WO2010090635A2 - Procédés de fabrication de craquelins en forme de coude - Google Patents

Procédés de fabrication de craquelins en forme de coude Download PDF

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Publication number
WO2010090635A2
WO2010090635A2 PCT/US2009/032949 US2009032949W WO2010090635A2 WO 2010090635 A2 WO2010090635 A2 WO 2010090635A2 US 2009032949 W US2009032949 W US 2009032949W WO 2010090635 A2 WO2010090635 A2 WO 2010090635A2
Authority
WO
WIPO (PCT)
Prior art keywords
dough
elbow
curvature
shaped
cracker
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2009/032949
Other languages
English (en)
Other versions
WO2010090635A3 (fr
Inventor
Kenchu A. Tham
Edward Kevin Mchugh
Steven Peter Zubanas
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Intercontinental Great Brands LLC
Original Assignee
Kraft Foods Global Brands LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kraft Foods Global Brands LLC filed Critical Kraft Foods Global Brands LLC
Priority to AU2009339426A priority Critical patent/AU2009339426A1/en
Priority to PCT/US2009/032949 priority patent/WO2010090635A2/fr
Priority to CN200980156355.7A priority patent/CN102858180B/zh
Priority to CA2751065A priority patent/CA2751065A1/fr
Priority to NZ594471A priority patent/NZ594471A/en
Publication of WO2010090635A2 publication Critical patent/WO2010090635A2/fr
Anticipated expiration legal-status Critical
Publication of WO2010090635A3 publication Critical patent/WO2010090635A3/fr
Ceased legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21C—MACHINES OR EQUIPMENT FOR MAKING OR PROCESSING DOUGHS; HANDLING BAKED ARTICLES MADE FROM DOUGH
    • A21C11/00—Other machines for forming the dough into its final shape before cooking or baking
    • A21C11/02—Embossing machines
    • A21C11/04—Embossing machines with cutting and embossing rollers or drums
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
    • A21D13/00—Finished or partly finished bakery products
    • A21D13/20—Partially or completely coated products
    • A21D13/24—Partially or completely coated products coated after baking
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT OF FLOUR OR DOUGH FOR BAKING, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS
    • A21D13/00—Finished or partly finished bakery products
    • A21D13/40—Products characterised by the type, form or use
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/10—Moulding

Definitions

  • the field relates to methods for producing cracker products, and more specifically, to methods for producing elbow-shaped cracker products using a cutting die.
  • Cracker products are generally formed by cutting out the desired shape of the cracker from a sheet of cracker dough and baking the cracker dough to form a baked cracker product.
  • Various approaches can be used to form the dough and cut the dough into pieces having the desired shapes for baking.
  • individual cutters or molds may be used to form the cracker dough into a desired shape.
  • More automated processes involve the use of cutting dies which define the shape of the prebaked dough piece.
  • the cutting die may be attached to a reciprocating cutting plate or a rotary cutting drum.
  • the rotary cutting dies are often desirable because sheets of cracker dough can be fed to the rotary cutting die and cut into their desired dough shaped pieces in a continuous process to increase throughput.
  • the circular shapes can be nested and closely spaced to reduce the waste/ rework, but the constraint of the circular shapes tend to result in some level of waste or rework due to unused dough between the cutout die blades. Again, applying the techniques suitable for circular cutting blades to form cutters for non-symmetrical shapes tends to result in unacceptable waste and throughput.
  • non-symmetrical shapes and especially relatively thin non-symmetrical shapes such as elbow shapes
  • nesting configuration need to be selected, but the particular shape itself, any curvature of the shape, weight, thickness and width of the shape all must also be considered. Adjusting one of these parameters tends to substantially affect the configuration of the die.
  • the difficulty lies in the constraint that the formed cracker needs to retain its non-symmetrical appearance, but still be formed using a robust cutting die and sheeting process to produce the cutout shapes with good through put and minimal breakage.
  • FIG. 1 is a flow diagram of an exemplary process for producing elbow shaped crackers;
  • FIG. 2 is a side cross-sectional view of an exemplary rotary die cutter;
  • FIG. 3 is top plan view of an exemplary cutting die cavity
  • FIG. 4 is a cross-sectional side view of a cutting die blade
  • FIG. 5 is a top plan view of a plurality of cutting die cavities
  • FIG. 6 is a top plan view of a plurality of cutting die cavities showing a nesting arrangement thereof.
  • FIG. 7 is a top plan view of different degrees of curvature of cutting die cavities.
  • an exemplary process and die configuration for forming elbow-shaped crackers is illustrated using a cutting die configured to produce good throughput and with minimal product breakage.
  • the shape of the elbow crackers are specifically configured to not only represent a recognizable elbow-shape, but at the same time have a configuration that is effective to be produced on a scrap-less cutting die in which substantially no unused material is left between adjacently cut pieces.
  • the elbow shaped crackers have a specific curvature of the top and bottom arcs forming the cracker shape, which retains the elbow-shaped configuration and permits a nesting arrangement with little to no displacement cavities between adjacent die cutouts that enables the scrap-less configuration of the die.
  • a cracker dough is first formed by mixing the dough ingredients and proofing the dough to form the cracker dough.
  • the cracker dough is sheeted to a desired thickness for the particular application.
  • the dough sheet is then advanced to a cutting die, which is preferably a rotary cutting die, where it is subjected to a plurality of elbow shaped cutting blades positioned on an outer surface of the cutting die to perforate the dough sheet into a plurality of elbow-shaped dough pieces.
  • the formed elbow-shaped dough pieces are then baked in an oven at a temperature and time to form the elbow- shaped crackers.
  • optional finishing steps may be carried out, such as applying oil to the crackers, applying a seasoning, flavor and/ or salt to the cooked cracker prior to packaging.
  • the dough weight, moisture level, and shape are combined to enable the cracker to be formed with low breakage, such as less than about 15 percent and, preferably, less than about 5 percent breakage.
  • the cutting die has a blade configuration selected to produce dough pieces having both a recognizable elbow-shape and, at the same time, also allow the dough sheet to be cut with substantially no wasted material between adjacently cut dough pieces to produce good throughput.
  • each individual dough piece (and the die blades configured to form such dough piece) has a configuration including degree of curvatures of the top and bottom sides, angle of inclination of the dough piece ends, dough weight, and outer surface areas that result in the recognizable elbow-shapes and, at the same time, also permit the arrangement of cutting die blades on the cutter surface to form such shapes that can be nested together so that the formed dough sheet is substantially free of material between die cavities. Changes in dough piece configuration, size, weight, or curvatures result in either a shape that does not resemble a recognizable elbow shape or results in a die configuration with waste product between die cavities.
  • dough is prepared by initially mixing 10 sponge ingredients to form a sponge or intermediate dough.
  • the ingredients included in the first mixing step generally include flour, yeast, enzyme, color, and water that are blended together in one or more steps to form the sponge or intermediate dough.
  • the intermediate dough is proofed 12 to form a proofed intermediated dough.
  • additional ingredients are mixed with the proofed intermediate dough in a second mixing step 14 to form a final dough, which may be proofed 16 for a second time to form a cracker dough.
  • the additional ingredients included in the second mixing step generally include flour, oil, salt, leavening agents, butter, cheese, and flavors.
  • the cracker dough is then formed into a continuous dough sheet 18 having a desired thickness correlating to a desired thickness of the formed dough pieces prior to baking.
  • the cracker dough may be advanced through one or more pairs of sheeting rollers flattening the cracker dough into a continuous dough sheet with a generally uniform thickness.
  • the final dough may be subjected to several pairs of sheeting rollers arranged in series to gradually press the final dough into a dough sheet.
  • the dough sheet is rolled until it has a generally uniform thickness of about 0.030 to about 0.040 inches. While the above described approach may be used to form the dough into the desired thickness, it will be appreciated that other suitable methods may also be used.
  • the dough sheet is next advanced to a cutting die, preferably a rotary cutting die where the dough sheet is cut 20 into individual dough pieces having the recognizable elbow shapes with no dough material left between each formed elbow-shaped piece.
  • a cutting die preferably a rotary cutting die
  • the unique shape of the elbow dough piece is what enables the arrangement on the cutting die to produces substantially no wasted material between adjacent cut pieces.
  • the dough pieces are baked 22 in an oven sufficient to obtain the desired moisture level and then packaged 24.
  • flavors, additives, and coatings may be applied 26 to the outer surface of the baked cracker.
  • an oil coating, salt, and or other cheese-based seasonings may be applied to the baked cracker prior to packing.
  • the cutting die is a rotary die 30, an example of which is shown in FIG. 2, where individual dough pieces are cut away from the dough sheet as it passes beneath the rotary die cutter 30.
  • the rotary die cutter 30 is a cylindrical drum 32 having an outer surface 34 with a plurality of cutting die cavities 36 disposed laterally across and peripherally around the outer surface 34.
  • the plurality of cutting die cavities 36 are formed from cutting knives 38 arranged in a wavelike or sinusoidal pattern across the outer surface 34 of the drum 32 (see, e.g., FIG. 5), which is effective to allow a nesting arrangement of the die cavities 36 in a manner that eliminates unused or wasted dough portions between individual cut dough pieces.
  • the individual cutting die cavities 36 are formed from the cutting knives 38 arranged about a periphery 40 of the die cavity 36 to form the shape of the elbow-cracker, where the periphery 40 has a top side 41 with a top or major curvature 42 and a bottom side 43 with a bottom or minor curvature 44 (FIG. 3) to produce the recognizable elbow-shaped dough piece and, at the same time, to also enable the sinusoidal nested arrangement of the plurality of die cavities 36 on the die 30 to form the scrap-less cutting die (see FIGS. 5 and 6).
  • the top degree of curvature 42 of the top side 41 of the cracker shape is different from the bottom degree of curvature 44 of the bottom side 43 of the cracker shape.
  • such combination of non-symmetrical major and minor curvatures 42 and 44 permit the dough to be cut into the recognizable elbow-shape, but still allow for the sinusoidal nesting pattern to produce a scrap-less cutting blade with substantially no unused material between adjacent cutting pieces.
  • the curvatures will be explained in more detail below in reference to FIG. 7 and Table 1.
  • the cylindrical drum 32 is rotatably mounted in a frame (not shown) along its axis X and positioned with its axis X substantially perpendicular to a direction of conveyor travel of the dough sheet.
  • the drum 32 includes the peripheral surface 34 on which the cutting dies 36 are disposed.
  • the drum 32 is positioned above a conveyor (not shown) upon which the dough sheet is advanced in a position to receive the dough sheet.
  • the drum 32 is offset vertically a distance from the conveyor surface approximately equal to the dough sheet thickness.
  • each cutting knife 38 extends radially from the drum peripheral surface 34 of the rotary cutting die 30, with a lower edge 62 disposed on the peripheral surface 34 of the drum 32 and extending radially therefrom with an upper cutting edge 60 radially spaced from the drum surface 34.
  • the cutting knives 38 should have a height, measured from the lower edge 62 to the upper cutting edge 60 that is approximately equal to or slightly larger than the generally uniform thickness of the dough sheet. In this regard, when the cutting knives 38 engage the dough sheet as it passes thereunder, the cutting knives 38 will penetrate through the dough to form and cut the elbow-shaped dough pieces.
  • Each individual cutting die cavity 36 has the periphery 40 in the form of elbow shaped die cups 31 defining elbow shaped recesses 35 therein.
  • the elbow-shaped die cups 31 are defined by the spaced and curved top and bottom sides 41 and 43, respectively, and a pair of spaced end portions 39.
  • the curved top and bottom sides 41 and 43 each have a degree of curvature 42 and 44, respectively, that are preferably different from each other and therefore, the top and bottom sides are not symmetrical. That is, the top and bottom sides do not extend in a parallel fashion to each other.
  • the spaced end portions 39 are inclined inwardly relative to one another defining an angle 50 or 51 therebetween.
  • the included angle 50 of the end portions 39 ranges from about 20 to about 40 degrees, and preferably about 40 degrees.
  • the angle can be defined as the angle of the end portion 39 relative to a horizontal axis Y bisecting the cavity 36.
  • the angle 51 would generally be between about 10 and about 20 degrees and, preferably, about 20 degrees.
  • the elbow shaped die cups 31 include curved corner junctures 52 formed at intersections between the end portions 39 and the top side 41 and bottom sides 43.
  • the die cavity 36 is configured to cut a dough piece having a surface area of about 0.6 to about 0.8 square inches and a dough weight of about 0.7 to about 0.8 grams (about 7 to about 8 grams per 10 dough pieces), which has been identified as important to form a dough piece and cracker product resembling the recognizable elbow-shape and also permit the product to be produced with little to no breakage. Less surface area generally increases the amount of product breakage and greater surface area typically does not resemble a typical-elbow shaped pasta noodle, which the cracker is intended to resemble.
  • the nesting arrangement 74 is in a sinusoidal pattern across the surface 34 of the drum 30. To achieve such nesting, it is the combination of the angle 50 of the end portions 36 relative to one another combined with the surface area and non-symmetrical curvatures 42 and 44 of the top and bottom sides 41 and 43 that permit the nesting arrangement 74 in such sinusoidal arrangement pattern with little to no space between the adjacent die cavities 36.
  • such configuration produces a nesting arrangement with a displacement area 54 between each adjacently positioned die cavity 36 that enables scrap-less cutting even with such non-symmetrical elbow-shaped dies.
  • This displacement area 54 is formed at each area of intersection of four adjacently positioned elbow-shaped die cups 31 as shown in FIG. 5. If the displacement area 54 is too large, it will press an excessive amount of the dough sheet against the conveyor during cutting by the rotary cutting die 30 to form dough waste. Dough waste formed from the displacement area 54 is not baked to form crackers and thus reduces throughput. It is the combination of the selected curvatures 42, 44, angles 50, and surface area of the dough piece that enable such nesting arrangement.
  • the nesting pattern 74 of the elbow shaped die cups 31 described above and an degree of curvatures 42 and 44 of the top and bottom sides 41 and 43 of the elbow shaped die cups 31 are utilized to form the perforations in the dough sheet.
  • the degree of curvature 42 and 44 of the top and bottom sides 41 and 43, respectively, is a measure of the curvature of each side and is generally related to the length of that side. This curvature can be defined by the effective diameter of the curve (D in inches), effective angle (A in degrees), sweep (S in degrees), and arc length (L in inches) of the curve.
  • the degrees of curvature 42 and 44 are different by about 1 to about 4 percent, which enables each elbow shaped die cup 31 to be nested closely in the sinusoidal pattern 74. That is, the bottom side 43 has a tighter degree of curvature ranging between about 1 to about 4 percent over the curvature of the top side 41. As shown in FIG.
  • acceptable degrees of curvature are defined by samples 2, 3, and 4.
  • Samples 1 and 5 which are relatively flat or overly curved did not have acceptable degrees of curvature because they either did not resemble an elbow shape (such as with sample 1), or they did not allow the scrap-less nesting arrangement 74 (such as sample 5).
  • the degree of curvature and particularly the nonsymmetrical degrees of curvature of the top and bottom sides of the elbow shape, is related to the amount of waste between die cavities.
  • a small difference in curvature between the top and bottom sides of the elbow-shaped is effective to form a nesting arrangement to produce the scrap-less cutting die.
  • elbow shaped die cups 31 with too great a degree of curvature 42 and/ or 44 could not be nested as tightly together.
  • the dough waste formed at the displacement areas 52 increased during rotary die cutting.
  • too small of a degree of curvature did not form a dough piece having an elbow-shape.
  • the plurality of cutting dies 36 are arranged into the wavelike or sinusoidal pattern 74 about the peripheral surface 34 of the drum 30.
  • the two-dimensional pattern 74 of FIG. 6 is wrapped peripherally about the cylindrical drum 30 such that peripheral rows 70 of cutting dies 36 extend around the circumferential periphery of the drum 30 and lateral rows 72 of cutting dies 36 extend laterally or longitudinally across the drum 30.
  • the individual cutting dies 36 defining elbow shaped recesses 35 are nested tightly together to form the peripheral rows 70 extending around the drum 30 so that the top side 41 of each cutting die 36 is nested adjacent the bottom side 43 of an adjacent cutting die 36 with ends 39 adjacent each other to form the lateral rows 72.
  • lateral rows 72 extend laterally across the surface of the drum 30. Laterally adjacent cutting dies 36 are flipped 180 degrees with respect to one another such that alternating cutting dies 36 have top sides 41 and bottom sides 43 facing opposite directions. So configured, the lateral rows 72 of cutting dies 36 form a wavelike or sinusoidal pattern. The lateral rows 72 should extend laterally across the drum 30 above the advancing dough sheet to a width as close to the edges of the dough sheet as possible to decrease the amount of dough waste formed along the edges of the rotary cutting die 31.
  • the formed dough pieces are advanced to an oven where they are baked to form cracker products.
  • the formed dough pieces are baked for a time and temperature sufficient to produce a cracker having a moisture level of about 2 to about 4 percent.
  • the process described herein are also configured to produce a cracker with low level of breakage, such as below about 15 percent and preferably below about 5 percent. It was discovered that a combination of a dough weight of individual elbow shaped dough pieces between about 0.7 and about 0.8 grams combined with a dough moisture level of about 2 to about 3 percent formed crackers with such low levels of breakage. A final dough with a reduced water level below about

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Food Science & Technology (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Polymers & Plastics (AREA)
  • Confectionery (AREA)
  • Manufacturing And Processing Devices For Dough (AREA)
  • Bakery Products And Manufacturing Methods Therefor (AREA)

Abstract

La présente invention concerne un procédé de formation de craquelins en forme de coude au moyen d'un emporte-pièce. Selon une mode de réalisation, le procédé comprend d'abord la préparation d'une pâte de biscuit, suivie de la formation de feuille avec la pâte de biscuit pour former une feuille de pâte ayant une certaine épaisseur. Ensuite, la feuille de pâte formée est déplacée vers l'avant à travers l'emporte-pièce pour former une pluralité de pièces de pâte en forme de coude à partir de la feuille de pâte. Les pièces de pâte formées présentent un degré de courbure non symétrique entre les faces supérieure et inférieure de sorte que les pièces de pâte formées aient une configuration en forme de coude reconnaissable et la pluralité de pièces de pâte formée sont emboîtées ensemble par l'emporte-pièce de sorte qu'il ne reste aucune pâte de biscuit en feuille entre les pièces de pâte emboîtées adjacentes.
PCT/US2009/032949 2009-02-03 2009-02-03 Procédés de fabrication de craquelins en forme de coude Ceased WO2010090635A2 (fr)

Priority Applications (5)

Application Number Priority Date Filing Date Title
AU2009339426A AU2009339426A1 (en) 2009-02-03 2009-02-03 Methods for producing elbow-shaped crackers
PCT/US2009/032949 WO2010090635A2 (fr) 2009-02-03 2009-02-03 Procédés de fabrication de craquelins en forme de coude
CN200980156355.7A CN102858180B (zh) 2009-02-03 2009-02-03 用于生产肘形饼干的方法
CA2751065A CA2751065A1 (fr) 2009-02-03 2009-02-03 Procedes de fabrication de craquelins en forme de coude
NZ594471A NZ594471A (en) 2009-02-03 2009-02-03 Methods for producing elbow-shaped crackers dough bread or bakery products

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2009/032949 WO2010090635A2 (fr) 2009-02-03 2009-02-03 Procédés de fabrication de craquelins en forme de coude

Publications (2)

Publication Number Publication Date
WO2010090635A2 true WO2010090635A2 (fr) 2010-08-12
WO2010090635A3 WO2010090635A3 (fr) 2016-03-31

Family

ID=42542562

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2009/032949 Ceased WO2010090635A2 (fr) 2009-02-03 2009-02-03 Procédés de fabrication de craquelins en forme de coude

Country Status (4)

Country Link
CN (1) CN102858180B (fr)
AU (1) AU2009339426A1 (fr)
CA (1) CA2751065A1 (fr)
WO (1) WO2010090635A2 (fr)

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5240731A (en) * 1992-06-24 1993-08-31 General Mills, Inc. Apparatus and methods for recouping scrap dough material
CN1099562A (zh) * 1993-09-01 1995-03-08 广东嘉士利集团股份有限公司 芝麻薄饼生产工艺
US6668484B2 (en) * 2000-10-12 2003-12-30 Riccobene Masonry Company, Inc. Garden edging system
CN100462010C (zh) * 2006-06-16 2009-02-18 广州市焙杰食品有限公司 一种多层韧性饼干的制备方法
WO2008028112A2 (fr) * 2006-08-31 2008-03-06 Kellogg Company Produits alimentaires de type biscuits soufflés et procédé de fabrication correspondant

Also Published As

Publication number Publication date
CN102858180B (zh) 2014-06-25
WO2010090635A3 (fr) 2016-03-31
CN102858180A (zh) 2013-01-02
AU2009339426A1 (en) 2011-08-18
CA2751065A1 (fr) 2010-08-12

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