Blunt-Tool Dough Scoring for Consistent Frozen Bread Expansion
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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 a blunt deformation tool 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 blades and wheels to deform the dough without actual cutting or slicing, establishing internal weak zones that open upon cooking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual scoring is performed after proofing to control expansion and create traditional look, then the dough can fully expand during proofing in intact form, but the scoring 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 incisions in the dough sheet while it is still in its initial state, allowing the scored dough to then undergo proofing and baking. This reverses the traditional sequence and enables automated scoring at high speed before the dough expands, solving both the precision and productivity contradictions.
2Productivity
If frozen un-proofed dough is scored before purchase, then bakery operators save time on scoring, but the changes during proofing make consistent pre-proof scoring difficult
Solution Approach 1:
The invention performs the scoring action preliminarily, before proofing and freezing. By scoring the dough while it is still in its initial un-proofed state at the manufacturing facility, the system ensures consistent scoring depth and pattern. The scored dough is then frozen and transported to bakeries, where it maintains the pre-established score lines through proofing and baking, achieving both operational efficiency and scoring consistency.
Solution Approach 2:
The patent utilizes parameter changes by controlling the physical state of the dough during scoring. The dough is kept in a cold, un-proofed state during the scoring operation to maintain structural integrity and consistent scoring. After scoring, the dough undergoes parameter changes during proofing (temperature increase, gas production) and freezing, but the score lines remain consistent because they were established when the dough was in its stable initial state.
3Productivity
If automated scoring is attempted on un-proofed dough, then productivity increases, but the dough changes during proofing affect scoring consistency
Solution Approach 1:
The system performs scoring as a preliminary action on un-proofed dough using automated devices that can operate at high speeds. The scoring is completed before the dough undergoes proofing changes, ensuring that the automated scoring process operates on dough with consistent physical properties, thereby maintaining both high productivity and reliable, consistent results.
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
The solution results in scored dough pieces that maintain integrity during proofing and freezing, ensuring consistent expansion and visual contrast between crust and interior upon baking, enhancing product uniformity and visual appeal.
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
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
after cutting and deformation scoring, the dough is frozen
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.