Continuous Wheat Dough Depolymerizer and Enzyme Regeneration
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Solution Overview
Problem
Current production lines for baked goods, particularly buns and hot dog buns, are monolines and cannot efficiently produce a variety of wheat dough products with different textures and sizes, making them uneconomical and inflexible for industrial use.
Innovation Solution
A continuous production method involving a kneading device, depolymerizer with screw conveyor and eccentric screw pump, dough band former, rolling device, cutting device, and optional active channels to shape dough pieces, allowing for the production of wheat pastries with varying structures and sizes using a single production line by adjusting shearing forces and using enzymes like glucose oxidase to regenerate the gluten network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single production line is used for multiple baked goods, then production flexibility and efficiency are improved, but the quality characteristics and texture consistency deteriorate
Solution Approach 1:
The production line incorporates adjustable shear forces in the depolymerizer that can be dynamically modified based on the specific baked good being produced. This allows the same production line to adapt to different dough types (yeast-based, sponge-dough, choux) while maintaining appropriate processing intensity for each, thereby preserving quality characteristics across product varieties
Solution Approach 2:
The system changes key processing parameters including shear rate in the depolymerizer, enzyme concentration (glucose oxidase), and processing temperature to match the specific requirements of different baked goods. This parameter adjustment enables one production line to handle multiple products while maintaining optimal quality for each
2Productivity
If high mechanical stress is applied to dough during processing, then production efficiency is improved, but the gluten network structure deteriorates
Solution Approach 1:
The depolymerizer applies controlled mechanical stress and shear forces to partially break down the gluten network before final product formation. This preliminary depolymerization, followed by enzyme-mediated regeneration, prepares the dough for efficient processing while preserving the necessary structural strength for the final baked good
Solution Approach 2:
Enzymes, particularly glucose oxidase, act as intermediaries to regenerate and strengthen the gluten network after mechanical depolymerization. This enzymatic reinforcement allows the dough to withstand subsequent high-speed processing while maintaining structural integrity and desired texture
3Manufacturing precision
If shear forces are reduced to preserve gluten structure, then product quality is improved, but production efficiency deteriorates
Solution Approach 1:
The system performs preliminary depolymerization with controlled shear forces, then uses enzymatic regeneration to restore gluten strength. This two-stage approach allows for more aggressive and efficient subsequent processing while maintaining final product quality, as the gluten network has already been prepared and strengthened
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 wheat pastries with different textures and sizes on a single production line with minimal adjustments, improving dough flow and structure, reducing air pockets, and enhancing gluten strength, thus increasing production flexibility and efficiency.
Implementation Method 1
the shear forces are adapted to the flour quality by varying the shear in the depolymerizer
Implementation Method 2
the gluten network is regenerated after depolymerization during further processing by the use of enzymes, in particular glucose oxidase
Implementation Method 3
at least one eccentric screw pump for depolymerization and degassing of the dough
Data Source
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AI summary
The present invention relates to a method for the continuous production of bakery products, in particular bakery products consisting of wheat doughs, comprising the following steps: a) producing at least one dough in at least one kneading device (1); b) introducing the at least one dough from the kneading device (1) into at least one device (2) comprising at least one conveying worm and at least one eccentric worm pump for depolymerizing and degassing the dough; c) introducing the depolymerized dough into at least one dough sheet former (3) so as to form a dough sheet; d) folding the dough sheet (4); e) introducing the folded dough sheet into at least one rolling device (5); f) cutting the dough sheet using at least one cutting device into a predetermined number of dough portions; g) optionally flat-rolling the dough portions; h) depositing the formed dough portions onto baking trays or into baking moulds (9); i) fermenting the dough portions (10); and j) baking the dough portions (12).