Continuous Dough Extrusion with Pressurized Liquid Injection
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Solution Overview
Problem
Existing methods for producing toast bread dough result in an uneven pore structure in the final product due to the discontinuous batch process and lack of control over gas distribution, leading to suboptimal texture and machinability.
Innovation Solution
A continuous extrusion method where powdered dough base material is pre-wetted with a preparation liquid under pressure before entering the extruder, allowing for targeted oxygen injection and pressure control to form a pre-dough, which is then kneaded and degassed to achieve a specific gluten structure and pore structure, enabling precise control over the dough's plastic properties and portioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a discontinuous batch process is used for dough production, then the process is simple to operate, but the pore structure in the final product becomes uneven
Solution Approach 1:
The patent implements a continuous extrusion process where dough base material is continuously fed through the extruder, mixed with liquid under pressure, kneaded, and extruded without interruption. This continuous operation eliminates the batch-to-batch variations inherent in discontinuous processes, ensuring uniform pore structure throughout the final product while maintaining operational simplicity through automated continuous processing.
2Strength
If mechanical energy is applied during extrusion to knead the dough, then the gluten structure develops, but thermal stress is generated that can damage heat-sensitive dough
Solution Approach 1:
The patent utilizes hydraulic pressure systems to inject liquid into the dough under controlled pressure (1-10 bar) during extrusion. This hydraulic action provides the necessary mechanical energy for gluten development through pressurized fluid injection rather than traditional mechanical shearing, significantly reducing thermal stress generation while achieving adequate mixing and structure development.
3Manufacturing precision
If gas is introduced into the dough during extrusion, then the pore structure is enhanced, but the gas distribution becomes uncontrolled
Solution Approach 1:
The patent introduces gas (typically CO2 or nitrogen) into the liquid component before the liquid is injected into the dough during extrusion. This preliminary gas saturation of the liquid ensures controlled, uniform gas distribution throughout the dough as the liquid is pressurized and injected. The gas is already dissolved or dispersed in the liquid before contact with the dough, preventing uncontrolled gas pockets and achieving homogeneous pore structure.
Solution Approach 2:
The patent employs pressurized liquid injection systems where gas-saturated liquid is injected under controlled pressure (1-10 bar) into the dough stream. This hydraulic injection method provides precise control over gas introduction rate, pressure, and distribution point, ensuring uniform gas dispersion throughout the dough matrix while maintaining complete control over the gas distribution pattern in the final extruded product.
4Productivity
If the extruder is designed for continuous operation, then productivity increases, but the device complexity increases
Solution Approach 1:
The patent designs the extruder system to perform multiple functions within a single continuous process: feeding dough base material, injecting liquid under pressure, kneading through mixing, introducing gas, and extruding the final product. This multi-functional integration eliminates the need for separate batch processing steps (mixing, kneading, proofing, shaping), achieving high productivity while keeping the overall system compact and manageable through functional consolidation rather than adding multiple separate devices.
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
This method allows for efficient production of a batter with adjustable pore structure, reducing thermal stress, improving gas absorption, and enabling precise control over the gluten structure, resulting in a uniform, machinable dough that can be easily portioned and baked to achieve desired texture in the final product.
Implementation Method 1
powdered dough base material, in particular grain flour, is wetted with a preparation liquid, which is sprayed onto the dough base material with a pressure by means of a nozzle device
Implementation Method 2
the pre-dough in the extruder with the targeted mixing in of an O 2 -containing Gas is kneaded by means of kneading elements
Implementation Method 3
in which hydration and thus formation of the gluten structure is already formed by the proteins in the dough base material
Implementation Method 4
the dough is withdrawn from the kneaded dough along at least one degassing section O 2 -containing gas
Data Source
AI summary
The invention relates to a method and a device for producing a dough, in particular a toast bread dough, using an extruder. The extruder has at least two extruder shafts, along which kneading elements for incorporating a gas into the dough are arranged at at least one kneading section. Gas can be drawn off along a degassing section, thus allowing a defined proportion of gas in the dough to be set. Furthermore, a forming tool for discharging the dough is provided at the extruder outlet. A nozzle assembly is arranged at an inlet area of the extruder, with which a preparation liquid can be sprayed under pressure onto a dough base to form a pre-dough.