Patent Publication Number: US-2006019015-A1

Title: Runny chocolate souffle dessert

Description:
FIELD OF THE INVENTION  
      This invention relates to a method of manufacturing a runny chocolate souffle dessert product. More particularly, this method includes the encrusting of a cookie dough about a chocolate paste filling to form the souffle dessert product, and heating of the product just before eating it. In this manner, during eating of the product, the runny chocolate filling exudes from the interior making the product enjoyable and delicious to eat.  
     BACKGROUND OF THE INVENTION  
      Baked dessert products are an important food choice for most consumers having key nutritional value for the user. The consumer demand for baked dessert products over the years has increased dramatically due to the ease of use, convenience, and availability of such baked dessert products. Many bakery and food producing companies are baking and freezing their baked dessert products and then shipping them to smaller stores, specialty bake stores, grocery stores, delicatessens, restaurants, supermarkets and the like. Further, individuals, families, catering companies, restaurants, company cafeterias, and fast food chains are requesting baked dessert products, which can be prepared with minimum preparation time by the user. But, at the same time, the user/consumer wants a high-quality dessert product having an above-average shelf life, as compared to standard types of baked dessert products.  
      This desire for a quality baked dessert product with minimal preparation time (further baking at the user level) has led to the widespread utilization of microwave ovens, as well as convection-type ovens to reheat and bake the dessert product for immediate consumption. While microwave energy will rapidly heat most food products, not all microwave-heated dessert products are able to deliver the same quality of product, as is characteristic of the more traditional conduction oven heated dessert products. This lack of quality is quite prevalent in the area of microwave heated dessert products. Dessert products that have been exposed to excessive microwave irradiation have an increased toughness and a rubber-like or leather-like texture.  
      There remains a need for a flavored souffle desert product that has a high quality and palatability (palatability refers to the mouth feel, and taste quality of the dessert product) after short exposure of time when rebaking/reheating of the dessert products using a microwave oven or a convection-type oven for a minimal amount of time. Additionally, the flavored souffle dessert product will have an above average, extended shelf-life of at least 3 months. The flavored souffle dessert product after reheating/rebaking will have an outer crisper cookie texture about an expanded flavored souffle inner filling. Further, the method of manufacturing the flavored souffle dessert is novel and unique with regard to the steps of inserting the dessert into a silicone molded baking tray, the freezing of the dessert products after a partial baking and the removing of the dessert products from the silicone baking tray.  
     DESCRIPTION OF THE PRIOR ART  
      Baked dessert products and method of manufacturing baked dessert products having various process methods have been disclosed in the prior art. For example, U.S. Pat. No. 4,948,602 discloses a baked cookie having a two phase interior filling. There is an oil based interior filling and a water based interior filling. The oil based interior filling coats at least part of the interior of the biscuit and enhances the taste of the cookie. Upon this cookie being heated in a microwave oven the water based filling expands and exudes out through the top of the cookie flowing down the exterior surfaces and coating these surfaces. This cookie is produced by co-extruding the dough and the oil based filling. The dough piece is then baked whereby there is formed a hollow interior section. The hollow interior section is then filled with the water based filling. This prior art patent does not teach or disclose the process for manufacturing of a flavored souffle dessert product of the present invention.  
      U.S. patent Publication No. US2002/0136797A1 discloses a ready to eat filled bagel dough product that can be produced by a method comprising preparing a bagel dough; sealing a quantity of filling material within a quantity of bagel dough to form a shaped, filled bagel dough product; adding topping to the shaped product; proofing the shaped product, and then (1) chilling or freezing the proofed, shaped product to reduce the filler core temperature, steaming the product for an amount of time sufficient to completely cook the dough, freezing the product for long term storage, and subsequently thawing and/or reheating in a microwave oven prior to consumption; or (2) chilling or freezing the proofed, shaped product to reduce the filler core temperature, steaming the product for an amount of time sufficient to completely cook the dough, again chilling the product to reduce the temperature of the filler, baking or browning the product, freezing the product for long term storage, and subsequently thawing and/or reheating in a microwave oven prior to consumption. This prior art patent publication foes not teach or disclose the process for manufacturing of a flavored souffle dessert product of the present invention.  
      None of the prior art references disclose the particular manufacturing process for making a flavored souffle dessert product of the present invention having novel and unique extruding, baking, freezing, and removal steps thereof.  
      Accordingly, it is an object of the present invention to provide a flavored souffle dessert product (i.e. chocolate) that has a high quality and palatability after rebaking or reheating of the dessert product using a microwave oven or a convection-type oven for a minimal amount of time.  
      Another object of the present invention is to provide a chocolate souffle dessert that has an above average, extended shelf-life of at least three (3) months.  
      Another object of the present invention is to provide a chocolate souffle dessert product that has an outer crisper cookie-like texture about an expanded chocolate souffle filling after reheating or rebaking.  
      Another object of the present invention is to provide a chocolate souffle dessert product having a novel and unique method of manufacturing with regard to the steps of inserting the plurality of dessert products into a plurality of baking cavities of a silicone baking tray, freezing of the plurality of dessert products within each of the plurality of baking cavities of the silicone molded baking tray after a partial baking of the dessert products and removing of the frozen dessert products from each of the baking cavities of the molded baking tray.  
      Another object of the present invention is to provide a chocolate souffle dessert product that can be mass produced in an automated and economical manner and is reasonably affordable by the user.  
     SUMMARY OF THE INVENTION  
      In accordance the present invention, there is provided a process for making a flavored souffle dessert product, including the following steps: Mixing and kneading of eggs, sugar, margarine/butter, flour, baking soda, salt and cocoa in a first mixing hopper to form a cookie dough; proofing the cookie dough in a proofing refrigerator at a temperature between 35° and 45° F. for a time period of at least 24 hours; stirring of a flavoring ingredient, corn syrup, vegetable oil, starch and water in a second mixing hopper to form a flavored paste filling; gelling of the flavored paste filling in a refrigerator at a temperature of 50° F. for a time period of at least 12 hours; encrusting an amount of the cookie dough about an amount of the flavored paste filling using an encrusting and extrusion machine; extruding the encrusted cookie dough and the flavored paste filling using the encrusting and extrusion machine for forming a flavored souffle dessert product and the dessert product having a weight in the range of 160 to 200 grams per; inserting the dessert products into a silicone molded cookie tray having a plurality of cavities therein; baking the dessert products within the plurality of cavities of the cookie tray in an oven at a temperature of at least 350° F. for a time period of at least 30 minutes; freezing the dessert products on a cooling rack within the plurality of cavities of the cookie tray in a freezer unit at a temperature of at least −20° F. for a time period of at least 45 minutes; removing the frozen dessert products from the plurality of cavities of the cookie tray to a conveyor belt; and placing the frozen dessert products in a shipping container for shipment to consumers. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      Further objects, features, and advantages of the present invention will become apparent upon the consideration of the following detailed description of the presently-preferred embodiment when taken in conjunction with the accompanying drawings, wherein:  
       FIG. 1  is a perspective view of the chocolate souffle dessert product of the preferred embodiment of the present invention showing the frozen dessert product prior to final baking;  
       FIG. 2  is an elevational view of the chocolate souffle dessert products of the present invention taken along lines  2 - 2  of  FIG. 1  in the direction of the arrows showing a cookie dough enclosing a chocolate paste filling of the frozen dessert product prior to the final baking;  
       FIG. 3  is a perspective view of the chocolate souffle dessert product of the present invention showing the baked dessert product after final baking by a consumer;  
       FIG. 4  is a perspective view of the chocolate souffle dessert product of the present invention taken along lined  4 - 4  of  FIG. 3  in the direction of the arrows showing an encrusted cookie dough about an expanded chocolate souffle filling of the baked dessert product after final baking by a consumer;  
       FIG. 5  is a process flow chart illustrating the present invention showing the method of food processing including the major component equipment involved in the manufacture of a runny chocolate souffle dessert product for the steps of mixing; stirring; encrusting; extruding; inserting; baking; freezing; removing and placing; and  
       FIG. 6  is a process flow chart illustrating the present invention showing the steps of shipping, rebaking or reheating of the chocolate souffle dessert product. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
      The method  10  of manufacturing a runny chocolate souffle dessert product  20  of the preferred embodiment of the present invention is represented in detail by  FIGS. 1 through 5  of the patent drawings. The method  10  of manufacturing the runny chocolate souffle dessert product  20 / 20 F, is shown in  FIG. 5  of the drawing and includes the following process steps of mixing and kneading  200 ; proofing  210 ; stirring  220 ; gelling  230 ; encrusting  240 ; extruding  250 ; inserting  260 ; baking  270 ; freezing  280 ; removing  290 ; and placing and shipping  300 . All of the processing steps  200 ,  210 ,  220 ,  230 ,  240 ,  250 ,  260 ,  270 ,  280 ,  290  and  300  are automated with the use of the appropriate food processing equipment, as shown in  FIG. 5 .  
      As shown in  FIGS. 1 and 2 , the completed runny chocolate souffle dessert product  20  or  20 F is shown after the step  270  of partial baking or after the step  280  of freezing. The dessert product  20  or  20 F includes a concave top  22 , tapered circular sides  24  and a flat bottom  26  being substantially cylindrically-shaped  28  having a hollow interior cavity  30  for retaining a chocolate paste filling  32  therein. The chocolate paste filling  32  is encircled/enclosed by a cookie dough crust  34  being partially baked in the step  270  of partial baking.  
      As shown in  FIGS. 3 and 4 , the runny chocolate souffle dessert product is shown after the step of rebaking  310  or the step of reheating  320 . The rebaked chocolate souffle dessert product  40  includes a slightly concave top  42 , tapered circular sides  44  and a flat bottom  46  being also substantially cylindrically-shaped  48  having a hollow interior cavity  50  for retaining the expanded chocolate souffle filling  52  therein. The expanded chocolate souffle filling  52  is enclosed by the rebaked cookie dough crust  54  being fully baked in the step  310  of rebaking or in the step of  320  of reheating.  
      The manufacturing process  10  for making a flavored souffle dessert product (i.e. a runny chocolate souffle dessert product  20 ), as depicted in the process flow diagram of  FIG. 5 , starts with the step of mixing and kneading  200 , wherein an operator combines the ingredients of eggs, sugar, margarine/butter, flour, baking soda, salt and cocoa in a first mixing hopper  60  to mix and knead the aforementioned ingredients to form a cookie dough  62 .  
      In the step of proofing  210 , the cookie dough  62  is then transferred by the operator to a proofing refrigerator  70  in order to allow the cookie dough to “set up” in this step of proofing  210 . The proofed cookie dough  72  is then refrigerated and proofed at a temperature of 35° F. to 45° F. for a time period of at least 24 hours.  
      Next, the operator proceeds to the step of stirring and mixing  220 , such the operator combines the ingredients of a flavoring (e.g. chocolate), corn syrup, vegetable oil, starch and water in a second mixing hopper  80  in order to stir and mix the aforementioned ingredients to form a flavored paste filling  82 . The flavored paste filling  82  is selected from a group consisting of chocolate, vanilla, lemon, orange, lime, strawberry, raspberry, custard, peach compote, apple compote, and combinations thereof.  
      In the step of gelling  230 , the flavored paste filling  82  is then transferred by the operator to a refrigerator unit  90  in order to allow the flavored paste filling to gelatinize for better extruding properties in this step of gelling  230 . The gelled flavored paste filling  92  is refrigerated in the refrigerator unit  90  to a temperature of at least 50° F. for a time period of at least 12 hours.  
      In the step of encrusting  240 , the operator now proceeds to connect the first mixing hopper  60  having the proofed cookie dough  72  therein and connect to the second mixing hopper  80  having the gelled flavored paste filling  92  therein to an encrusting and extrusion machine  100  in the step of encrusting  240 . The step of encrusting  240  includes the enclosing of a predetermined amount of proofed cookie dough  72  about a predetermined amount of gelled flavored paste filling  92 . The predetermined amount of proofed cookie dough  72  is in the range of 120 grams to 140 grams and the predetermined amount of gelled flavored paste filling  92  is in the range of 40 grams to 80 grams.  
      In the step of extruding  250 , the encrusting and extrusion machine  100  proceeds automatically to extrude the predetermined amount of proofed cookie dough  72  about the predetermined amount of gelled flavored paste filling  92  to form a flavored souffle dessert product (pre-baking)  102  in the step of extruding  250 , as shown in  FIG. 5 . Each of the extruded flavored souffle dessert products  102  has a weight in the range of 160 grams to 200 grams per individual serving. During the step of inserting  260 , each of the extruded flavored souffle dessert products  102  are then automatically inserted into a silicone molded cookie or muffin baking tray  110  having a plurality of cavities  112  therein. Each of the cavities  112  of the cookie/baking tray  110  receives an individual/single extruded flavored souffle dessert product  102  that is further molded into a substantially cylindrically shaped souffle dessert product  28 , as depicted in  FIGS. 1 and 2 .  
      In the step of baking  270 , the operator now proceeds to transfer the plurality of the molded flavored souffle dessert products  20  within the plurality of cavities  12  of (several) baking trays  110  to a baking oven  120  for the partial baking of the souffle dessert product  20  in this step of baking  270 . The flavored souffle dessert products  20  are baked in the bakery oven  120  at a temperature of at least 350° F. for a time period of at least 30 minutes.  
      In the step of freezing  280 , the operator then proceeds to immediately transfer the partially baked flavored souffle dessert products  20  within the plurality of cavities  112  of baking tray  110  to cooling racks  140  within a freezer unit  142  for the quick freezing of the partially baked dessert products  20  in this step of freezing  280 , as depicted in  FIG. 5 . The partially baked dessert products  20  are frozen in the freezer unit  140  at a temperature of at least −20° F. for a time period of at least 45 minutes for forming a frozen flavored souffle dessert product  20 F. In an alternate step of freezing  282 , the partially baked dessert products  20  are frozen in a nitrogen freezing tunnel unit  144  at a temperature between −40° F. to −50° F. for a time period of at least 15 minutes for producing a plurality of frozen flavored souffle dessert products  20 F.  
      In the step of removing  290 , the operator now removes the frozen flavored souffle dessert products  20 F from each of the cavities  112  of the silicone molded baking tray  110  to a moving food conveyor belt  150  in this step of removing  290 . A predetermined number of the frozen flavored souffle dessert products  20 F are removed from the food conveyor belt  150  and are then placed into a shipping container  160  for shipment to the user, as shown in  FIGS. 5 and 6 , in this step of placing and shipping  300 . The ultimate user, such as an individual, families, catering companies, restaurants, company cafeterias, fast food chains, bake stores, grocery stores, delicatessens and the like, then take the frozen souffle dessert product(s)  20 F from their freezer and reheat or rebake the frozen flavored souffle dessert product(s)  20 F for immediate consumption.  
      In the step of rebaking  310 , the user now places the one or more frozen flavored souffle dessert products  20 F on a flat cookie tray  170  and places the flat cookie tray  170  in a convection-type oven  172  for rebaking of the frozen flavored souffle dessert products  20 F in this step of rebaking  310 , as shown in  FIG. 6 . The frozen flavored souffle dessert products  20 F are rebaked in the convection-type oven  172  at a temperature of at least 325° F. for a time period of at least 15 minutes for forming the baked flavored (chocolate) souffle dessert product(s)  40 , as shown in  FIGS. 3, 4  and  6  of the drawings. Alternately, in the step of reheating  320  the user can now place one or more of the frozen flavored souffle dessert products  20 F on a flat microwave tray  174  and then place the flat microwave tray  174  in a microwave oven  176  for reheating of the frozen flavored souffle dessert product  20 F in this step of reheating  320 , as shown in  FIG. 6 . The frozen flavored souffle dessert product(s)  20 F are reheated in the microwave oven  176  at a high setting for a period of time between 90 seconds and 180 seconds.  
     ADVANTAGES OF THE PRESENT INVENTION  
      Accordingly, an advantage of the present invention is that it provides for a flavored souffle dessert product that has a high quality and palatability after rebaking or reheating of the dessert product using a microwave oven or a convection-type oven for a minimal amount of time.  
      Another advantage of the present invention is that it provides for a flavored souffle dessert that has an above average, extended shelf-life of at least three (3) months.  
      Another advantage of the present invention is that is provides for a flavored souffle dessert product that has an outer crisper cookie-like texture about an expanded flavored souffle inner filling after reheating or rebaking.  
      Another advantage of the present invention is that it provides for a flavored souffle dessert product having a novel and unique method of manufacturing with regard to the steps of inserting the plurality of dessert products into a plurality of baking cavities of a silicone molded baking tray, freezing of the plurality of dessert products within each of the plurality of dessert products within each of the plurality of baking cavities of the silicone molded baking tray after a partial baking of the dessert products and removing of the frozen dessert products from each of the baking cavities of the molded baking tray.  
      A further advantage of the present invention is that it provides for a flavored souffle dessert product that can be mass produced in an automated and economical manner and is readily affordable by the user.  
      A latitude of modification, change, and substitution is intended in the foregoing disclosure, and in some instances, some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.