Puff Pastry and Croissant Dough Lamination With Thinned Fold Lines
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Solution Overview
Problem
Existing methods for manufacturing puff pastry or croissant dough result in irregularities in the layers of dough and fat due to folding lines, leading to undesired behavior during baking.
Innovation Solution
A method involving local reduction of dough thickness at fold lines and sides before applying a fat layer, followed by folding and rolling, to create a homogeneous laminate with reduced irregularities, and a device comprising roller wheels and a folding mechanism to achieve this.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If folding lines are created during the manufacturing process, then the dough can be folded and laminated, but irregularities in layer thickness occur at the fold lines
Solution Approach 1:
The patent applies preliminary action by thinning the dough sheet at the fold lines before the actual folding operation. This pre-treatment ensures that when the fold is made, the thinned areas create thinner dough layers that prevent the formation of thick irregularities at the fold lines, thus maintaining layer thickness uniformity while still enabling the folding process
2Shape
If the dough sheet is folded over the fat layer, then the laminate structure is formed, but thick dough layers form at the fold lines causing irregularities
Solution Approach 1:
The patent applies local quality by creating a non-uniform dough sheet with specifically thinned regions at the fold lines while maintaining normal thickness in other areas. This localized thickness variation ensures that when folding occurs, only the thinned areas create thin dough layers in the final laminate, while the rest of the structure maintains proper thickness for forming the desired laminate shape
Data Source
Figure 1A~2B
Figure 3
Figure 4A~4B
AI summary
Method for manufacturing puff pastry or croissant dough, comprising the steps of: - Providing a sheet of dough that extends in a lengthwise and a widthwise direction; - Applying a layer of fat, in particular butter, to the sheet of dough, which extends in the lengthwise direction mainly over the length of the dough, and in the widthwise direction covers a part of the width of the dough, in particular half of the width, thereby leaving a part of the sheet of dough free on both sides in the widthwise direction; - Folding the parts of the sheet of dough that extend outside the layer of fat over the fat around a fold line that extends in the lengthwise direction and borders on the edge of the layer of fat; - before folding the sheet of dough locally reducing the thickness of the sheet of dough - at the fold lines; and/or at - at least one of the sides of the sheet of dough that extend in the lengthwise direction.