Crispy Pastry Products with Split Extremities

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Solution Overview

Problem

Croissants and similar laminated dough products often have thinner, drier, and less crispy extremities due to compression during the shaping process, which fails to meet consumer expectations for loose layering and mouthfeel.

Innovation Solution

A new method and cutting shape for croissants and similar dough products involve creating incisions in the corners or sides of the dough sheet, specifically in the angles formed between the base and the sides, to create split extremities that remain visible before and after baking, allowing for improved layering and crispiness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If the dough is rolled and folded into traditional shapes with extremities, then the product achieves its characteristic form, but the extremities become compressed, thinner, drier, and less crispy

Engineering Contradiction:

Improvecroissant shape with extremitiesVSAvoidmouthfeel quality at extremities

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The dough piece is segmented by making incisions at the extremities, dividing the continuous dough structure into sections. This segmentation prevents the extremities from becoming uniformly compressed and thin, allowing the incised portions to maintain better layering and moisture during rolling and baking, thereby improving mouthfeel quality.

Inventive Principle:

Principle #1Segmentation

2Productivity

If incisions are made in the base of the triangular dough to allow stretching and reduction, then the dough can be further processed, but the incisions do not create split extremities and do not improve loose layering at the tips

Engineering Contradiction:

Improvedough processing efficiencyVSAvoidlayering structure at extremities

Core Design Contradiction:

ProductivityVSShape

Solution Approach 1:

Instead of making incisions at the base of the triangle, the invention applies incisions specifically at the extremities (tips) of the dough piece. This local application of the incision technique creates split extremities with visible loose layering at the tips, while the base remains intact for proper rolling and shaping. The local quality change addresses the specific problem at the extremities without compromising overall processing efficiency.

Inventive Principle:

Principle #3Local quality

3Stability of the object's composition

If the extremities are kept intact during shaping, then the structure remains uniform, but the extremities become proportionally thinner and drier after baking

Engineering Contradiction:

Improveuniform dough structureVSAvoidcrispiness and moisture at extremities

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The incisions are made in advance during the shaping stage, before rolling and baking. This preliminary action creates predetermined split extremities that will maintain their structure and moisture content throughout the subsequent processing and baking stages. The pre-made incisions ensure that the extremities develop proper loose layering and crispiness, preventing them from becoming uniformly thin and dry.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12329167B2Crispy pastry products

Publication Date: 2025.06.17 VAMIX

AI summary

The present invention relates to a process for producing a more crispy food product based on multi-layered laminated dough such as croissants and the like, to the tools for making such products and the food products prepared according to this process.