Biscuit Debossing with Compliant and Metal Rollers

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Solution Overview

Problem

Existing biscuit manufacturing processes face challenges in debossing both the top and bottom surfaces without damaging the biscuit, particularly in high-volume production, where insufficient pressure results in inadequate debossing, and excessive pressure can damage integral features or cause defects.

Innovation Solution

A method and system for debossing both the top and bottom surfaces of biscuits using a rotary mold with a compliant roller to protect the top surface and a metal or polymeric roller to deboss the bottom surface, allowing for precise control of pressure and maintaining biscuit integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If excessive pressure is applied to deboss both top and bottom surfaces, then debossing effectiveness is improved, but biscuit structural integrity deteriorates

Engineering Contradiction:

Improvedebossing effectivenessVSAvoidbiscuit structural integrity

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The debossing operation is segmented into two separate stages: top surface debossing during rotary molding, and bottom surface debossing after baking. This segmentation allows each debossing operation to use optimized pressure levels appropriate for the biscuit's state at that stage, preventing structural damage while achieving effective debossing on both surfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The top surface debossing is performed as a preliminary action during the rotary molding stage, before the biscuit is baked. This allows the debossing to be formed in the dough state when it is more pliable and requires less pressure, preserving the biscuit's structural integrity for subsequent processing.

Inventive Principle:

Principle #10Preliminary action

2Strength

If insufficient pressure is applied to deboss both top and bottom surfaces, then biscuit structural integrity is maintained, but debossing effectiveness deteriorates

Engineering Contradiction:

Improvebiscuit structural integrityVSAvoiddebossing effectiveness

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pressure parameter is changed between the two debossing stages. During rotary molding, lower pressure is applied to the top surface. After baking, when the biscuit is more rigid, a different pressure level is applied to the bottom surface. This parameter change optimizes debossing effectiveness at each stage while maintaining overall structural integrity.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If a single roller is used to deboss both surfaces, then device complexity is reduced, but manufacturing precision deteriorates

Engineering Contradiction:

Improveroller system simplicityVSAvoiddebossing quality

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The debossing function is segmented between two different rollers: a first roller for top surface debossing during molding, and a second roller for bottom surface debossing after baking. Each roller is optimized for its specific function and timing, achieving high manufacturing precision without requiring an overly complex single-device solution.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first roller performs preliminary debossing during the molding stage, preparing the top surface. The second roller completes the debossing process on the bottom surface after baking. This sequential action with dedicated rollers ensures high precision for each surface while maintaining reasonable device complexity.

Inventive Principle:

Principle #10Preliminary action

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 approach enables effective debossing on both sides of biscuits, enhancing aesthetic appeal and consumer experience by revealing messages or images, while maintaining the structural integrity of the biscuit, even in high-volume production.

Implementation Method 1

the first roller being compliant and configured to contact and protect the top surface of the biscuit

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the second roller being opposed from the first roller and configured to deboss indicia into the bottom surface of the biscuit

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS11234443B2Biscuit with debossing on top and bottom

Publication Date: 2022.02.01 INTERCONTINENTAL GREAT BRANDS LLC

AI summary

A foodstuff, and a method and system of making the same, comprises a biscuit having a generally planar top surface and a generally planar bottom surface. The biscuit includes first indicia on the top surface that has a plurality of projections that extend from the top surface. The biscuit also includes second indicia on the bottom surface that has an imprint recessed from the bottom surface.