Macaron Shell Foot Formation via Diameter-to-Height Ratio Control
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Solution Overview
Problem
Achieving uniformity and ideal proportions in macaron shells, particularly the 'foot' layer, is challenging due to variations in dough composition and processing conditions during drying and baking.
Innovation Solution
A method involving a dough made of sugar, egg whites, and almonds, with specific density and ratios of diameter to height at different processing stages, including spraying, drying, and baking, to control the formation of the foot layer, using a conveyor belt, drying tunnel, and baking tunnel with controlled temperatures and durations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the macarons are dried before baking to create a crust, then the foot structure is formed, but the uniformity of the foot proportions becomes difficult to achieve
Solution Approach 1:
The patent applies preliminary action by controlling the dough's initial dimensions (diameter-to-height ratio between 4 and 5.5) before the drying and baking processes. This pre-establishment of geometric parameters ensures that when the crust forms and the shell expands during baking, the foot achieves uniform proportions. The method also includes preliminary conditioning of the dough to specific humidity and temperature ranges before processing.
Solution Approach 2:
The patent utilizes parameter changes by precisely controlling multiple variables throughout the process: dough density (650-850 g/L), diameter-to-height ratios at different stages (4-5.5 initially, 4.5-6 after drying, 3-4 after baking), temperature profiles during drying and baking, and humidity levels. These controlled parameter transformations ensure consistent foot formation while maintaining uniformity across batches.
2Manufacturing precision
If the dough composition and processing parameters are adjusted to achieve ideal foot proportions, then the uniformity improves, but the process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the processing into distinct sequential stages: dough preparation with specific density control, spraying onto conveyor belt, drying phase in a drying tunnel, and baking phase in a baking tunnel. Each stage has defined parameter ranges (e.g., diameter-to-height ratio targets for each stage) that can be independently controlled and monitored, simplifying the management of overall process complexity while ensuring uniformity.
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
Results in macaron shells with consistent dimensions and ideal foot proportions, ensuring uniformity and organoleptic properties by managing the crust formation and evaporation process effectively.
Implementation Method 1
This foot is created because the macarons are dried before they are baked. This creates a harder layer or crust on the outside of the shell that is exposed to the air. Moisture will try to evaporate from the shell during baking.
Implementation Method 2
Since this vapor cannot escape along the formed crust, the shell is pushed upwards to allow the vapor to escape.
Data Source
AI summary
The present invention relates to a method for producing macaron shells with a foot, wherein a dough is made, wherein in a first step the dough is sprayed into individual shells on a conveyor belt, where the shells are then transported through a drying tunnel and where the shells are then transported through a baking tunnel, where the ratio between the diameter and the height of the shell immediately after spraying the dough into separate shells on the conveyor belt is between 4 and 5.5, the ratio between the diameter and the height of the shell immediately after transport through the drying tunnel is between 4.5 and 6 and the ratio between the diameter and the height of the shell immediately after transport through the baking tunnel is between 3 and 4. The invention also relates to a macaroon with the aforementioned shell.