Rotary Molded Dough Composition for Deep Indentations

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Solution Overview

Problem

Rotary molding machines produce flat, shallow cookies, biscuits, and crackers due to shallow molds and friction requirements, limiting the depth of indentations and angles in the final products.

Innovation Solution

A reduced-fat dough composition including water, sugar, and flour, with added fat, is used to facilitate easier dough release from molds, allowing for deeper indentations and steeper angles by reordering ingredient addition and incorporating fat to reduce surface interactions and vacuum effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If shallow molds are used in rotary molding machines, then friction removal is facilitated, but the depth of indentations and angles in the final products is limited

Engineering Contradiction:

Improvefriction removalVSAvoiddepth of indentations and angles

Core Design Contradiction:

Ease of operationVSShape

Solution Approach 1:

The patent changes the physical-chemical parameters of the dough by modifying its composition (reducing fat content, adjusting water, sugar, and flour ratios). This alters the dough's adhesion properties and friction characteristics, enabling it to be released from molds with deeper indentations and steeper angles without compromising friction removal during the rotary molding process

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If traditional high-fat dough is used, then dough release from molds is easier, but the product has higher fat content and less texture

Engineering Contradiction:

Improvedough release from moldsVSAvoidfat content

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The patent modifies the chemical composition parameters of the dough by reducing fat content to 0-10% (compared to traditional high-fat dough) and adjusting the ratios of water, sugar, and flour. This creates a reduced-fat dough that maintains adequate release properties while achieving the desired lower fat content and enhanced texture

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite dough formulation combining reduced-fat ingredients with specific proportions of water, sugar, and flour. This composite material achieves the dual benefit of easier mold release and reduced fat content by optimizing the interaction between different components rather than relying solely on high fat content

Inventive Principle:

Principle #40Composite materials

3Shape

If deeper molds are used to create deeper indentations, then product depth and texture are enhanced, but friction removal becomes more difficult

Engineering Contradiction:

Improveproduct depth and textureVSAvoidfriction removal

Core Design Contradiction:

ShapeVSEase of operation

Solution Approach 1:

The patent changes the dough's physical parameters through composition modification (reduced fat, adjusted water-sugar-flour ratios), which alters its friction and adhesion characteristics. This enables the dough to be successfully released from deeper molds that would otherwise create excessive vacuum and friction effects, thereby achieving enhanced product depth and texture while maintaining ease of operation

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12089602B2Rotary molded food product and methods of making

Publication Date: 2024.09.17 GENERAL MILLS INC

AI summary

The present disclosure is directed to rotary molded products and methods of making rotary molded products. Methods of making rotary molded products include combining a reduced-fat dough with a fat to make a dough with the ability to be used in a novel array of rotary molded shapes. Dough pieces and cooked rotary molded products having novel features and dimensions are also provided.