Low Density Wafer Production Using Piston Accumulator Aeration
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Solution Overview
Problem
Existing methods for producing wafers with low effective density result in an inhomogeneous cellular structure, making them fragile and difficult to handle, as they rely on high water addition or chemical leavening agents, which compromise texture and flavor, and are limited by the destruction of bubbles during conventional pumping and baking processes.
Innovation Solution
A method involving a downstream aeration treatment of the batter mix, using a Mondomix mixing head to create a primary foam with high overrun, which is then mixed with the batter and deposited onto a heated surface using a piston accumulator to maintain consistent pressure and prevent bubble destruction, allowing for a homogeneous cellular structure and controlled deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high water addition or chemical leavening agents are used to reduce wafer density, then effective density is improved, but cellular structure homogeneity deteriorates and fragility increases
Solution Approach 1:
The patent applies preliminary action by pre-aerating the batter mix before deposition to intentionally introduce and stabilize air bubbles in advance. The Mondomix device creates a controlled foam structure prior to baking, ensuring homogeneous bubble distribution throughout the batter. This pre-prepared aerated structure prevents the inhomogeneity that would otherwise result from high water addition or chemical leavening, while maintaining low effective density and adequate structural strength.
2Quantity of substance
If chemical leavening agents are increased to achieve lower density, then effective density is improved, but off-flavors are generated
Solution Approach 1:
The patent replaces chemical leavening agents with a mechanical aeration system (Mondomix device) that physically incorporates air bubbles into the batter through high-shear mixing. This mechanical substitution eliminates the need for chemical leavening agents like ammonium bicarbonate or sodium bicarbonate, thereby achieving low effective density through physical foam structure rather than chemical gas generation, and avoiding the unpleasant off-flavors associated with excessive chemical use.
3Productivity
If conventional pumping is used to transport aerated batter, then productivity is improved, but bubble structure is destroyed
Solution Approach 1:
The patent introduces a piston accumulator as an intermediary device between the Mondomix aeration device and the deposition system. The accumulator receives and holds the aerated batter under controlled pressure, allowing the bubbles to stabilize before deposition. This intermediary buffering system prevents the direct mechanical stress of pumping from destroying the delicate bubble structure, while still enabling continuous production and maintaining productivity.
4Stability of the object's composition
If high shear mixing is applied to create foam, then cellular structure homogeneity is improved, but bubble destruction occurs during subsequent handling
Solution Approach 1:
The patent applies preliminary action by using the piston accumulator to hold and stabilize the aerated batter after high-shear foam creation but before deposition. This intermediate holding period allows the bubbles to equilibrate and the structure to strengthen slightly, reducing fragility. The controlled pressure environment in the accumulator prevents bubble collapse that would occur during rough handling, thereby maintaining both homogeneity and adequate strength.
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
This approach enables the production of robust wafers with a breakage force of at least 1N and an effective density of up to 0.16 g/cm³, maintaining wafer shape and preventing breakage during handling, while avoiding off-flavors associated with high chemical leavening agents.
Implementation Method 1
using a Mondomix mixing head to create a primary foam with high overrun
Implementation Method 2
subjecting the batter mix to an aeration treatment obtaining an aerated batter mix
Implementation Method 3
deposited onto a heated surface using a piston accumulator to maintain consistent pressure
Implementation Method 4
baking the mixed and aerated batter mix to obtain a wafer
Data Source
Figure 1
AI summary
The present invention relates to the production of wafers and more particularly to the use of a batter aerating system to obtain wafers with an effective density of at most 0.16 g/cm3, and with sufficient strength to be able to remove them from the wafer baking plates.