Method for discharging dough
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Filing Date
- 2024-10-07
- Publication Date
- 2025-04-10
Abstract
Description
Dough discharge method
[0001] The present invention relates to a method for extruding dough, such as bread dough, using a dough extrusion screw.
[0002] A method for discharging dough such as bread dough using a dough extrusion screw is known (Patent Document 1).
[0003] Japanese Unexamined Patent Publication No. 60-066932
[0004] In the device described in Patent Document 1, bridging occurs in the dough fed into the hopper, preventing sufficient dough from being fed to the screw. In this case, the dough discharge becomes unstable, and the thickness and density of the discharged dough sheet may not be uniform.
[0005] Therefore, an object of the present invention is to provide a dough discharging method that can improve the uniformity of the thickness and density of the dough sheet.
[0006] To achieve the above object, the method of the present invention for discharging continuous dough using a screw arranged in a discharge cylinder comprises supplying dough balls smaller than the pitch of the screw blades exposed at the inlet of the discharge cylinder from the inlet of the discharge cylinder to between the blades, and discharging the continuous dough from the outlet of the discharge cylinder.
[0007] In this dough discharge device, dough balls smaller than the pitch of the screw blades are supplied between the blades of the screw, so that the dough balls can be reliably supplied to the space between the discharge cylinder and the screw. As a result, the density of the dough discharged from the discharge cylinder is stable, and the thickness and density of the dough sheet can be made more uniform.
[0008] In the method of the present invention, the inlet of the discharge cylinder is preferably located at the longitudinal end face of the screw flight, and feeds the dough balls in the direction of the rotation axis of the screw.
[0009] In the method of the present invention, more preferably, the discharge cylinder extends in the vertical direction.
[0010] In the method of the present invention, more preferably, the screw has a plurality of flights.
[0011] In the method of the present invention, more preferably, the elongated dough strips are cut into dough balls by a cutting plate disposed at the inlet of the discharge cylinder and a rotating blade.
[0012] In the method of the present invention, more preferably, the outlet gap of the outlet of the discharge cylinder is annular, and the continuous dough is annular.
[0013] In the method of the present invention, it is further preferred that the annular outlet gap is formed by a discharge cylinder and a nozzle member arranged inside the discharge cylinder, and the nozzle member is caused to rotate eccentrically relative to the discharge cylinder so that the size of the outlet gap varies.
[0014] 1 is a schematic front view of a dough sheet supplying device including a dough discharging device. FIG. 2 is a schematic right side view of the dough sheet supplying device of FIG. 1. FIG. 3 is a schematic view showing the flow of dough in the dough sheet supplying device of FIG. 1. FIG. 4 is a perspective view of a dough opening device. FIG. 5 is a perspective view of a dough feeding screw. FIG. 6 is a cross-sectional view of the dough discharging device. FIG. 7 is a bottom view of the dough discharging device. FIG. 8 is a plan view showing the operation of the cutting device. FIG. 9 is a side view showing the operation of the cutting device. FIG. 10 is a plan view showing the operation of the cutting device. FIG. 11 is a side view showing the operation of the cutting device. FIG. 12 is a perspective view of a nozzle member of a modified example. FIG. 13 is a schematic view showing the flow of dough in a modified dough sheet supplying device. FIG. 14 is a perspective view of a modified dough opening device. FIG. 15 is a cross-sectional view of a modified dough discharging device. FIG. 16 is a schematic view of a second modified dough discharging device.
[0015] As shown in Figures 1 to 3, the dough sheet supplying device 1 includes a dough dividing device 2 that divides a dough lump D1 into elongated dough pieces D2, a conveying device 3 that conveys the elongated dough pieces D2, a dough discharging device 4 that receives the conveyed elongated dough pieces D2 and discharges annular dough pieces (continuous dough pieces) D4, a dough spreading device 5 that flattens the annular dough pieces D4 into flat dough sheets D5, and a discharging device 6 that discharges the dough sheets D5.
[0016] The dough dividing device 2 includes an upper hopper 21 that receives the dough lump D1, and a cutter 22 that is disposed below the upper hopper 21 and divides the lower portion of the dough lump D1 into elongated strips (like rods). The cutter 22 is, for example, a pair of rotary blade cutters (so-called star cutters) or a slide plate cutter.
[0017] The conveying device 3 includes a horizontal first conveyor 31 arranged below the dough dividing device 2, a second conveyor 32 arranged downstream of the first conveyor 31 and inclined downward toward the downstream side, and a sensor (not shown) that detects the dough being conveyed to the dough discharging device 4.
[0018] The dough discharge device 4 has a cylindrical hopper (discharge cylinder) 41 that extends vertically and has an inlet 41a and an outlet 41b (see FIG. 6), a dough feeding screw 7 located inside the hopper 41, an outlet device 8 that is located at the outlet (lower end) 41b of the hopper 41 and forms an annular outlet gap 8a (see FIG. 6) between it and the hopper 41, and a dough cutting device 9 that is located at the inlet (upper end) 41a of the hopper 41 and cuts the thin dough D2 into dough balls (small lumps of dough) D3. The dough discharge device 4 will be described in detail later.
[0019] As shown in FIG. 4 , the dough spreading device 5 includes a cutting section 51 that forms a cut in one circumferential position (downstream of the feeding device 6) of the annular dough D4, a pair of spreaders 52 and a pair of guide rollers 53 that spread the dough D4 on the feeding device 6, and a sensor 54 that detects the dough D4. The cutting section 51 includes a first plate-like member 51a that forms a cut in one position of the annular dough D4 and two second plate-like members 51b that extend diagonally downward from the first plate-like member 51a. The spreaders 52 are located below the cutting section 51 and on both sides of it. Each spreader 52 is configured to rotate multiple horizontally extending rollers along a circular orbit in a rotation direction R3. Each guide roller 53 extends horizontally and is located at an end of the spread dough and near the feeding device 6. The spreaders 52 and guide rollers 53 have known structures, so detailed description thereof will be omitted.
[0020] The delivery device 6 includes an upstream conveyor 61 located below the dough discharge device 4, a downstream conveyor 62 located downstream of the upstream conveyor 61, and a pair of gauge rollers 63 located between the upstream conveyor 61 and the downstream conveyor 62. The upstream conveyor 61 is configured to receive the spread dough D5 from above and transport it in the transport direction S.
[0021] 3, the notch 51, the pair of spreaders 52, and the pair of guide rollers 53 of the dough spreading device 5 are arranged downstream of the circular dough D4 in the conveyance direction S, and are configured to cut and spread the circular dough D4. As a result, the inner surface of the circular dough D4 becomes the upper surface of the dough D5 on the upstream conveyor 61.
[0022] Next, the dough discharge device 4 will be described in detail.
[0023] As shown in FIGS. 5 and 6, a cylindrical hopper (discharge cylinder) 41 is disposed concentrically with the rotation axis A of the screw 7, and has an upper surface 41c and a lower surface 41d.
[0024] The screw 7 includes a hollow rotating shaft 71, three helical blades 72 attached around the rotating shaft 71, and a screw drive unit 73 (see Figure 3) connected to the rotating shaft 71 and rotating the rotating shaft 71 around the rotation axis A.
[0025] The outer diameter of the inlet portion (upper portion) 71a of the rotary shaft 71 is substantially constant, and the outer diameter of the outlet portion (lower portion) 71b of the rotary shaft 71 is tapered so as to become larger toward the outlet 41b.
[0026] The outer diameter of each blade 72 is constant and slightly smaller than the inner diameter of the hopper 41 so that it rotates within the hopper 41. Each blade 72 includes an entrance section 72a located upstream and having a large lead angle (e.g., 30 degrees or more) and a feed section 72b located downstream and having a small lead angle (e.g., 20 degrees or less). The large lead angle is preferably determined so that the dough ball D3 cut by the dough cutting device 9 can smoothly reach the feed section 72b. Each blade 72 has an upper surface 72c and a lower surface 72d, which are longitudinal end surfaces. The upper surfaces 72c of the three blades 72 are located in the same horizontal plane. The entrance 41a of the hopper 41 is located at the upper surface 72c, and the upper surfaces 72c of the blades 72 are preferably located in the same plane as the upper surface 41c of the hopper 41. The lower surfaces 72d of the three blades 72 are located in the same horizontal plane. An entrance space S1 is defined between the entrance portion 72a of the blade 72 and the hopper 41, and a feed space S2 is defined between the feed portion 72b of the blade 72 and the hopper 41. The upper surface 72c of the blade 72 is exposed at the entrance 41a of the hopper 41. The circumferential pitch P of the blade 72 is a length corresponding to 120 degrees. The opening of the entrance space S1 at the upper surface 72c is, for example, 37 cm in the circumferential direction and 20 cm in the radial direction.
[0027] The screw driving unit 73 includes a housing 73a, a hollow shaft 73b rotatably supported by the housing 73a and connected to the rotary shaft 71, and a motor 73c that rotates the hollow shaft 73b.
[0028] 6 and 7, the outlet device 8 includes a cylindrical eccentric collar 81 that rotates eccentrically about the rotation axis A of the screw 7, a nozzle member 82 rotatably attached to the eccentric collar 81 via a bearing 85, a rotation prevention member 83 attached to the lower surface 82d of the nozzle member 82, and an outlet drive unit 84 (see FIG. 3) that rotates the eccentric collar 81. The outlet drive unit 84 includes a drive shaft 84a that is connected to the eccentric collar 81 and that passes through the rotation axis 71 and hollow shaft 73b of the screw 7, and a motor 84b that rotates the drive shaft 84a.
[0029] The nozzle member 82 includes an upstream-side expanded diameter portion 82a and a downstream-side nozzle portion 82b. The outer diameter of the expanded diameter portion 82a tapers toward the outlet 41b and is preferably substantially continuous with the outer diameter of the rotation shaft 71 of the screw 7. The outer diameter of the nozzle portion 82b is constant toward the outlet 41b. A pressing space S3 is defined between the expanded diameter portion 82a and the hopper 41, and a nozzle space S4 is defined between the nozzle portion 82b and the hopper 41. The lower surface 41d of the hopper 41 and the lower surface 82d of the nozzle member 82 are preferably located in the same horizontal plane. The annular outlet gap 8a is defined by the hopper 41 and the nozzle member 82. The annular outlet gap 8a includes a maximum gap C1 and a minimum gap C2. The upper surface 82c of the nozzle member 82 is slidable along the lower surface 72d of the blade 72 and is supported in the vertical direction by a bearing 85. As a result, the nozzle member 82 is configured to rotate eccentrically within the hopper 41. As the nozzle member 82 rotates once, the positions of the maximum gap C1 and the minimum gap C2 also rotate once around the rotation axis A. That is, the size of the outlet gap 8a fluctuates between the maximum gap C1 and the minimum gap C2 at any point. The maximum gap C1 is, for example, 6 to 20 mm, and the fluctuation range between the maximum gap C1 and the minimum gap C2 is, for example, 4 to 10 mm. The rotation prevention member 83 is configured to cooperate with the first plate-shaped member 51a of the dough spreading device 5 to prevent the nozzle member 82 from rotating on its own axis. The rotation speed (e.g., 100 to 400 rpm) of the nozzle member 82 (eccentric collar 81) is preferably greater than the rotation speed (e.g., 10 to 40 rpm) of the screw 7.
[0030] 8A to 10B, the dough cutting device 9, disposed at the entrance 41a of the hopper 41, includes a guide roller 91 and a cutting plate 92 disposed adjacent to the guide roller 91. The guide roller 91 is rotatable about an axis extending in the radial direction of the hopper 41 in a rotational direction R2 and is disposed obliquely with respect to the elongated dough D2 so as to guide the elongated dough D2 between adjacent blades 72 (the entrance space S1). The guide roller 91 includes a lower edge located in the same plane as the upper surfaces 72c of the blades 72. The cutting plate 92 includes a lower surface 92a located in approximately the same plane as the upper surfaces 72c of the blades 72, and the lower surface 92a is configured to cooperate with the upper surfaces 72c of the blades 72 to cut the dough ball D3 from the elongated dough D2.
[0031] Next, the operation of the dough sheet supplying device 1 will be described.
[0032] The dough lump D1 is fed into the upper hopper 21 of the dough dividing device 2, and the lower portion of the dough lump D1 is divided into elongated dough strips D2 using a cutter 22 located below the upper hopper 21. The cross section of the elongated dough strips D2 is, for example, 13 cm wide x 7 cm high, which is smaller than the pitch P of the blades 72. The elongated dough strips D2 are transported to the dough discharging device 4 by a first conveyor 31 and a second conveyor 32.
[0033] The elongated dough D2 is supplied from above to the hopper 41 by the downwardly inclined second conveyor 32. That is, the dough D2 is supplied in a direction substantially parallel to the rotation axis A of the screw 7. When a sensor (not shown) detects that the dough D2 has overflowed the hopper 41, it is preferable to reduce the speed of the first conveyor 31 and the second conveyor 32.
[0034] The elongated dough D2 is guided into the hopper 41 by a guide roller 91 (FIGS. 8A and 8B). The elongated dough D2 is directed in the circumferential direction of the hopper 41. When the leading end of the elongated dough D2 enters the space S1 of the hopper 41 (FIGS. 9A and 9B), the upper surface 72c of the blade 72 and the lower surface 92a of the cutting plate 92, which are rotating at a constant speed, cut the elongated dough D2 to form dough balls (small chunks of dough) D3 (FIGS. 10A and 10B). As a result, dough balls D3 are supplied one by one between the blades 72. In other words, the dough balls D3 are supplied in approximately the same direction as the rotation axis A of the screw 7. The size of the dough balls D3 is smaller than the pitch P, e.g., 13 x 7 x 18 cm. Since dough balls D3 smaller than the pitch P of the blades 72 are supplied between the blades 72 of the screw 7, the dough balls D3 can be reliably supplied to the space S1 between the hopper 41 and the screw 7. As a result, the density of the dough D4 discharged from the hopper 41 is stabilized, and the thickness and density of the dough sheet D5 can be made more uniform.
[0035] In the entrance space S1, the dough ball D3 is dropped by its own weight and sent to the feeding space S2. Then, the blades 72 push the dough ball D3 toward the outlet 41b in the feeding space S2 and the pressing space S3. Then, in the pressing space S3 and the nozzle space S4, the dough ball D3 is pressed to adhere to the nozzle space S3 and further bond (integrate).
[0036] The eccentric rotation of the nozzle member 82 changes the volume of the pressing space S3 and the volume of the nozzle space S4 (the size of the outlet gap 8a). Where the volume of the pressing space S3 is smaller, the integration of the dough is promoted. The area of the maximum gap C1 is more likely to eject the dough D4 than the area of the minimum gap C2. Because the area of the maximum gap C1 moves circumferentially due to the eccentric rotation, the area where the dough D4 is more likely to be ejected also moves circumferentially, thereby creating a circumferential flow of the dough and promoting uniformity in the thickness and density of the dough. Furthermore, varying the size of the outlet gap 8a creates a beating effect on the ejected dough D4, thereby promoting uniformity in the thickness and density of the dough D4. As a result, product weight variation can be reduced.
[0037] The incision section 51 forms incisions in the circular dough D4, and the dough D4 is spread by the spreader 52 and guide rollers 53 to form a dough sheet D5. The dough sheet D5 is fed onto the conveying surface of the delivery device 6. At this time, as shown in FIG. 4, the inner surface of the circularly discharged dough D4 faces upward. When the sensor 54 detects slack or tension in the dough sheet D5, it is advisable to increase or decrease the rotation speed of the screw 7 and nozzle member 82. The thickness of the dough sheet D5 is adjusted by the gauge roller 63, and the dough sheet D5 is delivered from the downstream conveyor 62.
[0038] Although the embodiments of the dough dispensing device and method according to the present invention have been described, the scope of the present invention is not limited to the above embodiments, and various modifications are possible without departing from the scope of the present invention.
[0039] The dough is not limited to bread dough, but may be pastry dough. A two-layer dough sheet may be formed without forming cuts in the circular dough D4.
[0040] Although the discharge cylinder (hopper) 41 extends vertically, it may also extend horizontally. In this case, the inlet 41a of the discharge cylinder 41 is generally provided on the side of the screw 7, and the blades 72 are exposed to the inlet 41a. The pitch P of the blades 72 is determined linearly. In the above embodiment, the screw 7 has three blades 72, but it may also have one, two or more blades.
[0041] In the above embodiment, the dough balls D3 cut from the elongated dough D2 are supplied to the hopper 41, but pre-formed dough balls D3 may also be supplied to the hopper 41. Furthermore, instead of supplying the elongated dough D2 divided by the dough dividing device 2, continuous elongated dough D2 may also be supplied.
[0042] In the above embodiment, the outer diameter of the nozzle portion 82b of the nozzle member 82 is constant toward the outlet 41b. However, it may decrease or increase toward the outlet 41b (the lower surface 82d). Furthermore, the outer peripheral surfaces of the expanded diameter portion 82a and the nozzle portion 82b may include spiral, linear, or protruding convex portions, and / or concave portions such as spiral, linear, or dimples. For example, as shown in FIG. 11 , the expanded diameter portion 82a' of the nozzle member 82 may include multiple concave portions 82e and multiple convex portions 82f extending linearly and radially and alternately arranged in the circumferential direction. In this case, the dough ball D3 that has entered the concave portions 82e (sandwiched between the convex portions 82f) is restricted from moving circumferentially relative to the expanded diameter portion 82a'. This promotes flow toward the outlet 41b and has the effect of uniforming the thickness and density of the dough ball D3 in the circumferential direction in the pressing space S3. As a result, the thickness and density of the dough D4 discharged from the outlet 41b are made uniform.
[0043] As in a modified dough sheet supplying device 101 shown in Fig. 12, the notching section 51, the pair of spreaders 52, and the pair of guide rollers 53 of the dough spreading device 5 may be arranged upstream of the annular dough D4 in the conveyance direction S to cut and spread the annular dough D4. As a result, as shown in Fig. 13, the outer surface of the annular dough D4 becomes the upper surface of the dough D5 spread on the upstream conveyor 61. In this way, by changing the location of the dough spreading device 5 depending on the properties of the dough, the upper surface of the dough D5 spread on the upstream conveyor 61 may become the inner surface of the annular dough D4 (see Fig. 4) or the outer surface (see Fig. 13).
[0044] As shown in FIG. 12 , a modified dough sheet supplying device 101 may employ a multi-roller stretcher 64 in place of the pair of gauge rollers 63 in the delivery device 6. The stretcher 64 includes a lower roller 64a disposed below the dough sheet D5, multiple spreading rollers 64c disposed circumferentially above the dough sheet D5, and a drive unit 64d that revolves the spreading rollers 64c around the circumference. Each spreading roller 64c is freely rotatable while revolving. The stretcher 64 may also include a drive unit that forcibly rotates each spreading roller 64c. The stretcher 64 is expected to stretch the dough sheet D5 more efficiently than a pair of gauge rollers 63. Therefore, the stretcher 64 can cause less damage to the dough sheet D5 than a pair of gauge rollers 63 when supplying the dough sheet D5 thinned to the desired thickness to the downstream conveyor 62.
[0045] As in the modified dough discharging device 4' shown in Figure 14, the outlet of the hopper 41' may be configured as a replaceable outer nozzle 91, and the diameter of the outlet 41b may be reduced. This forms a nozzle space S4 between the nozzle part 82b and the outer nozzle 91 of the hopper 41'. For example, by replacing the outer nozzle 91 with the nozzle member 82, the outer diameter and thickness of the annular dough D4 can be changed as desired. In other words, the dough width and thickness of the dough sheet D5 can be changed as desired.
[0046] In the above embodiment, the continuous dough D4 discharged by the dough discharging device 4 is circular. However, it may be a continuous dough D4' having an elongated cross section. For example, a second modified dough discharging device 104 shown in FIG. 15 includes a hopper (discharge cylinder) 141 extending laterally and having an inlet 141a and an outlet 141b, a dough feeding screw 107 disposed within the hopper 141, and a dough cutting device (not shown) disposed at the inlet 141a of the hopper 141 and cutting the thin dough D2 into dough balls (small chunks of dough) D3. The hopper 141 includes a cylindrical portion 141c on the inlet side and a tapered portion 141d on the outlet side. A feed space S2' is defined between the cylindrical portion 141c and the screw 107, and a pressing space S3' is defined inside the tapered portion 141d. The shaft of the screw 107 may extend inside the tapered portion 141d. In the dough discharging device 104, similar to the dough discharging device 4, the rod-shaped, elongated dough D2 is cut at the entrance 141a by the cooperation of a dough cutting device (not shown) and the screw 107 to form dough balls D3. As a result, dough balls D3 are fed one by one between the blades 172 of the screw 107. The blades 172 push the dough balls D3 toward the exit 141b in the feed space S2'. Then, in the pressing space S3', the dough balls D3 are pressed to adhere to each other and further bond (integrate). A continuous dough D4' with an elongated cross section (thin plate shape) is then discharged from the exit 141b.
[0047] 7, 107 Screw 8a Annular outlet gap 41, 41', 141 Hopper (discharge cylinder) 41a, 141a Inlet 41b, 141b Outlet 72, 172 Blade 72c Upper surface (longitudinal end surface) 82 Nozzle member A Rotation axis D3 Dough ball D4 Annular dough (continuous dough) D4' Continuous dough having an elongated cross section P Pitch
Claims
1. A method for discharging a continuous dough (D4) using a screw (7) arranged in a discharge cylinder (41, 41', 141), comprising: feeding a dough ball (D3) smaller than the pitch (P) of the blades (72) of the screw (7) exposed at the inlet (41a) of the discharge cylinder (41, 41', 141) from the inlet (41a) of the discharge cylinder (41) to between the blades (72), and discharging the continuous dough (D4) from the outlet (41b) of the discharge cylinder (41).
2. The method according to claim 1, wherein the inlet (41a) of the discharge cylinder (41, 41', 141) is located at the longitudinal end face (72c) of the flight (72) of the screw (7) and feeds the dough ball (D3) in a direction substantially the same as the direction of the rotation axis (A) of the screw (7).
3. The method according to claim 2, wherein the discharge cylinder (41, 41') extends in a vertical direction.
4. The method according to claim 3, wherein the number of teeth of the blades (72) of the screw (7) is two or more.
5. The method according to claim 4, wherein the elongated dough (D2) is cut by a cutting plate (92) arranged at the inlet (41a) of the discharge cylinder (41, 41', 141) and a rotating blade (72) to form the dough balls (D3).
6. The method according to claim 5, wherein the outlet gap (8a) of the outlet (41b) of the discharge cylinder (41, 41') is annular and the continuous fabric (D4) is annular.
7. The method according to claim 6, wherein the annular outlet gap (8a) is defined by the discharge cylinder (41, 41') and a nozzle member (82) arranged inside the discharge cylinder (41, 41'), and the nozzle member (82) is rotated eccentrically relative to the discharge cylinder (4, 41') so that the size of the outlet gap (8a) varies.