold from the first mold, the molded amount of dough adhering to the second mold; and f) baking the amount of molded dough on the second mold.

2. The method according to claim 1, characterized in that the second mold is rotated before baking so that the shaped amount of dough rests on the mold surface of the second mold under the influence of gravity.

3. The method of claim 1 or 2, wherein an endless arrangement of second shapes cooperates with a fixed set of first shapes.

4. Apparatus for producing a bowl-shaped food product from a dough to be baked freely, with a second mold and a first mold, each having mold surfaces which essentially define the shape of the food product, characterized in that the first mold has a release mechanism ( 14), the mold surface of which is a region of the mold surface of the first Form comprises, wherein the mold surface of the disengagement (14) and the remaining mold surface (16) of the first mold are displaceable relative to each other.

5. The device according to claim 4, characterized in that the ratio of the mold surface of the release (14) to the remaining mold surface (16) of the first mold is greater than one.

6. The device according to claim 4 or 5, characterized in that a plurality of second shapes (32) on a support plate (30) is arranged exchangeably.

7. Device according to one of claims 4 to 6, characterized in that a plurality of releasers (14) is fixedly arranged on a base plate (10) and that a plurality of openings (26) in a plate arrangement (12, 18) is provided , wherein a releaser (14) projects into an opening (26).

8. A food product made by a process according to any one of claims 1 to 3, of cookie dough, pretzel dough, or cracker dough. Wholemeal.

9. Food product according to claim 8, characterized in that it is provided with a filling.