Segmented Front Roller for High-Speed Dough Sheeting
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Solution Overview
Problem
Existing dough sheeting machines face challenges in producing very thin sheets at high speed due to dough adhesion issues, which complicates the recycling of rework and separation of cut products from rollers.
Innovation Solution
A sheeter with a front roller featuring alternating non-stick and non-release areas, including grooves for holding a stripper wire and a hoop or band, allows for efficient release of cut products and recycling of rework, enabling high-speed sheeting of very thin dough sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a conventional front roller is used, then the machine can operate at moderate speed, but the dough sticks to the roller preventing high-speed operation and very thin sheeting
Solution Approach 1:
The front roller surface is segmented into distinct non-stick zones and non-release zones. The non-stick zones allow dough to be released at high speed, while the non-release zones hold the web for recycling. This segmentation resolves the contradiction by providing different surface properties in different areas.
Solution Approach 2:
Different zones of the roller surface have different local properties: non-stick areas with low adhesion for releasing cut products, and non-release areas with high adhesion for holding the web. This local differentiation allows the roller to simultaneously enable high-speed operation and web recycling.
2Ease of operation
If the front roller releases all dough, then cut products can be separated easily, but rework cannot be carried back for recycling
Solution Approach 1:
The roller surface is divided into non-release zones that hold the web for recycling and non-stick zones that release cut products. This segmentation allows simultaneous achievement of easy product separation and effective rework recycling.
Solution Approach 2:
The stripper wire acts as an intermediary element that works in conjunction with the segmented roller surface. The wire helps separate cut products in the non-stick zones while the roller's non-release zones maintain web adhesion for recycling.
3Loss of substance
If stripper wires and bands are used to hold the web, then rework recycling is improved, but the design and operation becomes significantly more complex
Solution Approach 1:
The roller design merges the web-holding function directly into the roller surface through non-release zones, eliminating the need for separate stripper wires and bands. This integration simplifies the overall device while maintaining effective rework recycling.
Solution Approach 2:
The roller surface itself provides both the web-holding and product-release functions through its segmented structure, making the system self-sufficient without requiring additional external components like stripper wires or bands.
Data Source
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AI summary
To address the problems inherent in creating very thin sheets of dough (30) in a sheeting machine at high speed and with efficient recycling and re-sheeting of the re-work cut out from the sheet, a new sheeting machine with a new front roller (10) is provided, wherein the roller includes non-stick and non-release areas and a plurality of grooves in the non-release area.