Patent Publication Number: US-2017354156-A1

Title: Apparatus, System, and Process for Making a Bakery Product

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation-in-part and claims the benefit under 35 U.S.C. §119(e) of U.S. Non-Provisional patent application Ser. No. 13/938,492 filed on Jul. 10, 2013, entitled “Apparatus, System and Process for Making a Bakery Product,” which is incorporated by reference in its entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure generally relates to making a bakery product. 
     BACKGROUND 
     When making bakery products, and in particular, bread loaves, two different types of dough mixes are employed: a conventional batch mix and a continuous mix. The mix used in a conventional batch process provides a stiff dough that, on baking, produces a bread loaf having a firm texture that many consumers find highly desirable. An example of a conventional batch mix baked loaf of bread, is sold by Bimbo Bakeries USA, Inc. under the brand name Orowheat and others. A problem with any type of bread dough either continuous dough mix or conventional batch mix is that, after mixing of the ingredients called for by the mix&#39;s recipe, air pockets of different sizes are formed by the chemical reaction of the yeast, sugar, flour and other ingredients. As the dough is transferred from a mixer it ages and the dough starts to generate at the beginning small air pockets, but as the dough ages, the small air pockets become enlarged and different sized air pockets form, requiring conditioning. 
     In the batch process, the air pockets are reduced in size and rendered highly uniform in size by processing the dough using numerous pieces of equipment and processing steps as depicted in  FIGS. 2, 2A and 2B , and discussed subsequently in greater detail. A dough developer unit is used in the continuous process to render the air pockets uniform; however, this produces a soft dough. But this soft dough, on baking, produces a bread loaf having a soft, spongy texture. 
     SUMMARY 
     In brief, the apparatus, system, and process using a conventional batch process dough mix produces a stiff dough that, on baking, produces a bread loaf having a firm texture that many consumers find highly desirable. The apparatus, system, and process eliminate most of the equipment and process steps required using known equipment and process steps to make a bread loaf having a firm texture using a conventional batch mix. 
     The apparatus, system and process for making bakery products has one or more of the features depicted in the embodiment discussed in the section entitled DETAILED DESCRIPTION. The claims that follow define the apparatus, system and process, distinguishing them from the prior art; however, without limiting the scope of the apparatus, system and process as expressed by these claims, in general terms, some, but not necessarily all, of their features are: 
     One, the apparatus for making bread loaves includes a mixer in which ingredients to make a batch of bread dough are mixed. This batch provides a predetermined number of bread loaves. The apparatus converts the entire batch into individual packets of conditioned dough corresponding to the predetermined number of bread loaves to be produced from the batch. The individual packets are deposited individually directly in cavities of the pans within from 10 to 20 minutes after mixing the ingredients to portion the batch without flour dust and without additional processing of the dough prior to deposition in a pan cavity. 
     Two, a pan feeder continuously moves baking pans in a stepwise manner along a predetermined linear path, with each pan having at least one empty cavity sized and configured to bake a single bread loaf. The pan feeder includes a pair of aligned pan conveyors along the predetermined linear path along which the pans move that are spaced apart to provide a gap beneath the extrusion port to facilitate flushing waste matter from the apparatus during cleaning. 
     Three, a dough developer unit above the predetermined linear path reduces the size of air pockets within unconditioned dough, so that dough exiting the developer unit is conditioned. 
     Four, a first transfer pump continuously feeds the unconditioned dough from a holding hopper to the dough developer unit, and an extrusion unit below the dough developer unit and above the predetermined linear path continuously extrudes the conditioned dough into a dough stream. A second transfer pump continuously meters the conditioned dough from the extrusion unit through an extrusion port of a die manifold member of the extrusion unit. The extrusion port is in a face of a die manifold member from which the dough stream exits. 
     Five, a cutter unit above the predetermined linear path continuously cuts the dough stream into individual packets, a single packet to be deposited in an individual cavity in a pan moving along the predetermined path. The cutter unit includes a blade that moves through a predetermined closed path from a home position above the dough stream, along the face of the die manifold member past the extrusion port to sever the dough stream, and then away from the face of the die manifold in a manner to avoid interfering with the dough stream from continuing to exit unencumbered from the extrusion port. The blade is moved from a home position above the dough stream along a downward vertical-linear path at a first rate of speed and, after moving away from the face of the die manifold, is moved at an increased rate of speed to the home position at least in part along an upward vertical-linear path. 
     Six, the extrusion port is positioned relative to the predetermined linear path so that, upon cutting the dough stream, the single packet drops directly into a cavity of a pan positioned directly beneath the extrusion port. The extrusion port has a rectangular shape with opposed sides, each side comprising a laterally adjustable wedge-like slide element to enable the width of the extrusion port to be changed. The die manifold member includes a chamber having a generally flat top and flat bottom and outward sloping sides to form a generally shaped triangle configuration. There is an entry end at an apex of the triangular configuration and the extrusion port forms the base of the triangular configuration. 
     Seven, a control system delivers the dough stream to the cutter unit at a controlled volumetric feed rate and at a controlled pressure. The control system includes a monitoring element that senses the amount of conditioned dough being produced and, in response thereto, regulates the operation of the dough developer unit. The control system includes a pressure sensor that detects the pressure of the dough stream and a microprocessor programmed to operate speed controls as a function of the pressure. 
     The process of making a bread loaf from a conventional batch dough mix includes the following steps: 
     (a) continuously moving pans along a predetermined path, each pan including at least one cavity sized and configured for making a bread loaf, 
     (b) continuously conditioning a batch of unconditioned dough to reduce the size of air pockets within the unconditioned dough and so produce a conditioned dough, 
     (c) continuously extruding the batch of conditioned dough at a controlled volumetric feed rate and at a controlled pressure to provide a constant stream of conditioned dough, 
     (d) continuously cutting the stream of conditioned dough into individual packets, a single packet being directly deposited in an individual cavity of a pan moving along the predetermined path without additional processing of the dough prior to deposition in the cavity. 
     The batch makes a predetermined number of packets and the process is completed for the batch within a predetermined time period so that a last packet of the batch and a first packet of the batch have the same uniform density and uniform texture. The entire batch is converted into individual packets of conditioned dough corresponding to the predetermined number of bread loaves to be produced from the batch. The packets are deposited individually in cavities of the pans within from 10 to 20 minutes after mixing ingredients that make the batch. Upon formation of a packet, the packet drops due to gravity directly into a cavity of a pan without further processing of the packet after cutting the dough stream to form the packet. The dough stream is processed without the use of flour to treat the dough stream. 
     These features are not listed in any rank order nor is this list intended to be exhaustive. Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of this disclosure, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  depicts a schematic diagram illustrating a prior art continuous bread dough mixing system; 
         FIG. 2  depicts a schematic diagram illustrating a conventional batch bread dough mixing system; 
         FIG. 2A  depicts a side elevation view a bread loaf manufacturing line employing the prior art batch bread dough mixing system illustrated in  FIG. 2 ; 
         FIG. 2B  depicts a top plan view a bread loaf manufacturing line shown in  FIG. 2A ; 
         FIG. 3  depicts a schematic diagram illustrating the process for making a bakery product according to an embodiment of the present disclosure; 
         FIG. 4  depicts a front elevation view of the apparatus, with sections broken away according to an embodiment of the present disclosure; 
         FIG. 5  depicts a side elevation view of the apparatus, with sections broken away according to an embodiment of the present disclosure; 
         FIG. 6  depicts a top plan view of the extrusion divider unit of the apparatus illustrated in  FIGS. 4 and 5  according to an embodiment of the present disclosure; 
         FIG. 7  depicts a top plan view of the developer unit of the apparatus illustrated in  FIGS. 4 and 5 , with sections broken away according to an embodiment of the present disclosure; 
         FIG. 8A  depicts a side elevation view of a cutter of the dough divider unit positioned above the extrusion unit, which is above a series of empty pans moving beneath the extrusion unit according to an embodiment of the present disclosure; 
         FIG. 8B  depicts a cross-sectional view taken along line  8 B- 8 B of  FIG. 8A  according to an embodiment of the present disclosure; 
         FIG. 8C  depicts a diagram of a predetermined closed path the tip of a knife blade makes through one cycle of the cutter according to an embodiment of the present disclosure; 
         FIG. 8D  depicts a sectional view taken along line  8 D- 8 D of  FIG. 8A  according to an embodiment of the present disclosure; 
         FIG. 9  depicts a front elevation view of the cutter positioned to cut the dough stream from the extrusion unit according to an embodiment of the present disclosure; 
         FIG. 10A  depicts a side elevation view with the cutter in its home position according to an embodiment of the present disclosure; 
         FIG. 10B  depicts a side elevation view with the cutter in its down position according to an embodiment of the present disclosure; 
         FIG. 10C  depicts a side elevation view showing starting to return to the home position according to an embodiment of the present disclosure; and 
         FIG. 11  depicts a control circuit diagram for the apparatus according to an embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  depicts a continuous process (known as DO-Maker, Wallas and Thierman System) for making loaves of bread. In tank  1  mixing is conducted of all the basic ingredients to start a brew batch of a selected dough recipe, for example, to make whole-wheat, white, or multi-grain loaves of bread. The ingredients of this initial batch begin to ferment in tank  1 . While in a highly fluid liquid state, the entire contents of tank  1  are pumped into tank  2 . Tank  2  is a holding tank for the fermenting phase of the mixture of ingredients that is continuously transferred to a pre-mixer  3 . The fluid from tank  2  is metered as it is fed to pre-mixer  3 , and metered amounts of flour and oil are continuously added as this fluid flows into pre-mixer  3 . Pre-mixer  3  has at its intake end E 1  two ( 2 ) shaft agitators (not shown) constructed with radial flat narrow blades (not shown) at the intake E 1 . 
     At its discharge end E 2 , the agitators become dual augers (not shown) rotating away from each other, one clockwise and the other counterclockwise. The fluid from tank  2  is in a liquid state as it enters intake end E 1 , being a soft and watery viscous mix. As this mix exits tank  2  flour and shortening (oil) are added at the intake E 1 , all these ingredients are mixed at the same time continuously to become a very soft dough including air pockets that exits discharge end E 2 . The dough exits pre-mixer  3  in a constant and evenly pressurized continuous flow of dough to metering dough pump  4  that forwards this viscous dough to a dough developer unit DD. In dough developer unit DD, the dough is given its final mix and conditioning by kneading the viscous dough to render it of uniform density and uniform texture. Metering dough pump  4  pumps the metered dough as a continuous stream that is cut by guillotine type dual knife cutter  6 . The severed pieces individually drop into pans P being moved by indexer pan feeder  7  along a linear path in a stepwise manner. 
       FIGS. 2, 2A and 2B  depict a conventional batch process for making loaves of bread. When employing the prior art process illustrated in  FIG. 2 , extensive floor spaced and equipment is required as shown in  FIGS. 2A and 2B . This space and equipment is costly and demands maintenance. 
     In this batch process the ingredients for a selected bread recipe are mixed in conventional dough mixer  8 , which may have a temperature control system that maintains the temperature of the ingredients in the mixer at about 68 degrees Fahrenheit. When the ingredients are thoroughly mixed and in a viscous state, the whole batch of dough mix is dumped into the holding dough hopper of transfer dough pump  9 , transfers the dough to extrusion dough divider hopper  10   c  and into extrusion dough divider EDD. Extrusion dough divider EDD is built with a gear motor drive, and a dual auger feeder, and acts as a pump to pressurize the dough to a pre-set pressure value of a process recipe, set in a programmable logic controller (PLC) at a human-machine interface (HMI). In response to dough pressure sensor  12  located at a discharge end of extrusion dough divider EDD, the gear motor drive will speed up or slow down the auger rotational speed to satisfy the pressure set point value set in the recipe required pressure value. Metering dough pump  11  meters a constant volumetric dough flow at exit  10   a  of extrusion dough divider EDD. The rate of speed of the pump drive controls the rate and scaling-weight at which severed dough packets SDP are produced. The speed required of the dough metering pump gear motor drive is monitored by a human operator manually checking at pre-scheduled times (every 2 minutes or so) the weight of a sampled dough packet being cut by an extrusion dough divider guillotine-type knife. 
     Severed dough packets SDP require further processing. Namely, first severed dough packets SDP are rounded into dough balls by rounder unit  13 . The newly rounded dough balls are flour-dusted in duster  14  to prevent the dough balls from sticking to any surfaces while they are transported by conveyor belt  14   a  to sheet unit  15  to make the newly flour dusted dough balls into a very flat disk-like member. From sheet unit  15 , the dough disk-like members are conveyed to molder belt unit  16 , where, with the aid of static top pressure board adjustable up or down rolls, the dough disk like members are formed into individual cylindrical shape dough pieces, before they are deposited into an empty pan cavity. Bread pan indexer  7  synchronizes the deposit of the cylindrical shape dough pieces so an individual piece falls into a single pan cavity. 
     As illustrated in  FIG. 3 , the process has the advantage of a batch process in that the dough mix used produces the desired stiff texture bread loaf and the advantage of a continuous process that avoids the downstream processing steps and equipment depicted in  FIGS. 2A and 2B . Initially, all the ingredients of a conventional batch mix recipe to make a batch of bread dough are mixed in conventional mixer  8  to produce a conventional dough mix, which is significantly more viscous than the dough mix from pre-mixer  3  using a standard recipe in a continuous mix process. At first, this mix has therein small sized air pockets that become larger and different sized air pockets as the fresh dough mix ages. The air pockets are produced by the chemical reaction of yeast, sugar, flour and other ingredients. A single batch provides a predetermined number of bread loaves, for example, from about 1,400 to about 2,000 loaves per batch. 
     As soon as the ingredients have been thoroughly blended together and the reaction starts, a first transfer pump TPI immediately, continuously and directly feeds the unconditioned dough from mixer  8  into conventional dough developer unit DD. The now-conditioned dough flows directly into extrusion dough unit  11  having unique die manifold member  23  that is designed especially for high-speed production of pan-ready dough packets. The pan-ready dough packets made according to the process fall directly into a pan cavity upon being severed from a continuous dough stream by uniquely designed cutter  26  best illustrated in  FIGS. 10A through 10C . Thus, the process eliminates the downstream processing steps and equipment of the conventional batch process depicted in  FIGS. 2, 2A and 2B . 
     Conventional dough developer unit DD continuously conditions the batch of unconditioned dough to reduce the size of air pockets within the unconditioned dough. Ideally, the conditioned dough has a uniform density and a uniform texture as it exits dough developer unit DD that is maintained more or less constant throughout the entire processing of a batch of the dough mix. Dough developer unit DD ( FIGS. 4, 5, 7 ) has gear motor GM 1  that drives single auger  20 , and gear motor GM 2  that drives developer blade  21 . Developer gear motors GM 1  and GM 2  drive speeds (recipe speeds) may be manually or automatically set. In the former case, gear motors GM 1  and GM 2  drive speeds are monitored by a human operator who manually changes the set speeds at human-machine interface control panel HMI as required by the process recipe. Alternately, to maintain a constant uniform density and uniform texture of the dough, dough developer auger  20  and developer blade  21  rotational speeds will be increased or decreased according to an electronic speed control logic sequence in main control process programmable logic controller PLC ( FIG. 11 ). A sub-routine of program  101  of microprocessor MP of control circuit  100  provides automatic speed control to maintain a uniform density and uniform texture of the dough stream exiting dough developer unit DD. Thus, a conditioned dough is continuously fed to extrusion dough divider unit  11  at various speeds to maintain a uniform density and uniform texture. 
     In the process, conventional dough developer unit DD transforms large size air pockets within the unconditioned dough, dividing the larger air pockets into smaller size air pockets, so that dough exiting developer unit DD is conditioned with a uniform density and uniform texture. This achieves a uniform product quality and a uniform scaling. Consequently, in the process, a human operator does not periodically sample and weigh the dough packets to insure the individual bread loaves being made do not vary more than quality standards demand. Using dough developer unit DD, upon formation of a packet, the packet drops, due to gravity, directly into cavity C of pan P without further processing of the packet after cutting the dough stream to form the packet as shown in  FIGS. 10A-10C , and discussed subsequently in greater detail. 
     As illustrated in  FIGS. 4 and 5 , one embodiment of the apparatus embodying the system is generally designated by the numeral  10 . The movement of dough through apparatus  10 , and the operation of the various system components, are in a timed relationship that is under the control of circuit  100  shown in  FIG. 11 . In the system, the processing of a batch of dough from mixer  8  is completed within a predetermined time period so that last individual packet IP of the batch being processed and a first individual packet of this same batch have the same uniform density and uniform texture within a pre-established variation range. Typically, the entire batch is converted into individual packets IP of conditioned dough corresponding to the predetermined number of bread loaves to be produced from the batch. Packets IP are deposited individually in cavities C of pans P within 10-20 minutes after mixing ingredients that make the batch. 
     Extrusion dough divider unit  11  extrudes the conditioned dough into a dough stream DS ( FIGS. 5, 8A, 10A-10C ), and is built with dual auger dough feeder  29  ( FIGS. 4 ) driven by gear motor GM 3 . Control dough pressure sensor  12  ( FIGS. 3, 5 ) is at discharge end E 10  ( FIG. 5 ) of extrusion dough divider unit  11 . The speed of the extrusion dough divider&#39;s drive gear motor GM 3  is controlled by program  101  for microprocessor MP in response to the pressure detected by pressure sensor  12  and the command of the recipe speeds set values at the HMI. For the purpose of achieving a constant density before the dough is directed to an intake of second transfer metering dough pump TP 2  ( FIGS. 4, 5 and 6 ), this pump meters the conditioned dough from dough divider dual auger  29  to die manifold member  23 , which includes extrusion port EP from which the dough stream exudes. Control circuit  100  shown in  FIG. 11  includes means for operating transfer pumps TP 1  and TP 2  at predetermined regulated speeds. Control circuit  100  includes pressure sensor  12  ( FIGS. 5, 6 ) that detects the pressure of dough stream DS exiting extrusion divider unit  11  and microprocessor MP with program  101  to operate speed controls as a function of the detected pressure commanded by the process recipes at human-machine interface HMI. 
     The conditioned dough from dough developer unit DD is delivered to extrusion dough divider hopper  11 , and extrusion dough divider unit  11  extrudes the dough-through extrusion port EP ( FIG. 8B ) as a constant solid, wide flat dough stream DS of conditioned dough at a controlled volumetric feed rate and at a controlled pressure. In accordance with the process, cutter  26  immediately cuts the dough stream DS into individual dough packets IP that drop, due to gravity, directly into individual cavity C in pan P moving past the cutter. As best shown in  FIG. 4 , a pair of endless belt, pan feeder conveyors  7   a  ( FIGS. 4, 5, 6 ) aligned along path A are spaced apart to provide gap G directly beneath extrusion port EP of die manifold member  23 . As a batch of dough mix is processed, pans P continuously move in a step-wise fashion along predetermined path A and receive individual dough packet IP therein that drops into a pan directly below extrusion port EP. When the processing of one batch of dough mix is completed, apparatus  10  is cleaned whenever a batch of a different recipe is to be processed by the apparatus. When cleaning apparatus  10 , no pans P are covering or blocking gap G. Consequently, gap G is open between pan feeder conveyors  7   a . As apparatus  10  is flushed out with water, waste matter flowing out the extrusion port during cleaning flows from extrusion port EP and passes through gap G between pan feeder conveyors  7   a.    
     As best shown in  FIG. 8A , extrusion dough divider unit  11  includes cutter  26  that in a continuously cyclical manner cuts dough stream DS into individual packets IP ( FIGS. 8A, 9, 10B ). Dough developer unit DD is above extrusion dough divider unit  11  and feeds the conditioned dough into hopper  53  of extrusion dough divider unit  11 . Extrusion dough divider unit  11  has pipe  51  ( FIG. 6 ) that delivers directly and continuously dough stream DS to the cutter  26 . 
     Cutter  26  ( FIGS. 8A, 9, 10A, 10B, 10C ) includes pivotally mounted, arm mechanism AM driven by gear motor GM 5  that moves knife blade  28  through predetermined path X ( FIG. 8C ) that clears the dough divider&#39;s extrusion port EP in a manner to avoid interfering with dough stream DS exiting extrusion port EP. Path X is depicted in  FIG. 8C  and comprises: Starting with tip  28   a  of blade  28  at home position A ( FIG. 10A ), arm mechanism AM includes pair of arms  60  that move the blade downward towards a portion of dough stream DS that has passed through extrusion port EP, severing this portion, which falls directly into cavity C of pan P. Tip  28   a  of blade  28  moves along downward vertical-linear segment X 1  of the path X past extrusion port EP to point B ( FIG. 10B ), with tip  28   a  of blade  28  following linear segment X 1  as it passes by extrusion port EP to arrive at point B, the end of the downward vertical-linear segment. As the next portion of dough stream DS exits extrusion port EP, tip  28   a  of blade  28  moves from point B away from the face of the die element of manifold member  23 , and then along a substantially upward vertical-linear path, returning tip  28   a  of blade  28  to home position A without contacting the next portion of dough stream DS exiting the extrusion port. 
     As best shown in  FIG. 8D , pair of arms  60  are mounted at ends E 4  to pivot. Blade  28  is fixedly attached between pair of arms  60  to other ends E 7  of arms  60 . About midway along each arm  60  is follower arm FA interconnected to cam mechanism CM that actuates driver arm DA having one end E 10  fixedly attached to the cam mechanism. There are a pair of driver arms DA and blade  28  is mounted between ends E 9  of driver arms DA. Blade  28  is pivotally attached so it moves along path X as follower arm FA and cam mechanism CM interact. As cam  90  ( FIGS. 10A-10C ) of cam mechanism CM is rotated by cam mechanism&#39;s central drive shaft  62 , on a down stroke initiated from home position A shown in  FIG. 10A , tip  28   a  of blade  28  follows linear segment X 1  of path X. On reaching position B shown in  FIG. 10B , drive shaft  62  of cam mechanism CM initiates its upstroke, as shown in  FIG. 10C , causing follower arm FA to begin lifting arm  60  upwards and raising tip  28   a  of blade  28 . Simultaneously, tip  28   a  of blade  28  is moved away from the face of die element DE, by the action of driver arm DA pulling backward on end E 9  of arm DA, to pivot this end at bearing points E 7  of arms  60 , attached to floating knife block support elements E 8 , and continuously pulls tip  28   a  away from the face of the die element DE, with the aid of the pivot point E 7  at the end of arm  60 , attached to floating knife support blocks E 8 , by pivot shaft on E 7 , and then moves the tip towards the face of die element DE as the cam mechanism continuously rotates until home position A is reached. Program  101  includes a sub-routine that operates gear motor GM 5  at a faster rate of speed after severing dough stream DS, increasing the speed at which knife blade  28  returns to home position A. The cutting cycle is then again initiated. 
     As best shown in  FIGS. 8B and 8D , extrusion port EP is at a terminal end of chamber  50  in die element DE. Chamber  50  has entry end E 5  and extrusion port EP is at end E 6  opposed the entry end. Chamber  50  has a generally flat top and bottom and outward sloping sides to form a generally shaped triangle configuration. Extrusion port EP has a generally rectangular shaped open window that has an adjustable open area that allows the shape of the extrusion port to be laterally expanded or reduced. To achieve this each side of extrusion port EP includes a pair of spaced apart, adjustment wedge-slides  40 A,  40 B ( FIGS. 8B, 9 ). Each wedge-slide  40 A and  40 B has a semi-circle shape cut out on the inner end thereof facing chamber  50 . The adjustment of wedge-slides  40 A and  40 B in and outwards on each side of the window opening by repositioning the slides changes the weight of the product being processed at the time. The center of the extrusion port may have narrowing feature  52  that may provide better distribution of the dough packet into the pan. An individual, single, packet IP has a generally cylindrical configuration, typically a diameter from 1¼ to 2½ inch and a length from 8 to 16 inch. This size and configuration of packet IP is suitable upon baking to make one bread loaf, which is removed from pan&#39;s cavity C ( FIG. 8A ) in which the loaf was baked. As shown in  FIG. 9 , manually actuated adjustment mechanism  92  ( FIG. 9 ) with hand-operated wheel HW mechanically linked to wedge-slides  40 A and  40 B enables the slides to be move towards and away from a center of extrusion port EP. 
     Operation 
     In the embodiment where a constant uniform density and uniform texture of the dough is automatically controlled, every time a new batch of unconditioned dough is dumped into first transfer pump TP 1 , a mixer generated time (true) signal is sent as an input to programmable logic controller (PLC) at human-machine interface (HMI) shown in  FIG. 11 . Program  101  of programmable logic controller PLC starts a new sequential sub-routine upon receiving this time signal that: 
     1. Controls the speeds of developer blade gear motor drive GM 5  in an incremental timed sequence of a dough batch process time, slower when the dough batch is fresh and faster as the dough batch ages. After every dough batch process time, the programmable logic controller PLC is monitoring the time signal repeatedly automatically, without the aid of an operator to start a new sequential sub-routine. This sequential sub-routine controls the speeds of developer blade gear motor drive GM 2  to maintain a uniform density and texture (conditioning) of each dough batch through its entire process time period (typically from 10 to 20 minutes) in small incremental speed sequential control, as best predetermined by the process requirements. 
     2. Controls the speed of second transfer pump TP 2 , divider metering dough pump gear motor GM 3  in an incremental timed sequence of a dough batch process time, (slower when the dough batch is fresh and faster as the dough ages). After every dough batch process time, programmable logic controller PLC is monitoring the time signal repeatedly automatically, without the aid of a human operator to start a new sequential routine. This sequential sub-routine controls the speed of second transfer pump TP 2 , metering dough pump gear motor GM 4  to maintain a consistent volumetric dough flow to die manifold member  23  for achieving a consistent scaling weight of each dough packet IP being cut in small incremental speed sequential control, as best predetermined by the process requirements. 
     Transfer dough pump motor GM 1  starts to run on a demand signal created by a level sensor electronic eye DDE at the dough hopper if the eye signals a low level. First transfer pump TP 1  starts to supply unconditioned dough to dough developer unit DD until dough hopper  53  is filled to its highest level. Electronic eye DDE monitors the dough levels low and high at the dough hopper  53 , and as the dough level sensor is satisfied (high level) gear motor GM 2  variable speed drives can be started by programmable logic controller PLC, provided all safety and other support systems are ready. 
     Level sensor electronic eye EDDE monitors the dough levels low and high at dough hopper  53 , and as the dough level sensor is satisfied (high level) the dual auger, variable speed gear motor GM 3  can be started by programmable logic controller PLC, provided all safety and other support systems are ready. Gear motor GM 3  operates extrusion dough divider unit EDD to feed the dough as a continuous evenly pressurized dough stream DS. Pressure sensor  12  continuously monitors dough stream DS to confirm it satisfies the pressure value preset in the recipe for the type of bread loaf being made. Dough stream DS is fed directly into the intake of second transfer pump TP 2 . Pump TP 2  is a metering dough pump with variable speed gear motor drive GM 6 . The speed and volumetric capacity controls the volumetric rate of the dough being extruded through the die manifold member  23 . Arm mechanism AM is driven by servo motor GMS, which has speed cycles that are set in the recipe, the cycle rate being set to match the cuts/minute of the process, and to deliver the dough packets in a timed manner into empty pan cavity C. 
     3. The steps to start and run apparatus  10  are as follows:
         a. The operator selects a recipe number at human-machine interface HMI.   b. The operator makes any temporary recipe speed adjustment values.   c. When electronic eye DDE is satisfied, the system will be able to start, by pressing a start button at human-machine interface HMI.   d. Dough developer gear motor GM 2  starts to run to the speeds preset for the recipe for the type of bread loaf to be processed, auger dough feeder  20  moves the dough into developer blade  21  driven by GM 2 , discharging the dough into dough hopper  53  of extrusion dough unit  11  until the electronic eye senses that the dough level is satisfied. Variable speed gear motor drive GM 3  starts running dual auger  29 , feeding and pressurizing the dough to satisfy the preset pressure value in the recipe. As shown in  FIG. 5 , pressure sensor  12  continually monitors pressure at outlet end E 11  of extrusion dough unit  11  before pressurized dough stream DS is fed into intake end E 12  of second transfer pump TP 2 , which pushes a metered amount of the dough through die manifold member  23  at a predetermined volume rate. Each newly cut dough packet falls into each empty pan cavity C, pan feed conveyors  7   a  are cyclically controlled by a timing signal (clock) created in programmable logic controller PLC, which in turn controls the cyclical sequence of knife blade  28  and the pair of pan conveyors  7   a  in a synchronous sequential speed rate. This completes the running cycle of the process.   e. When electronic eye DDE senses a low-level condition, it demands more dough supply from first transfer pump TP 1 .   f. When the other electronic eye EDDE dough senses a low-level condition, it demands more dough supply from dough developer unit DD.   g. These conditions described on steps c, d, e, f, g above, are continuous repetitious cycles throughout the duration of each batch of dough processed through apparatus  10 .       

     Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. 
     The above presents a description of the best mode of carrying out the apparatus, system and process, and of the manner and process of making and using them, in such full, clear, concise, and exact terms as to enable a person skilled in the art to make and use. The apparatus, system and process are, however, susceptible to modifications and alternate constructions from the illustrative embodiment discussed above which are fully equivalent. Consequently, it is not the intention to limit the apparatus, system and process to the particular embodiment disclosed. On the contrary, the intention is to cover all modifications and alternate constructions coming within the spirit and scope of the apparatus, system and process as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the present disclosure.