Layered High-Gluten Pizza Dough for Reduced Snapback
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Solution Overview
Problem
Conventional high gluten pizza doughs exhibit significant snapback and lack of extensibility, making them difficult to handle and shape for restaurant operators.
Innovation Solution
A method and system for manufacturing layered pizza dough by combining fresh high gluten dough with up to 40% rework dough, sheeting, and lapping to form a layered structure, which reduces snapback and enhances extensibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional high gluten pizza dough is used, then the dough has high strength and elasticity, but it exhibits significant snapback and lacks extensibility making it difficult to handle
Solution Approach 1:
The dough is divided into multiple thin layers (typically 3-5 layers) through the lapping process. Each layer maintains the high gluten content and strength properties, but the segmented layered structure reduces overall snapback and improves extensibility, making the dough easier to handle while preserving the desired strength characteristics.
Solution Approach 2:
The invention changes the physical structure parameter of the dough from a single homogeneous mass to a multi-layered configuration. This structural parameter change transforms the dough's mechanical behavior, reducing snapback and improving extensibility while maintaining the high gluten content and strength of individual layers.
2Stability of the object's composition
If conventional high gluten pizza dough is used, then the dough maintains its shape well, but it shrinks back once stretched to the desired size or shape
Solution Approach 1:
By segmenting the dough into multiple thin layers, each layer can be stretched more easily without triggering strong snapback responses. The layered structure allows progressive deformation across layers, improving extensibility and adaptability while each individual layer maintains its shape stability.
Solution Approach 2:
The lapping process creates a multi-dimensional layered structure that adds complexity in the vertical dimension. This dimensional change allows the dough to accommodate stretching forces more effectively, as the layers can shift and deform independently, improving extensibility without sacrificing shape stability.
3Ease of operation
If fresh high gluten dough is mixed with rework dough to form combination dough, then extensibility improves, but the manufacturing process complexity increases
Solution Approach 1:
The invention merges fresh high gluten dough with rework dough in a controlled mixing process. This combination leverages the extensibility benefits of rework dough while maintaining the strength and quality of fresh dough, achieving improved ease of operation through material combination rather than process complexity.
Solution Approach 2:
The invention changes the compositional parameter of the dough by incorporating rework dough at controlled ratios (typically 10-30% of total dough weight). This parameter change in dough composition naturally improves extensibility without requiring complex manufacturing equipment or processes.
4Ease of operation
If the dough is sheeted and lapped to form multiple layers, then snapback is reduced, but the manufacturing time increases
Solution Approach 1:
The sheeting and lapping operations are performed in a continuous manufacturing process rather than as discrete batch operations. The dough sheet is continuously fed through the lapping mechanism, creating multiple layers in one continuous action. This continuity reduces manufacturing time while achieving the snapback reduction benefits of layered structure.
Solution Approach 2:
The invention extracts the time-consuming manual layering step by implementing an automated lapping mechanism that forms multiple layers in a single continuous operation. This extraction of the layering function from manual processes to automated machinery reduces manufacturing time while maintaining the snapback reduction benefits.
Data Source
AI summary
A method of manufacturing a layered pizza dough product with great extensibility includes forming a fresh high gluten dough, mixing the fresh high gluten dough with a rework dough to form a combination dough, sheeting the combination dough to form a sheeted dough, and lapping the sheeted dough to form a layered pizza dough. A system for manufacturing includes fresh and rework dough dispensers, a controller, a mixer for combining the fresh and rework doughs, an extruder and a lapper. A layered pizza dough product with great extensibility comprises eight to thirty layers of a high gluten pizza dough, wherein the high gluten pizza dough comprises up to about 40% rework dough by weight.