Puff Pastry Dough Folding With Local Fold-Line Thinning
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Solution Overview
Problem
Existing methods for manufacturing puff pastry and 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 application of fat to create a homogeneous laminate, combined with a device using roller wheels and folding mechanisms to ensure uniform layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the dough sheet is folded over the fat layer using conventional folding methods, then the puff pastry or croissant dough can be formed, but irregularities and non-uniform layer thickness occur at the fold lines
Solution Approach 1:
The thickness of the dough sheet is reduced at the fold lines before the folding operation. This preliminary action prepares the dough by creating thinner regions that will fold more uniformly over the fat layer, preventing irregularities during the folding process and ensuring homogeneous layer thickness in the final product.
Solution Approach 2:
The dough sheet is treated differently at different locations - specifically, the thickness is reduced only at the fold lines while other areas maintain their original thickness. This local modification ensures that the folding process produces uniform layers at the critical fold line regions without affecting the overall structure of the dough laminate.
2Manufacturing precision
If the dough sheet thickness is reduced at fold lines, then layer uniformity is improved, but the device complexity increases due to additional roller mechanisms
Solution Approach 1:
The roller device is divided into multiple independent roller units, each responsible for reducing the thickness of the dough sheet at specific locations (fold lines). This segmentation allows the complex thickness reduction function to be distributed across simpler, modular components, making the device more manageable and easier to manufacture while achieving the desired precision.
Data Source
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 doughat the fold lines; and/or atat least one of the sides of the sheet of dough that extend in the lengthwise direction.