Food or edible material: processes – compositions – and products – Surface coated – fluid encapsulated – laminated solid... – Isolated whole seed – bean or nut – or material derived therefrom
Reexamination Certificate
1999-09-02
2001-05-01
Bhat, Nina (Department: 1761)
Food or edible material: processes, compositions, and products
Surface coated, fluid encapsulated, laminated solid...
Isolated whole seed, bean or nut, or material derived therefrom
C426S465000, C426S497000, C426S502000, C426S503000, C426S560000
Reexamination Certificate
active
06224920
ABSTRACT:
The invention relates to a process for manufacturing coated or filled dry baked products and the like, such as crispbreads, torn rusks, for instance thin crispbreads, torn breadrings dried on a bread pole, and baked snacks. The products can be processed further, for instance, sprinkled on the surface or seasoned. With the process of the invention, products in the form of ready-for-use pieces, or products comprising a plurality of ready-for-use pieces, that are readily divisible into ready-for-use pieces are obtained. The products may be, for instance, crispbread- or thin-crispbread-based snacks.
The invention also relates to baked products manufactured with said process as well as their use for preparing further processed products.
The products according to the invention are typically wholemeal products and thus very high in fibre. Low-calorie and low-fat compositions can preferably be used as fillings/coatings. The invention allows manufacturing of products that are usable, for instance, as wholesome dietary products.
It has been observed that today the consumer desires, more and more, baked products of snack-type that are in the form of ready-for-use pieces, for instance, so called ‘bite-size’ products, or easily divisible into ready-for-use pieces. As regards these kinds of snack products, the aim is to obtain preferably small and thin products. In the manufacture of these products, problems have arisen from cereal ingredient.
When producing conventional, rectangular crispbread pieces, the, crispbread dough is baked in the oven as a continuous sheet or plate, and the ready-for-use pieces are formed after baking by cutting and sawing. This process has a disadvantage, for instance, that at baking step dark, scorched edges are in general formed in the dough sheet or plate that have to be cut off, and as a result product loss may be quite considerable. Product loss occurs also in connection with sawing ready-for-use pieces.
Finnish Patent 58,578 discloses a process for manufacturing crispbreads and corresponding products. In this process, breaking lines, i.e. weakening lines, permitting the breaking up of consumer pieces or serving pieces, are scored in a pre-baked product. The weakening lines are scored in the surface structure of the pre-baked product. Ready-for-use pieces are formed, for instance, by bending/breaking up in a transversal direction and sawing in a longitudinal direction. The manufacture of coated or filled products is not disclosed in this publication.
The manufacture of torn products, for instance, thin crispbreads, comprises an additional step of tearing the baked bread sheet. The torn thin crispbread sheet is divided into ready-for-use pieces after baking, and the pieces are dried and as a consequence they tend to bend/curl up.
In accordance with the prior art, filled dry baked products are in general manufactured by preparing first a filled sheet, and by separating the final ready-for-use pieces by cutting therefrom. This technique is known in relation to wafers, for instance, whereby the cutting is typically carried out by using a wire-type cutter. The wire-cutter technique is applicable to relatively soft material, such as wafers, but not to harder materials, such as crispbreads and thin crispbreads. On the other hand, the conventional sawing and cutting technique used for plain crispbreads is not applicable to filled products, since this technique, used in connection with filled products, has a negative effect on the quality of the product, and moreover, the substances used as fillings do not generally stand the heat generated by sawing. Raw material losses may also be considerable.
The manufacture of filled dry baked products is disclosed, for instance, in U.S. Pat. Nos. 4,518,617 and 4,391,832. These publications disclose the manufacture of filled wafer products, for instance, as a continuous process, whereby a layer of filling material is applied onto a wafer sheet prepared as an endless band and a second wafer sheet is arranged on top of the filling material layer. The filled wafer product in the form of a continuous sheet can then be used for making individual ready-for-use pieces, for instance, by cutting the sheet first longitudinally into narrow, continuous bands, and thereafter, by cutting these transversely into ready-for-use pieces. In the method, a particular attention has been paid to improved production capacity, reduced raw material loss and homogeneity of products.
Finnish Patent 83,283 also discloses filled wafer products and their manufacture. Confectionery bars, particularly chocolate-coated, cream-filled wafers, are manufactured in accordance with said Finnish patent. First is prepared a baked wafer sheet, onto which cream is applied, whereafter at least two cream-coated wafer sheets are cut into ready-for-use pieces. Thereafter, a coating is applied onto a product in the form of a ready-for-use piece. The method is characterized in that the wafer sheets are conveyed after baking in the oven and cooling into a curing tunnel where the cream is spread in carefully determined temperature and moisture conditions. The moisture content of the cream is also carefully determined. The vapour pressure of the cream is kept below the corresponding value of the wafers, in order that moisture may transfer from the wafers to the cream. Prepared in this way, the wafer coating will not crack or split during storage.
European Patent 682,872 discloses multi-layer snack products in which ready-for-use pieces are detached by cutting from a larger sheet.
U.S. Pat. No. 5,500,234 discloses a crispy, filled, multi-layer snack product that may be, for instance, a potato crisp. The products are characterized in that, as an isolating layer, they comprise an intervening layer of marshmallow whose function is to prevent the moisture from transferring from the filling into the crispy potato crisp or snack layer. In these products, filling/coating is applied on products that are in the form of separate, ready-for-use pieces, i.e. products are filled/coated in the form of individual pieces.
When the filling/coating is applied on products that are in the form of ready-for-use pieces, a problem arises, for instance, that the filling is not spread evenly up to the edges or filling is wasted. In addition, in coating individual pieces, high velocity is required of the equipment when pursuing reasonable production rates, which sets high requirements for the equipment. The higher the working velocity of the apparatuses, the more liable they are to malfunction.
It is essential to the process of the invention that a baked bread sheet, in the form of a continuous plate, is patterned for the formation of ready-for-use pieces while the starch in the bread sheet is in elastic state, the patterns being attached to one another and the bread sheet remaining essentially continuous. When coated products are manufactured, the coating is applied onto a patterned, hardened bread sheet while the sheet is still in the form of a continuous plate. When filled products are manufactured, a second patterned, hardened bread sheet is arranged onto a coated bread sheet in such a manner that the patterns match. The obtained product in the form of a plate is then divided along patterning lines, for instance, by breaking up into coated or filled products of one or more ready-for-use pieces.
In connection with the present invention, a hardened bread sheet refers to such a bread sheet whose starch is crystallized, non-elastic, after baking/drying.
The invention relates to a process for the manufacture of dry baked products that are in the form of ready-for-use pieces or divisible into ready-for-use pieces, in which process a dough sheet is prepared that is docked and baked in the oven, possibly torn and possibly dried.
The process is characterized by comprising following steps:
the baked bread sheet is patterned for the formation of ready-for-use pieces while the starch in the bread sheet is in elastic state, the patterns being attached to one another and the bread sheet remaining essentially continu
Haarasilta Sampsa
Pöntinen Erkki
Reinikainen Antero
Reinikainen Kauko
Bhat Nina
Nixon & Vanderhye P.C.
Vaasanmylly Oy
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