Segmented Packed Dough with Barrier Interfaces
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Solution Overview
Problem
Conventional ready-to-use fresh dough products have a limited storage lifetime, leading to deterioration of organoleptic properties, increased refrigeration needs, logistics challenges, and excessive waste, as they become soggy, sticky, or hard during storage, and require frequent deliveries.
Innovation Solution
A packed dough product comprising at least five ready-to-use fresh dough pieces stacked with barrier interfaces and flexible packaging, which limits yeast fermentation and maintains organoleptic properties for up to fourteen days, reducing refrigeration capacity and logistics complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If dough pieces are stored for several days at refrigeration temperature, then the storage lifetime is extended, but the organoleptic properties deteriorate and the dough becomes soggy, sticky, or hard
Solution Approach 1:
The dough pieces are segmented and stacked vertically in a multi-layer configuration within the packaging container, separated by barrier interfaces. This segmentation allows each layer to be independently managed and prevents the deterioration that occurs when dough pieces are stored in bulk, thereby maintaining organoleptic properties while extending storage lifetime.
Solution Approach 2:
Barrier interfaces are introduced as intermediary elements between stacked dough pieces. These barriers prevent direct contact and moisture transfer between adjacent dough layers, acting as mediators that preserve the organoleptic properties of each dough piece during extended refrigeration storage.
2Quantity of substance
If a high number of dough pieces are stored for several days, then the refrigeration capacity requirement increases, but the logistics and storage space requirements become excessive
Solution Approach 1:
The dough pieces are arranged in a vertical stacking configuration rather than horizontal spreading. This dimensional change from 2D to 3D arrangement maximizes the use of vertical space within the packaging container, allowing a high quantity of dough pieces to be stored in a compact volume, thereby reducing refrigeration storage capacity requirements.
Solution Approach 2:
Multiple dough pieces are nested within each other in a compact stacked arrangement inside the packaging container. This nesting configuration optimizes space utilization, allowing maximum quantity of dough pieces to be stored in minimal volume, reducing both storage capacity and logistics requirements.
3Ease of operation
If dough pieces are placed apart on stackable trays, then the handling is easier, but the yeast fermentation continues and the dough pieces expand and spread irregularly
Solution Approach 1:
The packaging container is segmented into multiple horizontal layers with barrier interfaces between them. Each layer acts as an independent compartment that confines the dough piece, preventing lateral expansion and spreading while maintaining uniform shape. The segmented structure allows easy handling of individual layers.
Solution Approach 2:
Barrier interfaces in the form of thin flexible films or papers are used to separate and constrain dough pieces in each layer. These thin film barriers provide just enough constraint to prevent irregular expansion while allowing the dough to maintain its shape, and they facilitate easy handling and removal of individual dough pieces.
4Productivity
If dough pieces are stored for extended periods, then the delivery frequency can be reduced, but the unused dough pieces must be thrown away after a few days generating waste
Solution Approach 1:
The packaging container is divided into multiple separable layers, each containing a dough piece. This segmentation allows the end user to remove and use individual layers as needed over time, rather than having to use all dough pieces simultaneously or discard the entire package. This eliminates waste by enabling progressive consumption.
Solution Approach 2:
Multiple dough pieces are prepared and packaged in advance in a single container with extended shelf life. This preliminary action allows the product to be delivered less frequently while ensuring that dough pieces remain usable for longer periods without deterioration, reducing both delivery frequency and waste from expired unused dough.
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
The packed dough product maintains satisfactory textural, culinary, and baking properties for an extended period, reducing waste and logistics needs, while allowing for longer storage intervals and easier handling.
Implementation Method 1
the stacked dough pieces are packaged together in the flexible packaging
Data Source
AI summary
The present invention belongs to the field of food processing and human nutrition. It particularly relates to a packed dough product comprising ready-to-use, fresh dough pieces; a dough assembly comprising said packed dough product; a method for preparing them and a method for storing them. The packed dough product has a prolonged lifetime, without compromising the organoleptic properties of the dough pieces. The packed dough product is useful for example for preparing home-delivered dough-based foodstuff, particularly pizzas.