Bread manufacturing methods

Abstract

This invention provides a method for producing freshly baked bread with excellent flavor and texture in a short amount of time. [Solution] The bread manufacturing method involves a baking machine that performs a second baking on bread that has been frozen in an unfinished state after the first baking to complete it. The second baking is a combination of multiple heating processes selected from four types of heating processes: a microwave process that heats the bread by irradiating it with microwaves, a grill process that heats the bread by irradiating it with infrared rays, a convection process that heats the bread by circulating hot air, and a steam process that heats the bread by generating steam, and includes at least a steam process. When a recipe specifying the order, time, and temperature of the heating processes is entered into the baking machine, the heating processes are automatically executed according to the recipe.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing bread.

Background Art

[0002] Refrigerated or frozen oven-baked bread or oven semi-baked bread may be transported and heat-treated or color baking may be performed in a store or at home. Patent Document 1 discloses a method for manufacturing frozen baked bread or frozen semi-baked bread including baking or semi-baking bread dough and then freezing it, wherein the baking or semi-baking step consists only of a baking or semi-baking step with superheated steam. Patent Document 2 discloses a method for thawing and baking bread in which superheated steam is injected into unfired frozen bread to perform thawing and baking simultaneously.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] According to the method disclosed in Patent Document 1, by baking with superheated steam, moisture transfer from the bread surface during frozen storage can be suppressed or prevented. However, when thawing and color baking are performed in a store or the like, moisture evaporates from the bread surface, deteriorating the flavor and texture of the bread. According to the method disclosed in Patent Document 2, when thawing and baking are performed simultaneously in a store or the like, superheated steam is injected, so the steaming effect by the steam works and excessive moisture is not taken away from the bread. However, when thawing and baking the bread simultaneously with only superheated steam, it is difficult to obtain a fragrant flavor and a crispy texture.

[0005] This invention has been made in view of the above problems, and aims to provide a method for manufacturing bread that allows for the mass production of bread up to a certain point in a manufacturing plant, while simultaneously providing freshly baked bread with superior flavor and texture to end consumers in a short time at stores near convenience stores or similar locations. [Means for solving the problem]

[0006] A bread manufacturing method according to one aspect of the present invention involves a baking machine performing a secondary baking on bread that has been frozen in an unfinished state after primary baking to complete it. The secondary baking is a combination of multiple heating processes selected from four types of heating processes: a microwave process that heats the bread by irradiating it with microwaves, a grill process that heats the bread by irradiating it with infrared rays, a convection process that heats the bread by circulating hot air, and a steam process that heats the bread by generating steam, and includes at least a steam process. When a recipe specifying the order, time, and temperature of the heating processes is input into the baking machine, the heating processes are automatically executed according to the recipe.

[0007] According to this embodiment, since the bread is baked once beforehand, freshly baked bread can be prepared in a short time. In the secondary baking, at least one of the heating processes that tend to reduce the moisture content of the bread—such as a microwave process, a grilling process, and a convection process—is used in combination with a heating process that does not tend to reduce the moisture content of the bread—such as a steaming process. This allows for adjustment of the moisture content of the bread, resulting in bread with superior flavor and texture.

[0008] In the above embodiment, the secondary firing may include all four heating steps.

[0009] According to this embodiment, since all four heating processes are included, the moisture content inside and on the surface of the bread can be further precisely adjusted by using a microwave process that easily reduces the moisture content inside the bread, a convection process that easily reduces the moisture content on the surface of the bread, and a grilling process that easily browns the bread while reducing the moisture content on the surface of the bread.

[0010] In the above embodiment, the recipe may be input into the baking machine by having the baking machine or a terminal capable of communicating with the baking machine read a two-dimensional code.

[0011] According to this configuration, complex instructions can be entered simply by scanning a two-dimensional code, thus speeding up recipe input and preventing human error.

[0012] In the above embodiment, the firing machine may be configured to operate a fan for ventilating the inside of the firing machine if the door of the firing machine has not been opened after a predetermined time has elapsed since the completion of secondary firing, and to stop the fan if the door has been opened.

[0013] According to this configuration, it is possible to prevent the bread that has been baked a second time from being overbaked by the residual heat inside the oven. The fan is only driven when the door is not opened after the second baking is complete, so the sound of the fan can inform the user that the bread that has been baked a second time is being left unattended.

[0014] In the above embodiment, the baking machine may be equipped with a tank for storing water that is the source of steam for the steam process in which steam is generated to heat the bread, and may be configured to drain all the water in the tank and empty the tank when secondary baking is not being performed.

[0015] According to this embodiment, the tank can be kept clean because all the water in the tank is drained at a predetermined time when secondary firing is not being performed.

[0016] In the above embodiment, the baking machine may be configured to shorten the heating time specified in the recipe if the temperature inside the oven exceeds a predetermined temperature.

[0017] Repeated secondary firing can make it difficult for the temperature inside the firing chamber to decrease, resulting in an undesirable high temperature state persisting. In this embodiment, the heating time specified in the recipe can be shortened to approach the desired temperature change in such cases.

[0018] In the above aspect, when ventilating the interior of the baking machine, the baking machine may be provided with a filter for capturing the oil generated from the bread during the secondary baking.

[0019] In the above aspect, when ventilating the interior of the baking machine, the baking machine may be provided with a guide member that bends the exhaust gas containing the oil generated from the bread during the secondary baking toward the front side where the door of the baking machine is located.

[0020] According to these aspects, it is possible to prevent the oil generated from the bread from soiling the wall surface on the back side of the baking machine.

Effect of the Invention

[0021] According to the present invention, it is possible to provide a method for manufacturing bread that can cook freshly baked bread with excellent flavor and texture in a short time.

Brief Description of the Drawings

[0022] [Figure 1] FIG. 1 is a perspective view showing an example of the external appearance of a baking machine used for secondary baking. [Figure 2] FIG. 2 is a perspective view showing an example of the internal structure of the baking machine with the housing cover removed. [Figure 3] FIG. 3 is a cross-sectional view taken by cutting the interior of the baking machine in half left and right. [Figure 4] FIG. 4 is a perspective view showing an example of the internal structure of the baking machine as viewed from the side opposite to FIG. 2. [Figure 5] FIG. 5 is a flowchart showing an example of a method for manufacturing bread according to an embodiment of the present invention.

Modes for Carrying Out the Invention

[0023] Referring to the accompanying drawings, preferred embodiments of the present invention will be described. In each figure, those denoted by the same reference numerals have the same or similar configurations. The present invention relates to a method for manufacturing bread in which the baking machine 10 performs secondary baking on bread that has been frozen in an incompletely baked state after primary baking to finish it in a completed state.

[0024] Figure 1 is a perspective view showing an example of the appearance of a baking machine 10 used for secondary baking. The baking machine 10 is installed, for example, in a convenience store, and heats frozen bread according to a recipe. The frozen bread may be prepared at a location different from where the baking machine 10 is installed (for example, a bread factory). Bread before secondary baking is bread that has been first baked and frozen, and is in an unfinished state that is underbaked compared to the finished state. Bread before secondary baking has, for example, a lighter brown color compared to the finished state after secondary baking, or a higher moisture content compared to the finished state.

[0025] As shown in Figure 1, the baking machine 10 includes an interior cavity 20 that can accommodate the bread to be baked, a door 30 that can open and close the interior cavity 20, and an operation panel 40 on which recipes and other information can be entered into the baking machine 10. In the example shown in Figure 1, the operation panel 40 includes a camera 41 that reads two-dimensional codes, a monitor 42 with touch panel functionality, and hardware keys 43 that can be physically operated.

[0026] In the following description, the side with the door 30 and the control panel 40 will be referred to as the front of the firing machine 10, and the side opposite the front will be referred to as the rear of the firing machine 10. Also, the side to the left of the control panel 40 as seen from the user operating it from the front will be referred to as the left side of the firing machine 10, and the side to the right will be referred to as the right side of the firing machine 10.

[0027] Figure 2 is a perspective view showing an example of the internal structure of the firing machine 10 with the housing cover removed. The firing machine 10 is equipped with various circuit boards, such as a control board 44 connected to the operation panel 40 and a power supply board 45 connected to the control board 44.

[0028] Figure 3 is a cross-sectional view of the oven cavity 20, cut in half horizontally. Figure 4 is a perspective view showing an example of the internal structure of the baking machine, viewed from the opposite side of Figure 2. As shown in Figure 3 or Figure 4, the baking machine 10 includes a tray 21 on which bread to be cooked can be placed, a magnetron 51 and waveguide 52 that constitute the range function, a grill heater 61 that constitutes the grill function, a convection heater 71 and convection fan 72 that constitute the convection function, a tank 81, a pump 82 and a heating steam generating heater 83 that constitute the steam function, and the like.

[0029] As shown in Figure 3, the tray 21 is formed in a flat shape from a microwave-transmitting ceramic material or the like, and constitutes the bottom surface of the interior 20. The magnetron 51 is positioned behind the interior 20 and irradiates microwaves. The waveguide 52 is positioned below the tray 21 and guides the irradiated microwaves into the interior 20. The grill heater 61 is positioned on the top surface of the interior 20 and irradiates infrared rays toward the tray 21. The convection heater 71 is positioned behind the interior 20 and heats the air around the convection fan 72. The convection fan 72 circulates the heated air into the interior 20.

[0030] As shown in Figure 4, a tank 81 capable of storing water that will become the source of steam is located adjacent to the control panel 40, with the end of the tank 81 exposed to the front of the firing machine 10. A pump 82 draws water from the tank 81 and supplies it to a heating steam generator 83. The heating steam generator 83 heats the supplied water to generate steam. In the example shown in Figure 4, the heating steam generator is configured to generate superheated steam, which is saturated steam that has been further heated.

[0031] When the interior 20 of the oven is ventilated, outside air is drawn in through the intake port 91 (shown in Figure 2), and the air inside the oven 20 is discharged through the exhaust port 92. In the example shown in Figure 4, the baking machine 10 is equipped with a filter 93 that captures oil generated from the bread during secondary baking when the interior 20 of the baking machine 10 is ventilated. The filter 93 is positioned between a fan, such as a convection fan 72 that ventilates the interior 20 of the baking machine 10, and the exhaust port 92.

[0032] The baking machine 10 may be equipped with a guide member 94 attached to an exhaust port 92 on the rear side of the baking machine 10, which bends the exhaust containing oil toward the front. In the example shown in Figure 4, the guide member 94 is a flat cylindrical body bent at approximately a right angle. With a filter 93 and a guide member 94, it is possible to prevent oil generated from the bread from contaminating the rear wall of the baking machine.

[0033] Figure 5 is a flowchart showing an example of a bread manufacturing method according to one embodiment of the present invention. As shown in Figure 5, the bread manufacturing method first involves preparing bread that has been partially baked and frozen in an unfinished state (step S1). This frozen bread is manufactured in a factory or other facility different from the convenience store where the end consumer purchases the bread, and the quantity ordered by each store based on past performance is delivered to the store. This allows for cost reduction, efficient production of a wide variety of breads, and ensures a shelf life through freezing. Each baking machine 10 in the store has a built-in chip or other device pre-set with the optimal baking temperature, time, and steam settings (amount and time) for each type of bread (melon bread, financier, croissant, donut, pizza, etc.) prepared at the factory. By specifying the recipe corresponding to each type of bread, parameters such as temperature and time in each step (S2-S5) in Figure 5 are controlled. At the store, each step (S2-S5) is performed when the end consumer purchases the bread, and the bread manufacturing is completed. First, the prepared bread is placed inside the oven cavity 20 of the baking machine 10 (step S2), and the recipe is entered into the baking machine 10 (step S3).

[0034] In this case, the recipe may be entered into the baking machine 10 by having the baking machine 10 or a terminal capable of communicating with the baking machine 10 read a two-dimensional code. Since complex instructions can be entered simply by scanning a two-dimensional code, recipe input can be expedited and human errors can be prevented.

[0035] The baking machine 10 bakes the bread a second time according to the input recipe to finish it. The second baking is a combination of multiple heating processes selected from four types of heating processes: microwave, grill, convection, and steam, and includes at least a steam process. In the illustrated example, the second baking includes all four types of heating processes.

[0036] In the microwave step, the bread is heated by irradiating it with microwaves to quickly defrost it (step S2). In the grill step, the bread is heated by irradiating it with infrared rays to brown the surface of the bread (step S3). In the convection step, hot air is circulated to heat the bread and evaporate excess moisture (step S4). In the steam step, steam is generated to heat the bread without reducing its moisture content (step S5). Note that the order of the heating steps is not limited to the example shown in Figure 5. Also, the oven may be configured to shorten the heating time specified in the recipe if the temperature inside the oven 20 exceeds a predetermined temperature.

[0037] Once the secondary baking is complete, open the door 30 (Step S6: Yes), remove the baked bread from the oven 20 (Step S8), and display it on the display fixtures in the sales area. If the door 30 of the baking machine 10 is not opened after a predetermined time (for example, 1 minute) has elapsed since the completion of the secondary baking (Step S6: No), the system may be configured to drive a fan such as a convection fan 72 to ventilate the oven 20 of the baking machine 10 (Step S7). This prevents the secondary baked bread from being overbaked by the residual heat in the oven 20 of the baking machine 10. If the fan is only driven when the door 30 is not opened after the completion of the secondary baking, the sound of the fan can inform the user that the secondary baked bread is being left unattended.

[0038] In the example shown in Figure 5, if the firing machine 10 is to be cleaned when secondary firing is not being performed (Step 9: Yes), the system is configured to drain all the water in the tank 81 to the heating steam generator 83, etc., to empty the tank 81 (Step S10). If cleaning is not performed (Step 9: No), secondary firing may be repeated. The timing for draining the tank 81 may be, for example, each time a day's worth of secondary firing is completed, or for example, each time one batch of secondary firing is completed.

[0039] According to the bread manufacturing method of one embodiment configured as described above, since the bread is baked again after being baked once, freshly baked bread can be prepared in a short time. In the secondary baking, at least one of the heating processes that tend to reduce the moisture content of the bread—a microwave process, a grilling process, and a convection process—is used in combination with a steaming process, which does not easily reduce the moisture content of the bread. This allows for adjusting the moisture content of the bread to produce bread with excellent flavor and texture.

[0040] In the example shown in Figure 5, since all four heating processes are included, it is possible to further fine-tune the moisture content inside and on the surface of the bread by using the microwave process, which easily reduces the moisture content inside the bread; the convection process, which easily reduces the moisture content on the surface of the bread; and the grill process, which easily browns the bread while reducing the moisture content on the surface of the bread.

[0041] The embodiments described above are provided to facilitate understanding of the present invention and are not intended to limit its interpretation. The elements, arrangement, materials, conditions, shapes, and sizes of the embodiments are not limited to those exemplified and can be modified as appropriate. Furthermore, it is possible to partially substitute or combine the configurations shown in different embodiments. [Explanation of Symbols]

[0042] 10...Baking machine, 20...Interior, 21...Tray, 30...Door, 40...Control panel, 41...Camera, 42...Monitor, 43...Hardware key, 44...Control board, 45...Power supply board, 51...Magnetron, 52...Waveguide, 61...Grill heater, 71...Convection heater, 72...Convection fan, 81...Tank, 82...Pump, 83...Heating steam generator, 91...Air intake, 92...Exhaust port, 93...Filter, 94...Guide member.

Claims

1. A method for manufacturing bread in which bread that has been frozen in an unfinished state after the first baking is baked once is baked again in a baking machine to finish it, The aforementioned secondary baking is a combination of multiple heating processes selected from four types of heating processes: a microwave heating process in which the bread is heated by irradiating it with microwaves, a grill heating process in which the bread is heated by irradiating it with infrared rays, a convection heating process in which the bread is heated by circulating hot air, and a steam heating process in which the bread is heated by generating steam, and includes at least the steam heating process. When a recipe specifying the order, time, and temperature of the heating process is input to the baking machine, the heating process is automatically executed according to the recipe. The bread manufacturing method further includes a ventilation step of driving a fan to ventilate the inside of the baking machine if the door of the baking machine is not opened even after a predetermined time has elapsed since the completion of the secondary baking. The baking machine is equipped with a guide member that, when ventilating the inside of the baking machine, bends the exhaust air containing oil generated from the bread during the secondary baking towards the front side where the door of the baking machine is located. The ventilation process informs the user that the door of the firing machine is not yet open by exhaust fumes discharged to the front of the firing machine and the sound of the fan operating. Bread manufacturing method.

2. The aforementioned secondary firing includes all four of the aforementioned heating steps. The method for producing bread according to claim 1.

3. The recipe is input into the baking machine by having the baking machine or a terminal capable of communicating with the baking machine read a two-dimensional code. The method for producing bread according to claim 1.

4. The firing machine is configured to stop the fan when the door is opened. The method for producing bread according to claim 1.

5. The baking machine is equipped with a tank for storing water that is the source of steam for the steam process, which generates steam to heat the bread, and is configured to drain all the water in the tank and empty the tank when the secondary baking is not being performed. The method for producing bread according to claim 1.

6. The baking machine is configured to shorten the heating time specified in the recipe when the temperature inside the chamber exceeds a predetermined temperature. The method for producing bread according to claim 1.

7. The aforementioned baking machine is equipped with a filter that captures oil generated from the bread during the secondary baking process when ventilating the inside of the baking machine. The method for producing bread according to claim 1.

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