Method for monitoring the cooking of dough in a cooking chamber

Abstract

The invention relates to a method for monitoring the cooking of a dough for baked goods, wherein the dough is cooked in a cooking chamber (1) over a known period of time under known cooking parameters until the end of the cooking process. The invention is characterized in that at least one sample of the dough is introduced into the cooking chamber (1) in at least one reference container (2), and at least one sample property which is relevant to the cooking process is measured on the at least one sample. The at least one cooking parameter is controlled using the measured sample property.

Description

[0001] Method for monitoring the proving of a dough in a cooking chamber

[0002] The present invention relates to a method and a device for controlling the cooking of baked goods in a cooking chamber.

[0003] Background of the invention

[0004] In industrial fermentation processes for baked goods, the proofing step determines quality and is therefore crucial for the economic viability of a process. If the proofing time is incorrectly set, the waste rate per baking cycle increases to up to 15% because the products no longer meet the manufacturer's quality criteria.

[0005] Since subsequent processes can only influence product defects that may arise due to poor fermentation quality to a very limited extent, monitoring the fermentation is essential for the further course of the process.

[0006] In industrial fermentation processes, a "short fermentation" is often desired. This means that the dough has a distinct shape and a sufficiently large volume. The dough is loose, elastic, and offers some resistance when lightly palpated. During the short fermentation, the dough has reached a certain level of maturity that allows it to be placed in the oven. At this stage, gas formation in the dough is still minimal. This results in finished baked goods with fine pores and an elastic, moist, and aromatic crumb.

[0007] The dough pieces are in the "nearly proof" or "3 / 4 proof" stage, at the beginning of the so-called proofing tolerance. The term "3 / 4 proof" means that the dough pieces have not yet reached their full proofing stage. The remaining proofing takes place during the so-called oven spring. This begins immediately after the dough pieces are placed in the oven.

[0008] For the purposes of the present invention, the desired degree of proofing before the dough pieces are placed in the oven is referred to as “end of proofing.”

[0009] In the case of under-proofing, extending the cooking time, as well as increasing the oven temperature and the dwell time in the oven, can lead to improved product quality. In the case of over-proofing, shortening the baking time may be a remedy.

[0010] If different doughs are placed in the cooking chamber, the end of cooking may occur at different times, even if the conditions in the cooking chamber, such as temperature and humidity, remain constant. Controlling this by measuring the conditions in the cooking chamber alone is difficult.

[0011] Furthermore, for some properties of the dough being cooked, such as temperature and humidity, invasive measurement (e.g., with sensors inside the dough itself) would be desirable. However, this would result in damage to the dough.

[0012] The problems outlined above are even more true for dough pieces in baking pans. Baking pan parts often consist of two mold halves held together by a locking mechanism, as described, for example, in WO2013 / 116884A1. In this case, precise determination of the cooking conditions is currently impossible. The systems are constantly moving throughout the entire process and therefore cannot be permanently connected to a sensor system.

[0013] Another problem concerns the occurrence of product defects due to inadequate cooking monitoring.

[0014] Particularly with a large number of dough pieces, which are baked, for example, in baking pans consisting of two pan halves, product defects lead to high levels of baked goods waste depending on the process cycle. Typical product defects include, for example, uneven dough porosity, dough leakage between the baking pan halves, poor dough formation in the baking pan, and a moderately loose crumb with overly dense porosity.

[0015] Experts are familiar with a wide variety of methods for controlling and monitoring cooking processes for all types of food. This is due to the fact that different cooking processes often lead to optimal results depending on the type and quantity of food being cooked.

[0016] For example, DE 102019107846 A1 discloses a method in which the size of the food being cooked is monitored during the cooking process using a camera device. The measured size is compared with a reference value, thus determining the cooking status of a food, preferably meat, vegetables, or fruit. However, the determination of other relevant sample properties is not provided for.

[0017] DE 102019107815 B4 discloses a method for operating a cooking appliance, wherein the temperature of the food during the cooking process is determined by a measuring probe on the surface of the food, and the outgoing heat radiation of the food is detected. The browning of the food is determined from the temperature difference.

[0018] From DE 102019101695 A1 a method for cooking food is known in which the food is detected by a thermal imaging camera and the high-frequency radiation introduced into the cooking chamber is changed accordingly by a control device in the event of a deviating heat distribution on the food.

[0019] DE 102008010099 B4 describes a method for determining the condition of a food item in a cooking chamber based on the measured current / voltage characteristics that occur during cooking. The current / voltage characteristics as well as the gas discharge and glow discharge spectra are used to obtain information about the cooking condition of a food item.

[0020] Furthermore, EP 3282818 A1 discloses a method and a device for heating food in a cooking chamber using a high-frequency generator. As a result, the food is specifically heated and browned close to the surface by the power of the high-frequency radiation, with the cooking process being ignored by the cooking appliance.

[0021] Finally, EP 2101229 B2 discloses a method for providing an intelligent human-machine interface for cooking appliances, in which the user is classified into one or more user classes based on actions performed on the cooking appliance. Classifying users automatically triggers personalized modification of work program parameters. However, monitoring of the food during the cooking process or evaluation of the cooking parameters is not provided.

[0022] None of the prior art documents cited above deals with monitoring the proofing of doughs for baked goods. Further prior art is disclosed in CN 102053137 A, which describes a method for measuring the volume of a dough during the proofing process. Simultaneous proofing or monitoring of the proofing of multiple doughs is not provided for.

[0023] US 2233372 A describes a method and apparatus for determining gas pressure, volume, permeability, temperature and electrical conductivity of a dough as such during baking.

[0024] Furthermore, DE 102019213638 A1 discloses a method for executing a baking program. Based on the determined volume, which is measured directly on the product to be cooked, various operating parameters of the baking program can be set. The introduction of different doughs into the cooking chamber is not discussed.

[0025] FR 2784861 A1 describes a device for measuring dough volume during proofing. Proofing monitoring is achieved exclusively by determining the volume of the dough being proofed.

[0026] FR 1406467 A discloses a device equipped with an electric bell that emits an acoustic signal when a certain dough volume is reached, signaling that the dough can be placed in the oven. The dough to be cooked is used as such to determine the volume.

[0027] GB 191419487 A relates to a device for proving dough, wherein an acoustic signal is triggered after a predetermined volume is reached.

[0028] Summary of the invention

[0029] The present invention is based on the object of providing an improved method for monitoring the cooking process of dough for baked goods.

[0030] The object is achieved by a method for controlling the proofing of a dough for baked goods, wherein the dough is cooked in a cooking chamber over a certain period of time under certain cooking parameters until the end of cooking, characterized in that at least one sample of the dough is introduced into the cooking chamber in at least one reference container and at least one sample property relevant to the proofing is measured on the at least one sample and that at least one cooking parameter is controlled based on the measured sample property.

[0031] A further aspect of the present invention relates to a reference container for carrying out a method comprising

[0032] - a sensor for determining the temperature within a sample of the dough

[0033] - a laser sensor for determining the volume of a sample of the dough and

[0034] - a capacitive sensor to determine the correct positioning of the reference container.

[0035] Short description of the characters

[0036] Fig. 1 shows the cooking chamber 1 including the reference container 2. The device of the present invention is mounted at a fixed location in the cooking chamber 1, ensuring that measurements are always taken at the same location for each reference container 2. The associated oven rack 7 is located directly behind the reference container 2, thus ensuring a clear assignment of the oven rack 7 to the reference container 2.

[0037] Fig. 2 shows the cooking chamber 1 including several reference containers 2 per rack trolley 7. Each rack trolley 7 is located directly behind a reference container 2, thus ensuring a clear assignment of rack trolley 7 to reference container 2.

[0038] Fig. 3a shows the reference container 2 according to the present invention in front view, comprising a temperature sensor 3, a laser sensor 4 and a capacitive sensor 5.

[0039] Fig. 3b shows a side view of the reference container 2, comprising a temperature sensor 3, a laser sensor 4 and a capacitive sensor 5.

[0040] Fig. 3c shows a schematic representation of the reference container 2 according to the present invention.

[0041] Description of Embodiments The present invention relates to a method for controlling the proofing of a dough for baked goods. The term "baked goods" refers to a food product based on cereals and / or cereal products, after the addition of water or water-containing liquids, as well as other food products, generally by kneading, shaping, loosening, and baking or cooking and extruding a dough and baking the same.

[0042] An unbaked, portioned, and pre-shaped dough is generally referred to as a "dough piece." In the following, the term "dough" should be understood to mean both unbaked and unshaped dough and unbaked, portioned, and pre-shaped dough.

[0043] Surprisingly, it has been shown that by measuring sample properties in a reference container, the ideal proofing time and the time until baking in the oven can be precisely determined. The present invention is based on the finding that conclusions can be drawn about the interrelationships of the overall process in conjunction with the measured sample properties of at least one sample of the very dough being proofed.

[0044] The term “reference container” makes it clear to the person skilled in the art that the dough sample is placed in a reference container in addition to the dough to be cooked in the cooking chamber so that that sample can be cooked over the same period of time and under the same cooking parameters as the dough in the cooking chamber.

[0045] This allows for an optimized cooking process in which the progress of the cooking process can be continuously monitored and parameter estimates for the cooking process can be made in advance.

[0046] The cooking parameters that can be selected are the temperature and / or humidity in the cooking chamber and / or the cooking time.

[0047] According to the method of the present invention, at least one cooking parameter is controlled based on the measured sample property. Preferably, the temperature and / or humidity in the cooking chamber are controlled. Control can be performed selectively (i.e., based on the discrete measurement of the sample property at a specific time). Continuous control is also possible.

[0048] The measurement of the sample property on the dough sample is typically carried out over the same period of time in which the dough to be cooked is in the cooking chamber.

[0049] In a particularly advantageous embodiment of the method, the temperature of the sample, the volume of the sample, the humidity of the sample and, if appropriate, several of these sample properties are measured as sample properties.

[0050] In particular, by collecting data for these properties in the sample in the reference container, the ideal time until "firing into the furnace" can be precisely determined.

[0051] In the following, the term “sample property” (in the singular), unless further specified, represents one or more measured sample properties.

[0052] Preferably, the sample property is determined by at least one sensor and / or at least one infrared camera.

[0053] According to a further embodiment, the method is characterized in that the temperature of the at least one sample of dough is determined by a temperature sensor, wherein the sensor is inserted into the sample to measure the temperature. The temperature can be monitored discretely or continuously.

[0054] In this embodiment, a particular advantage of the method according to the invention is shown, since the introduction of a temperature sensor into a dough would not be possible without damaging the dough or, in the case of a baking pan, not at all.

[0055] A particularly preferred embodiment of the method is characterized in that the volume of at least one dough sample is determined by a laser sensor. The volume is determined by discrete or continuous laser measurement of the dough surface in the vertical direction of extension. The volume of the sample is determined during the fermentation process by changing the filling level of the reference container with the dough. Until a characteristic curve is established, the end of the fermentation process can be adjusted manually by reaching a specific volume and / or a specific temperature.

[0056] A "characteristic curve" is a graphical representation of the relationship between the determined values ​​of a sample property and a defined cooking time. Based on the characteristic curves for the volume and / or temperature of at least one dough sample, the end of cooking time can be estimated.

[0057] The term “end of cooking” refers, as mentioned above, to the point at which the dough has reached the desired level of fermentation so that it can be put into the oven.

[0058] A particularly preferred embodiment of the method is characterized in that the end of cooking is determined by reaching a certain volume and / or a certain temperature of the at least one sample of the dough.

[0059] In a further preferred embodiment, the method of the present invention is characterized in that the at least one reference container containing the sample is placed in the vicinity of the dough to be cooked.

[0060] To standardize and secure proofing monitoring, fixed positions for the reference containers can be specified within the cooking chamber. The reference container is preferably raised from the ceiling of the cooking chamber via a hydraulic cylinder near the dough or the container for the dough to be proofed. Once the oven rack is in its place in the cooking chamber, the reference container is lowered.

[0061] A "dough rack" is a mobile rack for holding and transporting dough or containers for dough to be proofed, which can be fully inserted into a suitable oven. Dough racks or containers containing dough to be proofed can be stacked on top of each other in a rolling oven, allowing loading and unloading of the oven in a single operation.

[0062] In a particularly advantageous embodiment of the method, the correct positioning of the at least one reference container is determined by a sensor, in particular by a capacitive sensor. Fig. 1 shows that the at least one reference container 2 can be mounted at a fixed location in the cooking chamber 1, ensuring that measurements are always taken at the same location for each reference container 2. The associated oven rack 7 is located near the reference container 2, thus ensuring a clear assignment of oven rack 7 to reference container 2. In addition, the association between the reference container 2 and the oven rack 7 can be secured using RFID chips.

[0063] Once the proofing is complete, the reference container 2 can be moved back to the ceiling of the cooking chamber 1 and the oven rack 7 can be moved out of the cooking chamber 1 and placed into the oven.

[0064] As can be seen from the above, the method according to the invention can be used to monitor the proofing of various doughs by measuring the sample properties of a sample of the respective dough. As soon as the end of proofing has been reached for the dough in question based on the measured sample properties, the dough (or the dough rack carrying the dough) can be removed from the cooking chamber, while proofing continues for other doughs.

[0065] Fig. 2 shows that the proofing of different doughs, each located in a reference container 2 in the cooking chamber 1, can be measured. One sample per rack 7 is placed in each reference container 2. The corresponding rack 7 is located near the reference container 2, thus ensuring a clear assignment of rack 7 to reference container 2.

[0066] The method according to the invention is particularly suitable for baking processes in which the dough to be cooked is cooked in a closed container, in particular in a closed baking tin.

[0067] Several baking pans can be combined to form a baking pan combination. A baking pan combination can include baking pans of different sizes and shapes.

[0068] A large number of baking pans filled with dough can be placed in the cooking chamber in a stack of baking pans on a rack trolley. Monitoring the proofing of such a large number of doughs in baking pans has been extremely difficult until now.

[0069] In this embodiment of the method according to the invention, the temperature of at least one container for the dough to be cooked can preferably be determined by an infrared camera. The temperature of the baking pan assembly is recorded by an infrared camera mounted near the oven rack. The baking pan assembly temperature is preferably measured before the assemblies are placed in the cooking chamber.

[0070] In the method according to the invention, at least one cooking parameter is controlled based on the measured sample properties.

[0071] The temperature and / or volume of the at least one dough sample and / or the temperature of the at least one container for the dough to be cooked can be recorded discretely or continuously. A predetermined tolerance band can be specified here, within which the temperature and / or volume should ideally lie. Positive or negative deviations from the target values ​​serve to control the cooking time. As an additional control, the temperatures and / or volume can be shown directly on a display unit, whereby the affected racks can be marked to indicate that the cooking time needs to be adjusted. The affected rack can therefore be removed from the cooking chamber either before or after the originally intended end of cooking.

[0072] Preferably, at least one cooking parameter is controlled to influence the volume and / or temperature of the at least one sample of dough and / or the temperature of the at least one container for the dough to be cooked. If an actual value of a sample property lies outside a predetermined tolerance range, at least one cooking parameter can be controlled such that the actual value of the sample property lies within this tolerance range again.

[0073] The cooking parameters can be controlled manually or automatically.

[0074] Preferably, the threshold value of the minimum volume and / or the maximum volume of the at least one dough sample is changed based on the determined temperature of the at least one dough sample and / or the at least one container for the dough to be cooked. In the event of a change in temperature due to daily fluctuations in ambient conditions or deviations in the cooling device, the volume to be achieved can be adjusted based on a stored characteristic curve. This ensures that the cooking parameters are linked to the temperature. In a further embodiment of the present invention, a minimum volume and / or a maximum volume is compared with at least one stored threshold value, and the end of cooking is determined based on the comparison.In this embodiment, reaching a volume above the minimum volume threshold and / or below the maximum volume threshold is defined as a prerequisite for reaching the end of cooking.

[0075] As can be seen from the above, at least one cooking parameter during the current cooking process can be controlled based on the measured sample properties. It is also possible to control cooking parameters of subsequent cooking processes based on the sample properties determined from previous cooking processes.

[0076] In a further preferred embodiment, characteristic maps are created using the data of the determined sample properties and, based on the characteristic maps, the current cooking process is compared with the characteristic maps.

[0077] Continuous data collection is therefore planned, allowing for precise analysis of the ongoing fermentation process. In conjunction with the data obtained from the fermentation monitoring system, conclusions can be drawn about the interrelationships of the overall process. The measured values ​​can be plotted over time in a diagram, and the curve can be used to derive information about the fermentation progress.

[0078] The evaluations can be accessed in real time and the respective processes can be assigned to the individual production batches.

[0079] A further advantage concerns the determined characteristic maps for various test baking series, which can be created for different products under series conditions. The determined characteristic maps can be used to illustrate the fermentation process, to document the cooking parameters, and to evaluate the resulting measured sample properties. The determined characteristic maps represent a highly condensed source of information from which an assessment of the existing process conditions can be derived. Since it has been shown that the surface area-to-volume ratio in the closed baking process has a significant influence on the process conditions and parameters, the recorded sample properties during the cooking process are an important guideline for newly developed products.Using the findings from the series of measurements and the creation of characteristic maps, parameter estimates for the cooking and baking process can be made in advance.

[0080] This approach can reduce start-up rejects and the overall number of baking cycles required to produce a product of optimized quality. Comprehensive data collection also makes it possible to optimize throughput times, as the rise in the volume curve also provides information about the actual dough's maturity.

[0081] The created characteristic maps can also be used to control cooking parameters for future cooking processes. The current cooking process is compared with the previously created characteristic maps for previous processes. Deviations from the target values ​​of the previously determined characteristic maps are used to control the cooking parameters. Based on the determined characteristic maps, optimized control of at least one cooking parameter in future cooking processes is therefore possible.

[0082] Data recording and processing can be performed using suitable software. This software can then be used to create user-specific evaluations and regularly use them as key performance indicators for process control and monitoring. By networking the data from the various process steps, quality-relevant processes can be precisely monitored and controlled. Based on the collected data, the software evaluations can also be used to determine the influences of daily and seasonal fluctuations.

[0083] On the one hand, these findings will be used to scientifically prepare the parameters relevant to the technology, and on the other hand, the available information will be used to adapt the production parameters to changing environmental conditions.

[0084] Preferably, a visual and / or acoustic signal is triggered when the end of cooking is reached. This can prevent over-proofing and thus a loss of quality of the dough, as the dough can be removed from the cooking chamber and placed in the oven in good time.

[0085] Another aspect of the present invention relates to a reference container for carrying out a method. Figs. 3a, 3b, and 3c show that the present reference container 2 has a defined volume for measuring the sample properties relevant to proofing. For this purpose, the container comprises a laser sensor 4, a temperature sensor 3, and a preferably capacitive sensor 5. The laser sensor 4 is positioned in the center of the reference container 2. The temperature sensor 3 can be inserted into the dough via a hole in the bottom center of the cylinder.

[0086] According to one embodiment of the present invention, the reference container is characterized in that the at least one reference container has a bore at the bottom and that the sensor for temperature determination passes through the bore to the outside of the reference container.

[0087] Examples

[0088] Example 1 :

[0089] A pre-formed dough batch is placed into baking pans, which are then joined together to form a baking pan assembly. The filled baking pans or baking pan assemblies are placed in racks and transported to the cooking chamber. The racks are placed in their assigned positions within the cooking chamber, so that each rack is positioned below a reference container. The reference containers are lowered from the ceiling of the cooking chamber via hydraulic cylinders, and a sample of the dough mass from each rack is placed into a reference container.

[0090] The end of cooking is then manually set by reaching a specific sample volume. During the cooking process, the temperature and volume of each sample in the reference containers are measured and recorded. Once the desired volume of a sample is reached (after approximately 40 to 60 minutes of cooking time), the corresponding reference container is raised back to the ceiling of the cooking chamber and the corresponding rack is transported into the oven, where the dough is baked for approximately 20 to 30 minutes.

[0091] Example 2:

[0092] A batch of dough preformed by a dough forming machine is fed directly into the baking pans via a conveyor belt, which are then joined together to form a baking pan assembly. As the baking pan assembly passes an infrared camera, the temperatures of the baking pan assembly and the baking pan assembly are measured. The infrared camera is stationary above the conveyor belt. From these temperatures, an estimated cooking time can be determined, which can then be adjusted based on the actual development of the cooking process.

[0093] The baking pans are then placed in racks, and the measured temperature values ​​of the baking pans are assigned to the individual racks. The racks are transferred to the cooking chamber and placed in their assigned positions. A sample of the dough mass from each rack is placed in a reference container, as described in Example 1.

[0094] Before the proofing process begins, the end of the proofing process is manually set based on the reaching of a specific volume per sample. The measured temperatures of the baking pans of the individual racks are correlated with previously determined characteristic curves, and the desired volume per sample is automatically adjusted. The temperature and volume of each sample in a reference container are continuously measured and recorded during proofing. The recorded sample properties are correlated during the proofing process using process software (Microsoft Power BI and Azure Datawarehouse), and the proofing time for each sample is individually modified based on this data.

[0095] In addition, the determined sample properties are compared with characteristic curves during the cooking process and adjusted by controlling the cooking parameters accordingly. Once the desired sample volume is reached, the reference container for this sample is removed and the corresponding rack is transported into the oven where the dough is baked.

Claims

Claims 1. A method for controlling the proofing of a dough for baked goods, wherein the dough is cooked in a cooking chamber (1) over a certain period of time under certain cooking parameters until the end of cooking, characterized in that at least one sample of the dough in at least one reference container (2) is introduced into the cooking chamber (1) and at least one sample property relevant to the proofing is measured on the at least one sample and that at least one cooking parameter is controlled based on the measured sample property.

2. Method according to claim 1, characterized in that the temperature of the sample, the volume of the sample, the humidity of the sample and optionally several of these sample properties are measured as sample properties.

3. Method according to claim 1 or 2, characterized in that the sample property is determined by at least one sensor and / or at least one infrared camera.

4. Method according to one of the preceding claims, characterized in that the temperature of the at least one sample of the dough is determined by a temperature sensor (3), wherein the sensor for measuring the temperature (3) is introduced into the sample.

5. Method according to one of the preceding claims, characterized in that the volume of the at least one sample of the dough is determined by a laser sensor (4).

6. Method according to one of the preceding claims, characterized in that the end of cooking is determined by reaching a certain volume and / or a certain temperature of the at least one sample of the dough.

7. Method according to one of the preceding claims, characterized in that the at least one reference container (2) containing the sample is placed in the vicinity of the dough to be cooked.

8. Method according to claim 7, characterized in that the correct positioning of the at least one reference container (2) is determined by a sensor (5), in particular by a capacitive sensor (5).

9. Method according to one of the preceding claims, characterized in that the dough to be cooked is cooked in a closed container (6), in particular in a closed baking tin.

10. A method according to claim 9, characterized in that the proofing of a plurality of doughs is controlled in closed baking tins.

11. Method according to one of the preceding claims, characterized in that the temperature of at least one container (6) for the dough to be cooked is determined by an infrared camera.

12. Method according to one of the preceding claims, characterized in that a minimum volume and / or a maximum volume is compared with at least one stored threshold value and that the end of cooking is determined on the basis of the comparison and that the reaching of a volume above the threshold value for the minimum volume and / or below the threshold value for the maximum volume is determined as a prerequisite for reaching the end of cooking.

13. Method according to one of claims 9 to 12, characterized in that the threshold value of the minimum volume and / or the maximum volume of the at least one sample of the dough is changed based on the determined temperature of the at least one container (6) for the dough to be cooked.

14. Method according to one of the preceding claims, characterized in that characteristic maps are created from the data of the determined sample property and, on the basis of the characteristic maps, the current cooking process is compared with the characteristic maps.

15. Method according to one of the preceding claims, characterized in that an optical and / or an acoustic signal is triggered when the end of cooking is reached.

16. Reference container (2) for carrying out a method according to one of the preceding claims, containing - a sensor for determining the temperature (3) within a sample of the dough - a laser sensor for determining the volume (4) of a sample of the dough and - a capacitive sensor (5) for determining the correct positioning of the reference container.

17. Reference container (2) according to claim 16, characterized in that the at least one reference container (2) has a bore in the bottom and that the sensor for temperature determination (3) passes through the bore to the outside of the reference container (2).

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