Crustless Sandwich Bread Shaping With Rotary Crust Removal
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Solution Overview
Problem
Conventional methods for producing crustless sandwich bread result in uniform shapes due to the constraints of mold shapes and trimming tools, limiting the ability to create a variety of different shapes without significant changes to the production line or tools.
Innovation Solution
The method employs rotary cutting means to remove the crust, allowing for the creation of diverse shapes by moving the sandwich bread tangentially against high-speed rotating knives, with optional freezing to maintain a firm crust, and subsequent slicing and wrapping to achieve complex shapes like straight, curved, or polygonal forms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional mold-based shaping methods are used, then the production process is simple and straightforward, but the shape variety of the sandwich bread is limited and uniform
Solution Approach 1:
The bread is frozen before the crust removal operation to firm up the crust, making it easier to remove and shape without requiring complex real-time adjustments during the shaping process
Solution Approach 2:
The patent uses a rotary drum with multiple knives that can be adjusted to create different shapes. The system is dynamic and adaptable, allowing the same machine to produce various shapes by changing the knife configuration rather than requiring multiple fixed molds
2Adaptability or versatility
If the mold shape is changed to produce different bread shapes, then shape variety is improved, but the production line requires extensive modifications
Solution Approach 1:
The patent extracts the shaping operation from the mold-based process and separates it into a subsequent crust removal and shaping step. This allows the bread to be baked in a standard mold and then shaped later using a rotary drum with knives, eliminating the need to change molds for different shapes
Solution Approach 2:
The rotary drum shaping device serves multiple functions: it removes the crust and simultaneously creates various shapes by adjusting the knife positions. One device can produce multiple shapes, making the production line versatile without requiring extensive modifications
3Productivity
If high-speed rotary cutting means are used to remove crust, then shaping efficiency and variety are improved, but energy consumption increases
Solution Approach 1:
Freezing the bread before crust removal firms up the crust, making it easier to remove with the rotary knives. This preliminary action reduces the energy required for cutting by making the material more manageable
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 production of a wide range of attractive and complex shapes for sandwich bread, independent of initial mold shapes, through efficient crust removal and shaping using rotary cutting tools, enhancing product variability without requiring extensive changes to the production line.
Implementation Method 1
The rotary cutting means 20 are in the form of knives 26 mounted on a rotary drum 24 rotating at high speed
Implementation Method 2
Before passing onto the means of transport, and at least during the crust removal step, the sandwich bread is frozen at a surface temperature below about -20 °C so as to maintain a firm crust
Implementation Method 3
the pieces of the latter torn from the sandwich bread are removed according to the arrow A, for example by suction means 30
Data Source
Figure 1
AI summary
The present invention relates to a method for manufacturing crustless sandwich bread, comprising the steps consisting in: - producing a sandwich bread dough piece (5) by kneading, shaping, then fermentation in a mould, - cooking the dough piece in the mould, then allowing the cooked sandwich bread (5) to cool, - removing the crust from the sandwich bread (5) at least on its side faces, and characterized in that the step of removing the crust is carried out by scraping of the peripheral surface (6) of the sandwich loaf 5 using rotary cutting means (20).