Baking modules and production lines for natural products and their applications
The baking module, which uses an inverted truncated pyramidal tray and hot airflow, solves the problems of damage and uneven baking caused by product movement in the prior art, and achieves non-destructive uniform baking and efficient production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- BUHLER AG
- Filing Date
- 2022-12-13
- Publication Date
- 2026-08-04
AI Technical Summary
Existing baking equipment requires mechanical devices to move the product during the baking process, which leads to product damage and wear, and makes it difficult to achieve uniform baking, resulting in dust and broken particles.
The baking module employs an inverted truncated pyramidal tray, which uses hot airflow to evenly bake products within the tray, preventing product movement. The tray is equipped with grids and air inlets, and the hot air supply is configured with a rate of 4000 m³/h and a temperature range of 105°C to 250°C. Combined with seals and a variable fan, the airflow direction is adjusted.
It achieves uniform baking without product movement, reduces product damage and dust generation, and improves product traceability and production line sustainability.
Smart Images

Figure CN119072245B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of baking modules for baking natural products, particularly legumes, grains, seeds, and nuts, more preferably legumes, seeds, and nuts. The invention also relates to a production line for processing natural products, particularly baking legumes, grains, seeds, and nuts, said production line including a baking module according to the invention. Furthermore, the invention relates to the use of baking modules or production lines for baking natural products, particularly legumes, grains, seeds, and nuts. Background Technology
[0002] Baking natural products is a complex process that requires uniform baking of all products in a batch. To achieve uniform baking, existing baking methods and equipment require moving the product in an airflow or on a hot surface, or exposing the product to radiant heat, to ensure uniform heating of all particles and the entire surface of the product. Moving the product necessitates mechanical devices that tumble, vibrate, shake, rotate, or agitate loads to maintain its movement.
[0003] Most known industrial baking machines operate continuously, with product particles moving on belts, vibrating supports, or via airflow at different stages of the baking process. Baking is achieved by exposing the product particles to a set temperature of hot airflow, resulting in different degrees of baking, from shallow to deep.
[0004] Primarily designed for lower hourly outputs, some baking machines are designed as batch systems. What they have in common is that the product must be moved during the process to achieve a uniform baking effect. This movement can be achieved by tumbling the product in a drum or by moving arms or paddles that agitate the product during the process.
[0005] Moving products during the baking process can damage them, causing breakage and wear, which generates dust, waste, and particles. In equipment used for product movement, wear and breakage produce dust and particles, requiring cleaning and significant downtime. Furthermore, the mechanical devices used for product movement experience wear and breakage of moving parts, necessitating substantial maintenance and downtime.
[0006] Finally, it is necessary to control the volume of the product exposed to heat during the baking process to avoid over-baking or under-baking. In continuous baking machines, where the product itself is moved, the start-up and shutdown phases of the baking line can be challenging due to the accumulation and reduction of product layers.
[0007] The purpose of this invention is to provide a novel baking module and a novel production line that allows products to be baked without mechanical devices moving the products themselves during the baking process. Therefore, the purpose of this invention is also to reduce product damage and waste, and to reduce cleaning time due to dust and broken parts. Summary of the Invention
[0008] Therefore, the object of the present invention is to provide a novel baking module and a novel production line that completely overcomes or at least greatly reduces the aforementioned disadvantages of known systems.
[0009] According to the invention, these objectives are achieved, in particular, by the elements of the two independent claims. Furthermore, further advantageous embodiments can be derived from the dependent claims and the description.
[0010] Specifically, the object of the present invention is achieved by a baking module for baking natural products, particularly legumes, grains, seeds, or nuts. The baking module includes a tray, particularly a cubic tray, for holding the product to be baked. The tray includes a bottom in the form of an inverted truncated pyramid, on which a grid is covered a larger base. The mesh size of the grid is small enough to hold the product when it is placed on the grid. The tray also includes an opening opposite the inverted truncated pyramid, configured to introduce the product into the tray. The tray further includes an air inlet located on a smaller base of the inverted truncated pyramid. The baking module includes a first means for supplying hot air into the tray through the inlet, wherein the inlet and the first means for supplying hot air are configured to have a minimum of 4000 m² per meter of product height and per square meter of the larger base surface area of the inverted truncated pyramid. 3 The first device for supplying hot air is configured to supply air in a temperature range of 105°C to 250°C, preferably in a temperature range of 115°C to 200°C, more preferably in a temperature range of 125°C to 170°C, and particularly in a temperature range of 135°C to 150°C.
[0011] The inventors have discovered that it is necessary to bake products evenly in a tray, for a temperature range of at least 4000 m² for each meter of product height to be baked and for each square meter of surface area of the larger base of the inverted truncated pyramid. 3Hot air is supplied at a rate of [number] hours. Due to the baking module, large quantities of natural products can be baked evenly without moving the products themselves via hot airflow or another heat source. This is advantageous because it avoids damage to the products and the generation of dust and broken pieces. Furthermore, since the baking process is carried out in "batch" (a batch is the number of products in a tray), product traceability is improved. It is important to note that although the tray is part of the baking module, it is configured to be detachable from the module to transport the products to another module, such as a cooling module.
[0012] Preferred roasted natural products include tree nuts, ground nuts, grains and edible seeds, and legumes.
[0013] "Tree nuts" includes any kind of tree nuts, such as almonds, hazelnuts, chestnuts, walnuts, pecans, cashews, macadamia nuts, pistachios, pine nuts, and Brazil nuts. Preferably, tree nuts are almonds, hazelnuts, pecans, cashews, macadamia nuts, and pistachios.
[0014] "Ground nuts" includes any kind of ground nut, such as peanuts and tiger nuts. Preferably, ground nuts are peanuts.
[0015] "Certains and edible seeds" includes any kind of cereals and edible seeds, such as quinoa, amaranth, corn, rice, wheat, buckwheat, oats, malt, pumpkin seeds, chia seeds, sesame seeds, and sunflower seeds. Preferably, cereals and edible seeds include sunflower seeds, sesame seeds, oats, malt, and pumpkin seeds.
[0016] "Legumes" includes any kind of legume, such as soybeans, kidney beans, chickpeas, common peas, broad beans, lima beans, lupins, mung beans, tree beans, and red peas.
[0017] In an embodiment of the invention, the roasting module is a module for roasting cocoa beans. When roasting cocoa beans, a roasting temperature of 105°C to 135°C is preferably used, and more preferably a roasting temperature of 112°C to 130°C is used.
[0018] In an embodiment of the invention, the roasting module is a module used for roasting coffee beans. When roasting coffee beans, it is preferable to use a relatively high roasting temperature, i.e., a temperature in the range of 200°C to 250°C.
[0019] In another embodiment of the invention, based on the physical properties of the natural product to be baked, such as bulk density and geometry, the inlet and first device for supplying hot air are configured to provide at least 4000 m² of hot air per meter of height of the product to be baked and per square meter of the larger base surface area of the inverted truncated pyramid. 3 A flow of hot air is provided at a rate of / hour.
[0020] In a first preferred embodiment of the invention, the baking module includes a lid for covering the opening, wherein the lid includes an outlet for guiding hot air out of the tray. This is advantageous because the lid allows for reduced heat loss, thereby reducing baking time. Furthermore, by isolating the contents of the tray from the environment, the lid allows for increased reproducibility of the baking process.
[0021] In a second preferred embodiment of the invention, the lid of the tray includes a seal, preferably an inflatable seal, to allow a tight connection between the lid and the tray, thereby forcing airflow through the product. Herein, "airtight" means an air loss of less than 5% by volume, preferably less than 2% by volume, and most preferably less than 1% by volume. Due to the tight connection between the lid and the tray, the airflow direction can be changed at least once during baking, either from top to bottom or vice versa. This facilitates uniform baking of the entire load on the tray, thereby further improving the uniformity of the product.
[0022] Therefore, the baking module advantageously includes a device for reversing the direction of hot air flow.
[0023] In another preferred embodiment of the invention, the baking module includes means for regulating the temperature of the hot air supplied to the tray. This allows different baking recipes to be executed depending on, for example, the type and / or quantity of products in the tray.
[0024] In another preferred embodiment of the invention, the baking module includes a temperature sensor for measuring the temperature inside the tray. This allows for temperature control during the baking process.
[0025] In another preferred embodiment of the invention, the baking module includes a humidity sensor for measuring the humidity level within the tray. This allows for humidity control during the baking process.
[0026] In another preferred embodiment of the invention, the means for regulating the temperature of hot air is configured to receive data from a temperature sensor and / or a humidity sensor, and to regulate the temperature of the hot air to be supplied to the tray based on the received data.
[0027] In another preferred embodiment of the invention, the first device for supplying hot air to the tray includes a variable-speed conveying fan to adjust the airflow according to the density of the products in the tray.
[0028] In another preferred embodiment of the invention, the baking module includes a variable-speed fan to regulate the airflow exiting the tray through an outlet.
[0029] In another preferred embodiment of the invention, the inlet is connected to an air filter, particularly a HEPA filter.
[0030] In another preferred embodiment of the invention, the inlet includes a seal, preferably an inflatable seal, to allow a tight connection between the inlet and the tray, thereby forcing airflow through the product. Herein, "airtight" means an air loss of less than 5% by volume, preferably less than 2% by volume, and most preferably less than 1% by volume. Due to the tight connection between the lid and the tray, the airflow direction can be changed at least once during baking, either from top to bottom or vice versa. This facilitates uniform baking of the entire load on the tray, thereby further improving the uniformity of the product.
[0031] In another preferred embodiment, particularly in larger production lines comprising more than one baking module, the piping of each baking module includes a seal, which is preferably configured to expand once the tray is placed at the piping to make the connection between each piping and one or more trays airtight. Herein, "airtight" means an air loss of less than 5% by volume, preferably less than 2% by volume, and preferably less than 1% by volume. This allows the airflow direction to be changed at least once during baking, either from top to bottom or vice versa. After the airflow passes through the tray from the air inlet at the bottom of the tray, the air is then vented through the outlet of the tray lid. Alternatively, air can be pushed into the tray through the outlet of the tray lid and vented through the inlet at the bottom of the tray.
[0032] In another embodiment of the invention, both the inlet and the pipe of the baking module include seals, preferably inflatable seals.
[0033] In another preferred embodiment of the invention, the inlet and conduit of each baking module in the production line include a seal, preferably an inflatable seal. In a more preferred embodiment of the invention, the lid of the tray of each baking module in the production line also includes a seal.
[0034] In a second aspect, the object of the invention is achieved by a production line for natural products, particularly seeds, grains, legumes, and nuts, more preferably seeds, legumes, and nuts, wherein the production line includes a preheating module for heating the natural products to 40°C to 120°C, preferably 60°C to 90°C, particularly 70°C to 80°C; a cooling module for cooling the products to ambient temperature; and a baking module according to the invention located between the preheating module and the cooling module, wherein the production line includes means for moving trays containing the products from the preheating module to the baking module and from the baking module to the cooling module. For example, such means may be an electric chain conveyor with a frequency converter.
[0035] If the preheating and / or cooling modules are also equipped with seals and devices for reversing the direction of hot air flow, the direction of hot air flow in these modules can also be reversed.
[0036] In an embodiment of the production line of the present invention, the flow directions in the preheating module and the cooling module are from bottom to top, respectively.
[0037] In a particular embodiment of the invention, air in the preheating module is drawn out at the top, rather than pushed from the bottom to the top.
[0038] In a preferred embodiment of the invention, at least one module of the production line is made of stainless steel. In a particularly preferred embodiment, all modules of such a production line are made of stainless steel.
[0039] The production line according to the invention allows for the complete processing of natural products, including preheating, baking, and cooling steps, without the need to transport the products themselves. This avoids product damage and the generation of dust and broken pieces.
[0040] In a first preferred embodiment of this invention, the production line includes a pasteurization module located between a preheating module and a baking module, the pasteurization module being used to pasteurize the product. Due to the pasteurization module, the product can be baked after pasteurization.
[0041] In a second preferred embodiment of the production line, the pasteurization module and one or more baking modules are located in a cleanroom area.
[0042] In another preferred embodiment of this aspect of the invention, the preheating module includes a second means for supplying hot air to the tray, wherein the second means is configured to supply air at a temperature of 40°C to 120°C, preferably 60°C to 90°C, and particularly 70°C to 80°C, through an inlet to the tray. This allows for uniform preheating of the product.
[0043] In another preferred embodiment of this aspect of the invention, the cooling module includes means for supplying cooling air to the tray, wherein the means for supplying cooling air is configured to supply air at a temperature of 15°C to 35°C through an inlet to the tray. This allows for uniform cooling of the product.
[0044] In another preferred embodiment of this aspect of the invention, the production line includes a controller for regulating the temperature of the air supplied to the trays by the preheating module, baking module, and cooling module. This allows for complete control over the temperature conditions in the different modules.
[0045] In another preferred embodiment of this aspect of the invention, the controller is configured to control the means for moving the tray between modules. This allows control over the time the product remains in each module.
[0046] In another preferred embodiment of this aspect of the invention, the preheating module, cooling module, and baking module each include a separate cover for covering the tray opening, wherein the cover has an outlet for guiding air out of the tray. This minimizes the processing time of each module.
[0047] Currently, the production line can bake up to 6 tons of natural products per hour, with the initial moisture content of the natural products ranging from approximately 4 to 10 percent of their total weight.
[0048] In this invention, the production line (total length: 9.8 meters; total width: 4.8 meters) including the preheating module, pasteurization module, baking module and cooling module is also sustainable because the maximum floor space of the production line with a production capacity of 1 ton per hour is 47 square meters.
[0049] To further increase the sustainability of the baking module and production line, the air used is at least partially recirculated. In one embodiment, advantageously, the air is dried after leaving the baking module and before being at least partially carried into the preheating module.
[0050] The present invention also relates to the use of a baking module having the above-mentioned parameter settings, and the use of a production line having the above-mentioned parameter settings for baking natural products, particularly for baking beans, grains, seeds or nuts, and more preferably for baking beans, seeds, tree nuts or ground nuts having the above-mentioned parameter settings.
[0051] Brief description of the attached figures
[0052] Figure 1 This is a perspective view of the tray of the baking module according to an embodiment of the present invention;
[0053] Figure 2 This is a cross-sectional view of the tray of the baking module according to an embodiment of the present invention;
[0054] Figure 3 This is a perspective view of the baking module according to an embodiment of the present invention;
[0055] Figure 4 This is a side view of a production line according to an embodiment of the present invention. Detailed Implementation
[0056] Figure 1 A baking module 10 according to an embodiment of the present invention is shown (see Figure 4 A schematic perspective view of tray 11. As shown, tray 11 is generally preferably cubic and has an opening 12 through which products to be baked (such as beans, seeds, or nuts) can be inserted. The opening 12 can be covered by a lid 13, such as... Figure 3As shown. The lid 13 preferably includes an air outlet 14 for guiding hot air and baking by-products outside the tray 11. (As shown) Figure 4 As shown, the baking module 10 (similar to the preheating module 20 and the cooling module 40) includes means (not shown here) for lowering and raising the cover 13 to close and open the opening 12.
[0057] like Figure 2 As shown, tray 11 includes a bottom in the form of an inverted truncated pyramid 15. A grid is formed on the larger base 15a of the truncated pyramid, with mesh small enough to hold the product to be baked. The smaller base 15b is connected to an air inlet 16 (see...). Figure 3 An air inlet 16 is used to supply air to the tray 11. The air inlet 16 is connected to a conduit 17 for supplying hot air to the tray 11, particularly in the roasting module 10, where the temperature of the hot air is between 115°C and 200°C, preferably between 125°C and 170°C, and particularly between 135°C and 150°C. The inventors have found it necessary to uniformly roast the products in the tray 11 to provide hot air within the aforementioned temperature range, and for each meter of product to be roasted (see...). Figure 2 Where L defines the product level in tray 11 and the surface area of the larger base 15a of the inverted truncated pyramid per square meter is at least 4000 m². 3 Hot air is supplied at a rate of [temperature] / hour. Therefore, the hot air supply device for inlet 16 and baking module 10 is configured to supply hot air at such a temperature and flow rate. Using the baking module 10, large quantities of natural products, such as beans, seeds, or nuts, can be baked without transporting the products themselves, thus avoiding damage to the products and the generation of dust.
[0058] Preferably, inlet 16 and / or pipe 17 have seals, preferably inflatable seals. This means that inlet 16 or pipe 17 has a seal, or both have seals.
[0059] Pallet 11 advantageously includes fork openings 18 for inserting forklift forks. This allows pallet 11 to be easily transported, for example, from a warehouse to belt 50, which allows pallet 11 to be moved from one module of production line 100 (see [link to product details]). Figure 4 Move to another module.
[0060] like Figure 4 As shown, the baking module 10, as well as the pasteurization module 30 and the preheating module 20, preferably include a sensor 19. The latter is presumably used to measure the temperature and / or humidity within the tray 11.
[0061] Figure 4A side view of a production line 100 according to an embodiment of the present invention is shown. The production line 100 includes a preheating module 20, a baking module 10, a pasteurization module 30, and a cooling module 40. Each of the preheating, baking, and cooling modules has its own dedicated cover 13, 23, 43, which covers the tray 11 when it is placed within the respective module. The preheating module 20 includes means 27 for inserting hot air at a temperature between 40°C and 120°C, preferably between 60°C and 90°C, and particularly between 70°C and 80°C, into the tray 11 through an inlet 16. Similarly, the cooling module 40 includes means 47 for inserting air at a temperature between 15°C and 35°C into the tray 11 through an inlet 16. The pasteurization module 30 includes a chamber 31 configured to generate sub-atmospheric pressure around the tray 11, wherein means for inserting dry steam onto the product within the tray 11 is disposed in the chamber 31. In addition, the pasteurization module 30 includes a device 37 for air insertion. Each module 10, 20, 30, and 40 includes a belt 50 with a motor 51 (see [link to document]). Figure 3 This allows tray 11 to be moved from one module to another.
[0062] Production line 100 allows for the complete processing of natural products, such as beans, seeds, or nuts, including preheating, roasting, pasteurization, and cooling to ambient temperature. Because all these steps are performed on the natural products held within tray 11, product damage due to transportation, common in prior art production lines, is avoided.
[0063] Finally, it should be noted that the foregoing has outlined a relevant non-limiting embodiment. Those skilled in the art will recognize that modifications can be made to the disclosed non-limiting embodiments without departing from their spirit and scope. Therefore, the described non-limiting embodiments should be considered merely illustrative of some more prominent features and applications. Other beneficial results can be achieved by applying the non-limiting embodiments in different ways or modifying them in ways known to those skilled in the art.
[0064] Furthermore, each given parameter setting can be combined with any other single or multiple parameter settings, and such combinations can also be included within the scope of this invention.
Claims
1. A baking module (10) for baking natural products, the baking module (10) comprising a tray (11) for receiving products to be baked, wherein the tray (11) comprises a bottom in the form of an inverted truncated pyramid (15), a grid covering a large base (15a) of the inverted truncated pyramid, wherein the mesh of the grid is small enough to hold the products to be baked when placed on the grid, the tray (11) further comprising an opening (12) opposite to the inverted truncated pyramid (15), the opening (12) being configured to introduce the products to be baked into the tray (11), the tray (11) further comprising an air inlet (16) located on a small base (15b) of the inverted truncated pyramid, the baking module (10) comprising a first means for supplying hot air into the tray (11) through the inlet (16), Its features are, Said inlet (16) and said first means for supplying hot air are configured to provide a flow of hot air at a rate of at least 4000 m 3 per 1 m of height of product to be toasted and per 1 m of surface area of the large base (15a) of the inverted truncated pyramid, and said first means for supplying hot air are configured to supply air in a temperature range of 105°C to 250°C.
2. The baking module (10) according to claim 1, wherein the first device for supplying hot air is configured to supply air in a temperature range of 115°C to 200°C.
3. The baking module (10) according to claim 2, wherein the first device for supplying hot air is configured to supply air in a temperature range of 125°C to 170°C.
4. The baking module (10) according to claim 3, wherein the first device for supplying hot air is configured to supply air in a temperature range of 135°C to 150°C.
5. The toasting module (10) according to any one of claims 1-4, wherein, The baking module (10) includes a cover (13) for covering the opening (12), wherein the cover (13) includes an outlet (14) for guiding hot air out of the tray (11).
6. The baking module (10) according to any one of claims 1-4, wherein, The baking module (10) includes a device for regulating the temperature of the hot air to be supplied to the tray (11).
7. The baking module (10) according to any one of claims 1-4, wherein, The baking module (10) includes a sensor (19) for measuring the internal temperature of the tray (11) and / or for measuring the humidity level inside the tray (11).
8. The baking module (10) according to claim 7, wherein the means for adjusting the temperature of the hot air is configured to receive data from the sensor (19) and adjust the temperature of the hot air to be supplied to the tray (11) according to the received data.
9. The baking module (10) according to any one of claims 1-4, wherein the inlet (16) is connected to an air filter.
10. The baking module (10) according to claim 9, wherein the air filter is a HEPA filter.
11. The baking module (10) according to any one of claims 1-4, wherein the inlet (16) is connected to a pipe (17) for supplying hot air to the tray (11).
12. The baking module (10) according to any one of claims 1-4, wherein the inlet (16) and / or pipe (17) includes a seal.
13. The baking module (10) according to claim 12, wherein the seal is an inflatable seal.
14. The baking module (10) according to any one of claims 1-4, wherein the first means for supplying hot air to the tray (11) includes a variable-speed conveying fan to adjust the airflow according to the density of the product in the tray (11).
15. The baking module (10) according to any one of claims 1-4, comprising means for reversing the direction of hot air flow.
16. A production line (100) for processing natural products, wherein, The production line (100) includes a preheating module (20) for heating natural products with hot air at a temperature of 40°C to 120°C; a cooling module (40) for cooling the products to ambient temperature; and a baking module (10) located between the preheating module (20) and the cooling module (40) according to any one of claims 1 to 11, wherein the production line (100) includes means for moving the tray (11) containing the products from the preheating module (20) to the baking module (10) and from the baking module (10) to the cooling module (40).
17. The production line (100) according to claim 16, wherein, The production line (100) includes a pasteurization module (30) for pasteurizing the product between the preheating module (20) and the baking module (10).
18. The production line (100) according to claim 16 or 17, wherein the preheating module (20) includes a second means (27) for supplying hot air to the tray (11), wherein the second means (27) is configured to supply air at a temperature of 40°C to 120°C through the inlet (16) of the tray (11).
19. The production line (100) according to claim 16 or 17, wherein the cooling module (40) includes means for supplying cooling air to the tray (11), wherein the means for supplying cooling air is configured to supply air at a temperature of 15°C to 35°C through the inlet (16) of the tray (11).
20. The production line (100) according to claim 16 or 17, wherein, The production line (100) includes a controller for regulating the temperature of the air supplied to the tray (11) by the preheating module (20), the baking module (10) and the cooling module (40).
21. The production line (100) according to claim 20, wherein the controller is configured to control means for moving the tray (11) between the modules.
22. The production line (100) according to claim 16 or 17, wherein, The preheating module (20), the cooling module (40) and the baking module (10) each include a separate cover (13, 23, 43) for covering the opening of the tray (11), wherein the cover (13, 23, 43) has an outlet for guiding air out of the tray (11).
23. The production line (100) according to claim 16 or 17, wherein, The pallet (11) advantageously includes a fork opening (18) for inserting forklift forks.
24. The production line (100) according to claim 16 or 17, comprising at least two baking modules (10).
25. The production line (100) according to claim 16 or 17, wherein the inlet (16) and / or pipe (17) of each baking module (10) includes a seal.
26. The baking module (10) according to claim 25, wherein the seal is configured to expand once the tray (11) is placed at the inlet (16) and / or pipe (17) to make the connection between the tray (11) and the inlet (16) and / or pipe airtight.
27. The use of the baking module according to any one of claims 1 to 15 or the production line according to any one of claims 16 to 26 for baking natural products.
28. The use according to claim 27, wherein the natural product is a legume, grain, seed, tree nut, or ground nut.
29. The use according to claim 28, wherein the legumes are soybeans, kidney beans, chickpeas, common peas, broad beans, lima beans, lupins, mung beans, tree beans, and red snap beans.
30. The use according to claim 28, wherein the grains and seeds are sunflower seeds, sesame seeds, oats, malt, and pumpkin seeds.
31. The use according to claim 28, wherein the tree-grown nut is an almond, hazelnut, pecan, cashew, macadamia nut, and pistachio, and / or the ground-grown nut is a peanut.