Pre-Scored Frozen Dough Sub and Steak Rolls

A plurality of dough pieces are produced using a rotary dough cutter comprises an annular cutter body configured to be rotatably driven, a plurality of arcuate sidewalls extending circumferentially about the cutter body, a plurality of radial divider walls extending across respective sidewalls, and a plurality of interior blades extending radially relative to the body between the sidewalls. The plurality of walls define a plurality of dough cutter molds. During conveying of a sheet of dough to the rotary dough cutter, the plurality of dough pieces are cut by the plurality of walls and scored with the plurality of interior blades. After being cut and scored, the dough pieces are removed from within the dough cutter molds with the assistance of a sequentially timed, regulated and adjustable fluid ejection system, and then frozen.

BACKGROUND OF THE INVENTION

The invention generally pertains to the art of food production and, more specifically, to the production of pre-scored, frozen bread products, particularly sub and steak rolls.

Bakery operators sometimes purchase partially finished food products that are then finished in the bakery before being sold to consumers. For example, bakery operators can purchase frozen bread dough, which they thaw, proof and bake prior to sale. Depending on the desired bread product, the bread dough may be scored after proofing and before baking. Generally, it is preferred that the amount of time and labor required to finish such partially finished food products is kept to a minimum. Accordingly, it would be desirable to provide bread dough products, such as frozen sub or steak rolls, which are effectively and efficiently manufactured with scores prior to being frozen and sent to bakery operators or grocery stores for purchase by consumers.

SUMMARY OF THE INVENTION

The invention achieves the above goal by providing a method and machinery configured to automatically score dough pieces during formation of the dough pieces from a dough sheet. Specifically, a rotary dough cutter comprises an annular cutter body configured to be rotatably driven, a plurality of arcuate sidewalls extending circumferentially about the cutter body, a plurality of radial divider walls extending across respective sidewalls, and a plurality of interior blades extending radially relative to the body between the sidewalls. The various walls define a plurality of dough cutter molds with, except for various walls of the outermost cutter molds located at terminal ends of the cutter body, each wall forming a common part of adjacent dough cutter molds. Each of the plurality of interior blades is located spaced from and between successive divider walls in a respective one of the plurality of dough cutter molds. With movement of the dough sheet and rotation of the rotary dough cutter, the dough pieces are cut from the dough sheet with the plurality of walls, and the dough pieces are scored with the plurality of interior blades. After being cut and scored, the dough pieces are removed from within the dough cutter molds with the assistance of a fluid ejection system, and then frozen. The fluid ejection system includes a plurality of outlets exposed to each dough cutter mold and a fluid supply system for directing and timing the injection of fluid, such as air, to the outlets in a specified set of dough cutter molds which have just completed cut and scoring operations. In addition, the fluid ejection system includes a flow distribution control assembly for selectively adjusting flow characteristics of the fluid to the various dough cutter molds to assure proper dough product ejection based on parameters of the dough, such as dough density and formulation.

Additional objects, features and advantages of the invention will become more readily apparent from the following detailed description of preferred embodiments thereof when taken in conjunction with the drawings wherein like reference numerals refer to common parts in the several views.

DETAILED DESCRIPTION OF EMBODIMENTS

Detailed embodiments of the present invention are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to employ the present invention. Additionally, as used in connection with the present invention, terms such as “parallel” and “perpendicular” do not necessarily require, for example, that the relevant items be perfectly parallel. Instead, these terms include a margin of error of +/−5° (regardless of whether the error is by design or due to inherent manufacturing limitations) so long as the error does not prevent the present invention from functioning as intended.

With initial reference toFIG.1, there is shown a portion of a production line for producing dough pieces in accordance with the present invention. Specifically,FIG.1shows a dough sheet100being transported in a direction105by a conveyor system110. In the embodiment illustrated, conveyor system110includes a conveyor belt115on which dough sheet100is supported. However, other conveyor systems known in the art can be used with the present invention. Although not shown, it should be understood that the dough of dough sheet100is formed in a batch maker or the like and then processed into dough sheet100.

Dough sheet100passes beneath a rotary dough cutter120, which is configured to repeatedly cut dough pieces, such as in a form needed to make sub or steak rolls, from dough sheet100as dough sheet100is transported in direction105. For example,FIG.1shows a plurality of dough pieces125. Rotary dough cutter120is supported above dough sheet100on a longitudinally extending driveshaft130, with rotary dough cutter120and driveshaft130being aligned perpendicular to direction105. Rotary dough cutter120is configured such that contact between rotary dough cutter120and dough sheet100or conveyor belt115causes rotary dough cutter120to rotate in a direction135as dough sheet100and conveyor belt115travel in direction105. Alternatively, a motor and transmission (not shown) can be provided for driving rotary dough cutter120to rotate in direction135.

Adjustable side plates140and141are located at opposite ends of rotary dough cutter120. In the embodiment shown, each side plate140,141is provided with a plurality of circumferentially spaced indicia, such as in the form of notches, generally indicated at145for plate141. The purpose and function of side plates140and141will be discussed further below. However, at this point, it should simply be noted that shaft130and rotary dough cutter120are configured to rotate relative to side plates140and141. Also shown in this figure is a fluid supply hose155leading to side plate140from a pressure regulating controller160which receives fluid from a source, preferably a pneumatic source such as in the form of an air compressor (not shown) through a hose162. Overall, the source, hose162, pressure regulating controller160and fluid supply hose155collectively combine to define a fluid supply system as will be detailed further below with reference to air being the supplied fluid although other fluids, preferably in a gaseous state, could be employed. In a preferred embodiment of the invention, a corresponding fluid supply system is associated with side plate141. In general, air under pressure enters rotary dough cutter120through side plates140and141and is timely distributed throughout rotary dough cutter120for use in ejecting dough pieces125from rotary dough cutter120after formation of dough pieces125from dough sheet100, as explained further below.

FIGS.2and3show rotary dough cutter120separate from dough sheet100and conveyor system110but with driveshaft130and side plates140and141still present. Rotary dough cutter120includes a main body200, such as in the form of a substantially cylindrical sleeve as referenced hereinafter. A plurality of arcuate walls205extends radially outward from sleeve200. Walls205define a plurality of dough cutter molds210. In other words, walls205can be considered to be the exterior walls or sidewalls of dough cutter molds210. Because there is no negative space provided between the dough cutter molds210, each wall205, except for walls205of the outermost cutter molds210located at terminal ends (not separately labeled) of the rotary dough cutter120, forms a common part of adjacent dough cutter molds210. For example, a wall205adefines part of two different dough cutter molds210aand210b. Actually, given the offset nature of longitudinally spaced cutter molds210, wall205aactually forms one full side wall and two half side walls as clearly shown in these figures.

In addition to walls205, each dough cutter mold210is further defined by a pair of circumferentially spaced, radial divider walls, one of which is labeled215. More specifically, each divider wall215directly interconnects two longitudinally adjacent walls205such that an outer periphery of each dough cutter mold210is defined by a pair of spaced, parallel walls205which are interconnected by a pair of spaced divider walls215. Walls205and215act as blades and are configured to cut dough pieces125from dough sheet100, with one dough piece125being received in and shaped by each dough cutter mold210. This cutting action can be performed in various ways, including using sharp blades, blunt edge cutters, perforation forming cutters or the like. Accordingly, in operation, walls205and215extend all the way through dough sheet100and engage conveyor belt115. Due the structure of dough cutter mold210and particularly the configuration of walls205and215, the only dough from dough sheet100that could be considered “wasted” during formation of dough pieces125, i.e., the amount of dough sheet100that does not end up as one of dough pieces125, is outside the terminal ends of sleeve200(and perhaps adjacent the corners of molds210if rounded). This minimization is accomplished by covering sleeve200with dough cutter molds210which exhibit a repeated use of a common shape, with minimal, if any, gaps.

Dough cutter molds210also include a plurality of interior blades220extending radially outward from sleeve200. Each interior blade220is located within a respective dough cutter mold210at a position spaced from each of the walls205and215defining the particular dough cutter mold210. More specifically, each interior blade220includes angled end portions222and223radially leading from sleeve200to an elongated central portion224which is radially recessed relative to walls205. In accordance with a preferred embodiment of the invention, each end portion222,223terminates directly adjacent a respective divider wall215so as to be cantilevered from sleeve200, preferably bifurcating a respective dough cutter mold210. Interior blades220are configured to score dough pieces125as dough pieces125are formed. Although interior blades220could be sharp so as to cut into but not all the way through dough sheet100, in preferred embodiments, interior blades220are dull and score dough pieces125by only pushing down and deforming the dough, thereby altering the gluten matrix of the dough and weaking the dough piece125along the score. While only one interior blade220is shown in each dough cutter mold210, it should be understood that dough cutter molds210can include multiple interior blades220if desired.

With particular reference toFIG.3, the end faces (not separately labeled) of sleeve200are shown provided with markings230which, in the embodiment shown, are aligned with a respective series of divider walls215. In addition, each end face is provided with a series of spaced openings, one of which is labeled at235, with each opening235leading to a passage within sleeve200as will be detailed further below. Each of side plates140and141includes a through hole240which is offset from a central opening245used in mounting side plate140,141upon shaft130. Sleeve200is mounted for co-rotation with shaft130with opposing collars250, each being configured to receive a set screw252and a key255, which extends parallel to and interconnects driveshaft130, a respective collar250and sleeve200(see alsoFIG.4). On the other hand, each side plate140,141does not co-rotate with driveshaft130but rather is supported on driveshaft130, such as through a bearing mount260, and retained in a desired position by a collar265. As will be detailed more fully below, each side plate140,141can be rotatably adjusted relative to a respective face plate of rotary dough cutter120and forms part of a flow distribution control assembly. To this end, through hole240is adapted to be in fluid communication with air supply hose155.

FIG.4is a cross-section of rotary dough cutter120taken a longitudinal centerline ofFIG.2, without the inclusion of side plates140and141, bearing mounts260, collars265or end portions of shaft130. Initially it should be noted how this view highlights the manner in which walls205and interior blades220extend radially outward from sleeve200, with walls205extending radially farther than interior blades220, e.g., about ¼″ to ⅜″ more. In addition, this figure depicts each mold21including a base275, while a central bore305extending longitudinally through sleeve200. Driveshaft130extends through central bore305to mount rotary dough cutter120to driveshaft130. Furthermore, depicted is rotary dough cutter120including a plurality of air passages310extending longitudinally through shaft200and terminating in a respective one of openings235at each end of sleeve200. A plurality of air outlets (shown arranged as pairs of outlets312and313which form part of an overall fluid ejection system) are open to a respective air passage310, extend radially from air passage310through a respective base275and into a dough cutter mold210on either side of an interior blade220. Passages310receive fluid (again preferably air) from supply hose155, with the air then being injected through outlets315to dough cutter molds210. As stated above, fluid pressure is used to help discharge dough pieces125from dough cutter molds210. Passages310, which are part of the fluid supply system and, correspondingly, the overall fluid ejection system, receive the pressurized fluid selectively based on the periodic alignment of openings240, fully or partially, with one or more openings235leading to respective passages310during rotation of sleeve200relative to side plates140and141. Preferably, the air supply is controlled to be supplied in strategically timed pulses from each longitudinal side of sleeve200, with the air flow meeting in the middle regions of sleeve200in essentially simultaneously supplying air to an aligned set of dough cutter molds210. Given the successive alignment of openings and the timed pulsing of pressurized air, dough pieces125are discharged only from the desired dough cutter molds210at a precise moment of the continuous production process. Therefore, a specified series of axially aligned dough cutter molds210are supplied with air through air passages310based on the rotational position of rotary dough cutter120relative to side plates140and141, thereby providing for the timely ejection of dough pieces125. As only the openings240provided in side plates240and241are directly supplied with the air, the amount of air supplied at a given moment in the process to each opening235and corresponding passage310can be varied by adjusting an alignment position of the side plates240and241. Therefore, presence of side plates240and241provide a flow distribution control assembly for selectively adjusting flow and timing characteristics of the fluid to the sets of dough cutter molds210, with any adjustment being aided in accordance with the invention due to the inclusion of indicia145and/or markings230.

The enlarged mold view ofFIG.5further illustrates how walls205and215, as well as base275, define an interior region of a dough cutter mold210. In operation, rotation of rotary dough cutter120results in this interior region being filled with dough to create a dough pieces125, with walls205and215cutting dough piece125from dough sheet100and shaping dough piece125, with one preferred manner having the outermost edges (not separately labeled) of walls205and215being radiused to establish blunt edge cutters which function to cut by pulling an upper skin of the dough down to a lower skin and pinching the skins, thereby creating rounded sides for each dough piece125. At the same time, interior blade220within region400scores the dough piece125. After some additional rotation of rotary dough cutter120, the dough piece125located in interior region400is discharged from interior region400by forcing air first through a first set of air outlets312aand312bat a leading end portion of mold210, then a second set of outlets312band312bat a trailing end portion. For this purpose, although four such air outlets are shown for each dough cutter mold210, the actual number, size and location of the air outlets can vary, particularly depending on factors such as the size of the air outlets, the composition of dough sheet100, the supply pressure of the incoming air, and the like. Eventually, further rotation of rotary dough cutter120results in another series of dough pieces125being received in respective interior regions400and simultaneously discharged. This cycle repeats continuously so long as dough sheet100is present and rotary dough cutter120is rotating.

After formation of cut and scored dough pieces125, the dough pieces125are preferably frozen, most preferably in an un-proofed state. At this point, it should be noted that “un-proofed” in accordance with the invention means that no substantial or intentional actions are taken to promote proofing. Rather, the dough pieces are, at the very least, frozen shortly after being formed so as to save proofing for later. Thereafter frozen, un-proofed dough piece can be transported to a bakery operator, for example, who thaws, proofs, bakes and sells the resulting bread product. Of course, the dough pieces, frozen or otherwise, could be sold through other avenues, such as delivery to a grocery store for sale directly to a consumer who cooks the dough piece to create the bread product.

As previously indicated, the invention is mainly concerned with the continuous production of sub or steak rolls.FIG.6shows such a bread product. Specifically,FIG.6shows a bread product400, which corresponds to dough piece125after baking. As such, bread product400has an upper surface405, lower surface410, side surfaces415and end surfaces420. In the central portion of bread product400, the score created as described above has opened up, forming an elongated opening425. This occurs during baking of dough piece400as dough piece400expands and breaks due to the weakening of the dough matrix during scoring. Again, in accordance with the invention, dough product400is in the form of a sub or steak roll. However, it should be recognized that other bread products can certainly be produced in accordance with the present invention.

Based on the above, it should be readily apparent that the present invention provides dough products that are continuously cut, scored and forcibly ejected from molds prior to being proofed and frozen (i.e., before being purchased by bakery operators), as well as an apparatus and method for producing the dough products. While certain preferred embodiments of the present invention have been set forth, it should be understood that various changes or modifications could be made without departing from the spirit of the present invention. In general, the invention is only intended to be limited by the scope of the following claims.