Dough Ring Forming Device with Integrated Core Hole Displacement
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Solution Overview
Problem
Existing methods for forming rings, such as doughnuts and bagels, require multiple processing stations, leading to positioning errors, dough loss, and damage to the dough skin, which affects the quality and flavor of the final product.
Innovation Solution
A method and device that use a centering ring and press ram to pre-shape the dough into a cylindrical form, followed by a displacement rod to create a core hole without removing dough, minimizing waste and maintaining a closed skin, allowing for high-quality ring formation in fewer steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple processing stations are used to form rings, then the shaping process can be completed, but positioning errors occur and manufacturing precision deteriorates
Solution Approach 1:
The patent combines multiple processing functions (shaping, core hole formation, and skin closure) into a single integrated processing station. The forming tool includes a shaping cavity, a core hole forming element, and a skin closing element that work together in one operation, eliminating the need for multiple separate stations and their associated positioning errors.
Solution Approach 2:
The forming tool is segmented into distinct functional elements (shaping cavity, core hole forming element, skin closing element) that operate sequentially within a single station. This allows each function to be optimized independently while maintaining precise positioning through the integrated design.
2Manufacturing precision
If dough is punched out to form the core hole, then the ring shape is created, but a high percentage of dough is lost
Solution Approach 1:
Instead of punching out and discarding the dough core, the invention redirects and repositions it to form the inner surface of the ring. The dough that would have been waste is now utilized to create the inner skin of the ring, converting a harmful loss into a beneficial structural component.
Solution Approach 2:
The invention recovers the dough core that would normally be discarded during punching. By redirecting this dough through the skin closing element, it is recovered and transformed into the inner surface layer of the ring, eliminating waste and improving dough utilization.
3Productivity
If the core hole is punched out, then the ring is formed, but the dough skin is damaged and quality deteriorates
Solution Approach 1:
The skin closing element performs a preliminary action to close and seal the dough skin around the core hole area before the ring is completed and subjected to frying. This prevents grease penetration and maintains skin integrity, countering the potential harmful effect of skin damage in advance.
Solution Approach 2:
The integrated forming process provides beforehand cushioning by ensuring the dough skin is properly sealed and closed during the forming operation itself. This protective action is built into the process, cushioning the skin against subsequent damage during frying and handling.
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 approach reduces dough residue, maintains the dough's skin integrity, and enables the production of high-quality rings with minimal waste, allowing for both pre-pressed and non-pre-pressed dough pieces to be formed efficiently.
Implementation Method 1
the mass portion, in particular the dough piece, is pushed by means of a press ram against the abutment into an approximately cylindrical form with uniform thickness
Implementation Method 2
by means of the displacement rod a core hole, more particularly a centrally arranged core hole, is made in the mass portion, particularly the dough piece, wherein the displacement rod penetrates into the mass portion
Implementation Method 3
the core is punched out by the cutout ring
Data Source
AI summary
The present teaching relates to a method for forming rings from dough or other masses. A mass portion is positioned into a forming device on an abutment under a pressing device, wherein the pressing device has a centering ring, a displacement rod, a cut-out ring and a press ram. The centering ring is placed on the abutment, wherein the mass portion is laterally enclosed by means of the centering ring and is pressed by means of the press ram against the abutment into an approximately cylindrical form with a uniform thickness. A core hole is made in the mass portion by means of the displacement rod, so that a thin core of the mass portion remains between the abutment and the displacement rod. The core is punched out by the cut-out ring, and the press ram is lifted off the mass portion formed into a ring.