SYSTEM FOR PRODUCING FLATBREAD, AND METHOD FOR THE PROVISION OF SAME

Abstract

A system for producing flatbread, comprising a closed portion capsule (1) that has a pre-shaped dough body (7) arranged therein, preferably an individual portion dough body, consisting of a, preferably, yeast-free dough material on the basis of flour and water and preferably on the basis of wheat flour and water, in order to produce flatbread in a domestic flatbread baking device, with the dough body (7) being shaped. According to the invention, the dough body (7) comprises a dough crust all the way around made of the dough material and enclosing a core that consists of a mass of raw dough.

Claims

1-19. (canceled)

20. A system for producing flatbread, comprising a closed portion capsule (1) having a pre-formed dough body (7) disposed therein, made of a dough material on the basis of flour and water, for producing flatbread in a household flatbread baking device or flatbread baking device by deforming the dough body (7), wherein the dough body (7) is removed or unpacked from the portion capsule (1) in the household flatbread baking device or flatbread baking device, wherein the dough body (7) has a fully circumferential dough crust (8) which is made of the dough material, wherein said dough crust is formed in the dough material by heat application and which encloses a core made of raw dough, wherein a mean layer thickness of the dough crust (8) is in a value range between 0.5 mm and 4.0 mm, wherein a moisture weight percentage of the dough crust (8) is between 6 and 20 w %, and/or wherein a moisture weight percentage of the core is between 28 and 50 w %, and/or wherein a moisture weight percentage of the core is higher than a moisture weight percentage of the dough crust (8) by at least 8 w %, and a smallest diameter of the dough body (7) is at least 20 times larger than the mean layer thickness of the dough crust (8).

21. The system according to claim 20, wherein the portion capsule (1) has a capsule container (2), which surrounds the dough body (7), and wherein the capsule container (2) is closed by means of a lid film (3).

22. The system according to claim 20, wherein the dough body (7) in the portion capsule (1) is surrounded by protective gas.

23. The system according to claim 20, wherein a mean layer thickness of the dough crust (8) is in a value range between 0.8 mm and 3.0 mm.

24. The system according to claim 20, wherein a moisture weight percentage of the dough crust (8) is between 10 and 16 w %, and/or wherein a moisture weight percentage of the core is between 30 and 40 w %, and/or wherein a moisture weight percentage of the core is higher than a moisture weight percentage of the dough crust (8) by at least 15 w %.

25. The system according to claim 20, wherein a smallest diameter of the dough body (7) is at least 30 times larger than the mean layer thickness of the dough crust (8).

26. The system according to claim 20, wherein the dough body (7) extends along three Cartesian spatial axes x, y, z, which are disposed at right angles to each other, and wherein the extension along each spatial axis is no more than ten times, the respective extension along each of the two other spatial axes.

27. The system according to claim 20, wherein the color of the dough crust (8) and/or of the core in the CIELAB color space with the Cartesian base coordinates L*, a*, b*is defined by L* between 60 and 85 and/or a* between 0.25 and 2.5 and/or b* between 15 and 30 according to EN ISO 11664-4:2011, and/or wherein the color of the dough crust (8) in the CIELAB color space with the Cartesian base coordinates L*, a*, b* is defined by L* between 60 and 80 and/or a* between 0.25 and 2.5 and/or b* between 15 and 30 according to EN ISO 1164-4:2011, and/or wherein the color of the core in the CIELAB color space with the Cartesian base coordinates L*, a*, b* is defined by L* between 75 and 85 and/or a* between 0.15 and 0.6 and/or b* between 20 and 25 according to EN ISO 11664-4:2011, and/or wherein the color of the dough crust (8) differs from the color of the core in the CIELAB color space with the Cartesian base coordinates L*, a*, b* by no more than one or by more than one of the following base-coordinate values: L* between 0 and 40 and/or a* between 0 and 3.3 and/or b* between 0 and 20.

28. A method for providing a system according to claim 20, comprising a closed portion capsule (1) having a dough body (7) disposed therein for being processed into flatbread by deforming the dough body (7) in a household flatbread baking device or flatbread baking device, the method comprising the steps of: a) providing raw dough (9) on the basis of flour and water; b) forming a dough body (7) from the raw dough (9); c) during and/or after step b), heating the full circumference of the dough body (7), thereby producing the fully circumferential dough crust which encloses the core of still raw dough (9), wherein a mean layer thickness of the dough crust (8) is in a value range between 0.5 mm and 4.0 mm; d) transferring the dough body (7) with the dough crust (8) into a portion capsule (1) and closing the portion capsule (1).

29. The method according to claim 28, wherein prior to or by means of the forming step b), a dough portion to be formed is portioned.

30. The method according to claim 28, wherein the heating step c) is carried out by means of a contact heater and/or by means of an infrared heater.

31. The method according to claim 30, wherein the contact heater (10) has multiple heating elements (11, 12) which can be displaced relative to each other and which, during the heating step c), are in contact with and heat multiple sides of the dough body (7).

32. The method according to claim 31, wherein after a predetermined period of time, during the heating step c), the heating elements (11, 12) are displaced relative to each other in such a manner that steam escapes.

33. The method according to claim 31, wherein the heating step c) is performed in such a manner that a steam atmosphere is formed at the outer circumference of the dough body (7) within the contact heater.

34. The method according to claim 29, wherein the heating step c) is performed in such a manner that the temperature of the dough body (7) is greater than 60 C., at the outer circumference and is no more than 60 C. at a depth of no more than 4 mm to be measured perpendicular to and starting from the outer circumference.

35. The method according to claim 29, wherein the heating step c) is carried out in such a manner that the die color of the dough crust (8) and/or of the core in the CIELAB color space with the Cartesian base coordinates L*, a*, b* is defined by L* between 60 and 85 and/or a* between 0.25 and 2.5 and/or b* between 15 and 30 according to EN ISO 11664-4:2011, and/or in such a manner that the color of the dough crust (8) in the CIELAB color space with the Cartesian base coordinates L*, a*, b* is defined by L* between 60 and 80 and/or a* between 0.25 and 2.5 and/or b* between 15 and 30 according to EN ISO 1164-4:2011, and/or in such a manner that the color of the core in the CIELAB color space with the Cartesian base coordinates L*, a*, b* is defined by L* between 75 and 85 and/or a* between 0.15 and 0.6 and/or b* between 20 and 25 according to EN ISO 11664-4:2011, and/or in such a manner that the color of the dough crust (8) differs from the color of the core in the CIELAB color space with the Cartesian base coordinates L*, a*, b* by no more than one or by more than one of the following base-coordinate values: L* between 0 and 40 and/or a* between 0 and 3.3 and/or b* between 0 and 20.

36. The method according to claim 29, wherein the dough body (7) is cooled prior to being transferred into the capsule.

37. A use of a system according to claim 20, comprising a household flatbread baking device or flatbread baking device in which the dough body (7) with the dough crust (8) is removed from the portion capsule (1) and the dough body (7) is transferred into a deforming device for deforming the dough body (7) into a flatbread by breaking up the dough crust, and the flatbread is baked during and/or after deformation.

38. A method for producing a flatbread using a household flatbread baking device or flatbread baking device by employing a system according to claim 20, the method comprising the steps of: opening the portion capsule (1) and transferring the dough body (7) with the dough crust (8) into a deforming device of the household flatbread baking device or flatbread baking device, deforming the dough body (7) by means of a deforming device by breaking up the dough crust (8), baking the flatbread during and/or after deformation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0058] Other advantages, features and details of the invention are apparent from the following description of preferable embodiments and from the drawings.

[0059] FIG. 1: is a flow chart of a preferable variation of a method according to the invention for providing a portion capsule with a dough body packaged therein,

[0060] FIG. 2: is an illustration showing a portion capsule with a dough body,

[0061] FIG. 3: is a diagram showing a preferable temperature distribution within the dough body after a heating step, and

[0062] FIG. 4: is an illustration showing a contact heater which is configured as a press forming tool for carrying out the forming and heating step to shape the dough body and to form the crust.

DETAILED DESCRIPTION

[0063] In the figures, identical elements and elements having the same function are marked with the same reference signs.

[0064] In the course of a preferable process flow, which is illustrated in FIG. 1, homogenous raw dough on the basis of water and flour, in this case wheat flour and water, is provided in step I.

[0065] In step II, the raw dough is portioned into individual portions, which have a weight between 35 g and 45 g in this specific embodiment.

[0066] In step III, the portioned individual portions are formed into a lump-shaped (defined) lump congruent in shape to the inner contour of a portion capsule by press-forming by means of a press-forming tool, and in step IV, the dough body is heated, whereby a fully circumferential dough crust which encloses the core of still raw dough is formed. The heating step IV is carried out in such a manner that substantially no browning of the dough crust occurs. The temperature at the inside of the dough is 65 C. in the embodiment at hand and drops steeply in the direction of a geometrical center of the dough body.

[0067] In step V, the previously heated dough body is cooled, and in step VI, it is transferred into a portion capsule and the portion capsule is closed. Specifically, the dough body is received in a portion capsule, which is then hermetically closed by sealing of a lid film.

[0068] FIG. 2 shows a portion capsule 1 comprising a vat-shaped capsule container 2, which is closed by a lid film 3. The lid film 3 is sealed in a circumferential sealing portion 4, in this case outside of a circumferential groove, for example, which can be omitted, if applicable.

[0069] An inner volume 6 of the portion capsule holds a pre-formed dough body 7 which consists entirely of a dough material, the dough body 7 having a fully circumferential dough crust which is formed by the dough material and which encloses a core of raw dough 9. After transport and storage, the dough body 7 is removed from its package in a household baking device, where it is deformed into a flatbread shape by breaking up the dough crust 8 and baked.

[0070] FIG. 3 shows, by way of example, the temperature distribution and the temperature curve from the outside to the inside in a dough body 7 after the heating step. As can be seen, the maximum temperature on the outer side, i.e. at the outer circumference of the dough body, is 110 C. or just below and then drops sharply, a temperature level of approximately 20 C. prevailing after a distance d of about 3 mm to 4 mm from the outer circumferential surface in this specific embodiment. In FIG. 4, a preferable embodiment of a contact heater 10 for carrying out the heating step c) to form the crust is shown by way of example. The contact heater 10 shown is also configured as a press-forming tool in order to carry out method step b), i.e. to form the dough body 7 by press-forming in the case at hand.

[0071] As can be seen in FIG. 4, the contact heater 10 is composed of multiple parts and, in this specific embodiment, comprises first and second heating elements 11, 12, wherein the heating elements 11, 12 are displaceable relative to each other pneumatically in the embodiment at hand by displacing a triangular heating element 11, which is located at the top in the drawing plane, relative to a vat-shaped stationary heating element 12. In the case at hand, the heating elements 11, 12 are made mainly of stainless steel and are heated to a temperature of 180 C.

[0072] Once a dough portion 7 has been introduced into a cavity 13 provided by heating element 12, the heating elements 11, 12 are displaced toward each other by active displacement of heating element 11, whereby the dough 9 is fully contacted and shaped and simultaneously heated and a uniform fully circumferential dough crust 8 forms. At the same time, the heating elements 11, 12 exert a pressing force on the dough 9 to form the dough body 7. In FIG. 4, a contour of the dough 9 prior to the actual press-forming process is shown; after the pressing process, that is after the pressing has been released in the case at hand, the shape of the resulting dough body 7 corresponds to the inner contour of the heating elements 11, 12. The pressing is released after a defined period of time, such as 0.5 s in the case at hand; this causes a circumferential gap to be formed between the heating elements 11, 12, through which steam can escape, while the heating elements 11, 12 continue to be in contact with and heat the dough body 7 after release of the pressing. The crust formation process is completed after a total heating duration of 20 s in the case at hand, whereupon the dough body 7 with the dough crust 8 is removed from the cavity 13, the triangular heating element 11 first having to be lifted to do so, of course.

REFERENCE SIGNS

[0073] 1 portion capsule

[0074] 2 capsule container

[0075] 3 lid film

[0076] 4 sealing portion

[0077] 6 inner volume of the portion capsule

[0078] 7 dough body

[0079] 8 dough crust

[0080] 9 dough

[0081] 10 contact heater

[0082] 11 heating element

[0083] 12 heating element

[0084] 13 cavity