Blunt Deformation Scoring for Frozen Dough Pieces
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Solution Overview
Problem
Automated scoring of un-proofed bread dough is challenging due to the changes it undergoes during proofing, making consistent manual scoring time-consuming and difficult for commercial operations.
Innovation Solution
Employing blunt deformation tools to pre-stress un-proofed dough by creating weak zones along score lines through deformation, either before, after, or simultaneously with cutting, using a combination of rotating blades and wheels to establish scores that remain intact during proofing and freezing, but open during baking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual scoring is performed after proofing, then the dough can fully expand and traditional look is achieved, but the process is time consuming and operationally challenging
Solution Approach 1:
The patent applies preliminary action by scoring the dough before proofing instead of after. The scoring device creates deformations in the un-proofed dough, which then guide expansion during the proofing and baking processes. This reverses the traditional sequence and enables automated high-speed scoring while maintaining consistent results through the proofing expansion.
Solution Approach 2:
The patent changes the physical state parameter of the dough from un-proofed to proofed, and utilizes this transformation to achieve the scoring effect. By scoring un-proofed dough and allowing it to proof, the dough's expansion during proofing opens up the score lines, creating the desired visual effect automatically without manual intervention after proofing.
2Extent of automation
If pre-proof scoring is attempted, then automation is possible, but the dough changes during proofing make consistent scoring difficult
Solution Approach 1:
The invention performs the scoring action preliminarily on un-proofed dough before the dough undergoes significant changes during proofing. This timing ensures that the score lines are established when the dough is still relatively stable and predictable, enabling consistent automated scoring that maintains precision throughout the proofing process.
Solution Approach 2:
The patent strategically times the scoring operation to occur when the dough is in un-proofed state, before major parameter changes occur during proofing. This parameter state selection ensures that the scoring device can consistently create uniform deformations that will reliably open during subsequent proofing and baking.
3Loss of time
If frozen un-proofed dough includes pre-made scores, then bakery operators benefit from time savings, but maintaining score integrity through freezing and proofing is challenging
Solution Approach 1:
The scoring is performed preliminarily on un-proofed dough before freezing, creating deformations that are resilient to the freezing process. These pre-established score lines remain intact through freezing and subsequent proofing, reliably opening during baking to provide the desired effect without compromising score integrity.
Solution Approach 2:
The patent scores the dough in its un-proofed state before freezing, at a parameter state where the dough structure can accommodate the score lines. This timing ensures that the scores survive the freezing-thawing-proofing cycle and reliably open during baking, maintaining score integrity throughout the process while saving time for bakery operators.
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
Produces uniformly scored dough pieces that maintain integrity during proofing and freezing, resulting in consistent expansion and visual contrast upon baking, enhancing the aesthetic and functional attributes of the final bread product.
Implementation Method 1
a blunt deformation tool is employed to deform the dough, either before, after or simultaneously with a dough cutting operation, to pre-stress the dough in scoring regions to establish weak zones which open up along score lines upon cooking the dough
Implementation Method 2
After the deformation tool is no longer pressing on the dough, the dough actually rebounds or re-expands in the scoring region(s) while weak zones are established
Implementation Method 3
a series of rotating, circular blunt-edge dough cutters creates a series of strips entirely by pressing the upper skin toward the lower skin to pinch the upper and lower skins together while cutting
Data Source
AI summary
Frozen un-proofed dough pieces are produced by cutting a dough sheet into strips and producing a score through an upper skin of each strip with at least one blunt deformation tool prior to freezing. The un-proofed dough pieces are formed by mass production, with an un-proofed dough sheet being cut to form dough strips which are then cut into the un-proofed dough pieces, with the score for each un-proofed dough piece being formed by pressing the upper skin of the dough down into the body of the dough, thereby deforming and pre-stressing the dough to create weak zones, either before, during or after the individual un-proofed dough pieces are actually created, but before freezing. Upon heating, openings are established in the upper skin along score lines.