Fully automatic machine for uniform shaping of Barbari breads

Abstract

It is a fully automatic Berber kneading machine that performs all the tasks of kneading, spreading, rubbing the dough and combing, and is transferred into the oven by only one person. Its size is small, and in Berber bakeries, all the tables are assembled using this machine, and it does the work instead of two people, and its dough is uniform, as a result, all parts of the bread are baked evenly and there is no waste.

Description

Description of the invention: -1Invention title: Fully automatic machine for uniform shaping of barbarian breads An Automatic Device for forming duo semi-thickness Breads 2- Technical field of invention: Greek food industry 3- Technical problems and statement of the objectives of the invention: In general, the percentage of bread waste in Iran is very high, and Berber breads, among others, have a waste percentage of about 40% due to their uneven thickness, which is why they are of low quality. They also have a slow baking speed and occupy a lot of space in the bakery. For the following reasons: - Separate manual bargaining stage and separate table setting. -The stage of transferring the dough balls to a large table on which a large amount of bran has been poured. -The step of pouring the napkin over the grains of dough arranged on the large table. -The step of rubbing and spreading the napkin over the dough. -The step of combing each dough by hand. -The stage of transferring each of the combed doughs into the oven. -When transferring the dough by hand into the oven, the dough is stretched, leaving some parts thin and some parts thick. This causes uneven baking of the bread, which is clearly visible in bakeries. The purpose of this invention for which registration is requested is to solve the above problems. Thus: - First, the dough, almost soft like Berber dough, is prepared in a mixer according to the procedure and left there for a while until the initial fermentation process is complete and bubbles from fermentation are visible. -Then the fermented dough is transferred into the machine's all-steel tank by the baker, so that it can hold approximately the same amount of dough made from a 40-kilogram bag. -In this machine, the dough is rolled by rollers with a relatively large distance from which a thick dough comes out and with an adjustable width, continuously. This increases the speed of rolling, as it is uninterrupted and continuous. Also, the table for arranging the rolls is eliminated. -The relatively large distance between the rollers causes very little pressure to be applied to the dough, especially since the dough is soft, a significant portion of the dough descends by gravity without any pressure, as a result of which the bubbles resulting from fermentation do not escape from the dough, which will improve the quality of the bread. Also, the thickness of the dough will be uniform over the entire surface, and as a result, the entire bread will bake evenly. -Then the napkin is rubbed onto the dough by a roller on which the napkin tank is placed tangentially. The amount or quantity of the napkin is adjusted by the sliding valve of the napkin tank. Since this is continuous, it greatly reduces the time of transferring the napkin and it is rubbed onto the dough completely evenly. -In the next step, circular combs with intervals of about one and a half centimeters, which rotate through the chain gear from the driving force of the machine and whose height or the depth of the combs can be adjusted with a screw, comb the dough automatically. This work is also continuous and minimizes time. -Then a circular cutter with Teflon coating, which has a separate motor, cuts the dough. The length of the dough is adjusted by an electronic system connected to this cutter by adjusting the time interval between the cutter movements. In this way, the size or weight of the dough is adjusted only once, as determined by the Grain Department. This work is also continuous and takes minimal time. -Then the fully prepared dough is taken by the baker with a steel paddle and placed into the oven. -If the baker determines that the prepared dough still needs to rest, he can use a number of steel plates, for example twenty, measuring about 20 by 35 centimeters, and arrange them, which are numbered, in shallow drawers (due to the thickness of the dough being more than a centimeter) that take up little space, and transfer them from number one to number 25 to the oven. In this interval, if he is alone, he turns off the machine, whose switch is very close to the baker, only for a short time, and otherwise the transfer work is continued by the baker's assistant. -Therefore, in a bakery that works with this machine, if it is not busy, one person is enough, and if the baking volume is large, two people are enough. This depends on the location of the bakery. -Also, all these steps are carried out on a conveyor that is specifically designed for automatic confectionery industries. - To prevent the dough from sticking to the conveyor, a hopper filled with bran is located at the beginning of the conveyor, which transfers the required amount of bran onto the conveyor with an adjusting screw. -At the bottom of the conveyor is a steel blade and a large container that separates the bran remaining on the conveyor from the conveyor and pours it into the container. This bran is reused and no bran is wasted. -In this way, the large table on which the dough was spread and the napkin and combing steps were performed on it individually for each dough is also eliminated. This direct transfer will also minimize time and greatly reduce the occupancy rate. 4- Description of the status of previous technical knowledge: The expression of prior technical knowledge is required to establish an inventive step, and the scope of prior technical knowledge can include general information and written and unwritten documents in different languages. The inventor of this device (me) has previously conducted about 30,000 hours of research work with the direct participation of the Grain and Bread Research Institute, which has resulted in patents in the field of solving the problems of bread waste and increasing the quality of bread, with numbers 27350 dated 05 / 31 / 1380, 29076 dated 08 / 13 / 1382, and number 39621 dated 01 / 20 / 1387. Which is valid until 1401. Also, I have made these inventions after obtaining a standard license and obtaining a certificate of approval from the Scientific Research Organization of Iran by establishing a workshop and making a large number of these devices and they are working in different parts of the country under the trade name of Beaver Sanat Nan Noor. These devices had an indirect heat oven and the heat reached the bread by radiation and the dough and bread had no contact with the flame. Numerous other companies have also made molds and ovens for tafton and lavash breads, which are used in many bakeries. But no company has made an automatic shaping machine for Berber breads, and only a very few Berber bakeries use a single-crank device, which neither reduces time nor does it perform the other steps of transferring to the primary table and the large table, rubbing the napkin, combing, cutting, and transferring to the oven. All of the aforementioned steps are still done manually as before. 5- Automatic provision of a solution to the existing technical problem along with a detailed, sufficient and integrated description of the invention: The recently invented machine follows the same previous inventions but for barbarian breads that no one has done before in this field or has done to a much more limited extent (the same single-barrel kneader mentioned above). In addition to making the dough thickness the same across the entire surface of the bread, which results in the entire bread being baked evenly and without waste, this automatic machine uses fully fermented dough, which plays a fundamental role in the quality of the bread and reduces excess or dead times and automates and speeds up all time-consuming manual steps, bringing bread waste to near zero. Also, the size of this machine is about 125 x 40 cm. It takes up very little space and both large tables of Berber bakeries are assembled. As mentioned in the previous section, this invention, like previous inventions and research, was aimed at reducing or eliminating bread waste due to uneven baking and preventing the use of unfermented dough. Because the dough that is fermented becomes somewhat soft, most bakers cannot work on it by hand, and usually hand-shape and bake the dough before fermentation, when it can be more easily shaped by hand. "In this machine, I invented, manual steps that are imprecise and irregular and often use unfermented dough are automated. As a result, in addition to greatly reducing waste, the quality of bread is also increased and the baking process becomes easier. It takes up very little space and both large tables of the Berber bakery are dismantled." In No. 3 of the description of the invention, the function of each part of my invented device is explained in detail, along with the problems it solves, which do not seem necessary to repeat. In this machine, the fully fermented dough is first pushed onto a special conveyor by rollers spaced about a centimeter apart without pressure, using the force of the dough's weight and dough's adhesion. This action preserves the bubbles resulting from the fermentation of the dough, and due to the uniformity of the flattened dough, it has uniform baking, greatly reducing bread waste and increasing the quality of the bread. - Then, a substance called rubal, which is rubbed on Berber breads, is automatically and evenly rubbed onto the dough, which will give the bread a better appearance. - The thickness of the dough in this machine is completely uniform. - Then, the desired shape is given to the dough by solid, toothed Teflon blades that are permitted in the food industry. It will also cause the bread to bake more deeply. - Then the dough is set to the desired size and weight determined by the baker, which is done by a switch on the machine's electrical panel. Obviously, after setting or selecting the size and weight of all loaves, the size and weight will be the same. - In the last stage, the prepared dough is transferred to the rotary oven or traditional Berber ovens by a very light steel paddle. Because during the dough movement on the conveyor, the bottom of the dough is impregnated with bran, the dough does not stick to the steel plate, which measures about 20 by 35 centimeters. - Because the machine's gearbox is equipped with an inverter, the machine's speed and cooking speed can be adjusted from the volume control panel. Also, this machine does not require three-phase electricity. 6--Explanation of shapes, maps, diagrams: Also, the images must be referenced to the numbers that appear in the drawing to express the features of the invention in a way that allows an expert in the field to understand the invention and the relationship between its components. For a better understanding of the invention, if figures, maps or diagrams are necessary, the applicant must draw and arrange them in a way that an expert in that field can understand them, and the inclusion of this clause is also in a way in line with the complete and effective disclosure of the invention. It should be noted that the maps and diagrams must be drawn by the relevant software and their files must be provided in PDF, Word or Image format. For example, circuit diagrams should be provided with Protel or PCB software. If the claimed subject matter of the invention is a device or a device, the drawing should display its technical details in a concise and visual manner. You can use industrial drawing software such as AutoCAD, 3DMax, SPSS, etc. to prepare the drawing. 1- Bran and flour tank����� 2- Rollers under the tank������ 3- Ethylene plastic tank����� 4- Dough tank 5- Opening and closing valve for dough output�� 6- Dough output adjustment dial�� 7- Bran and flour output adjustment dial 8- Primary conveyor roller�� 9- Inlet conveyor adjustment box�� 10- Machine chassis�� 11 Inverter gearbox motor 12- Power transmission chains�� 13- Roller cleaning blades�� 14- Dough thickness adjustment plate 15- Dough cutting motor�� 16- Napkin holder adjustment screw�� 17- Napkin tank for Barbari breads 18- Napkin transfer roller�� 19- Large dough cutting pulley�� 20- Small dough cutting pulley 21- Dough cutting blade with adjustable speed and dough size. 22- Dough outlet opening and closing lever. 23- Combers and separators�� 24- Three-layer conveyor for confectionery industries�� 25- Output conveyor adjustment box 26- Bran and flour re-collection blade 27- Bran and flour collection container 28- The machine panel is equipped with speed adjustment for the entire machine, cutting speed adjustment, dough size and weight adjustment. 29- Wheels Explanation of the function of the device components and device drawings: - The device drawings and the naming of each part are as follows: - Shaping is done in multiple and gradual stages with a relatively large distance between the rollers without applying pressure to the dough so that the bubbles caused by fermentation, which have a great impact on the quality of the bread, do not come out of the dough. (Vertical, profile, horizontal and 3D views are attached) (No. 2) - In this machine, the prepared dough is transferred into the machine tank after initial fermentation, and as shown in the figures or drawings, the rest of the shaping steps are done automatically, and the flattened dough of the desired thickness is transferred into the oven or bread baking oven by a small rectangular tray. (No. 4) Gearbox motor equipped with inverter to adjust speed without requiring much power because very little pressure is applied to the dough. (No. 11) -Special motor with timer and series of microswitches and relays for cutting dough, which electronically adjusts the time interval between cutting dough, thus allowing easy adjustment of the weight and size of the dough (No. 15) -A special dimmer is connected in the panel so that the inverter's own dimmer is not used because it is expensive. To adjust the speed of the entire device. (No. 28) -Conveyor for the confectionery industry with middle rubber for transporting dough (No. 24) -Conveyor left and right adjustment systems and conveyor stiffness adjustment, inlet section (No. 9) - Touch flour to completely coat the conveyor with bran to prevent the dough from sticking to the conveyor (number 1). All this bran is again separated from the conveyor by a blade under the conveyor and when the conveyor returns, it is poured into a large container to be used again. In this way, no bran is thrown away. (No. 26) -Automatic conveyor cleaning system which is carried out by the same bran separator blade. (No. 26) - Lockable wheels for easy movement. (No. 29) - Electrical panel for installing all adjustment and on / off switches. (No. 28) - Bran collection container (No. 27) - Output conveyor adjustment box (No. 25) - Combers and furrowers (No. 23) - Dough cutting blade with adjustable speed and pause time to adjust and select the weight and size of the dough (No. 21) - Lever for opening and closing the dough valve (No. 22) - Small dough cutter (No. 20) - Large dough cutter (No. 19) - Napkin transfer roller (No. 18) - Napkin holder for Barbari breads (No. 17) - Napkin quantity adjustment screw (No. 16) - Dough thickness adjustment plate (No. 14) - Roller cleaning blades (No. 13) - Power transmission chains (No. 12) - Device chassis (number 10) - Primary roller for moving the conveyor (number 8) - Output and bran amount adjustment box (No. 7) - Dough thickness and output adjustment dial (No. 6) - Ethylene poly tank (No. 3) 7: Advantages of the invention: This machine is fully automatic and does not require any hand contact in all stages. From a hygienic point of view, it has the following important features and benefits: 1- Bread waste approaches zero because the entire surface of the bread has the same thickness and cooks evenly. 2- Fermented dough must be used to shape the dough, which improves the quality of the bread and ensures that the bread is baked completely. 3- During shaping, because very little pressure is applied to the dough and the viscosity of the dough itself and the force of gravity are used to shape the dough, bubbles resulting from fermentation do not escape from the dough, which improves the quality of the bread. 4- The cooking speed increases because cooking is continuous and has no dead time. 5-The space it occupies is reduced by at least 80% because both bakery tables fold up. 6- The number of users or technicians for bakeries that bake less than 8 40-kilogram bags per day is reduced to approximately one person and for more than 8 bags to two people. In fact, the number of users is halved. 7- The cooking process becomes easy. 8- It can be adjusted to suit any taste. 8: Explanation of at least one implementation method for applying the invention: A dough maker makes the dough in a mixer and after transferring it, turns on the machine and the formed and uniform dough, which is automatically rubbed with a napkin and cut into adjustable sizes, is then arranged with a small paddle or by hand in vertical racks that take up much less space than the current tables. These racks are prepared for approximately thirty numbered paddles. As a result, it takes about 13 minutes to fill the racks. This is the appropriate time for intermediate fermentation, which is emphasized by experts at the Grain and Bread Research Institute. Then, from number one, the dough is transferred to the rotary oven without manual intervention. During this time, the machine is turned off to empty the racks. During the baking period, the forming machine is turned on again and the paddles are arranged in the racks in the same order. This process is carried out continuously. In this way, the dough is prepared for baking without manual intervention and completely uniform, and the intermediate rest or rest after shaping is performed to improve the quality. And it takes up little space.In bakeries that bake more and are busy, only one other person sells the bread. 9- Explicitly mentioning the industrial application of the invention if the nature of the invention does not indicate this; The industrial application or applications of the invention must be mentioned if the nature of the invention does not indicate this. Failure to explicitly mention the industrial application in this section and the inadequacy and clarity of this in the invention can provide the basis for the use or abuse of this right in the future by profit-seeking individuals and competitors. So far, no automatic machine has been introduced in the bread industry for shaping barbarian breads, and so far this work has been done manually. In the manual method: - The dough thickness is uneven. This causes the thicker parts to be undercooked and increases bread waste. - The manual steps for this type of bread are relatively long and time-consuming, wasting the time of bread buyers. - In the manual method, the tables where the dough is rolled out are often wooden and are never washed. This makes the manual method unhygienic. - In the manual method, the presence of two relatively large tables takes up space in the bakery. - In the manual method, the presence of several users or technicians is necessary. In this invention: The fully automatic Berber bread shaping machine has the following advantages when used in Berber bakeries: -This machine is fully automatic. As a result, all steps do not involve hand contact and have an important hygienic feature. -Bread waste approaches zero because the entire surface of the bread has the same thickness and bakes evenly. -Fermented dough must be used to shape the dough. This improves the quality of the bread and ensures complete baking. -During shaping, because very little pressure is applied to the dough and the viscosity of the dough itself and the force of gravity are used to shape the dough, the bubbles caused by fermentation do not come out of the dough. This also improves the quality of the bread. -The cooking speed is also increased because cooking is continuous and has no dead time. -The space it occupies is reduced by at least 80% because both bakery tables fold up. -The number of users or technicians for bakeries that bake less than 8 40-kilogram bags per day is reduced to approximately one person, and for more than 8 bags, to two people. In fact, the number of users is halved. -The cooking process becomes easy. -It can be adjusted for every taste in terms of bread size, bread weight, bread thickness, bread width and length, machine speed, and amount of napkins.

Claims

Claim What is claimed: Claim 1) What is claimed is a device for shaping, flattening and cutting dough for barbarian breads consisting of four smooth and polished rollers with a distance of more than 6 mm that rotate and guide the dough in the tank on these rollers onto the conveyor for subsequent operations. This device has the following components: . Steel tank to hold the dough above the rollers . Four polished rollers . Non-stick dough separating blades . Metal chassis on which components and parts are mounted . . Conveyor for the pastry and bread industries . Napkin guiding system for barbarian breads consisting of rollers, envelopes, blades and regulators . . Non-stick rotating combs to create grooves on the dough . . Electronic system with a timer to adjust the dough size . . Roller bearings on the back of the rollers to adjust the dough thickness . . Conveyor cleaning blade . . Motor and gearbox with inverter to provide driving force with adjustable speed. . Linear dough cutting system connected to an electronic timer that cuts dough to the desired size and consists of a non-stick rotating blade, pulleys, and belts. .Contact system for transferring bran onto the conveyor, consisting of a tank and an adjustable valve tangential to the conveyor. . Two steel paddles for transferring dough to the rotary oven. . Conveyor carrying the paddles that are filled in turn and without manual intervention. . Electronic system for counting the number of cut doughs, each of which becomes a loaf. . Dough outlet valve opening and closing system consisting of a lever and a movable blade. . Gears and chains, pulleys and belts for transmitting power to the systems forming the machine. . Body to cover the machine and prevent contact with the user's hands while operating the machine. Claim 2) According to claim number 1, instead of using a screw or cylinder that presses on the dough and causes bubbles to come out from the initial fermentation, and also because the Berber dough has a lot of moisture and is very sticky, this device uses polyethylene rollers with special blades that are very smooth and polished, and the distance between them is more than 6 mm. Considering the looseness of the Berber dough, it helps with the force of gravity. For the first time, PTF separator blades, which are the most non-sticky of their kind, are used to push the dough. Due to the very low pressure on the dough, the bubbles caused by the fermentation of the dough are preserved and the quality of the bread is increased. Claim 3) According to claims 1 and 2, in this machine, the dough is rolled flat without the need for manual spreading, which results in uniform thickness. To prevent the dough from changing in thickness when transferred from this machine to the oven, a steel paddle with a handle, which is attached to the machine, is used. As a result, bread baked with this dough has uniform baking and greatly reduces waste, and unlike ordinary breads, it does not have undercooked or burnt parts. Claim 4) According to claim 1, 2 and 3, in this dough base machine or on the conveyor, a unique ArdTouch system is used with a tank full of bran and the ability to adjust the amount of bran to prevent the dough base from sticking. Under the conveyor, a blade and a container under it prevent the wastage of bran stuck to the conveyor and at the same time, everything is separated from the conveyor in the next round. Claim 5) According to claims 1 and 3, this device uses for the first time an automatic transfer system for the Berber bread roll in a completely uniform manner with the ability to adjust its amount, because the roll is made of cooked starch and is sticky and comes out of the hole or gap of each container only once and then closes itself. Therefore, this device uses a roller transfer system without a grooved container, which is completely unique. Claim 6) According to claim 5, after transferring the napkin onto the dough, the combing step on the Berber dough, which is usually done by hand, is uniquely performed using specially shaped, completely non-stick PTF combs, and the amount of indentation of the comb can be adjusted according to the user's choice. Claim 7) According to claims 1 and 6, in this device, after rubbing a napkin on the dough, a linear cutting system is used to cut the dough using a non-stick Teflon circular blade equipped with a relay and a cam that is controlled by an electronic circuit equipped with a timer. By changing the time interval between cuts from the timer on the panel, the length of the bread is adjusted to the user's choice. In this way, the size or weight of the dough is adjusted according to what is determined by the Grain Department, and this work is continuous and takes minimal time. Claim 8) According to claims 1, 2, 6 and 7, the speed of the entire machine is controlled by a volume that is connected to the inverter of the motor gearbox of the machine, and this volume is also connected to the electronic timer of the cut-off, which acts as a pizza cutter with a rotating plate, and the length of the dough is determined by adjusting the time of the cut-off, and as a result, the length of the dough does not change as the speed of the entire machine decreases and increases, and all systems decrease and increase at a fixed ratio. Claim 9) According to claims 1, 7 and 8, the conveyor for transferring the cut dough onto the steel paddle for transferring the dough to the oven is also driven by the machine's driving force, and each time a filled paddle is removed, the next paddle is automatically filled for removal, resulting in the machine operating continuously and without stopping. Claim 10) According to claims 1 and 8, the device has a drive equipped with an inverter and a volume regulator that changes the speed of all components of the device at a constant ratio, as a result of which the length and size of the bread always remain constant at any speed, and the transmission of forces is carried out by a chain and pulley gear with the ability to adjust the distances and maintain the size ratios of the rollers with a safety cover.

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