Crustless Sandwich Bread Baking Process
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Solution Overview
Problem
Existing processes for producing crustless sandwich bread result in significant production waste due to the removal of the crust, which constitutes about 48% of the bread's weight, and previous alternatives like microwave or steam cooking fail to maintain the desired texture and organoleptic properties.
Innovation Solution
A process involving oven-baking at a temperature of 145-175°C for 50-70 minutes using a conventional oven with heat transmission by conduction, radiation, and convection, which reduces the crust thickness and density, thereby reducing waste to about 40% while maintaining the product's quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If baking is performed in a conventional oven at high temperature (200°C-260°C) for short time (30-38 minutes), then productivity is improved, but the crust becomes thick and dense resulting in significant waste (48% of bread weight)
Solution Approach 1:
The patent applies parameter changes by modifying the baking temperature from the conventional high range (200°C-260°C) to a lower range (145°C-175°C) and extending the baking time accordingly (50-70 minutes). This parameter transformation allows the crust to become thinner and less dense, reducing crust waste from 48% to approximately 40% of bread weight, while still achieving complete baking of the sandwich bread.
2Loss of substance
If baking temperature is reduced to 145-175°C for 50-70 minutes, then crust waste is reduced, but baking time is extended
Solution Approach 1:
The patent resolves this contradiction by systematically changing the baking parameters: lowering the temperature to 145°C-175°C and proportionally extending the time to 50-70 minutes. This parameter adjustment creates a new operating point that achieves thinner, less dense crust (reducing waste to ~40%) while maintaining complete baking, representing an optimized balance between waste reduction and time consumption.
3Loss of time
If microwave or steam cooking is used instead of conventional oven, then baking time is reduced, but organoleptic properties and texture are degraded
Solution Approach 1:
The patent maintains reliability of organoleptic properties by using conventional oven heating methods (thermal conduction, convection, and radiation) rather than microwave or steam cooking. The modified temperature-time parameters (145°C-175°C for 50-70 minutes) preserve the traditional baking mechanism that creates desirable crust and crumb structure, ensuring consumer acceptance remains high while still reducing crust waste.
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 process achieves a significant reduction in production waste while preserving the organoleptic and textural properties of the bread, as confirmed by consumer acceptance tests and chemical/physical analyses, with improved environmental and economic benefits.
Implementation Method 1
conventional oven in which baking is performed by means of transmission of heat to the food by means of conduction
Implementation Method 2
conventional oven in which baking is performed by means of transmission of heat to the food by means of conduction and/or thermal radiation and/or convection
Implementation Method 3
conventional oven in which baking is performed by means of transmission of heat to the food by means of conduction and/or thermal radiation and/or convection
Data Source
AI summary
A process for producing crustless sandwich bread, which comprises the steps of: depositing semifinished products of a sandwich bread dough in moulds, oven-baking these semifinished products, obtaining corresponding loaves of sandwich bread, cooling the loaves of sandwich bread and removing the crust from all the sides thereof, the oven-baking step being performed in an oven at a temperature of 145-175°C for a time period comprised between 50 and 70 minutes.