WO2011099032A2

WO2011099032A2 - Method and system for producing dough products

Info

Publication number: WO2011099032A2
Application number: PCT/IN2011/000062
Authority: WO
Inventors: Prakash Tambe
Original assignee: Prakash Tambe
Priority date: 2010-02-10
Filing date: 2011-01-31
Publication date: 2011-08-18
Also published as: WO2011099032A3

Abstract

A system and method for preparing multi-layered dough products are disclosed. The system includes a plurality of extruders, a billeting mechanism, a conveyor mechanism, a pin roller assembly, and a heating mechanism. The plurality of extruders is arranged one after the other and form extruded multi-layered dough. The billeting mechanism receives the multi-layered dough and form a multi-layered billet therefrom. The conveyor mechanism receives the extruded dough layers and aligns the extruded dough layers one above the other and feed the extruded multi-layered dough to the billeting mechanism. The pin roller assembly rolls, in a different angular direction, to obtain multi-layered rolled billets having two surfaces rolled through 360 degrees. The heating mechanism heats both the surfaces of the multi-layered rolled billets sequentially to form the multi-layered dough products from the multi-layered rolled billets.

Description

METHOD AND SYSTEM FOR PRODUCING DOUGH PRODUCTS

FIELD OF THE INVENTION

The present invention generally relates to methods and apparatus for preparing dough products.

Particularly, the present invention relates to a method and a system for preparing multi-layered dough products.

BACKGROUND OF THE INVENTION

Dough products, such as chapatti, phulka, bhakri, paratha, kulcha, thalipeet, dhapata, dosa, uttappa, appam, idli, khakara, puri, bhatura, luchi, naan, roti, Tortilla, pita and poli are a staple food in many parts of the world. The dough products are majorly made up of flour mixed with other dry or liquid ingredients. Additionally, the dough products may also include salt, flavorants, leavening agents and the like, based on a user requirement. The above- mentioned mixture is then kneaded to form dough and shaped into variable forms. Further, the mixture may be baked, steamed, cooked, broiled, cooked over direct heat or fried and converted into the desired dough products.

Generally, in households the dough products are prepared manually. It is always desirable that all the dough products prepared are of good taste, good appearance, good texture, and the like. This, of course, involves a considerable amount of skill, and also occupies a considerable amount of time. Accordingly, to eliminate the human component involved in the preparation of various dough products, various dough product preparing machines are manufactured in the prior art.

For example, GB patent GB293966 discloses a dough rolling or priming machine. The dough rolling or prirning machine includes a roller or rollers (such as pinning rollers) or their equivalents, working over a table or tables or like supporting-means. The rollers and tables have relative angular adjustment to vary the direction of rolling. Preferably the dough is passed under a succession of rollers and is turned through an angle between each pair. However, the disclosure of the GB patent number GB293966 is limited to the dough rolling or priming machine only.

US 3,821,452 patent discloses a process for the continuous production of multilayered food product from a plurality of substantially spherical materials each comprising an outer layer of dough and a filling encrusted by said dough. The process includes feeding materials onto a movable base, one upon the other, said movable base being movable in one direction to convey said materials from the feeding location to another location for further processing. Further, compressing said materials upon feeding each material upon said movable base and before the feeding of a subsequent material, using a descendable press platen positioned above the movable base. The process further includes re-compressing the compressed material by a press roller. The process further comprises the cutter tooth for performing cutting operation on the multilayer food product. However, the process disclosed by US 3,821,452 patent is unable to produce a food product having comparatively good organoleptic properties. EP publication EPO 104742 discloses a method for producing a laminate baked Chicago-style or thick-crust product. The method includes the steps of formulating dough, mixing the dough, sheeting the dough, providing a fat layer, rolling the dough sheet, cutting the dough roll, proofing, pressing and baking the dough. The product is stated to be suitable for topping followed by freezing, packaging, and sale of the pizza to the home consumer market. The method may utilize fat substances that are stated to be suitable to produce separate laminate layers of dough in the finished dough product, such as a pizza shell. However, the method disclosed by EP 1602281 publication is unable to produce a food product having comparatively good organoleptic properties.

EP publication EP0213204 discloses dies for an extruder used for the processing of food, and more particularly to dies for an extruder used to obtain continuously organized meat-like formed products by using raw protein materials for foods, such as defatted soy bean powder and meat of a high moisture content of livestock. The patent document discloses an extruder provided with a temperature controlling jacket that has a fluid passage in an outer periphery of the barrel so that a temperature of the barrel is controlled by the fluid flowing therein. However, the disclosure of the EP publication number EP0213204 is limited to extruder only.

US patent 4,806,090 discloses an apparatus for use when manufacturing a substantially circular dough product, said apparatus includes a turntable defining a planar surface, and conical roller means adapted to cooperate with said turntable and defining a rolling line in the region of the roller close to said planar surface, the turntable being rotatable to permit effective movement between said rolling line and the turntable, the apparatus being provided with means to cause the roller and turntable to move from a relative space to part position to an operative position with a reduced spacing there between for a predetermined operational period of time and to cause the roller and the turntable subsequently to return to the initial spaced apart position. However, the apparatus of the US4806090 patent is unable to prepare multi-layered dough products.

US publication US 20030134016 discloses a method for making a laminated pizza crust. The pizza crust is produced by resting a formulated dough mixture, cutting the dough, rolling the dough into a sheet, extruding high-melt margarine on to the sheet and folding it over the margarine to form a fatted dough, stretching the fatted dough, piling the fatted dough onto itself to create several layers, stretching the dough a second time, piling and rolling the dough again, stretching the dough a final time to a predetermined thickness, puncturing the dough sheet, cutting the dough sheet into pre-determined pizza shapes, and finally baking the shapes. The baked crust can be topped with pizza ingredients and frozen. However, the method as disclosed by the US publication number US 20030134016 is unable to prepare multi-layered dough products.

EP publication EP 1602281 discloses a process and an apparatus for production of a bakery product in the shape of a multi-layered grid of short crust pastry filaments. The process includes the steps of: a) preparing at least one short crust pastry dough mixture b) forming, by extrusion of said at least one dough mixture , a number of superimposed layers of short crust pastry dough mixture filaments c) cooking said semi-finished product in a baking oven. The apparatus may include at least two grooved rollers, operated by a suitable motor, that compress the dough mixture loaded in the hopper and force it towards the extrusion nozzles. However, the process and an apparatus disclosed by EP 1602281 publication are unable to produce a food product having comparatively good organoleptic properties.

Although, the prior art dough producing machines are used for producing dough products, the prior art dough producing machines have various limitations. For example, the dough products prepared by the prior art dough producing machines do not possess good taste. Further, the prior art dough producing machines are unable to produce multi-layered dough products. Furthermore, the dough products prepared by the prior art dough producing machines do not exhibit good organoleptic properties.

Accordingly, there is a need of a dough product preparing system that is adapted to produce dough products having good taste. Further, there is a need of a dough product preparing system that is adapted to produce multi-layered dough products. Furthermore, there is a need of a dough product preparing system that is adapted to produce a dough product having good organoleptic properties.

OBJECTS OF THE INVENTION

An object of the present invention is to provide a dough product preparing system and method that are adapted to produce a dough product having good taste.

Another object of the present invention is to provide a dough product preparing system and method that are adapted to produce multi-layered dough products. Yet another object of the present invention is to provide a dough product preparing system and method that are adapted to produce discrete multi-layered dough products.

Further, an object of the present invention is to provide a dough product preparing system and method that are adapted to produce a dough product having good organoleptic properties.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention there is provided a system for preparing multi-layered dough products. The system includes a plurality of extruders, a billeting mechanism, a conveyor mechanism, a pin roller assembly, and a heating mechanism. The plurality of extruders is arranged one after the other. Each of the plurality of extruders is adapted to extrude a discrete layer of the multi-layered dough products to form extruded multi-layered dough. The billeting mechanism includes a plurality of punching stations. The billeting mechanism is adapted to receive the multi-layered dough and form a multi-layered billet. The conveyor mechanism is arranged between the extruders and the billeting mechanism. The conveyor mechanism is adapted to receive the extruded dough layers and align the extruded dough layers one above the other and feed the extruded multi-layered dough to the billeting mechanism. The pin roller assembly includes a plurality of multiple pin rolling stations. The plurality of multiple pin rolling stations is adapted to roll, in a different angular direction, to obtain multi-layered rolled billets having two surfaces rolled through 360 degrees. The heating mechanism includes a plurality of heating stations. The heating stations adapted to heat the multi- layered rolled billets received from the pin roller assembly. The heating mechanism is adapted to heat both the surfaces of the multi-layered rolled billets sequentially to form the multi-layered dough products from the multi- layered rolled billets.

Typically, each of the plurality of extruders includes a hopper, a jacketed extruder barrel, and a jacketed die. The hopper is adapted to accommodate dough therein. The jacketed extruder barrel is adapted for pressing the dough. The jacketed extruder barrel includes a screw. The jacketed die is adapted to prepare a layer of the dough to a pre-determined form. The jacketed die and the jacketed extruder barrel are adapted to maintain temperature of said dough within a pre-determined temperature limit.

Preferably, the jacketed die includes a temperature sensor.

Further, each of the plurality of extruders includes adjustable blades adapted to vary thickness of the multi-layered dough products.

In one embodiment of the present invention, the plurality of extruders is vertically disposed over said billeting mechanism.

Additionally, the each of the plurality of punching stations includes a punch, a billet releaser, a guide plate, and an oil smearing mechanism. The punch is adapted to facilitate formation of said plurality of billets from the multi-layered dough structure. The billet releaser is disposed within the punch and adapted for facilitating release of a billet formed by the punch. The guide plate is adapted to guide vertical motion of the punch. The oil smearing mechanism is adapted to facilitate application of oil on the punch for prevention of sticking of the billet to the billeting mechanism and for fusing of all layers of the multi-layered dough products together.

Typically, position of the billet releaser is adjusted depending on thickness of the multi-layered dough products.

Preferably, each of the plurality of multiple pin rolling stations includes a conveyor assembly, an adjustable pin roller and a deflector plate. The conveyor assembly includes a belt disposed over a pair of pin rollers. The adjustable pin roller is functionally coupled to the conveyor assembly and adapted to facilitate rolling of the billet in a particular angular direction. The deflector plate is adapted to facilitate movement of the billet.

Further, each of the plurality of heating station includes a conveyor assembly, a heating means and a deflector plate. The conveyor assembly includes a slat chain conveyor formed of a plurality of metal slats and disposed over a pair of sprockets. The heating means is disposed within the conveyor assembly for hpating of the billets. The deflector plate is adapted to facilitate movement of the billet.

The metal slats may be chamfered for preventing direct exposure of the billets to heating.

Furthermore, the system may include a de-steaming mechanism for removal of steam contained inside the multi-layered dough products. The de-steaming mechanism includes a lift-up conveyor and a fall down guide. Also, the system may include at least one cooling hood for facilitating controlled cooling of the multi-layered dough products. The at least one cooling hood includes a meshed conveyor and a hood disposed over the meshed conveyor.

In one embodiment of the present invention, the conveyor assembly includes a belt, wherein the belt is sprinkled with flour to prevent sticking of the layers of the multi-layered dough structure on the belt.

In accordance with another aspect of the present invention there is provided a method for preparing multi-layered dough products. The method includes the following steps: extruding a plurality of discrete dough layers to form extruded multi-layered dough; billeting the extruded multi-layered dough by punching to form a plurality of multi-layered billets; rolling the plurality of multi-layered billets by means of a plurality of pin rollers to obtain a rolled billet rolled through 360 degrees; and heating sequentially on operative both surfaces of rolled multi-layered billets to obtain multi-layered dough products.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The invention will now be explained in relation to the accompanying drawings, in which:

Figure 1 illustrates a general arrangement of a plurality of extruders and a billeting mechanism, in accordance with one embodiment of the present invention; Figure 2 illustrates an enlarged view of a tip portion of the extruder die encircled in Figure 1 depicting adjustable blades;

Figure 3 illustrates a sectional view of a punching station of the billeting mechanism shown in Figure 1 ;

Figure 4 illustrates a general arrangement of a pin roller assembly, in accordance with one embodiment of the present invention;

Figure 5 illustrates an enlarged view of a pin rolling station of the pin roller assembly of Figure 4;

Figure 6 illustrates a general arrangement of a heating mechanism, in accordance with one embodiment of the present invention;

Figure 7 illustrates sectional view of chamfered metal slats of the heating mechanism of Figure 6;

Figure 8 illustrates schematic view of a de-steaming mechanism and cooling hoods in accordance with one embodiment of the present invention; and

Figure 9 illustrates a flow diagram illustrating a process for producing a dough product, in accordance with one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The invention will now be described with reference to the accompanying drawings which do not limit the scope and ambit of the invention. The description provided is purely by way of example and illustration.

Referring to Figures 1 to 9, a system and a method for preparing multi-layered dough products are disclosed. The system and the method of the present invention is adapted to produce multi-layered dough products such as but not limited to, a chapatti, a phulka, a bhakri, a paratha, a thalipeet, a dhapata, a Tortilla, a puri, a bhatura, a naan, a roti, a poli, a dosa, an uttappa, an appam, a pita and the like. Also, the multi-layered dough products prepared by the system and the method of the present invention are discrete. Further, the multi-layered discrete dough products prepared by the system and the method of the present invention exhibits improved organoleptic properties.

Referring to Figure 1 to 8, the system for preparing the multi-layered dough products is disclosed. The system includes a plurality of extruders 100,^■ a billeting mechanism 200, a pin roller assembly 300 and a heating mechanism 400.

Now referring to Figures 1 and 2, a plurality of extruders, such as 100a, 100b, 100c, (hereinafter collectively referred to as "plurality of extruders 100") is depicted in accordance with one embodiment of the present invention. Each of the plurality of extruders 100 is arranged one after the other. Further, in one embodiment of the present invention, each of the plurality of extruders 100 is vertically disposed over the billeting mechanism. However, the present invention is not limited to any particular disposition of the plurality of extruders 100. Further, each of the plurality of extruders 100 includes a hopper 102, a jacketed extruder barrel 104, and a jacketed die 106.

The hopper 102 is adapted to accommodate dough therein. The jacketed extruder barrel 104 is adapted to press the dough. The jacketed extruder barrel 104 includes a screw. Thus, the prepared dough is entered into the jacketed die 106. The jacketed die 106 is adapted to extrude a discrete layer of the dough entered through the jacketed extruder barrel 104 to a pre-determined form. Also, the jacketed die 106 and the jacketed extruder barrel 104 are adapted to maintain temperature of the dough within a pre-determined temperature limit. More specifically, in one embodiment of the present invention, the jacketed die 106 includes a temperature sensor for measuring the temperature of the dough contained in the jacketed die 106. Based on the temperature measured by the temperature sensor, the flow of the coolant fluid is regulated through the jacket of the jacketed die 106 to maintain the temperature of the dough within a predetermined temperature limit. In one embodiment of the present invention, the temperature sensor is positioned in a thermo well 108.

Further, a discharge end 110 (shown in Figure 2) of the jacketed die 106 includes a pair of adjustable blades, such as 112a and 112b (shown in Figure 2) (hereinafter collectively referred to as "pair of adjustable blades 1 12"). The pair of adjustable blades 112 is adapted to vary thickness of the multi-layered dough products by varying the distance between the pair of adjustable blades 1 12. Further, each of the plurality of extruders 100 is adapted to extrude a discrete layer of the multi-layered dough product to form extruded multi-layered dough. For example, as the present embodiment discloses three extruders, the dough product obtained contains three layers. However, the present invention is not limited to any particular number of extruders used. Accordingly, the number of the extruders may be varied depending on the number of layers of the dough product required.

In use, the extruder 100a extrudes a first discrete layer of the multilayer dough product on a belt of a conveyor mechanism 1 14. The belt may be a Teflon belt. However, the present invention is not limited to any particular material used for manufacturing the belt. The belt is sprinkled with the flour at appropriate locations. The flour is contained in flour boxes 1 16a and 116b. The flour box 1 16a is positioned at the beginning of the first conveyor assembly 1 14 and the flour box 1 16b is positioned before a press roll 1 18. The flour disposed on the belt is adapted to prevent sticking of the layers of the multi-layered dough structure on the belt. Further, the first layer is sprayed with edible oil by means of a first oil spray 120a.

Furthermore, a second layer of the multilayer dough product is extruded on the first layer by means of the extruder 100b. The oil sprayed on the first layer prevents sticking of the second layer over the first layer and thus maintains the layers of the multi-layer dough product discrete. Then, oil is sprayed on the second layer disposed on the first layer by means of a second oil spray 120b. Further, a third layer of the multilayer dough product is extruded on the second layer by means of the extruder 100c. Subsequently, the floor is sprinkled on the multi-layered dough structure (in the present embodiment three layered dough structure) by means of the floor box 116b. Latter, the multi-layered dough structure is slightly pressed by the press roller 118. Accordingly, this multi layer dough structure thus formed is conveyed to the billeting mechanism 200 by means of the conveyor mechanism 1 14. The conveyor mechanism 114 arranged between the extruders 100 and the billeting mechanism 200. The conveyor mechanism 114 is adapted to receive the extruded dough layers and align the extruded dough layers one above the other and feed said extruded multi-layered dough to the billeting mechanism 200.

The billeting mechanism 200 is adapted to form a plurality of multi-layered billets from the multi-layered dough formed by the plurality of extruders 100. The billeting mechanism 200 includes a plurality of punching stations, such as a punching station 202 (described in detail in conjunction with Figure 3). The plurality of multi-layered billets thus formed is conveyed to a billet conveyor belt 122. The billet conveyor belt 122 may be sprinkled with flour to prevent sticking of the billets thereto. The swarf portion remained after formation of the plurality of billets is discarded by means of a lift roller 124. Further, the swarf portion is collected in a left over tray 126. The swarf portion thus collected may be used for preparing other dough products, such as Puri and the like.

Now referring to Figure 3, the punching station 202 is described. The punching station 202 includes a punch 204, a billet releaser 206, a guide plate 208, an oil smearing mechanism (not shown), a base plate 210, a first plate 212, a second plate 214 and a holding plate 216. The punch 204 is adapted to facilitate formation of the plurality of multi-layered billets from said multi-layered dough structure. In one embodiment of the present invention, the punch 204 may have a cylindrical hollow structure. However, the present invention is not limited to any particular structure of the punch 204. More specifically, the punch 204 is adapted to vertically move up and down to facilitate punching operation. The billet releaser 206 is disposed within the punch and adapted to facilitating release of a billet formed by the punch 204. In one embodiment of the present invention, position of the billet releaser 206 is adjusted depending on thickness of the multi-layered dough products by moving the billet releaser 206 into the holding plate 216. The guide plate 208 is adapted to guide vertical motion of the punch 204. The oil smearing mechanism is adapted to facilitate application of oil on the punch 204 for prevention of sticking of the billet to the billeting mechanism and for fusing of all layers of the multi-layered dough products together. The base plate 210 is adapted to support the punch 204, the billet releaser 206, the guide plate 208, the oil smearing mechanism and the holding plate 216 thereon.

In one embodiment of the present invention, the first plate 212 is of rubber. However, the present invention is not limited to any particular material used for manufacturing the first plate 212. Similarly, in one embodiment of the present invention, the second plate 214 is of mild steel. However, the present invention is not limited to any particular material used for manufacturing the second plate 214. The first plate 212 and the second plate 214 are adapted to prevent shearing of the belt of the first conveyor assembly 114 during punching operation by the punch 204.

In use, the punch 204 is adapted to shear the multi-layered dough to form a multi-layered billet there from. Further, as the punch 204 moves upward after punching, the punch may take the billet along with it. The billet releaser 206 is adapted to facilitating release of the billet that is moving along with the punch 204. Now referring to Figure 4, a general arrangement of the pin roller assembly 300 is disclosed. The pin roller assembly 300 includes a plurality of multiple pin rolling stations, such as a multiple pin rolling station 302. Although, in the present embodiment of the present invention, the plurality of multiple pin rolling stations are twelve, the present invention is not limited to any particular number of the plurality of multiple pin rolling stations. Each of said plurality of multiple pin rolling stations 302 is adapted to receive the multi-layered billet and roll the multi-layered billet in a particular angular direction so that the billet is rolled through 360 degree of rotation. In one embodiment of the present invention, the billet having 6 mm to 15mm thickness and 60 to 100 mm diameter may be rolled to a thickness of 1.5 to 5 mm thickness and diameter of 150 to 300mm. However, the present invention is not limited to any particular value of the diameter and thickness of the billet before and after rolling operation.

Now referring to Figure 5, each of the multiple pin rolling station 302 includes a conveyor assembly 304, an adjustable pin roller 306, and a deflector plate 308. The conveyor assembly includes a belt 310 disposed over a pair of pin rollers 312a and 312b. In one embodiment of the present invention, the belt 310 is of Teflon. However, the present invention is not limited to any particular material used for manufacturing the belt 310. In other embodiments of the present invention, the belt 310 may be manufactured of various other materials known in the art. The adjustable pin roller 306 is functionally coupled to the conveyor assembly 304 and adapted to facilitate rolling of the billet in a particular angular direction. The adjustable pin roller 306 is adapted to adjust its position depending on the thickness of the billet. The deflector plate 308 is adapted to facilitate movement of the billet. The deflector plate 308 may be made adjustable to enable rolling in different directions.

In one embodiment of the each of the multiple pin rolling station 302 further includes a tensioner roller 314 and a pair of flour troughs 316a and 316b. The tensioner roller 314 is adapted to maintain proper tension in the belt 310. The pair of flour troughs 316a and 316b is adapted to facilitate continuously coating of the belt 310 and the adjustable pin roller 306 with flour to prevent sticking of the billets to the belt 310 and the pin rollers 306.

In use, the multi-layered billet from the billet conveyor belt 122 is conveyed to the pin roller assembly 300. More specifically, the multi-layered billet is conveyed to a first rolling station. In the first rolling station, the billet is rolled in a particular angular direction. Further, the billet rolled in the . first rolling station is moved to a second rolling station by means of the deflector plate 308. Accordingly, the billet is rotated through 360 degree of rotation, once the roller is moved out of the last rolling station. More specifically, the multiple pin rolling station 302 are adapted to roll, in a different angular direction, to obtain multi-layered rolled billets having two surfaces rolled through 360 degrees.

Referring to Figure 6, a general arrangement of the heating mechanism 400 is disclosed. The heating mechanism 400 includes a plurality of heating stations 402a to 402e. The heating mechanism 400 is adapted to heat the multi-layered rolled billets received from the pin roller assembly 300 and thereby prepare the multi-layered dough products from the billets. Further, the each of the heating station 402 includes a conveyor assembly 404, a heating means 406 and a deflector plate 426. The heating means 406 is disposed within the conveyor assembly 404 for heating of the billets The heating means may include but not limited to gas burners, heat dispensers, and the like. The conveyor assembly 404 includes a slat chain conveyor 408 disposed over a pair of sprockets 410a and 410b. The conveyor assembly 404 includes a plurality of metal slats 412a and 412b (shown in Figure 7). The deflector plate 426 is adapted to movement of the billets.

Further, in one embodiment of the present invention, the heating mechanism 400 may further include a body frame 414, an oil spray device 416a and 416b, a chain 418, a hood 420, a geared motor 422, and a brush roller and a tray assembly 424. The body frame 414 is adapted to support various components of the heating mechanism 400. The oil spray device 416a and 416b are adapted to spray edible oil over the billets. The chain 418 is adapted to transfer power from the geared motor 422 to the heating stations 402. The hood 420 is adapted to facilitate removal of flue gases and water vapors from the heating mechanism 400. The brush roller 424 is adapted to clean the metal slats 412a and 412b for facilitating removal of the carbon residue and particles of billets sticked to the metal slats 412a and 412b. Referring to Figure 7, the plurality of metal slats 412a and 412b is chamfered for preventing direct heating of the billets.

In use, the billet from the last rolling station is conveyed over the heating station 402a. The heating station 402a is comparatively long than the remaining heating stations. The heating station 402a includes a pair of heating means 406. Also, the heating temperature provided by the heating station 402a is more than the heating temperature provided by remaining heating stations 402b to 402e. More specifically, the heating temperature provided by the heating stations 402a to 402e decreases from heating station 402a to 402e. In one embodiment of the present invention, the heating temperature provided by the heating stations 402a to 402e decreases from 300 degree C to 80 degree C. However, the present invention is not limited to any particular temperature range. Further, the billet heated over the heating station 402a is conveyed over the heating station 402b by means of the deflector plate 426. The deflector plate 426 is adapted to reverse the heating side of the billet. Accordingly, heating of the billet takes place at every heating station by reversing the side of the billet. Accordingly, the heating mechanism 400 is adapted to heat both the surfaces of the multi-layered rolled billets sequentially to form the multi-layered dough products. The heating stations 402d and 402e include the oil spray devices 416a and 416b for spraying of the edible oil over the billets. Additionally, the multi- layered discrete dough products prepared from the billets by heating in the heating mechanism 400 is conveyed to a de-steaming mechanism 500.

Referring to Figure 8, the de-steaming mechanism 500 along with a pair of cooling hoods, such as 600a and 600b, is disclosed. The de-steaming mechanism 500 is adapted for removal of steam contained inside the multi- layered dough products. The de-steaming mechanism 500 includes a lift-up conveyor 502 and a fall down guide 504. The lift-up conveyor 502 is adapted to convey the multi-layered discrete dough products to a certain height and facilitate guided fall of the multi-layered discrete dough products through the fall down guide 504 for removal of the steam contained inside the multi-layered discrete dough products. After removal of the steam from the multi-layered discrete dough products, the multi-layered discrete dough products are conveyed over the pair of cooling hoods 600a and 600b. The pair of cooling hoods 600a and 600b is arranged sequentially one after the other. Each of the cooling hoods 600a and 600b is adapted for facilitating controlled cooling of the multi-layered dough products. Further, each of the cooling hoods 600a and 600b includes a meshed conveyor 602 and a hood 604. The meshed conveyor 602 is adapted to facilitate proper ventilation for facilitating proper cooling of the multi-layered dough products. The hood 604 is adapted to prevent over exposure of the multi-layered dough products to the environment. The hood 604 includes an exhaust ducting 606 for facilitating removal of flue gases and water vapors from the cooling hoods 600a and 600b.

Working of the invention

Referring to Figure 9, a flow chart depicting working of the system for preparing multi-layered dough products is disclosed. Initially, before preparation of the dough in a dough mixer, quality of raw materials, such as wheat, water, oil and the like is tested. For example, the wheat quality is tested for glutenin, gliadins, proteins and the like. Further, depending on the contents of glutenin, gliadins, proteins, and the like present in the wheat, different wheat flours are mixed to balance the quantity of the glutenin, the gliadins and the proteins and the like present in the dough. Accordingly, based on the contents of the glutenin, the gliadins and the proteins, other ingredients for preparation of dough, such as but not limited to quantity of floor, quantity of salt, quantity of oil, quantity of water at a pre-determined temperature and the like are adjusted. Also, the ingredients for preparation of the dough may be decided based on final dough product to be prepared. The other ingredients may include flavorants, leavening agents and the like. Additionally, while preparation of the dough, depending on the contents of glutenin, gliadins, proteins, and the like present in the wheat; mixing speedy temperature of mixing, time of mixing and resting time is regulated. The various ingredients for preparation of the dough may be mixed in the dough mixer.

Further, the dough formed in the dough mixture is carried to the plurality of extruders 100 (refer to Figures 1 and 2 in conjunction with Figure 9) for forming multi-layered dough structure. The extruder 100a extrudes a first discrete layer of the multilayer dough product on a belt of a first conveyor assembly 1 14. The belt is sprayed with the flour at appropriate locations. The flour is contained in flour boxes 116a and 116b. The flour box 1 16a is positioned at the beginning of the first conveyor assembly 114 and the flour box 1 16b is positioned before a press roll 118. The flour disposed on the belt is adapted to prevent sticking of the layers of the multi-layered dough product on the belt. Further, the first layer is sprayed with edible oil by means of a first oil spray 120a.

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Furthermore, a second discrete layer of the multilayer dough product is extruded on the first layer by means of the extruder 100b. The oil sprayed on the first layer prevents sticking of the second layer over the first layer and thus maintains the layers of the multi-layer dough product discrete. Then, oil is sprayed on the second layer disposed on the first layer by means of a second oil spray 120b. Further, a third layer of the multilayer dough product is extruded on the second layer by means of the extruder 100c. Subsequently, the floor is sprinkled on the multi-layered dough structure (in the present embodiment three layered dough structure) by means of the floor box 116b. Latter, the multi- layered dough structure is slightly pressed by a press roller 1 18. Accordingly, the plurality of extruders is adapted to form extruded multi-layered dough. Accordingly, this multi-layered dough thus formed is conveyed to the billeting mechanism 200 (refer to Figures 1 and 3 in conjunction with Figure 9). The billeting mechanism 200 is adapted to form a plurality of multi-layered billets from the multi-layered dough. The plurality of multi-layered billets thus formed is conveyed to a billet conveyor belt 122. The swarf portion remained after formation of the plurality of billets is discarded by means of a lift roller 124. Further, the swarf portion is collected in a left over tray 126. The swarf portion thus collected may be used for preparing other dough products, such as Puri and the like.

Further, the multi-layered billets from the billet conveyor belt 122 are conveyed to the pin roller assembly 300 (refer to Figures 4 and 5 in conjunction with Figure 9). More specifically, the multi-layered billets are conveyed to a first rolling station. In the first rolling station, the billet is rolled in a particular angular direction. Further, the billet rolled in the first rolling station is moved to a second rolling station by means of the deflector plate 308. Accordingly, the billet is rotated through 360 degree of rotation, once the roller is moved out of the last rolling station. Accordingly, the plurality of multiple pin rolling stations is adapted to roll, in a different angular direction, to obtain multi-layered rolled billets having two surfaces rolled through 360 degrees.

Furthermore, the multi-layered rolled billets from the last rolling station is conveyed over the heating station 402a (refer to Figures 6 and 7 in conjunction with Figure 9). The heating station 402a is comparatively long than the remaining heating stations. Also, the heating temperature provided by the heating station 402a is more than the heating temperature provided by remaining heating stations 402b to 402e. More specifically, the heating temperature provided by the heating stations 402a to 402e decreases from heating station 402a to 402e. Further, the billet heated over the heating station 402a is conveyed over the heating station 402b by means of the deflector plate 426. The deflector plate 426 is adapted to reverse the heating side of the billet. Accordingly, heating of the billet takes place at everey heating stations by reversing the side of the billet. The heating stations 402d and 402e include the oil spray devices 416a and 416b for spraying of the edible oil over the billets. Additionally, the multi-layered discrete dough products prepared from the billets by heating in the heating mechanism 400 is conveyed to a de-steaming mechanism 500. Accordingly, the heating mechanism 400 is adapted to heat both the surfaces of said multi-layered rolled billets sequentially to form the multi-layered dough products from the multi-layered rolled billets.

The de-steaming mechanism 500 (refer to Figure 8 in conjunction with Figure 9) is adapted for removal of steam contained inside the multi-layered dough products. The lift-up conveyor 502 is adapted to convey the multi-layered discrete dough products to a certain height and facilitate guided fall of the multi-layered discrete dough products through the fall down guide 504 for removal of the steam contained inside the multi-layered discrete dough products. After removal of the steam from the multi-layered discrete dough products, the multi-layered discrete dough products are conveyed over the pair of cooling hoods 600a and 600b.

The pair of cooling hoods 600a and 600b is arranged sequentially one after the other. Each of the cooling hoods 600a and 600b is adapted for facilitating controlled cooling of the multi-layered dough products. The meshed conveyor 602 is adapted to facilitate proper ventilation for facilitating proper cooling of the multi-layered dough products. The hood 604 is adapted to prevent over exposure of the multi-layered dough products to the environment. The exhaust- ducting 606 of the hood 604 facilitates removal of flue gases and water vapors from the cooling hoods 600a and 600b. Accordingly, the multi-layered dough product thus prepared provides improved organoleptic properties with respect to prior art dough products.

Organoleptic properties of a dough product such as a chapatti prepared by the system and the method of the present invention

1. Puffing: Puffing provided by the chapatti is complete and rapid. The puff height provided by the chapatti is significant.

2. Appearance: The chapatti has attractive silky appearance with uniform surface.

3. Texture and overall quality: The texture of the chapatti is significantly soft, smooth and pliable.

4. Colour: The color of the chapatti prepared by amber colored wheat is creamish.

5. Aroma - The aroma provided by the Chapatti is typically wheaty.

6. Flavor/Taste: The chapatti prepared by above-mentioned system is

sweetish and has a pleasing flavor.

7. Pliability: The chapatti is adapted to retain soft and pliable structure and also provides soft eating quality.

8. Moisture: The chapatti is adapted to retain moisture for longer period of time.

9. Tearing ease: The chapatti is adapted to be torn easily and smoothly.

Further, the chapatti is adapted to be easy to chew and tear. Technical Advancements and Economic Significance

The dough product preparing system of the present invention is adapted to produce a dough product having good taste. Further, the dough product preparing system is adapted to produce multi-layered dough products. Furthermore, the dough product preparing system of the present invention is adapted to produce a dough product having good organoleptic properties. Moreover, the method for preparing dough products embodying the present invention is adapted to produce multi-layered dough products having good organoleptic properties.

Wherever a range of values is specified, a value up to 10% below and above the lowest and highest numerical value respectively, of the specified range, is included in the scope of the invention.

While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the invention. These and other changes in the preferred embodiment of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

Claims

1. A system for preparing multi-layered dough products, the system comprising:

• a plurality of extruders arranged one after the other, each of the plurality of extruders adapted to extrude a discrete layer of said multi-layered dough products to form extruded multi-layered dough;

• a billeting mechanism comprising a plurality of punching stations and adapted to receive said multi-layered dough and form a multi-layered billet;

• a conveyor mechanism arranged between said extruders and said billeting mechanism and adapted to receive said extruded dough layers and align said extruded dough layers one above the other and feed said extruded multi-layered dough to said billeting mechanism;

• a pin roller assembly comprising a plurality of multiple pin rolling stations adapted to receive said multi-layered billet, wherein said plurality of multiple pin rolling stations is adapted to roll, in a different angular direction, to obtain multi-layered rolled billets having two surfaces rolled through 360 degrees; and

• a heating mechanism comprising a plurality of heating stations adapted to heat said multi-layered rolled billets received from said pin roller assembly, wherein said heating mechanism is adapted to heat both the surfaces of said multi-layered rolled billets sequentially to form said multi-layered dough products from said multi-layered rolled billets.

2. The system as claimed in claim 1, wherein each of said plurality of extruders comprises,

• a hopper for accommodating dough therein;

• a jacketed extruder barrel for pressing said dough, said jacketed extruder barrel comprising a screw , and

• a jacketed die for preparing a layer of said dough to a predetermined form, wherein said jacketed die and said jacketed extruder barrel are adapted to maintain temperature of said dough within a pre-determined temperature limit.

3. The system as claimed in claim 2, wherein said jacketed die comprises a temperature sensor.

4. The system as claimed in claim 1, wherein each of said plurality of extruders comprises adjustable blades adapted to vary thickness of said multi-layered dough products.

5. The system as claimed in claim 1, wherein said plurality of extruders is vertically disposed over said billeting mechanism.

6. The system as claimed in claim 1, wherein each of said plurality of punching stations comprises,

i. a punch for facilitating formation of said plurality of billets from said multi-layered dough structure; ii. a billet releaser disposed within said punch and adapted for facilitating release of a billet formed by said punch;

iii. a guide plate for guiding vertical motion of said punch; and iv. an oil smearing mechanism for facilitating application of oil on said punch for prevention of sticking of said billet to said billeting mechanism and for fusing of all layers of said multi-layered dough products together.

7. The system as claimed in claim 6, wherein position of said billet releaser is adjusted depending on thickness of said multi-layered dough products.

8. The system as claimed in claim 1, wherein each of said plurality of multiple pin rolling stations comprises,

• a conveyor assembly comprising a belt disposed over a pair of pin rollers;

• an adjustable pin roller functionally coupled to said conveyor assembly and adapted to facilitate rolling of said billet in a particular angular direction; and

• a deflector plate for facilitating movement of said billet.

9. The system as claimed in claim 1 , wherein each of said plurality of heating station comprises,

• a conveyor assembly comprising a slat chain conveyor formed of a plurality of metal slats and disposed over a pair of sprockets; • a heating means disposed within said conveyor assembly for heating of said billets;

• a deflector plate for facilitating movement of said billet.

10. The system as claimed in claim 9, wherein said metal slats are chamfered for preventing direct exposure of said billets to heating.

1 1. The system as claimed in claim 1, further comprising a de-steaming mechanism for removal of steam contained inside said multi-layered dough products, said de-steaming mechanism comprises a lift-up conveyor and a fall down guide.

12. The system as claimed in claim 1, further comprising at least one cooling hood for facilitating controlled cooling of said multi-layered dough products, said at least one cooling hood comprises a meshed conveyor and a hood disposed over said meshed conveyor.

13. The system as claimed in claim 1, wherein said conveyor mechanism comprises a belt, wherein said belt is sprinkled with flour to prevent sticking of said layers of said multi-layered dough structure on said belt.

14. A method for preparing multi-layered dough products, the method comprising the following steps:

• extruding a plurality of discrete dough layers to form extruded multi-layered dough; billeting the extruded multi-layered dough by punching to form a plurality of multi-layered billets;

rolling the plurality of multi-layered billets by means of a plurality of pin rollers to obtain a rolled billet rolled through 360 degrees; and

heating sequentially on operative both surfaces of rolled multi-layered billets to obtain multi-layered dough products.