Abstract:
A non-round, preportioned dough intermediate used to reduce wasted space in shipping materials and to provide increased handling abilities. The non-round, preportioned dough intermediate has at least four sides being connected by at least four non-corner members. When placed in abutting, adjacent relation, a plurality of non-round, preportioned dough intermediates occupies about 80% to about 99.9% of a definable perimeter bounding the plurality of non-round, preportioned dough intermediates. By having less open space, less packaging materials are required and there is reduced opportunity for topical particulates to fall off of the dough intermediates and into unused space.

Description:
PRIORITY CLAIM  
       [0001]     The present application claims priority to U.S. Provisional Application Ser. No. 60/600,297 filed Aug. 10, 2004, and entitled “PRE-PORTIONED DOUGH UNIT INTERMEDIATES”, which is herein incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The invention relates generally to forming and packaging dough unit intermediates. More specifically, the invention is directed to a process for continually forming pre-portioned dough unit intermediates requiring minimal packaging while providing for a visually appealing baked product.  
       BACKGROUND OF THE INVENTION  
       [0003]     Due to the demands and stresses of modern life, many people no longer have the time or desire to create meals or desserts from scratch. Instead, people often purchase ready-to-eat products that are prepared for immediate consumption without further preparation or ready-to-bake products that are prepared so as to go directly from the pantry, refrigerator or freezer to the oven or other associated baking appliance. In addition, commercial bakers frequently make use of ready-to-bake products to save time when preparing the large quantities of baked goods they often prepare on a daily basis.  
         [0004]     One ready-to-bake product that continues to gain in popularity is ready-to-bake cookies, for example cookies sold by the Pillsbury division of General Mills, Inc., which can go from a refrigerated or frozen dough state to a freshly prepared, hot cookie in a matter of minutes. The only preparation steps required are to heat the oven, remove the dough intermediate from the packaging, place the dough intermediate on a cooking sheet and place the cooking sheet within the oven. Not only can fresh cookies be prepared in just a few minutes, the individual or commercial baker can be assured that the taste and general appearance will be of a consistent quality without any concern for possible errors from preparation of the dough from scratch.  
         [0005]     Ready-to-bake cookie intermediates are currently prepared in one of two ways. First, the cookie intermediates can be individually extruded to form precisely portioned dough pucks. These dough pucks are extruded in a round shape. The round dough pucks are either manually or automatically positioned on a shipping tray and may be stacked on top of each other in a plurality of layers. Due to their round nature, gaps are present between adjacent dough pucks as the edges of each round dough puck are in contact at only point. This empty space represents an added packaging cost. In addition, the empty space provides a point for particulates such as chocolate chips, nuts and other commonly used particulate to fall out of or from the top of the dough pucks.  
         [0006]     The second manner used to form ready-to-bake cookie intermediates is to extrude a large sheet of cookie dough, which is then cut or scored to form square cookie products. In this manner, individual cookie intermediates are not consistently portioned there can be significant size deviations from one intermediate to the next. In addition, it may be difficult to separate individual cookie intermediates from the sheet.  
         [0007]     While the current methods for forming ready-to-bake cookie intermediates provide for tasty baked cookies, the current methods either require excess packaging materials or may result in inconsistent cookie sizes. As such, it would be advantageous to prepare the ready-to-bake cookie intermediates in a manner that reduces the amount of packaging necessary for a given number of cookie intermediates while providing for a pre-portioned and consistent quality of cookie intermediate.  
       SUMMARY OF THE INVENTION  
       [0008]     The invention addresses the aforementioned needs by providing a process for individually extruding a preportioned cookie intermediate in a non-round shape. When packaging a plurality of these non-round dough intermediates, a given number of dough intermediates requires less space than the traditional round dough intermediates as non-round dough intermediates adjacent one another are in contact along almost an entire side surface of the non-round intermediate. As there is less open space, there is less space for any particulates to fall between adjacent dough intermediates. The individually extruded non-round dough intermediates provide for a clear delineation between individual dough intermediates such that the individual intermediates can be easily and consistently separated. When the intermediates are aligned in abutted arrangement, the increased contact along adjacent dough intermediates provides rigidity to a dough set allowing the entire dough set to be removed from the packaging and handled as a unit.  
         [0009]     In one example embodiment, a plurality of pre-portioned dough intermediates are extruded to form individual non-round dough intermediates. The plurality of non-round dough intermediates can be placed, either manually or automatically, on a packaging carrier. Adjacent dough intermediates are aligned and substantially abutted to form dough sets comprising a plurality of dough intermediates. As adjacent dough intermediates are in contact along the majority of a side, each dough set has a quality of rigidity allowing an entire dough set to be manipulated as a single unit.  
         [0010]     In another example embodiment, the invention comprises a non-round dough intermediate.  
         [0011]     In another example embodiment, the invention comprises a dough set of aligned and abutted dough intermediates.  
         [0012]     In another example embodiment, the invention comprises an extrusion form for forming non-round dough intermediates.  
         [0013]     In another example embodiment, the invention comprises a process for extruding non-round dough intermediates.  
         [0014]     In another example embodiment, the invention comprises a process for reducing unused packaging space with non-round dough intermediates.  
         [0015]     As used throughout the specification and claims, the term “non-corner” refers to a junction between adjacent sides of a dough intermediate, wherein the adjacent sides are joined in a non-perpendicular arrangement.  
         [0016]     As used throughout the specification and claims, the term “pre-proportioned” refers to the individual formation of dough intermediates such that the dough intermediates generally comprise the same appearance, shape, volume and size.  
         [0017]     As used throughout the specification and claims, the term “intermediate” refers to a dough unit requiring a further processing step such as, for example, cooking with a suitable thermal process prior to consumption by an end user.  
         [0018]     The above summary of the various embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]     The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:  
         [0020]      FIG. 1  is a top view of a loaded shipping tray having a plurality of pre-portioned, round cookie intermediates of the prior art.  
         [0021]      FIG. 2  is a top view of a loaded shipping tray having a sheet of scored, square cookie intermediates of the prior art.  
         [0022]      FIG. 3  is a top view of an extruded, pre-portioned cookie intermediate having a non-round shape.  
         [0023]      FIG. 4  is a section view of the extruded, pre-portioned cookie intermediate of  FIG. 3 .  
         [0024]      FIG. 5  is a side, view of an extrusion process.  
         [0025]      FIG. 6  is a top view of an extrusion form.  
         [0026]      FIG. 7  is an end view of the extrusion process of  FIG. 5 .  
         [0027]      FIG. 8  is a top view of a dough set.  
         [0028]      FIG. 9  is a top view of a dough set.  
         [0029]      FIG. 10  is a side view of layered dough sets. 
     
    
       [0030]     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0031]     Referring now to  FIGS. 1 and 2 , prior art formats of packaged cookie dough intermediates are depicted. As shown in  FIG. 1 , a plurality of generally circular cookie intermediates  100  are arranged in abutted, adjacent relation surrounded by a definable perimeter  102 . Circular cookie intermediates  100  can be formed by extruding a cookie dough  104  through a circular die in an extruder. Cookie dough  104  comprises a cookie dough such as sugar cookie dough, oatmeal cookie dough, chocolate chip cookie dough or peanut butter dough. Alternatively, cookie dough  104  can comprise other types of suitable baking dough such as a biscuit dough. By extruding each circular cookie intermediate  100  individually, the circular cookie intermediates  100  can be consistently formed to be the same size, shape and volume. Generally circular cookie intermediates  100  are arranged such that adjacent intermediates touch at a single contact point  106 . In some instances, adjacent circular cookie intermediates  100  may have an increased contact surface resulting in shingling which may require a cutting step to separate adjacent cookie intermediates  100  or may result in breakage such that adjacent circular cookie intermediates  100  do no have equivalent sizes, shapes and/or volumes. Between adjacent cookie intermediates  100  is open space  108 . Open space  108  represents unused packaging space, which translates into unused and excess packaging materials resulting in extra packaging costs and increased storage size requirements. The plurality of circular cookie intermediates  100  occupy 78.9% of the definable perimeter  102  such that open space  108  represents 21.1% of definable perimeter  102  as illustrated in the Table 1 below.  
                   TABLE 1                           Assumptions:   Qty. 9 circular cookie intermediates 100           3 inch diameter           arranged in 3 × 3 grid           adjacent cookie intermediates in contact at contact           point 106           Total intermediate area = 63.9 in 2 (7.1 multiplied           by 9)           Definable Perimeter 102 - 81 in 2  (9 inches × 9 inches)           63.9/81 = 78.9% of Bounding Area occupied by cookie           intermediate 100           Open space = 100 − 78.9 = 21.1%                  
 
         [0032]     In addition, circular cookie intermediates  100  may have particulate matter, for example chocolate chips, candies, nuts and the like, on a top surface  110  which can fall off of the circular cookie intermediate  100  and into open space  108 .  
         [0033]     As shown in  FIG. 2 , an alternative format for packaging prepared dough intermediates includes an extruded a sheet  112  of cookie dough  104 . The sheet  112  is scored to form a plurality of square cookie intermediates  114  that are defined by grooves or scores  116 . Scores  116 , which may extend at least partially through the sheet  112  are further described in U.S. Pat. No. 6,024,997 to Blaschke et al. The sheet  112  fully occupies 100% of the definable perimeter  102 . As shown in  FIG. 2 , sheet  112  does not allow for any open space between the square cookie intermediates  114 . As such, the amount of packaging required for square cookie intermediates  114  is kept at a minimum. Preferably, the cutting member is positioned such that the square cookie intermediates  114  have a consistent size however there is no mechanism by which the cutting member insures that the individual square cookie intermediates  114  are equivalently portioned. In addition, separation of the square cookie intermediates  114  requires a a cutting or breaking step along the scores  116  in order to separate the individual intermediates. Depending upon the positioning of the cutting member and the cutting/breaking of the sheet  112  along the scores  116 , there can be a wide size variation in the size, shape and volume of the separated square cookie intermediates  114 .  
         [0034]     As shown in  FIGS. 3 and 4 , an embodiment of a non-round cookie intermediate  120  is depicted. Non-round cookie intermediate  120  has a top surface  122 , a bottom surface  124  and a perimeter surface  126 . Perimeter surface  126  can resemble a rectangular-like or square-like shape and is defined by at least four sides  128 . Adjacent sides  128  do not come into perpendicular contact to form corners but instead are joined by four non-corner segments  130 . Non-corner segments  130  can comprise any of a variety of non-perpendicular junctions between the adjacent sides  128  such as, for example, arcs or angled lines that extend between and connect adjacent sides  128 . Sides  128  have a contact length  132  and are separated from the opposed side by a dough length  134 . Dough length  134  generally corresponds to the diameter for the circular cookie intermediate  100  and the side lengths for the square cookie intermediate  114 . Typically for cookies, dough length  134  can range from about 0.5 to about 4.0 inches in length. For non-round cookie intermediate  120 , a ratio of contact length  132  to dough length  134  can be within a range of about 0.1 to about 0.9. Non-round cookie intermediate  120  also has an intermediate thickness  136  which can range from about 0.25 to about 2.0 inches. Non-round cookie intermediate  120  is preferably dimensioned to form a round cookie product when baked.  
         [0035]     As illustrated in  FIG. 5 , non-round cookie intermediate  120  is formed by an extrusion process utilizing a conventional extruder, for example extruders of the type currently manufactured and sold by APV Baker of Peterborough, United Kingdom or Bepex GMBH of Leingarten, Germany. Cookie dough  104  is fed into an extruder  138  and is forced through an extrusion form  140  to form a continuous dough rope  142 . The dough rope  142  is sliced with a cutting member  144  to form the non-round cookie intermediate  120 . After the non-round cookie intermediate  120  has been sliced, non-round cookie intermediate  120  can be positioned on a packaging carrier  145  and carried by a conveyor  146  for additional processing, such as refrigerating, freezing and packaging. By extruding and slicing each non-round cookie intermediate  120 , each non-round cookie intermediate  120  is pre-portioned and has the same size, shape and volume.  
         [0036]     As shown in  FIG. 6 , extrusion form  140  has at least one non-circular aperture  147  and may include multiple apertures  147  depending upon desired capacity. Non-circular aperture  147  resembles the non-round cookie intermediate  120  and is defined by at least four sides  148 . Adjacent sides  148  do not come into perpendicular contact but are instead joined by at least four non-corner aperture segments  150 . The non-corner aperture segments  150  can comprise any of a variety of non-perpendicular junctions between the adjacent sides  148  such as, for example, arcs or angled sides that extend between and connect adjacent sides  148 . Sides  148  have a side length  152 . Opposed sides  148  are separated by a separation length  154 . To form non-round cookie intermediate  120 , a ratio of side length  152  to separation length  154  can be at a range of about 0.1 to about 0.9. When extrusion form  140  includes a plurality of apertures  147 , the apertures  147  are separated by an aperture separation distance  156  which ranges from about 0.01 inches to about 0.25 inches.  
         [0037]     When the extrusion form  140  includes multiple apertures  147 , a row  158  of non-round cookie intermediates  120  can be simultaneously extruded and positioned on the conveyor  146  as shown in  FIG. 7 . Initially, the non-round cookie intermediates  120  are spaced apart by the aperture separation distance  156 . The conveyor  146  is then lifted causing sides  128  of adjacent non-round cookie intermediates  120  to abut one another along the contact length  132  to create a dough set  160  as shown in  FIG. 8 . Because of the contact along contact length  132  of adjacent non-round cookie intermediates  120 , dough set  160  is imparted with a level of rigidity allowing the dough set  160  to be manipulated, such as lifted or placed, as a single unit. Rigidity can be further imparted to the dough set  160  by freezing the dough set  160 . As shown in  FIGS. 9 and 10 , the dough set  160  can incorporate a plurality of rows  158  and may be stacked in a plurality of layers  162 .  
         [0038]     As shown in  FIG. 9 , the dough set  160  resides within the definable perimeter  102 . Due to increased contact between non-round cookie intermediates  120  along contact length  132 , total open space  108  is significantly reduced as compared to the circular cookie intermediates  100  as shown in  FIG. 1 . When the ratio of contact length  132  over dough length  134  is maintained within a range of about 0.1 to about 0.9, dough set  160  can occupy from about 80% to about 99.9% of the definable perimeter  102 . Correspondingly, open space  108  is reduced to from about 0.1% to about 20% of the definable perimeter  102 . By reducing open space  108 , less unused space is used in packaging materials resulting in lower packaging costs and smaller storage sizes. In addition, reducing the open space  108  reduces the potential for or incidence of particulates  164  such as chocolate chips, candy, nuts and the like from falling out of the cookie dough  104  or off the top surface  122  and into the open space  108 . By having more particulates  164  on the top surface  122 , the non-round cookie intermediate  120  is more visually appealing and prevents wasting particulates  164 . Dough set  160  retains the advantages associated with proportioned cookie intermediates as opposed to the square cookie intermediates  114  as dough set  160  is easily separable into the individual non-round cookie intermediates  120  which will have a consistent size, shape and appearance when baked.  
         [0039]     Although various embodiments of the invention have been disclosed here for purposes of illustration, it should be understood that a variety of changes, modifications and substitutions may be incorporated without departing from either the spirit or scope of the invention.