Abstract:
The present invention is directed to an improved apparatus for processing dough intermediates that are less developed, softer or which have enhanced water or moisture levels. More specifically, the present invention relates to the use of an improved dough transport module, that has one or more protuberances extending generally perpendicularly from a supporting surface which supports the dough intermediate for a sufficient interval of time during processing so as to eliminate the waste and loss of dough intermediates prior to processing or packaging steps.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     None. 
     FIELD OF THE INVENTION 
     The present invention is directed to an apparatus for handling loose dough intermediates, such as moisture enhanced, softer and/or less developed dough. The apparatus of the present invention reduces the fallout of the intermediates formed from this dough so as to avoid unintentional loss or waste and machine downtime occasioned by dough intermediates falling out of the processing line prior to packaging or further treatment or handling. 
     BACKGROUND OF THE INVENTION 
     The present invention is directed to an improved apparatus for processing dough intermediates that are less developed, softer or which have enhanced water or moisture levels. More specifically, the present invention relates to the use of an improved dough transport module, that is incorporated into a cutter bar configuration and that has one or more protuberances extending generally perpendicularly from a supporting surface which supports the dough intermediate for a sufficient interval of time during processing so as to eliminate the waste and loss of dough intermediates prior to processing or packaging steps. 
     The production of food products on a commercial scale presents constant challenges to the manufacturer in achieving economies and the consumer in obtaining acceptable products. The manufacturer attempts to extract processing efficiencies while at the same time achieving an end product that is suitable for consumers. The consumer on the other hand, looks for a food product that evokes a feeling of having created the product from “scratch” (through the appearance provided by the product, as well as the olfactory and organoleptic properties) but yet be easy to prepare and serve. 
     One of the problems for the manufacturer in meeting the challenges presented by these conflicting needs, aside from potential increases in costs due to improving ingredient quality, is usually related to the difficulties in preparing and processing the dough intermediates. That is, the dough and dough intermediates are typically more difficult to handle and can range from a stickier dough to a more “loose” dough or suffer from other problems from which conventional processing equipment cannot readily accommodate. While the dough intermediates needs to be retained in the processing apparatus, it also needs to release readily from the apparatus in order to complete the necessary manufacturing steps. 
     Another problem faced by the manufacturer is that fragile and deformable products such as dough and dough intermediates as well as the resulting finished product will show visible scars or distresses as a result of rough handling. As such, the manufacturer needs to treat such material gently so as not to create an aesthetically displeasing product. 
     In order to provide the consumer with more desirable and flavorful biscuits, such as one having improved texture, fluffiness and moisture, it has been found, for example, that it is necessary to change or increase the level of moisture in the dough. However, increasing the level of moisture typically causes difficulties in processing the dough intermediates as well as subsequently filling the dough cans or other packaging adapted to handle the dough. It is believed that this problem results from the dough having higher flowability, or being looser, due to the increased moisture level or water content, and as such can be more difficult to handle during processing. 
     It has been found that when using conventional dough handling equipment, the enhanced moisture dough, or loose dough has a tendency to fall or drop out of the dough processing equipment prematurely. The vibrations of the equipment cause the dough fill cups to empty as the cups advance through the various processing steps to the package filling equipment that will distribute the dough intermediates to the waiting dough packages. 
     Some of the drawbacks associated with processing doughs or dough intermediates that have premature fallout, such as those dough intermediates that are more loose than conventional dough products, include containers or packages that are not completely filled (as the dough fallouts before reaching the packaging station) deformation or irregularities in the dough intermediate or the final product produced from such intermediate (due to the addition of gripping appliances to hold the dough in position) and process or machine clogging and downtime to clean or adjust the apparatus. 
     Typically, dough and dough intermediates have a tendency to be increasingly sticky and as such there has been a regular and constant development to reduce the amount of contact (surface area of the equipment) between the dough processing apparatus and the dough itself in order to avoid cleaning and handling difficulties. It has been surprisingly been found that by increasing the surface area of the transport modules through at least the packaging stations, that enhanced dough or dough intermediates that have such increased moisture levels can reach the packaging and post forming processing areas without the problems associated with premature fallout of the dough or dough intermediates. However, such gripping devices cannot be overtly aggressive as the devices can distort the appearance of the dough product. In addition, increasing the size of the cups used in transporting the dough intermediates add an excessive amount of weight to the apparatus, causing additional wear and tear on the equipment. 
     What is therefore needed is an enhanced apparatus for handling softened, moisture enhanced or other difficult to handle dough that does not add additional complexity to the processing apparatus but still provides an efficient and effective apparatus to deliver the dough or dough intermediates to the packaging or other post formation treatment steps. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention overcomes the foregoing drawbacks by placing a series of prearranged protuberances or extensions internally in a dough-processing module. The protuberances or extensions can be positioned at any point on the internal face of the walls of the modules, and extend perpendicularly from the walls to actively engage, but not detrimentally, the dough intermediates. The protuberances provide a temporary holding means to retain the moisture enhanced dough intermediate in the module for a sufficient amount of time to enable the plunger to remove the dough intermediate from the cup or module structure. The protuberances are placed in an area of the face of that is generally slightly away from the end edges of the device. 
     In one embodiment of the present invention, a dough intermediate transport module is described and comprises a substantially rigid outer frame. The rigid frame has a predetermined shape that corresponds to a prearranged configuration that aids in forming a finished dough product. The rigid frame further has an externally extending configuration and an internally arranged configuration. At least one protuberance is provided and extends substantially perpendicularly from the internally arranged configuration. The protuberance on the internally arranged configuration prevents a dough intermediate from falling out of the dough transport module prior to applying motive force to remove the dough intermediate from the dough transport module. 
     A still further embodiment of the present invention relates to dough intermediate transport module that has a plurality of generally planar surfaces. Each of the generally planar surfaces having first and second longitudinally extending side edges, first and second transversely extending end edges and first and second faces. The generally planar surfaces are connected one to another along one of the first and second longitudinally extending side edges to form a geometric configuration. At least one protuberance is provided and extends substantially perpendicularly from one of the first and second faces of one of the plurality of generally planar surfaces. The protuberance is disposed in an area of one of the first and second faces that is at least slightly away from one of the first and second transversely extending end edges and the protuberance aids in retaining a softened dough intermediate in the transport module during processing. 
     These and other objects of the invention will become clear from an inspection of the detailed description of the invention and from the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which: 
     FIG. 1 is a cross sectional view of a protuberance disposed on an internally configured arrangement of a dough transport module of the present invention; 
     FIG. 1A illustrates a generally planar surface of the present invention having first and second ends, one of which is tapered and further illustrating a protuberance disposed in an area not adjacent to one of the first and second ends; 
     FIG. 1B provides a plan view of the present invention showing a number a protuberances disposed on each of the generally planar surfaces of the internally configured arrangements of a dough transport module of the present invention; 
     FIG. 2 provides an illustration of a plurality of modular transports affixed to one another to form a cutter bar in connection with the present invention; 
     FIG. 3 illustrates a schematic of a dough and dough intermediate forming line as used in the present invention; 
     FIG. 4 shows a depiction of a dough intermediate positioned within a dough transport module; 
     FIG. 5 illustrates a hexagonal dough transport module having protuberances on each of the generally planar surfaces; 
     FIG. 6 depicts a hexagonal dough transport module having protuberances on alternate generally planar surfaces; 
     FIG. 7 provides a hexagonal dough transport module having protuberances on adjacent generally planar surfaces; and 
     FIG. 8 provides a square dough transport module having protuberances on pre-selected surfaces. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention. 
     As used herein, the term “intermediate” or “dough intermediate” refers to a dough product that is in an intermediate, physical step or phase and requires one or more further treatment or processing steps in order to complete the preparation of the finished product so that it is suitable for human or animal consumption. The additional treatment step may include, cooking, baking, heating, frying or the like, but is not to be construed as being limited thereto. 
     Turning now to FIG. 1, an exemplary embodiment of the module of the present invention is shown by reference to numeral  10 . The module  10 , here illustrated as a hexagon, is constructed from a number of generally planar walls  12 . Each of the generally planar walls  12  (referring to FIG. 1A) has a first face  13  and a second face  15  as well as first and second transversely extending end edges  17  and  19  and first and second longitudinally extending side edges  21  and  23 . A protuberance or extension  14  is shown attached to the first face  14  of the generally planar surface  12 . The protuberance or extension  14  extends substantially, generally perpendicularly from the first face  13  of the generally planar surface  12  into the internal configuration of the transport module of FIG.  1  and is disposed so as not to be adjacent one of the first or second transversely extending end edges  17  and  19 . The internal configuration is generally complimentary of the external configuration of the transport module  10 . 
     Also as illustrated in FIG. 1A, one of the first and second transversely extending end edges may be in the form of a tapered end  16  so as to permit ease of entry of the dough intermediate into the module  10 . That is, the tapered end  16  serves as a cutting end or edge for the dough as it is pressed into the modules as illustrated in FIG. 3. A tapered end  16  may be provided on each of the generally planar surfaces  12  or only on predetermined surfaces, such as the leading or trailing edge depending on the direction the dough is being applied, or as according to the needs of the specific application such as to provide some aesthetic or other feature. 
     In a further embodiment of the present invention, a hexagonally shaped module  10  is illustrated in FIG.  1 B and is provided with a series of protuberances  14 , a total of six, only three of which are shown, on each of the generally planar surfaces  12  of the dough intermediate transport module  10 . Obviously, if the module  10  were of a different geometric shape, i.e. square, round, pentagonal, triangle, heptagonal, etc. a different number of protuberances  14  may be provided. 
     Each of the protuberances  14  extends inwardly of the interior configuration (into the interior of the hexagon) and extends generally perpendicularly from the sidewall. The protuberance  14  extends a distance ranging from 1 to 4 mm with about 2-3 mm being preferred and from 2.5 mm to 3 mm being further preferred. The length of the protuberances ranges roughly from 20-30 mm and preferably about 22-27 mm but generally runs the width of the generally planar surface  12  or the width of the first and second transversely extending end edges  17  and  19 . The transverse extension of the protuberance  14  is generally greater than half the width of the face  12  of the module  10 . The width of the protuberance  14  is approximately 0.3 inches to 0.4 inches with roughly 0.35 inches being preferred. In one embodiment, the protuberance  14  is centered about one half inch from the end edge, specifically the end edge having the tapered end  16 . The positioning of the protuberance  14  is desirably arranged to slow or reduce the egress of the dough intermediate out of the module  10  prior to being dispensed into the waiting dough containers. 
     The shape of the protuberances  14  themselves is not necessarily critical, however, in one embodiment of the present invention the shape of the protuberance is generally rounded so as to slightly grip and hold the dough intermediate, but not create a significant indentation, rip or other distortion in the dough. It has been found that the protuberances  14  extends from the planar surface  12  a distance of 2.5 mm to 3 mm successfully held the dough intermediates in the modules for approximately five minutes during downtime of the processing apparatus. The dough intermediates after preparation (cooking or baking) did not contain any detrimental defects (such as rips or distortions) caused by use of the protuberances as described above. 
     Turning now to FIG. 2, a series of dough transport modules  10  are connected to one another at the second face  15  of the generally planar surface  12 . The connection is achieved through spot welds (not shown) that may appear on the transverse end edges  13  and  15  of the modules  10 . The attachment may also be accomplished through the use of clips, adhesives or other means that are suitable and provide adequate holding strength for the modules  10 . 
     The arrangement of modules  10 , as shown in FIG. 2 in a honeycomb appearance, has been incorporated into a cutter bar, which is designated generally by reference to numeral  18 . In an exemplary embodiment, up to 48 modules or cups  10  may be included in each cutter bar. A series of cutter bars  18  may be connected end to end via a connection bar  20  to create an endless belt configuration. In one embodiment, there may be 38 cutter bars in a single endless belt unit. The connection bar  20  is used to couple one cutter bar  18  to the next and as illustrated the connection is completed through use of a dovetail type arrangement, which is held in position through the use of pins or bolts (not shown). Other connection configurations are possible such as tongue and groove, slotted configurations, etc. but the connection should be flexible so that the belt may be rotated around one or more axis&#39;s. 
     FIG. 3 is illustrative of a schematic apparatus, generally designated at  30 , for processing the loose dough intermediates of the present invention. As illustrated, a series of cutter bars  18  are connected end to end to form an endless loop. The dough, illustrated by reference to numeral  32  is brought into contact with the cutter bars  18  by a conveyor  33 , but other arrangements are possible, such as the use of an extruder, gravity feed hopper, etc. 
     The dough  32 , upon reaching the cutter bars  18  is then carried by the endless belt formed by the cutter bars  18  and is then pressed via a compression roller  34  into the individual modules of the cutter bars  18 . The tapered end  16  of each of the modules facilitates cutting of the dough and pressing the dough into each of the modules  10 . The cutter bar  18  advances to a dispensing or packaging station  36  at which motive force  38  (for example a vacuum) is applied to a series of plungers  40  to press the dough  32  from the cutter bars  18  into waiting dough containers  46  such as dough cans and then withdraw the plungers from the containers  46 . While dough cans are illustrated, obviously any sort of dough packaging may be used in connection with the present invention such as envelopes, flexible sleeves, boxes, and the like. 
     Each of the plungers  40  is provided with a ramming head  42  that is sized and configured to push the dough out of each of the individual modules and into the waiting dough containers  46 . A conveyor belt  44  or other advancing mechanism is provided to continually supply empty dough containers  46  to the packaging area. The conveyor belt  44  also serves to support the dough containers  46 . After the dough has been removed from the cutter bars  18  and the individual modules  10 , the cutter bars  18  are advanced again by a drive means  48 , illustrated in FIG. 3 as a drive wheel where the cutter bars  18  are then readied for another filling cycle. 
     After each of the dough containers has been filed, the conveyor  44  moves the filled containers off to a weighing station (not shown) to confirm that an adequate amount of dough or dough intermediates has been placed into the individual containers  46 . 
     Turning now to FIG. 4, the module  10  is illustrated in a filled condition showing the dough intermediate  32 ′ being retained by at least a pair of generally perpendicularly extending protuberances  14 . As shown in FIG. 4, a plurality of the protuberances  14  are used to hold the dough intermediate  32 ′ in place. 
     FIGS. 5 through 8 are other illustrative embodiments of the present invention and include exemplary uses of the protuberances  14  in various configurations, including having the protuberances  14  on each of the generally planar surfaces as shown in FIG. 5; alternate walls as illustrated in FIG. 6; on adjacent walls as provided in FIG. 7; and in an alternate geometric configuration in FIG.  8 . It should be understood that the internal and external configuration of the modules  10  could be used in forming or creating the intended shape of the dough intermediate. 
     Ideally, the dough intermediates through use of the present invention should be able to be retained in each of the modules or cups  10  for at least five minutes. 
     The present invention is used for a variety of dough intermediates such as in the formation of biscuits, rolls, buns and the like, but can also be used for other dough intermediate applications such as for example cookies, pastries, bread, bars and the like. 
     It will thus be seen according to the present invention a highly advantageous dough intermediate module transport apparatus has been provided. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products.