FIELD OF INVENTION-

The disclosures made herein relate generally to Auto feeding, Auto dosing to continuous mixer, for efficiently making high quality dough for bakery products like biscuit, cake, Swiss roll and cream of different flavor for cream biscuits.

PRIOR ART-

In the existing system as given in US Patent 435256 wherein said An automatic dough- processing apparatus which includes a vertical assembly constituted by a tubular processing chamber whose upper end communicates with a metering tube of enlarged diameter to which flour is supplied. Coaxially mounted within the assembly is a rotating shaft having a main screw section of uniform diameter operating within the chamber and a conical valve section operating within the tube. Slid able within the metering tube is a ring which surrounds the valve section to define an annular valve orifice, the ring being axially shift able by an adjusting element to set the size of the orifice. The flour admitted into the chamber by the metering tube is hurled by the main screw section against the inner wall of the chamber to create a thin flour film thereon which is bombarded by the solution to form a paste, the paste being then kneaded.

In the existing system as given in US Patent 4691625 wherein said a process and system are provided for the continuous production of uniform density pretzel dough. The ingredients of the pretzel dough are continuously supplied to a continuous operating assemblage and the dough is continuously produced, utilizing a relatively short retention time in the mixer. Within the continuous operating assemblage are mixing units and conveying units in ratio of approximately three to one, respectively.

In the existing system as given in US Patent 6113956 wherein said A food preparation method for teething rusks (200) includes the steps of mixing flour (10), yeast (11) and water (12) in a mixer (13) to form a "well-developed" dough (100). The dough (100) passes through a kneading machine (14) sheeting machine (15) and is allowed to "rest" on a resting conveyor (16). A cutting machine (17) cuts the dough (100) into strips (101) and the fingers of dough (102), the fingers (102) being proved in a prover (18) before being at least partially baked in an oven (19). The baked rusks (200) are conditioned under controlled heat and humidity conditions in a conditioner (20) before being allowed to cool in the packing room (21) and packed in packaging machine (22) for distribution and sale. In the existing system as given in WO 2005/036971 Al/ AU 2004/281184 Al Patent application wherein said Reducing the digestion of digestible carbohydrates in a digestible carbohydrate-based material, and reducing the absorption of the digestion produces) of digestible carbohydrates (that is, simple sugars) within the small intestine. The undigested digestible carbohydrate and the unabsorbed digestion products pass through the small intestines and into the colon, where they are fermented. In effect, the food materials made by practicing the present invention cause a controlled amount of digestible carbohydrate to bypass the small intestine, resulting in the fermentation of digestible carbohydrates in the colon. The invention also provides for processing of a digestible carbohydrate-based ingredient with a non-digestible food film material, to form a reduced digestible carbohydrate food having a protective food film network, which can inhibit or prevent digestion of the digestible carbohydrate. The present invention also provides for processing of a digestible carbohydrate-based ingredient with a non-digestible food film material, to provide a resulting reduced digestible carbohydrate food containing a viscosity-building component that contributes to the formation of a viscous intestinal chyme that can inhibit or prevent digestion of the digestible carbohydrate and can inhibit adsorption of digestion products of digestible carbohydrates in the small intestine.

In the existing system as given in United States Patent 3876805 wherein said Dough developer and conditioner products especially adapted to the bakery trade are prepared from whey protein concentrates obtained by particular membrane filtration processes to remove lactose and mineral salts. Natural dough conditioners and developers are prepared by mixing the whey protein concentrates with a gluten activating agent from the group of edible sulfhydryl reducing substances (cysteine, glutathione and sulfite salts). Complete or "total" dough conditioners are prepared by blending the whey protein concentrates with dough conditioning agents selected from the general group of edible fatty acids surfactants (mono/diglycerides-, ethoxylated monoglycerides-, and polyoxyethylene sorbitan derivatives- of long chain fatty acids; sodium and calcium stearoyl lactylates) and drying or solidifying the blends to produce free-flowing protein concentrates possessing emulsifying and dough conditioning properties. Such total dough conditioners can be used as is, or including one of the edible sulfhydryl reducing substances. In all forms of the described dough developer and conditioner products, the protein content possesses an unexpectedly high degree of sulfhydryl activity in the form of active available ~SH groups, thus enabling such products to be effectively employed in dough development and conditioning reactions in various bakery processes.

In the existing system as given in US Patent 4873098 wherein said Oven spread is controlled in the production of soft cookies which comprise unbleached flour by using a cold water swelling granular starch material having a cold water solubility of least 50%. The doughs of the present invention may be used in the production of single dough soft cookies or in the production of multi-textured cookies having extended shelf lives. The granular starch material reduces cookie spread and unexpectedly provides a shelf-stable, more moist and tender texture in cookies which contain high humectant levels without loss of machinability of the dough. In the existing system as given in United States Patent 3888996 wherein said A bakery formulation useful as a substitute for at least a part of the nonfat dry milk normally included in bread and like bakery products which includes approximately 87-89 percent soy flour, 5-7 percent soy isolate, 0.2-0.5 percent ascorbic acid with the remainder being edible calcium salts of which at least 50 percent of the salts being calcium lactate.

In the existing system as given in European Patent EP 1388287 wherein said A method of producing filled bakery products, consisting of a wafer-like crisp envelope and a creamy filling, on an industrial scale, which method comprises the steps of spreading a wafer batter into a layer (9) 0.5 to 5 mm thick and adjusting its moisture content to 15-30%, thereby to provide a dough sheet (11) that is plastically deformable and can be processed mechanically, from which an envelope (14) is formed for said filling (3) that is being then baked in an oven (15) at 150-250 DEG C for 15-30 seconds to provide a continuous tubular filled blank (14a) in which the envelope (2) has a moisture content of 3-8%, being typical of wafer, and which is then cut up transversely to provide cuttings that form said filled bakery products.

OBJECT OF THE INVENTION -

Traditionally, batch mixing process is used for making dough in bakery industry. But we have a process which will eliminate all the disadvantages of the batch mixing process and introduce continuous mixing with auto dosing, auto feeding system by which the dough will be made available continuously to the production unit in the exact quantity required as per the quality norms prescribed.

Disadvantages of Batch mixing machine-

• Only manual operation

• Heavy, weighing about 5 tons approximately.

• Operation requires constant monitoring.

• Connected loads is high - 18 to 27 KW

• Product variance from batch to batch is possible.

• Large space required because of the size of the machinery.

• Discharge of the dough is difficult.

• Because of the variation in the Dough, variation in the quality of the end product suffers as follows:

• shrinkage

• hardness variation

• breakages

• over or under baking or variation in moisture content

• spillage and wastage

• Dough consistency is not uniform.

• Constant monitoring and supervision are required.

• Cleaning is the most difficult part of this system. In case of service and maintance, this needs a major shutdown of the plant unless stand by facility is provided.

Advantage of Continuous mixer

Machine is automated by using invented auto dosing system. Hence manual operation is eliminated.

Light, weighing about one ton only.

Operation is simple and remains accurate once it is set, since it is automated and controlled by PLC.

Connected load is 7.5 to 15 KW.

No variance at all in the product since it is smaller in size.

Discharge of the dough is easy and automatic.

As this is a continuous process, there is no variation in the quality of the product and hence all the problems mentioned in the batch processing system are eliminated resulting in good quality end product.

BACKGROUND OF THE INVENTIO

Mechanisms reduce human efforts and reduce manpower, but need closer and complex human supervision. If consistent and close supervision is not provided, costly process errors will occur. Automation eliminates complex human supervision by taking full control over the operations of the mechanized equipment and provides a consistent and thorough process control through the well built process program and the instruction built in the system. Automation eliminates complex human supervision, human error as well as constant human training due to staff turnover and retirement.

By automation continuous mixer can control the organolaptic quality of the dough which guarantees very precise mixing, unparalleled consistency and uniform dispersion of the entire ingredient (like liquid. Solid, powder, high viscose, syrup thereof) and increased productivity.

Many industries have the need to mix solid streams with liquid streams. The type of stream is different in the manufacturing processes of different industries. The solid can be in granular or powdered form, also, quantities of ingredients handled in many of these processes is large. Hence desired consistency and homogeneity of the mixed product is beneficial to the industries and consumer. Mixing of solids and liquid to these industries is currently carried out in volumetric, batch and continuous weighing methods such as loss in weight. All these current methods have the problem of inconsistency in the dispensing of solids, measured as weight of solid dispensed per unit time. STATEMENT OF INVENTION-

The inventor has invented Auto feeding, Auto dosing to continuous mixer, for efficiently making high quality dough for bakery industry. Which has some unique features like accurate dough formation, very accurate automatic dosing and automatic feeding system, Continuous output control, No vaporization due to the closed system. Quality and consistency of the product are maintained throughout. Machine is designed in such a manner as to make operation very easy. Space required for installation is very less. Due to the cylindrical shape of this machine; it is very easy to open and clean it unlike in the batch making. It maintains the hygienic rules for the food industry.

DETAILED DESCRIPTION OF DRAWING

Figure 1- It is a front plan view of the invention showing flow sheet of process for making dough, solid stream, flour and liquid is creamer.

Figure 2- It is a front plan view of the invention showing display of better performance of incremental weighing and feeding.

DETAILED DESCRIPTION OF INVENTION-

Accordingly, in one aspect, this invention is based on auto feeding, auto dosing to continuous mixer, for efficiently making high quality dough for bakery industry. The mechanism is as follows-

Pre-weighed material like sugar, milk powder, chemicals, preservatives and liquids like lecithin, malt glucose, water and inverted sugar syrup which go in to the making of the dough are fed in to a creaming machine called Creamer in which the cream is made up by agitation. This cream is then fed in to a tank which is mounted on load cells to ascertain the exact weight of the cream to be pumped out. The cream in this tank is circulated through pipe lines and when the cream is to be fed in to the continuous mixer, the valve fixed above the continuous mixer is opened and the cream is fed in to the continuous mixer in the exact quantity as required. Before the cream is fed in to the continuous mixer, the cream mass is determined by a mass flow meter fixed on the pipe line. Another ingredient is flour which comes from the flour handling system and is fed to the flour cyclone. From the flour cyclone, small quantities of flour are fed in to an augur feeder. From the augur feeder, the flour is fed through a screw system in to a weighing pan mounted on load cells , to determine the weight of the flour to be fed in to the continuous mixer.

In the continuous mixer, pre blending of the cream and the flour takes place in the pre- blending section of the machine. The dough thus made is then kneaded for consistency, elasticity thereof in the kneading section inside the cylinder. The whole process of pre- blending and kneading the dough is achieved by mechanism of horizontal screws inside the cylinder of the continuous mixer.

The finished dough is then unloaded on conveyor and fed to production line continuously.

In this invention each stage of the operation from the feeding of materials into the creamer and feeding of flour and then the mixing of these in the continuous mixer is controlled by PLC (Programmable logical control).Data for these various operations are fed into the PLC.Therefore accurate feeding and proper mixing are achieved.

Automatic dosing system

Auto dosing is an automated system of feeding the equipment with liquid products. Automatic ingredients conveying, weighing & filling in the mixer as per batch capacity. Ingredients are stored in silos and then dosing is done automatically directly into the mixers it is the ideal way to ensure the correct calibrated dose at the right time every time. Benefits of automatic dosing: ADVANTAGES OF CONTINUOS MIXER WITH NEW AUTO DOSING SYSTEM

• Accurate dough formation with correct dose every time.

• Very accurate and automatic feeding system.

• Continuous output control.

• No vaporization due to the closed system.

• Quality and consistency of the product are maintained throughout.

• Machine is designed in such a manner as to make operation very easy.

• Space required for installation is very less.

• Due to the cylindrical shape of this machine, it is very easy to open and clean it unlike in the batch making.

• It maintains the hygienic rules for the food industry.

• There is no shut down needed as service and maintance require lesser time.

• Too less disassembly for cleaning

• Mixing of powders and liquids in very different proportions is possible.

• Allows consistency and liquid in very different proportions are possible.

• Allows consistency and homogeneity of the finished product.

• Higher productivity than batch making system.

• Fewer breakdowns - Manual dosing allows clogging of machines tubes

• NO costly wastage by overdosing and no messy spillage

• NO direct contact with potentially hazardous substances

• Better quality products and more cost effective than manual dosing which means savings

• Strong and sanitary safe design

• Versatile design for multiple products like-Bakery, biscuit, chocolates, confectionery, dairy and dessert thereof.

Technical Design and Features

• Size- 100 kg./hr. to 6000 kg./hr. capacity

• Material of construction fully stainless steel grade 304 or 316

• Pressure tested water/steam j acket for conditioning.

• Electro pneumatic control valves.

• PLC based operated control panel (IP 65) with touch screen/monitor.

• Creamer recirculation via-pumps et or external homogenizer.

• Approx.75% shorter creaming time for bakery product.

• Connected load is lesser than big mixer/blender.

• Due to mechanical profile of mixing, some of the ingredients used can be reduced as it disperses/emulsifies. Additional features

• Easily Dough transfer

• IT Interface with existing control

• IT Interface with existing control and PLC