Multi-layered Sponge Cake Infrared Pre-baking
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Solution Overview
Problem
Current methods cannot continuously produce sponge cakes with multiple layers of different colors, flavors, and aromas from a single base dough without mixing components, limiting production efficiency and quality.
Innovation Solution
A continuous method involving distributing a base sponge cake dough into multiple portions, adding specific additives to create distinct layers, treating each layer with mid-wave infrared radiation, and baking in a convection oven, allowing for independent control of each layer's characteristics and preventing layer mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to produce multi-layered sponge cakes, then different layers can be obtained, but continuous production is not achieved and components may mix
Solution Approach 1:
The patent applies preliminary action by treating each dough layer with infrared radiation immediately after deposition to create a pre-baked surface. This pre-treatment establishes a stable boundary before the next layer is added, preventing mixing during continuous production while maintaining the ability to produce multiple layers continuously.
Solution Approach 2:
The infrared radiation treatment acts as an intermediary mechanism between layer deposition and final baking. By introducing this intermediate step, the system enables continuous production while ensuring layer separation integrity through the creation of a stabilized surface that prevents component mixing.
2Adaptability or versatility
If multiple additives are mixed into the base dough, then different flavors and colors can be achieved, but layer differentiation is lost due to mixing
Solution Approach 1:
The patent applies segmentation by dividing the base dough into separate portions and treating each portion independently with specific additives. Each layer receives its own colorant and/or flavoring in separate mixing operations, ensuring that the composition of each layer remains distinct and identifiable while still achieving variety across layers.
Solution Approach 2:
The patent implements local quality by adding specific additives (colorants and/or flavorings) to specific portions of the base dough based on the desired characteristics of each individual layer. This allows different regions (layers) to have different properties (flavor, color) while maintaining clear boundaries between them through the sequential deposition and infrared treatment process.
3Manufacturing precision
If infrared radiation is applied to all layers, then surface treatment is achieved, but the last layer cannot be properly baked
Solution Approach 1:
The patent applies partial action by treating only the first n-1 layers with infrared radiation, while the final layer is deposited and then the entire multi-layer structure undergoes conventional baking. This partial infrared treatment provides sufficient surface consistency for the treated layers without interfering with the final baking process, simplifying the overall manufacturing procedure.
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
Enables the production of multi-layered sponge cakes with enhanced sponginess and distinct flavor/color profiles, maintaining quality and allowing for large-scale production without compromising organoleptic or dimensional characteristics.
Implementation Method 1
treating each layer with mid-wave infrared radiation
Implementation Method 2
baking the multi-layered sponge cake in a convection oven at a temperature between 200 and 250 °C during a period between 8 and 22 minutes
Data Source
Figure 1
Figure 2~3a
Figure 3b~3c
AI summary
The invention relates to a method for continuously producing a multi-layered sponge cake that comprises preparing at least two doughs of different compositions from the same base dough, dispensing one of the layers of dough and, prior to dispensing the subsequent layer, treating the surface of the previously deposited layer with infrared radiation. Additionally, the present invention also relates to the multi-layered sponge cake obtained by the method described and the facility used for carrying out said method.