Patent Publication Number: US-2013243906-A1

Title: Method and System of Making a Leavened Dough Composition

Description:
This patent claims the benefit of U.S. Provisional Application Ser. No. 61/612,379, filed Mar. 18, 2012, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     FIELD  
     The present disclosure relates to leavened dough compositions and, in particular, to a method and a system for making a leavened dough composition using a sponge and dough process. 
     BACKGROUND  
     Baked goods, such as breads, are made by preparing a dough and then baking the dough in an oven. In a commercial bakery, the dough is typically prepared according to either a two-stage process or a one-stage process. The two-stage process is referred to as the sponge and dough process. The sponge and dough process produces a baked good that some consumers consider to be superior in taste, texture, and aroma, as compared to baked goods prepared using other methods of dough preparation, such as the one-stage process. In particular, the sponge and dough process produces a crumb that is soft and resilient and a crust that is tender, but uniformly thick and strong. 
     The first stage of making dough with the sponge and dough process is to make a sponge. The sponge (also referred to as a poolish, biga, slurry, chef, levain, or pre-ferment) is made by mixing water, flour, and yeast. Typically, the sponge includes a portion of the total amount of flour and most of the yeast to be used in the dough. After the ingredients of the sponge are mixed, the sponge is allowed to leaven for a predetermined time period, the length of which is dependent on the type of baked good to be made. During leavening, the sponge ferments, a process in which the yeast consumes carbohydrates in the flour and expels various gases including carbon dioxide. The gases expelled by the yeast cause the sponge to increase in volume, a process commonly referred to as “rising.” 
     The sponge is added to the remaining portion of the flour and the water after the sponge the predetermined time period to form the dough. Depending on the type of baked good to be made, salt, oil, and other ingredients may also be added to the dough. 
     Next, the dough is typically scaled into subsections, which have a weight suitable for baking. For example, in a commercial bakery the dough is scaled into subsections that have a suitable weight for producing a loaf of bread. Machines deposit the subsections of dough into a pan. 
     After the subsections of dough have been deposited into a pan, they leaven for another predetermined time period. This second leavening period is referred to as “proofing.” During proofing the subsections of dough are placed in a space of controlled humidity and temperature, which encourages further fermentation. After proofing the twice-leavened dough is ready to be baked. 
     The sponge and dough process of dough making is not the fastest or most efficient process to produce a dough; accordingly, in some commercial bakeries, the one-stage process of dough making is used. In the one-stage or straight-dough process of dough making the entire portions of water, flour, yeast, and other ingredients, are combined in one step to form the dough directly without forming a sponge. The one-stage process of dough making typically results in a baked good that lacks the complex aroma, flavor, and texture of baked goods made using the sponge and dough process. 
     What is needed, therefore, is an improvement in the efficiency of using the sponge and dough process in a commercial bakery. 
     SUMMARY  
     According to one embodiment of the disclosure a method of making a leavened dough composition includes making a sponge with a mixing device, and separating the sponge into a plurality of subsections with a separating apparatus. 
     The method further includes transporting the plurality of subsections with a transporting device. The transporting device includes an endless belt and the method further includes depositing the plurality of subsections onto the endless belt. 
     The method still further includes (i) depositing the sponge into a trough, (ii) resting the sponge in the trough, and (iii) separating the sponge with the separating apparatus after the resting. 
     According to the method, the sponge comprises a first portion of flour and a first portion of yeast. The sponge is added to a second portion of flour after the separating to form the leavened dough composition. 
     According to the method, the leavened dough composition includes a second portion of yeast. The first portion of yeast is at least 98% of a total amount of yeast in the leavened dough composition. The second portion of yeast is less or equal to 2% of the total amount of yeast. The first portion of flour is approximately 70% of a total amount of flour in the leavened dough composition. The second portion of flour is approximately 30% of the total amount of flour in the leavened dough composition 
     According to the method, the mixing device is a first mixing device, and the method further includes (i) transporting the plurality of subsections to a second mixing device, (ii) adding a portion of flour to the second mixing device, and (iii) mixing the plurality of subsections and the portion of flour in the second mixing device to form the leavened dough composition. 
     According to another embodiment of the disclosure a method of making a leavened dough composition with a sponge comprised of flour, water, and yeast, includes viding the sponge into a plurality of subsections. 
     The method further includes (i) depositing at least a portion of the plurality of subsections onto a transport device, which includes an endless belt, (ii) serially transporting the deposited subsections to a mixing device with the transport device, (iii) adding a first portion of flour to the mixing device, (iv) adding a first quantity of water to the mixing device, and (v) mixing the deposited subsections, the first portion of flour, and the first quantity of water in the mixing device to form the leavened dough composition. 
     The method still further includes resting the sponge before the dividing. 
     According to the method, the sponge includes only a second quantity of water, a second portion of flour, and a portion of yeast. 
     According to yet another embodiment of the disclosure a system for making a leavened dough composition includes a mixing device and a separating device. The mixing device is configured to make a sponge. The separating device is configured to separate the sponge into a plurality of subsections. 
     The system further includes a transporting device configured to transport the plurality of subsections. 
     According to the system, the mixing device is a first mixing device, and the transporting device transports the plurality of subsections to a second mixing device and/or a third mixing device. 
     According to the system, the transporting device includes at least one endless belt, and the separating device is further configured to deposit each subsection of the plurality of subsections onto the at least one endless belt. 
     The system further includes an elevator configured to discharge the sponge into the separating device. The elevator is unsuitable to deposit the sponge into the second mixing device and the third mixing device. In particular, the elevator elevators the sponge to a first predetermined height. The second mixing device includes a sponge opening. The sponge opening is positioned at a second predetermined height. The first predetermined height is less than the second predetermine height. 
     According to the system, the transporting device extends through at least one of an opening in a wall and an opening in a ceiling. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a block diagram of a portion of a system for making a leavened dough composition, as described herein; 
         FIG. 2  is a block diagram of another portion of the system for making a leavened dough composition, as described herein; 
         FIG. 3  is a flowchart depicting a method of making the leavened dough composition using the system shown in  FIGS. 1 and 2 ; and 
         FIG. 4  is a block diagram of a portion of a prior art system for making a leavened dough composition. 
     
    
    
     DETAILED DESCRIPTION 
     For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification, It is understood that no limitation to the scope of the disclosure is thereby intended. It is further understood that the present disclosure includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the disclosure as would normally occur to one skilled in the art to which this disclosure pertains. 
     As shown in  FIGS. 1 and 2 , a system  100  for making a leavened dough composition includes a mixing device  108 , numerous troughs  116 , and numerous batches of a sponge  124 , some of which are positioned in a fermentation area  128 . As described herein, the system  100  separates the sponge  124  into easily transportable chunks  168  in order to simplify the dough making process. Each component of the system  100  is descried below followed by a description of a method  300  ( FIG. 3 ) of operating the system. 
     The mixing device  108 , which is also referred to herein as a mixer or as a sponge mixer, receives the ingredients that are used to make the sponge  124 . The mixer  108  includes a bowl  132  and an agitator  136 , among other components. The bowl  132  holds the ingredients of the sponge  124 , which typically weigh between one thousand pounds (1000 lbs.) and fifteen hundred pounds (1500 lbs.). The agitator  136  moves relative to the bowl  132  to sweep and fold the ingredients within the bowl. The bowl  132  is tilt-able in order to discharge the contents (i.e. the sponge  124 ) from the mixer  108  and into one of the troughs  116  as shown by the bold arrow in FIG,  1 . The mixer  108  is additionally or alternatively any mixer as known to those of ordinary skill in the art, including mixers having a greater mixing capacity, mixers having less mixing capacity, and mixers in which the sponge  124  is manually removed therefrom. 
     The troughs  116  are wheeled containers that hold the sponge  124  and enable the sponge to be moved within the bakery. The troughs  116  are sized to contain the sponge  124  even after it has risen as a result of yeast action. Typically, the troughs  116  are formed from stainless steel, mild steel, or another suitable material. Each of the troughs  116  weighs approximately five hundred pounds (500 lbs.). The troughs  116  are additionally or alternatively any trough as known to those of ordinary skill in the art. 
     With reference to  FIG. 2 , the system  100  further includes an elevator  140 , a separating device/apparatus  144 , a transporting/transport device  148 , a mixing device  152 , and a mixing device  156 . The elevator  140  is a lifting device that lifts and tilts one of the troughs  116  to discharge the sponge  124  contained therein. The elevator  140  is positioned near the separating device  144  so that the discharged sponge  124  falls into the separating device (as shown in  FIG. 2 ). The elevator  140  is additionally or alternatively any elevator known to those of ordinary skill in the art. 
     The separating device  144 , which may also be referred to herein as a chunker, a chunking device, or a separator includes a chute  160  and a cutting device  164 . The chute  160  is a funnel-like guide that catches the sponge  124  as it is discharged from the trough  116 , The chute  160  guides the sponge  124  to the cutting device  164 . The viscosity of the sponge  124  enables it to move to the cutting device  164  by force of gravity alone; accordingly, mechanical assistance is not needed to move the sponge to the cutting device. 
     The cutting device  164  of the separator  144  cuts, divides, and/or separates the sponge  124  into subsections referred to herein as chunks  168 . The chunks  168  weigh approximately forty to fifty pounds (40 to 50 lbs.) and are approximately one foot wide by one foot tall by four feet long (1 ft×1 ft×4 ft). From a typical sponge  124  the cutting device  164  forms approximately twenty (20) to thirty (30) of the chunks  168 . The chunks  168  exit the cutting device  164  and are received by the transporting device  148 . 
     The transporting device  148  serially transports the chunks  168  to the mixers  152 ,  156 . The transporting device  148  includes a horizontal section  172 , a vertical section  176 , a horizontal section  180 , and a controller  184 . The horizontal section  172  extends between the separator  144  and the vertical section  176 . The vertical section  176  extends between the horizontal section  172  and the horizontal section  180 . The horizontal section  180  extends between the vertical section  176  and the mixer  152  and the mixer  156 . The controller  184  supplies power to the sections  172 ,  176 ,  180  according to an electronic program stored within the controller (electric wires and data lines extend from the controller to the sections  172 ,  176 ,  180 , but are not shown in  FIG. 2 ). The transporting device  148  is described as “serially” transporting the chunks  168  since the chunks are transported in series in single file, similar to bits of data being transmitted serially or current flow through a serial circuit. As a result of the viscosity of the sponge  124 , the chunks  168  generally maintain their shape as they are transported by the transporting device  148 . 
     The horizontal section  172  includes an endless belt  188  onto which the chunks  168  are deposited from the cutting device  164  of the separator  144 . The controller  184  causes the endless belt  188  to rotate to move the chunks  168  toward the vertical section  176 . 
     The vertical section  176  includes an endless belt  192  and an endless belt  196 . The endless belts  192 ,  196  rotate to transport the chunks  168  from the horizontal section  172  to the horizontal section  180 . The chunks  168  are pressed between the endless belts  192 ,  196  to generate enough friction to lift the chunks. The controller  184  causes the endless belts  192 ,  196  to move the chunks  168  toward the horizontal section  180 . 
     The horizontal section  180  includes an endless belt  200  and an endless belt  204 . The endless belt  200  receives the chunks  168  as they are discharged from the vertical section  176  and deposits the chunks onto the endless belt  204 . Accordingly, the controller  184  causes the endless belt  200  to rotate so that the chunks  168  move away from the vertical section  176 . The endless belt  204  deposits the chunks  168  into one of the mixer  152  and the mixer  156 . In particular, the controller  184  causes the endless belt  204  to rotate in a first direction to deposit the chunks  168  in the mixer  152  and a second direction to deposit the chunks in the mixer  156 . The controller  184  may cause chunks  168  to be deposited into the each mixer  152 ,  156  until its associated bowl (not shown) is full, or the controller may alternately deposit the chunks into the mixers so that one chunk is deposited into the mixer  152  and the next chunk is deposited into the mixer  156 , and so on. 
     Although the transporting device  148  is shown as having a horizontal section  172 , a vertical section  176 , and a horizontal section  180 , the transporting device additionally or alternatively includes any arrangement of sections as may be needed to transport the chunks  168  from the separating device  144  to one or more mixers  152 ,  156 . For example, the transporting device  148  may include an inclined section (not shown), a helical section (not shown), and/or a non-linear section (not shown). 
     The mixer  152  and the mixer  156  are substantially identical to the mixer  108 . The mixers  152 ,  156  are referred herein as dough mixers since the mixers mix additional ingredients with the sponge  124  to form a dough composition  208 . 
     The system  100  makes a leavened dough composition, referred as dough  208 , using the two-stage dough making process. The term “dough” and “dough composition”, as used synonymously herein, refers to a composition including the sponge  124  and one or more of flour, water, and yeast. Accordingly, the sponge  124  is an ingredient of the dough  208 . The dough  208  has a consistency that is suitable for handling by dough-handling equipment, as is commonly found in a commercial bakery, i.e. the dough has the proper viscosity, weight, and tackiness to be handled effectively. The dough  208  is baked in an oven to make a leavened baked good, such as bread. To simplify comparison of the dough  208  to the sponge  124 , the dough is described as having 100% of the flour, 100% of the water, and 100% of the yeast. 
     The term “sponge”, as used herein, is a composition that is different than the dough  208 . The sponge  124  is a combination of flour, water, and yeast, but as compared to the dough  208  the sponge includes less than 100% of the flour, less than 100% of the water, and at least approximately 98% of the yeast. In an exemplary sponge  124  for making white bread, the sponge contains approximately 70% of the flour as compared to the total amount of flour in the dough (by weight or volume), approximately 65% of the water as compared to the total amount of water in the dough (by weight or volume), and at least 99% of the yeast as compared to the amount of yeast in the dough (by weight or volume). Accordingly, the sponge  124  has a consistency that is different than the dough  208 , and may require equipment that is different, or that is setup differently, than the dough-handling equipment. Specifically, the sponge  124  made to the above-described proportions of ingredients is typically much more vicious than the dough  208  that results therefrom and is much tackier than the dough. Additionally, since the sponge  124  is an ingredient of the dough  208 , it is not suitable by itself for making a leavened baked good according to the two-stage dough making process. 
     The system  100  is operable according to the method  300  illustrated by the flowchart of  FIG. 3 . Beginning with block  304 , water, flour, and yeast are added to the mixer  108  in a proportion that is suitable to form the sponge  124 . Next, the mixer  108  is activated to mix the ingredients of the sponge  124  into a viscous mass. When the mixer  108  has sufficiently mixed the ingredients, the sponge  124  is discharged into one of the troughs  116 . 
     As shown in block  308 , after the sponge  124  is placed in one of the troughs  116 , the trough is moved to the fermentation area  128  for predetermined time period during which the sponge rests. The water in the sponge  124  is supplied at a temperature that causes the yeast to activate. During the predetermined time period, the sponge  124  ferments and rises. 
     With reference to block  312 , after the predetermined time period the trough  116  containing the rested sponge  124  is moved to the elevator  140 . The elevator  140  discharges the sponge  124  into the separating device  144 , which separates the sponge into chunks  168 . 
     Next, as shown in block  316 , the transporting device  148  transports the chunks  168  to either the mixer  152  or the mixer  156 . Transporting the chunks  168  with the transporting device  148  greatly simplifies and streamlines the process of moving the rested sponge  124  to the dough mixers  152 ,  156 . The elevator  140  is conveniently located with respect to the fermentation area  128  so that the troughs  116  containing rested sponge  124  are moved only a short distance before they are unloaded. Additionally, the transporting device  148  is modular to enable the chunks  168  to be routed anywhere in the bakery, including through an opening in a wall, an opening in the floor, and around obstructions. In particular, the transporting device  148  may be routed through areas in which it is simply not possible or practical to wheel one of the troughs  116 . 
     Thereafter, as referenced in block  320 , when a suitable numbers of chunks  168  have been transported to the mixers  152 ,  156  the remaining ingredients of the dough  208  including one or more of water, flour, and yeast are added to the mixers. The mixers  152 ,  156  mix the additional ingredients into the chunks of sponge to form the dough  208 . Then the mixers  152 ,  156  discharge the dough  208  onto an endless belt  210 . 
     The endless belt  210  moves the dough  208  to a divider (not shown), which scales the dough into subsections that are specific to the type of baked good to be made. The subsections are deposited into pans and then rest for another predetermined time period in which additional fermentation occurs. After this second resting period, which is referred to as proofing, the dough  208  is baked in an oven to produce the baked good. 
     As shown in  FIG. 4 , a portion of a prior art bakery  400  includes two trough elevators  404 ,  408  for lifting troughs  412  and two dough mixers  416 ,  420  for mixing dough (not shown). Additionally, numerous sponges  424  are shown, which are substantially identical to the sponge  124 . The elevators  404 ,  408  lift the troughs  412  so that the sponge  424  can be discharged directly into one of the mixers  416 ,  420 . A separate elevator  404 ,  408  is required for each of the mixers  416 ,  420 . Generally, each of the elevators  404 ,  408  is operated by a laborer. 
     The system  100  offers numerous advantages over the prior art bakery  400 . First, the system  100  eliminates one of the elevators  404 ,  408  and one of the laborers of the bakery  400 . Second, the system  100  replaces the two “high-lift” elevators  404 ,  408  with one “low-lift” elevator  140 . The low-lift elevator  140  is capable of lifting the sponge  124  to a predetermined height. The mixers  152 ,  156  include a sponge opening  206  that is positioned at a second predetermined height. Since the first predetermine height is less than the second predetermined height the elevator  140  is unsuitable to deposit the sponge  124  in the mixers  152 ,  156 . Third, the system  100  prevents a laborer from having to wheel the troughs  116  containing the rested sponge  124  from the fermentation area ( 128  in  FIG. 1 ) to the dough mixers  416 ,  420 . It is noted that the low-lift elevator  140  is unable to discharge the sponge  124  into the mixers  152 ,  156 , since it is not capable of lifting the sponge to the height of the bowl (not shown) of the mixers  152 ,  156 . 
     In the prior art bakery  400  the sponge  424  is discharged into the mixers  416 ,  420  as whole unit, because it was thought that separating the sponge into chunks would adversely affect the resultant baked good and/or adversely affect the production process for at least two reasons. First, it was thought that the sponge  124 ,  424  would be too viscous to flow through the separator  144  without mechanical assistance. It was determined, however, that the sponge  124 ,  424  flows through the separator  144  without requiring any mechanical assistance. Second, it was thought that the separator  144  would damage the gluten structure of the sponge  124 ,  424 . In particular, it was thought that the shearing action of separator  144  would reduce the viscoelastic properties of the wheat gluten proteins that are formed when the flour and the water of the sponge  124 ,  424  are mixed. However, it has been determined that the gluten proteins of the sponge  124 ,  424  are not noticeably affected by the separating, with the result that the dough  208  is just as strongly structured as dough made from a sponge that is not separated into the chunks  168 . 
     With reference again to the system  100  of  FIGS. 1 and 2 , separating the sponge  124  into chunks  168  results in numerous benefits to the dough making process. First, the chunks  168  are degassed more effectively by the dough mixer  152 ,  156  as compared to the degassing characteristics of the sponge  124  as a whole (as is done in the bakery  400 ). “Degassing” the sponge  124  refers to expelling carbon dioxide from the sponge by sweeping and folding the sponge in the dough mixers  152 ,  156 . A sponge  124  that is more properly “degassed” is more easily mixed with the remaining ingredients of the dough  208 . Accordingly, chunking the sponge  124  results in a homogenous dough  208  with a uniform density. Also, less energy is required to degas the sponge  124  after it has been separated resulting in reduced energy costs. 
     While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the disclosure are desired to be protected.