WO2020051673A1 - Low stress dough feeding apparatus - Google Patents
Low stress dough feeding apparatus Download PDFInfo
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- WO2020051673A1 WO2020051673A1 PCT/CA2018/000172 CA2018000172W WO2020051673A1 WO 2020051673 A1 WO2020051673 A1 WO 2020051673A1 CA 2018000172 W CA2018000172 W CA 2018000172W WO 2020051673 A1 WO2020051673 A1 WO 2020051673A1
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- WIPO (PCT)
- Prior art keywords
- dough
- rollers
- roller
- extracting
- flattening
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Classifications
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- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21C—MACHINES OR EQUIPMENT FOR MAKING OR PROCESSING DOUGHS; HANDLING BAKED ARTICLES MADE FROM DOUGH
- A21C3/00—Machines or apparatus for shaping batches of dough before subdivision
- A21C3/04—Dough-extruding machines ; Hoppers with moving elements, e.g. rollers or belts as wall elements for drawing the dough
-
- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21C—MACHINES OR EQUIPMENT FOR MAKING OR PROCESSING DOUGHS; HANDLING BAKED ARTICLES MADE FROM DOUGH
- A21C3/00—Machines or apparatus for shaping batches of dough before subdivision
- A21C3/02—Dough-sheeters; Rolling-machines; Rolling-pins
Definitions
- the present invention relates to a dough feeding system for use as part of an industrial bread making line.
- the dough feeding system is configured to form and convey a continuous belt of dough for further processing before it is cut into individual units, formed, and then either baked immediately or frozen for later use.
- the described dough feeding system is particularly suitable for doughs used to make flat breads, as it is configured to provide for minimal handling of and stress on the dough. This results in a softer, more flexible product that can ultimately be used to create a more uniform final product with improved properties of taste and texture.
- the process of forming the dough belt from a mass of newly mixed dough is typically the step that places the most pressure on the dough, and can result in the problematic, overworked dough described above.
- This invention addresses the above-noted problems with industrial equipment for forming a dough belt which may ideally be used to form a bread using high gluten flours, such as flat breads.
- a dough feeding apparatus that involves a far gentler treatment and conveyance of the dough belt following its formation than is currently provided by existing machines. This ultimately results in a more relaxed and uniform dough and final product with better shape and texture.
- the general object of the present invention is to provide a dough belt forming and feeding apparatus that places less pressure and stress on the dough, and gently conveys it for further processing, as part of an industrial dough-making line.
- the dough feeding apparatus comprises a first set of rollers located in a hopper for containing and conveying the dough following mixing.
- Each of the first set of rollers has the cross-sectional shape of a pinwheel with relatively few points.
- the rollers are spaced relatively far from each other, and at a set diagonal angle relative to each other so that dough being conveyed between the rollers is gently scooped and passed along between the rollers, rather than being tightly compressed as it proceeds through.
- the pinwheel-shaped rollers result in the formation of a belt of dough that has received a minimum of processing and compression upon its formation.
- the dough feeding apparatus comprises a second set of substantially flat rollers that can be adjustable to provide for a desired thickness of the dough belt.
- the second set of rollers which serve as dough-flattening rollers, are cylindrical, with flat exteriors preferably coated in a food-grade rubber, which provides friction to the dough as it passes through.
- the flattening rollers are also equipped with supplementary scraping devices that can redirect and convey any dough that inadvertently adheres to the rollers during dough passage.
- One out of a pair of flattening rollers may be fixed in place, with the other being adjustable so that the space between the rollers, which correlates to the thickness of the dough belt, can be adjusted as appropriate for the product being prepared.
- the dough feeding apparatus also includes a hopper attached to an enclosure with at least two removable sides that are positioned on either side of the two sets of rollers.
- the edges of roller parts that contact the dough are placed substantially flush with the removable sides of the hopper to minimize the possibility of dough being misconveyed laterally. Rather, the roller parts and hopper sides are configured so that substantially all of the dough is directed downwards through the rollers in order to form a dough belt.
- the individual units in the two sets of rollers are arranged at angles of approximately 15-45 degrees relative to each other, with 22-35 being more preferred, and 25 degrees being the most preferred. This results in a saving of space for the machinery, as the rollers can be contained in a smaller enclosure. This configuration further facilitates the general downward path of the dough, being fed by both gravity and by the friction of the rollers themselves, through the industrial dough making line.
- the present invention provides a dough feeding mechanism that is ideal for use as part of an industrial dough making line or baking line used to make flatbreads.
- a dough feeding mechanism that is ideal for use as part of an industrial dough making line or baking line used to make flatbreads.
- the dough feeding apparatus further provides a means of adjusting the thickness of the dough belt.
- one or both of the flat rollers may be movable so that the distance between them can be set by the user.
- only one of the pair of flat rollers is so movable lt is attached by a rail connected to a worm gear provided with a manual adjusting knob, connected to a graduated counter that allows the user to set the thickness.
- the adjustment can be electronically performed, if the rollers and their connecting pieces are appropriately equipped with a motor for this task.
- a method for using the dough feeding apparatus of the present invention is also provided.
- the dough feeding apparatus can be used and set manually as described above, or may also be connected to a programmable logic controller which can be used to program the speeds of rotation of the two sets of rollers.
- the rollers may be rotated at varying speeds.
- the flat set of rollers would typically be set or programmed to run at a slightly faster speed, depending on the consistency of the dough being fed through. Operational speeds may vary depending on the preferred conditions for the particular type of dough.
- the low stress dough feeding apparatus described herein is well-placed to facilitate the automated production of high quality, consistent product with desired texture, even when using high-gluten flours.
- Figure 1 is an exploded top perspective view of the hopper and lower enclosure of the dough feeding apparatus, with the enclosure sides disassembled.
- Figure 2 is a further top perspective view of the hopper and enclosure of the dough feeding apparatus, partially assembled.
- Figure 3 is a perspective view of one of the pinwheel-shaped rollers.
- Figure 4 is a perspective view of one of the flat rollers.
- Figure 5 is a cross-sectional view of the interior of the hopper, which also shows the sets of rollers and their respective turning directions.
- Figure 6 shows a side view of the hopper.
- Figure 7 shows a front view of the hopper and enclosure completely assembled with the rollers partially visible.
- Figure 8 shows a close-up view of an embodiment of the adjusting wheel, counter, the chain belt, and pulley used with the flat set of rollers.
- top”,“front”,“back” etc. are for illustrative convenience and refer to a specific orientation. However, such terms are not to be construed in a limiting sense as it is contemplated that various components will, in practice, be utilized in orientations that are the same as, or different than those described or shown.
- Figure 1 discloses the hopper 1 and enclosure 2, which are the first components of the dough feeding apparatus that the dough encounters, following mixing and kneading in a separate industrial mixer (not shown).
- the hopper 1 takes the general shape of a truncated upside down pyramid.
- the enclosure 2 is shown in disassembled form, and is comprised of a pair of end panels 3a and 3b and a pair of elongated panels 4a and 4b.
- the end panels 3a and 3b each have keyed slots 5 which are configured to closely fit the lateral edges of the respective elongated panels 4a and 4b.
- braces 6 which are installed on an exterior side of the elongated panels 4a and 4b.
- the braces 6 may be equipped with hand-adjustable knobs (not shown) which connect with a rail (also not shown), the ends of the rail being inserted into rail receiving holes 7 in the end panels 3a and 3b. This provides a simple manner in which the enclosure 2 may be manually assembled for use, and manually disassembled between uses when cleaning is necessary.
- the two elongated panels 4a and 4b may be made of any suitable non-stick material, such as stainless steel or a durable plastic, most preferably a stainless steel.
- the two end panels 3a and 3b may similarly be made of any appropriate non-stick material such as plastic or stainless steel, most preferably plastic for reasons to facilitate easier handling and cleaning.
- roller-receiving holes 8 which have been machined out of the end panels 3a and 3b. In use, these holes are used to hold pinwheel-shaped rollers as described below.
- the two end panels 3a and 3b also feature bottom edges that incorporate a stepped cut out. The angle of the step in the cut out approximately follows the relative angle of the roller-receiving holes 8. The stepped cut out is so configured so that the enclosure can accommodate further rollers to be installed on the same or similar angle relative to each other as that seen between the roller-receiving holes 8.
- the angle between the roller receiving holes 8 may be anywhere from 15 to 45°.
- roller receiving holes 8 in addition to being configured at a set angle relative to each other, are also spaced by a fixed distance apart from each other. The actual distance will ultimately depend on capacity of the bread dough-making line and hopper, but distances in the range of 15-35 cm have been found to work well.
- Figure 2 shows a top perspective view of the partially assembled hopper 1 and enclosure 2.
- the rails are again not shown, but it can be better seen in this drawing how they may be used to secure the elongated panels 4a and 4b to the end panels 3a and 3b.
- Figure 3 shows a perspective view of a pinwheel-shaped roller 9a in isolation.
- This particular embodiment has six points. Five to eight points would also be workable as part of this invention, with the most preferred number of points being six. It will be evident to the skilled person that the points of the pinwheel, comprised of sides 10a and 10b, are not symmetrical. That is, they have been appropriately angled to scoop and convey a fluid substance such as dough. The dimension of side 10b is shorter than that of 10a. As shown in Figure 3, it can be envisioned that if the roller 9a is turning in a clockwise direction, dough would be captured by the side 10b and gently urged in a generally downward direction.
- the points of the pinwheel-shaped roller 9a may have straight profiles, as shown herein, or may be curved when seen in profile.
- the points of the pinwheel-shaped roller 9a may be constructed from any durable material that would not overly adhere to dough. Suitable materials include stainless steel or plastic.
- the ends 11a and lib of the roller 9a will be appropriately configured to be installed into the previously described roller receiving holes 8 located in the end panels 3a and 3b.
- roller receiving holes 8 located in the end panels 3a and 3b.
- a convenient way is to install toothed gear panels on the ends 11a and lib and connect one of them to a standard motor by way of a belt or chain, with the other gear rotating freely.
- FIG 4 shows a perspective view of a flattening roller 12a in isolation.
- a pair of flattening rollers works in concert with a pair of pinwheel-shaped rollers to form a dough belt.
- Flattening roller 12a may be made of any suitable material, such as stainless steel and has a smooth surface 13 which may be covered by a food- grade rubber which will provide appropriate friction to the dough as it proceeds through the dough feeding apparatus.
- Flattening roller 12a is also equipped with ends 14a and 14b, which may similarly be outfitted with known means to effectuate turning such as the toothed gear panels described above.
- FIG. 5 Shown in Figure 5 is a side cross-sectional view of an assembled dough feeding apparatus.
- the hopper 1 is shown in profile and is the source of the mixed dough that is used to form a dough belt.
- the end panel 3a that would be installed at the front of the enclosure is not shown, however the back end panel 3b of the enclosure 2 is visible in this view, as are the braces 6 that were previously described.
- knobs 15 which secure rail 16 to create the enclosure 2.
- Pinwheel-shaped rollers 9a and 9b can be seen in profile. They are installed at angles of 15 to 45° relative to each other in the pinwheel receiving holes 8 as described previously. The rollers 9a and 9b shown here are installed at relative angle of 25°. It can also be seen that rollers 9a and 9b are not installed in the same orientation; rather in profile it can be seen that the rollers are mirror images of each other. In addition to being installed at angles relative to each other, the rollers 9a and 9b are spaced apart from each other so that dough travelling between them will not encounter a significant amount of compression, twisting, stretching, or wringing. The spacing between the rollers 9a and 9b may be anywhere between 15-35 cm.
- the diameter from comer to comer may be anywhere between 12 to 18 cm, depending on the capacity of the machine.
- rollers 9a and 9b will also be turned in opposite directions, towards each other.
- roller 9a would turn clockwise
- roller 9b would turn counter-clockwise.
- both rollers 9a and 9b turning inwards towards each other, they will operate to pull down and convey dough between them.
- This configuration allows for gentler treatment of the dough as it is being formed into a belt in between these pinwheel-shaped rollers 9a and 9b. Dough is fed downward partially by gravity, but is also being formed and pulled by first being scooped by the points of the pinwheel-shaped roller 9b and then passed on to pinwheel shaped roller 9a.
- the pinwheel- shaped rollers 9a and 9b thereby form a dough belt, but with far less of the compressing, shearing, or pulling force that has been inherent in dough extracting rollers of the prior art.
- Such formation of the dough belt using the mechanisms described herein does not comprise speed of manufacture.
- Dough belts can be formed at a rate of 10 m/min using the invention, which is an acceptable industrial rate of manufacture for bread dough. [0038] It is contemplated that if a large volume of dough is fed through the hopper 1, there may be some back-up of dough as the pinwheel-shaped rollers 9a and 9b operate.
- the sides of the hopper 1 funnel inwards to direct the dough to the central path between the pinwheel-shaped rollers 9a and 9b, and are configured such that excess dough will not tend to be displaced laterally to the outside of the pinwheel-shaped rollers 9a and 9b. As well, with this configuration, any excess dough will be urged upwards back into the hopper 1, for immediate use in the continued formation of a dough belt. In this way, the“oldest” dough is used first, with newer dough being continually fed through the top of the hopper 1. This results in the dough not having the opportunity to remain in the hopper 1 for an extended period of time, which would likely result in the dough drying out.
- the dough After the dough is roughly formed into a belt by the scooping and passing actions of pinwheel-shaped rollers 9a and 9b, the dough next encounters flattening rollers 12a and 12b, which compress the dough belt to an appropriate thickness for further processing.
- the flattening rollers 12a and 12b are similarly placed at the previously described range of angles relative to each other, with approximately 25° again being the most preferred angle. Similar to the pinwheel-shaped rollers 9a and 9b, the flattening rollers 12a and 12b are turned in opposite directions towards each other. Specifically, flattening roller 12a will turn clockwise, and flattening roller 12b will turn counter clockwise.
- the permanent angle between the pair of pinwheel- shaped rollers 9a and 9b facilitates a gentler formation and handling of the dough belt which is better suited for making bread doughs with high gluten flour content.
- An additional advantage of this configuration is that the dough forming apparatus requires less lateral space within a breadmaking machine or line. The space saving by partially stacking the rollers means that a smaller overall dough-making machine is needed, which takes up less factory floor space.
- the two pairs of rollers 9a/9b and 12a/12b should not be turned at the same rate lt is necessary for the flattening rollers to have a faster rpm, otherwise there will be a back-up of the dough belt between the two pairs of rollers.
- Speeds that have been found to work well are 18 rpm for both of the pinwheel-shaped rollers 9a and 9b, and 20 rpm for both of the flattening rollers 12a and 12b.
- Scrapers 18 are also attached to the flattening rollers 12a and 12b, by way of a post 17 attached to stationary inner portions of the rollers 12a and 12b.
- Scrapers 18 are configured as flat blades which will serve to detach any dough which may inadvertently adhere to the flattening rollers 12a or 12b. This can be an issue with doughs with particularly high water content. As shown, the free edge of scraper 18 is mechanically biased to have close contact with the rubber surface of the flattening roller 12a as it turns. Scraper 18 can therefore effectively dislodge sticky dough.
- Scraper 18 may be constructed from a variety of materials. Plastic or a metal such as brass have been found to be effective. Scraper 18 may be attached to its respective post 17 by way of a knob or bolt which may be removed to permit the user to adjust the angle and point of intersection of the scrapers 18 relative to the flattening rollers 12a and 12b. This attachment means further allows the scrapers 18 to be removed to allow for cleaning or replacement of the scrapers 18.
- roller 12a is fixed in place, and movable roller 12b is installed along a rail 20, which is partially visible in Figure 5, but better viewed in Figures 6 and 8.
- a manual adjusting wheel 19 that can be used to move flattening roller 12b closer or further away from flattening roller 12a, so as to be able to set the thickness of the resulting dough belt.
- FIG. 6 a further side view of the exterior of the dough feeding apparatus is seen. Now visible are toothed gear wheels 21 which have been installed at the end of the previously described pinwheel-shaped rollers 9a and 9b. Toothed gear wheels 21 which are fitted into each other as shown are an advantageous way to configure the invention; the wheels 21 will be guaranteed to move at the same rate relative to each other. As well, only one motor would be required to drive one of the rollers 9a or 9b.
- the fixed flattening roller 12a is connected to a standard motor by way of a belt or chain (not shown). Toothed geared wheels are fitted onto the corresponding ends of flattening rollers 12a and 12b.
- the toothed geared wheel of the fixed flattening roller 12a is connected by a chain belt to the toothed geared wheel of the moveable flattening roller 12b, thus ensuring that the flattening rollers 12a and 12b rotate at the same rate relative to each other.
- the inner surface of the chain belt engages the toothed geared wheel of the fixed flattening roller 12a and is further engaged with a tensioner pulley (not shown).
- the tensioner pulley causes the outer surface of the chain belt to remain engaged with the tooth geared wheel of the moveable flattening roller 12b as the moveable flattening roller 12b moves along the rails 20.
- FIG 7 a side view of the dough feeding system is shown.
- the hopper 1 and enclosure 2 are shown assembled with the end panels, 3a and 3b, which are engaged with the elongated panels 4a and 4b. Visible in this view are the knobs 15 and rail 16, used to secure the end panels 3a and 3b, which are to the elongated panels, 4a and 4b, to form the enclosure 2.
- a suitable mechanism to prevent movement of the end panels 3a and 3b along the rail is used.
- the rail 16 is threaded where it engages the receiving holes of end panels 3a and 3b.
- Outer nuts 29 and inner nuts 30 are threaded onto these portions of the rail 16 and engage the outer and inner surfaces of end panels 3a and 3b, to prevent movement of the end panels 3a and 3b along the rail 16. Also shown in profile are the two pin wheel -shaped rollers, 9a and 9b including their respective circular toothed gear panels 21 on their ends. Figure 7 further shows in profile a flattening roller 12a, and the manual adjusting wheel 19 connected to a graduated counter 22 and shaft 23.
- the manual adjusting wheel 19 may be connected to a graduated counter 22 on the shaft 23 so that the user may conveniently set the thickness of the resulting dough belt that is the most appropriate target thickness for the product being made.
- Worm screws 24 are connected to the shaft 23 and are engaged with worm gears 25 connected to rails 20.
- the rails 20 are connected to flattening roller support structures 26 configured to support the weight of movable flattening roller 12b and allow the free rotation of the flattening roller 12b.
- the flattening roller support structures 26 comprise a flattening roller receiving hole 27 for engaging the ends 14a, 14b of the flattening roller 12b.
- the flattening roller support structures 26 are disposed within respective support structure housings 28 which act as a guide for the flattening roller support structure 26 as they are moved along their respective rails 20.
- the invention described above provides a low-stress dough feed-in component for use in the industrial manufacture of breads, and is particularly well-adapted for the manufacture of flatbreads using dough made of high-protein flour. This configuration allows for a gentler, less stressful treatment of the dough and ultimately results in dough that, because it is soft and not over-worked or over-stressed, can be more readily and uniformly shaped, and baked to have the desired textural features for the type of flatbread being prepared.
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Abstract
The present invention relates to a dough feeding system for use as part of an industrial bread making line. The dough feeding system is configured to form and convey a continuous belt of dough for further processing before it is cut into individual units, formed, and then either baked immediately or frozen for later use. The described dough feeding system is particularly suitable for doughs used to make flat breads, as it is provided with pinwheel-shaped rollers for scooping dough from a dough mass, to form a dough belt. The dough belt is thus gently formed and passed onwards to further rollers which press the dough into the desired thickness. This configuration provides for minimal handling of and stress on the dough. This results in a softer, more flexible product that can ultimately be used to form a more uniform final product with improved properties.
Description
LOW STRESS DOUGH FEEDING APPARATUS
FIELD OF THE INVENTION
[0001] The present invention relates to a dough feeding system for use as part of an industrial bread making line. The dough feeding system is configured to form and convey a continuous belt of dough for further processing before it is cut into individual units, formed, and then either baked immediately or frozen for later use. The described dough feeding system is particularly suitable for doughs used to make flat breads, as it is configured to provide for minimal handling of and stress on the dough. This results in a softer, more flexible product that can ultimately be used to create a more uniform final product with improved properties of taste and texture.
BACKGROUND OF THE INVENTION
[0002J Industrial bread making lines are known, and typically involve a stream of dough that is mixed, pulled, and processed between multiple sets of rollers before it is cut, shaped, and baked. Such typical dough processing machinery has proven to work well for many types of bread. However, when such existing machinery is used to make flatbreads such as naan, pizza doughs, lavash, chapatis, and tortillas, it has been frequently found that the dough becomes over- worked, over-handled, and tough. This can cause problems in the later processing steps for the dough. Toughened dough results in a less uniform final product, as it may become overly hard and elastic, and therefore less readily able to stay uniformly flattened prior to baking. In particular, an overly elastic dough will tend to spring back under pressure. Such toughened dough is also a challenge to form into uniform shapes as is generally preferred by consumers.
[0003] The reason for the challenge in processing flatbread dough recipes in particular is that many industrial recipes for flatbread use specialized flours that have higher amounts of gluten. Gluten, when combined with moisture, creates elasticity in the dough. High gluten flours tend to impart desired features for flatbreads such as crispiness on the exterior and a chewy interior. However, when processed using the powerful motors and compressing rollers of
the typical industrial breadmaking lines, the flatbread dough is apt to become dense, overworked, and tough.
[0004] ln the process of making large industrial quantities of dough, the flour, water, and any other ingredients used for the particular recipe are mixed and kneaded in large batches in an industrial mixer. Following these steps, the dough is processed into a uniform belt or column of dough, which can then be sent down a conveyor belt for further processing, cutting, shaping, and finally, baking and packaging.
[0005] The process of forming the dough belt from a mass of newly mixed dough is typically the step that places the most pressure on the dough, and can result in the problematic, overworked dough described above. This invention addresses the above-noted problems with industrial equipment for forming a dough belt which may ideally be used to form a bread using high gluten flours, such as flat breads. What is provided is a dough feeding apparatus that involves a far gentler treatment and conveyance of the dough belt following its formation than is currently provided by existing machines. This ultimately results in a more relaxed and uniform dough and final product with better shape and texture.
SUMMARY OF THE INVENTION
[0006] The general object of the present invention is to provide a dough belt forming and feeding apparatus that places less pressure and stress on the dough, and gently conveys it for further processing, as part of an industrial dough-making line.
[0007] In one aspect, the dough feeding apparatus comprises a first set of rollers located in a hopper for containing and conveying the dough following mixing. Each of the first set of rollers has the cross-sectional shape of a pinwheel with relatively few points. The rollers are spaced relatively far from each other, and at a set diagonal angle relative to each other so that dough being conveyed between the rollers is gently scooped and passed along between the rollers, rather than being tightly compressed as it proceeds through. The pinwheel-shaped rollers result in the formation of a belt of dough that has received a minimum of processing and compression upon its formation.
[0008] In a further aspect, the dough feeding apparatus comprises a second set of substantially flat rollers that can be adjustable to provide for a desired thickness of the dough belt. The second set of rollers, which serve as dough-flattening rollers, are cylindrical, with flat exteriors preferably coated in a food-grade rubber, which provides friction to the dough as it passes through. The flattening rollers are also equipped with supplementary scraping devices that can redirect and convey any dough that inadvertently adheres to the rollers during dough passage. One out of a pair of flattening rollers may be fixed in place, with the other being adjustable so that the space between the rollers, which correlates to the thickness of the dough belt, can be adjusted as appropriate for the product being prepared.
[0009] In a still further aspect, the dough feeding apparatus also includes a hopper attached to an enclosure with at least two removable sides that are positioned on either side of the two sets of rollers. The edges of roller parts that contact the dough are placed substantially flush with the removable sides of the hopper to minimize the possibility of dough being misconveyed laterally. Rather, the roller parts and hopper sides are configured so that substantially all of the dough is directed downwards through the rollers in order to form a dough belt.
[0010] In a still further aspect, the individual units in the two sets of rollers are arranged at angles of approximately 15-45 degrees relative to each other, with 22-35 being more preferred, and 25 degrees being the most preferred. This results in a saving of space for the machinery, as the rollers can be contained in a smaller enclosure. This configuration further facilitates the general downward path of the dough, being fed by both gravity and by the friction of the rollers themselves, through the industrial dough making line.
[0011] As embodied and broadly described below, the present invention provides a dough feeding mechanism that is ideal for use as part of an industrial dough making line or baking line used to make flatbreads. As a result of the gentler treatment of the dough belt as compared to existing equipment, resulting products do not get overkneaded or overworked, are more uniform, and can be readily configured to have the desired textures of crispiness on the exterior and chewiness in the interior.
[0012] In a preferred embodiment, the dough feeding apparatus further provides a means of adjusting the thickness of the dough belt. In particular, one or both of the flat rollers may be movable so that the distance between them can be set by the user. In a particularly preferred embodiment, only one of the pair of flat rollers is so movable lt is attached by a rail connected to a worm gear provided with a manual adjusting knob, connected to a graduated counter that allows the user to set the thickness. In another aspect, the adjustment can be electronically performed, if the rollers and their connecting pieces are appropriately equipped with a motor for this task.
[0013] A method for using the dough feeding apparatus of the present invention is also provided. The dough feeding apparatus can be used and set manually as described above, or may also be connected to a programmable logic controller which can be used to program the speeds of rotation of the two sets of rollers. The rollers may be rotated at varying speeds. In particular, the flat set of rollers would typically be set or programmed to run at a slightly faster speed, depending on the consistency of the dough being fed through. Operational speeds may vary depending on the preferred conditions for the particular type of dough.
[0014] As consumer tastes change to embrace different types and styles of bread, including many international styles of flatbread, the low stress dough feeding apparatus described herein is well-placed to facilitate the automated production of high quality, consistent product with desired texture, even when using high-gluten flours.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will now be better understood with reference to the description and to the accompanying drawings in which:
[0016] Figure 1 is an exploded top perspective view of the hopper and lower enclosure of the dough feeding apparatus, with the enclosure sides disassembled.
[0017] Figure 2 is a further top perspective view of the hopper and enclosure of the dough feeding apparatus, partially assembled.
[0018] Figure 3 is a perspective view of one of the pinwheel-shaped rollers.
[0019] Figure 4 is a perspective view of one of the flat rollers.
[0020] Figure 5 is a cross-sectional view of the interior of the hopper, which also shows the sets of rollers and their respective turning directions.
[0021] Figure 6 shows a side view of the hopper.
[0022] Figure 7 shows a front view of the hopper and enclosure completely assembled with the rollers partially visible.
[0023] Figure 8 shows a close-up view of an embodiment of the adjusting wheel, counter, the chain belt, and pulley used with the flat set of rollers.
[0024] In these figures, preferred embodiments of the invention are illustrated by way of examples. It is to be expressly understood that the description and drawings are only for the purpose of illustration and are an aid for understanding. They are not intended to define the limits of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] As used herein, any usage of terms that suggest an absolute orientation (e.g.
“top”,“front”,“back” etc.) are for illustrative convenience and refer to a specific orientation. However, such terms are not to be construed in a limiting sense as it is contemplated that various components will, in practice, be utilized in orientations that are the same as, or different than those described or shown.
[0026] Turning now to the figures, Figure 1 discloses the hopper 1 and enclosure 2, which are the first components of the dough feeding apparatus that the dough encounters, following mixing and kneading in a separate industrial mixer (not shown). The hopper 1 takes the general shape of a truncated upside down pyramid. The enclosure 2 is shown in disassembled form, and is comprised of a pair of end panels 3a and 3b and a pair of elongated
panels 4a and 4b. The end panels 3a and 3b each have keyed slots 5 which are configured to closely fit the lateral edges of the respective elongated panels 4a and 4b. Also visible in this view are braces 6 which are installed on an exterior side of the elongated panels 4a and 4b. The braces 6 may be equipped with hand-adjustable knobs (not shown) which connect with a rail (also not shown), the ends of the rail being inserted into rail receiving holes 7 in the end panels 3a and 3b. This provides a simple manner in which the enclosure 2 may be manually assembled for use, and manually disassembled between uses when cleaning is necessary.
[0027] The two elongated panels 4a and 4b may be made of any suitable non-stick material, such as stainless steel or a durable plastic, most preferably a stainless steel. The two end panels 3a and 3b may similarly be made of any appropriate non-stick material such as plastic or stainless steel, most preferably plastic for reasons to facilitate easier handling and cleaning.
[0028] Also visible in Figure 1 are roller-receiving holes 8 which have been machined out of the end panels 3a and 3b. In use, these holes are used to hold pinwheel-shaped rollers as described below. The two end panels 3a and 3b also feature bottom edges that incorporate a stepped cut out. The angle of the step in the cut out approximately follows the relative angle of the roller-receiving holes 8. The stepped cut out is so configured so that the enclosure can accommodate further rollers to be installed on the same or similar angle relative to each other as that seen between the roller-receiving holes 8.
[0029] The angle between the roller receiving holes 8 may be anywhere from 15 to 45°.
Most preferred is a range between 22-35°, and further preferred is the angle of 25°. The roller receiving holes 8, in addition to being configured at a set angle relative to each other, are also spaced by a fixed distance apart from each other. The actual distance will ultimately depend on capacity of the bread dough-making line and hopper, but distances in the range of 15-35 cm have been found to work well.
[0030] Figure 2 shows a top perspective view of the partially assembled hopper 1 and enclosure 2. The rails are again not shown, but it can be better seen in this drawing how they may be used to secure the elongated panels 4a and 4b to the end panels 3a and 3b.
[0031] Figure 3 shows a perspective view of a pinwheel-shaped roller 9a in isolation.
This particular embodiment has six points. Five to eight points would also be workable as part of this invention, with the most preferred number of points being six. It will be evident to the skilled person that the points of the pinwheel, comprised of sides 10a and 10b, are not symmetrical. That is, they have been appropriately angled to scoop and convey a fluid substance such as dough. The dimension of side 10b is shorter than that of 10a. As shown in Figure 3, it can be envisioned that if the roller 9a is turning in a clockwise direction, dough would be captured by the side 10b and gently urged in a generally downward direction. The points of the pinwheel-shaped roller 9a may have straight profiles, as shown herein, or may be curved when seen in profile.
[0032] The points of the pinwheel-shaped roller 9a may be constructed from any durable material that would not overly adhere to dough. Suitable materials include stainless steel or plastic.
[0033] The ends 11a and lib of the roller 9a will be appropriately configured to be installed into the previously described roller receiving holes 8 located in the end panels 3a and 3b. There are many known means by which to effectuate turning of the roller 9a when incorporated into the dough feeding apparatus of the invention. A convenient way is to install toothed gear panels on the ends 11a and lib and connect one of them to a standard motor by way of a belt or chain, with the other gear rotating freely.
[0034] Figure 4 shows a perspective view of a flattening roller 12a in isolation. As shown in the description to follow, a pair of flattening rollers works in concert with a pair of pinwheel-shaped rollers to form a dough belt. Flattening roller 12a may be made of any suitable material, such as stainless steel and has a smooth surface 13 which may be covered by a food- grade rubber which will provide appropriate friction to the dough as it proceeds through the dough feeding apparatus. Flattening roller 12a is also equipped with ends 14a and 14b, which may similarly be outfitted with known means to effectuate turning such as the toothed gear panels described above.
[0035] Shown in Figure 5 is a side cross-sectional view of an assembled dough feeding apparatus. The hopper 1 is shown in profile and is the source of the mixed dough that is used to
form a dough belt. For illustrative purposes, the end panel 3a that would be installed at the front of the enclosure is not shown, however the back end panel 3b of the enclosure 2 is visible in this view, as are the braces 6 that were previously described. Now visible in this view are knobs 15 which secure rail 16 to create the enclosure 2.
[0036] Pinwheel-shaped rollers 9a and 9b can be seen in profile. They are installed at angles of 15 to 45° relative to each other in the pinwheel receiving holes 8 as described previously. The rollers 9a and 9b shown here are installed at relative angle of 25°. It can also be seen that rollers 9a and 9b are not installed in the same orientation; rather in profile it can be seen that the rollers are mirror images of each other. In addition to being installed at angles relative to each other, the rollers 9a and 9b are spaced apart from each other so that dough travelling between them will not encounter a significant amount of compression, twisting, stretching, or wringing. The spacing between the rollers 9a and 9b may be anywhere between 15-35 cm. A spacing in the range of 17 cm, measuring from the centers of each roller, has been found to work well. In terms of dimensions of the individual pinwheel-shaped rollers 9a and 9b, the diameter from comer to comer may be anywhere between 12 to 18 cm, depending on the capacity of the machine.
[0037] In addition to being mirror images of each other, the rollers 9a and 9b will also be turned in opposite directions, towards each other. In particular, in operation, roller 9a would turn clockwise, and roller 9b would turn counter-clockwise. In this configuration, with both rollers 9a and 9b turning inwards towards each other, they will operate to pull down and convey dough between them. This configuration allows for gentler treatment of the dough as it is being formed into a belt in between these pinwheel-shaped rollers 9a and 9b. Dough is fed downward partially by gravity, but is also being formed and pulled by first being scooped by the points of the pinwheel-shaped roller 9b and then passed on to pinwheel shaped roller 9a. The pinwheel- shaped rollers 9a and 9b thereby form a dough belt, but with far less of the compressing, shearing, or pulling force that has been inherent in dough extracting rollers of the prior art. Such formation of the dough belt using the mechanisms described herein does not comprise speed of manufacture. Dough belts can be formed at a rate of 10 m/min using the invention, which is an acceptable industrial rate of manufacture for bread dough.
[0038] It is contemplated that if a large volume of dough is fed through the hopper 1, there may be some back-up of dough as the pinwheel-shaped rollers 9a and 9b operate. As shown, the sides of the hopper 1 funnel inwards to direct the dough to the central path between the pinwheel-shaped rollers 9a and 9b, and are configured such that excess dough will not tend to be displaced laterally to the outside of the pinwheel-shaped rollers 9a and 9b. As well, with this configuration, any excess dough will be urged upwards back into the hopper 1, for immediate use in the continued formation of a dough belt. In this way, the“oldest” dough is used first, with newer dough being continually fed through the top of the hopper 1. This results in the dough not having the opportunity to remain in the hopper 1 for an extended period of time, which would likely result in the dough drying out.
[0039] After the dough is roughly formed into a belt by the scooping and passing actions of pinwheel-shaped rollers 9a and 9b, the dough next encounters flattening rollers 12a and 12b, which compress the dough belt to an appropriate thickness for further processing. The flattening rollers 12a and 12b are similarly placed at the previously described range of angles relative to each other, with approximately 25° again being the most preferred angle. Similar to the pinwheel-shaped rollers 9a and 9b, the flattening rollers 12a and 12b are turned in opposite directions towards each other. Specifically, flattening roller 12a will turn clockwise, and flattening roller 12b will turn counter clockwise.
[0040] As already mentioned above, the permanent angle between the pair of pinwheel- shaped rollers 9a and 9b facilitates a gentler formation and handling of the dough belt which is better suited for making bread doughs with high gluten flour content. An additional advantage of this configuration is that the dough forming apparatus requires less lateral space within a breadmaking machine or line. The space saving by partially stacking the rollers means that a smaller overall dough-making machine is needed, which takes up less factory floor space.
[0041] The two pairs of rollers 9a/9b and 12a/12b should not be turned at the same rate lt is necessary for the flattening rollers to have a faster rpm, otherwise there will be a back-up of the dough belt between the two pairs of rollers. Speeds that have been found to work well are 18 rpm for both of the pinwheel-shaped rollers 9a and 9b, and 20 rpm for both of the flattening rollers 12a and 12b.
[0042] Scrapers 18 are also attached to the flattening rollers 12a and 12b, by way of a post 17 attached to stationary inner portions of the rollers 12a and 12b. Scrapers 18 are configured as flat blades which will serve to detach any dough which may inadvertently adhere to the flattening rollers 12a or 12b. This can be an issue with doughs with particularly high water content. As shown, the free edge of scraper 18 is mechanically biased to have close contact with the rubber surface of the flattening roller 12a as it turns. Scraper 18 can therefore effectively dislodge sticky dough. Scraper 18 may be constructed from a variety of materials. Plastic or a metal such as brass have been found to be effective. Scraper 18 may be attached to its respective post 17 by way of a knob or bolt which may be removed to permit the user to adjust the angle and point of intersection of the scrapers 18 relative to the flattening rollers 12a and 12b. This attachment means further allows the scrapers 18 to be removed to allow for cleaning or replacement of the scrapers 18.
[0043] It is also possible to adjust the distance between the two flattening rollers 12a and
12b. In this embodiment, roller 12a is fixed in place, and movable roller 12b is installed along a rail 20, which is partially visible in Figure 5, but better viewed in Figures 6 and 8. There is a manual adjusting wheel 19 that can be used to move flattening roller 12b closer or further away from flattening roller 12a, so as to be able to set the thickness of the resulting dough belt.
[0044] ln Figure 6, a further side view of the exterior of the dough feeding apparatus is seen. Now visible are toothed gear wheels 21 which have been installed at the end of the previously described pinwheel-shaped rollers 9a and 9b. Toothed gear wheels 21 which are fitted into each other as shown are an advantageous way to configure the invention; the wheels 21 will be guaranteed to move at the same rate relative to each other. As well, only one motor would be required to drive one of the rollers 9a or 9b.
[0045] Better visible in Figure 6 is the rail 20 along which the flattening roller 12b may move in accordance with a setting chosen by the operator of the machine, and effectuated by turning of the manual adjusting wheel 19. There are a number of ways to effect the movement of the movable flattening roller 12b. In this embodiment, the fixed flattening roller 12a is connected to a standard motor by way of a belt or chain (not shown). Toothed geared wheels are fitted onto the corresponding ends of flattening rollers 12a and 12b. The toothed geared wheel of
the fixed flattening roller 12a is connected by a chain belt to the toothed geared wheel of the moveable flattening roller 12b, thus ensuring that the flattening rollers 12a and 12b rotate at the same rate relative to each other. The inner surface of the chain belt engages the toothed geared wheel of the fixed flattening roller 12a and is further engaged with a tensioner pulley (not shown). The tensioner pulley causes the outer surface of the chain belt to remain engaged with the tooth geared wheel of the moveable flattening roller 12b as the moveable flattening roller 12b moves along the rails 20.
[0046] In Figure 7, a side view of the dough feeding system is shown. The hopper 1 and enclosure 2 are shown assembled with the end panels, 3a and 3b, which are engaged with the elongated panels 4a and 4b. Visible in this view are the knobs 15 and rail 16, used to secure the end panels 3a and 3b, which are to the elongated panels, 4a and 4b, to form the enclosure 2. A suitable mechanism to prevent movement of the end panels 3a and 3b along the rail is used. In the embodiment presented in Figure 7, the rail 16 is threaded where it engages the receiving holes of end panels 3a and 3b. Outer nuts 29 and inner nuts 30 are threaded onto these portions of the rail 16 and engage the outer and inner surfaces of end panels 3a and 3b, to prevent movement of the end panels 3a and 3b along the rail 16. Also shown in profile are the two pin wheel -shaped rollers, 9a and 9b including their respective circular toothed gear panels 21 on their ends. Figure 7 further shows in profile a flattening roller 12a, and the manual adjusting wheel 19 connected to a graduated counter 22 and shaft 23.
[0047] In Figure 8, a perspective view of the thickness adjusting mechanism is shown.
The manual adjusting wheel 19 may be connected to a graduated counter 22 on the shaft 23 so that the user may conveniently set the thickness of the resulting dough belt that is the most appropriate target thickness for the product being made. Worm screws 24 are connected to the shaft 23 and are engaged with worm gears 25 connected to rails 20. The rails 20 are connected to flattening roller support structures 26 configured to support the weight of movable flattening roller 12b and allow the free rotation of the flattening roller 12b. The flattening roller support structures 26 comprise a flattening roller receiving hole 27 for engaging the ends 14a, 14b of the flattening roller 12b. The flattening roller support structures 26 are disposed within respective support structure housings 28 which act as a guide for the flattening roller support structure 26 as they are moved along their respective rails 20.
[0048] The invention described above provides a low-stress dough feed-in component for use in the industrial manufacture of breads, and is particularly well-adapted for the manufacture of flatbreads using dough made of high-protein flour. This configuration allows for a gentler, less stressful treatment of the dough and ultimately results in dough that, because it is soft and not over-worked or over-stressed, can be more readily and uniformly shaped, and baked to have the desired textural features for the type of flatbread being prepared.
[0049] While the invention has been described with reference to specific embodiments, it will be appreciated that numerous variations, modifications, and embodiments are possible. For instance, there are many known mechanisms available in machinery design that may be used interchangeably with the specific mechanical solutions contemplated above. Accordingly, all variations, modifications and embodiments are to be regarded as being within the spirit and scope of the invention.
Claims
1. An apparatus for extruding dough, comprising: a hopper having a top end and a bottom end; a chamber removably attached to said bottom end of said hopper, said chamber comprising four sides and having a top end and a bottom end; said chamber accommodating a first dough extracting roller and a second dough extracting roller, said second dough extracting roller being placed at an angle of 15-45° relative to said first dough extracting roller; said dough extracting rollers each having a cylindrical core with a perimeter, and a plurality of protrusions along said perimeter; each of said protrusions of said dough extracting rollers being three-sided, having a first side located at said perimeter, a second side and a third side, said second sides being longer than said third sides; said first dough extracting roller being adapted to turn in a clockwise direction, and said second dough extracting roller being adapted to turn in a counter-clockwise direction, to convey dough between said dough extracting rollers; a first dough flattening roller and second dough flattening roller installed at the bottom end of said chamber, said second dough flattening roller being placed at an angle of 15-45° relative to said first dough flattening roller; said first dough flattening roller being adapted to turn in a clockwise direction, and said second dough flattening roller being adapted to turn in a counter-clockwise direction to further convey dough received from said dough extracting rollers; said second dough flattening roller being movable along a track towards and away from said first dough flattening roller to permit a user to set a desired thickness for said dough.
2. The apparatus of claim 1 , wherein the angle of both the dough extracting rollers and the dough flattening rollers is 22 to 35°.
3. The apparatus of claim 1 or 2, wherein the angle of both the dough extracting rollers and the dough flattening rollers is 25°.
4. The apparatus of any of claims 1-3, wherein there are between five to eight protrusions on each of said dough extracting rollers.
5. The apparatus of any of claims 1-4, wherein there are six protrusions on each of said dough extracting rollers.
6. The apparatus of any of claims 1-5, wherein said four sides of said chamber are detachable from each other.
7. The apparatus of any of claims 1 -6, wherein said dough extracting rollers are provided with gear wheels to effect turning of said rollers.
8. The apparatus of any of claims 1-7, wherein said dough flattening rollers are provided with gear wheels to effect turning of said rollers.
9. The apparatus of any of claims 1-8, wherein said track for said second dough flattening roller is provided with gradations to facilitate positioning of said second dough flattening roller.
10. A method of forming a belt of dough using the apparatus of any of claims 1-9, consisting of: calibrating said dough flattening rollers by positioning said second dough flattening roller to form a belt of desired thickness; providing dough into the hopper of said apparatus; rotating said dough extracting rollers and said dough flattening rollers to form said dough into the belt of dough.
Priority Applications (1)
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PCT/CA2018/000172 WO2020051673A1 (en) | 2018-09-14 | 2018-09-14 | Low stress dough feeding apparatus |
Applications Claiming Priority (1)
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PCT/CA2018/000172 WO2020051673A1 (en) | 2018-09-14 | 2018-09-14 | Low stress dough feeding apparatus |
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WO2020051673A1 true WO2020051673A1 (en) | 2020-03-19 |
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PCT/CA2018/000172 WO2020051673A1 (en) | 2018-09-14 | 2018-09-14 | Low stress dough feeding apparatus |
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Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3999926A (en) * | 1975-03-11 | 1976-12-28 | Machines Bertrand S.A. | Apparatus for shaping dough lumps |
JP2001061401A (en) * | 1999-08-25 | 2001-03-13 | Kobird Co Ltd | Method and apparatus for spreading fermented dough while degassing dough |
EP2510791A2 (en) * | 2011-04-13 | 2012-10-17 | Neuenkirchener Maschinenfabrik Emil Kemper GmbH | Device for forming a sheet of dough from supplied dough portions |
-
2018
- 2018-09-14 WO PCT/CA2018/000172 patent/WO2020051673A1/en active Application Filing
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3999926A (en) * | 1975-03-11 | 1976-12-28 | Machines Bertrand S.A. | Apparatus for shaping dough lumps |
JP2001061401A (en) * | 1999-08-25 | 2001-03-13 | Kobird Co Ltd | Method and apparatus for spreading fermented dough while degassing dough |
EP2510791A2 (en) * | 2011-04-13 | 2012-10-17 | Neuenkirchener Maschinenfabrik Emil Kemper GmbH | Device for forming a sheet of dough from supplied dough portions |
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