Fryer and frying method

Abstract

A system for cooking dough products is provided, the system comprising: a conveyor for conveying dough products; and a plurality of oil distributors configured to distribute a flow of cooking oil onto the dough products on the conveyor to coat the dough products with cooking oil, thereby cooking the dough products. A method for cooking confectionery products is also provided, the method comprising: providing such a cooking system by conveying uncooked dough products on a conveyor through a flow of cooking oil distributed from the plurality of oil distributors to produce cooked dough products.

Description

Technical Field

[0001] This invention relates to the field of food fryers and cooking methods thereof. More specifically, this invention relates to fryers and methods for cooking confectionery products. Background Technology

[0002] Fried sweet treats are popular in many countries and include products such as donuts, French donuts, and churros. Broadly speaking, donuts fall into two categories: cake donuts and yeast donuts. Cake donuts and yeast donuts share many ingredients and are primarily distinguished by the leavening agent used in the recipe. Yeast donuts use yeast in the dough, which is proofed to produce a light and fluffy texture in the final product. In contrast, cake donuts are batter-based rather than dough-based and use chemical leavening agents, such as baking powder. Compared to yeast donuts, cake donuts rely less on gluten formation within the product to provide the desired structure and texture.

[0003] Both cake donuts and yeast donuts are deep-fried, resulting in a high fat content in the final product. Various attempts have been made to prepare healthier donuts, such as by reducing sugar, fat, and / or calorie content. However, all existing attempts have produced significantly poorer texture and taste in the final product. One way to reduce the calorie content of sugary products is to increase the water content. However, in baking, this is known to negatively impact the product's leavening ability and increase the dough's stickiness, making it difficult to handle efficiently.

[0004] The applicant has developed an alternative method to improve the healthiness of donuts, as described in patent application EP22178229.5. This involves adjusting the donut recipe to improve the structure so that the dough can be pre-cooked, for example, by baking or steaming. Such methods are effective, but increase processing costs and require careful balancing of ingredients and additives to provide the necessary dough structure.

[0005] The calorie content of donuts can also be reduced by lowering the oil content of the dough product. JPH03127941 A describes reducing the total oil content of dough products by avoiding deep-frying them in oil, and instead spraying oil onto the uncooked (or partially cooked) dough, followed by a cooking step using hot air. Therefore, oil spraying is insufficient to cook the dough product, and a final cooking step using hot air is necessary. However, it is known in baking that cooking the product with hot air after oil treatment can cause the dough to become over-dehydrated, resulting in dry donuts.

[0006] This invention aims to provide a healthier sugar product that does not have the problems of existing technologies. Summary of the Invention

[0007] According to a first aspect of the invention, a system for cooking dough products is provided. The system may include a conveyor for conveying the dough products. The system may include a plurality of oil dispensers. The oil dispensers may be configured to distribute a flow of cooking oil onto the dough products on the conveyor, for example, to coat the dough products with cooking oil, thereby cooking the dough products. Thus, the system is configured to provide a flow of cooking oil to the dough products on the conveyor to provide a cooking oil film across the entire surface of the dough products, thereby cooking the dough products. The cooking oil film may be continuous. Furthermore, a constant flow of hot cooking oil provides a constant heat delivery toward the dough products. Oil spraying cannot provide sufficient heat to quickly cook dough products, requiring a longer cooking process or subsequent cooking processes, which results in the dough products drying out and becoming less palatable to consumers, and also leads to faster oxidation and therefore faster degradation of the cooking oil. Compared to oil spraying, the present invention allows for rapid cooking of dough products by covering the entire surface of the dough products with a flow of cooking oil, which cooks the product evenly from all sides, thereby allowing for more uniform and faster cooking without soaking the dough products in an oil bath. This invention enables the use of a stream of cooking oil to provide sufficient heat to cook dough products without requiring separate downstream cooking steps.

[0008] The inventors have discovered that by coating a dough product with cooking oil, the entire surface of the dough product can be cooked effectively and evenly. Furthermore, this can be achieved through better control and reduced cooking time (e.g., reduced frying time). In this way, the hot cooking oil consistently covers and simultaneously heats the dough product, rapidly heating it so that the cooking oil can deliver all the heat required to complete the cooking of the dough product. Therefore, subsequent cooking steps, such as oven baking which typically takes longer than cooking the product with hot oil to remove moisture from the dough product, are unnecessary, resulting in a thoroughly dried cooked dough product. Components of the system can be similar to those supplied by Lynnmoore Engineering Co Ltd, King's Lynn, United Kingdom.

[0009] As the dough product passes through a stream of cooking oil, the oil can coat the dough product. For example, the oil dispenser can resemble a chocolate dip coater or frosting dip coater used for decorating confectionery. The dispenser can be configured to supply a laminar flow of cooking oil. The inventors currently consider a laminar flow of cooking oil preferred because it minimizes the splashing of hot oil, which increases its oxidation. Further advantageously, a smooth oil flow also helps the oil adhere to or bind to the surface of the dough product, for example, as an oil film, and flow around the surface of the cooked product. This coating action ensures that the cooking oil flows across the entire surface of the dough product, including the surface opposite the oil dispenser, compared to a conventional floating fryer that cooks only one side of the product at a time. Therefore, the present invention provides improved and uniform heat transfer from the oil to the entire surface of the dough product, thereby improving the final product and reducing cooking time.

[0010] An oil distributor can be configured to dispense a curtain of cooking oil. A cooking oil curtain is preferred over a spray or shower because it reduces oil exposure to air, thus reducing oxidation. The oil distributor may include an elongated outlet that thus creates the cooking oil curtain along its length. The oil distributor may include a weir. The weir may include an oil inlet, a well, and a lip over which the cooking oil flows. The oil distributor can be identical. The oil distributor may extend across the entire width of the conveyor, i.e., in a direction perpendicular to the direction of travel of the conveyor. In an alternative embodiment, the oil distributor may supply a cooking oil spray or shower, or be configured to coat one or more linear flows of cooking oil in a dough product.

[0011] The conveyor can be configured to allow cooking oil to pass through it. The conveyor can be configured to guide the cooking oil away from the dough product positioned thereon. The conveyor can be configured so that the cooking oil does not pool on the conveyor, for example, it does not come into contact with the dough product. Such embodiments reduce the amount of cooking oil entering the dough product, thus providing a healthier product. Therefore, by preventing oil pooling, the dough product is not located in an oil pool, which can be absorbed into the product, resulting in a higher-calorie product.

[0012] The system may further include one or more blowers. The blowers may be configured to supply an airflow to the cooked dough product, for example, to remove residual oil. The blowers may be unheated. The blowers may be heated. One or more blowers may be air knives. The air knives may be configured to supply an air curtain to the cooked dough product. As used herein, the term "air knife" refers to a blower with linear nozzles, for example, to provide a thin air curtain. Preferably, the blowers have sufficient power to supply a high-speed air jet or air curtain. The inventors have discovered that oil is typically absorbed into the dough through capillary action, and therefore the blowers minimize the contact time of the oil on the surface after cooking. One or more blowers are configured to blow oil away from the dough product, rather than as a further cooking step. Preferably, the blowers are positioned less than 40 s, 35 s, 30 s, 25 s, 20 s, 15 s, or 10 s after the final oil dispenser. It should be understood that the time-limited position will reflect a variable physical position depending on the conveyor speed. For example, the blower is positioned so that the dough product passes underneath within the aforementioned time limit. A shorter time between the final oil dispenser and the blower is also desirable because the oil will be hotter and less viscous, and therefore easier to remove from the surface.

[0013] The system may further include chambers. The chambers may house at least a plurality of oil dispensers. The chambers may house a blower. The chambers may include an inlet opening. The chambers may include an outlet opening. A conveyor may be configured to transport dough products from the inlet opening to the outlet opening. The conveyor may extend through the inlet opening and / or the outlet opening, for example, to cooperate with additional conveyors or product handling equipment.

[0014] The chamber may include a top and / or surface extending around the base. The chamber can retain heat from the heated oil; for example, the internal temperature of the chamber may be higher than ambient temperature. The internal air temperature within the chamber may be 20°C to 200°C, 30°C to 190°C, 40°C to 180°C, 50°C to 170°C, 60°C to 160°C, 70°C to 150°C, 80°C to 140°C, 90°C to 130°C, 100°C to 120°C, or 110°C. It should be understood that the endpoints of the ranges can be combined in any way herein. It should be understood that the temperature within the chamber will be a gradient, with the temperature at the inlet opening being lower than the temperature immediately adjacent to the first oil distributor. The chamber may include a heater for increasing the temperature within the chamber. The heater may include one or more heating elements, a gas stove, an infrared heater, or other suitable heating device. Thus, the chamber can be used to function as an oven for baking the dough product as it passes over a conveyor. The chamber may include one or more fans or air circulation devices for better heat distribution within the chamber.

[0015] In some embodiments, the system may further include an oven configured to pre-bake dough products. For example, the oven may be positioned before an oil dispenser. The oven may have temperatures of 100°C to 180°C, 110°C to 170°C, 120°C to 160°C, 130°C to 150°C, or 140°C. The system may be configured to provide a dwell time of 30 s to 120 s, 40 s to 110 s, 50 s to 100 s, 60 s to 90 s, or 70 s to 80 s in the oven for the dough products. Additionally or alternatively, the system may further include a steamer configured to pre-cook the dough products. For example, the steamer may be positioned before an oil dispenser. The steamer may have temperatures of 100°C to 180°C, 110°C to 170°C, 120°C to 160°C, 130°C to 150°C, or 140°C. In some implementations, the oven and / or steamer are integrated with the chamber. The conveyor can pass through the oven and / or steamer section before passing through an additional section including an oil dispenser. It should be understood that the endpoints of the range can be combined in any way herein.

[0016] The system can have a distance of at least 20 cm between the input opening and the first oil distributor among a plurality of oil distributors. This distance can be at least 30 cm, 40 cm, 50 cm, 60 cm, 70 cm, 80 cm, 90 cm, 100 cm, 110 cm, 1200 cm, or 130 cm. In some embodiments, the distance can be less than 200 cm, 180 cm, 160 cm, 150 cm, 140 cm, 130 cm, 120 cm, 110 cm, 100 cm, 90 cm, 80 cm, 70 cm, 60 cm, or 50 cm. The aforementioned distance can include the distance between the input opening and the oil flow from the first oil distributor among the oil distributors. The system can be configured to provide a residence time of 30 s to 120 s, 40 to 110 s, 50 to 100 s, 60 to 90 s, or 70 to 80 s for the dough product in the chamber before the first oil distributor. It should be understood that the endpoints of the range can be combined in any way in this document.

[0017] The system may further include a proofing machine. The proofing machine can be configured to maintain uncooked dough products under conditions that promote dough proofing. The proofing machine can have an internal temperature of 25°C to 40°C, 27°C to 38°C, 28°C to 37°C, 30°C to 35°C, 31°C to 34°C, or 32°C to 34°C. The proofing machine can have an internal relative humidity of 50% to 80%, 55% to 75%, or 60% to 70%. The proofing machine can have more than one zone, whereby these zones have different temperatures and / or humidity levels. The uncooked dough products can be maintained in the proofing machine for 30 to 55 minutes, 35 to 50 minutes, 40 to 45 minutes, 41 to 44 minutes, or 42 to 43 minutes. It should be understood that the endpoints of the ranges can be combined in any way herein. The inventors have discovered that the more the dough proofs, the more bubbles and foam are formed on the upper surface of the product (i.e., the area where the cooking oil first comes into contact). By allowing the dough to proof for a shorter period, the product is less prone to air bubbles and foaming. Shorter proofing times result in less dough expansion and a "weaker" dough, meaning it has less gluten structure formed. The inventors have also discovered that this reduction in proofing can be mitigated by pre-baking the dough within the cavity and by selecting the oil temperature and flow rate.

[0018] The system may include additional conveyors for transporting the proofed dough product from the proofer to, for example, a conveyor and oil dispenser and / or an oven and / or steamer. The additional conveyors may include one or more conveyor belts formed of elastic and / or flexible materials. Preferably, the belt material is highly elastic. The elastic conveyor belts may be configured to cushion the proofed dough product when it comes into contact with the additional conveyor, for example, when it swings off from the proofer. Careful handling is desired to prevent deformation of the proofed product or the escape of gases, as the product is typically fragile and is routinely placed directly into the fryer to minimize impact. The conveyors may be of the type supplied by Lynnmore Engineering Ltd. of Kingsleyn, UK.

[0019] The system may further include one or more tracks. Multiple oil dispensers may be connected to these tracks, for example, such that the positions of the multiple oil dispensers are adjustable. The tracks may include a series of mounting points, to which the oil dispensers may be connected, for example, by mechanical fasteners. The position of the dispenser may be adjustable in one or both directions. One direction may be parallel to the length of the conveyor, for example, the dispenser may move longitudinally along the conveyor and / or the system. For example, the dispenser may move toward and away from the end of the chamber and / or the blower. One direction may be perpendicular to the length of the conveyor, for example, this direction may be (approximately) vertical, and the dispenser may be configured to rise and fall. In some embodiments, the dispenser may rise and fall relative to the track. In other embodiments, the track may rise and fall, for example, relative to the conveyor. The system may be configured such that the oil dispenser is positioned as far away as possible from the input opening, so that the dough product undergoes a pre-baking step.

[0020] The conveyor may be a ring conveyor. The conveyor may include a belt through which oil can flow. The belt may include links, a mesh, or a similar construction. The belt may be porous. The belt may include a series of orifices through which oil can flow. The orifice size may be between 1 mm and 15 mm, 2 mm and 14 mm, 3 mm and 13 mm, 4 mm and 12 mm, 5 mm and 11 mm, 6 mm and 10 mm, 7 mm and 9 mm, or 8 mm. It should be understood that the endpoints of the range can be combined in any way herein. The orifices may be circular, square, or any other shape. The orifice size of the belt is a balance between the need to support delicate, uncooked dough products and the expectation of allowing oil to flow quickly away from the product.

[0021] The conveyor may include a belt positioned above the oil tray. The oil tray may be configured to capture oil from the oil distributor. The system may further include a recirculation pump configured to supply oil from the oil tray to the oil distributor.

[0022] The system may further include a heater for heating the oil. The heater may include one or more heating elements. The heating elements may be located within the oil tray to heat the oil therein. The heating elements may be located substantially below the distributors. This arrangement avoids oil cooling throughout the system (e.g., in the collection area). Additionally or alternatively, the system may include one or more in-line heaters configured to heat the oil within the pipes connecting the oil tray and the oil pump and / or between the oil pump and multiple oil distributors. Additionally or alternatively, the heater may include one or more electric heating elements, gas-powered heaters, heat exchangers, or induction heaters.

[0023] The system may further include a filter for filtering the oil. The filter may be located within the oil tray, within a filter unit, and / or within a pipe connecting the oil tray and the oil pump. Preferably, the filter is located before the oil pump.

[0024] The system can be configured to supply oil from the oil distributor at temperatures ranging from 150°C to 200°C. Optionally, the system can be configured to supply oil from the oil distributor at temperatures ranging from 160°C to 190°C, 165°C to 185°C, 170°C to 180°C, or 175°C. It should be understood that the endpoints of the ranges can be combined in any way herein.

[0025] The system can be configured to supply oil from the oil distributor at a flow rate of 10 liters / min to 80 liters / min (L / min) per distributor. The system can be configured to supply oil from the oil distributor at flow rates of 15 L / min to 75 L / min, 20 L / min to 70 L / min, 25 L / min to 65 L / min, 30 L / min to 60 L / min, 35 L / min to 55 L / min, 40 L / min to 50 L / min, or 45 L / min. The oil distributor can have an outlet with a width of 50 cm to 150 cm, 60 cm to 140 cm, 70 cm to 130 cm, 75 cm to 125 cm, 80 cm to 120 cm, 90 cm to 110 cm, or 100 cm. The outlet can have a height (i.e., the length perpendicular to the width measurement) of 1 mm to 10 mm, 2 mm to 9 mm, 3 mm to 8 mm, 4 mm to 7 mm, or 5 mm to 6 mm. The outlet can have a height of 5 cm. 2 Up to 150 cm 2 10 cm 2 Up to 140 cm 2 20 cm 2 Up to 130 cm 2 30 cm 2 Up to 120 cm 2 40 cm 2 Up to 110 cm 2 50 cm 2 Up to 100 cm 2 60 cm 2 Up to 90 cm 2 or 70 cm 2 Up to 80 cm 2 The cross-sectional area. The system can be configured to provide 0.1 liters / cm². 2 Up to 15 liters / cm 2 0.5 liters / cm 2 Up to 14 liters / cm 2 1 liter / cm2 Up to 13 liters / cm 2 2 liters / cm 2 Up to 12 liters / cm 2 3 liters / cm 2 Up to 11 liters / cm 2 4 liters / cm 2 Up to 10 liters / cm 2 5 liters / cm 2 Up to 9 liters / cm 2 6 liters / cm 2 Up to 8 liters / cm 2 Or 7 liters / cm 2 The flow rate through the oil distributor outlet. The system may include an oil pump with an output of up to 200 L / min to 300 L / min. The oil pump may have an output of 50 L / min to 350 L / min, 75 L / min to 325 L / min, 100 L / min to 300 L / min, 125 L / min to 275 L / min, 150 L / min to 250 L / min, 175 L / min to 225 L / min, or 200 L / min. It should be understood that the endpoints of the range can be combined in any way herein. The output of the oil pump divided by the number of oil distributors used, and therefore the flow rate from the distributors, can be reduced by using more oil distributors or increased by shutting down the oil distributors. Similarly, since the flow will be dispersed across the outlet, the flow rate at a single point on the conveyor will vary with the outlet size of the oil distributor. In a range of implementations, the system includes an oil pump with a maximum output of 200 L / min to 300 L / min and 3 to 6 oil distributors.

[0026] The system can be configured to supply air from the blower at ambient temperature. For example, the ambient temperature can include 10°C to 25°C. Alternatively, the blower may include a heater and can be configured to supply air at temperatures above ambient temperature (e.g., 25°C to 150°C, 50°C to 125°C, or 75°C to 100°C). Alternatively, the blower may include an air inlet from within the chamber to provide air at temperatures above ambient. The system can be configured to supply air at a 50 m... 3 / hour to 250 m 3 / hour, 75 m 3 / hour to 225 m 3 / hour, 100 m 3 / hour to 200 m 3 / hour, 125 m 3 / hour to 175 m 3 / hour or 150 m 3Air is supplied from the blower at a flow rate of 100 m / h. The system may include an air pump or fan configured to operate at 100 m / h. 3 / hour to 500 m 3 / hour, 150 m 3 / hour to 450 m 3 / hour, 200 m 3 / hour to 400 m 3 / hour, 250 m 3 / hour to 350 m 3 / hour or 300 m 3 Air is supplied to one or more blowers per hour. It should be understood that the velocity of the air leaving the blowers can vary depending on the size and number of blower outlets. Blowers may include air knives with outlets of 50 cm to 150 cm, 75 cm to 125 cm, 80 cm to 120 cm, 90 cm to 110 cm, or 100 cm. It should be understood that the greater the distance between the blower outlet and the conveyor, the greater the air entrainment, and the more turbulent the air output will become. Blower outlets may be located 5 cm to 15 cm above the surface of the conveyor, or 5 cm to 14 cm, 7 cm to 13 cm, 8 cm to 12 cm, 9 cm to 11 cm, or 10 cm above the surface of the conveyor. It should be understood that the endpoints of the range can be combined in any way herein.

[0027] The conveyor can have speeds of 0.5 cm / s to 2 cm / s, 0.75 cm / s to 1.75 cm / s, 0.8 cm / s to 1.7 cm / s, 0.9 cm / s to 1.6 cm / s, 1 cm / s to 1.5 cm / s, 1.1 cm / s to 1.4 cm / s, or 1.25 cm / s. In some embodiments, the conveyor speed is 0.9 cm / s to 1.0 cm / s. The system can be configured such that the residence time of the dough product in the oil is 10 s to 80 s, 15 s to 70 s, 20 s to 60 s, 25 s to 55 s, 25 s to 50 s, 30 s to 45 s, or 35 s to 40 s. It should be understood that the endpoints of the range can be combined in any way herein.

[0028] According to a second aspect of the invention, a method for cooking confectionery products is provided. The method may include providing a cooking system as described above. The method may include conveying uncooked dough on a conveyor through a flow of cooking oil dispensed from a plurality of oil dispensers to produce cooked dough. Preferably, no further cooking steps are required because the flow of cooking oil from the plurality of oil dispensers provides sufficient heat to cook the dough product without further cooking steps. Since the system is configured to provide cooking oil in a flow to the entire surface of the dough product, the dough product can be cooked quickly and evenly. Furthermore, by providing an oil flow instead of simply immersing the dough product partially or completely in the cooking oil, a greater rate of heat transfer can be achieved, and therefore a greater cooking rate, resulting in a more pleasingly moist product. Although deep frying brings the dough product into direct contact with the oil, the moisture released from the dough product and the heat absorbed through the dough product lower the local temperature of the cooking oil. In contrast, the flow of cooking oil maintains a more uniform temperature because it is in contact with the dough product for only a short time before being replaced by fresh cooking oil.

[0029] The cooking system may include one or more blowers configured to supply an airflow to a cooked dough product, and the method may include conveying the cooked dough through the airflow from the one or more blowers to remove residual cooking oil.

[0030] The method may include operating the system under the conditions described above, and the statements of the first aspect may be combined with the second aspect, and vice versa.

[0031] The method may include conveying uncooked or partially cooked dough through cooking oil at a temperature of 160°C to 190°C and / or having a flow rate of 10 L / min to 80 L / min per oil dispenser. The method may also include conveying dough through oil flows from 3 to 6 (i.e., 3, 4, 5, or 6) oil dispensers.

[0032] Dough products can include dough-based confectionery products. Dough products can include sweet or savory donuts. The dough can contain any conventional dough composition. Dough products can be non-planar. Dough products can be shaped into any form, such as spheres, oblate spheroids, ellipsoids, balls, solid rings, or smooth, curved three-dimensional surfaces with any aspect ratio. The inventors have found that smooth, curved three-dimensional shapes of dough products facilitate complete coating of cooking oil across the entire surface of the dough product, including the surface opposite the oil dispenser. Smooth, curved three-dimensional shapes of dough products are preferred because they prevent excessive splattering when coating the dough product with cooking oil, which increases the oxidation of the cooking oil. Dough products can have the shape of a conventional donut, such as a ring-shaped donut (essentially a circle with a central hole) or a filled donut (a flattened sphere). Dough products can have a thickness of 10 mm or more. Dough products can have a thickness that is 10% or more, 20% or more, 30% or more, 40% or more, or 50% or more larger than their diameter. Very thin dough products (such as tortillas) do not need to be completely wrapped during cooking because heat can easily pass through them.

[0033] In a range of embodiments, the dough comprises 40% to 60% by weight wheat flour, 0.5% to 3% by weight yeast, 0% to 5% by weight oil and / or fat, and 20% to 40% by weight water.

[0034] The dough may contain 42% to 58% by weight, 44% to 56% by weight, 45% to 55% by weight, 46% to 54% by weight, 48% to 52% by weight, or 50% by weight of wheat flour. The dough may contain 0.75% to 2.75% by weight, 1% to 2.5% by weight, 1.25% to 2.25% by weight, or 1.5% to 2% by weight of yeast. The yeast may be fresh or dried. The dough may contain 0.1% to 4.5% by weight, 0.5% to 4% by weight, 1% to 3.5% by weight, 1.5% to 3% by weight, or 2% to 2.5% by weight of oil. The oil may be any edible liquid or solid oil, such as rapeseed oil, sunflower oil, vegetable oil, coconut oil, palm oil, shortening, or the like. The dough may contain 22% to 38% by weight, 24% to 36% by weight, 25% to 35% by weight, 26% to 34% by weight, 28% to 32% by weight, or 30% by weight of water. It should be understood that the endpoints of the ranges may be combined in any way herein.

[0035] The dough may contain 0% to 20% by weight of donut concentrate or additives. The donut concentrate may be a blend of one or more of flour, sugar, emulsifiers, leavening agents, whey powder, stabilizers, and / or flour treatment agents. The additives may contain the same blends, but omit flour and / or sugar. The dough may contain at least 0.1%, 0.25%, 0.5%, or 0.75% by weight of donut concentrate or additives. In some embodiments, the dough may contain 1% to 19% by weight, 3% to 17% by weight, 5% to 15% by weight, 7% to 13% by weight, 9% to 11% by weight, or 10% by weight of donut concentrate or additives. In many commercial donut concentrates, the largest proportion is wheat flour, in which case the weight percentage of additives in the dough will be significantly lower than the weight percentage of the total concentrate in the dough. It should be understood that the endpoints of the ranges may be combined in any way herein.

[0036] The dough may contain 0% to 2% by weight of salt. The dough may contain 0.1% to 1.9% by weight, 0.2% to 1.7% by weight, 0.3% to 1.5% by weight, 0.4% to 1.3% by weight, 0.5% to 1.1% by weight, 0.6% to 1.0% by weight, or 0.7% to 0.9% by weight of salt. It should be understood that the endpoints of the ranges may be combined in any way herein.

[0037] According to a third aspect of the invention, a dough-based confectionery product is provided, which is produced according to the methods described herein. The confectionery product may be a donut, such as a ring-shaped donut or a spherical donut. Attached Figure Description

[0038] The invention will now be described with reference to the following figures, in which:

[0039] Figure 1 This is a perspective view of a system used for cooking confectionery products;

[0040] Figure 2 This is a perspective view of the system, with the top removed;

[0041] Figure 3 It is a longitudinal cross-section through the system as viewed from the side; and

[0042] Figure 4 It is a close-up view of a cross-section of a part of the system. Detailed Implementation

[0043] Now go to Figure 1 and Figure 2The diagram illustrates a system 1 for cooking dough products. The system includes a chamber 2 mounted on a support frame 21 to raise the chamber 2 to a normal working height. The chamber 2 is formed by a top 22 and a base 23. The top 22 has a top surface 25, a pair of side surfaces 27 on opposite sides of the top surface 25, end faces 29, and a series of angled panels 26 extending between the top surface 25 and the side surfaces 27. Each end face 29 has an orifice 31 serving as an inlet and outlet for the system.

[0044] exist Figure 2 In the diagram, top 22 has been removed to show the internal components of system 1. The system has a conveyor 32 with a pair of rollers 33 and a continuous belt (not shown) extending therebetween. A series of belt supports 35 extend along the length of the system to support the upper surface of the belt, and a series of transverse members 36 are positioned along the length of the conveyor 32 to provide further support and facilitate oil flow. The rollers 33 are positioned outside chamber 2 to convey product into and out of chamber 2. The belt (not shown) is configured to allow cooking oil to pass freely and is preferably a chain link, mesh, or similar construction. The belt may include orifices of any suitable size to allow oil flow; for example, the mesh may be a 4 mm square mesh (4×4 mm mesh), or it may have larger orifice sizes, such as up to 15×15 mm square mesh.

[0045] For further reference Figure 3 and Figure 4 The base 23 is positioned below the top 22 and extends beyond each of the end faces 29. The base 23 has an oil tray 37 extending below the conveyor 32 and is configured to receive oil falling through the conveyor. A heater, such as a heating element 45, is disposed therein, which is immersed in the oil within the oil tray 37 during use. The oil tray 37 has a reservoir 39 at its end, which is connected via an oil conduit 40 to an oil pump 41 and subsequently to an oil manifold 43, whereby oil is distributed to a series of six weirs 47. The weirs 47 are mounted on a pair of rails 49 connected to the side 27 of the top 22. The rails 49 have a pair of slots 491 (see...). Figure 4 Fastener 493 extends through the groove to secure the position of the track 49. Therefore, the groove 491 allows for simple height adjustment of the track 49, and thus, simple height adjustment of all weirs 47 above the conveyor 32. Each weir 47 is connected to the oil manifold 43 via a flexible hose 46, allowing the weir 47 to be easily moved along the track and installed in place (e.g., with mechanical fasteners). A valve 48 is provided between the oil manifold 43 and the flexible hose 46, allowing each weir 47 in the system to be activated / deactivated according to user requirements and the cooking method being performed. The system also includes an air pump 51 connected to a pair of blower outlets in the form of air knives 53.

[0046] Now go to Figure 4 A close-up view of a cross-section through system 1 is shown. Each weir 47 includes a pair of mounting plates 471, which can be attached to a track via mechanical fasteners. The weir 47 is formed of a metal plate such as stainless steel and has a rear wall 473, a lower surface 475, and a nozzle 477. The rear wall 473, lower surface 475, and nozzle 477 thus define a well 470 therein. The nozzle 477, in turn, has a barrier 479 and a lip 481, with a fine groove provided between the barrier and the lip to act as an oil distributor outlet, allowing oil to flow between the barrier 479 and the lip 481. In the illustrated embodiment, the nozzle 477 has a width of approximately 95 cm, and the distance between the barrier 479 and the lip 481 is approximately 5 mm. The rear wall 473 is provided with a mesh filter 483, which defines an inlet 482 into which the end of a flexible hose 46 supplies oil. The mesh filter 483 serves as a simple filter to prevent any remaining solids from flowing into the well and disrupting the oil flow, allowing the oil entering the weir 47 to fill the well 470. As the oil level within the well 470 rises, it eventually reaches the nozzle 477 and flows over the lip 481 to the conveyor 32 below. The weir 47, and particularly the nozzle 477 (e.g., the lip 481 and barrier 479), is configured to guide the oil layer flow on the lip 481 onto the conveyor 32 below, allowing the conveyor to pass through the oil curtain. Furthermore, the oil flow rate entering the weir 47, oil selectivity (and therefore characteristics such as viscosity), and oil temperature all affect the weir 47's ability to form an oil layer flow on the lip, and can therefore be adjusted as needed according to the cooking process being performed.

[0047] An air knife 53 extends vertically across the conveyor 32 and is connected to an air pump 51 via a conduit 53. The air knife has an outlet slot 533 therein, which faces the conveyor 32 to provide an air curtain through which the conveyor 32 passes.

[0048] During cooking, the system is heated by heating elements 45 located within an oil tray 37 at the base 23. A top 22 extends above the base 23 to form a chamber 2, i.e., a substantially enclosed cavity in which the cooking method takes place. Conveyors 32 extend from both ends of the chamber 2 to transport raw product into and from the chamber 2, and can be integrated with any conventional food handling and conveying system, such as additional conveyors. By providing chamber 2 instead of using an open fryer, more heat is retained within the system, thus reducing convective energy loss and cooking the product faster. Hot oil is pumped from wells 39 via oil pump 41 to weirs 47, each of which can be independently positioned and controlled to provide a highly adaptable system. Valves 48 can be opened or closed depending on which weir the user wishes to operate, controlling the flow of oil from each weir. Thus, the oil flow rate can be regulated across all weirs by adjusting the pump rate, but similarly, individual weirs can be balanced or reduced by controlling valves 48.

[0049] Uncooked products are transported by conveyor 32 (e.g., in...) Figure 2 and Figure 3 The product (picked up from the left side of the container) enters chamber 2. The heat within chamber 2 can act as part of the baking step, continuing to cook the product even when it is not under oil. The product then passes under a series of weirs 47 and through a curtain of hot oil falling from the weirs 47. The oil laminar flow from the weirs causes the oil to adhere to the surface of the product, thus ensuring a consistent coating on the surface of the cooked product. The oil laminar flow reduces splattering when it comes into contact with the product—splattered oil reduces the energy transferred to the product, which, in addition to potential uneven cooking and surface coloring, increases process costs by increasing heating requirements. The oil is then drained from the surface of the product, conveyed by a conveyor belt, and placed in an oil tray for recycling and / or filtration. The product then continues forward under a blower (e.g., an air knife 53) to remove residual oil from the surface of the product. The cooked product then exits the distal end of chamber 2, where it can be transported for further processing, such as cooling, garnishing, and packaging.

[0050] In some embodiments (not shown), the system may have additional cooking equipment preceding the chamber. For example, the system may further include an oven or steam oven preceding the chamber for pre-baking or pre-steaming confectionery products. Such an oven may be a conveyor-based oven and thus fed directly into conveyor 32 of system 1, or it may need to be transported from a conventional oven. The system may be integrated with subsequent downstream equipment (such as coolers or drying equipment) or decorating and / or filling systems.

[0051] Therefore, System 1 provides the operator with numerous adjustable points to achieve the desired cooking method. For example, the total frying time is a function of the conveyor speed and the number of oil dispensers supplying oil to the dough product. It has been found that the surface temperature of the dough product drops rapidly when it is no longer in the cooking oil, for example, after passing through the oil dispensers. Because the oil flows out of the product rapidly, the product will not be fried when there is no oil supply from the oil dispensers. Therefore, to increase the frying time, a slower conveyor and / or more oil dispensers are required.

[0052] The total cooking time is a function of the conveyor speed and the length of the conveyor, as this includes any baking time before, during, or after the frying step, for example, due to the temperature rise inside the chamber.

[0053] The position of the weir relative to the conveyor further provides a mechanism for regulating the cooking profile the product will undergo. As mentioned above, the surface temperature of dough drops rapidly when not in oil. Therefore, a short, constant frying method can be achieved by grouping the oil distributors together. Similarly, a long, variable cooking profile can be achieved by spacing the oil distributors apart. Such a profile can represent alternating cycles of baking and frying, such as low-energy transfer and high-energy transfer. The oil distributors can be grouped together in different configurations to provide different frying steps. For example, they can be grouped closely together and moved away from the inlet side endwall, so that the product undergoes a pre-baking step due to the internal temperature of the chamber before a single uniform frying step. Such a pre-baking step can be a complement to or alternative to a pre-baking step using an oven or steamer. In some examples, the weirs can be configured as two or more groups with different flow rates or even oil temperatures, so that the product passes through two or more different frying zones, such as a high-flow-rate, high-energy zone; a lower-flow-rate, lower-energy zone; or variations thereof. Therefore, the system of the present invention has more variables that can be adjusted to achieve a desired final product, such as final coloring and core temperature.

[0054] As described above, the embodiment in the attached diagram has six weirs, but the system can have any suitable number, and the weirs can be controlled individually (e.g., in some cooking methods, all of them may not be necessary). The position of the weirs relative to the blower also defines the contact time of the oil on the surface of the cooked product, and therefore a longer distance between the weirs and the blower will be expected to result in more oil being absorbed into the product. Additionally, due to the internal temperature of the chamber, the longer distance between the weirs and the blower can serve as a baking step after frying.

[0055] The operating parameters of the weirs themselves can be controlled to provide the desired cooking method. Although the oil temperature in the illustrated embodiment will be uniform across the system, the flow rate of oil from the weirs can be set individually, for example, by adjusting the valves between the manifold and each weir. In conventional deep fryers, the cooking rate depends on the oil temperature. However, in this system, the cooking rate also depends on the oil flow rate, where a high oil flow rate from the weirs results in faster heat transfer to the product, and thus a faster cooking rate. The frying rate needs to be configured so that the center of the product is fully cooked without overcooking or scorching the outer surface. This can be advantageous because it provides the desired browning of the product's surface while reducing contact time, thereby minimizing oil absorption in the product. Another advantage is the precise control of product expansion during cooking. When dough products are heated, they expand (often referred to as "oven springs") due to the heating and expansion of gases (such as CO2) trapped within the gluten matrix in the dough. Therefore, the present invention provides very precise control over how much and when heat is supplied to the product in a manner unattainable in conventional floating fryers. As discussed above, the dough is preferably under-proofed to obtain a weaker dough and avoid bubbling on the product surface. This increased control over the heat supplied to the product during frying provides greater control over expansion and can therefore compensate for the reduced expansion during proofing.

[0056] Another advantage is that the weir height can be adjusted as described above according to the desired cooking method. A lower weir means less air exposure to the oil, which therefore reduces oil oxidation and extends the life of the cooking oil. At the same time, the weir height can be set to ensure smooth oil flow over the surface of the product. The viscosity of the oil means that it can coat the product to fry all surfaces.

[0057] Example

[0058] Example A - Fat Content

[0059] A standard yeast donut dough is prepared, consisting of the following components: 51% wheat flour, 10.5% donut concentrate, 1.7% fresh yeast, 1.6% rapeseed oil, 0.7% reducing sodium salt, and 34.5% water. The donut concentrate is made from Puratos... ® Easy Donut available ™The dough contained wheat flour, dextrose, emulsifiers (E471, E481), leavening agents (E450, E500, E501), whey powder, rapeseed oil, salt, stabilizers (E412, E466), and flour treatment agent (E300). The dough was formed into small balls and allowed to rise. They were then fried using three different techniques to assess the effect on the fat content of the product. The three cooked samples were then cooled and analyzed, and the results are shown in Table 1 below.

[0060] Comparative Example 1 - The proofed donuts were fried in a conventional floating fryer at 180°C for 90 seconds on each side. The donuts had a pleasant golden-brown color.

[0061] Sample 2 - Use Figures 1 to 4 System 1 shown is used to fry donuts. The proofed donuts are transferred to a conveyor and passed through the system. The system operates with 4.5 oil dispensers (i.e., four weirs are fully open and the other weir is at half flow); the conveyor speed is set to 1.1 cm / s. -1 The oil pump was set to 50% of its maximum frequency, supplying oil to the four weirs at approximately 125 L / min, with the oil temperature between 170°C and 180°C. An air pump was positioned between the two air cutters at a speed of 400 m... 3 / hour maximum output split operation.

[0062] Sample 3 - Donuts pre-baked using System 1 before frying. The proofed donuts were baked in a fan-operated oven at 140°C for 75 seconds, with the fan speed set to 1. The pre-baked donuts were then transferred to System 1, and the cooking method of Example 2 was repeated.

[0063]

[0064] Table 1

[0065] The mass gain was calculated by weighing the donuts removed from the proofing machine and then subtracting that weight from the mass measured after frying. The value was normalized relative to 40g of donuts to allow for direct comparison. The samples were then sent for external analysis to determine fat, saturated fat, and moisture content. An Oracle from CEM was used. ™ The RapidNMR fat analyzer was used to measure fat content. Saturated fat content was determined by gas chromatography, and moisture content was determined by drying the sample in an oven at 103°C and weighing the remainder.

[0066] The inventors have discovered that frying donuts using System 1 (i.e., samples A2 and A3) produces donuts with a similar pleasant coloring to Comparative Example 1. However, the system produces donuts with a significantly reduced fat content compared to conventional frying. A3 was found to have a higher moisture content than Comparative Example A1, which is reflected in the softer texture achieved in the final product. The moisture content of sample A2 was not obtained, but its texture was as soft and pleasant as A3, and therefore it was concluded that its moisture content was equal to or higher than Comparative Example A1. Not wishing to be bound by theory, it is believed that shorter frying times and faster cooking result in greater moisture retention in the final product.

[0067] Example B - System Configuration

[0068] In the second series of experiments, a second batch of dough for making confectionery products was prepared as described in Example A and cooked using System 1 described herein. Various settings of System 1 were adjusted to provide nine cooking profiles—the system settings are shown in Table 2 below. This was done using an iPhone... ® The effect of the oil on the color of cooked products was studied using the Colormeter software application (ColorMeter RGB colorimeter developed by White Marten GmbH), and the results are recorded in Table 3. The Colormeter results define three properties of the surface color of cooked confectionery products as defined by the International Commission on Illumination (CIE). “L” indicates lightness, with lower numbers indicating a darker tinted surface, and “a” and “b” are the red / green and yellow / blue coordinates, respectively. The oil temperature was maintained between 170°C and 180°C, allowing for direct comparison with other system settings.

[0069]

[0070] Table 2

[0071] In the data in Table 3 below, the value of L indicates the darkness / lightness of the surface of the fried donuts and is therefore used as a representative of the cooking level performed. As shown by Examples B1 to B3, increasing the conveyor speed results in a lighter surface color on the product due to the reduced time the product spends in hot oil. This test was then repeated with the oil pump speed set to 50% (down from 75%). Examples B4 to B6 are all lighter than the equivalent Examples B1 to B3, indicating that the oil pump speed can be selected to increase or decrease the amount of energy transferred to the surface of the donuts without changing the oil temperature. Examples B7 to B9 were then operated under maximum cooking conditions by opening all the oil weirs in the six-weir system and operating the oil pump at maximum speed. Examples B7 to B9 all produce a deeper surface color compared to the comparative examples operated with fewer weirs and lower oil flow rates. Finally, Example B10 is a repetition of Example B4 and was implemented to demonstrate the consistency of the cooking method and system, providing a very close approximation of darkness and color profile.

[0072]

[0073] Table 3

[0074] The inventors have discovered that a ColorMeter L value of 35 to 45 represents a pleasing cooking result. Below L=35, the product tends to be too dark and overcooked. Above L=45, the product tends to be too light and undercooked.

Claims

1. A system for cooking dough products, the system comprising: A conveyor for transporting dough products. Multiple oil dispensers are configured to distribute a flow of cooking oil onto the dough product on the conveyor to provide a cooking oil film across the entire surface of the dough product, thereby cooking the dough product.

2. The system of claim 1, wherein the conveyor is configured to allow cooking oil to pass through the conveyor and / or guide cooking oil away from the dough product positioned on the conveyor.

3. The system according to any one of the preceding claims, further comprising one or more blowers configured to supply an airflow to the cooked dough product to remove residual oil, and optionally, wherein the one or more blowers are air knives configured to supply an air curtain to the cooked dough product.

4. The system according to any one of the preceding claims, the system further comprising a chamber accommodating at least the plurality of oil distributors and optionally the blower.

5. The system according to any one of the preceding claims, wherein the chamber includes an input opening and an output opening, and wherein the conveyor is configured to convey the dough product from the input opening to the output opening.

6. The system according to any one of the preceding claims, wherein the system has a distance of at least 200 mm between the input opening and the first oil distributor of the plurality of oil distributors.

7. The system according to any one of the preceding claims, the system further comprising one or more tracks, and wherein one or more of the plurality of oil distributors are connectable to the one or more tracks such that the position of the plurality of oil distributors is adjustable.

8. The system according to any one of the preceding claims, wherein the conveyor includes a belt located above an oil tray configured to capture oil from the oil distributor, and wherein the system further includes a recirculation pump configured to supply oil from the oil tray to the oil distributor.

9. The system according to any one of the preceding claims, wherein the system is configured to supply oil from the oil distributor at a temperature of 160°C to 190°C and / or at a flow rate of 10 L / min to 50 L / min per distributor.

10. The system according to any one of the preceding claims, wherein the system is configured to operate at ambient temperature and / or at 50 m 3 / hour to 250 m 3 Air is supplied from the blower at a flow rate of / hour.

11. The system according to any one of the preceding claims, wherein the conveyor has a speed of 0.5 cm / s to 2 cm / s, and optionally, wherein the system is configured such that the dough product has a residence time in the oil of 10 s to 80 s.

12. The system according to any one of the preceding claims, further comprising an oven configured to pre-bake the dough product at a temperature of 100°C to 180°C prior to the plurality of oil dispensers, and optionally, wherein the system is configured to provide a dwell time of the dough product in the oven of 30 s to 120 s.

13. A method for cooking confectionery products, the method comprising: Provide a cooking system according to claim 1, Uncooked dough products on the conveyor are fed through a stream of cooking oil dispensed from the plurality of oil dispensers to produce cooked dough products.

14. The method of claim 13, wherein the uncooked dough product is conveyed through cooking oil having a temperature of 160°C to 190°C and / or a flow rate of 10 L / min to 50 L / min per oil dispenser.

15. A dough-based confectionery product produced by the method according to claim 13 or 14.

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