WO2004080185A1 - Appareil de cuisson de biscuits amylaces souffles - Google Patents

Appareil de cuisson de biscuits amylaces souffles Download PDF

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Publication number
WO2004080185A1
WO2004080185A1 PCT/IB2004/000977 IB2004000977W WO2004080185A1 WO 2004080185 A1 WO2004080185 A1 WO 2004080185A1 IB 2004000977 W IB2004000977 W IB 2004000977W WO 2004080185 A1 WO2004080185 A1 WO 2004080185A1
Authority
WO
WIPO (PCT)
Prior art keywords
cake
cracker
starchy
servo motor
baking
Prior art date
Application number
PCT/IB2004/000977
Other languages
English (en)
Inventor
Luc Jacops
Marc Hendrickx
Walter Gers
Paul Otten
Original Assignee
Mars, Incorporated
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mars, Incorporated filed Critical Mars, Incorporated
Publication of WO2004080185A1 publication Critical patent/WO2004080185A1/fr

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Classifications

    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23LFOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10Cereal-derived products
    • A23L7/161Puffed cereals, e.g. popcorn or puffed rice
    • A23L7/174Preparation of puffed cereals from wholegrain or grain pieces without preparation of meal or dough
    • A23L7/178Preparation of puffed cereals from wholegrain or grain pieces without preparation of meal or dough by pressure release with or without heating
    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23LFOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10Cereal-derived products
    • A23L7/117Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
    • A23L7/126Snacks or the like obtained by binding, shaping or compacting together cereal grains or cereal pieces, e.g. cereal bars
    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23PSHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/10Moulding
    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23PSHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/30Puffing or expanding
    • A23P30/32Puffing or expanding by pressure release, e.g. explosion puffing; by vacuum treatment
    • A23P30/36Puffing or expanding by pressure release, e.g. explosion puffing; by vacuum treatment in discontinuously working apparatus

Definitions

  • the invention relates to an expanded cake baking apparatus and to a control system for controlling same. More particularly, the invention relates to an apparatus for production of expanded cakes or crackers from starchy granular materials such as rice, corn, wheat, barley, cereals, oats, soya bean and other cereal mixtures thereof, wherein the finalised product has a self-sustaining structure.
  • One known method of producing expanded (puffed) cakes or crackers from starchy granular material such as a rice involves introducing the starchy rice material into a baking mold comprising an upper and lower mold plate. A cavity is defined between the mold plates, which are disposed opposite to each other.
  • At least one of the upper or lower mold plates is capable of moving relative to the other plate so that the baking mold can operate between a charging stage in which material is introduced into to the baking cavity prior to the baking cycle; an operative stage in which the volume of the baking cavity is alterable during the baking cycle; and a discharging stage in which the cake or cracker is discharged from the chamber after the baking cycle.
  • the starchy granular material is subjected to a compressive step in which a compressive force is applied to said starchy granular material while being subjected to heat in a hermetic environment, and an expansion step in which the compressive force is released from said starchy granular material and Ihe environment is no longer hermetic, to thereby cause the starchy granular material to expand to form a cake or cracker having a substantially self-sustaining structure;
  • Control using pneumatic drivers can be problematic due to deviations in the quantity of air fed from a compressor to an air cylinder which will affect movement of the drive punch, possibly resulting in a non-uniform cracker. Furthermore, air compressors can be noisy and may require a high level of maintenance and a large duty of energy to operate.
  • GB-A-2165437 An alternative form of drive mechanism is taught in GB-A-2165437, which employs highly engineered rotary cam plates to drive the lower mold plate in an apparatus for the production of puffed cereal cakes and crackers.
  • the cam plate is rotated at substantially constant speed by a drive motor, and the profiled rim of the cam plate abuts against a drive punch to directly drive the lower mold plate.
  • These rotary cam plates can be mechanically complex and require a high degree of precision in order to position the lower mold relative to the upper mold at particular points within the baking cycle. This is particularly the case when a high degree of precision is required in releasing the lower mold from the upper mold for expansion of the rice cake material.
  • the cam suffers from serious problems of wear due to the high forces being applied directly to the mold punch, and the apparatus is noisy in use.
  • EP-A-0359740 discloses yet another drive mechanism which implements a hydraulic ram to move the lower mold relative to the upper mold.
  • a problem with hydraulic rams is that the position of the ram will depend upon the viscosity (and hence the temperature) of the oil, thereby making control difficult. For example, if the alignment of the lower mold relative to the upper mold is calibrated when the temperature of the oil is elevated and therefore the viscosity low, the alignment of 'cold start' drive shaft will be different at start-up of the drive mechanism due to the lower temperature of the oil and hence higher viscosity.
  • the present invention provides an apparatus for producing an expanded starchy cake or cracker from a starchy granular material according to a method in which said material undergoes a baking cycle comprising a compressive step in which a compressive force is applied to said starchy granular material while being subjected to heat, and an expansion step in which the compressive force is released from said starchy granular material to thereby cause it to expand to form said cake or cracker having a substantially self-sustaining structure
  • said apparatus comprising: a mold defining at least one cake or cracker-forming chamber for containing starchy granular material therein, said mold having at least one movable mold element to alternate the chamber between: a charging stage in which the starchy granular material is introduced to the cake or cracker-forming chamber prior to the baking cycle; an operative stage in which the volume of said chamber is alterable during said baking cycle for subjecting said starchy granular material to
  • the drive mechanism for movement of the moveable mold element is operatively actuated by the servo motor through a suitable coupling and under the control of the controller.
  • the term "operatively actuated" signifies that the controller is adapted or programmed to operate the servo motor for programmable periods of time and/or at varying angular speeds and directions and/or for programmable total angles of rotation at the different stages of the process, and especially at different parts of the operative stage.
  • the position of the movable mold element is a function of the total angular movement of the servo motor shaft relative to a reference position.
  • the servo motors and controllers used in the present invention are clearly distinct from the drive motors of the kind used in GB-A-2165437, which are adapted to drive a cam plate at constant angular velocity at least throughout the stages of the cereal cake production process.
  • Servo motors have not hitherto been used in this application, in part because it is not possible to control the process with sufficient precision by the use of limit switches to regulate the position of the movable molding element. Instead, the present inventors have found that the servo motor can be regulated to carry out the process in an accurate and repeatable fashion, either by operating the servo according to a predetermined program, and/or by using feedback from one or more signals generated by the servo.
  • the servo is pre-programmed to carry out a predetermined operating cycle.
  • the controller controls the position of the servo, typically by sending control pulses to the servo (e.g. 4086 pulses for one complete rotation of the servo shaft) in accordance with a predetermined program.
  • control pulses e.g. 4086 pulses for one complete rotation of the servo shaft
  • This provides a high degree of reproducibility without a need for limit switches or other sensors to control the position of the mold punch.
  • such equipment must be reprogrammed to optimise the process for each product and cannot ideally accommodate variations in the amount of feed material supplied to the mold.
  • the angular position of the servo motor drive shaft is preferably controllable to +/-10°, more preferably +/-1°.
  • a sensor is associated with said servo motor, the sensor being adapted to monitor an operating variable of said servo motor to thereby produce a signal representative of said operating variable.
  • the controller may include a feedback control loop to generate the control response for controlling the operating variable of the servo motor during the baking cycle.
  • the operating variable may be the speed of the servo motor shaft. This parameter can be integrated in the controller to give the exact position of the mold punch.
  • the operating variable can include the torque of the servo motor shaft, since this allows the optimum pressure to be applied to the product during the compression step, and/or allows expansion to be initiated when the pressure reaches a predetermined level.
  • the drive mechanism converts the rotary motion of the servo shaft into a linear motion of the movable mold element.
  • the drive mechanism permits high precision control of the position of the movable mold element.
  • the drive mechanism is adapted to convert one complete revolution of the servo drive shaft into a linear movement of the movable mold element of from 1 to 500 micrometers, more preferably from 4 to 100 micrometers.
  • the linear position of the movable mold element is controllable to +/-0.1mm or less, more preferably to +/-20 ⁇ m or less, and most preferably to +/-10 ⁇ m or less.
  • the drive mechanism comprises a drive shaft coupled to said at least one movable mold element and an eccentric coupling between the drive shaft and the servo motor.
  • the eccentric coupling may for example be a rotary plate driven by the servo motor (optionally via a step-down gear) and eccentrically coupled to the drive shaft, whereby in use, the servo motor drives said rotary plate and said rotary plate actuates the drive shaft to move the movable mold element.
  • the drive mechanism further comprises a gear mechanism to step down the rotary speed imparted to the coupling by the servo motor.
  • the drive shaft may drive the movable mold element directly.
  • the movable mold element is driven through a linkage as described for example in WO88/06425 or EP-A-0359740.
  • the linkage comprises a two-arm joint hinged together at on end, the unhinged end of one arm being swingably connected to the movable mold element and the unhinged end of the other arm being swingably connected to a fixed shaft of the apparatus to be rotatable thereabout.
  • the linkage is then driven by the drive shaft extending from the region where the two arms are hinged together.
  • the apparatus preferably further comprises a limit stop or limit switch at a predetermined limit position of the movable mold element, usually a limiting open position of the mold.
  • a limit stop or limit switch at a predetermined limit position of the movable mold element, usually a limiting open position of the mold.
  • the precise control provided by the servo mechanism enables thinner cereal cakes to be made in a controlled and reproducible fashion.
  • the apparatus is configured and programmed such that the height of the mold cavity during the compression step of the operating stage is from 0.01 to 2mm, preferably from about 0.1 to about 1mm, for the production of very thin cakes.
  • the present invention provides a method of making an expanded self sustaining starchy cake or cracker, the method comprising: providing a cake or cracker baking apparatus according to the first aspect of the invention; in a charging stage, opening the cake or cracker forming chamber, and charging a starchy granular material into the cake or cracker-forming chamber; in an operative stage, operating said servo motor and heating element so as to subject said starchy granular material to compression and heating, followed by rapid expansion; and in a discharging stage, opening the cake or cracker forming chamber to allow the cake or cracker to be discharged from the chamber.
  • the method according to this aspect of the invention further comprises a step of initiating the apparatus by operating the servo motor to move the movable mold element to a predetermined limit position.
  • This position may be a limit stop or switch as described above. It is a particular advantage of the present invention that the precise control provided by the servo mechanism enables the duration of the operative stage to be reduced below the current 11-16 seconds conventional for cereal cakes. In the methods of the present invention, the duration of the operative stage is preferably less than about 10 seconds, and more preferably from about 2 to about 7 seconds.
  • the precise control provided by the servo mechanism enables thinner cereal cakes to be made in a controlled and reproducible fashion.
  • the process is preferably adapted to produce puffed cereal cakes having a mean thickness of from about 1 to about 5mm, and/or preferably a density per unit area of from about 0.01 to about 0.05g/cm 2 .
  • Figure 1 shows a schematic illustration of a cereal cake baking apparatus according to the invention
  • the cereal cake baking apparatus 10 includes a mold 12, a drive mechanism 16, and a servo motor 18.
  • the mold 12 consists of an upper mold plate 20 and a lower mold plate 22.
  • the upper mold plate 20 has an array of cylindrical mold punches 24 projecting from its surface that are received in corresponding mold cavities of the lower mold plate 22. In this way a single movable mold element can drive the production of a plurality of smaller cereal cakes.
  • the rice cake baking apparatus 10 shown in Fig. 1 is shown in its charging stage.
  • the method of charging the mold 12 is known to those skilled in the art and will not be disclosed here in detail.
  • the upper mold plate 20 is mounted on a support 23 that is fixed to the frame of the apparatus.
  • the lower mold plate 22 sits on a punch shaft 32 which extends through a guide frame 26 which is connected to a fixed support 21.
  • the guide frame 26 is used to guide the punch shaft 26 as the lower mold plate 22 travels relative to the upper mold plate 20 in the direction of arrow 40.
  • the punch shaft is supported on a linkage, which comprises a two arms 27,28 linked together by a hinge or pivot 25, the unhinged end of one arm 27 being swingably connected to the end of the punch shaft and the unhinged end of the other arm 28 being swingably connected to a shaft fixed to the lower frame 24 of the apparatus.
  • the drive mechanism 16 further comprises a drive shaft 34 linked at one end to the hinge 25.
  • the other end of the drive shaft 34 is eccentrically fastened to a rotary plate 36, so that the eccentric motion of the rotary plate 36 will raise and lower the punch shaft 32 as the drive shaft 34 moves linearly.
  • the servo motor 18 drives the rotary plate 36 via a gearbox (not shown) which regulates the speed of the rotary plate.
  • the gear ratio of the box is 1 :45.16 in order to decrease the speed of rotation of the rotary plate relative to the servo and thereby offer great control over the movement of the lower mold plate 22 relative to the upper mold plate 20 during the baking cycle.
  • the servo motor is controlled by electric pulses from the control circuit; 4086 pulses result in one complete rotation of the servo motor. In conjunction with the step-down effect of the gearbox and the lever arm arrangement of the drive mechanism, this gives exceptional control over the vertical movement of the mold plate.
  • the vertical movement of the mold plate is controllable to within +/-5 ⁇ m.
  • a speed sensor (not shown) is located adjacent to the servo motor shaft to monitor the speed of the servo motor 18. Typically, the maximum speed of the servo motor 18 is 2000 rpm, although the usual speed for production of rice cakes is 1200 rpm.
  • the sensor transmits a signal to an amplifier which sends an amplified speed signal to the controller via a signal transmission line.
  • a torque sensor may likewise be operatively associated with the servo motor.
  • Parboiled rice kernels having a moisture content of about 12% by weight are charged into the baking chambers by methods known in the art. In order to achieve a very thin final product, the kernels are charged at an area density of only about 0.03g/cm 2 .
  • the compressive step for the baking cycle is initiated in which the servo motor 18, controlled by the controller, drives the rotary cam plate 36 to raise the punch shaft 32 toward the upper mold plate 20.
  • the final position of the punch shaft may determined by a sending predetermined number of pulses sent to the servo (this assumes that the optimum position for this particular process and cake thickness has been predetermined, and that the apparatus has been initiated by locating a stop element beforehand).
  • the feedback from the torque sensor can be used to stop the compression at a predetermined optimum initial pressure in the molds.
  • Heating elements 29 are located in the mold plates 20 and 22 to provide a heat source for baking the granular rice material. The combination of heat and pressure renders the rice gelatinous and plastic. The grains flow together to form a bonded mass.
  • the expansion step is initiated and the lower plate 22 is released from the upper plate 20 by lowering the punch shaft 32 rapidly, and the pressure within the chamber is reduced.
  • the gelatinous rice material undergoes expansion due to the pressure reduction within the baking chambers and the release of gases emitted during the baking process.
  • the expansion causes the gelatinous material to rapidly cool and form a rice cake or cracker having a self-sustaining structure.
  • the molds are opened and the rice cakes or crackers are ejected from the mold 12 by methods known in the art.
  • the speed of the servo motor can be adjusted for each baking cycle time period, it is possible to achieve a desired pressure change profile within the chambers and therefore control the expansion rate of the rice cake or cracker. Controlling the power output of the servo motor also allows the operator of the baking apparatus to achieve a relatively constant pressure during the compressive step of the baking cycle and the controlled expansion rate of the resulting cake or cracker results in a uniform finished product.
  • Control over the speed of the servo motor leads to other advantages such as accuracy in movement of the lower mold plate relative to the upper mold plate.
  • the improved control over the speed of the servo motor 18 also results in the average baking cycle time of the rice cakes being reduced from an average cycle time of 11 sec with the known prior art to 6 sec, thereby increasing the throughput of the baking apparatus.
  • the controller is used to alter the speed of the servomotor 18, it is not necessary to have a finely engineered rotary cam plate in order to gain the desired pressure reduction profile within the chamber as the controller can be tuned empirically.
  • control system of the above described embodiment provides better control over the dimensions and expansion rate of the starchy granular material in the cake or cracker baking process in comparison to using a hydraulic or pneumatic drive or a highly engineered cam plate. Additionally, better control over the servo drive results in an improvement in the accuracy of the baking apparatus at start-up, hence better 'cold start' reproducibility for the cake or cracker product.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Food Science & Technology (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Nutrition Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Confectionery (AREA)

Abstract

L'invention porte sur un appareil (10) permettant de fabriquer une galette ou un biscuit amylacés soufflés à partir de matières granuleuses amylacées. Le procédé consiste à soumettre ces matières à un cycle de cuisson comprenant une étape de compression et une étape d'expansion. Ledit appareil comprend les éléments suivants : un moule (12) délimitant au moins un logement à même de former une galette ou un biscuit permettant de contenir les matières granuleuses amylacées, ledit moule (12) comportant au moins une partie amovible (22) ; un corps de chauffe (29) servant à cuire lesdites matières granuleuses amylacées dans ledit logement pendant le cycle de cuisson ; un élément d'entraînement (16) couplé à la partie amovible précitée du moule (22) ; un servomoteur (18) couplé audit élément d'entraînement (16) servant à mettre en fonctionnement ledit élément d'entraînement (16) en vue de déplacer la partie amovible du moule (22) ; et un régulateur servant à régler ledit servomoteur (18).
PCT/IB2004/000977 2003-03-11 2004-03-10 Appareil de cuisson de biscuits amylaces souffles WO2004080185A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0305571A GB2399274A (en) 2003-03-11 2003-03-11 Expanded starchy cake baking apparatus
GB0305571.2 2003-03-11

Publications (1)

Publication Number Publication Date
WO2004080185A1 true WO2004080185A1 (fr) 2004-09-23

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PCT/IB2004/000977 WO2004080185A1 (fr) 2003-03-11 2004-03-10 Appareil de cuisson de biscuits amylaces souffles

Country Status (2)

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GB (1) GB2399274A (fr)
WO (1) WO2004080185A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007134480A1 (fr) * 2006-05-16 2007-11-29 Jialing Wang Moule à gâteaux tournant

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
MX349125B (es) * 2012-02-22 2017-07-11 Flatev Ag Método y aparato para la preparación automática de pan plano que usa cápsulas que comprenden una porción de pasta.

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4328741A (en) 1979-06-06 1982-05-11 Kabushiki Kaisha Airin Apparatus for producing crackers
BE902360A (nl) 1985-05-07 1985-09-02 Waele Herman De Inrichting voor de bereiding van voedingsprodukten op basis van granen.
GB2165437A (en) 1984-10-16 1986-04-16 Airin Kk Production of cakes of granular material
WO1988006425A1 (fr) 1987-02-25 1988-09-07 Berghe Rene Van Den Appareil et procede pour la production de biscuits en materiau granulaire
US6238196B1 (en) * 1997-04-24 2001-05-29 Frigoscandia Eguipment Ab Molding apparatus
WO2003079797A1 (fr) * 2002-03-19 2003-10-02 Tyson Foods, Inc. Dispositif et procede servant a aplatir des tortillas

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4328741A (en) 1979-06-06 1982-05-11 Kabushiki Kaisha Airin Apparatus for producing crackers
GB2165437A (en) 1984-10-16 1986-04-16 Airin Kk Production of cakes of granular material
BE902360A (nl) 1985-05-07 1985-09-02 Waele Herman De Inrichting voor de bereiding van voedingsprodukten op basis van granen.
WO1988006425A1 (fr) 1987-02-25 1988-09-07 Berghe Rene Van Den Appareil et procede pour la production de biscuits en materiau granulaire
EP0359740A1 (fr) 1987-02-25 1990-03-28 Rene Van Den Berghe Appareil et procede pour la production de biscuits en materiau granulaire.
US6238196B1 (en) * 1997-04-24 2001-05-29 Frigoscandia Eguipment Ab Molding apparatus
WO2003079797A1 (fr) * 2002-03-19 2003-10-02 Tyson Foods, Inc. Dispositif et procede servant a aplatir des tortillas

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007134480A1 (fr) * 2006-05-16 2007-11-29 Jialing Wang Moule à gâteaux tournant

Also Published As

Publication number Publication date
GB2399274A (en) 2004-09-15
GB0305571D0 (en) 2003-04-16

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