WO2013138581A1 - Produit alimentaire multicouche et son procédé de préparation - Google Patents

Produit alimentaire multicouche et son procédé de préparation Download PDF

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Publication number
WO2013138581A1
WO2013138581A1 PCT/US2013/031294 US2013031294W WO2013138581A1 WO 2013138581 A1 WO2013138581 A1 WO 2013138581A1 US 2013031294 W US2013031294 W US 2013031294W WO 2013138581 A1 WO2013138581 A1 WO 2013138581A1
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WO
WIPO (PCT)
Prior art keywords
food product
layered food
insert
leavened
baking
Prior art date
Application number
PCT/US2013/031294
Other languages
English (en)
Inventor
Peter Jacobson
Marc De Longree
Original Assignee
Arlington Valley Farms Llc
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
Priority claimed from US13/419,505 external-priority patent/US10448653B2/en
Application filed by Arlington Valley Farms Llc filed Critical Arlington Valley Farms Llc
Publication of WO2013138581A1 publication Critical patent/WO2013138581A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
    • A21D17/00—Refreshing bakery products or recycling bakery products
    • A21D17/004—Refreshing bakery products or recycling bakery products refreshing by thawing or heating
    • A21D17/006—Refreshing bakery products or recycling bakery products refreshing by thawing or heating with microwaves
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
    • A21D13/00—Finished or partly finished bakery products
    • A21D13/10—Multi-layered products
    • A21D13/11—Multi-layered products made of two or more doughs, e.g. differing in composition, colour or structure
    • A21D13/14—Multi-layered products made of two or more doughs, e.g. differing in composition, colour or structure with fillings
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
    • A21D13/00—Finished or partly finished bakery products
    • A21D13/30—Filled, to be filled or stuffed products
    • A21D13/36—Filled wafers
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
    • A21D8/00—Methods for preparing or baking dough
    • A21D8/06—Baking processes
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
    • A23P20/20—Making of laminated, multi-layered, stuffed or hollow foodstuffs, e.g. by wrapping in preformed edible dough sheets or in edible food containers
    • A23P20/25—Filling or stuffing cored food pieces, e.g. combined with coring or making cavities
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21B—BAKERS' OVENS; MACHINES OR EQUIPMENT FOR BAKING
    • A21B5/00—Baking apparatus for special goods; Other baking apparatus
    • A21B5/02—Apparatus for baking hollow articles, waffles, pastry, biscuits, or the like

Definitions

  • the claimed subject matter relates generally to filled food products, and more particularly to a multi-layered food product and method for forming the multi-layered food product.
  • a multi- layered food product comprises a filling encapsulated by a substantially baked yeast-leavened dough.
  • the encapsulated filling is further
  • a method for forming a multi-layered food product.
  • One step of the method includes substantially baking an insert in a first bi-molded plate assembly.
  • the insert comprises a filling that is completely enveloped by a yeast-leavened dough.
  • the substantially baked insert is placed into a second bi-moided plate assembly so that the substantially baked insert is located atop a first amount of a chemically-leavened batter layer.
  • a second amount of the chemically-leavened batter is then poured into the second bi- molded plate assembly so that the second amount of the chemically- leavened batter substantially or completely envelops the substantially baked insert.
  • the second bi-moided plate assembly is heated for a time and at a temperature sufficient to bake the multi-layered food product.
  • FIG. 1 A is a perspective view of a multi-layered food product in accordance with one aspect of the present invention.
  • Fig. 1 B is a cross-sectional view taken along Line 1B-1 B in Fig. 1A;
  • FIG. 2A is a perspective view of a multi-layered food product in accordance with another aspect of the present invention.
  • Fig. 2B is a cross-sectional view taken along Line 2B-2B in Fig. 2A;
  • FIG. 2C is a perspective view of a substantially baked insert comprising a portion of the multi-layered food product in Figs. 2A-B;
  • Fig. 2D is a cross-sectional view taken along Line 2D-2D in Fig. 2C;
  • FIG. 3A is a perspective view of a multi-layered food product in accordance with another aspect of the present invention.
  • Fig. 3B is a cross-sectional view taken along Line 3B-3B in Fig. 3A;
  • FIG. 4 is a process flow diagram illustrating a method for forming a multi-layered food product according to another aspect of the present invention
  • Fig. 5 is a schematic diagram showing an automated assembiy line system used to form the multi-layered food product of the present invention
  • Fig. 6 is a schematic diagram showing an alternative configuration of the automated assembly line system in Fig. 5;
  • Fig. 7A is a perspective view of a first bi-molded plate assembly for forming the substantially baked insert in Figs. 2A-D;
  • Fig. 7B is a top view of a second baking plate of the first bi- molded plate assembly in Fig. 7A;
  • Fig. 8A is a perspective view of a second bi-molded plate assembly for forming the muiti-iayered food product in Figs. 1A-2D, the second bi-molded plate assembiy comprising a lid member and a receptacle member;
  • Fig. 8B is a side view of the second bi-molded plate assembly in Fig. 8A;
  • Fig. 9A is a side view of the lid member shown in Fig. 8A;
  • Fig. 9B is a top view of the lid member shown in Fig. 9A;
  • Fig. 10A is a side view of the receptacle member shown in Fig. 8A;
  • Fig. 10B is a top view of the receptacle member shown in Fig. 10A;
  • Fig. 11 is a process flow diagram illustrating a further aspect of the method shown in Fig. 4;
  • Fig. 12 is a process flow diagram illustrating a method for forming a multi-layered food product according to another aspect of the present invention.
  • Fig. 13 is a schematic diagram showing an alternative configuration of the automated assembly line system in Fig. 6.
  • the claimed subject matter relates generally to filled food products, and more particularly to a multi-layered food product and method for forming the multi-layered food product.
  • Figs. 1A-2D illustrates a multi-layered food product 10 or 10' that combines the strength and functionality of yeast-leavened bread with the delicate eating quality of a quick bread or cake.
  • the multi-layered food product 10 or 10' of the present invention combines a yeast-leavened dough insert 12 or 12', which gives the product its necessary support to be eaten by hand, with a chemicaliy-ieavened batter 14 that gives the product a soft and appealing eating quality, which is absent in purely yeast-ieavened bread products. Additionally, the multi-layered food product 10 or 10' can be initially warmed in a microwave and then reconstituted in an oven or toaster to yield a food product having a crispy exterior and a soft interior without the chewy or tough consistency of a typical yeast-leavened bread product.
  • the multi-layered food product 10 or 10' has a molded configuration (e.g., puck-shaped) and a partially uniform color.
  • the partially uniform color gives the multi-layered food product 10 or 10' the appearance of a home-baked meal or snack that has been prepared on a griddle, pan or Panini.
  • the muiti-!ayered food product 10 or 10' is shown as having a puck-shaped configuration, it will be appreciated that the product can have any desirable shape and size that makes the product versatile and easy to consume.
  • the multi-layered food product 10 can have any shape and size that enables a consumer to easily eat the multi-layered food product at home or on-the-go without any mess.
  • the molded configuration of the multi-layered food product 10 or 10' also allows the product to be quickly and easily reconstituted for consumption in a microwave and/or toaster, or simply by oven.
  • the multi-layered food product 10 comprises a substantially baked insert 12 or 12' that includes a filling16, which is completely enveloped or encapsulated by a yeast-leavened dough 8.
  • the substantially baked insert 12 or 12' is completely enveloped or encapsulated by a chemically-leavened batter layer 14.
  • the substantially baked insert 12 or 12' has a molded configuration (e.g., a puck-iike shape).
  • the substantially baked insert 12 or 12' additionally includes a filling 16 that is completely enveloped or encapsulated by the yeast-leavened dough 18.
  • the filling 16 can comprise any desired solid or semi-solid food product that is typically included as part of a meal or snack.
  • Examples of fillings 16 can include fruit, cheese, eggs, meat (e.g. , ham, bacon, sausage, hamburger, chicken, turkey, etc.), vegetables, sauces, and/or a combination thereof.
  • the multi-layered food product 10 or 10' combines the distinctive structural and taste characteristics of yeast- and chemically- leavened breads into a single food product.
  • Yeast-leavened breads use fermentation to create carbon dioxide "bubbles" and thereby ieaven the dough. Fermentation begins by mixing the necessary ingredients together to develop a strong gluten structure, which allows the dough to accumulate carbon dioxide. Leavening continues to occur in the proofing stage, in which a low heat and high humidity environment promotes optimal yeast fermentation.
  • Yeast leavening is highly regarded as contributing desirable tastes and aromas to bread. For example, yeast-leavened breads tend to have a smooth outer crust and airy, flaky interiors.
  • Chemically-leavened breads are formed by the reaction of bicarbonate compounds with acid-reactive ingredients.
  • Sodium bicarbonate is the most commonly used chemical leavening agent, but potassium and ammonium bicarbonates are also used.
  • Chemical leavening typically occurs in two stages. The first stage releases carbon dioxide during mixing, while the second stage releases carbon dioxide during the baking process by the activation of certain chemical leavening ingredients.
  • One advantage of chemical leavening is the quick formation of carbon dioxide bubbles within a dough or batter mixture, without the need for proofing. Unlike yeast-leavened breads, quick breads are known for having a slightly coarse texture and soft crusts.
  • the weight-percent (wt-%) of the chemically-leavened batter 14, the filling 16, and the yeast-leavened dough 18 can be varied to impart the multi-layered food product 10 or 10' with desired structural and taste characteristics.
  • the wt-% of the filling 16 can be about 15% to about 60% of the total weight of the multi- layered food product 10 or 10 r
  • the wt-% of the yeast-leavened dough 18 can be about 10% to about 60% of the total weight of the multi-layered food product
  • the wt-% of the chemically-leavened batter Iayer 14 can be about 15% to about 60% of the total weight of the multi-layered food product.
  • the leavening agents and/or other ingredients used to form the chemically-leavened batter !ayer 14 and the yeast-leavened dough 18 can also be varied depending upon the particular structural and taste characteristics of the multi-layered food product 10 or 10'.
  • the wt-% of yeast to flour in the yeast-leavened dough 18 can be about 3% to about 6%.
  • one or a combination of chemical leavening agents e.g., baking powder
  • the wt-% of the chemical leavening agent (e.g., baking powder) to flour in the chemicaliy-!eavened batter Iayer 14 can be about 0% to about 8%.
  • Figs. 2A-D illustrate a muiti-iayered food product 10' according to another aspect of the present invention.
  • the multi-layered food product 10' can have a molded configuration (e.g., puck-shaped) and a partially uniform color.
  • the multi-layered food product 10' is shown as having a puck-shaped configuration, it will be appreciated that the product can have any desirable shape and size that makes the product versatile and easy to consume.
  • the substantially baked insert 12' has a molded configuration (e.g., a puck-like shape) and is defined by oppositely disposed first and second major surfaces 20 and 22. At least one of the first and second major surfaces 20 and 22 can include a finger member 24 that projects outwardly from at least one of the first and second major surfaces. As shown in Fig. 2C, for example, each of the first and second major surfaces 20 and 22 can include a plurality of finger
  • the finger members 24 generally serve to secure the substantialiy baked insert 12' within the chemically-leavened batter layer 14 and prevent the insert from "sinking" to either side of the multi-layered food product 10'. It should be appreciated that, where desired, the first and/or second major surfaces 20 and 22 may not include any finger members 24.
  • the finger members 24 are formed from the yeast-leavened dough 18 and are dispersed about the first and second major surfaces 20 and 22.
  • the finger members 24 can be dimensioned (e.g., have a sufficient height, width, and width) to keep the substantially baked insert 12' from sinking to either side of the muiti-iayered food product 10'.
  • the finger members 24 may or may not be visible about the muiti-iayered food product 10'.
  • the finger members 24 can be symmetrically or
  • the finger members 24 can have any desired shape or configuration, such as the dome-shaped configuration shown in Fig, 2C. Although not shown, it will be appreciated that one or more of the finger members 24 can alternatively have a ridge-like configuration that extends across a!i or only a portion of the first major surface 20 and/or the second major surface 22.
  • Figs. 3A-B illustrate a multi-layered food product 10" according to another aspect of the present invention.
  • the multi-layered food product 10" can have a molded configuration (e.g., puck-shaped) and a partially uniform color.
  • the multi-layered food product 10" is shown as having a puck-shaped configuration, it will be appreciated that the product can have any desirable shape and size that makes the product versatile and easy to consume.
  • the multi-iayered food product 10" can have any shape and size that enables a consumer to easily eat the muiti-layered food product at home or on-the-go without any mess.
  • the molded configuration of the multi-layered food product 10" also allows the product to be quickly and easily reconstituted for consumption in a microwave and/or toaster, or simply an oven.
  • the multi-layered food product 10" can comprise a insert 12" including a filling 16 that is completely enveloped or encapsulated by a yeast-leavened dough 18, As described above, the filling 16 can comprise any desired solid or semi-solid food product that is typically included as part of a meal (e.g., fruit, cheese, eggs, meat, vegetables, sauces, and/or a combination thereof) or snack.
  • a meal e.g., fruit, cheese, eggs, meat, vegetables, sauces, and/or a combination thereof
  • the weight-percent (wt-%) of the filling 16 and the yeast- leavened dough 18 can be varied to impart the multi-layered food product 10" with desired structural and taste characteristics.
  • the wt-% of the filling 16 can be about 25% to about 75% of the total weight of the multi-layered food product 10
  • the wt-% of the yeast-leavened dough 18 can be about 25% to about 75% of the total weight of the multi-layered food product.
  • another aspect of the present invention includes a method 30 for forming a multi-layered food product 10 or 10'.
  • the method 30 is performed using an automated assembly line system (Figs. 5-6) comprising first and second automated assembly lines 50 and 52.
  • the first automated assembly line 50 is for preparing the substantially baked insert 12 or 12' and comprises a series of upper and lower ioop- shaped tracts 54 and 56, a portion of each of which is disposed within an oven 58.
  • the upper and lower tracts 54 and 56 of the first automated assembly line 50 include a plurality of first baking plates 60 securely mounted thereto that can be securely mated together to form a plurality of first bi-molded plate assemblies 62 (Figs. 7A-B).
  • each of the first bi-molded piate assemblies 62 formed by each of the first baking plates 60 have a puck- or disc-shaped configuration and form a cavity 64 therebetween.
  • the cavity 64 is defined by first and second plates 66 and 68.
  • the dimensions (e.g., height, width, length, cavity depth, etc.) of the first and second plates 66 and 68 can be about equal so that the dimensions of the substantially baked insert 12 or 12' formed by the method 30 are also about equal.
  • An inner surface 70 of each of the first and second plates 66 and 68 can include at least one depression 72 for forming the finger members 24.
  • each of the depressions 72 can have a dome-shaped configuration for producing finger members 24 having a configuration as shown in Figs. 2A-D. it wili be appreciated that the depressions 72 can have any configuration for forming finger members 24 with any
  • each of the first bi-molded plate assemblies 62 can be made of a rigid, heat-conductive materia! (e.g., a metal or metal alloy).
  • the second automated assembly line 52 is for preparing the multi-layered food product 10 or 10' and comprises a continuous, loop-shaped tract 74 having an upper portion 76 and a lower portion 78. A portion of the second assembly line 52 is seated within an oven 80. The tract 74 of the second assembly line 52 is operably mated to opposing rotation members 82, each of which is separately or jointly powered by a power source (not shown). As described in greater detail below, the second assembly line 52 also includes an automatic removing system 84, a first batter injector 86, an insert feeding system 88, and a second batter injector 90.
  • the second assembly line 52 also comprises a plurality of second baking plates 92, each of which includes at least one of a second bi-molded plate assembly 94 (Figs. 8A-B). As shown in Fig. 5, the second assembly line 52 includes fourteen second baking plates 92 having six of the second bi-molded plate assemblies 94 in each. It will be appreciated that the number of the second baking plates 92, as well as the number of the second bi-molded plate assemblies 94 comprising each of the second baking plates can be varied depending upon production needs and the configuration of the second assembly line 52.
  • each of the second bi-moided plate assemblies 94 comprises a receptacle member 96 and a lid member 98.
  • AH or only a portion of each of the second bi-molded plate assemblies 94 can be made of a rigid, heat-conductive materia! (e.g., a metal or metal alloy).
  • the receptacle member 96 and the lid member 98 each have a generally circular or oval-shaped configuration and include a cavity 100 (Figs. 9A and 10A).
  • the cavities 100 of the lid member and the receptacle member form a molded baking cavity 102.
  • the molded baking cavity 102 can have a diameter of about 6 cm to about 15 cm, and a depth of about 1 cm to about 5 cm.
  • the molded baking cavity 102 is designed to hold and bake all the components of the multi-layered food product 10 or 10'
  • each of the second bi-molded plate assemblies 94 has a disc-like shape and is defined by oppositely disposed first and second major surfaces 104 and 106.
  • the first major surface 104 has a generally smooth, flat configuration that gradually tapers around the edge 108 towards the second major surface 06.
  • the second major surface 106 is adapted for mating with the receptacle member 96. As shown in Fig. 9A, the cavity 100 of the lid member 98 extends from the second major surface 106 towards the first major surface 104 such that the cavity is recessed within the second major surface.
  • the cavity 100 of the lid member 98 defines a volume capable of holding between about 0% and about 40% of the multi-layered food product 0 or 10' during the baking process.
  • the receptacle member 96 has a rounded, pan-shaped configuration.
  • the receptacle member 96 includes oppositely disposed first and second major surfaces 1 0 and 112 and an annular side wall 1 4 that extends between the first and second major surfaces.
  • the cavity 00 of the receptacle member 96 extends between the first major surface 110 and the bottom surface 16 of the receptacle member.
  • the cavity 100 of the receptacle member 96 defines a volume that is greater than the volume of the lid member 98.
  • the cavity 100 of the receptacle member 96 is capable of holding between about 60% and about 100% of the multi-layered food product 10 or 10' during the baking process.
  • one or more of the second bi- molded plate assemblies 94 can include an imprinting surface (not shown in detail) for imparting all or only a portion of a surface of the multi-layered food product 0 or 10' with a decorative design.
  • one or more surfaces defining the cavity 100 of the second bi-molded plate assembly 94 can include at least one depressed and/or raised imprinting surface having a decorative or aesthetically pleasing design.
  • the imprinting surface may additionally or optionally serve to securely positioning the substantially baked insert 12 or 12' during baking.
  • the imprinting surface may assist in maintaining the substantially baked insert 12 or 12' proportionally in the center of the cavity 100 during baking.
  • the method 30 can begin by heating the first baking plates 60 to a predetermined temperature (e.g., about 250 °F. to about 450 °F.). Either prior to, contemporaneous with, or subsequent to Step 32, the raw components of the multi-layered food product 10 or 10' are prepared.
  • a predetermined temperature e.g., about 250 °F. to about 450 °F.
  • the yeast-leavened dough 18 can be formed by scaling (e.g., measuring out) the needed ingredients, which may include flour (e.g., about 27% to about 68% of the total batch weight), water (e.g., about 21 % to about 57% of the total batch weight), milk powder (e.g., about 0% to about 9% of the total batch weight), eggs (e.g., about 2% to about 15% of the total batch weight), gluten (e.g., about 2% to about 5% of the total batch weight), sugar (e.g., about 2% to about 15% of the total batch weight), oil (e.g.
  • yeast e.g., about 1 % to about 5% of the total batch weight
  • salt e.g. , about 0.5% to about 2% of the total batch weight
  • other ingredients may be added to adjust the flavor or improve the functionality of the yeast-leavened dough 18.
  • ingredients that can be added to adjust the flavor of the yeast-leavened dough 18 can include butter, cheese, spices, natural flavorings, and fruit or nut inclusions.
  • ingredients that may be added to improve the functionality of the yeast-leavened dough 18 can include baking enzymes, monoglycerides, fats and oils.
  • ingredients are scaled, the ingredients are then mixed and kneaded together for a period of time sufficient to develop the giuten structure of the yeast-leavened dough 18.
  • the fully developed, yeast-leavened dough 18 is then ready for subsequent use.
  • a measured amount of one or more fillings 16 is "encrusted” inside a measured amount of the yeast-!eavened dough to form the insert 12 or 12'.
  • the measured amount of filling 16 may range from about 15 grams to about 99 grams, and the measured amount of the yeast- leavened dough 18 may range from 12 grams to about 128 grams.
  • the formed product comprises a ball-shaped insert 12 or 12' that is completely enveloped by the yeast-leavened dough and includes the filling at its center.
  • the insert 12 or 12' can be passed through a molding or shaping device (not shown) so that upper and/or lower portions of the insert are partially flattened.
  • the molded insert 12 or 12' is then placed into a bakery proofing chamber 1 18 (Fig. 5) for a period of time sufficient to adequately "rise” or "proof the insert prior to baking.
  • the proofing time can vary from about 10 minutes to about 60 minutes, depending upon the type and size of the yeast-leavened dough 18 and the filling 16. After the insert 12 or 12' is adequately proofed, it is ready for subsequent use.
  • the chemically-leavened batter layer 14 is prepared. Creation of the chemically-leavened batter layer 14 begins by scaling the necessary ingredients, which may include water (e.g., about 29% to about 68% of the total batch weight), flour (e.g.
  • eggs e.g., about 5% to about 30% of the total batch weight
  • sugar e.g., about 0% to about 17% of the total batch weight
  • milk powder e.g., about 0% to about 12% of the total batch weight
  • oil e.g., about 0% to about 15% of the total batch weight
  • baking powder e.g., about 0.5% to about 5% of the total batch weight
  • baking soda e.g. , about 0% to about 2% of the total batch weight
  • salt e.g., about 0.5% to about 3% of the total batch weight
  • ingredients may be added to adjust the flavor or improve the functionality of the chemically-leavened batter layer 14.
  • ingredients that may be added to adjust the flavor of the chemicaily-ieavened batter layer 14 may include butter, cheese, meat, natural flavors or spices, fruits, nuts, and the like.
  • ingredients that may be added to improve the functionality of the chemicaily-!eavened batter layer 14 may include oils, fats, emulsifiers, and the like.
  • the ingredients are then thoroughly mixed until they are adequately combined into a partially liquid form, typically in a large temperature-controlled stirring vat (not shown).
  • the mixed ingredients may then be transferred to a second batter mixer (not shown) where additional ingredients can be added (e.g., eggs), stirred at high speeds, and properly aerated.
  • the resultant chemically-leavened batter layer 14 may then be placed inside a temperature-controlled container (e.g., first and second batter injectors 86 and 90) that will be used to deposit the chemically-leavened batter during the baking process.
  • a temperature-controlled container e.g., first and second batter injectors 86 and 90
  • the insert 12 or 12' Prior to, simultaneous with, or following preparation of the insert 12 or 12' and the chemically-leavened batter 14, the insert can be substantially baked at Step 34.
  • an insert 12 is taken from the proofing chamber 1 18 and deposited into a first baking plate 60 (e.g. , the second plate 68 of a first bi-moided plate assembly 62).
  • the insert 12 or 12' can be deposited into the first baking plate 60 by any one or combination of mechanisms known in the art, such as via a robotic arm, conveyor belt system 40 (Fig. 6), or by hand.
  • the baking plate rotates about the lower tract to securely mate with another baking plate, thereby forming a plurality of first bi-molded plate assemblies 62.
  • the baking plates 60 then move through an oven 58 (e.g., a tunnel oven) for a time and at a temperature sufficient to substantially bake the insert 12 or 12'.
  • an oven 58 e.g., a tunnel oven
  • substantially baked can mean that the insert 12 or 12' is baked about 80%, about 85%, about 90%, about 95% or 100% (completely baked).
  • the first baking plates 60 can move through oven 58 so that the insert 12 or 12' is completely or 100% baked and, thus, free from liquid or moisture.
  • the first baking plates 60 can move through oven 58 for a time of about 20 seconds to about 90 seconds and at a temperature of about 250°F to about 450°F to substantially or completely bake the insert 12 or 12'.
  • the baking plates are separated as shown in Fig. 5 so that the substantially baked insert 12 or 12' can be removed from the plates and deposited into the insert feeding system 88.
  • the substantially baked insert 12 or 12' produced by the method 30 can be deposited into the insert feeding system 88 by any one or combination of mechanisms known in the art, such as a transfer machine 142 (Fig. 6) that removes the substantially baked insert 12 or 12' from the first baking plates 60 and then passes the insert onto a conveyor belt system 140, Prior to depositing the substantially baked insert 12 or 12' into the insert feeding system 88, the second baking plates 92 (and thus each of the second bi-molded plate assemblies 94) are heated to a predetermined temperature
  • Step 36 Upon heating each of the second bi-mo!ded plate assemblies 94 to the predetermined temperature and forming the components of the multi-layered food product 10 or 10', the second assembly line 52 is activated so that the tract 74 progressively moves in a clock-wise motion at a predetermined rate.
  • the first batter injector 86 is operated to pour a first amount of the chemicaliy-leavened batter layer 14 into the cavity 100 of each of the receptacle members 96.
  • the first amount of the chemically- leavened batter layer 14 is delivered in an amount sufficient to cover at least a substantia! portion of the bottom surface 1 16 of each of the receptacle members 96.
  • the total amount of the chemically-leavened batter layer 14 that is poured into the receptacle members 96 can vary between about 10 grams and about 128 grams, depending upon the type of multi-!ayered food product 10 or 10' being made. It will be appreciated that a pan release agent ⁇ e.g., baking oil) can be applied to all or only a portion of the molded baking cavity 102 prior to the addition of the raw components to prevent or mitigate sticking.
  • a pan release agent ⁇ e.g., baking oil
  • the second baking plates 92 are advanced along the second assembly line 52 to the insert feeding system 88.
  • the insert system 88 is then activated to place a substantially baked insert 12 or 12' atop the first amount of the chemically-leavened batter layer 14 already in each of the receptacle members 96.
  • the substantially baked insert 1 or 12' is placed atop the first amount of the chemically-leavened batter layer 14 so that no portion of the insert comes into contact with each of the receptacle members 96.
  • a substantially baked insert 12 or 12' is placed in each of the receptacle members 96 so that each insert is at least partially enveloped or encapsulated by the first amount of the chemicaily-leavened batter layer 14.
  • the volume of each of the receptacle members 96 filled by the first amount of the chemically-leavened batter layer 14 and the substantially baked insert 12 or 12' can be from
  • the second batter injector 90 is operated to pour a second amount of the chemically-leavened batter layer 4 into each of the receptacle members 96 (Step 42).
  • the second amount of the chemically-leavened batter layer 14 is delivered in an amount sufficient to fill an additional 20% to about 65% of the cavity 100 of each of the receptacle members 96.
  • the second amount of the chemically- leavened batter layer 14 is poured into each of the receptacle members 96 such that each of the substantially baked inserts 12 or 12' is substantially or completely enveloped by the chemically-leavened batter layer.
  • each of the second bi-molded plate assemblies 94 is arranged to form the molded baking cavity 102.
  • the second major surface 106 of each of the lid members 98 is securely mated with the first major surface 110 of each of the receptacle members 96 to form a heated and sealed molded baking cavity 02.
  • the baking cavity 102 can include holes, vents, or other apertures that permit the release of steam from the baking cavity while preventing leakage of product components.
  • Steps 36-44 of the method 30 plus a first baking period are conducted during a first period of time (Step 46), which is about 10% to about 40% of the total time required to bake the multi-layered food product 10 or 10'.
  • the second baking plates 92 are rotated about the rotation members 82 (indicated by arrows) so that each of the second bi-molded plate assemblies 94 is inverted (Step 120) (Fig. 1 ). Inverting the second bi-molded plate assemblies 94 allows the chemically- leavened batter layer 14 to distribute better within each of the molded baking cavities 102, while also facilitating more even baking throughout the multi-layered food product 10 or 10'. After inverting the second baking plates 92, the second baking plates are heated for a second period of time, which is greater than the first period of time (Step 122).
  • the second period of time can be about 60% to about 90% of the total time needed to bake the multi-layered food product 10 or 10'.
  • the yeast-leavened dough 18 and the chemically- leavened batter layer 14 can be combined to form a partially seamless, borderless product.
  • the automatic removing system 84 separates the lid member 98 and the receptacle member 96 of each of the second bi-molded plate assemblies 94 after the multi-layered food product 10 or 10' has been sufficiently baked. Since each of the receptacle members 96 is inverted, separation of the lid members 98 from the receptacle members allows the multi-layered food product 10 or 10' to be easily removed from the second bi-mo!ded plate assemblies 94 via gravity. Alternatively, the multi-layer food product 10 or 10' can be removed by a suction mechanism (not shown) once the bi-molded plate assemblies 94 have rotated back around the rotation members 82 and the iid members 98 have opened.
  • the multi-layered food product After removing the multi-layered food product 10 or 0' from each of the bi-molded plate assemblies 94, the multi-layered food product is cooled for an appropriate period of time before freezing, wrapping and packaging.
  • the packaged, multi-layered food product 10 or 10' can be boxed and further frozen ahead of distribution to the marketplace.
  • another aspect of the present invention includes a method 130 for forming a multi-layered food product 0".
  • the method 130 is similar to the method 30 illustrated in Fig. 4.
  • the method 130 can be performed using an automated assembly line that is identical or similar to the first automated assembly line 50 described above.
  • the method 130 can be performed using bi- mo!ded plate assemblies (not shown) that are similar to the first bi-molded plate assemblies 62 described above.
  • each of the receptacle members comprising the bi-molded plate assemblies can have a volume that is about the same as the volume of the lid members.
  • the method 130 can begin by heating the bi- molded plate assemblies to a predetermined temperature ⁇ e.g., about 300 °F. to about 450 °F,).
  • a predetermined temperature e.g., about 300 °F. to about 450 °F.
  • the raw components of the multi-layered food product 10" can be prepared.
  • the yeast-leavened dough 18 can be formed by scaling (e.g., measuring out) the needed ingredients (as described above). As aiso described above, it will be appreciated that other ingredients may be added to adjust the flavor or improve the functionality of the yeast- leavened dough 8.
  • the ingredients can then be mixed and kneaded together for a period of time sufficient to develop the gluten structure of the yeast-leavened dough 18.
  • a measured amount of one or more fillings 16 can be "encrusted" inside a measured amount of the yeast-leavened dough 18 using a known bakery machining process.
  • the measured amount of filling 16 may range from about 15 grams to about 99 grams, and the measured amount of the yeast-leavened dough 18 may range from 12 grams to about 128 grams.
  • the formed product comprises a bail-shaped insert 12" that is completely enveloped or encapsulated by the yeast-leavened dough and includes the filling at its center.
  • the insert 12" can be passed through a molding or shaping device (not shown) so that upper and lower portions of the insert are partially flattened.
  • the molded insert 12" is then placed into a bakery proofing chamber 118 for a period of time sufficient to adequately "rise” or "proof the insert prior to baking.
  • the proofing time can vary from about 10 minutes to about 60 minutes, depending upon the type and size of the yeast-leavened dough 18 and the filling 16. After the insert 12" is adequately proofed, it is ready for subsequent use.
  • the insert 12" Upon heating each of the bi-molded plate assemblies to the predetermined temperature and forming the raw components of the multi-layered food product 10", the insert 12" can be placed into a receptacle member of a bi-molded plate assembly (Step 32) and the lid member mated with the receptacle member to form a sealed baking cavity (Step 44).
  • the insert 12" can be entirely baked at Step 46.
  • an insert 12" is taken from the proofing chamber 118 and deposited into the receptacle member of a bi-molded plate assembly, it will be appreciated that the insert 12" can be deposited into the receptacle member by any one or combination of mechanisms known in the art, such as via a robotic arm, conveyor belt system 140 (Fig. 6), or by hand .
  • the receptacle members and the lid members rotate about the tracts of an oven 58 (e.g., a tunnel oven) to securely mate with another and thereby form a plurality of bi-moided plate assemblies.
  • an oven 58 e.g., a tunnel oven
  • the bi-molded plate assemblies then move through the oven 58 for a time and at a temperature sufficient to completely bake the insert 12".
  • the bi-molded plate assemblies can move through oven 58 so that the insert 12" is baked to completion (100% baked).
  • the first bi-mo!ded piate assemblies can move through the oven 58 for a time of about 1 minute to about 4 minutes and at a temperature of about 300°F to about 450°F to completely bake the insert 12".
  • the receptacle members and the lid members are separated as shown in Fig. 5 so that the multi-layered food product 10" can be removed from the plates and cooled for an appropriate period of time before freezing, wrapping and packaging.
  • the packaged, multi-layered food product 10" can be boxed and further frozen ahead of distribution to the marketplace.
  • the present invention can include an alternative assembly line system 200 (Fig. 13) for forming a multi-layered food product 10 or 10'.
  • the assembly line system 200 comprises a series of upper and lower loop-shaped tracts 202 and 204, a portion of each of which is disposed within an oven 206.
  • the upper and lower tracts 202 and 204 include a pluraiity of baking plates 208 (not shown in detail) securely mounted thereto that can be mated together to form a plurality of bi-mo!ded plate assemblies (not shown) (as described above).
  • the lower tract 204 has a greater length than the upper tract 202, which allows the components of the multi-layered food product 10 or 10' to be supplied to the baking plates 208 as shown in Fig. 13.
  • Other components of the assembly line system 200 are similar or identical to those shown in Fig. 6 and described above, such as a bakery proofing chamber 212, a conveyor belt system 214, a second oven 216, a transfer machine 218, a first batter injector 220, an insert feeding system 222, a second batter injector 224, and an optional automatic removing system 225.
  • the oven 206 is different than the oven 52 described above.
  • the baking plates are heated to a predetermined temperature (as described above).
  • the first batter injector 220 is operated to pour a first amount of a chemically-leavened batter layer 14 into each of the baking plates 208.
  • the baking plates 208 are then advanced along the lower tract 204 (e.g., clockwise) to the insert feeding system 222, which is activated to place a substantially baked insert 12 or 12' atop the first amount of the chemically-leavened batter layer 14 already in each of the baking plates 208.
  • the second batter injector 224 is operated to pour a second amount of the chemically-leavened batter layer 14 into each of the baking plates (as described above).
  • the baking plates of the upper tract 202 rotate (e.g., counter-clockwise) to securely mate with the baking plates of the lower tract 204, thereby forming the plurality of bi-molded plate assemblies.
  • the bi-molded plate assemblies move through the oven 206 for a time and at a temperature sufficient to completely bake the muiti- layered food product 10 or 10' (as described above).
  • the total bake time is about 30 seconds to about 200 seconds.
  • the baking plates of the lower and upper tracts 204 and 202 are separated so that the substantially baked multi-layered food product 10 or 10' is removed from each of the bi-molded plate assemblies (e.g. , by gravity or the automatic removing system 225) and cooled for an appropriate period of time before freezing, wrapping and repackaging.
  • the packaged, mufti-!ayered food product 0 or 10' can be boxed and further frozen ahead of distribution to the marketplace.

Abstract

L'invention concerne un produit alimentaire multicouche comprenant un fourrage enrobé de pâte levée à la levure et sensiblement cuite au four. Le fourrage enrobé est encore enveloppé dans une couche de pâte levée chimiquement et sensiblement cuite au four.
PCT/US2013/031294 2012-03-14 2013-03-14 Produit alimentaire multicouche et son procédé de préparation WO2013138581A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US13/419,505 2012-03-14
US13/419,505 US10448653B2 (en) 2009-12-01 2012-03-14 Multi-layered food product and method for forming

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WO2013138581A1 true WO2013138581A1 (fr) 2013-09-19

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10457804B2 (en) 2009-12-01 2019-10-29 Arlington Valley Farms Llc Sandwich and method for forming
US10537111B2 (en) 2009-12-01 2020-01-21 Arlington Valley Farms Llc Multi-layered food product and method for forming
US11910799B2 (en) 2009-12-01 2024-02-27 Arlington Valley Farms Llc Multi-layered food product and method for forming

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3250625A (en) * 1963-08-26 1966-05-10 Ray J Thelen Partially yeast-chemically leavened laminated foodstuffs
US4948603A (en) * 1988-08-16 1990-08-14 Griffith Laboratories U.S.A., Inc. Process for preparing storage stable, readily reconstituted frozen comestibles and frozen comestibles produced thereby
EP0540521B1 (fr) * 1990-07-20 1995-03-22 The Pillsbury Company Produit alimentaire enrobe de pate et recouvert d'une pate a frire cuisant au four a micro-ondes
US5520937A (en) * 1990-07-20 1996-05-28 The Pillsbury Company Microwaveable batter-coated dough
US20050025862A1 (en) * 2003-07-29 2005-02-03 Schwan's Food Manufacturing, Inc. Multi-component dough
WO2005112664A1 (fr) * 2004-05-17 2005-12-01 Bernard Matthews Limited Ameliorations apportees ou se rapportant a des produits farcis
US20060073246A1 (en) * 2004-10-05 2006-04-06 The J.M. Smucker Company Method and apparatus for making commercial crustless sandwiches and the crustless sandwich made thereby
US20080057157A1 (en) * 2006-08-31 2008-03-06 Helbert Almeida Puffed Cracker-Like Food Products And Method Of Making
US20110135792A1 (en) * 2009-12-01 2011-06-09 Arlington Valley Farms Llc Sandwich and method for forming

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3250625A (en) * 1963-08-26 1966-05-10 Ray J Thelen Partially yeast-chemically leavened laminated foodstuffs
US4948603A (en) * 1988-08-16 1990-08-14 Griffith Laboratories U.S.A., Inc. Process for preparing storage stable, readily reconstituted frozen comestibles and frozen comestibles produced thereby
EP0540521B1 (fr) * 1990-07-20 1995-03-22 The Pillsbury Company Produit alimentaire enrobe de pate et recouvert d'une pate a frire cuisant au four a micro-ondes
US5520937A (en) * 1990-07-20 1996-05-28 The Pillsbury Company Microwaveable batter-coated dough
US20050025862A1 (en) * 2003-07-29 2005-02-03 Schwan's Food Manufacturing, Inc. Multi-component dough
WO2005112664A1 (fr) * 2004-05-17 2005-12-01 Bernard Matthews Limited Ameliorations apportees ou se rapportant a des produits farcis
US20060073246A1 (en) * 2004-10-05 2006-04-06 The J.M. Smucker Company Method and apparatus for making commercial crustless sandwiches and the crustless sandwich made thereby
US20080057157A1 (en) * 2006-08-31 2008-03-06 Helbert Almeida Puffed Cracker-Like Food Products And Method Of Making
US20110135792A1 (en) * 2009-12-01 2011-06-09 Arlington Valley Farms Llc Sandwich and method for forming

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10457804B2 (en) 2009-12-01 2019-10-29 Arlington Valley Farms Llc Sandwich and method for forming
US10537111B2 (en) 2009-12-01 2020-01-21 Arlington Valley Farms Llc Multi-layered food product and method for forming
US11910799B2 (en) 2009-12-01 2024-02-27 Arlington Valley Farms Llc Multi-layered food product and method for forming

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