METHOD AND APPARATUS FOR PRODUCE A LAYERED FOOD PRODUCT

Description

[0001] The invention relates to a method for producing a layered food product, a device for connecting a first substantially plate-shaped food product part to a plate-shaped covering, and the use of a heating device.

[0002] From DE 197 41 717 C1, DE 10 2013 226779 B3 and EP 3 199 030 A1, devices and methods for producing long-life baked goods with an upper baked part, a lower baked part and an intermediate layer are known.

[0003] For example, a liquid, creamy or pasty mass can be applied between two pieces of pastry, which binds the pieces together and then hardens more or less.

[0004] The disadvantage of sandwich-type food products, such as a combination of pastry pieces and a chocolate layer, is often that the intermediate layer, for example the chocolate layer, is not well placed, is distributed unevenly over the pastry piece and / or may even ooze out of the pastry pieces.

[0005] To make sandwich-like food products more visually appealing, it is common practice to provide the intermediate layer as a sheet-like, dimensionally stable layer. This layer must be bonded to the lower and upper baked parts.

[0006] It is known to create this bond using a joining process. Possible joining methods include gluing, assembling, filling, pressing, and pressing. In particular, a joining compound, which must be applied to the filling layer, can act as an adhesive layer between the filling layer and the baked item.

[0007] The joining compound can be provided on the surface of the intermediate layer in the form of ribbed edges, knobs or similar structures.

[0008] If an adhesive material is used, its taste and consistency must match the other layers and must not increase the product's cost. When joining without an additional adhesive layer, a sufficiently high force must generally be exerted on the joining partners. This can impair the layer quality or detract from the visual appearance that is being optimized. Furthermore, there is a risk of breakage with joining partners made of brittle materials, such as baked goods.

[0009] The object is therefore to provide a method and a device which overcomes the disadvantages of the known method and which, in particular, provides a precisely placeable and well-maintained connection between two layers in a simple manner.

[0010] The object is achieved by a method for producing a layered food product comprising at least a first, substantially plate-shaped food product part and a plate-shaped coating arranged on this plate-shaped food product part. A plate-shaped object is understood here to be an object having two opposing surfaces whose extent is greater than their distance. Each of the surfaces defines one side of the object.

[0011] The corresponding food product part and / or topping thus have two opposing surfaces, which essentially determine its shape. The food product part is a dimensionally stable part, namely a baked item. The topping can consist of a topping mass, which can be a fat mass, a chocolate mass, a compound mass, a sugar mass, a fondant mass, a jelly, a jam, a fruit mass, and / or another hardening water- and sugar-based mass.

[0012] The procedure includes the following steps.

[0013] First, a slab-shaped covering is manufactured or prepared. The covering is preferably dimensionally stable at room temperature, meaning it retains its shape under its own weight.

[0014] The covering has a raised area on at least one side that is raised from a plane. The surface of the plate-shaped covering is therefore not flat on at least one side. The covering consists of a plate-shaped base layer with two opposing, preferably parallel, flat surfaces, and at least one raised area located thereon.

[0015] Preferably, several raised areas are provided on one side. The edge surface of the plate-shaped covering is preferably designed to have a visually appealing shape, as it is visible in the finished food product. It is, for example, smooth. However, grooves or raised areas can also be provided.

[0016] In a further step, the at least one raised area of ​​the plate-shaped covering is heated. Preferably, all raised areas on one side are heated, preferably simultaneously, if there are multiple raised areas. This makes the covering material easier to deform under pressure. The material may melt during the heating process.

[0017] In a further step, at least one plate-shaped food product part is produced or prepared. This is positioned on the side of the coating with the heated raised area.

[0018] The bond between the food product part and the coating is then created, with a force being exerted in particular that acts toward the food product and / or toward the side of the coating with the heated raised area. The heated raised area acts similarly to an adhesive. When the food product part is positioned on the heated raised area, it deforms and forms a bonding layer between the coating and the food product part.

[0019] Therefore, no separate adhesive material is required. The resulting layered food product can consist solely of the food product part and the topping compound. No disturbing bonding layer is visible at the edge of the layered food product.

[0020] Because the heated raised area is easier to deform than the unheated covering mass, only a small amount of force is required to bond the surface. The weight of the covering or the food product part may be sufficient. Thus, the bond is created without damaging the covering or the food product part.

[0021] The provided sheet-like covering may have a raised area or areas on only one side. A second sheet-like food product part may be arranged on the other side, already connected to the sheet-like covering. A decoration may also already be applied to the other side.

[0022] The raised area can consist of the same covering compound as the sheet-like base layer. However, the raised area can also comprise a different or modified compound that is particularly well-suited for bonding. For example, the raised area can have a higher fat content than the sheet-like base layer. The compound with the higher fat content crystallizes more rigidly and thus has better adhesive properties.

[0023] The covering can, for example, be produced in a mold that specifically defines the profile of the at least one raised area on one side of the covering. For this purpose, the covering compound is poured into a mold and solidified therein. The covering can then be removed from the mold. The mold has, in particular, at least one corresponding recess at the bottom, in which the at least one raised area is formed. The mold also defines the surface finish of the edge surface of the covering. This is preferably smooth.

[0024] In an advantageous further development of the invention, a second food product is produced or provided, which is placed on a not yet solidified topping mass that is still in the mold. In particular, the second food product part is pressed down. Since the topping is not yet solidified, a bond is established between the topping and the second food product part. The topping is only solidified, for example, by cooling, when the second food product part is bonded to the topping.

[0025] Preferably, the dimensions of the first and second food product parts, as well as the topping, correspond to one another, so that the first and second food product parts, as well as the topping, can lie on top of one another in a sandwich-like manner, without one layer protruding laterally over another.

[0026] In a further process step, the second food product part can be transferred together with the topping, whereby the topping is removed from the mold. Preferably, the second food product and the topping are moved away from the mold, in particular, they are also rotated so that the raised area faces upward. The raised areas formed by the mold are then accessible for heating.

[0027] Preferably, the second food product part, together with the topping connected to it, is placed in a counter-mold such that the at least one raised region faces away from the counter-mold. The at least one raised region can then, for example, face upwards, so that a tool, for example, can be brought to the topping from above and the raised region can be heated.

[0028] The raised area can be heated after removal from the mold, the first food product part can be brought close to the topping, and then a bond can be created between the topping and the first food product part. This creates a sandwich-like food product.

[0029] Since the covering is manufactured in a mold and is not affected by subsequent processing steps, the edge surface of the plate-shaped covering meets all optical requirements.

[0030] If the mold size is selected according to the size of the food product pieces and the food product pieces are placed precisely, the coating can reach very precisely to the edge of the food product piece. The finished food product can then have a smooth edge surface.

[0031] Preferably, the raised region has a shape that tapers with increasing distance from the plane prior to heating. For example, the raised region is conical in shape.

[0032] The raised area may have a circular or oval base, or it may be ribbed or ring-shaped.

[0033] The region of the raised area furthest from the plane, in particular a peak, is preferably more than 1 mm from the plane.

[0034] The length of the maximum diameter of the base of the raised area is preferably at least 3 mm.

[0035] The minimum dimensions guarantee that the raised area contains sufficient covering mass to achieve an adhesive effect.

[0036] In particular, along all diameters of the plane, the sum of all raised areas does not cover more than 8 / 10, preferably not more than 3 / 4, of the length of the diameter.

[0037] Preferably, the distance between the base area of ​​the at least one raised region and the edge of the plane corresponds to at least 1 / 20 of the smallest diameter of the plane.

[0038] The heated material cannot penetrate beyond the edge of the plane.

[0039] In an advantageous embodiment, the at least one raised region is specifically heated by a heating device. In particular, and essentially, only the at least one raised region of the covering is heated and, in particular, softened. This ensures that the plate-shaped base layer of the plate-shaped covering is neither softened nor deformed.

[0040] In a further process step, the food product part connected to the topping can be cooled. The food product part and the connected topping form a layered food product or a layered food sub-product. The food product or the food sub-product can, for example, be passed through a cooling tunnel.

[0041] The food product or food sub-product can then be further processed, for example, decorated and / or packaged.

[0042] The object is further achieved by a device for joining a first, substantially plate-shaped food product part to a plate-shaped covering. The plate-shaped covering has at least one region raised from the plane on at least one side. The device serves for producing a layered food product or a layered food part product and, in particular, for carrying out a method as described above.

[0043] According to the invention, the device has a device for heating the at least one region raised from the plane and a device for receiving, positioning and in particular for pressing the first food product part.

[0044] Preferably, the device comprises a device for casting covering mass, which comprises a mold for forming the covering with at least one raised area and a dosing device for the covering mass.

[0045] The casting device is preferably arranged upstream of the heating device. A transfer device can be located between the casting device and the heating device, with which the coating is removed from the mold and preferably rotated so that the at least one raised area is accessible to the heating device. The transfer device can be, for example, a belt, a robot arm, or a mold turner.

[0046] Preferably, the mold has a profile in the base region that defines at least one raised area. The profile is designed, for example, such that the at least one raised area tapers with increasing distance from the plane.

[0047] In an advantageous embodiment of the invention, the device has a device for receiving, positioning and in particular pressing a second food product part.

[0048] This could, for example, be a pick and place unit that brings and places the second food product parts.

[0049] This is preferably arranged directly downstream of the device for pouring the topping mass or is designed together with the device for pouring, so that the second food product part can be applied to the not yet solidified topping mass which is in the mold.

[0050] In a further advantageous embodiment, the device comprises a transfer device for transferring the second food product part connected to the topping. The transfer device can be, for example, a pick-and-place unit, a conveyor belt, a robot arm, and / or a mold changer.

[0051] In this process, the second food product part connected to the coating is removed from the mold so that the at least one raised area of ​​the heating device is accessible. Preferably, the second food product part is moved and / or rotated in translation together with the coating.

[0052] The device for heating the at least one raised region is a device that enables targeted heating of at least one limited region, which is preferably smaller than the flat surface of the coating. In particular, the heating device comprises a shielding template.

[0053] Advantageously, the heating device is a device that enables the targeted heating of at least one raised area with a circular or oval base. The length of the maximum diameter of the base is preferably at least 3 mm.

[0054] Alternatively or additionally, the device can enable the heating of an area with a rectangular base. The device is preferably designed to heat areas with a maximum diameter of up to 3 mm. Furthermore, the device is preferably designed so that the areas adjacent to the raised areas do not receive any direct heat supply.

[0055] According to the invention, the device for heating the at least one raised area comprises an infrared heating field.

[0056] Advantageously, the device comprises a cooling device for cooling a food product part connected to the topping.

[0057] The object is further achieved by using a device for heating at least one raised area on one side of a plate-shaped covering and subsequently connecting the covering to a plate-shaped food product part.

[0058] The invention is explained below in exemplary embodiments with reference to drawings.

[0059] It shows Figure 1 shows a schematic representation of a first method step; Figure 2 shows a schematic representation of a second method step; Figure 3 shows a schematic representation of a third method step; Figure 4 shows a schematic representation of a fourth method step; Figure 5 shows a schematic representation of a fifth method step; Figure 6 shows a schematic representation of a sixth method step; Figures 7a-d show schematic representations of examples of different shapes; Figure 8 shows a first example of a covering in plan view; Figure 9a shows a further example of a covering in plan view; Figure 9b shows a further example of a covering in plan view; Figure 9c shows a further example of a covering in plan view.

[0060] The Figures 1-6show steps of an exemplary method in a schematic representation.

[0061] In the method according to the invention, a plate-shaped covering 3 can first be produced, which has at least one region 4 raised from a plane 6 on at least one side 5. The covering can, for example, have two raised regions 4.

[0062] The covering 3 is produced, for example, in a mold 7 which determines the profile of the raised areas 4.

[0063] Production takes place in a casting device 20. In this device, coating material is metered from a metering device 21, in this case a nozzle, into the mold 7. Of course, many molds can be filled simultaneously using a plurality of nozzles.

[0064] For example, chocolate mass warmed to room temperature can be dosed into mold 7 and solidified there.

[0065] As in Figure 2For example, as shown, a second food product part 2 is provided. The second food product may be a pastry part.

[0066] As in Figure 3 As shown, the second food product part 2 can be placed on the topping 3 which is still in the mold 7, preferably before the topping 3 has solidified.

[0067] The coating 3 adheres to the second food product part 2 and thus, after the coating mass has solidified, a permanent connection is created between the coating 3 and the second food product part 2.

[0068] If necessary, an additional force can be applied, for example the second food product part 2 can be pressed against the covering 3.

[0069] Preferably, the outer contours of the second food product part 2 and the coating 3 correspond. The food product part 2 connected to the coating 3 can then be cooled, for example, in a cooling tunnel. For this purpose, the coating 3 can remain in the mold 7 or be removed therefrom.

[0070] As in Figure 4 As shown, the second food product part 2 can be transferred together with the topping 3, wherein the topping 3 is removed from the mold 7. The second food product part 2 can be rotated together with the topping 3 and placed in a counter-mold 8 so that the at least one raised region 4 points away from the counter-mold 8.

[0071] The counter-mold 8 has a receptacle 9 for the second food product part 2.

[0072] As in Figure 5As shown, the raised area 4 is heated. This is preferably done using a heating device 10, comprising an infrared heating field 11 and a shielding template 12. The shielding template 12 ensures that a targeted heating of a limited area takes place, which is smaller than the surface of the covering 3. In particular, the edge area 13 of the covering 3 is not heated, so that the edge surface 14 retains the shape and surface texture predetermined by the mold 7.

[0073] Depending on the coating material, more or less heat is introduced. It is sufficient if the coating material of the raised areas deforms under the weight of the food product part 1 (see Figure 6 ).

[0074] As in Figure 6 As shown, a first food product part 1 can be provided, which is positioned on the side 5 of the covering 3 with the heated raised areas 4, see Figure 4 .

[0075] The connection between food product part 1 and coating 3 is then created. The heated coating material adheres to the first food product part 1 and, after the coating mass has solidified, a permanent connection is created between the coating 3 and the first food product part 1. The coating 3 then has a flat shape and forms a layer running parallel to the food products 1 and 2.

[0076] If necessary, an additional force can be applied, for example, the first food product part 1 can be pressed against the coating 3. The layered food product 30 can then be cooled.

[0077] Figures 7a-d show schematic representations of examples of different forms 7a, 7b, 7c, 7d.

[0078] With the molds 7a, 7b and 7c, a plurality of raised areas 4 are achieved, while in the mold 7d only one raised area 4 can be produced.

[0079] What all shapes 7a, 7b, 7c, and 7d have in common is that the raised areas have a minimum distance 15 from the edge surface 14. This distance is preferably at least 1 mm.

[0080] The tip 17 of the at least one raised region 4 has a distance 16 from the plane which is preferably greater than 1 mm.

[0081] Figure 8 shows a first example of a covering 3 with a raised area 4 in plan view. The covering has an oval base. The maximum diameter 18 of the base of the raised area 4 is at least 3 mm.

[0082] The length of the maximum diameter 18 of the base area of ​​the raised region preferably corresponds to a maximum of 9 / 10 of the maximum length 19 of level 6.

[0083] Figures 9a-9cshow further examples of a covering 3 with raised areas 4 in plan view.

[0084] The raised pads 3 can, as in Figure 9a shown, arranged in stripes, as in Figure 9b shown, in staggered rows or, as in Figure 9c shown in parallel rows.

Claims

1. A method for producing a layered food product (30), which comprises at least a first, essentially plate-shaped food product part (1, 2), namely a first pastry part, and a plate-shaped covering (3) arranged thereon, which consists of a covering composition, is a fat-based mass, a chocolate-based mass, a compound-based mass, a sugar-based mass, a fondant-based mass, a jelly, a jam, a fruit-based mass and / or a water- and sugar-based mass that hardens in a different way, characterized by the following steps: - producing or providing the plate-shaped covering (3) in a form (7), the covering (3) having on at least one side (5) at least one area (4) projecting from a plane (6), the form determining the profile of the at least one projecting area (4) on one side of the covering (3); - heating the projecting area (4); - producing or providing at least one food product part (1, 2) ; - positioning the food product part (1) on the side of the covering (3) with the heated projecting area (4); - producing the connection between the food product part (2) and the covering (3), in particular pressing the food product part (1) onto the heated projecting area (4), wherein the at least one projecting area is selectively heated by a heating device (10) so that the plate-shaped base layer of the plate-shaped covering is not softened and does not deform.

2. The method according to claim 1, wherein a second food product part (2), namely a second pastry part, is produced or provided, which is placed on the not yet solidified covering mass in the mold (7) and in particular pressed on.

3. The method according to claim 2, wherein the second food product part (2) is replaced together with the covering (3), wherein the covering (3) is removed from the mold (7).

4. The method according to claim 3, wherein the second food product part (2) together with the covering (3) is placed in a counter mold (8) so that the at least one projecting area (4) faces away from the counter mold (8).

5. The method according to one of claims 1-4, wherein the area of the projecting area furthest from the plane, in particular the tip (17) of the at least one projecting area (4), is at a distance (16) from the plane (6) which is greater than 1 mm, the length of the maximum diameter (18) of the base of the projecting area is at least 3 mm and / or the length of the maximum diameter (18) of the base of the projecting area is at most 9 / 10 of the maximum length (19) or width of the plane (6).

6. The method according to any one of claims 1-5, wherein along all diameters of the plane the sum of all projecting areas does not cover more than 8 / 10, preferably not more than 3 / 4, of the length of the diameter.

7. The method according to any one of claims 1-6, wherein the device for heating (10) the at least one projecting area (4) comprises an infrared heating field (11) and a shielding template (12).

8. A device for connecting a first, essentially plate-shaped food product part (1, 2), namely a first pastry part, to a plate-shaped covering (3), which has at least one projecting area (4) on at least one side , for producing a layered food product (30), in particular for carrying out the method according to one of claims 1-7, characterized in that the device comprises a device for heating (10) the area (4) projecting from the plane (6) and a device for receiving, positioning and preferably pressing on the first food product part (2), wherein the device for heating (10) the at least one projecting area (4) allows for targeted heating of a limited area, preferably smaller than the planar surface of the covering (3), wherein the device for heating (10) the at least one projecting area (4) comprises an infrared heating field (11) and a shielding template (12).

9. The device according to claim 8, wherein the device comprises a device for casting (20) covering material (3) comprising a mold (7) for molding the covering (3) with at least one projecting area (4) and a metering device (21) for the covering material.

10. The device according to claim 9, wherein the mold (7) defines a profile of the at least one projecting area (4) that tapers with increasing distance from the plane.

11. The device according to any one of claims 8 to 10, wherein the apparatus comprises a device for receiving, positioning and preferably pressing a second food product part (1).

12. The device according to claim 11, wherein the device comprises a transfer device for transferring the second food product part (2) connected to the covering (3).

13. The device according to claim 12, wherein the device comprises a counter-mold (8) for depositing a food product part (2) connected to the covering (3).

14. The device according to one of claims 8-13, wherein the heating device (10) allows for the targeted heating of at least one projecting area (4) with a circular or oval base area , the maximum diameter of which is preferably at least 3 mm, and / or wherein the heating device (10) enables the targeted heating of at least one projecting area (4) with a substantially rectangular base area.