Patent Publication Number: US-2019195562-A1

Title: Method and apparatus for optimizing a baking process

Description:
TECHNICAL FIELD 
     The system described herein relates to a method and an apparatus for optimizing a baking process, in particular in commercial baking facilities such as bakeries, baked goods factories and showrooms with baking ovens. 
     BACKGROUND OF THE INVENTION 
     In commercial baking facilities, in particular in food retail showrooms having baking ovens, preparation tables are used to prepare pieces of dough for treatment in the baking oven. Baked goods carriers, usually baking trays, are placed on work surfaces, for example stainless steel surfaces, of the preparation tables which are suitable for food processing and are filled with pieces of dough by trained personnel. This filling process is carried out by trained professionals in craft bakeries. In contrast, in food retail, it is often carried out by quickly trained sales personnel without special knowledge in the field of baking. In order to nevertheless fill the baked goods carriers in a largely correct manner, filling plans are arranged close to the work surfaces of the preparation tables, from which the personnel can gather the correct filling with different pieces of dough. However, working according to the filling plans also requires a considerable amount of experience and skill in order to correctly understand and implement the information on the filling plans. 
     The document EP 2 106 700 B1 discloses a baking system in a supermarket, in which a display/input apparatus is provided at a loading point and can be used in two ways. Either an operator reads the type of baked goods to be loaded from the display of the display/input apparatus and accordingly loads carrier elements for the baked goods, or the operator loads the carrier elements according to his selection and indicates the corresponding information relating to the type or quantity of baked goods which have been loaded to the controller of the baking system via the display/input apparatus. 
     SUMMARY OF THE INVENTION 
     It is desirable to improve (e.g., optimize) the preparation process of the baking process and possibly also to improve the baking process itself. 
     In some embodiments of the system described herein, provided is a method for improving (e.g., optimizing) a baking process. The method may include placing a baked goods carrier onto a work surface; and filling the baked goods carrier with pieces of dough. The method additionally may include the following steps:
         transmitting display data, by means of a computer, to a digitally controlled display apparatus close to the work surface for displaying desired filling;   capturing the actual filling by means of an image recording apparatus and transmitting the captured data to the computer;   evaluating the captured data by means of the computer and comparing them with the data relating to the desired filling; and   acting on the filling process and/or the baking process by means of the computer.       

     The filling plan may be displayed by means of a digitally controllable display apparatus, for example a screen or a projector. Therefore, not only may a controller transmit information relating to the type and quantity of baked goods to the operating personnel, as in EP 2 106 700 B1, but rather the exact filling plan having the positions and orientations of the baked goods may be displayed to the operating personnel. The screen may hang above the work surface. However, it also may be arranged under the work surface if the work surface is transparent and is composed of glass, for example. In this case, the baked goods carrier may be placed directly beside the display on the screen, with the result that the specifications for the desired filling on the screen may be captured together with the actual filling on the baked goods carrier at a glance. Alternatively, the display apparatus may be a projector. The projection may be cast onto a screen or a bright building wall close to the work surface. However, it also may be cast onto the work surface itself. In some embodiments, the work surface may be white or a bright color and as matte as possible so that the projected representation is clearly and easily discernible. 
     Furthermore, in some embodiments, the actual filling is captured by an image recording apparatus and the captured data are transmitted to the computer. The capture can be carried out either at the same time as the display or in alternating fashion with the display. Such an alternating procedure may be useful, in particular, in the case of a projection onto the work surface itself so that the capture may capture pieces of dough which are actually present and not capture projected pieces of dough. 
     The captured data may be compared by the computer with the data relating to the desired filling. The computer may act on the filling process and/or the baking process on the basis of this comparison. 
     For example, the computer may be configured to prompt the output of an alarm signal in the event of incorrect filling. For this purpose, a signaling apparatus, such as a loudspeaker or a light, may be coupled to the computer and controlled to emit a signal when incorrect filling is determined. However, the alarm signal also may be emitted by the display apparatus itself. For example, a representation of the actual filling, in which the incorrect filling may be optically highlighted, may be superimposed on the desired filling displayed by the display apparatus. The incorrect filling may be represented more brightly, for example, or may be marked with a color boundary. In the case of a display directly by means of projection on the work surface, it may be particularly simple to shift the piece of dough, which may be at the location of the marked display of its positioning, in such a manner that it is at the optimum location for the baking process. 
     The computer also may be coupled, via an interface, to the baking oven into which the filled baked goods carrier (baking tray) is introduced for baking. On the basis of the captured actual filling, the computer may therefore transmit optimized baking parameters to the baking oven in order to act on the baking process and improve the latter. Baking ovens are usually loaded with a plurality of baked goods carriers. If these are all filled on a work surface of the type described here, baking parameters may be determined on the basis of the filling data relating to all baked goods carriers. The baking parameters may include, for example, the baking temperature, baking time, time and amount of water added to produce baking fumes. 
     In order to assign a particular baked goods carrier to a particular baking process, at least one capture unit may be connected to the computer, which capture unit may capture the introduction of a filled baked goods carrier into a baking oven. For example, a barcode or a QR code may be assigned to the baked goods carrier, which code may be captured by the image recording apparatus during filling and may be stored together with the data relating to the specific filling of the baked goods carrier. A capture unit which reads the barcode or QR code captures the introduction of the baked goods carrier into the baking oven. In this case, the capture unit may capture the code of the baked goods carrier directly during introduction. In this case, the capture unit may be a camera close to the oven door, for example. However, it is also possible for the baked goods carrier to be introduced into a baking trolley in an intermediate step and to then no longer be readable. Only the baking trolley or the uppermost baked goods carrier in the baking trolley then may be read at the baking oven. For this purpose, the introduction of the baked goods carrier into a baking trolley may be captured and it suffices for only the uppermost barcode on the uppermost baked goods carrier to be read at the baking oven in order to obtain the complete information relating to the filling of all baking trays in the baking trolley. An important factor is that each baked goods carrier may be tracked until it is introduced into the baking oven so that the baking parameters can be adjusted to the filling of each baked goods carrier. Other identification marks, for example RFID tags, or else optical recognition by means of image evaluation, naturally also may be used for this purpose. A capture unit also may capture the removal of the baked goods from the oven and thus may assess the quality of the baking result on the basis of optical features such as coloration of the baked goods and size of the baked goods. 
     In practice, the data for the desired filling and/or the baking parameters may be stored on a data storage unit coupled to the computer. Both the transmission of data from and to the computer and the transmission of data from and to the data storage unit may be carried out via the Internet. A person running a plurality of food retail stores having baking ovens therefore may operate a central computer and a central data storage unit, possibly with a backup system, in order to control the displays and the image capture devices of all preparation tables having work surfaces. On the one hand, this may save costs of repeatedly setting up and maintaining a plurality of data processing systems. In some embodiments, only the main system and possibly the backup system may need to be set up and financed. Furthermore, the central system may process a larger number of data items, with the result that evaluation of the data and adaptation of the desired data using an algorithm having artificial intelligence may take place in a very much more reliable manner than in the case of individual decentralized computers in each store. Finally, the networked and centrally controlled data capture and data output by means of a central computer standardizes the baking results in the various sales outlets. 
     In order to specify the desired filling and to capture and compare the actual filling, it is also possible for the central computer to be installed at the manufacturer of the baking ovens and to be connected to the different sales outlets or sites of the baking ovens via the Internet. In this manner, the manufacturer may collect the data from the sales outlets belonging to different customers and may use said data to improve the system. 
     The following display apparatuses are possible for image display:
         a screen;   a projector, in particular a video projector such as an LCD projector (also called digital projector) or a laser projector;   AR glasses (augmented reality glasses).       

     As mentioned, the representation may be directly discerned on the work surface, in particular if a projector above the work surface is used, or else if a screen below a transparent work surface is used. The operating personnel also may wear augmented reality glasses (AR glasses—also called data glasses) which virtually project information in front of the eyes of the person wearing the glasses, while he still may see the outside world. Such data glasses are known and may include, for example, Google Glass or Microsoft HoloLens. 
     The image recording apparatus may be the following, for example:
         a two-dimensional monochrome camera;   a two-dimensional color camera;   a stereoscopic camera, that is to say a 3-D camera (either monochromatic or in color);   a time-of-flight (ToF) camera (monochromatic or in color); or   a laser scanner.       

     A laser scanner captures a three-dimensional image and individually scans the pixels. Both a stereoscopic camera (camera having two objectives which produces two images) and a time-of-flight camera, which also captures the time of flight of the light at the same time as the brightness or color of the pixels, produce a three-dimensional representation with each image in the case of simultaneous capture of all pixels. 
     The computer analyzes the image data and may take any of the following data into account:
         type of baked goods;   quantity of baked goods;   orientation of the baked goods;   state of the baking tray (present, not present, damaged, soiled, correct type of baking tray (color, coating), baking paper present);   distances between the baked goods; and   distances between the baked goods and the edge of the tray.       

     The computer also may calculate the requirement for baked goods or may determine it on the basis of empirical values which it has obtained over its operating time. Furthermore, the computer may capture the number of baked goods produced and the number of baked goods consumed or sold and may calculate the requirement for baked goods therefrom. The computer therefore may calculate flexible optimum filling patterns for the different baking trays on the basis of the calculated or determined requirement for different baked goods and may individually display said patterns for each filling process on the preparation table. As a result of an error signal in the event of a deviation from the specified filling, the computer may improve the filling process. The computer may use the required baked goods to calculate the complete baking orders, that is to say the desired filling of all baked goods carriers which are to be introduced into the baking oven for a baking process. In this case, the computer considers which baked goods may be optimally baked together (for example Kaiser rolls and split rolls). The computer usefully groups the baked goods on a baking tray and groups the different baking trays for a baking process. In this case, the computer also may capture, by means of the image recording apparatus, the actual filling of each individual baked goods carrier which may be introduced into the oven for a baking process, including all possible instances of incorrect filling, and—as mentioned above—may calculate the optimum baking parameters therefrom, for example the baking time and baking temperature, and may transmit them to the baking oven. 
     The software for controlling the filling and the parameters determined and specified thereby may be improved (e.g., optimized) by means of optimization algorithms according to artificial intelligence methods. The results and sequences of the baking processes may be recorded in this case by means of manual input or automatic monitoring, for example by means of image capture, and may be used to improve the parameters. At least one of the following parameters may be improved:
         the baking parameters;   the evaluation of the image data;   the desired filling of the baked goods carriers; and   the grouping of the baked goods which are combined with one another on a baking tray and/or during a baking process.       

     In this case, it may be advantageous if the computer monitors and controls as many baking processes as possible at as many baking stations as possible. It also may be useful if either an image recording apparatus and/or the personnel operating the baking oven transmit(s) information relating to the baking result to the computer. Information such as brightness and color may be captured most easily using an image recording apparatus. The same image recording apparatus as for observing the filling process or else another image recording apparatus may be used for this purpose. 
     An apparatus for optimizing a baking process may have a work surface for the placement of a baked goods carrier. One or more of the following features additionally may be present:
         a digitally controlled display apparatus close to the work surface for displaying desired filling;   a computer for transmitting display data to the display apparatus; and   an image recording apparatus for capturing the actual filling, which apparatus may be coupled to the computer for the purpose of transmitting the captured data.       

     A computer program product for evaluating the captured data and for comparing them with the data relating to the desired filling and for acting on the filling process and/or the baking process may run on the processor of the computer. In particular, the results of the program product may be improved according to artificial intelligence methods. A signaling apparatus may be coupled to the computer. The computer may be coupled to a baking oven via a data interface. At least one data storage unit may be coupled to the computer. The computer may be connected to the Internet for the purpose of transmitting data. As a result, the method may be implemented at different locations by means of a computer which has been centrally set up and communicates with the devices at the different locations via the Internet. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further practical embodiments and advantages of the system described herein are described below in connection with the drawings: 
         FIG. 1  shows a three-dimensional illustration of a first embodiment of a preparation table according to the system described herein; 
         FIG. 2  shows a second embodiment of a preparation table in a three-dimensional illustration; 
         FIG. 3  shows a third embodiment of a preparation table in combination with a baking oven; and 
         FIG. 4  shows a displayed representation which may be used in the method according to embodiments of the system described herein. 
     
    
    
     DESCRIPTION OF THE VARIOUS EMBODIMENTS 
     A preparation table  10  having a table frame  12  can be seen in  FIG. 1 . The table frame  12  has drawers  14  on the sides and a storage compartment  16  in the center. The work surface  18  of the preparation table  10  may be composed of a material suitable for food processing, for example stainless steel. 
     According to the system described herein, a display apparatus, a flat LCD screen  20  in the present case, may be arranged above the work surface  18 . The screen  20  may be usefully arranged on a wall (not illustrated) of the work area in which the preparation table  10  is situated. An image recording apparatus  22  may be likewise arranged on a wall or ceiling (not illustrated) of the work area. The image recording apparatus  22  may be directed to the work surface  18 . The image recording apparatus  22  may be a conventional camera, a 3-D camera which operates in the stereoscopic method, a laser scanner or a ToF camera (likewise a 3-D camera). The image recording apparatus  22  may capture baking trays which are arranged on the work surface  18  and are filled with pieces of dough for baking. This process is described further below. 
     The image recording apparatus  22  and the screen  20 , which forms the display apparatus, may be connected to a computer  24  via data lines  26 . The computer  24  may evaluate the images recorded by the image recording apparatus  22  and compare the data determined therefrom with desired values. In particular, the pieces of dough which have been placed on the trays and can be identified by means of a shape comparison may be captured. The distance which must exist between one piece of dough and the adjacent piece of dough or the edge of the baking tray may be determined on the basis of the detected pieces of dough. 
     The computer  24  may specify the filling of a baking tray, that is to say the type and number and position of the pieces of dough to be placed on the tray. This may be carried out, for example, on the basis of a manual input of the baked goods to be produced. The operating personnel may specify the respective number of different baked goods to be produced in a baking process via a keyboard or another input apparatus (or else via voice input), for example. The computer  24  then may use the number and type of baked goods required to determine the optimum position of the baked goods on the baking tray(s) if the baking oven is designed to bake a plurality of baking trays arranged above one another. However, the computer  24  also may be coupled to a cash register system, with the result that it may be provided with information relating to how many baked goods of a particular type are sold in a particular period. The computer  24  may use the captured sales figure and sales speed of each type of baked goods to calculate how many baked goods of each type should be baked again. The coupling of a cash register system to a data processing unit for the purpose of determining the required number of baked goods is described in detail in the document DE 10 2005 016 769 B4 by the applicant. In said document, an automatic baking apparatus is controlled using the determined requirement numbers for the different baked goods. In the present case, the determined requirement for baked goods may be used to calculate the optimum filling of the baked goods carriers (baking trays) and to display it to the operating personnel filling the baked goods carrier via the display apparatus, namely the screen  20 . 
     If the filling of a baked goods carrier captured by the camera  22  deviates from the specified desired filling, a signal may be output. For example, the screen  20  may be provided with a loudspeaker which outputs a signal tone. Alternatively, an optical signal may be emitted either by means of a representation on the screen  20  or by means of an additional warning lamp (not illustrated). Alternatively or additionally, the incorrectly positioned piece of dough may be displayed on the screen  20  and highlighted in color. At the same time, the desired position may be displayed on the screen  20 , with the result that the operating personnel may correct the incorrect positioning of the piece of dough. 
       FIG. 2  shows an alternative embodiment of a preparation table  10 ′. In this case, the display apparatus, namely the screen  20 ′, is arranged under the work surface  18 ′. In the present case, the work surface  18 ′ is transparent and is composed of glass, for example. Since the baked goods carriers/baking trays also may be placed onto the work surface  18 ′, the screen  20 ′ may have been shifted to the left. The baked goods carriers may be placed onto the right-hand section of the work surface  18 ′ for filling. 
       FIG. 2  schematically illustrates that the components interacting with one another may be connected to one another via the Internet  28 . The computer  24  and the screen  20 ′ in the preparation table  10 ′ are again connected via data lines  26 . The image recording apparatus  22  may have a WLAN module which communicates with a WLAN router  30  which may be connected to the Internet  28 . 
     In the embodiment in  FIG. 3 , the work table  10  is again free from a display apparatus. In this case, the display apparatus is formed by a projector  32  which may be an LCD projector or a laser projector, for example. In this embodiment, the image recording apparatus  22 ′ is arranged on the opposite side of the preparation table  10 . However, it also may be on the same side or else may be mounted together with the projector  32  in a housing. Both the projector  32 , which forms the display apparatus, and the image recording apparatus  22 ′ communicate with the Internet  28  via a WLAN router  30 . However, it is apparent to a person skilled in the art that the data connection to the Internet  28  may have any desired configuration. Radio communication standards other than WLAN (for example Bluetooth) may be used. Mobile data communication standards such as LTE or UMTS also may be used. Finally, all devices may be connected to the Internet  28  via data lines  26 . In  FIG. 3 , the computer  24  and a baking oven  34  may be connected to the Internet  28  via data lines  26 . The baking oven  34  may have a control module  35  which has a data interface for connecting the data line  26 . A capture unit  33  may be arranged on the baking oven  34  and may be likewise connected to the Internet  28  via a data line  26 . The capture unit  33  may be a camera which captures barcodes on the baked goods carriers and/or on baking trolleys on which the baked goods carriers are transported into the baking oven  34 . Further capture units may be arranged in the premises in which the filled baked goods carriers are handled so that each baked goods carrier may be completely tracked until it is introduced into the baking oven. If appropriate, the correct arrangement of baked goods carriers in the baking trolley also may be displayed by means of further output units or displays, with the result that the real-time display of the filling information relating to the baked goods carriers may be combined with the real-time display of the loading information for the baking trolley. This excludes baked goods which require different baking programs being arranged on a baking trolley. 
     If the capture unit  33  is in the form of a camera, it also may capture image data from the finished baked goods upon removal from the baking oven and may transmit them to the computer. These image data may be used to improve the baking parameters and the filling of the different baked goods carriers. 
     It is obvious to a person skilled in the art that a data network other than the Internet  28  may be used. If all devices are arranged inside one building, a local area computer network (LAN) may be used. However, since the Internet  28  is the most widespread of all data networks, it may be sensible to use the Internet  28  for the required transmission of data. Each device also may be coupled to the data network using a data connection other than that illustrated. 
     The baking oven  34  in  FIG. 3  may be situated in the same room as the preparation table  10  or in an adjacent room. The computer  24  may be at a great distance from the preparation table  10  and also from the baking oven  34 . For example, a central computer  24  may control the preparation tables  10  and/or baking ovens  34  in a plurality of sales outlets in different cities or countries. The computer  24  may be operated, for example, by the head office of a chain of sales outlets. 
     It also may be possible for the computer  24  to be operated by the manufacturer of the baking oven  34 . The manufacturer has a great deal of experience with its products and with baking technology in general. Therefore, it may be possible for the manufacturer of the baking oven  34  to select optimum programs for filling the baked goods carriers. In addition, the computer  24  may have program modules which are used for self-optimization by using artificial intelligence. The data from the image recording apparatus  22 ,  22 ′ may be used for the self-optimization. It also may be possible to arrange further image recording apparatuses (not illustrated) in the vicinity of the baking oven  34 , which image recording apparatuses capture the baking result and assess the baking quality by means of image evaluation. Alternatively or additionally, the operating personnel may input information relating to the baking quality by means of an input apparatus. If the computer  24  is arranged at the head office of a sales chain, the data from all sales outlets may be taken into account. In contrast, if the computer  24  is arranged at the manufacturer of the baking oven  34 , the data from all participating customers of the baking oven manufacturer may be taken into account for the optimization and the manufacturer may provide the digital filling instruction as a special service with its baking oven systems. 
     In the drawings, the computer  24  has an internal data storage unit  25  in the form of an installed drive. However, the data also may be stored on an external data storage unit, for example a cloud memory. The computer also may be integrated in the control module  35  of the baking oven  34 . In this case, the data storage unit may be either locally likewise arranged in the control module  35  or may be arranged in a decentralized manner in the cloud or on a server belonging to the manufacturer. 
       FIG. 4  shows, for example, a representation, as may be displayed by the display apparatus  20 ,  20 ′ or  32 . A frame  36  defines the contours of the baked goods carrier, generally a baking tray. This frame  36  may be projected onto the work surface  18  so that the operating personnel place a baking tray in the frame  36 . Alternatively, the baking tray may be arranged at any desired point on the work surface and the frame  36  may be projected onto the position of the baking tray. Schematic representations of bread rolls  38 , pretzels  40  and croissants  42  may be displayed either by the projector  32  or by the screen  20 ,  20 ′ as the display apparatus. In the case of the display by the projector  32  in particular, image processing software may project the representations directly onto the position on the baking tray onto which the corresponding piece of dough is to be placed. At least one stop which defines the position of the baking tray may be provided for this purpose. The image processing software then calculates the corresponding positioning of the pieces of dough with respect to this stop. However, the baking tray also may be freely placed onto the work surface  18  and the image processing software may determine the position of the baking tray and calculate the positions of the representations of the pieces of dough on this baking tray. The operating personnel need then only place a piece of dough for a bread roll onto the corresponding bread roll representation  38 , a piece of dough for a pretzel onto a pretzel representation  40  or a piece of dough for a croissant onto a croissant representation  42 . 
     The representations  38 ,  40 ,  42  for the baked goods initially may be projected onto a baked goods carrier by a projector  32  in a green color, for example. If a piece of dough has been placed on the tray, the color of the projection may be changed to red, with the result that the operating personnel already discern solely from the color whether a piece of dough has already been placed on the tray. If a piece of dough has been placed incorrectly, in particular at incorrect positions, the desired position of the piece of dough may be displayed in a yellow color or another signal color and may flash, for example. The viewer&#39;s attention may be therefore drawn to the fact that the piece of dough is not correctly at the location intended for it. 
     As mentioned above, the number and type of pieces of dough to be placed on the tray may be specified by the computer  24 . The computer may store, for example, empirical values which reveal the time at which what number of which baked goods should be produced. In addition, the computer may capture sales figures via a cash register system and may take them into account when requesting new baked goods. The computer may calculate optimum filling of the baked goods carriers and optimum loading of the baking oven on the basis of the currently required baked goods. Depending on the quantity of baked goods and the type of baked goods, they may be oriented on the baked goods carrier in an improved manner. 
     However, the computer  24  also may use the image recording apparatus  22 ,  22 ′ to capture further states, for example the state of the baking tray, whether a baking tray is actually present, whether a baking tray is damaged or soiled or whether the correct size, coating or color of the baking tray is used, or else whether baking paper is used on the baking tray. 
     The apparatus described above and the method described above make it possible to instruct even personnel with little experience to optimally fill baked goods carriers. In this case, not only the requirements of the baking process but also the current sales speeds and product requirements may be taken into account if the computer for controlling the filling of the baked goods carriers is coupled to a cash register system. 
     The features of the system described herein, in the drawings and in the claims, may be essential to the implementation of the system described herein in its various embodiments both individually and in any desired combinations. The invention is not restricted to the embodiments described. It may be varied within the scope of the claims and taking into account the knowledge of a relevant person skilled in the art.