Method and Device for Producing Products From Warm Dough

Abstract

Disclosed is a method for producing products from warm dough, which includes producing a dough by means of cooking; dispensing the dough into a first container up to a predetermined level; inserting, while the dough is warm, a first forming cutting mold provided with a plurality of tubular cells in the shape of the product to be obtained, for example, a croquette, to fill each of the cells with the dough; and rapidly cooling, thereby forming the croquettes, which are pushed out by means of a first ejector mold to obtain a plurality of croquettes simultaneously. Any leftover dough is dispensed warm into a second container provided with a movable separator, which moves after dispensing, until the dough reaches the predetermined level, and the previous steps are repeated.

Claims

1. A method for producing products from warm dough, comprising producing a dough by means of cooking, which is dispensed into a first container up to a predetermined level, corresponding to a dimension of the product to be obtained, the method further comprising: inserting into the first container with the warm dough, a first forming cutting mold provided with a plurality of tubular cells that comprise the shape of a model of the product to be obtained, to simultaneously fill each one of the tubular cells with the dough, applying a rapid cooling to the set of the previous phase, extracting the first forming cutting mold from the first container, and tightly inserting extensions of a first ejector mold into the tubular cells of the first forming cutting mold to eject each product formed in each of said tubular cells to the outside.

2. The method, according to claim 1, wherein the dispensing phase to fill the first container to a previously established level is selected between filling up to a mark established in the first container, filling by weighing the first container with the dough, and a computer-programmed automatic filling.

3. The method, according to claim 1 which, in the case where there is leftover dough with an insufficient volume to fill the first container to the predetermined level, the method comprises: dispensing said warm leftover dough into a second container, provided with a movable separator, moving the movable separator until the leftover dough reaches the predetermined level, inserting into the second container, with the dough warm, a second forming cutting mold configured to insert the movable separator and provided with a plurality of tubular cells with the shape of the product to be obtained, to simultaneously fill each of the tubular cells with the leftover dough, applying a rapid cooling of the set of the previous phase, extracting the second forming cutting mold from the second container, and tightly inserting extensions of a second ejector mold into the tubular cells of the second forming cutting mold, to eject each product formed in said tubular cells to the outside, to obtain the same product model as with the first container.

4. The method, according to claim 1, further comprising a pasting-breading phase of the product ejected and formed in each of the tubular cells and a packaging phase of the same.

5. The method, according claim 1, wherein the product to be obtained is croquettes.

6. A device for producing products from warm dough, comprising: a first container configured to house a warm dough of a product to be obtained up to a predetermined level, corresponding to a height of the product to be obtained, a first forming cutting mold comprising a plurality of tubular cells in the shape of a model of the product to be obtained, and a first ejector mold comprising a plurality of extensions configured to be introduced tightly into the tubular cells of the first container.

7. The device, according to claim 6, wherein the plurality of tubular cells of the first forming cutting mold and the plurality of extensions of the ejector mold are arranged adjacent to each other, forming rows and columns.

8. The device, according to claim 6, comprising: a second container, configured to dispense leftover warm dough of the product to be obtained with an insufficient volume to fill the first container up to the predetermined level, which on the inside of at least one of the side walls thereof comprises marks for signaling positions; a separator, configured to fit inside the second container, and to move the leftover warm dough up to a selected position in which the separator is located in correspondence with one of the marks and the dough reaches the same predetermined level of the first container, corresponding to the product model to be obtained; a second forming cutting mold, comprising a plurality of tubular cells in the shape of the product model to be obtained, and aligned forming rows and columns, to be inserted into the warm dough of the second container, wherein between each of said rows or columns of the cells, the same comprises a slot to allow for the insertion of the separator into the slot corresponding to the selected position, and a second ejector mold comprising a plurality of extensions configured to be tightly introduced into the tubular cells of the second forming cutting mold.

9. The device, according to claim 8, wherein the first and second container, the first and second forming cutting mold, and the first and second ejector mold comprise handles that protrude laterally.

10. The device, according to claim 8, wherein the external measurements of the first and second forming cutting mold fit with the internal measurements of the first and second container, respectively.

11. The device, according to claim 8, wherein the first and second container comprise stacking corners.

12. The device, according to claim 8, comprising a support for an element selected between the first and second forming cutting mold.

13. The device, according to claim 12, wherein the support comprises a frame supported by legs, into which an element selected between the first and second forming cutting mold is inserted.

14. The device, according to claim 9, wherein the first and second container comprise a recess for housing the handles of the first and second forming cutting mold.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0079] The terms Fig., Figs., Figure, and Figures are used interchangeably in the specification to refer to the corresponding figures in the drawings.

[0080] To complete the description, and for the purpose of helping to make the features of the invention more readily understandable, this description is accompanied by a set of figures constituting an integral part of the same, which by way of illustration and not limitation represents the following:

[0081] FIG. 1 shows a schematic representation of the phases that constitute the process of the invention.

[0082] FIG. 2 shows an exploded perspective view of the different components of the device, according to an embodiment of the invention.

[0083] FIG. 3 shows an exploded perspective view of the components of the device in an embodiment in the case where there is excess croquette dough.

[0084] FIG. 4 shows a perspective view of the support that is used to hold the components shown in the previous figures in the production of the croquettes.

[0085] FIG. 5 shows a section along the longitudinal axis of the first forming cutting mold represented in FIG. 2.

[0086] FIG. 6 shows a section along the longitudinal axis of the second forming cutting mold represented in FIG. 3.

[0087] FIG. 7 shows a section along the longitudinal axis of the first ejector mold of

[0088] FIG. 2.

[0089] FIG. 8 shows a section along the longitudinal axis of the second ejector mold of FIG. 3.

DESCRIPTION OF THE INVENTION

[0090] Below, with the help of the previously mentioned figures, the device is described along with the production method of the invention for producing a product from warm dough, which in the example are croquettes, comprising the following phases (FIG. 1):

[0091] 1. Producing a dough by means of cooking (1), under the same conditions as it is currently done, but in this case with the advantage of allowing the dough to be produced with the desired texture, contrary to current methods, since the invention adapts to any type of dough texture. This is possible due to the rest of the phases and devices used, which are described below.

[0092] 2. The dough from the cream cooker, warm kneading machine or similar, is then dispensed (2) warm into the first containers (7) (FIG. 2), until the dough reaches a predetermined level, which in the embodiment corresponds to the height or length of the croquette model to be obtained. The control of the filling up to this level can be done manually or automatically, either by controlling the weight of the dough, placing the first containers on a floor scale, dispensing it until it reaches a level marked in the first containers or by programming when the dispensing is exclusively automatic. To facilitate the handling of the first containers, the same have been provided with handles (13).

[0093] 3. Once the dough has been dispensed warm into the first containers (7), a first forming cutting mold (8) is inserted (3) into each of them, which comprises a plurality of tubular cells (9), provided in the shape of the croquette model to be obtained, which in the example is a cylindrical shape, and which are arranged in rows and columns, so that they fit tightly inside the first containers (7). In this way, there are no remnants of dough on the sides and all the dough remains inside the cells (9) of the first forming cutting molds (8), thus achieving the shape of the chosen croquette without product loss, the thickness of which is established by the cross section of the tubular cells (9) and the height by the filling level of the dough in the first containers. To facilitate this phase, the first forming cutting molds (8) are equipped with a handle (13) that fits into a slot (14) provided in the first containers (7).

[0094] 4. Then, rapid cooling (4) is applied to the set of the previous phase, made up of the dough, the first containers (7) and the first forming cutting molds (8), which now form a single operating unit. This cooling is done without the dough having to rest, so that the production process is considerably shortened by means of the invention. Cooling is done conventionally, which according to standards is carried out for 2 hours, keeping the interior of the dough below approximately 10? C., which may vary depending on existing regulations. It is important to mention that at this point there is no need to worry about the possibility that the rapid and/or excessive cooling of the devices used for this purpose (blast chillers, rapid cooling tunnels . . . ), may crack the dough or make the dough brittle because the shape of the croquette has already been obtained, and thus, in phase (1) any texture can be obtained, as indicated.

[0095] 5. Once the dough has cooled, the forming cutting mold (8) is extracted (5) from inside the first container (7), by means of the handles (13) thereof, cleaning the inside of said first container, leaving no dough inside the same. Then, the forming cutting mold (8) is placed on a support (10) and on the area where the croquettes are to be placed, for example directly on a paster-breader, to continue with the process. To facilitate this operation, the support (10) comprises a frame (11) with legs (12) as a table, in which the first forming cutting mold is inserted, which is equipped with handles (13), which abut against said frame and facilitate the handling thereof.

[0096] Therefore, in the invention the dough is not required to rest, as in the state of the art, so there is no need to use an intermediate chamber for the dough to rest, allowing the whole process to be done linearly, without interruption due to the need for the dough to rest. In addition, these features of the invention prevent any cross contamination or bacterial growth from occurring.

[0097] 6. Extensions (15) of a first ejector mold (16) are then inserted (6) tightly into the tubular cells (9) of the first forming cutting mold (8), so that the croquettes are pushed downwards, exiting through the lower part of the tubular cells (9).

[0098] Given that there is a plurality of tubular cells (9), in this phase, a plurality of croquettes is simultaneously obtained, which, depending on the thickness of the croquette, can be hundreds of croquettes, unlike the state of the art in which this function is carried out in one of the outlet nozzles of the filling machines, normally one or two, and in the cases of greater volume up to 8 simultaneous outlet nozzles. Therefore, the invention produces croquettes extremely quickly, considerably increasing the production thereof, and in such a way that it leaves practically no time for the growth of bacteria.

[0099] Consequently, the described method and device avoid direct contact with the dough by the operator, thus preventing any type of product contamination therefrom.

[0100] In the case, in which at the end of phase (2), meaning after filling the first containers (7), there is a certain amount of leftover dough that has an insufficient volume to fill a first container (7) up to the predetermined level, the use of a second container (7) (FIG. 3) is envisaged, into which said leftover dough is dispensed, the configuration of which is the same as that of the first container (7), but with the difference in that it comprises a series of marks (17) arranged facing each other on two of the facing side walls thereof. These marks are intended to indicate different positions at which a separator (18) is to be situated, which fits inside the second container (7), between said side walls, in such a way that it is configured to allow the leftover dough, dispensed in the second container (7), to move to a position in which the separator (18) is aligned with one of the marks (17) and the dough reaches the same predetermined level for the first container (7), a position which allows for the insertion in the second container of a second forming cutting mould (8), to carry out the phase (3), as described below.

[0101] Thus, the configuration of the second forming cutting mould (8) is the same as that of the first forming cutting mold (8), but with the difference in that it is provided with slots (19) which, when inserting (3) the second mold (8) into the second container (7), the same are aligned with the marks (17), such that one of said slots (19) is inserted into the separator (18), thus obtaining the same croquette model as with the first containers (7). Consequently, any remaining final dough that does not fit the size of the first containers is used, regardless of the amount, minimizing product loss as much as possible.

[0102] Then, while the rapid cooling of the dough in the first containers (7) is taking place, the leftover dough dispensed into the second container (7) is cooled, and the second forming cutting mold is extracted (5) to carry out the phase (6), which in this case is done by means of a second ejector mold (16), the same as the first mold (16), but adapted to be able to be tightly inserted into the second mold (8).

[0103] The described method is very easy and convenient to carry out manually, but it can obviously also be mechanized and/or automated, if so preferred.

[0104] Lastly, any of the phases that are conventionally carried out after obtaining the shape of the croquette, such as a pasting-breading phase, and the subsequent packaging for distribution and sale, are carried out.

[0105] It has been envisaged that the containers can be stacked, and thus on the bottom face of the bases thereof, and close to the corners, they have been provided with stacking corners, not shown as they are the conventional type, such as corners made up of projections provided with two angular sections parallel to two adjacent sides of the containers.