Multivariable baking method and device therefor

Abstract

A multivariable method for continuously producing bakery products including: producing a first dough phase, applying the first dough phase to a first conveyor belt, inputting the relaxed first dough phase into a second kneading device and producing a second dough phase, applying the second dough phase to a second conveyor belt, transferring the dough strip onto a third conveyor belt, folding the dough strip, inserting the dough strip into a second rolling device, cutting the dough strip into a predetermined number of dough pieces, loading baking molds with the dough pieces, fermenting the dough pieces baking the dough pieces, removing the baked bakery product, and cooling the bakery product, and cooling the baking molds after the baked bakery product has been removed.

Claims

1. A multivariable method for the continuous production of large bakery items and small bakery items in a single production line, comprising: producing a first dough phase from dough-forming raw materials at a temperature of 20 C. to 30 C. in at least one first continuous kneading device; applying the first dough phase from the first kneading device onto a first transportation belt in order to relax the dough; introducing the relaxed first dough phase into at least one second continuous kneading device and producing a second dough phase by feeding dough-stressing raw materials at a temperature of 25 C. to 35 C.; applying the second dough phase from the second kneading device onto a second transportation belt, thereby forming an inhomogeneous dough sheet on the second transportation belt; transferring the inhomogeneous dough sheet from the second transportation belt to a third transportation belt by way of at least one dough sheeter, the dough sheeter producing a homogenous dough sheet on the third transportation belt, the third transportation belt having at least one first rolling device which shears the homogenous dough sheet to a thickness of 3 mm to 50 mm thereby forming a rolled dough sheet, and transferring the rolled dough sheet onto a fourth transportation belt for relaxation; folding the rolled relaxed dough sheet; introducing the folded dough sheet into at least one second rolling device, wherein the folded dough sheet is sheared to a thickness of 2 mm to 20 mm; cutting the dough sheet into a predetermined number of dough portions; filling square-shaped baking molds or square-shaped baking trays having predefined constant dimensions with the dough portions; fermenting the dough portions in the open baking molds; baking the dough portions in the baking molds or trays, wherein a baking oven that is used for baking includes a plurality of baking zones having at least four heat-transfer variants comprising conduction, convection, radiation, and condensation, and wherein the baking oven may be operated at dissimilar load levels; automated retrieval of the baked bakery product from the baking mold, and cooling of the bakery product; and cooling the baking molds or trays after retrieval of the baked bakery product.

2. The method as claimed in claim 1, wherein the step of folding the relaxed dough sheet comprises folding the relaxed dough sheet onto a fifth transportation belt, in a manner transverse to the running direction of the fifth transportation belt, that is disposed perpendicularly to the fourth transportation belt.

3. The method as claimed in claim 1, wherein the homogeneous dough sheet is folded in a manner parallel with a running direction of the transportation belt, along a longitudinal axis of the dough sheet.

4. The method as claimed in claim 1, wherein the folded dough sheet is rolled in the at least one second rolling device to a final dough thickness of 2 mm to 10 mm.

5. The method as claimed in claim 1, wherein the dough sheet, after folding and renewed rolling, is cut in a longitudinal direction and in a transverse direction into a predetermined number of dough portions by using at least one cutting device.

6. The method as claimed in claim 1, wherein the cut dough portions are rolled up in a running direction, to transverse axis of said dough portions, and the rolled-up dough portions are molded to a predetermined shape.

7. The method as claimed in claim 1, wherein lateral faces of the baking molds are identical.

8. The method as claimed in claim 1, wherein the fermentation temperature is between 30 and 35 C. and the fermentation time is between 30 and 120 min.

9. The method as claimed in claim 1, wherein the dough portions are baked in the baking molds at temperatures between 150 and 250 C.

10. The method as claimed in claim 1, wherein the baking time is between 5 and 35 min depending on the dough to be baked.

11. The method as claimed in claim 1, wherein the convection heat-transfer variant of the baking oven is precisely regulated in a product-specific manner by selectively switching on vertical and horizontal turbulences.

12. The method as claimed in claim 1, wherein the cooling of the baking molds after retrieval of the baked bakery product is performed using a water jet at temperatures between 20 and 30 C.

13. A device for carrying out a method as claimed in claim 1, the device comprising: at least one first kneading device, and at least one second kneading device, which are interconnected by way of a first transportation belt; at least one second transportation belt for transferring the dough sheet that exits the second kneading device into one at least one funnel device and onto at least one third transportation belt; at least one first rolling device; at least one fourth transportation belt for transferring the dough sheet that has been rolled in the first rolling device onto at least one fifth transportation belt; at least one second rolling device for folding the dough sheet that has been infed on the fourth transportation belt; at least one cutting device for cutting the dough sheet into a predetermined number of dough portions; at least one device for filling the baking molds with the cut dough portions; at least one baking oven for baking the dough portions in the baking molds; at least one robot for retrieving the bakery products from the baking molds; at least one first cooling device for cooling the baking molds after retrieval of the baked bakery product; and at least one second cooling device for cooling the bakery products.

14. The method as claimed in claim 1, further comprising automated covering of the baking molds that are filled with the fermented dough portions.

15. The method as claimed in claim 14, further comprising automated removal of the cover from the baking molds.

16. The method as claimed in claim 1, wherein a water jet is used to cool the baking molds after retrieval of the baked bakery product.

17. The method of claim 1, wherein the dough-forming raw materials for the first dough comprise water, sourdough, and flour, and the dough-stressing materials for the second dough phase comprise fat and sugar.

18. The method as claimed in claim 1, wherein the dough sheet is sheared in the first rolling device to a thickness of 10 mm to 40 mm.

19. The method as claimed in claim 18, wherein the dough sheet is sheared to a thickness of 20 mm to 35 mm.

20. The method as claimed in claim 16, wherein the automated covering of the baking molds that are filled with the fermented dough portions is performed using at least one robot.

21. The method as claimed in claim 17, wherein the automated removal of the covers from the covered baking molds, and the automated retrieval of the baked bakery product from the baking mold are performed in each case by means of a robot.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) The present invention will be explained in more detail hereunder with reference to FIG. 1 by way of a plurality of exemplary embodiments. In the drawing:

(2) FIG. 1 shows a schematic illustration of an embodiment of the method according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

(3) FIG. 1 shows a schematic overview of an embodiment of the present method, wherein a first dough phase is produced in a first kneader 1, for example a first kneading worm, from dough-forming raw materials such as wheat flour, water, and/or sourdough. After a predetermined time and an input of energy while kneading, which may vary depending on the desired bakery product, the first dough phase is deposited from the first kneader 1 onto a first transportation belt. The dough remains on the transportation belt or relaxation belt for a time of for example 30 s, before being introduced into the second kneader 2. Post-kneading of the dough is performed in the second kneader 2 with the addition of dough-stressing raw materials, in particular fat and other types of sugar and sugar-based alcohols.

(4) After applying the second dough phase from the kneader 2 onto a second transportation belt, so as to form a second dough sheet, the latter is transferred from the second transportation belt by way of at least one dough sheeter 3 having a funnel device and roller pairs onto a third transportation belt. The dough sheeter 3 requires the formation of a homogenous dough sheet, which is deposited onto the third transportation belt. The third transportation belt is part of a lamination installation or dough-rolling installation that is provided with a roller that is disposed in a linear manner as first rolling device 4. Upstream of the rolling device, the thickness of the dough sheet that is deposited onto the third transportation belt is 40 mm, for example. The first rolling device 4 may be composed of a rolling-out unit or of a multiple-roller system which is equipped with an upper and a lower motive-powered roller, enabling the dough sheet to be rolled to a dough thickness or dough height, respectively, of 30 mm and less, depending on the desired bakery product. In this way, the dough thickness of the dough sheet after exiting the first rolling device 4 in the case of the production of a toast loaf is around 6 mm, in the case of milk rolls around 4 mm, and in the case of ciabatta rolls 10 mm.

(5) A further relaxation step is performed once the dough sheet has exited the first rolling device 4 onto a fourth transportation belt. The relaxation step of the rolled dough sheet on the fourth transportation belt is followed by folding the relaxed dough sheet, either in the running direction or in a manner vertical to the running direction. The type of the folding procedure is again determined by the type of the desired bakery product. In this way, the rolled dough may be applied onto a fifth transportation belt that is disposed so as to be vertical to the fourth transportation belt, said rolled dough being deposited or laminated in a perpendicular multi-layered manner during the transition from the fourth transportation belt to the fifth transportation belt. The stability of the dough structure is increased as a result. The dough thickness is increased by a factor of 10 to 30.

(6) In another variant, the dough is folded inward in the running direction of the running belt, that is to say laterally by 180 in relation to the central axis from the right or the left, as a result of which the dough-sheet thickness is increased by a factor of 10 to 30.

(7) The folded dough sheet is subjected to a further shearing or rolling process, respectively, in a second rolling device 5 composed of a multiple-roller system and a calibrator unit. Shearing or rolling, respectively, of the folded dough sheet to a dough thickness of 2 mm and more, again depending on the desired bakery product, is performed in the second rolling device 5. In this way, the dough thickness after exiting the second rolling device 5 is around 3 mm for a toast loaf, around 2 mm for a milk roll, and around 5 mm for ciabatta rolls.

(8) After the rolled dough sheet has exited the second rolling device 5 and been deposited onto a further transportation belt, the dough sheet is cut in the longitudinal direction and transverse direction into a predetermined number of dough portions, depending on the desired bakery product, using at least one cutting device 6.

(9) Thus, in the case of a toast loaf, the dough sheet is first cut in the longitudinal direction (that is to say in the running direction of the dough sheet) into three dough sheets running in parallel, and the three dough sheets are subsequently cut in the transverse direction and rolled up in a manner perpendicular to the running direction. The dough portions thus obtained are subjected to a further cutting step into four equally sized dough pieces which are rotated in the running direction by 90 and are placed onto a square baking tray (10001000 mm, or 11001100 mm). One baking tray accommodates 24 toast loaves.

(10) If milk rolls are to be obtained, the dough sheet is first cut in the longitudinal direction (that is to say in the running direction of the dough sheet) into a plurality (3 to 10, preferably 5 to 7) dough sheets running in parallel, and the longitudinally cut dough sheets are subsequently cut in the transverse direction. The dough portions thus obtained are again rolled up in a manner perpendicular to the running direction and are placed onto a square baking tray (for example 10001000 mm, or 11001100 mm). One baking tray may comprise 84 milk rolls, for example.

(11) Also in the case of ciabatta rolls, the dough sheet is first cut in the longitudinal direction (running direction of the dough sheet) into a plurality of dough sheets running in parallel, the latter being subsequently cut in the transverse direction. The dough portions thus obtained are again rolled up in a manner perpendicular to the running direction and are placed onto a baking tray (10001000 mm). One baking tray may comprise 70 ciabatta rolls, for example.

(12) After the dough portions have been cut and deposited into the respective baking molds, the fermentation process is performed in the baking molds at varying fermentation temperatures which are chosen depending on the desired bakery product. After the fermentation process, the baking molds, using a first robot 7, may be covered with respective lids. The covered baking molds are infed to the baking oven and are baked for a predetermined time that depends on the desired bakery product. Toast loaves and sandwich loaves are preferably lidded prior to the baking process. However, the latter may also be baked without lids, like small bakery items.

(13) Using at least one second robot 8, de-lidding of the baking molds is performed after the baking process, and retrieval of the bakery products is performed using a third robot 9.

(14) After retrieval of the bakery products by way of the at least one third robot 9, the baking molds are cooled using a water jet 10 and water evaporation. The amount of water for cooling the molds is calculated according to the mold weight and the required temperature differential.

(15) The bakery products are cooled and subsequently packed.

(16) The parameters for methods for the production of toast loaves, milk rolls, and ciabatta rolls are illustrated in a summarized manner in the following table.

(17) TABLE-US-00001 Ciabatta Parameter Toast loaf Milk roll roll Dough 24 C. 26 C. 29 C. temperature kneader 1 Dough 27 C. 29 C. 30 C. temperature kneader 2 Output 50 Hz 50 Hz 40 Hz 1.sup.st kneader Output 40 Hz 35 Hz 40 Hz 2.sup.nd kneader Gap width 6 mm 4 mm 10 mm calibrator unit 1 Gap width 3 mm 2 mm 5 mm calibrator unit 2 Fermentation 34 C. 32 C. 32 C. temperature Fermentation 57 min 115 min 45 min time Relative air 85% 80% 88% humidity (fermentation) Baking time 25 min 10 min 12 min Oven 200 C.-190 C. 220 C.-180 C. 240 C.-200 C. temperature Vertical Total Without 30% upon convection baking time vertical commencement from below convection of the baking time Horizontal Without Upon 60% upon convection convection commencement commencement onto the of the of the surface of the baking time baking time baked goods Mold cooling 212 g water 372 g water 159 g water by water per mold per mold per mold evaporation Mold 1070 1070 mm 1070 1070 mm 1070 1070 mm dimensions Products per 24 98 70 mold