Cookie Dough Shape Retention via Fat-Sugar Ratio
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Solution Overview
Problem
Current cookie dough compositions result in flattened cookie pieces during baking, leading to undesirable 'doubles' when coated with chocolate, as the flattened surfaces merge during the coating process.
Innovation Solution
A method involving a dough with a specific moisture content and a high melting point fat to sugar ratio of 1:1, shaped into a webbed sheet and baked to maintain a rounded form, which is then separated into individual pieces to prevent flattening and allow for proper coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cookie dough compositions are used, then the dough is easy to manufacture, but the cookie pieces flatten during baking causing doubles during coating
Solution Approach 1:
The patent applies parameter changes by modifying the dough composition parameters, specifically using a fat-to-sugar ratio of approximately 1:1 by weight and controlling moisture content at 8-15% w/w before baking. These parameter adjustments prevent excessive spreading during baking while maintaining manufacturability.
Solution Approach 2:
The patent uses composite materials by combining specific types of fats (including hydrogenated vegetable fats, palm oil, or cocoa butter) with sugars and starches in controlled proportions. This composite dough formulation creates a structure that maintains shape during baking while remaining workable during manufacturing.
2Productivity
If the cookie pieces are flattened during baking, then the baking process is simple, but the pieces merge during chocolate coating creating doubles
Solution Approach 1:
The patent applies preliminary action by pre-shaping the dough into rounded cookie pieces before baking using molds or shaping equipment. This preliminary shaping ensures the pieces maintain their rounded form through baking and into the coating process, preventing merges during chocolate coating operations.
Solution Approach 2:
The patent changes the thermal and rheological parameters of the dough by controlling fat content and type, which affects how the dough behaves during baking. The specific fat-to-sugar ratio and moisture content create a dough that sets properly during baking to maintain shape, enabling efficient coating without doubles.
3Manufacturing precision
If the dough moisture content is high, then the dough is easier to shape, but the cookie pieces spread more during baking
Solution Approach 1:
The patent applies parameter changes by precisely controlling the moisture content parameter at 8-15% w/w before baking. This optimized moisture level provides sufficient workability for shaping while preventing excessive spread during baking, achieving both shape control and ease of operation.
Solution Approach 2:
The patent applies local quality by having different moisture distributions or characteristics in different parts of the dough formulation. The controlled moisture content works in conjunction with specific fat and sugar components to create localized properties that facilitate shaping in some aspects while preventing spread in others during baking.
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 method ensures that cookie pieces remain rounded after baking, minimizing the occurrence of 'doubles' during chocolate coating and enabling the production of uniformly coated confectionery products like M&M'S Brand Milk Chocolate Candies.
Implementation Method 1
a high melting point fat to sugar ratio of about 1 : 1 to form a rounded cookie piece that minimizes flattening during baking
Implementation Method 2
baking said webbed sheet to form a baked webbed sheet comprising shaped baked good regions corresponding to said shaped dough regions
Data Source
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AI summary
Systems, methods, and formulas are disclosed for producing a shaped baked good with a rounded shape. In one embodiment, the formula may include a high melting point fat and a granular sugar at a weight ratio of about 1:1 to form a rounded cookie piece that minimizes flattening during baking. The cookie composition may be formed by passing a cookie dough between opposing rollers or press plates to form a web. The web may then be baked, rehydrated, separated, and deflashed to form individual rounded cookie pieces.