Laminated Bakery Sheet Forming for Clean Portion Separation
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Solution Overview
Problem
Existing packaged bakery products, particularly soft-dough products, are difficult to divide into parts without using cutting tools, leading to the formation of fragments or crumbs.
Innovation Solution
A process involving lamination, forming, compaction, leavening, and baking of dough to create a laminated sheet with a regular pattern of ridges and depressions, allowing easy division into parts using minimal pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a soft-dough bakery product is made from naturally leavened dough, then the product has a soft texture and good taste, but it is difficult to divide into parts without using cutting tools and produces fragments or crumbs
Solution Approach 1:
The dough is divided into multiple laminated layers during the forming step, creating a structured internal architecture. This segmentation allows the product to be easily separated into distinct portions along the layer interfaces without requiring cutting tools, while maintaining structural integrity within each layer
Solution Approach 2:
The invention creates a composite structure by laminating dough layers with different properties. The alternating layers of dough and air pockets form a composite material that combines the softness of the dough with the ease of separation provided by the layered structure, enabling clean division without crumbs
2Shape
If a laminated structure is created by successive puffing operations, then the product has layered texture, but the process complexity increases
Solution Approach 1:
The laminated structure is created during the forming step by depositing and folding the dough sheet before baking. This preliminary action establishes the layered architecture in advance, eliminating the need for complex successive puffing operations during baking while still achieving the desired laminated texture
Solution Approach 2:
The invention replaces the complex mechanical system of successive puffing operations with a simpler depositing and folding mechanism. The laminated structure is formed by mechanical manipulation of the dough sheet during forming, substituting multiple thermal-mechanical puffing cycles with a single forming operation
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 process results in a packaged bakery product that can be easily divided into parts without cutting tools, maintaining structural integrity and minimizing crumbs, with a clear break line defined by the depressions on its surface.
Implementation Method 1
The depositing conveyor belt is provided with retractable deposition means adapted to perform a movement of advancement and retraction in relation to the receiving conveyor belt
Implementation Method 2
subjecting the folded sheet of dough thereby obtained to a compaction step, thereby obtaining a compacted sheet of dough
Implementation Method 3
subjecting the compacted sheet of dough to a leavening step under controlled conditions of temperature and moisture, thereby obtaining a leavened sheet of dough
Implementation Method 4
baking the leavened sheet of dough for a time period between 10 and 40 minutes, preferably between 15 and 25 minutes, and at a temperature between 160°C and 230°C, preferably between 180°C and 200°C
Data Source
Figure 1a
Figure 1b
Figure 2a
AI summary
Process for obtaining a packaged shelf-stable bakery product, in particular a soft-dough bakery product, comprising a forming step during which a laminated sheet of dough is deposited, by means of retractable deposition means, from a depositing conveyor belt to a receiving conveyor belt, followed by compaction, leavening and baking steps, as well as an optional step of horizontally cutting and filling; the present invention also relates to a bakery product obtainable by said process.