METHOD AND INSTALLATION FOR THE INDUSTRIAL MANUFACTURE OF BAKERY PRODUCTS

Abstract

A method and installation for the industrial manufacture of bakery products is provided. The method includes placing, optionally after shaping, at least one piece of dough on a support plate, and subjecting the dough to a rising stage. The method further includes, upstream of the rising step, a step where the dough is placed on a substrate heated to a temperature of between 80 C. and 180 C. for the formation of a film on the surface of the dough through contact with said heated substrate.

Claims

1-8. (canceled)

9. A method for the industrial manufacture of bakery products, wherein said method comprises the steps of: placing, optionally after shaping, at least one piece of dough on a support plate; subjecting the dough to a rising stage; wherein, before the rising step, a step is taken where the dough is placed on a substrate heated to a temperature of between 80 C. and 180 C. for the formation of a film on the surface of the dough through contact with said heated substrate.

10. The method for the industrial manufacture of bakery products according to claim 9, wherein the dough is transported, by means of a conveyor belt, over a heating table forming said heated substrate, and the dough is placed on said substrate plate after formation of the film.

11. The method for the industrial manufacture of bakery products according to claim 9, wherein the dough is placed on a substrate plate at a temperature elevated to between 80 C. and 180 C. forming said heated substrate for the production of the film.

12. The method for the industrial manufacture of bakery products according to claim 9, wherein after placing the dough on the heated substrate, said dough is pressed on said heated substrate.

13. The method for the industrial manufacture of bakery products according, wherein said bakery products include long or elongated breads, rolls, baguettes, Parisian breads, and/or round loaves.

14. An installation for the industrial manufacture of bakery products, said installation comprising: means for conveying and placing at least one piece of dough on a support plate; means for transporting the support plate through at least one rising unit; wherein the installation further comprises, upstream of the rising unit, an arrangement for placing the dough on a substrate heated to a temperature of between 80 C. and 180 C. for the formation of a film on the surface of the dough in contact with said heated substrate.

15. The installation for the industrial manufacture of bakery products according to claim 14, wherein it comprises a conveyor belt for conveying and placing a piece of dough on a support plate, under the conveyor belt a heating table extends substantially constituting the heated substrate.

16. The installation for the industrial manufacture of bakery products according to claim 14, wherein it comprises a heating member for heating the support plate for placing the dough on said support plate at a temperature raised to between 80 C. and 180 C.

17. The installation for the industrial manufacture of bakery products according to claim 14, wherein it comprises a pressing member for pressing the dough onto the heated substrate.

18. The installation for the industrial manufacture of bakery products according to claim 14, wherein said bakery products include long or elongated breads, rolls, baguettes, Parisian breads, and/or round loaves.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Understanding this description will be facilitated by reference to the accompanying drawings in which:

[0044] FIG. 1 is a schematic representation, and a longitudinal cross-section, illustrating a particular embodiment of the method and a part of the industrial manufacturing facility for bakery products according to the invention;

[0045] FIG. 2 is a schematic representation similar to FIG. 1, in a view from above;

[0046] FIGS. 3A, 3B, and 3C each represent a cross-section illustrating in detail the pieces of dough respectively before, during, and after forming a film on the bottom surface of said pieces of dough according to one embodiment; and

[0047] FIG. 4 is a schematic representation, and a longitudinal cross-section, illustrating a particular embodiment of the method and a part of the industrial manufacturing facility for bakery products according to the invention;

DETAILED DESCRIPTION OF EXAMPLARY EMBODIMENTS OF THE INVENTION

[0048] As shown diagrammatically in FIGS. 1 to 4 of the accompanying drawings, this invention relates to a method and an installation 1 for the industrial manufacture of bakery products, such as baguettes, Parisian breads, long or elongated breads, round loaves, or even torpedo loaves or rye breads.

[0049] Preferably, the bakery products produced by the implementation of the method of the invention and by means of the installation 1 of the invention, part of which is shown in the Figures of the attached drawings, are products requiring a shaping step.

[0050] In addition, the method and the installation 1 are particularly suitable for the industrial production of this type of products, which are reputed to have no added fat in their recipe and which must be delivered without residues of flouring.

[0051] Also, products produced by the implementation of the method of the invention are, more preferably, products whose fat content is less than or equal to 0.5% by weight, relative to the total weight of the product.

[0052] The method of the invention, for the industrial manufacture of bakery products as described above, comprises, at least, the following steps: [0053] placing, optionally after shaping, at least one piece of dough 2 on a support plate 3a, 3b; [0054] subjecting the at least one piece of dough 2 to a rising stage.

[0055] In addition, the method according to the invention comprises an additional step upstream of the step of subjecting the dough 2 to a rising stage. This additional step comprises: [0056] placing the at least one piece of dough 2 on a heated substrate 4a, 4b, wherein said substrate is heated to a temperature of between 80 C. and 180 C., and forming a film 5 or skin on a part of the surface of the at least one piece of dough 2, which part of the surface is facing said heated substrate 4a, 4b, and/or is in contact with said heated substrate 4a, 4b.

[0057] Most commonly, after the rising step, we proceed to a total or partial baking of the pieces of dough 2. However, it is also possible that risen pieces of dough 2 may be frozen for delayed baking.

[0058] For example, the dough 2 may be conveyed, by means of a conveyor belt 6, moving above a heating table 7. This then forms said heated substrate 4a. The at least on piece of dough 2 is subsequently placed on a support plate 3a, shown in FIG. 1, after the film 5 or skin is formed.

[0059] In another example of the method of the invention, with reference to FIG. 4, the at least one piece of dough 2 is placed on a support plate 3b which is previously brought to a temperature of between 80 and 180 C. In this example, the support plate 3b comprises a tray, which tray 3b forms, in this case, said heated substrate 4b to produce the film 5 or skin.

[0060] Whatever the embodiment chosen for the method of the invention, said at least one piece of dough 2 is preferably be pressed onto said heated substrate 4a, 4b, in order to further improve the formation of the film 5.

[0061] This invention also relates to an installation 1, a part of which is visible in particular in FIGS. 1 and 2 of the accompanying drawings, said installation 1 being intended for the industrial manufacture of bakery products, such as long or elongated breads, bread rolls, baguettes, Parisian breads, round loaves etc.

[0062] This installation 1, particularly advantageous for the implementation of the method of the invention, comprises a means for conveying and placing at least one piece of dough 2 on a support plate 3a, 3b. In routine fashion, such means of conveyance will take the form of one or more conveyor belts.

[0063] This installation 1 also comprises a means for transporting the support plate 3a, 3b through, at least, one rising unit. In routine fashion, such means for transporting will take the form of one or more conveyors. However these transport means are not shown in detail in the accompanying Figures. The said rising unit, which is arranged downstream of the position where the at least one piece of dough 2 is placed on a support plate 3a, 3b, is not shown in the accompanying Figures. The installation 1 may also comprise a dough baking unit, this unit being, however, quite optional.

[0064] According to the invention, upstream of the rising unit, the installation 1 comprises a means for placing the at least one piece of dough 2 on a heated substrate 4a, 4b at a temperature of between 80 C. and 180 C. for the formation of a film 5 or skin on the part of the surface of the piece of dough 2 which is in contact with said heated substrate 4a, 4b.

[0065] Thus, a piece of dough 2, resulting for example from an installation with an upstream production and dough division, and not shown in the Figures, is conveyed by one or more conveyor belts towards its placement upon the support plate 3a, 3b.

[0066] According to a first exemplary embodiment, illustrated in FIGS. 1 to 3, the conveyor belt 6 extends above a heating table 7 the temperature of which is adjustable between room temperature and about 180 C., preferably between 80 C. and 180 C., and even more preferably between 100 C. and 150 C. The heating table 7 then substantially forming the heated substrate 4a.

[0067] Thus, a piece of dough 2 placed on the conveyor belt 6 is heated, especially at its contact zone with the latter, by said heating table 7 extending below, resulting in the formation of the film 5.

[0068] By means of an adjustable feed speed of the conveyor belt 6 and/or a discontinuous operation of the latter and/or the length of the heating table 7 under this belt, the time is determined for a piece of dough 2 to be exposed to the influence of this heating for the formation of the film 5.

[0069] The heating table 7 preferably incorporates, but is not limited to, one or more oil radiator(s) as a heating means.

[0070] Advantageously, transversely above the conveyor belt 6 and the heating table 7, pressing members 8 extends. The pressing members 8 provide the means of applying pressure on the pieces of dough 2. The pressing members 8 are configured so that the pieces of dough 2 are pressed upon the heated substrate 4a, by moving the dough 2 under the appropriate pressure means.

[0071] In particular, these pressing members 8 can take the form of a roller 81 shown in solid lines in FIG. 1, or of a pressure band 82, shown in dashed lines in the same Figure. Preferentially the pressing members 8 are subjected to a driving device for driving the pressing members 8 in a direction identical to the conveyor belt 6 on which said pieces of dough 2 rest, or even at a similar speed so as to simply accompany the pieces of dough 2 during their passage under these pressing members 8. In particular, the driving of the pressing members 8 is configured so that the driving direction of the part of the pressing members 8 facing the conveyor belt 6 is preferably in the same direction of the driving direction of the conveyor belt 6.

[0072] The distance or height of placement of this roller 81 or of the pressure band 82 above the conveyor belt 6 is advantageously adjustable in order to be able to adjust the force of the pressure applied through them to a piece of dough 2.

[0073] In the case of a pressure band 82, it extends above the dough 2 by coming to wrap around two transverse return rollers, and moves in accompaniment to the pieces of dough 2 during the application of pressure on the conveyor belt 6. Said pressure band 82 is furthermore adjustable, preferably on an angle with respect to this conveyor belt 6, to produce a variable pressure on a piece of dough 2 between the engagement upstream of the latter under this band 82 and its clearance downstream.

[0074] It should be noted here that the pieces of dough 2, especially after shaping, have a certain elasticity, often referred to as dough strength. Accordingly, the pieces of dough 2 will tend to regain their original shape. However, this is done with a certain remanence, and pressure applied only locally and lasting a period of time achieves the desired goal and is specified below.

[0075] With reference to FIGS. 3A to 3C, the pieces of dough 2, shaped or not, which arrive above the heating table 7 are pressed between the pressing members 8, for example a roller 81 or a pressure band 82, and the conveyor belt 6. This pressure is intended to ensure placing an extended section of the circumference of the pieces of dough 2 into contact with the heated substrate 4a to form the film. Said heated substrate constituted for example, by the heating table 7 and/or the conveyor belt 6.

[0076] The extended section of the pieces of dough 2, brought into contact with the heating table 7, is represented by crosshatching in FIG. 3B, where the pieces of dough 2 are pressed by the pressing members 8. In FIG. 3C, after passing under the pressing members 8, the elasticity of the dough results in a recovery of the initial shape of the pieces of dough 2. FIG. 3A illustrates the narrow section of the pieces of dough 2 placed on the belt 6 before applying pressure to said pieces of dough 2.

[0077] Thus, preferably, bringing an extended section of the circumference of the pieces of dough 2 into contact with the heated substrate 4a has the effect of creating a thin film 5 or skin under said dough 2. The thin film 5 results from a superficial drying of the base of the piece of dough 2. The width of this film 5, as well as its thickness, are adjustable through the pressure exerted when bringing the pieces of dough 2 into contact with the heated substrate 4a and the duration of this contact. In most cases, this contact of the pieces of dough 2 with the substrate heated to a temperature between 80 C. and 100 C., is on the order of 5 to 10 seconds. When the pieces of dough 2 return to their initial shape following the passage under the pressing members 8, the base where the insulating film 5 has formed is partially raised so that this insulating film 5 is advantageously present, in the end, on the lower surface of the pieces of dough 2 and on the lower part of its flanks, as shown in FIG. 3C.

[0078] Following the formation of the insulating film 5 on the surface of the pieces of dough 2 in contact with the heated substrate 4a here constituted by the heating table 7, said pieces of dough 2 are placed on the support plate 3a, for delivery to the downstream rising unit.

[0079] According to an alternative exemplary embodiment, equally interesting, described with reference to FIG. 4, said installation 1 comprises a heating means, not shown, for the support plate 3b, which heating means preferably comprise a heater which is configured for heating the support plate 3b up to a temperature preferably to between 80 C. and 180 C., more preferably between 100 C. and 150 C. Accordingly, the pieces of dough 2 are placed on said support plate 3b at a raised temperature.

[0080] In other words, in this embodiment, the pieces of dough 2, after optionally shaping, are conveyed and placed onto a heated support plate 3b. When the pieces of dough 2 are placed on the support plate 3b, the bottom area of the pieces of dough 2 is subjected to a high temperature, for forming the insulating film 5 or skin. The support plate 3b then substantially forms the heated substrate 4b for the formation of the film or skin.

[0081] Here, the empty support plate 3b is heated to an adjustable temperature of up to 180 C., before the optionally formed pieces of dough 2 are placed thereon.

[0082] Subsequently, the pieces of dough 2 are placed onto the support plate 3b. As schematically shown in FIG. 4, only a limited portion of the circumference of the pieces of dough 2 is in contact with the preheated support plate 3b, in particular the part of the circumference that is in contact with the support plate 3b.

[0083] In this embodiment also, the installation 1 is advantageously completed by a means of applying pressure to the pieces of dough 2 by use of a pressing member 8. Again, the pressure is applied for the purpose of ensuring that an extended section of the circumference of the pieces of dough 2 will come into contact with the heated substrate 4b, in this case the support plate 3b. This results in the formation of an insulating film 5 on an extended section of the circumference. Said extended film 5 ensures that insulating function of said film 5 is at least substantially maintained, even after the pieces of dough 2 have doubled or tripled in volume during its rise.

[0084] In the particular case illustrated in FIG. 4 attached, where the support plate 3b has a plurality of cells so that each may receive a piece of dough 2, including long or elongated breads, the pressing member 8 may advantageously be presented in the form of rollers 83.

[0085] These latter extend substantially perpendicular to the cells of the support plate 3b and are mounted on a common transverse drive axis 84, motorized or not, and configured perpendicularly to the direction of said cells. The number of rollers 83 being preferentially equivalent to the number of cells in the plate 3b. In addition the shape of the rollers 83 is configured appropriate to the shape of the cells.

[0086] This second embodiment of the method and of the installation of the invention has a considerable advantage in the case of conventional shaping and dispensing methods in which it is not possible to locate the bottom or the base of the shaped piece of dough before its placement. The placement of the pieces of dough into the cells of the plate is being done transversely with a shaped piece of dough, which is presented parallel to the empty cell of the plate, and wherein the placement is being made by rotating the piece of dough during its fall into the cell.

[0087] More generally, the method and the installation 1 according to the invention make it possible to eliminate, or at least to greatly reduce, the need for flouring the dough 2 and/or the support plate 3a, 3b prior to placement.

[0088] There are three major advantages to the removal of flouring, especially in the field of industrial production of bakery products: [0089] improvement in the quality of the crust on the bottom of the finished product because excessive flour on the bottom constitutes a thermal insulator and its elimination, or its reduction, reinforces the heat exchange on the bottom of the loaf; [0090] significant reduction in the pollution that flouring represents throughout an industrial production circuit, and in particular, through the reduction of flouring and flour dust in suspension in the air, the risk of starting a fire is reduced; [0091] significant reduction in the fouling of the rising and/or baking supports, thus allowing for less frequency in the obligation to wash and dry said supports.

[0092] In addition, the production can be carried out without the inconvenience of solid pans, i.e., that do not have perforations, the latter being responsible for the presence of bumps on the finished product constituting a distinctive devaluing sign.

[0093] In addition, the presence of the insulating film on the bottom of the dough avoids the formation of a multitude of hollows at the time of baking the product, the latter usually resulting in an evacuation of the moisture from the dough to said plate by which it is retained during production when using a solid plate without flouring.

[0094] In summary, the invention relates to a method for the industrial manufacture of bakery products, wherein said method comprises the steps of: [0095] placing, optionally after shaping, at least one piece of dough 2 on a support plate 3a, 3b; [0096] subjecting the dough 2 to a rising stage;

[0097] The method is particular in that, upstream of the rising step, a step is taken where the dough 2 is placed on a substrate 4a, 4b heated to a temperature of between 80 C. and 180 C. for the formation of a film 5 on the surface of the dough 2 through contact with said heated substrate 4a, 4b.

[0098] The invention also relates to an installation 1 for the industrial manufacture of such products.

[0099] The invention makes it possible to produce bakery products industrially without the need to flour the pieces of dough or the rising supports, while imparting an artisanal appearance to the products.