Automated Crown-Shaped Tart Shell Production via Rotary Extrusion and Matrix Lining
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Solution Overview
Problem
Current methods lack an automated process for producing crown-shaped tart shells on an assembly line, as existing production lines are not equipped to handle the unique shape of crown-shaped tart pans or cavities.
Innovation Solution
A method involving a conveyor system with an extrusion module to fill a rotary cell support cylinder with dough, a deposition module to eject and place separate dough rolls into crown-shaped recesses, and a lining module using a matrix to shape the dough into a complete shell, ensuring the dough covers the recess without sticking, facilitated by air valves and heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional tart pan shaping methods are used, then production is simple, but automation is not achievable for crown-shaped shells
Solution Approach 1:
The production process is divided into distinct modular stages: extrusion module for dough preparation, deposition module for placing dough rolls, and lining module for shaping. Each module performs a specific function, enabling automated production while maintaining manageable system complexity through functional segmentation.
Solution Approach 2:
A matrix is introduced as an intermediary tool in the lining module. The matrix receives crushed dough from the deposition module and transfers it to the tart pan shell, enabling automated shaping without direct mechanical contact that would complicate the equipment design.
2Manufacturing precision
If multiple separate dough rolls are deposited in each recess, then complete shell coverage is achieved, but deposition complexity increases
Solution Approach 1:
Instead of attempting to deposit a single complex-shaped dough piece, the solution segments the dough into multiple simpler rolls that are deposited separately. The deposition module places several separate dough rolls into each recess, which are then consolidated by the matrix during the lining step, achieving complete coverage through simple repeated actions.
Solution Approach 2:
Multiple dough rolls are deposited in advance into each recess before the lining step. This preliminary placement of multiple dough portions ensures that when the matrix is applied, there is sufficient dough material distributed throughout the recess to guarantee complete shell coverage without requiring complex real-time adjustment mechanisms.
3Manufacturing precision
If dough is deposited in crown-shaped recesses, then correct shell shape is achieved, but dough detachment from matrix becomes difficult
Solution Approach 1:
The physical state of the matrix is changed by heating it to a temperature above the melting point of chocolate or fat-based coatings. This parameter change prevents the dough from sticking to the matrix during the lining process, enabling easy detachment after shaping while maintaining the precision of the crown-shaped form.
Solution Approach 2:
A coating layer of chocolate or fat-based material is applied to the matrix as an intermediary barrier between the matrix surface and the dough. This coating prevents direct adhesion between dough and matrix, facilitating easy detachment after the lining step while preserving the accurate crown-shaped geometry imprinted by the matrix.
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
Enables the fully automated production of crown-shaped tart shells on an assembly line, ensuring even coverage and easy detachment from the matrix, enhancing efficiency and consistency in manufacturing.
Implementation Method 1
an ejector equipped with air valves which release air between the ejector and the dough roll in order to prevent the dough from sticking to the ejector
Implementation Method 2
the lining step includes the heating of the matrix in order to prevent the dough covering the shell of the recess from sticking to the matrix
Implementation Method 3
the lining step further includes the injection of air between the matrix and the dough covering the shell of the recess in order to facilitate the detachment from the matrix
Data Source
AI summary
A method and an installation for the automated preparation of crown-shaped tart shells, comprising the conveying on a conveyor of crown-shaped recesses, the recesses being successively subjected to an extrusion step, a deposition step and a lining step, in which the extrusion step includes the filling of at least one cell of a rotary cell support cylinder with dough, the deposition step includes the ejection of the dough rolls out of the rotary cell support cylinder and the deposition on a shell of each recess of at least two separate dough rolls, and the lining step includes the crushing of the dough rolls deposited in each recess by means of a matrix complementary in shape to the recess in order to form a dough covering at least the shell of the recess.