Bread Dough Conditioning System for Uniform Texture
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Solution Overview
Problem
Conventional bread dough mixing processes, whether batch or continuous, result in uneven air pocket formation leading to either firm or soft bread textures, requiring extensive equipment and processing steps to achieve desired uniformity.
Innovation Solution
A system and process that uses a conventional batch mix to produce a stiff dough by continuously conditioning the dough to reduce air pocket size, extruding it into individual packets, and depositing them directly into pans without additional processing, utilizing a dough developer unit, transfer pumps, and a cutter unit to maintain uniform density and texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional batch mix is used to produce stiff dough, then the bread loaf has a firm texture that consumers desire, but the air pockets become uneven in size during aging requiring extensive conditioning equipment and processing steps
Solution Approach 1:
The patent applies preliminary action by immediately conditioning the dough right after mixing, before the air pockets have a chance to become uneven during aging. The system conditions the dough continuously as it is formed, preventing the development of uneven air pockets rather than correcting them later. This eliminates the need for extensive downstream conditioning equipment and processing steps.
Solution Approach 2:
The patent implements continuity of useful action by maintaining continuous conditioning action throughout the entire dough formation process. Instead of discrete batch conditioning steps, the system continuously conditions the dough as it is extruded and formed, ensuring uniform air pocket distribution is maintained throughout the entire production run without interruption.
2Manufacturing precision
If a dough developer unit is used to reduce air pocket size and uniform them, then the dough becomes conditioned, but the resulting bread loaf has a soft, spongy texture rather than firm
Solution Approach 1:
The patent applies parameter changes by carefully controlling the degree and type of conditioning applied to the dough. Instead of heavy conditioning that would create soft, spongy texture, the system uses mild conditioning that uniformly distributes air pockets while preserving the firm texture characteristics. The conditioning parameters are adjusted to achieve uniformity without excessive softening.
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 eliminates the need for extensive downstream processing and equipment, ensuring consistent, uniform texture and density across all bread loaves, achieving a firm bread texture similar to conventional batch mixes while simplifying the production process.
Implementation Method 1
a dough developer unit above the predetermined linear path reduces the size of air pockets within unconditioned dough, so that dough exiting the developer unit is conditioned
Implementation Method 2
a first transfer pump continuously feeds the unconditioned dough from a holding hopper to the dough developer unit
Implementation Method 3
an extrusion unit below the dough developer unit and above the predetermined linear path continuously extrudes the conditioned dough into a dough stream
Implementation Method 4
a cutter unit above the predetermined linear path continuously cuts the dough stream into individual packets
Implementation Method 5
upon cutting the dough stream, the single packet drops directly into a cavity of a pan positioned directly beneath the extrusion port
Data Source
AI summary
A system to make a bread loaf includes means for moving continuously pans along a predetermined path, each pan including at least one cavity sized and configured for making a bread loaf. Means conditioning continuously a batch of unconditioned dough reduces the size of air pockets therein to form a conditioned dough. Means continuously extrude the batch of conditioned dough at a controlled volumetric feed rate and at a controlled pressure to provide a constant stream of conditioned dough that is continuously cut into individual packets. The entire batch is converted into individual packets of conditioned dough corresponding to a predetermined number of bread loaves to be produced from the batch, with all the packets deposited individually in cavities of the pans within 10-20 minutes after mixing ingredients that make the batch.