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Production of thin, irregular chips with scalloped edges and surface bubbles

a technology of irregular chips and scalloped edges, which is applied in the field of baking snacks, can solve the problems of localized unleavened or thinned areas, and does not prevent the attainment of discrete bubbles, and achieve the effects of promoting surface bubble production, reducing or controlling bubbling, and being sufficiently hydrated

Inactive Publication Date: 2005-03-10
INTERCONTINENTAL GREAT BRANDS LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention is about a method and apparatus for making thin, baked chips that have a unique texture and appearance. The method involves compressing a thin dough sheet between counter-rotating gauge rolls to a thickness of less than or equal to 0.035 inches while maintaining the surface of each gauge roll at a temperature of about 85°F to about 95°F to prevent sticking, tearing, and shredding of the dough sheet. The resulting dough sheet is then transferred to a rotary cutter that has rows of blunt-edged or rounded cutting elements that produce differently shaped dough pieces. The baked snack chips made from this thin dough have a crispy, crunchy texture and appearance, with surface bubbles and blisters. The method also allows for the production of scallops around the entire periphery of each dough piece.

Problems solved by technology

Dockering or piercing of the dough prior to baking results in localized unleavened or thinned areas and does not prevent the attainment of a plurality of discrete bubbles.

Method used

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  • Production of thin, irregular chips with scalloped edges and surface bubbles
  • Production of thin, irregular chips with scalloped edges and surface bubbles
  • Production of thin, irregular chips with scalloped edges and surface bubbles

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0055] The dough may be formed by first blending the sucrose, pregelatinized waxy maize starch, and pregelatinized potato starch via a mixer at low speed (about 20 rpm) for about 30 seconds. Paselli WA4 is an unmodified, non-crosslinked, pregelatinized potato starch that is cold water swelling. Paselli WA4 has a moisture content of about 8.75% by weight, a sulfated ash content of 0.8% maximum, and a pH in a 5% aqueous solution of about pH 6. The particle size distribution of Paselli WA4 may be less than or equal to 25% on a #45 screen.

[0056] About 75% by weight of the water may be preheated to a temperature of about 145-165° F. and admixed with the blend for about 2 minutes at a mixer speed of about 20 rpm to substantially hydrate the pregelatinized waxy maize starch and pregelatinized potato starch.

[0057] The soybean oil, high fructose corn syrup, and most of the remaining water may be admixed with the blend for about 1 minute at a mixer speed of about 20 rpm. The flour, salt, so...

examples 2-3

[0064] A dough may be made according to the process of Example 1. The baked dough may be topped with topping ingredients as follows:

Example 2WeightWeight %Baked Dough125 lbs. 3.90 oz 88.2 wt. %Soybean Spray Oil 14 lbs. 4.45 oz.10.1 wt. %Flour Salt 2 lbs. 7.08 oz. 1.7 wt. %

[0065]

Example 3WeightWeight %Baked Dough125 lbs. 3.63 oz79.0 wt. %Soybean Spray Oil 23 lbs. 12.44 oz.15.0 wt. %Sour Cream and Onion 9 lbs. 8.17 oz. 6.0 wt. %Seasoning

[0066] The dough of Examples 2 and 3 may be sheeted and fed to water-chilled final gauge rollers having a gap of 0.034 inches to obtain an average dough sheet thickness of 0.0345 inch (0.030 inch minimum and 0.042 inch maximum). The chilled water temperature for the final gauge rollers may be about 40° F. to about 42° F. The temperature of the dough in the lay-time conveyor may be about 97° F. The temperature of the dough after the four-roll sheeter may be about 92° F. The temperature of the dough just before the final gauge rollers may be about 88° ...

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Abstract

A dough sheet for producing thin, baked chips is obtained continuously by compressing a dough sheet to a thickness of less than or equal to about 0.035 inch between counter-rotating gauge rolls while maintaining the surface of each gauge roll at a temperature of about 85° F. to about 95° F. Maintaining the gauge roll surface temperature at about 85° F. to about 95° F. avoids sticking, tearing, and shredding of the thin dough sheet as it is compressed and transferred by the gauge rolls, even at high production rates or line speeds. A rotary cutter is employed to obtain thin, irregularly shaped, scallop-edged snacks in a variety of shapes from a single dough sheet without producing dough scraps between the pieces.

Description

[0001] This application claims priority of provisional application U.S. Ser. No. 60 / 402,304, filed Aug. 9, 2002, the disclosure of which is incorporated by reference in its entirety.FIELD OF THE INVENTION [0002] The present invention relates to the production of thin, baked snacks having an irregular shape, scalloped edges, a chip-like crispy texture and surface bubbles. The present invention also relates to an apparatus for producing the snacks. BACKGROUND OF THE INVENTION [0003] In the production of baked snacks from a dough, such as a wheat-based dough, generally the thinner the dough the more chip-like is the baked snack in crispness and appearance. Also, the more irregular the shape of the snack, and the greater the variety of shapes, the greater is the impression of a chip-like appearance rather than a cracker appearance. Cohesive, machinable doughs which can be sheeted, stretched, and cut into pieces may be produced at room temperature when the doughs possess a high content o...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): A23L1/164A23L11/00
CPCA23L1/1645A23L1/164A23L7/117A23L7/13
Inventor MIHALOS, MIHAELOS N.SCHWARTZBERG, JESSICA H.JANULIS, THEODORE N.BAUMANN, BARBARA E.FERGUSON, STEPHANIE M.FORTE, ZENA E.
Owner INTERCONTINENTAL GREAT BRANDS LLC
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