Dough Divider Block Shearing for Uniform Form Production
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Solution Overview
Problem
Existing dough dividing systems fail to consistently produce uniform dough forms of specific size and shape, leading to inconsistent bread quality and increased waste and production costs.
Innovation Solution
A dough dividing system comprising a hopper and a divider assembly with a divider block and actuators that move the block between positions to separate dough into uniform forms, using pressure and lubrication to ensure consistent size and shape, and optionally incorporating sensors and modular inserts for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional dough dividing systems are used, then dough forms can be separated from the constituent mass, but the dough forms lack consistent size and shape
Solution Approach 1:
The dough division process is segmented into distinct phases: filling phase (hopper to divider block), shearing phase (separation from main mass), and transfer phase (to receptacle). The divider block itself is segmented with multiple cavities that can be independently filled and emptied, allowing precise control over each dough form's size and shape while maintaining system simplicity through modular operation.
Solution Approach 2:
The divider block is designed with movable cavities that dynamically transition between filling and emptying positions. The system uses dynamic pressurization during filling and controlled depressurization during emptying, allowing the dough to be precisely shaped and transferred while maintaining consistency. This dynamic approach enables uniform dough forms without requiring complex fixed molds for each cavity.
2Productivity
If dough is separated into individual forms, then baking of individual loaves can proceed, but waste increases and production costs rise
Solution Approach 1:
The system creates precise copies of the desired dough form geometry using the divider block cavities as templates. Each cavity is designed to produce an exact replica of the target dough shape and size, minimizing variability and reducing waste from rejected non-conforming dough forms. This copying approach ensures high productivity with consistent quality across all dough forms.
Solution Approach 2:
The system controls dough form parameters (size, shape, density) by adjusting filling pressure, filling time, and cavity geometry. By precisely controlling these parameters, the system maximizes the usable portion of each dough batch, minimizing waste while maintaining high production rates for individual loaf baking.
3Reliability
If dough forms are separated from the constituent mass, then individual bread loaves can be baked, but the dough forms lack consistent composition and dimensions
Solution Approach 1:
The system incorporates sensors that monitor dough properties during filling and provide feedback to the control system. This feedback loop adjusts filling pressure and duration in real-time to maintain consistent dough form composition and dimensions, ensuring reliable bread quality without requiring overly complex manual intervention or post-processing controls.
Solution Approach 2:
The divider block cavities are pre-configured with specific geometries and volumes that define the target dough form characteristics. The filling process is preliminarily controlled by pre-setting pressure and time parameters, ensuring that each dough form achieves consistent composition and dimensions before transfer to the baking stage, thereby guaranteeing reliable bread quality.
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 system enables the production of consistently sized and shaped dough forms, reducing waste and production costs by ensuring uniformity and minimizing stress on the dough, thus improving bread quality and efficiency.
Implementation Method 1
a first actuator operable to move the divider block between a first position in which the divider block cavity is positioned under the hopper outlet, and a second position in which the divider block cavity is positioned over a receptacle inlet
Implementation Method 2
pressurizing the divider block cavity to force the dough in the divider block cavity into a receptacle
Implementation Method 3
a lubrication system including at least one port positioned above the divider block cavity when the divider block is in the second position for directing a lubricant into the divider block cavity as the dough is pushed out of the divider block cavity
Data Source
AI summary
A dough dividing system is disclosed including a hopper for receiving dough and a divider assembly. The hopper includes a hopper inlet and a hopper outlet. The divider assembly includes a divider block having a divider block cavity, and a first actuator operable to move the divider block between a first position in which the divider block cavity is positioned under the hopper outlet, and a second position in the divider block cavity is positioned over a receptacle inlet. Dough enters the divider block cavity when the divider block cavity is in the first position and the dough is sheared as the divider block moves to the second position.