U.S. patent application number 10/737953 was filed with the patent office on 2004-07-08 for apparatus and method for cold-proofing multiple dough pieces.
Invention is credited to Guilfoyle, David P., Spillner, Wayne K..
Application Number | 20040131741 10/737953 |
Document ID | / |
Family ID | 25458632 |
Filed Date | 2004-07-08 |
United States Patent
Application |
20040131741 |
Kind Code |
A1 |
Guilfoyle, David P. ; et
al. |
July 8, 2004 |
Apparatus and method for cold-proofing multiple dough pieces
Abstract
An apparatus and method are disclosed that allows multiple
pieces of frozen dough to proof without heat or added humidity. The
apparatus comprises a metal enclosure, devices to support trays of
dough, and doors that allow access to the dough and to selectively
open or close the enclosure, such that in the closed position the
doors substantially seal the apparatus. Within the enclosure, the
frozen dough is thawed, proofed, and held for controlled time
periods at controlled temperatures while placed in a refrigerated
chamber. A particular step may be accelerated under heat.
Inventors: |
Guilfoyle, David P.;
(Columbus, OH) ; Spillner, Wayne K.; (Westerville,
OH) |
Correspondence
Address: |
NEAL, GERBER, & EISENBERG
SUITE 2200
2 NORTH LASALLE STREET
CHICAGO
IL
60602
US
|
Family ID: |
25458632 |
Appl. No.: |
10/737953 |
Filed: |
December 17, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10737953 |
Dec 17, 2003 |
|
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09929882 |
Aug 14, 2001 |
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Current U.S.
Class: |
426/549 |
Current CPC
Class: |
A21D 6/00 20130101; A21D
8/02 20130101; A21C 13/00 20130101 |
Class at
Publication: |
426/549 |
International
Class: |
A21D 010/00 |
Claims
What is claimed is:
1. A method for proofing dough comprising the steps of: thawing
frozen dough at a first temperature above 32.degree. F.; proofing
the thawed dough at a second temperature above 32.degree. F. in a
substantially enclosed environment; and holding the proofed dough
at a third temperature above 32.degree. F. in a substantially
enclosed environment.
2. The method of claim 1, wherein the first temperature and the
second temperature are approximately equal.
3. The method of claim 1, wherein the second temperature and the
third temperature are approximately equal.
4. The method of claim 1, wherein the first temperature comprises a
temperature between approximately 35.degree.-50.degree. F.
5. The method of claim 4, wherein the first temperature comprises a
temperature between approximately 38.degree.-40.degree. F.
6. The method of claim 1, wherein the thawing step is maintained
for up to approximately 12 hours.
7. The method of claim 1, wherein the second temperature comprises
a temperature between approximately 35.degree.-50.degree. F.
8. The method of claim 7, wherein the second temperature comprises
a temperature between approximately 38.degree.-40.degree. F.
9. The method of claim 1, wherein the proofing step is maintained
for up to approximately 24 hours.
10. The method of claim 1, wherein the third temperature comprises
a temperature between approximately 35.degree.-50.degree. F.
11. The method of claim 10, wherein the third temperature comprises
a temperature between approximately 36.degree.-40.degree. F.
12. The method of claim 1, wherein the holding step is maintained
for up to approximately 40 hours.
13. The method of claim 1, wherein the dough comprises a water
activity level of between approximately 0.929-0.999.
14. The method of claim 13, wherein the dough comprises a water
activity level of between approximately 0.940-0.980.
15. A method for proofing dough comprising the steps of:
accelerated thawing of frozen dough at a first temperature between
approximately 40.degree.-100.degree. F. for approximately 40-240
minutes in a substantially enclosed environment; proofing thawed
dough at a second temperature above 32.degree. F. in a
substantially enclosed environment; and holding proofed dough at a
third temperature above 32.degree. F. in a substantially enclosed
environment.
16. The method of claim 15, wherein the first temperature comprises
a temperature between approximately 75.degree.-90.degree. F.
17. The method of claim 15, wherein the thawing step is maintained
for approximately 50-120 minutes.
18. The method of claim 15, wherein the second temperature
comprises a temperature between approximately 35.degree.-50.degree.
F.
19. The method of claim 15, wherein the proofing step is maintained
for up to approximately 24 hours.
20. The method of claim 15, wherein the third temperature comprises
a temperature between approximately 35.degree.-50.degree. F.
21. The method of claim 15, wherein the holding step is maintained
for up to approximately 40 hours.
22. The method of claim 15, wherein the accelerated thawing
comprises presetting the temperature of the substantially enclosed
environment to the first temperature for approximately 30-60
minutes.
23. The method of claim 22, wherein the frozen dough is placed into
the substantially enclosed environment preset to the first
temperature.
24. The method of claim 15, wherein the proofing comprises
presetting the temperature of the substantially enclosed
environment to the second temperature.
25. The method of claim 24, wherein the thawed dough is placed into
the substantially enclosed environment preset to the second
temperature.
26. A method for proofing dough comprising the steps of: thawing
frozen dough at a first temperature above 32.degree. F.;
accelerated proofing of thawed dough at a second temperature
between approximately 40.degree.-100.degree. F. for approximately
40-240 minutes in a substantially enclosed environment; and holding
proofed dough at a third temperature above 32.degree. F. in a
substantially enclosed environment.
27. The method of claim 26, wherein the first temperature comprises
a temperature between approximately 35.degree.-50.degree. F.
28. The method of claim 26, wherein the thawing step is maintained
for up to approximately 12 hours.
29. The method of claim 26, wherein the second temperature
comprises a temperature between approximately 75.degree.-90.degree.
F.
30. The method of claim 26, wherein the proofing step is maintained
for approximately 50-120 minutes.
31. The method of claim 26, wherein the third temperature comprises
a temperature between approximately 35.degree.-50.degree. F.
32. The method of claim 26, wherein the holding step is maintained
for up to approximately 40 hours.
33 The method of claim 26, wherein the accelerated proofing
comprises presetting the temperature of the substantially enclosed
environment to the second temperature for approximately 30-60
minutes.
34. The method of claim 33, wherein the thawed dough is placed into
the substantially enclosed environment preset to the second
temperature.
35. The method of claim 26, wherein the holding comprises
presetting the temperature of the substantially enclosed
environment to the third temperature.
36. The method of claim 35, wherein the proofed dough is placed
into the substantially enclosed environment preset to the third
temperature.
Description
RELATED APPLICATION DATA
[0001] The present Application is a Divisional Application of U.S.
Non-Provisional application Ser. No. 09/929,882, entitled
"Apparatus and Method for Cold-Proofing Multiple Dough Pieces" and
filed on 14 Aug. 2001.
BACKGROUND OF THE INVENTION
[0002] This invention relates to the field of dough proofing in
general, and in particular to an apparatus and method for
cold-proofing or hot-proofing multiple pieces of dough.
[0003] Proofing refers to the leavening or raising of dough. Dough
prepared by mixing flour, water, yeast, carbohydrates, and other
ingredients leavens or rises through yeast growth and metabolism of
carbohydrates. Yeast metabolism of carbohydrates produces carbon
dioxide, which causes the dough to expand, "proofing" the
dough.
[0004] As noted in U.S. Pat. No. 4,674,402 issued to Raufeisen,
proofing is a function of time, temperature, and humidity. U.S.
Pat. No. 4,792,456 issued to Katz discloses that faster proofing is
preferred because it retards microbial growth, improves shelf life
of the finished product, and optimizes quality. Accordingly, U.S.
Pat. No. 5,580,591 issued to Cooley states that proofing is optimal
at elevated temperatures, around 95.degree. F., which increase
yeast activity.
[0005] Along with elevated temperatures, humidity aids proofing by
preventing the dough from drying out. Controlling the level of
humidity during proofing was addressed in the past with devices
using steam generators or humidifiers, which added heated water
vapor to the interior of the proofing device. Such devices are
disclosed, for example, in Raufeisen, U.S. Pat. No. 4,635,540
issued to Dowds, and U.S. Pat. No. 5,072,666 issued to Hullstrung.
In addition to steam generators, Raufeisen and U.S. Pat. No.
4,023,476 issued to Burgess disclose that such devices employed
blowers or air heaters to circulate the heated water vapor inside
the device.
[0006] As acknowledged in Raufeisen, the use of such steam
generators or humidifiers caused problems with condensation and
mineral deposits within the generators, which adversely impacted
steam generation and therefore the level of humidity. Hullstrung
also noted problems with maintaining uniformity in the atmosphere
within such proofing devices. And the use of dough proofed
conventionally at elevated temperatures has been limited by a short
shelf life after proofing, about two to three hours, often
resulting in wasted dough. Problems with proofing conditions have
also been known to affect the quality of dough, yielding dough of
inconsistent or undesirable quality by drying out the dough surface
or impeding yeast growth, which affects the aroma, flavor, and
texture of the finished product.
[0007] Because of the need for elevated temperatures, moreover,
proofing has been accomplished in devices separate from those for
other steps in preparing dough for use in making the finished
product. For example, Raufeisen discusses a process whereby the
dough must be transferred between devices for thawing, proofing,
and refrigerating, requiring intensive labor and effecting less
than ideal conditions for dough development during exposure to
ambient conditions.
[0008] In the past, dough proofing devices have been insulated, as
noted in Raufeisen, and provided enclosed atmospheres of selected
temperatures and humidity levels, as noted in Hullstrung. As
explained in Hullstrung, proofing devices consequently tended to be
elaborate--necessitating not only insulation, but as mentioned
above, steam generators or humidifiers and blowers or air
heaters--and their operation complicated.
[0009] Thus, there is a need for an apparatus or method for
proofing dough that yields dough of consistent and desirable
quality, preferably with an extended shelf life. A need exists also
for an apparatus or method that simplifies dough proofing, for
example, by eliminating the use of externally regulated humidity.
Yet another need exists for an apparatus or method for
cold-proofing multiple pieces of dough.
SUMMARY OF THE INVENTION
[0010] The present invention substantially overcomes the foregoing
problems and achieves an advance in the art by providing an
enclosure defining an enclosed volume in which multiple pieces of
frozen dough can proof. To that end, the enclosure is adapted to
carry multiple dough pieces. The enclosure is preferably thermally
conductive and adapted to be received by a thermally controlled
chamber. In another aspect of the invention the enclosure includes
a door to provide access to enclosed volume.
[0011] In another aspect of the invention, a method comprises the
step of thawing frozen dough at a temperature above 32.degree. F.
The method also includes proofing the thawed dough at a temperature
above 32.degree. F. in a substantially enclosed environment. The
method further includes holding the proofed dough at a temperature
above 32.degree. F. in a substantially enclosed environment for up
to 48 hours.
[0012] The following detailed description and drawings will aid in
better understanding the objects, advantages, features, properties,
and relationships of the present invention. The description and
drawings set forth an illustrative aspect of the invention and
demonstrate the various ways in which the principles of the
invention may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In the drawings:
[0014] FIG. 1 is a perspective view of an exemplary enclosure for
proofing dough, in accordance with an aspect of the present
invention, shown with the doors removed;
[0015] FIG. 2 is an exploded perspective view of the enclosure of
FIG. 1; and
[0016] FIG. 3 is a flow diagram representing exemplary steps in
cold-proofing multiple pieces of dough using the enclosure in
accordance with an aspect of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0017] To create an environment in which multiple pieces of dough
16 can proof, an aspect of the present invention provides an
enclosure 1 defining an enclosed volume 2. Protrusions 3 are
located on the inner surface of the enclosure 1 for supporting
trays 14, which may be slid into the enclosure 1 and supported by
the protrusions 3 or any type of supporting device, such as
shelves. In an aspect of the present invention, the trays 14 are
made of metal or other conductive materials.
[0018] As shown in FIG. 1, the enclosure 1 may comprise half
cavities or volumes created by an optional partition or middle
shelf 4. As will become apparent, adding a partition 4 provides
certain advantages by allowing flexibility in the number of dough
pieces 16 that can be accommodated by the apparatus.
[0019] More specifically, as shown in FIG. 2, the enclosure 1 may
comprise a top 5 and a bottom 6 connected by two side panels 7, 8
and four doors 9, 10, 11, 12, where two doors 9, 10 or 11, 12
stacked end to end extend the length of a side panel, 7 or 8. The
doors 9, 10, 11, 12 allow access to the front and rear of volumes
defined by the enclosure 1 and may be operable in an open or closed
position. While four doors are illustrated, any number of doors may
be used.
[0020] To substantially prevent ventilation and enhance humidity
retention, optional strips of elastic material or gaskets 13 may be
attached to the edges of the side panels 7, 8 or doors 9, 10, 11,
12. The enclosure 1 may also incorporate wheel-mounting plates 14
and wheels 15 for mobility. Any number of wheels or rollers may be
attached to the bottom 6 to impart mobility to the enclosure 1.
Further, no wheels are necessary to practice the invention.
Optional handles 16 may also ease movement of the enclosure 1.
[0021] Although FIGS. 1 and 2 illustrate the enclosure 1 as a
rectangular structure, other shapes may be used that are capable of
creating an enclosure 1. In addition, the enclosure 1 may be
adapted to carry multiple dough pieces 16, which may be referred to
as shells or discs, in a number of ways. The dough pieces 16, may
be placed on trays 14 that are supported by the protrusions 2 or
any type of supporting device, such as shelves. In an aspect of the
present invention, the trays 14 are made of metal, but other
materials can be used without departing from the invention.
[0022] To allow the temperature of the enclosure 1 to readily adapt
to that of the environment external to the enclosure 1, whether
refrigerated or heated, the enclosure 1 comprises a thermally
conductive material, such as stainless steel or aluminum. However,
the enclosure 1 may be comprised of numerous other conductive
materials--including plastic and metal composites. To proof dough
16, the enclosure 1 is placed into a thermally controlled chamber
(not shown). The thermally controlled chamber provides temperatures
utilized in the proofing method of the present invention that are
above or below room temperature.
[0023] In a thermally controlled chamber, the doors 9, 10, 11, 12
of the enclosure 1 may be selectively fixed in an open position to
allow the air of the chamber to flow through the enclosure 1. The
doors 9, 10, 11, 12 may also be set into a closed position to
substantially seal the enclosure 1 and create an internal volume 3
with its own environment. The humidity within this environment may
be regulated by adjusting the amount of dough or number of dough
pieces placed into the enclosed volume 3. This is a result of the
moisture contained in the dough. As the dough thaws, frozen water
molecules melt, which allows the water to evaporate from the dough,
thereby releasing water vapors. Inside the enclosure 1,
substantially sealed, the released water vapors generate and
maintain a naturally humid environment.
[0024] In an aspect of the invention, as shown in FIG. 1, the
partition 4 of the enclosure 1 separates the enclosure 1 into two
sections 20. Any number of sections 20 may be used by adding more
partitions 4, although the following description illustrates only
two sections 20. When the enclosure 1 is used at half capacity, the
two separate sections 3 ensure proper humidity for cold-proofing by
providing the volumes of the sections 3 appropriate for fewer dough
pieces. In essence, the partition 4 allows for micro-environments
for proofing dough, adding flexibility to enclosure 1. Furthermore,
the separate sections 3 preserve the quality of dough by limiting
access--and the accompanying unwanted ventilation--to one cavity at
a time as the dough is accessed for removal from the enclosure 1.
The enclosure 1 allows for consistent cold-proofing of multiple
dough pieces 16, by thawing, proofing, and holding the dough 16 in
a substantially constant environment.
[0025] FIG. 3 is a flow diagram illustrating the method of the
invention. The dough preferably comprises a water activity level of
between approximately 0.929-0.999, as measured against the activity
level of water itself, which is 1.000. This measurement refers to
the amount of mobilized water molecules in the dough. A high level
of water activity ensures that yeast remains active and viable at
the temperatures preferably used in the cold-proofing method of the
present invention. In one aspect of the invention, the dough
formulation comprises a water activity level of between
approximately 0.940-0.980.
[0026] Before beginning the method of the present invention, raw
dough is prepared and divided into pieces, which may be optionally
flattened and shaped into shells or discs, although any other
shapes may be used to practice the invention. At step 315, the
dough is quick-frozen at a temperature between approximately
-40.degree. and -60.degree. F., and after freezing are held at
approximately -10.degree. F. At this temperature the yeast remains
inactive. The dough may then be transported to restaurants for
proofing. To thaw the frozen dough and initiate yeast activity at
step 320, one or more, trays of frozen dough pieces may be stacked
into the enclosure 1, for example, by placing the trays on the
inner protrusions 2. The enclosure 1 may then be placed into a
thermally controlled chamber at a temperature above the freezing
point of water, for example, between approximately
35.degree.-50.degree. F. Alternatively, thawing may occur at a
temperature between approximately 38.degree.-40.degree. F. The
doors 9, 10, 11, 12 of the enclosure 1 may be left open to allow
air flow around the dough, which shortens the time required to thaw
the dough, although the dough pieces will also thaw if the doors 9,
10, 11, 12 are in a closed position. The dough pieces may be thawed
for about half a day.
[0027] At step 325, once the dough pieces thaw, the dough releases
moisture. To create a substantially enclosed volume 2 for proofing,
the apparatus doors 9, 10, 11, 12 are closed, naturally humidifying
the enclosed environment. As the dough pieces continue to release
moisture, the enclosure 1 retains the moisture and thereby
maintains a humid environment. In an aspect of the invention, the
proofing step is maintained for about a day at a temperature
between approximately 35.degree.-50.degree. F. Proofing may also
occur at a temperature between approximately 38.degree.-40.degree.
F.
[0028] At step 330, the proofed dough pieces are ready to be used
in making a finished product and can be held in the environment
with the doors 9, 10, 11, 12 of the enclosure 1 closed. In
particular, the dough can be maintained at a temperature between
approximately 35.degree.-50.degree. F. In another aspect of the
invention, the temperature range is maintained between
approximately 36.degree.-40.degree. F. At the 36.degree.-40.degree.
F. temperature range, the dough pieces last for an extended shelf
life of about a day and a half to two days, thus minimizing waste.
Specifically, dough held at a temperature of approximately
35.degree. F. may have a shelf life of up to two days. Generally,
the shelf life decreases with increasing temperature. The
cold-proofing method of the present invention also accommodates up
to eight hours of access to the dough in the enclosure 1 without
substantially compromising consistency of quality.
[0029] In a further aspect of this method for cold-proofing dough,
the proofing may be accelerated in times of dough shortage or
temperature error during any particular step. FIG. 3 illustrates
how a step prior to the holding in cold-proofing at step 330 may be
expedited. Either the thawing at step 320 or proofing at step 325
may be accelerated by applying heat to the dough. In an aspect of
the present invention, the accelerated thawing at step 340 or
accelerated proofing at step 345 may occur with the doors 9, 10,
11, 12 of the enclosure closed at a temperature of approximately
80.degree. F. for about 60-90 minutes, with the dough formulation
dictating the optimal amount of time. Alternatively, the
accelerated thawing at step 340 or the accelerated proofing at step
345 can occur at a temperature between approximately
75.degree.-90.degree. F. for about 50-120 minutes. Still further,
the accelerated thawing at step 340 or the accelerated proofing at
step 345 can occur at a temperature between approximately
40.degree.-100.degree. F. for 40-240 minutes.
[0030] To accelerate the thawing at step 340 or proofing at step
345, a first enclosure 1 is initially placed--without any dough
pieces and with the doors 9, 10, 11, 12 in an open position--into
the thermally controlled chamber and preheated for about 30-60
minutes. In an aspect of the present invention, the enclosure 1 may
also be preheated for about 40 minutes. Frozen or thawed dough
pieces may then be loaded into the preheated enclosure 1 and
allowed to thaw or proof, respectively, with the apparatus doors 9,
10, 11, 12 closed. Following accelerated thawing at step 340 or
accelerated proofing at step 345, the dough pieces may be loaded
into a second enclosure 1 that has been preset to a temperature
specified for the next step. Cold-proofing may thereafter resume
with the proofing step 325 or holding step 330, as appropriate.
[0031] The invention is not confined to the aspects herein
illustrated and described, and embraces such variations and
modifications as may be within the ordinary skill of the artisan in
this trade and as come within the scope of the following
claims.
* * * * *