Integrated Checkweigher for Dough Proofer Weight Control
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Solution Overview
Problem
Existing dough processing equipment in industrial bakeries faces challenges in maintaining consistent dough piece weights at high production rates, requiring labor-intensive manual adjustments and generating flour dust due to complex machinery.
Innovation Solution
An integrated apparatus and method that includes a dough divider, a proofer with a checkweigher, and load cells to continuously monitor and adjust dough piece weights, using a controller to adjust the operating rate of the divider, ensuring uniform target weights without human intervention and minimizing flour dust.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual sampling and adjustment is used to monitor dough piece weights, then weight accuracy can be maintained, but labor intensity increases and production efficiency decreases
Solution Approach 1:
The system performs self-monitoring and self-adjustment of dough piece weights through automated checkweighing and controller feedback, eliminating the need for manual sampling and adjustment by operators
Solution Approach 2:
The controller receives weight measurements from the checkweigher and automatically adjusts the divider operating rate based on the measured weights, creating a closed-loop feedback system that maintains weight accuracy continuously
2Measurement precision
If complex weighing apparatus with belts and slides is used, then dough piece weight can be measured, but flour dust generation increases
Solution Approach 1:
The weighing function is extracted from the traditional complex mechanical weighing apparatus and integrated into the existing proofer system, eliminating the need for separate belts, slides, and load cells that generate flour dust
Solution Approach 2:
The checkweigher is merged with the proofer to form an integrated system, combining the weighing function with the existing dough handling infrastructure and avoiding the flour dust problems of separate mechanical weighing systems
3Measurement precision
If separate weighing machine is used to monitor dough pieces, then weight control is achieved, but space requirement increases
Solution Approach 1:
The checkweigher is integrated with the proofer system, combining multiple functions (dough proofing and weight monitoring) into a single piece of equipment, thereby eliminating the need for separate weighing machines and reducing overall space requirements
Solution Approach 2:
The proofer is designed to serve multiple functions: it proofs the dough pieces and simultaneously houses the checkweigher for weight monitoring, making the equipment multi-functional and space-efficient
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
Achieves continuous monitoring and precise adjustment of dough piece weights, reducing variations and flour dust, thereby enhancing production efficiency and reducing labor costs.
Implementation Method 1
a plurality of load cells associated with respective gates, each load cell configured to produce weight data indicative of a weight of the respective dough piece
Data Source
AI summary
Disclosed are embodiments of a dough proofer for a commercial bakery that can receive dough pieces from a dough divider onto trays. Each tray has cups that hold dough pieces. The trays are moved through the proofer by a conveyor system. The proofer has a checkweigher. The checkweigher also uses the same conveyor system and has (1) a tray tipper that tips a tray of dough pieces to make the dough pieces fall out of the tray; (2) a row of gates under the tray to receive and hold the dough pieces and release the dough pieces so that they fall back into their original cups and tray; (3) a row of load cells associated with gates that produces weight data indicative of dough piece weights; and (4) a controller that controls the divider based upon the weight data so that the dough pieces exhibit a substantially uniform target weight.