Apparatus and method for producing dough items with docking pattern

Abstract

An apparatus (10) for producing docked dough pieces (45) with a rotary cutter formed as a shaft (65, 66) includes a blade (67, 68) that extends radially outward from an outer surface (135) of the cutting roller or shaft (65, 66) and defines an interior area (69, 70) enclosed by the blade (67, 68). Groups of docking pins (120, 130) extend radially outward from the outer surface (135) of the shaft (65, 66) and are located in the interior area (69, 70) enclosed by the blade (67, 68). The docking pins (120, 130) are configured to dock the dough piece (45) by creating patterns of holes (420, 430) in the dough piece (45).

Description

APPARATUS AND METHOD FOR PRODUCING DOUGH ITEMS WITHDOCKING PATTERNFIEUD OF THE INVENTION

[0001] The invention generally pertains to cutter wheels. More particularly, the invention pertains to a sheeting or cutting machine with an improved cutter wheel employing docking pins to dock food items.BACKGROUND OF THE INVENTION

[0002] Due to the time demands placed on consumers, the preparation of food products and meals from scratch has decreased and the popularity of partially premade foods has increased dramatically. One such group of premade products includes baked or fried food products made of dough. Upon frying or baking pieces of these products, moisture within the dough is converted to steam causing the pieces to expand. The outer surfaces of each dough piece lose moisture faster than the center of each piece because of rapid heat transfer at the outer surface during frying or baking. When the outer surface dries sufficiently, the outer surface forms a skin which prevents the steam from escaping. The steam accumulates between the outer surfaces of the pieces during frying or baking. The trapped steam causes the sides of the dough piece to separate, or delaminate, forming a hollow void. This phenomenon is referred to as “puffing”, “pillowing” or “blistering.

[0003] Depending on the formula and processing, some dough pieces, such as taco shells are cooked by being passed through a fryer. The dough pieces will puffor pillow while passing through a fryer due to the steam. The puffing or pillowing causes issues with breakage of the taco shells since the puffed areas of the shells are weakened. The puffing also changes the shape of the taco shells and, therefore, causes problems with nesting since the taco shells are no longer uniformly shaped. Often the puffing also results in blisters which break, causing holes and detracting from the appearance of the dough products.

[0004] Another problem with making tacos is that each taco must be cut as a round shape. In order to cut round tacos out of sheets of dough, often a cutter wheel is employed so that round shapes are continuously cut from the dough sheet in an extremely rapid manner. Usually, the cutter wheel is formed of a cylindrical shape and has cutters mounted on its outer circumferential shape. Such an arrangement allows for continuous processing of tacos. However, there still exists a need in the art to make sure the products resistant to pillowing or blistering, while maintaining the rapid production of the products.SUMMARY OF THE INVENTION

[0005] In general, the invention is directed to an apparatus for producing docked dough pieces. More particularly, the invention includes cutter wheels with a docking pattern of pins for dough products, such as taco shells. The apparatus includes a conveyor system for conveying raw dough sheets or tortilla to a rotary cutter. The rotary cutter includes a shaft having an outer surface. A blade extends radially outward from the outer surface of the shaft. The blade defines an interior area on the outer surface of the shaft. The blade is configured to cut a dough piece from a dough sheet into a shape based on the shape of the blade.

[0006] For example, when a circular shaped cut is desired to form circular shaped dough pieces from the dough sheet, the blade on the roller is shaped to produce a circular product. Of course, since the blade is formed on the outer surface of a roller, the shape of the blade itself is not circular but instead generally conforms to a circular shape mapped onto the cylindrical outer surface of the roller. Docking pins extend radially outward from the outer surface of the shaft and are located in the interior area enclosed by the blade. The docking pins are configured to dock the dough piece by creating a pattern of holes in the dough piece.

[0007] The docking pins are arranged as spaced protrusions. Preferably, the docking pins are arranged in two groups which are separated by a straight clear area having no docking pins. In the case of a taco, the clear area corresponds to a spine of the taco. The blade has a shape which corresponds to the outer circular edge of a taco. When the dough piece is cut, the cutter forms the dough piece into a circle with an area free of holes that extends along a diameter of the circle, and which corresponds to the straight clear area on the cutter. The area free of holes also follows the spine of the taco and passes through a center of the circular shape.

[0008] In a first preferred embodiment each of the rectangular docking pins has a rectangular base mounted on the surface. A rectangular main body is connected to the rectangular base. Finally, a top, shaped as a wedge with a point, is connected to the main body. Preferably the point has a blunt flat tip. The overall shape of each rectangular docking pins forms a rectangular hole in the dough pieces.

[0009] In a second preferred embodiment, each of the docking pins has a round base mounted on the surface. A cylindrical main body is connected to theround base. A conical top is connected to the cylindrical main body. Preferably, the top has a blunt flat tip. The overall shape of each docking pin forms a circular hole in the dough piece.

[0010] The process for making docked dough pieces includes conveying the dough sheet to the rotary cutter and then cutting a dough piece from the dough sheet with the blade while simultaneously docking the dough piece by creating a pattern of holes in the dough piece with the docking pins. Preferably, creating the pattern of holes includes forming two groups of holes with the clear straight area with no holes between the two groups of holes. The holes formed in the dough piece are of any desired shape such as square or round and reduce puffiness caused by pillows and blisters forming in the dough products when the dough products pass through a fryer. Docking the raw tortillas with the pins before the tortillas are baked and fried compresses the tortillas in some areas and at least reduce the size of the pillows created in the fryer.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 is a perspective view of a dough processing machine for processing a dough sheet.

[0012] Figure 2 is an upper perspective view of the dough processing machine of Figure 1.

[0013] Figure 3 is a lower perspective view of the underside of dough processing machine of Figure 1 showing two cutting rollers.

[0014] Figure 4 is a perspective view of one of the cutting rollers of Figure 3 showing a close-up view of rectangular docking pins in accordance with a first preferred embodiment of the invention.

[0015] Figure 5 is a side view of the cutting roller of Figure 4 showing a close-up view of circular docking pins in accordance with a second preferred embodiment of the invention.

[0016] Figure 6 is a top view of the cutting roller of Figure 4 with a schematic view of the pattern of docking holes made by the docking pins in the dough sheet.

[0017] Additional objects, features and advantages of the invention will become more readily apparent from the following detailed description of preferred embodiments thereof when taken in conjunction with the drawings wherein like reference numerals refer to common parts in the several views.DETAILED DESCRIPTION OF EMBODIMENTS

[0018] The following detailed description should be read with reference to the drawings in which similar elements in different drawings are numbered the same. The detailed description and the drawings, which are not necessarily to scale, set forth illustrative and exemplary embodiments and are not intended to limit the scope of the disclosure.

[0019] Selected features of any illustrative embodiment can be incorporated into an additional embodiment unless clearly stated to the contrary. While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be describedin detail. As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear, with it being understood that this provides a reasonable expected range of values in the order of + / - 10% of the stated value (or range of values). In addition, any numerical range recited herein is intended to include all sub-ranges subsumed therein. Overall, it should be understood, however, that the intention is not to limit aspects of the disclosure to the particular illustrative embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.

[0020] Figure 1 illustrates a dough processing machine 10. Dough processing machine 10 is preferably configured for taco production, and can include various types of electronic thickness control, pinch point gap control, and other related systems and functionality. The embodiments disclosed herein have applicability to a variety of different types of food rolling machines and food cutters, however, dough processing machine 10, configured to make tacos, provides useful context for appreciation of the embodiments disclosed herein.

[0021] With continued reference to Figure 1, dough processing machine 10 includes a hopper assembly 20, a roller assembly 22 and a support frame assembly 26. Support frame assembly 26 is in the form of a housing which can include and support various types of devices for operations of dough processing machine 10. Roller assembly 22 includes two sheeter rollers, a rear roller 30 and a front roller 40, that are both generally cylindrical. Rear roller 30 and front roller 40 are rotated in opposite directions and can be driven at the same speed or slightly different speeds, depending on desired performance characteristics. Rear roller 30 and frontroller 40 are positioned generally parallel to each other. Roller assembly 22 can include an electric motor and an appropriate gear reduction mechanism (not separately shown) for driving a shaft of one or both of rear roller 30 and the front roller 40. Further details of an electric motor and drive system can be found in US 2021 / 0298314, incorporated herein by reference. Roller assembly 22 is attached to support frame assembly 26. Hopper assembly 20 is supported above roller assembly 22. Hopper assembly 20 supplies dough to rear roller 30 and front roller 40 so that dough processing machine 10 produces round shaped dough pieces 45 on a conveyor 50.

[0022] More specifically and with reference to Figure 2, rear roller 30 and front roller 40 are mounted parallel to each other to define a pinch point gap 60. Hopper assembly 20 (Figure 1) is mounted above rear roller 30 and front roller 40 so as to support dough (not separately shown), such as masa above pinch point gap 60. As rear roller 30 and front roller 40 are driven in counter-rotating directions, the masa is pulled into pinch point gap 60. A thin layer of dough is discharged from the pinch point gap and adhered to an outer surface of front roller 40.

[0023] With reference to Figure 3, roller assembly 22 can also include cutting rollers 65 and 66. As the sheet of dough moves counterclockwise along with front roller 40, the dough is passed between cutting roller 66 and outer surface of the front roller 40. The dough sheet is cut producing round shaped dough pieces 45, as shown in Figure 1.

[0024] Turning to Figures 4 and 5. Preferably, cutting rollers 65 and 66 are identical and therefore only cutting roller 66 will be discussed. Cutting roller 66 is designed for taco manufacturing, and thus includes round-shaped raised cutting walls or blades 67 and 68 which extend radially outward from cutting roller orshaft 66 and form recessed interior areas 69 and 70 for cutting round shaped dough pieces 45. While round shapes are shown, cutting roller 65 could cut the dough sheet into any desired shape. Cutting roller 65 represents two embodiments of the invention.

[0025] A first embodiment, as best seen in Figure 4, within round shaped cutting blade 67 employs rectangular docking pins. Blade 67 extends radially outward from an outer surface of cutting roller 66 and is formed by wrapping a circular shaped cutting blade onto a cylindrical cutting roller 66. In operation, cylindrical cutting roller 66 will form round shaped dough pieces 45. Within the recessed area 69 two groups (120, 130) of docking pins are formed. Each docking pin 131, extends radially outward from the outer surface 135. An enlarged versions of pin 131 is shown in a circle in Figure 4. Pin 131 includes a rectangular base 132, having a length and a width, formed on the outer surface 135 of cutting roller 66. Since the cutting roller 66 is in the shape of a cylinder, the rectangular base 132 is formed with a slight curve to match the curve of the cutting roller surface 135. Rectangular base 132 is preferably solid and has four angled wall surfaces, two of which are labelled (136, 137) extending away from the cutter roller surface 135 and toward each other. As a result, rectangular base 132 becomes narrower as rectangular base 132 extends from surface 135, with the width and length of rectangular base 132 being shorter at the distal end of the rectangular base 132 versus at the proximal end of rectangular base 132 with the distal end also being in the shape of a rectangle. A main body portion 140 extends from rectangular base 132. Preferably, main body portion 140 also has a rectangular shape. Main body portion 140, unlike rectangular base 132 has side wall surfaces 141, 142 that extend parallel to each other from a lower portion to anupper portion. The upper portion is therefore preferably about the same size as the bottom portion. A wedge 150 is mounted on the upper portion and is formed with two sidewall surfaces which extend from the upper portion and come to a point 160 with a flat tip.

[0026] A straight clear area 170 within blade 67 is free of docking pins. The lack of pins in the straight clear area 170 separates the docking pins into the two groups (120, 130)- Straight clear area 170 corresponds to the area of dough piece 45 that will form the spine of a taco as discussed in more detail below with regard to Figure 6.

[0027] Preferably, the two groups (120, 130) of pins are symmetrical. The docking pins are preferably formed in rows and columns. A first row 181 will extend entirely across recessed area 67 and along straight clear area 170. First row 181 preferably has around 17 docking pins. Second and third rows (182, 183) preferably have around 15 docking pins each. A fourth row 184 has around 13 docking pins, a fifth 185 has 11, a sixth 186 has 9, while a seventh row 187 has 5. The number of rows and the number of docking pins may vary but, preferably, there are more docking pins in each row near center clear area 170 verses rows formed away from center clear area 170. The second group of docking pins 130 is preferably formed as a mirror image of the first group 120 of docking pins.

[0028] A second embodiment, best seen in Figure 5, is shown within round shaped cutting blade 68. Cutting blade 68 is also formed by wrapping a circular shaped cutting pattern onto cylindrical cutting roller 66. Again, within the recessed area two groups of docking pins (280, 290) are formed. Each docking pin 200 includes a circular base 210, having a diameter, formed on outer surface 135 of cutting roller 66. Since cutting roller 66 is a cylinder, circular base 210 isformed with a slight curve to match the curve of cutting roller surface 135. Circular base 210 is preferably solid and has a continuous sloped or angled wall surface 215 extending away from cutter roller surface 135 and formed as a partial or truncated cone shape. As a result, circular base 210 becomes narrower as circular base 210 extends from surface 135, with the diameter of circular base 210 being shorter at the distal end of circular base 210 versus at the proximal end of circular base 210. The distal end is also in the shape of a circle. A main body portion extends from circular base 210. Preferably, main body portion 220 also has a circular shape. Main body portion 220, unlike circular base 210, has side wall surfaces 225 that extend parallel to each other from a lower portion to an upper portion thereby forming a cylindrical shape. The upper portion is therefore preferably about the same size as the bottom portion. A cone shaped top 230 is mounted on the upper portion and is formed with a sidewall surface which extends from the upper portion and comes to a flat tip.

[0029] In a manner similar to the first embodiment, the circular docking pins are arranged in two groups 280, 290. Between groups 280, 290 is a straight clear area 300 within blade 68 that is free of docking pins. Preferably the two groups of pins are symmetrical. The docking pins are preferably formed along circular arcs. A first arc 311 will only have around 3 pins and will be locate near the center of the circular area. A second arc 312 will have about 6 pins and the next arc will have about 7 pins, and so on, until the eighth arc 319, which will extend entirely around the group of docking pins and have about 24 pins. Finally, an outermost arc 320 of pins will follow blade 68 but is preferably formed with spaced pins such that only about 16 pins are located in the outermost arc. The number of arcs and the number of docking pins in each arc may vary but preferably there are moredocking pins in each arc away from straight clear area 300 verses arcs formed away from straight clear area 300. Second group 290 of docking pins is preferably formed as a mirror image of first group 280 of docking pins.

[0030] With reference to Figure 3, during operation, the rotation of front roller 40, when dough pieces 35 are cut, cutting roller 66 forms each dough piece 45 into the shape of a circle with a clear area 370, 375 free of holes that extends along a diameter of the circle, and which corresponds to the straight clear area 170, 300 on the cutter. The clear area 370, 375 free of holes also corresponds to the spine of the taco and passes through a center of the circular shape. As such the clear area extends along the diameter / spine of the taco.

[0031] As can be best seen in Figure 6, the pattern of docking pins is transferred onto dough pieces 45 such that the pattern of the first embodiment produces two patterns 420, 430 of generally rectangular holes in the dough piece and the pattern of the second embodiment produces two patterns 420, 430 of generally circular holes. The holes extend through dough piece 45 and provide for venting of steam and also connect an upper surface of dough piece 45 to a bottom surface, not separately shown, and thus prevents puffing or delamination.

[0032] The process for making docked dough pieces 45 includes conveying the dough sheet to cutting roller 66 and simultaneously cutting dough piece 45 from the dough sheet with blade 67 and docking dough piece 45 by creating patterns 420, 430, 480, 490 in dough piece 45 with the groups of docking pins 120, 130, 280, 290. Preferably, creating the patterns of holes includes forming two groups of holes with clear areas 370, 375 with no holes between the two groups of holes.

[0033] As can be seen from the discussion above the embodiments include an apparatus and method for producing dough products resistant to pillowing or blistering, while maintaining the rapid production of the products. Although various illustrative embodiments are described above, any of a number of changes may be made to various embodiments without departing from the scope of the invention as described by the claims. For example, the order in which various described method steps are performed may often be changed in alternative embodiments, and in other alternative embodiments one or more method steps may be skipped altogether. Optional features of various device and system embodiments may be included in some embodiments and not in others. Therefore, the foregoing description is provided primarily for exemplary purposes and should not be interpreted to limit the scope of the invention as it is set forth in the claims.

Claims

CLAIMS1. An apparatus for producing dough pieces, the apparatus comprising: a conveyor system: a rotary cutter including: a shaft having an outer surface; a blade extending radially outward from the outer surface of the shaft, wherein the blade defines an interior area enclosed by the blade and an exterior area, said blade being configured to cut a dough piece from a dough sheet; and docking pins extending radially outward from the shaft, wherein the docking pins are located in the interior area and are arranged as spaced protrusions and configured to dock the dough piece by creating a pattern of holes in the dough piece.

2. The apparatus of claim 1, wherein the docking pins are arranged into two groups of docking pins.

3. The apparatus of claim 2, wherein the two groups of docking pins are separated by a clear area having no docking pins.

4. The apparatus of claim 3, wherein the blade has a circular shape with a diameter passing through a center of the circular shape and the clear area extends along the diameter.

5. The apparatus of claim 1, wherein each of the docking pins has a round base mounted on the surface, a cylindrical main body connected to the round base and a conical top connected to the cylindrical main body.

6. The apparatus of claim 1, wherein each of the docking pins has a rectangular base mounted on the surface, a main body connected to the rectangular base and a wedge shaped top connected to the main body.

7. A rotary cutter including: a shaft having an outer surface; a blade extending radially outward from the outer surface of the shaft, wherein the blade defines an interior area enclosed by the blade and an exterior area, said blade being configured to cut a dough piece from a dough sheet; and docking pins extending radially outward from the shaft, wherein the docking pins are located in the interior area and are arranged as spaced protrusions and configured to dock the dough piece by creating a pattern of holes in the dough piece.

8. The rotary cutter of claim 7, wherein the docking pins are arranged into two groups of docking pins.

9. The rotary cutter of claim 8, wherein the two groups of docking pins are separated by a clear area having no docking pins.

10. The rotary cutter of claim 9, wherein the blade has a circular shape with a diameter passing through a center of the circular shape and the clear area extends along the diameter.

11. The rotary cutter of claim 7, wherein each of the docking pins has a round base mounted on the surface, a cylindrical main body connected to the round base and a conical top connected to the cylindrical main body.

12. The rotary cutter of claim 7, wherein each of the docking pins has a rectangular base mounted on the surface, a main body connected to the rectangular base and a top connected to the main body.

13. A method for producing dough pieces, the method comprising: conveying a dough sheet to a rotary cutter having a shaft with an outer surface including a blade and docking pins extending radially outward from the outer surface of the shaft; and simultaneously cutting a dough piece from the dough sheet with the blade and docking the dough piece by creating a pattern of holes in the dough piece with the docking pins.

14. The method of claim 13 wherein creating the pattern of holes includes forming two groups of holes.

15. The method of claim 14 wherein creating the pattern of holes includes forming two groups of holes with a clear area with no holes between the two groups of holes.

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