Baking Pan Limiting Device for Filling Position Control
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Solution Overview
Problem
Current methods for producing snack products like sandwich rolls with fillings are not economically attractive and lack process simplicity, particularly in industrial settings where efficient manufacturing of pre-baked or fully baked tub-shaped rolls with U-shaped cross-sectional profiles is challenging.
Innovation Solution
A method using a two-part baking pan with a limiting device inside the upper half to prevent filling material from being pushed above a desired level during fermentation, allowing the dough to rise and encase the filling while maintaining a regular shape, and enabling efficient production of snack products with a longitudinal groove for easy topping application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If filling material is placed on dough blank before fermentation, then the snack product has a filling, but the filling material is pushed above the desired level during fermentation
Solution Approach 1:
A limiting device is positioned in the upper half of the baking pan before fermentation to prevent the filling material from being pushed above the desired level. This preliminary constraint counteracts the upward force generated during dough fermentation, maintaining filling position stability throughout the process.
Solution Approach 2:
The limiting device acts as an intermediary element between the filling material and the rising dough. It provides a physical barrier that allows the dough to expand while preventing the filling from moving excessively, thus mediating the interaction between these two components during fermentation.
2Manufacturing precision
If a complex manufacturing process is used for filled rolls, then the product quality can be maintained, but the production is not economically attractive
Solution Approach 1:
The limiting device is integrated directly into the upper half of the baking pan, merging the shaping function and the filling containment function into a single component. This eliminates the need for separate operations to control filling position, simplifying the manufacturing process while maintaining product quality consistency.
Solution Approach 2:
The baking pan with the integrated limiting device performs multiple functions automatically during the fermentation and baking process. The limiting device self-regulates the filling position without requiring additional manual intervention or complex control systems, making the process economically attractive.
3Strength
If the dough is allowed to rise freely, then the dough develops good texture, but the filling material is displaced and the shape becomes irregular
Solution Approach 1:
The limiting device is strategically positioned only in areas where filling displacement is a problem, while leaving other areas of the baking pan open to allow free dough expansion. This localized constraint maintains dough texture quality in the constrained areas while preserving shape regularity overall.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the manufacturing process, ensures cohesive connections between dough and filling, and produces snack products with a consistent shape and structure, enhancing production capacity and ease of topping application, resulting in an economically viable and efficient industrial production process.
Implementation Method 1
After a dough blank has been placed in the lower half of the baking tray, the baking tray is closed and placed in a fermentation cabinet for a fermentation process
Data Source
Figure 1A~4B
Figure 5A~5B
AI summary
The invention relates to a method for producing a snack product (5, 5', 5"), wherein a fermentable dough blank is placed in a lower baking tray half of a baking pan (1) and covered with a solid filling (7, 7"), whereupon the baking pan (1) is closed by means of an upper baking tray half and a dough fermentation is subsequently carried out, wherein a limiting device (4) arranged in the upper baking tray half holds the filling substantially in its original position or near its original position, while the dough expands in the baking pan and partially encases the filling;whereupon the baking mold (1) is fed into a baking device and the expanded dough is pre-baked until a predetermined consistency is reached or fully baked until ready for consumption and optionally further processed, resulting in a snack product in which the filling is embedded in the dough and at least partially bonded to the dough by form and/or material adhesion, and wherein the snack product has an open longitudinal groove (6) on its upper surface. The invention further relates to a device for carrying out the method and to the snack product produced by this method.