Cutting equipment for dough products

Abstract

An apparatus includes a cutting surface including at least one cutting element having a top. The cutting element also has an inner sidewall extending from the cutting surface to the top at an inner sidewall angle, an outer sidewall extending from the cutting surface to the top at an outer sidewall angle, and a shoulder disposed on the inner sidewall between the base and the top. The inner sidewall angle is different from the outer sidewall angle.

Description

Technical Field

[0001] The present disclosure describes a cutting apparatus suitable for producing a plurality of uniformly shaped dough products. Background Art

[0002] In making dough products, it is known to form the dough into a sheet between a pair of counter-rotating sheeter rollers, peel the dough from the rear roller (e.g., with a wire) so that the dough adheres only to the front roller, and then cut a pattern from the sheet by rotating a so-called cutting roller against the surface of the front roller.

[0003] The patterned sheet is then peeled off the front roller (e.g., with a wire), the product piece falls onto a conveyor belt, and the surrounding web of "reprocessed" dough (if any) is returned to a hopper above the two sheeter rollers to be reassembled into fresh dough or the reprocessed dough is directed to waste.

[0004] There is a continuing need to reduce waste. Therefore, it is desirable to provide a cutting roll that can effectively cut a desired pattern while minimizing the amount of waste. Summary of the invention

[0005] Various aspects and embodiments of the invention are set out in the accompanying claims.These and other aspects and embodiments of the invention are also described herein.

[0006] In one aspect, an apparatus is configured with a cutting surface comprising at least one cutting element having a top with a flat surface. The cutting element also has an inner sidewall extending from a base to a top at an inner sidewall angle, and an outer sidewall extending from a base to a top at an outer sidewall angle. The inner sidewall angle is different from the outer sidewall angle. The apparatus may include a roller having a cutting surface disposed on an outer peripheral surface of the roller.

[0007] In one embodiment, the inner sidewall angle is about 5° or more greater than the outer sidewall angle. In some cases, the inner sidewall angle is at least 20° or more. Alternatively or additionally, the outer sidewall angle is about 20° or less.

[0008] The shoulder is disposed on the inner sidewall between the base of the cutting element and the top of the cutting element. The shoulder has a base and a sidewall extending from the shoulder base to the top of the cutting element at a shoulder sidewall angle. In one embodiment, the inner sidewall angle is about 5° or more greater than the shoulder sidewall angle. In some cases, the inner sidewall angle is at least 20° or greater. Alternatively or additionally, the shoulder sidewall angle is about 20° or less.

[0009] Typically, the width of the shoulder base is greater than the width of the top planar surface, and in some cases, the width of the shoulder is about 1.5 times or more the width of the top planar surface. In some embodiments, the shoulder has a height measured from the shoulder base to the top planar surface that is less than the height of the top planar surface measured from the top planar surface to the cutting surface. In these cases, the shoulder height can be between about 20% and about 40% of the height of the top surface.

[0010] In one aspect, the outer sidewall and the shoulder sidewall define a cutting angle such that the cutting angle is less than the inner sidewall angle, and in some cases less than about 5°.

[0011] The cutting elements can have any suitable shape, such as a parallelogram, a circle, an oval, an ellipse, or a complex geometric shape. In one embodiment, at least one cutting element is elliptical, and it is contemplated that all cutting elements are elliptical. In those cases where the cutting elements are elliptical, the major axis of each ellipse is about 1.5 to about 2.0 times the length of the minor axis.

[0012] It is also contemplated that the cutting elements may be the same or different sizes, and in one embodiment, all cutting elements are of equal size.

[0013] Where the device comprises a plurality of cutting elements, each cutting element may be spaced apart from an adjacent cutting element. Alternatively, the cutting elements may be arranged such that a portion of an outer sidewall of one of the plurality of cutting elements contacts a portion of an outer sidewall of an adjacent cutting element of the plurality of cutting elements. In other embodiments, the cutting elements may be arranged such that a portion of an outer sidewall of one of the plurality of cutting elements contacts a portion of an outer sidewall of at least four adjacent cutting elements of the plurality of cutting elements. In other embodiments, the cutting elements may be arranged such that a portion of an outer sidewall of one of the plurality of cutting elements contacts a portion of an outer sidewall of six adjacent cutting elements of the plurality of cutting elements.

[0014] It has been found that by controlling the geometry of the cutting elements and the pattern of the cutting elements on the cutting surface, the amount of waste can be reduced while effectively cutting the dough to provide a plurality of similarly shaped food products. For example, where the cutting elements are oval, the cutting elements can be arranged in alternating rows so that the ends of the major axes of each cutting element in a row are approximately at the center points of the cutting elements in the adjacent rows. As a result, a gap having a generally triangular shape with curved sides is produced. In some aspects, the volume of the gap is at least less than one-thirtieth of the volume of each cutting element.

[0015] The invention extends to methods, systems, kits of parts and apparatus substantially as described herein and / or as illustrated with reference to the accompanying drawings.

[0016] The present invention extends to any novel aspect or feature described and / or shown herein. In addition, device aspects can be applied to method aspects, and vice versa. In addition, any, some and / or all features in one aspect can be applied to any, some and / or all features in any other aspect in any appropriate combination.

[0017] It should also be understood that specific combinations of the various features described and defined in any aspect of the invention may be implemented and / or provided and / or used independently. BRIEF DESCRIPTION OF THE DRAWINGS

[0018]

[0013] The above-described aspects and other features, aspects and advantages of the described apparatus will become better understood with regard to the following description, appended claims and accompanying drawings.

[0019] Figure 1 is a perspective view of a cutting device according to the present disclosure.

[0020] Figure 2 is a plan view of a portion of a cutting pattern or cutting surface having a plurality of cutting elements disposed on a rotating drum of a cutting apparatus.

[0021] Figure 3 is a top view of a single cutting element;

[0022] Figure 4 is a cross-sectional view taken along line 3-3 showing a single cutting element.

[0023] Figure 5 is with Figure 5 The same cross-sectional view is provided to better illustrate the features of the cutting element.

[0024] describe

[0025] Those skilled in the art will appreciate that this discussion is merely a description of specific embodiments and is not intended to limit the broader aspects of the described device.

[0026] Go to Figure 1 , depicts a product assembly line 2 including a cutting device 4. The product assembly line 2 has a dough sheet 12 having a first surface 14 and a second surface 16, the dough sheet 12 traveling from right to left on a conveyor 8 that moves in the direction indicated by arrow 10. Although not shown, it is understood that dough is formed in a batch maker or the like and transferred to the product assembly line 2 where the dough is processed into dough sheets 12. As shown in this portion of the product assembly line 2, the dough sheet 12 is fed by the conveyor 8 to the cutting device 4. The cutting device 4 rotates in the direction indicated by arrow 6 as the dough sheet moves in the feed direction (indicated by arrow 10).

[0027] The cutting device 4 includes at least one (typically a plurality) of cutting patterns, cutting dies or cutting elements 40 disposed on the outer or cutting surface 32 of a cylindrical rotatable drive drum 30 for forming and cutting the dough sheet 12 into a desired number of uniformly shaped pieces 18. The plurality of cutting elements 40 are mounted relative to the conveyor 8 so that as the dough sheet 12 travels in the feed direction 10, the cutting elements 40 engage the dough sheet 12 to cut and sever the dough to provide a plurality of cuts in the dough sheet to form individual dough pieces or products 18 and intermediate recyclable dough pieces 19. The drum 30 may be actively driven or driven by frictional engagement between the cutting elements 40 and the dough sheet 12 or the conveyor 8. In operation, the cutting elements 40 extend all the way through the dough sheet 12 to lightly engage the conveyor 8 and completely sever the dough sheet 12.

[0028] It should be understood that the dough sheet 12 can have any suitable thickness, and of course, the size (height or depth) of the cutting element 40 varies accordingly to form products 18 of different depths or thicknesses. After cutting is performed in the dough sheet 12, the cut pieces 18 continue to travel on the conveyor 8 to a post-processing station (not shown). The post-processing station may include, for example, proofing, baking, freezing and / or packaging.

[0029] In other embodiments, it is contemplated that the cutting element 40 is disposed on a pressing element rather than on the surface of a rotating drum, such that the pressing element intermittently contacts a portion of the dough sheet to cut the dough sheet into a desired number of uniformly shaped pieces.

[0030] In one aspect, the rotating drum 30 can be mounted on the drive shaft 20. Side plates 22 (only one of which is shown) can be mounted on either side of the rotating drum 30. Each side plate 22 can include an elongated side end portion 24, respectively, which extends in the direction of travel 10 of the dough sheet. Each elongated side end portion 24 includes a notch 26 to receive a pivot 28 extending parallel to the drive shaft 20. When necessary, such as at the end of a production cycle, the pivot 28 allows the rotating drum 30 and the drive shaft 20 to pivot and lift off the dough sheet 12. A dough roller (not shown) can be freely rotatably mounted on the pivot 28.

[0031] It should be understood that a plurality of cutting elements 40 are disposed on the outside of the rotating drum 30 to define the cutting surface 32. The cutting elements 40 can be disposed on the outer surface in any suitable manner. In one embodiment, the various cutting elements 40 are disposed as part of a sleeve that extends around the outer surface and is fixed to rotate with the drum 30. Alternatively, the cutting elements 40 can be disposed directly on the outer surface in any suitable manner, depending on the material forming the cutting elements. For example, the cutting elements 40 can be provided by engraving, laser etching, etc. It is conceivable that various suitable materials can be used for the cutting elements 40, such as metals, plastics, coated metals, etc. As an example, the cutting elements can be formed by metals such as stainless steel coated with polytetrafluoroethylene.

[0032] refer to Figure 2 , shows a plan view of a portion of a cutting pattern or cutting surface 32 disposed on a rotating drum 30 to form a cutting device 4. It should be understood that the cutting pattern or cutting surface 32 has a size suitable for completely covering or surrounding the drum 30. It should be understood that the cutting surface 32 includes a plurality of cutting elements 40, each cutting element 40 having the same or substantially the same shape.

[0033] Each cutting element 40 may have any suitable shape, such as a parallelogram, a circle, an oval, an ellipse, or a generally rectangular shape defined by its outer sidewall 50 (e.g., Figure 4 As shown in Figure 2, the complex geometric shape defined by Figure 3 In one embodiment best shown in FIG, the cutting element 40 is elliptical, and it is contemplated that all cutting elements 40 are elliptical. In those cases where the cutting element 40 is elliptical, each ellipse has a major axis 42 and a minor axis 44, such that their intersection defines a center or center point 46.

[0034] The length of the major axis 42 is about 10 mm to about 50 mm, or about 15 mm to about 40 mm, or about 20 mm to about 30 mm, and may be about 20 mm to about 25 mm, or about 23 mm. The length of the minor axis is about 2 mm to about 25 mm, or about 5 mm to about 20 mm, or about 9 mm to about 15 mm, or about 13 mm. In some aspects, the major axis is about 1.5 times to about 2.0 times the length of the minor axis 44. The lengths of the major axis 42 and the minor axis 44 are measured as the distance from each of the corresponding outer side walls 50.

[0035] Return to reference Figure 2, where the cutting elements 40 are shown as elliptical, the cutting elements 40 may be arranged in alternating rows such that the ends of the major axis 42 of each cutting element 40 in one row are approximately at the center point 46 of the cutting elements 40 in the adjacent row. It should also be understood that the plurality of cutting elements 40 may be arranged such that a portion of the outer sidewall 50 of one of the plurality of cutting elements 40 contacts a portion of the outer sidewall 50 of an adjacent cutting element in the plurality of cutting elements 40. In other embodiments, the cutting elements 40 may be arranged such that a portion of the outer sidewall 50 of one of the plurality of cutting elements 40 contacts a portion of the outer sidewall 50 of at least four adjacent cutting elements in the plurality of cutting elements 40. In other embodiments, the cutting elements 40 may be arranged such that a portion of the outer sidewall 50 of one of the plurality of cutting elements 40 contacts a portion of the outer sidewall 40 of six adjacent cutting elements in the plurality of cutting elements 40.

[0036] It should also be understood that by arranging cutting elements 40 in a manner such that a portion of outer sidewall 50 of one of the plurality of cutting elements 40 contacts a portion of outer sidewall 50 of an adjacent cutting element in the plurality of cutting elements 40, gap 90 is created. In some cases, gap 90 is generally triangular with curved (concave) sides. In some aspects, the volume of gap 90 is at least less than one-thirtieth of the volume of each cutting element 40.

[0037] In those cases where the cutting elements 40 are oval and the cutting elements are arranged so that a portion of the outer sidewall 50 of one of the plurality of cutting elements 40 contacts a portion of the outer sidewall 50 of at least two adjacent cutting elements, the two sides 94a, 94b can have approximately the same length, and one of the sides 92 can be longer than the other two sides. The shorter two sides 94a, 94b can have a length of about 1 mm to about 6 mm, or about 2 mm to about 5 mm, or about 3 mm. The long side 92 can have a length of about 2 mm to about 8 mm, or about 3 mm to about 6 mm, or about 4 mm. By arranging the cutting elements 40 in an appropriate manner, the size or volume of the gap 90 is small, which reduces the amount of waste (or recyclable) blocks 19.

[0038] It is also contemplated that in some embodiments, each cutting element 40 may be spaced apart from adjacent cutting elements 40. In other words, in this case, each cutting element 40 does not contact another cutting element 40, and there is a gap between each adjacent cutting element 40.

[0039] Now go to Figure 4 and Figure 5, depicts a cross-sectional view of a single cutting element 40. Each cutting element 40 has a top 60 with a flat surface 62 having a width 64. The top width 64 refers to the width at the top of the cutting element 40 (and can be considered the thickness of the cutting element). The top width 64 is in the range of about 0.2 mm to about 0.6 mm, or about 0.3 mm to about 0.5 mm, or about 0.4 mm.

[0040] The top surface 62 is at a cutting element height or cutting depth 66, which is the distance between the top surface 62 and the top 34 of the cutting surface. The cutting element height or cutting depth 66 can vary depending on the thickness of the dough. In one example, when the dough has a thickness of about 1.8 mm to about 2.4 mm, the cutting element height (or cutting depth) 66 can be in the range of about 3.0 mm to about 4.0 mm, or about 3.5 mm.

[0041] Each cutting element 40 has an inner sidewall 70 and an outer sidewall 50. The inner sidewall 70 extends from the top 34 of the cutting surface toward the top surface 62 at an inner sidewall angle 72. The outer sidewall 50 extends from the top 34 of the cutting surface to the top surface 62 at an outer sidewall angle 52. Figure 5 As best shown in FIG. 1 , the inside wall angle 72 and the outside wall angle 52 refer to the angle of the side wall relative to an imaginary line 54 that is orthogonal to the top 34 of the cutting surface. The inside wall angle 72 is also referred to as the release angle, which is related to the cutting of the dough. It is desirable that the inside wall angle 72 is greater than both the outside wall angle 52 and the cutting angle, which will be defined in more detail below, so that the cutting element 40 releases from the dough after cutting the dough.

[0042] It should be understood that the inner sidewall angle 72 is greater than the outer sidewall angle 52. In various embodiments, the inner sidewall angle 72 can be greater than the outer sidewall angle 52 by about 5° or more, or about 10° or more, or about 15° or more, or about 20° or more. In some cases, the outer sidewall angle 52 ranges from about 5° to about 15°, or about 7° to about 13°, or about 8° to about 10°, or about 9.5°. In some cases, the inner sidewall angle 72 ranges from about 15° to about 35°, or about 20° to about 30°, or about 25°.

[0043] Back to Figure 4 , the inner sidewall 70 is provided with a shoulder 80, which is provided between the top surface 62 and the top surface 34 of the cutting surface. The shoulder 80 interrupts the inner sidewall 70 so that the inner sidewall 70 does not extend to the top wall 60. Instead, the shoulder 80 is provided with a sidewall 84 extending from the base 82 of the shoulder to the top 60 at a shoulder sidewall angle 86. Figure 5, the shoulder sidewall angle 86 is the angle between the shoulder sidewall angle 86 and an imaginary line 89 normal to the top 34 of the cutting surface.

[0044] In some aspects, the shoulder sidewall angle 86 can be the same or substantially the same as the inner sidewall angle 72. In other aspects, the shoulder sidewall angle 86 is different from the inner sidewall angle 72. In various embodiments, the inner sidewall angle 72 can be about 5° or more, or about 10° or more, or about 15° or more, or about 20° or more greater than the shoulder sidewall angle 86. In one aspect, the shoulder sidewall angle 86 ranges from about 8° to about 12° or about 9° to about 11°, and in some cases is about 10.5°.

[0045] The width 83 of the base 82 of the shoulder is greater than the width 64 of the top. In some cases, the width 83 of the shoulder is about 1.2 to about 2.0 times the width 64 of the top, or about 1.4 to about 1.6 or about 1.5 times the width 64 of the top. The shoulder width 83 ranges from about 0.4 to about 0.8 mm, or about 0.5 mm to about 0.7 mm, or about 0.6 mm.

[0046] In addition, the shoulder has a height 88, which is the height measured from the shoulder base 82 to the top flat surface 62. The shoulder height 88 is less than the cutting element height 66. In some cases, the shoulder height 88 is about 15% to about 30% of the cutting element height 66. In some embodiments, the shoulder height 88 is about 0.3 mm to about 1.3 mm, or about 0.5 mm to about 1.1 mm, or about 0.7 mm to about 0.9 mm, or about 0.8 mm.

[0047] like Figure 5 As best shown in FIG. 1 , the combination of outer sidewall angle 52 and shoulder sidewall angle 86 defines a cutting angle 100. In some cases, cutting angle 100 ranges from about 5° to about 35°, or from about 10° to about 30°, or from about 15° to about 25°, or about 20°. Ideally, cutting angle 100 is small to effectively cut the dough, and in some cases, cutting angle 100 is less than the release angle.

[0048] Advantageously, by providing the cutting elements described above, substantially similar dough pieces 18 may be produced without generating undesirable amounts of waste.

[0049] Although the concept of the present disclosure allows for various modifications and alternative forms, specific exemplary embodiments of the present disclosure have been shown by way of example in the accompanying drawings. However, it should be understood that the concept of the present disclosure is not intended to be limited to a specific disclosed form; the present invention is intended to cover all modifications, equivalents and alternatives that fall within the spirit and scope of the present invention defined by the claims.

[0050] In general, a cutting device for forming dough-based products is described. The cutting device has a cutting surface including at least one cutting element including a top. The cutting element has an inner sidewall extending from a base to the top at an inner sidewall angle, an outer sidewall extending from the base to the top at an outer sidewall angle, and a shoulder disposed on the inner sidewall between the base and the top. The inner sidewall angle is different from the outer sidewall angle.

[0051] Aspects of cutting equipment are also addressed in the following numbered clause groups, which describe:

[0052] 1. An apparatus comprising a cutting surface, the cutting surface comprising at least one cutting element, the cutting element comprising a top, the cutting element having:

[0053] an inner sidewall extending from the base to the top at an inner sidewall angle;

[0054] an outer sidewall extending from a base to the top at an outer sidewall angle; and

[0055] a shoulder disposed on the inner sidewall between the base and the top;

[0056] Wherein, the inner side wall angle is different from the outer side wall angle.

[0057] 2. The apparatus of clause 1, wherein the inner sidewall angle is approximately 5 degrees or more greater than the outer sidewall angle.

[0058] 3. Apparatus according to clause 1 or 2, wherein the inner sidewall angle is in the range of about 15° to about 35°.

[0059] 4. Apparatus according to any of the preceding clauses, wherein the outer sidewall angle is from about 5° to about 15°.

[0060] 5. The apparatus of any preceding clause, wherein the top portion has a planar surface, the planar surface has a width, and the width of the shoulder is greater than the width of the top planar surface.

[0061] 6. The apparatus of clause 5, wherein the width of the shoulder is about 1.5 times or more the width of the top planar surface.

[0062] 7. Apparatus according to any preceding clause, wherein the shoulder has a height measured from the base of the shoulder to the top which is less than a height of the top measured from the top to the cutting surface.

[0063] 8. The apparatus of clause 7, wherein the shoulder height is between about 20% and about 40% of the height of the top surface.

[0064] 9. Apparatus according to any of the preceding clauses, wherein the at least one cutting element is elliptical.

[0065] 10. Apparatus according to clause 9, wherein all cutting elements are oval.

[0066] 11. Apparatus according to claim 10, wherein all said cutting elements are of equal size.

[0067] 12. The apparatus of clause 11, wherein each ellipse has a major axis that is about 1.5 to about 2.0 times the length of the minor axis.

[0068] 13. Apparatus according to any of the preceding clauses, comprising a plurality of cutting elements.

[0069] 14. The apparatus of clause 13, wherein a portion of the outer sidewall of one of the plurality of cutting elements contacts a portion of the outer sidewall of an adjacent one of the plurality of cutting elements.

[0070] 15. The apparatus of clause 14, wherein a portion of the outer sidewall of one of the plurality of cutting elements contacts a portion of the outer sidewalls of at least four adjacent cutting elements of the plurality of cutting elements.

[0071] 16. The apparatus of clause 15, wherein a portion of the outer sidewall of one of the plurality of cutting elements contacts a portion of the outer sidewalls of six adjacent ones of the plurality of cutting elements.

[0072] 17. Apparatus according to any one of the preceding claims, wherein the apparatus comprises a roller having the cutting surface provided on an outer peripheral surface of the roller.

Claims

1. An apparatus comprising a cutting surface, the cutting surface comprising a plurality of cutting elements, each cutting element comprising: a top portion, which has a flat surface; a continuous inner sidewall extending from a base of the cutting element to the top of the cutting element at an inner sidewall angle, wherein the inner sidewall angle is in the range of 15° to 35°; a continuous outer sidewall extending from a base of the cutting element to the top at an outer sidewall angle, wherein the outer sidewall angle is in the range of 5° to 15°, a portion of the outer sidewall of one of the plurality of cutting elements contacts a portion of the outer sidewall of an adjacent one of the plurality of cutting elements, wherein the inner sidewall angle is greater than the outer sidewall angle; and A shoulder is disposed on the inner sidewall between the base of the cutting element and the top of the cutting element, wherein the shoulder has a base and a sidewall, the sidewall of the shoulder extending from the base of the shoulder to the top of the cutting element at a shoulder sidewall angle, the shoulder sidewall angle being equal to or less than the inner sidewall angle.

2. The device according to claim 1, wherein: The inner sidewall angle is 5 degrees or more greater than the outer sidewall angle.

3. The device according to claim 1, wherein: The planar surface of the top portion has a width, and the width of the shoulder portion is greater than the width of the planar surface of the top portion.

4. The device according to claim 3, wherein: The width of the shoulder is 1.5 times or more the width of the flat surface of the top.

5. The device according to claim 1, wherein: The shoulder has a height measured from a shoulder base to the planar surface of the top that is less than a height of the top measured from the planar surface of the top to the cutting surface.

6. The device according to claim 5, wherein: The height of the shoulder is between 20% and 40% of the height of the top portion measured from the flat surface to the cutting surface.

7. The device according to claim 1, wherein: At least one of the cutting elements is elliptical.

8. The device according to claim 7, wherein: All cutting elements are oval in shape.

9. The device according to claim 8, wherein: All said cutting elements are of equal size.

10. The device according to claim 9, wherein: Each ellipse has a major axis whose length is 1.5 to 2.0 times that of the minor axis.

11. The apparatus according to any one of claims 1 to 10, wherein: A portion of the outer sidewall of one of the plurality of cutting elements contacts a portion of the outer sidewalls of at least four adjacent cutting elements of the plurality of cutting elements.

12. The device according to claim 11, wherein A portion of the outer sidewall of one of the plurality of cutting elements contacts a portion of the outer sidewalls of six adjacent cutting elements of the plurality of cutting elements.

13. The device according to claim 12, wherein: The apparatus includes a roller having the cutting surface provided on an outer peripheral surface of the roller.

14. The apparatus according to any one of claims 1 to 10, wherein: The apparatus includes a roller having the cutting surface provided on an outer peripheral surface of the roller.

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