Dough Stamping for Wickerwork Roll Embossing
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Solution Overview
Problem
Traditional methods for manufacturing rolls with a wickerwork-like embossing, such as hand-folded Kaiser rolls, are complex and time-consuming, resulting in an impression resembling a fan screw rather than wickerwork, and affect the baking nature and crust cracking of the rolls.
Innovation Solution
A method involving applying a notch pattern to the dough before bulging, using star-shaped knives to create a radial indentation that anchors during baking, ensuring a deeper position and desired braiding effect, and allowing for mechanical production on an industrial scale.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If hand-folded traditional Kaiser rolls are made using artisanal braiding, then the wickerwork-like impression and crust quality are improved, but the manufacturing complexity and time consumption increase significantly
Solution Approach 1:
The patent applies the copying principle by using a stamp with blade elements that replicate the wickerwork pattern. Instead of manually braiding the dough, a stamp is pressed into the dough surface to create an indentation pattern that mimics the appearance of hand-folded Kaiser rolls. This copying approach achieves the desired wickerwork-like impression while dramatically reducing manufacturing complexity and time consumption.
2Productivity
If knife-shaped stamps with blades inserted in a pattern are used to imitate braiding, then the manufacturing time is reduced, but the overall impression resembles a fan screw rather than wickerwork and adversely affects baking nature
Solution Approach 1:
The patent applies the local quality principle by configuring the stamp blades to create indentations with specific local characteristics. The blades are arranged and dimensioned to produce elongated indentations that locally resemble the overlapping folds of wickerwork, rather than uniform circular patterns. This local differentiation in indentation shape and distribution creates the authentic wickerwork appearance while maintaining mechanical manufacturing efficiency.
3Ease of manufacture
If the notch pattern is applied after bulging, then the manufacturing process is simplified, but the indentation does not maintain a deeper position and crust quality deteriorates
Solution Approach 1:
The patent applies the preliminary action principle by applying the notch pattern to the dough surface before the bulging process. The stamp creates indentations in the relatively flat dough, and then the subsequent bulging process causes the dough to expand and the indentations to deepen and become more pronounced. This preliminary application ensures the notches maintain a deeper position and do not get pushed apart during proofing, while still allowing for efficient mechanical manufacturing.
4Shape
If star-shaped knives are used for stamping, then the radial indentation pattern is achieved, but the dough tension during rolling may create uneven patterns
Solution Approach 1:
The patent applies the dynamics principle by allowing the dough to be in a specific dynamic state during stamping. The dough is kept relatively flat and stable during the stamping process to ensure uniform radial indentation patterns, then undergoes controlled bulging that dynamically transforms the pattern. The process exploits the viscoelastic properties of dough, allowing precise pattern formation during stamping followed by natural relaxation and expansion during bulging and proofing, which enhances rather than degrades the pattern uniformity.
Data Source
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AI summary
The present invention relates to a method for manufacturing rolls, comprising the steps of providing one or more dough pieces, each portioned by weight for forming one roll, applying a notch pattern to a side intended as the final top of each of the one or more dough pieces, and then bulging the dough pieces.