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Patent Searching and Data


Title:
COMPACT DOUGH BELT FORMING APPARATUS
Document Type and Number:
WIPO Patent Application WO/2020/051671
Kind Code:
A1
Abstract:
The present invention relates to a compact and substantially enclosed dough belt forming apparatus for use as part of an industrial bread making line. The dough belt forming apparatus is configured to form and convey a continuous belt of dough for further processing before it is proofed, cut into individual units, and then either baked immediately or frozen for later use. The described dough belt forming apparatus is particularly suitable for doughs used to make flat breads, as it is provided with internal conveyors for the conditioning phase of the dough, which protects the dough from drying out from exposure. Multiple levels of internal conveyors are provided, which allows for the apparatus to be more compact than comparable machinery of the prior art.

Inventors:
SHABANZADE MOHAMMADREZA (CA)
SVENNINGSON BIRGER ERNST (CA)
Application Number:
PCT/CA2018/000170
Publication Date:
March 19, 2020
Filing Date:
September 14, 2018
Export Citation:
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Assignee:
GOTHIA HOLDINGS INC (CA)
International Classes:
A21C3/02; A21C3/00; A21C3/04; A21C9/08
Foreign References:
EP2342971A12011-07-13
JP2001061401A2001-03-13
US6272979B12001-08-14
Attorney, Agent or Firm:
KIM, Selena (CA)
Download PDF:
Claims:
CLAIMS

What is claimed is the following:

1. An apparatus for forming a dough belt comprising: a top side, a bottom side, a front side, a back side, and two lateral sides defining an interior; a hopper located at the top side; a dough extractor connected to said hopper; a plurality of conveyor lines within said interior, wherein the front side comprises an exit point for said dough belt and further comprises a substantially solid surface; the back side also comprises a substantially solid surface; the top side comprises a substantially solid surface that provides a cavity for said hopper; and the lateral sides each comprise a substantially solid surface.

2. The apparatus of claim 1 , wherein the lateral sides further comprise windows.

3. The apparatus of any one of claims 1 - 2, wherein one or both of the front side and the back side further comprise vents.

4. The apparatus of any one of claims 1-3, wherein the bottom side is connected to a plurality of feet each incorporating a sole; and wherein the bottom side is parallel to said soles.

5. The apparatus of any one of claims 1-4, wherein each of the plurality of conveyors has two ends, and an end of at least one of the plurality of conveyors is angled towards said top side.

6. The apparatus of any one of claims 1-5, wherein at least one of the plurality of conveyors is an angled conveyor, the angled conveyor defining an angle between said angled conveyor and said bottom side, the angle being between 1-12 °.

7. The apparatus of claim 6, wherein said angle is between 3-10°.

8. The apparatus of claim 7, wherein said angle is between 5-8.5°.

9. The apparatus of any one of claims 1 to 8, wherein the plurality of conveyors comprises three conveyors, and a first conveyor is angled at 5° relative to said bottom side, and a second conveyor is angled at 8.5° relative to said bottom side.

10. The apparatus of any one of claims 1 to 9, further comprising a dough extruder.

11. The apparatus of any one of claims 1 to 10, further comprising at least one flour duster.

12. The apparatus of any one of claims 1 to 11 , further comprising an air cleaner.

13. A method of forming a belt of dough using the apparatus of any of claims 1-12 consisting of: providing dough to the hopper of said apparatus; processing said dough through said dough extruder; transporting said dough along said plurality of conveyors up to said exit point.

14. The method of claim 13, wherein following the step of processing said dough through said dough extruder, said dough is dusted with flour.

15. The method of claims 13 or 14, wherein during the step of transporting said dough, said dough is compressed by rollers.

Description:
COMPACT DOUGH BELT FORMING APPARATUS

FIELD OF THE INVENTION

[0001 ] The present invention is for a compact and substantially enclosed dough belt forming apparatus for part of an industrial breadmaking line. The dough belt forming apparatus is configured to form and convey a continuous belt of dough for further processing before it is portioned and sent for final processing. The described apparatus is particularly suitable for doughs made with high gluten flour that benefit from a longer period of rest and conditioning prior to final proofing, forming, and baking. Comparable lines of the prior art have required long, open conveyor lines that exit an extruder section of a dough forming apparatus, and spend significant portions of time in open air within the factory. The invention provides a compact, substantially enclosed solution which offers numerous benefits.

BACKGROU D OF THE INVENTION

[0002] lndustrial bread making lines are known, and have traditionally been used to make a variety of types of bread, from traditional loaves and rolls to flatbreads. When making large quantities of most types of bread, it has been found to be most efficient to form a stream or belt of dough that is extruded from a larger mixed quantity of dough, the belt of dough then being further subjected to additional steps in the breadmaking process which will be familiar to bakers. In particular, following the initial mixing of ingredients and kneading, it is typical to allow dough to rest for a period of time. This allows the gluten contained within the dough to develop and form a network, which then provides the dough with features of strength and elasticity. The dough may then be further rolled or kneaded, dusted with flour at one or more stations, and proofed during a further period in which the yeast in the dough is allowed to work and the dough rises. Some of the above steps may occur multiple times depending on the dough and the recipe. The final typical steps in the process are for the dough to be formed into individual serving units, baked or frozen for later baking, and packaged.

[0003] The majority of the above steps have typically occurred stepwise in long, horizontal conveyor lines which have been largely open to factory air. This has resulted in some problems and inconveniences. Because periodic dusting of the dough with flour is a typical step in making most types of bread, this has resulted in reduced air quality within such facilities. As well, leaving dough on conveyors in open air increases the risk of the dough drying out or encountering contaminants. Such risks have been less significant for types of dough in which the process from start to finish is relatively fast. However, for preparing many types of yeast- containing flatbreads, this becomes a higher risk. This is because many flatbread recipes utilize high gluten flours, which necessitate a longer rest and conditioning period following formation of the dough belt. The long periods of time required for such rest and conditioning of the dough, when performed on open conveyor lines, can increase the risk of exposed portions of the dough becoming overly dry, which will reduce the quality of the resulting product.

[0004] In addition, the long conveyors of the prior art are inefficient in terms of floor space. Such conveyors as part of breadmaking lines can only be accommodated in relatively large industrial settings.

[0005] A dough making apparatus which provides the necessary rest and conditioning time for the dough belt following extrusion in a protected environment, yet supports a continuous, stepwise manufacturing process which is practical to implement and can be readily adapted for use with a variety of recipes and requirements, including recipes for flatbreads containing high gluten flours, would be beneficial.

SUMMARY OF THE INVENTION

[0006] The general object of the present invention is to provide a compact and substantially enclosed apparatus for formation of a stream or belt of dough, as part of an industrial dough-making line.

[0007] In one aspect, the dough belt making apparatus comprises a substantially enclosed machine which can process the dough from extrusion up until the end of the dough conditioning process. The apparatus comprises a hopper through which dough enters, an extruder which forms the dough into a belt, and multiple levels of conveyors which incorporate additional devices which may optionally be used depending on the type of dough being formed. For instance, rollers and flour dusters may be stationed along the conveyors for use as needed.

[0008] In a further aspect, the dough belt making apparatus comprises multiple levels of conveyor lines which may be installed at angles. The multiple levels allow the dough to enjoy the required resting and conditioning time while contained within the walls of the machine, and also reduces the amount of horizontal space needed for use of the machine. If some or all of the conveyor belts are installed at angles, one may accommodate increased lengths for the individual conveyor belts within the overall enclosure of the machine. The machine may be configured to include multiple levels of conveyor belts, such as two to five, most preferably three.

[0009] In a still further aspect, the dough belt making apparatus includes a lowermost conveyor belt having an upward incline so that the dough belt exits the machine on an upward angle. This feature permits the machine to be utilized with a larger variety of further processing equipment for the dough, including proofers and molders which may require feeding of dough at various heights.

[0010] In a still further aspect, the dough feeding apparatus comprises a dough extruder with rollers that have been stacked on a diagonal angle, to reduce the amount of horizontal space needed to accommodate the extruder.

[0011] In a still further aspect, the dough feeding apparatus includes one or more air cleaning devices that removes excess airborne flour from the internal cavity of the machine, preventing escape from the machine, and thereby improving air quality and general cleanliness of the factory.

[0012] As embodied and broadly described below, the present invention provides a dough belt making apparatus that is ideal for use as part of an industrial dough making line or baking line. It is versatile and can be used with traditional breads or with international flatbread recipes, which are becoming increasingly popular and mainstream to the point that it is now advantageous to develop means to manufacture them in large industrial quantities, without compromising quality. The relatively compact nature of the apparatus means that a far smaller amount of floor space is needed to accommodate the functions offered by the apparatus. To illustrate, in a preferred embodiment, the machine is approximately 3.5 meters in length. This may be contrasted with comparable lines of the prior art which require approximately 15 meters of length for the same functions.

[0013] The enclosed nature of the machine reduces the amount of unincorporated flour which reaches the factory air, which can be detrimental for cleanliness and for worker health. Its enclosed nature is also advantageous for the final product quality. For breads requiring long periods of conditioning and rest, such as flatbreads, there is less opportunity for the dough to dry out during the process than compared with open-air machines of the prior art. It is also less likely that particulate matter or other contaminants will fall into the dough and become embedded in the final product.

[0014] ln a preferred embodiment, the dough belt making apparatus also incorporates a programmable logic controller which can be used to set desired parameters. Advantageously, depending on the dough being manufactured, the apparatus can be configured so that the user can electronically set the speed of the conveyors, activate rollers to flatten the dough belt as needed, activate dusting stations, and activate air cleaners. In addition to any such computerized features, some features may also be set manually. For instance, it can be equally convenient for calibrating rollers (which are used to set the thickness of the dough belt) to be adjusted by manual means such as a lever or wheel.

[0015] A method for using the dough belt making apparatus of the present invention is also provided. The dough belt making apparatus can be used and set manually, digitally, or both. Different settings and programs can be recorded depending on the particular recipe being prepared. The invented apparatus is a versatile machine that can be successfully used with traditional European bread and dough recipes as well as traditional middle Eastern or Indian flatbread recipes such as pita, naan, and chapatis.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention will now be better understood with reference to the description and to the accompanying drawings in which: [0017] Figure 1 is a right side view of the apparatus with the right wall of the enclosure removed.

[0018] Figure 2 is a left side view of the apparatus with the left wall of the enclosure removed and certain mechanisms removed for simplicity.

[0019] Figure 3 is a left side view of the apparatus with the left wall of the enclosure removed.

[0020] Figure 4 is a top front perspective view of the apparatus.

[0021] Figure 5 is a side view of the apparatus.

[0022] ln these figures, preferred embodiments of the invention are illustrated by way of examples. It is to be expressly understood that the description and drawings are only for the purpose of illustration and are an aid for understanding. They are not intended to define the limits of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] As used herein, any usage of terms that suggest an absolute orientation (e.g.

“top”,“front”,“back” etc.) are for illustrative convenience and refer to a specific orientation. However, such terms are not to be construed in a limiting sense as it is contemplated that various components will, in practice, be utilized in orientations that are the same as, or different than those described or shown.

[0024] Turning now to the figures, Figure 1 discloses the dough belt making apparatus 1 which features an enclosure 2, containing further components of the apparatus within. The right wall of enclosure 2 is not shown in Figure 1 to better show internal components of the apparatus. The right wall of enclosure 2 can be better viewed in Figures 4 and 5. Enclosure 2 is most conveniently made from a durable, light-weight, wipable material such as stainless steel sheeting. [0025] Starting from the top of the apparatus, hopper 3 is adapted to receive quantities of dough from an industrial mixer (not shown). On both sides of hopper 3 are shown safety rails 4, only one of which is visible in this view. The safety rails 4 are attached to the outer enclosure 2. Visible below hopper 3 is a dough extruding apparatus 5 which features two sets of rollers, extraction rollers 6 and calibrating rollers 7 which cooperate to form a dough belt from a mass of dough introduced through the hopper 3. As shown, each of the members of the pairs of extraction rollers 6 and calibrating rollers 7 are configured diagonally relative to each other. In the context of this compact apparatus 1, the diagonal orientations between the sets of rollers ultimately allow for the configuration of a narrower extruder 5 overall that requires less horizontal space within the dough belt forming apparatus 1 than if rollers 6 and 7 were horizontally placed as is the case in prior art dough making equipment. Also visible is a wheel 8 which may be used to move one member of the pair of calibrating rollers 7 closer or further from its corresponding member in order to set the thickness of the dough as it travels between calibrating rollers 7.

[0026] As the dough belt is formed in the apparatus 1, it exits between the calibration rollers 7 and lands on first conveyor 9. First conveyor 9 comprises a food-grade moving belt made out of any suitable material such as a food-grade rubber. The moving belt in this embodiment is configured to turn in a clockwise direction so that a dough belt landing on it is transferred along the conveyor 9 towards the right side. In the depicted embodiment, the dough will also continue along first conveyor 9 and between roller units 10.

[0027] Next, the dough will land on second conveyor 11, and be transported in a direction to the left. In the depicted embodiment, the dough also traverses two additional roller units 10. The dough then lands on third conveyor 12 which travels towards the right in this embodiment. At the end of third conveyor 12, the dough exits the machine at exit 13. During its time in transit on the multiple levels of conveyors up until its exit from apparatus 1, the dough is subjected to the previously described rest and conditioning time, punctuated at intervals by further actions of rolling and dusting.

[0028] In this particular embodiment, there are three lines of conveyors. Numbers of conveyors may vary, and can be as little as two and as high as five, being limited by the height of the apparatus 1. If an even number of conveyors is employed, such as two or four, the location of exit 13 will need to be moved to account for the end point of the lowermost conveyor.

[0029] All conveyors are of standard construction, incorporating moving belts and being configured for movement using gears or comparable mechanisms. The conveyors are horizontally oriented, and may be parallel to the floor of the machine or may be inclined on an angle, generally anywhere from 0-12°. For example, conveyor 11 in the embodiment shown is inclined at an angle of 8.5° relative to the bottom 14 of the machine, which is parallel to the floor. Conveyor 12 in the embodiment shown is inclined at an angle of 5° relative to the bottom of the machine. Upwardly angled conveyors such as conveyors 11 and 12 seen in Figure 1 are advantageous, because the dough belt, when transitioning from the prior conveyor, only needs to drop by a reduced distance to the next conveyor, and may thereby more smoothly transition between levels with reduced risk of cracking or breaking. As well, the enclosure 2 for the apparatus 1 can accommodate longer conveyors when they are installed on angles.

[0030] It is also particularly advantageous to angle the final conveyor, which is the third conveyor 12 in Figure 1, upwards. Apparatus 1 is used for only part of the breadmaking process, namely dough extrusion, calibration, and conditioning. When the dough exits the machine at exit 13, it can be subjected to additional steps performed by other equipment, such as proofing, baking, and packaging. A variety of machines made by various manufacturers may be used to accept the dough belt as it exits apparatus 1 at exit 13. By angling conveyor 12 upwards, apparatus 1 is likely to be compatible with a larger variety of machines for next steps which may accept the dough at various heights.

[0031] Turning to Figure 2, the machine can be viewed from the left side. At the bottom of the machine is a plurality of motors 15, which, when outfitted with belts and connected to gear wheels as seen in Figure 3, can be employed to turn conveyor belts as well as individual rollers such as those of roller units 6, 7, and 10. The workings of such motors, gear wheels, and belts are well-known and will not be elaborated here. Rotational speeds in the range of 10-16 rpm for the belts have been found to work well.

[0032] The enclosure 2 is also outfitted with feet 16 to raise the machine off the floor, which facilitates cleaning underneath the machine. The bottom of each foot 16 incorporates a sole which contacts the floor of the facility. The bottom 14 of the enclosure 2 is largely open, save for some struts 17 and additional framing (not visible in this view) on which motors 15 can be placed. The bottom 14 is also parallel to the floor and the soles of each foot 16.

[0033] Flour dusters 18 may also be stationed periodically along the path defined by the conveyors. Such dusters 18 are known in the art, and consist of a container which may be filled with flour, and which is adapted to puff small quantities of flour to dust sections of the dough belt as needed. In this particular embodiment, four such flour dusters 18 are provided. Because the apparatus 1 is largely enclosed, loose flour that does not get incorporated into the dough belt is less likely to contaminate the surrounding air in the facility. Such flour would eventually fall down under the enclosure 2 and can be removed afterwards.

[0034] Another optional accessory that may be installed in apparatus 1 is an air cleaner

(not shown), which may also be used to remove excess flour from the apparatus 1. An air cleaner will typically incorporate a vacuum pump to remove airborne flour from within the enclosure 2.

[0035] Figure 3 is a further left side view of apparatus 1. Sample configurations for gear belts 19 connected to the aforementioned motors 15 have been included in this view. Framing 20 is also connected to the enclosure 2.

[0036] Figure 4 shows a right side view of the exterior of apparatus 1. Previously described wheels 8 for calibrating rollers can be seen, and are configured to be readily accessible to the user. Also visible in this view are handles 21 which are used for opening doors 24 that provide access to the flour compartments of previously described flour dusters 18. In this way, the user has ready access to these components, which periodically require refilling. Windows 22 provide a means to observe the manufacturing process while also providing limited aeration to the mechanisms and dough within.

[0037] Computer panel 23 is also visible in Figure 4. As referred to previously, portions of the apparatus 1 may be digitally controlled, such as speeds for conveyors 9, 11, and 12, activation of flour dusters 18, or activation of air cleaners. The appropriate combination of speeds and settings will typically be arrived at by the user for a particular recipe, using experience as well as some trial and error. Computer panel 23 may be conveniently accessed to provide pre-set programs containing settings for running apparatus 1.

[0038] Figure 5 shows a perspective right side view of apparatus 1. Doors 24 for accessing flour dusters 18 are readily visible. Additional features include vents 25 which may work with windows 22 for providing aeration and circulation so that the apparatus interior does not become overly hot or humid.

[0039] The invention described above provides a dough belt manufacturing apparatus for use in the industrial manufacture of breads, and is particularly well-adapted for the manufacture of flatbreads using dough made of high-protein flour, which require a longer period of conditioning and rest to make a high quality product. Because such doughs for flatbreads can be conditioned on the multi-level conveyors in an enclosed space, they are less likely to become dried out or to encounter contaminants. As well, there is a significant savings of space by using multi-level conveyors stacked in an enclosed machine rather than the open-air linear conveyors of the prior art. The approximate dimensions of a sample embodiment of the described apparatus 1 are 3.5 metres in length, 2.2 metres in height, and 1.7 metres in width. In terms of length, comparable equipment of the prior art typically requires 15 metres or more to accomplish the same functions.

[0040] While the invention has been described with reference to specific embodiments, it will be appreciated that numerous variations, modifications, and embodiments are possible. For instance, there are many known mechanisms available in machinery design that may be used interchangeably with the specific mechanical solutions contemplated above. Accordingly, all variations, modifications and embodiments are to be regarded as being within the spirit and scope of the invention.