Method and apparatus for producing a corrugated pasta sheet, facilitating adherence of sauce to surface

Abstract: A method for producing a corrugated pasta sheet (2), facilitating the adherence of the sauce to the surface, in which the pasta sheet (2) is obtained by forcibly extruding the dough through a slot (3) in a die plate (4), comprising the stages during which at least one surface (5) of the sheet (2) is crimped repeatedly using at least one raised arm-type flexible, elasticised blade (6) whose free end (7) comes into contact with the sheet (2). The blade (6) is inflected reciprocally by the dragging action exerted on it by the sheet (2) as it passes through the slot (3) and by the returning action produced by its elastic properties. An apparatus (1) putting into operation the method described above also forms part of the invention [Figure 1]

Description: The present invention applies to the automatic pasta-making machinery sector and relates, in particular, to a method for producing a corrugated pasta sheet which facilitates the adherence of the sauce to the surface, and an apparatus which puts this method into operation. A fundamental element characterising the construction of automatic pasta-makers, which demands constant, generalised research on the part of all constructors in the sector, is the machine's capacity to produce pasta with a rough surface texture, thereby helping the sauce to adhere to the surface once the pasta has been prepared and improving the quality of the dish created. Although several types of pasta with grooved surface are already well known, endless attempts to construct a machine which is capable of producing corrugated pasta in the form of a sheet produced by extruding the dough forcibly through a slot in a die plate have revealed the difficulties involved; these prevent the desired results from being obtained in a practical way at an industrial level. Several prototype machines constructed in the past to obtain this product were in fact equipped with extremely complex mechanisms which were not only costly, but were also unreliable and prevented production from progressing at a regular rate; the result, on the one hand, was that the machines were unable to supply a product of consistent, lasting quality, and on the other, that they required frequent servicing and setting up procedures. Some pasta producers have now chosen to overcome the problem in a different way, attempting to obtain a corrugated surface by means of a heating effect produced during the production process. The process basically consists of the pasta being fed through the hole in the die plate at a high temperature and then blasted by a strong current of cold air, accelerated by purposely-designed fans, before being rolled by fitted rollers. By cooling the sheet, the upper layers of the pasta tend to cool down much more rapidly than the internal layers which remain at a higher temperature for a longer period of time. This operating stage produces a corrugated surface which remains intact, even when the pasta is rolled and cut as required, and passes on to the next stages in the production cycle. The basic problem with this method, however, is the fact that the rough texture produced disappears totally once the pasta is immersed in hot water for cooking. Immersion in hot water in fact causes all the layers of the pasta, both internal and external, to homogenise. From the facts described above, it is therefore apparent that this type of operating method produces a corrugated effect of merely aesthetic quality which, disappearing as soon as the pasta is cooked, does not in any way facilitate the coating of the sauce which is generally added once the pasta has been cooked and removed from the water. The aim of the present invention is to provide a method whereby corrugated pasta is produced which is genuinely capable of retaining the sauce; a method which is simple and reliable; which is capable of ensuring that consistent quality standards are maintained over a period of time; and which can be put into operation with the use of machinery of relatively simple construction, cheap to run, durable and requiring minimal servicing. A method and an apparatus for extruding dough is known, e.g., from DE-A- 4 014 535. This aim is achieved in accordance with the present invention by a method for producing a corrugated pasta sheet, facilitating the adherence of the sauce to the surface, in which the pasta sheet is obtained by forcibly extruding the dough through a slot in a die plate. The method according to one or more of the attached claims is characterised by the fact that it comprises the stages during which at least one surface of the sheet is crimped repeatedly, using at least one raised arm-type flexible, elasticised blade whose free end comes into contact with the sheet. The blade is bent out of its non-deformed configuration by the reciprocal dragging action exerted on it by the sheet as it passes through the slot and the returning action produced by its elastic properties. The blade acts as a vibrating element which, together with the die plate, enables material on the surface of the pasta sheet to be transferred from one point to another; such transfer producing a pattern on the surface of the pasta sheet while it is being extruded. The use of a single blade, which works on only one surface of the pasta, allows pasta to be produced which is suitable for fillings, such as tortellini, ravioli and similar forms, or types of pasta which are wrapped over to enclose a filling, such as cannoli. The use, on the other hand, of two blades mounted facing each other, allows pasta shapes such as tagliatelle, farfalle and similar to be produced. Given the relative ease with which the bending characteristics producing the vibrating movement of the blade can be varied, by selecting appropriate construction materials and measurements for the blade, for example, or by mounting more than one blade, each with different characteristics, the method defined by the invention can be used to produce a vast range of rough surface textures, with a variety of geometrical shapes and profiles of different sizes. This therefore allows pasta to be produced which has different, novel characteristics, in terms of both the use to which it is put for the preparation of specific dishes and its external appearance. In accordance with the present invention, an apparatus is also supplied, according to claim 11, with which the method is put into operation, adopting an embodiment which, apart from the vibrating blade, is of a static type and, being free of any moving parts, is capable of ensuring reliable, safe and repetitive performance over a long period of time. The technical characteristics of the invention, based on the above-mentioned aims, are clearly described in the claims set out below and the advantages offered are made clearer in the description which follows, read with reference to the attached drawings which illustrate an embodiment, intended merely as an example without restriction: figure 1 is an overall view of the apparatus according to the present invention; figure 2 is a partial view of a detail from figure 1; figures 3 and 4 are partial views of two distinct, alternative variations of the detail illustrated in figure 2; figure 5 is a drawing of an alternative embodiment of the apparatus to that illustrated in figure 1; figure 5a is an enlarged scale drawing of a variant of figure 5; figures 6 and 7 are front views of a scale enlargement of a detail taken from figure 5, illustrated as two alternative embodiments; figures 8a to 8g illustrate corresponding types of pasta, fresh or dried, which can be made with the apparatus illustrated in the preceding figures. A method and an apparatus 1, operated in accordance with the method, are described with reference to the attached drawings, designed to produce a corrugated pasta sheet 2 which facilitates the adherence of the sauce. The apparatus 1, illustrated in figure 1, basically consists of a press used to extrude the dough 12 which in turn comprises, merely by way of example without restriction, a tubular extrusion chamber 13 mounted next to and connected to a tub 14 where the dough 12 is re-mixed and a die plate 4 with a gauged slot 3. A screw conveyor 15, operated by the relevant drive units 18, fitted inside the extrusion chamber 13, picks up the dough 12 from the open, lower base 16 of the tub 14 and transfers it without interruption along a duct 17 leading to the die plate 4, towards the gauged slot 3, forcing the dough 12 out of the slot 3 and thereby causing it to take on the shape of the contour of the hole. Outside the die plate 4, the apparatus 1 comprises either one or two flexible, elasticised blades 6, each mounted transversally to the feed path 8 of the sheet 2 as it passes through the slot 3; it is secured to the die plate 4; it is raised and moved by the die plate 4 towards the sheet 2 in such a manner that its free end 7 comes into contact with the sheet 2. As the sheet 2 is fed through the slot 3, the blade 6 is inflected reciprocally by the dragging action exerted on it by the sheet 2 as it passes through the slot 3 and the returning action through which it regains its non-deformed configuration, by virtue of its elastic properties. The reciprocating bending and elastic returning movement of the blade 6, together with the fact that the blade 6 is in continuous contact with the sheet 2, brings about a transfer of material in the dough, affecting the outer layers of the surface 5 of the sheet 2 in a manner which produces a characteristic crimped texture on the surface of the sheet 2 (see also figure 8a). It is pointed out that the corrugated texture on the sheet 2 produced by crimping the surface 5 is brought about by actually transferring the dough 12 from one point to another over its surface 5 and therefore remains unaltered even after the pasta has been immersed in hot water for cooking. It is evident from figure 3 that the embodiment of the apparatus 1 which envisages the use of only one blade 6 is particularly suitable for the production of sheets 2 of pasta which are corrugated on only one side, applicable, for example, for the preparation of pasta with fillings of various types such as "orecchiette" (see figure 8d); "ravioli" (see figures 8e and 8f); "tortellini or tortelloni" (see figure 8g); and also for pasta shapes which require the sheet 2 to be rolled, and possibly enclose a filling (see figure 8c). If, on the other hand, the apparatus 1 is equipped with a pair of blades 6, (see figure 2), mounted on either side of the slot 3 in the die plate 4, both the upper and lower outer surfaces 5 of the pasta sheet 2 can be corrugated and other types of pasta obtained, such as those illustrated in figure 8b and known as "farfalle" (bow ties). As far as the design of the corrugated profile is concerned, tests have been carried out on blades 6 of a thickness of approximately 0.3 mm. constructed in extra-raw stainless steel, and have produced very satisfactory results. The example illustrated above should be treated as merely an example of a possible solution, as it is clear from what has been described above, that, by altering the geometric and physical characteristics capable of influencing the inflection of the blade 6, the design and depth of the corrugated finish on the pasta can be varied with relative ease in order to obtain a vast range of products which also differ in appearance. The corrugation design can in fact be modified with the use of single-layer blades 6 of differing lengths and thicknesses, selected appropriately; otherwise, composite blades 6 can be used, made up of more than one layer, one on top of the other, and combined, adopting the lengths, thicknesses and/or construction materials most appropriate. The invention described not only fully achieves the basic object whereby a corrugated pasta sheet 2 is produced whose characteristics endure, remaining intact during the cooking process without any alteration to its geometric form, but also allows macaroni to be extruded whose external surface 5, or even internal surface 5, is corrugated around its circumference. To this end, the apparatus 1 can be constructed in such a way that the pasta is extruded through a ring-shaped slot 3 (see figures 5 and 5a). The parameter of the ring-shaped slot 3 is defined by the combination of an outer edge 10 of the die plate 4 and the surface 20 facing it of a insert pin 21 fitted across the die plate 4; in this case, the surface 20 marks the internal edge 11 of the slot 3. This apparatus 1, which has already been fully described, can be used to produce a sheet 2 which is substantially tubular in shape and is later cut into pieces of an appropriate length by cutting equipment 22, also of a conventional type. If the slot 3 is fitted with a ring-shaped blade 6, secured to the die plate 4 along its outer edge 23 and constructed with a number of adjacent circular segments 9, each capable of bending independently of the others, which are fitted along the circumference of the slot 3 and positioned so that they converge on the tubular sheet 2, the external surface 5 of the tubular sheet 2 can be corrugated by applying a series of circumferential embossed markings which follow on, one after the other, in the direction in which the sheet is being fed 8, in the present case, representing the line of axis of the tubular sheet 2. Again in this case, by varying the shape and number of segments 9, as illustrated by way of example in figures 6 and 7, considerable scope is given to the corrugation design applied to the pasta as it is extruded. Specific reference is made in figures 6 and 7 to an embodiment of the apparatus 1 which is capable of corrugating the outer surface 5 of the tubular sheet 2; there is no reason however why the inner surface cannot be corrugated in the same way. In fact, it is immediately evident from figure 5a that this result can be obtained if the blade 6 is structured in such a way that it is rigidly secured to the insert pin 21 along its inner edge 24 and its outer edge 23 is turned to face the die plate 4, left free to enclose the internal edge 11 of the extrusion slot 3, together with the die plate 4. The invention described above can be subject to numerous modifications and variations, without departing from the scope of the inventive concept. Moreover, all the details may be substituted by technically equivalent elements.

Claims: A method for producing a corrugated pasta sheet (2), facilitating the adherence of the sauce to the surface, in which the pasta sheet (2) is obtained by forcibly extruding the dough through a gauged slot (3) in a die plate (4), characterised in that it comprises the stage during which at least one surface (5) of the sheet (2) is crimped repeatedly using at least one raised arm-type flexible, elasticised blade (6) which is mounted transversally to the feed path (8) of the sheet (2) as it passes through said slot (3) in such a manner that its free end (7) comes into contact with the sheet (2); the blade (6) being inflected reciprocally by the dragging action exerted on it by the sheet (2) as it passes through the slot (3) and by the returning action produced by its elastic properties, thereby acting as a vibrating element which enables material on said surface (5) of the pasta sheet (2) to be transferred from one point to another; such transfer producing a pattern on said surface (5) of the pasta sheet (2). The method according to claim 1, characterised in that both the upper and lower outer surfaces (5) of the pasta sheet (2) can be crimped with the use of a pair of the corresponding blades (6), mounted on either side of the slot (3) in the die plate (4). The method according to one of the above claims, characterised in that the flexible blade or each of the flexible blades (6) is constructed with a single layer. The method according to claim 3, characterised in that the blade or each of the blades (6) is constructed with more than one layer, one on top of the other. The method according to any one of the above claims, characterised in that the blade (6) is constructed in extra-raw stainless steel. The method according to claim 4, characterised in that the blade (6) has a thickness of approximately 0.3 mm. The method according to one of the above claims in which the pasta is extruded forcibly through a ring-shaped slot (3), characterised in that the sheet (2) is crimped by at least one blade (6) constructed with at least one circular segment (9)converging on the sheet (2). The method according to claim 7, characterised in that the blade (6) is constructed with a number of the segments (9), each capable of bending independently of the others, which are fitted along the slot (3) in the die plate (4). The method according to either claim 7 or 8, characterised in that the segment or each of the segments (9) is secured firmly to the outer edge (10) of the slot (3) in the die plate (4). The method according to either claim 7 or 8, characterised in that the segment (9) is secured firmly to the inner edge (11) of the slot (3) in the die plate (4). An apparatus to produce a corrugated pasta sheet (2), facilitating the adherence of the sauce to the surface, comprising a die plate (4) with a gauged slot (3); the pasta sheet (2) being obtained by forcibly extruding the dough through said slot (3); the apparatus (1) being characterised in that it comprises at least one arm-type flexible, elasticised blade (6) which is raised above the die plate (4) and is mounted transversally to the feed path (8) of the sheet (2) as it passes through said slot (3) in such a manner that its free end (7) comes into contact with the sheet (2); the blade (6) being inflected reciprocally by the dragging action exerted on it by the sheet (2) as it passes through the slot (3) and by the returning action produced by its elastic properties, thereby acting as a vibrating element which repeatedly crimps at least one surface (5) of the sheet (2). An apparatus according to claim 11, characterised in that it comprises a pair of the blades (6), mounted on either side of the slot (3) in the die plate (4). An apparatus according to one of the above claims 11 to 12, characterised in that the flexible blade or each of the flexible blades (6) is constructed with a single layer. An apparatus according to one of the above claims 11 to 12, characterised in that the blade or each of the blades (6) is constructed with more than one layer, one on top of the other. An apparatus according to any one of the above claims, characterised in that the blade (6) is constructed in extra-raw stainless steel. An apparatus according to claim 11, characterised in that the blade (6) has a thickness of approximately 0.3 mm. An apparatus according to one of the above claims 11 to 16, characterised in that the blade or each of the blades (6) is mounted directly on the die plate (4). An apparatus according to one of the above claims in which the pasta is extruded forcibly through a ring-shaped slot (3), characterised in that the blade (6) is constructed with a circular segment (9) converging on the sheet (2). An apparatus according to claim 18, characterised in that the blade (6) is constructed with a number of the segments (9), each independent of the others, which are fitted, at least partially, along the slot (3) in the die plate (4). An apparatus according to either claim 18 or 19, characterised in that the segment (9) is secured to the outer edge (10) of the slot (3) in the die plate (4). An apparatus according to either claim 18 or 19, characterised in that the segment (9) is secured to the inner edge (11) of the slot (3) in the die plate (4).

Inventors: ANNICCHIARICO FRANCO, ANNICCHIARICO, FRANCO
Applicants: PASTE TIPICHE REGIONALI S R L, PASTE TIPICHE REGIONALI S.R.L.
Application year: 2000
Main classification: A21C11
IPC codes: A21C3, A21C11