RU2005379C1 - Kneading device and dough paste production method - Google Patents

Abstract

FIELD: baking industry. SUBSTANCE: in kneading device body there are working tools having kneading augers and cutting members alternating in the product advancement direction. The augers mix and advance dough along the body, and the members regularly cut dough. Extrusion is performed in a screw extruder or on rollers. The temperature of dough with moisture content 25-40% mass does not get higher than 50 C, and kneading is done within 6-60 s. EFFECT: higher efficiency. 13 cl, 11 dwg

Description

 The invention relates to a kneading device and a method for preparing raw dough for pasta.

 A known method of preparing a pasty mass, including mixing the starting components in the working chamber using two kneading bodies mounted on parallel shafts, extruding the resulting dough and cutting it into pasta.

The invention is based on the object of providing an apparatus for the manufacture of products testoprigotovleniya not Fills improve dough temperature above 60-70 ° ^C. To this technology until recently been used almost exclusively for open trays dough mixing all components with the subsequent installation of one or more single-shaft screw for the formation of a protein skeleton or for dough preparation and increase the pressure necessary for the final molding from 80 to 120 bar. Thus, it is possible not only to control the temperature, but also to lower it significantly below the critical point of 60-70 ^о С, due to which the product is not exposed to irreversible harmful effects. The simplest proof of this is that the scraps formed after molding can be reloaded into the original raw dough without sacrificing its quality.

 The task is carried out using a device containing a closed housing with an opening for supplying components and an unloading nozzle, continuous working bodies installed on the shafts on the shafts - kneading screws and cutting elements. It is preferable to make the first set of kneading augers in the form of a feeding screw pair, and the last set in the form of a pushing screw pair.

 Most preferably, the sequential installation of three or more sets of screw pairs, between each of which a set of pairs of cutting elements is installed. In another preferred embodiment, the working shafts can be made to rotate in one direction, the two shafts having one drive designed for at least 200 rpm, preferably 20-100 rpm: especially 40-70 rpm. In general, working shafts can rotate in opposite directions. The advantage of this option is the structural simplification of the device or drive. You can also apply more than two, for example three or more interacting shafts with different kneading, feeding or braking effects.

It is recommended to place a cooler or heat exchanger in a stationary housing. This makes it possible to heat before operating the entire apparatus to the optimum processing temperature since at low temperature, for example less than ²⁰ ° C, testoprigotovlenie difficult and slow.

 Pipes for supplying components, especially grits and water, are located directly on the first section of the device, equipped with screw elements and made as a two-roll low-pressure dough mixing machine. Most preferably, the device is implemented as a short low-pressure kneading machine, which is installed in combination with a long single-roll extruder for preparing pasta. A single-roll extruder partially fulfills the task of homogenization along with a significant increase in pressure. At the same time, it turned out to be possible to achieve optimal load sharing in comparison with the option having only two separate devices; since the dough preparation from the point of view of the protein skeleton in the dough mixing machine is completed, although the dough is moisture, but not sticky, due to which the transfer is not fraught with the danger of sticking or blockage and can occur simply under the influence of its own weight. In this regard, it is preferable to make the outlet open, i.e., without an extrusion nozzle. This hole is preferably smaller than the cross section of the twin cylinder, but larger than the free working section between the shafts and the twin cylinders. The last set of cutting elements cuts the dough into segments and without increasing the pressure in the area of the discharge tip, the last set of screw elements in the direction of the test passes unloads the pieces of dough.

 The active length of the screw of the single-roll screw extruder is preferably not less than twice the active length of the working body of the kneading device, and it is most preferred that the screw of the roller screw extruder as a whole has a length of not less than 2.5 times longer than the length of the working body of the kneading device .

 For the highest quality pasta, a nozzle is preferably installed between the two-roll low-pressure dough mixer and the single-roll screw extruder to reduce air pressure.

 In the mold area of a single-roll screw extruder, you can place a pump for the manufacture of products such as cannelloni or ravioli.

 The invention also relates to a method for preparing raw dough for pasta with a moisture content of 25-40 wt. %, which during the final pressing using a screw press or during further processing by rollers gets the desired shape and cut.

 The purpose of this method is to simplify dough preparation, especially creating the possibility of its better control, with achieving the highest quality of the final product, while simplifying the solution of hygiene problems.

As a result of the method, a dough with a moisture content of 25-40 wt. % For the pasta, the dough temperature during testoprigotovleniya is 20-70 ^C, preferably 40-50 ^{° C,} and the process itself testoprigotovleniya performed for 6-60 seconds.

 As a result of the implementation of this method, thermal co-generation of test proteins is prevented.

 The method is as follows.

 The initial components are processed at the first stage by an interacting pair of working shafts by alternately sequentially kneading and cutting to obtain an unpressed raw dough, and at the second stage, the raw dough is homogenized in a single-roll press or given to its desired shape using high-pressure test rolling rollers or rollers.

 This method for the first time allows you to separate the actual preparation of the dough (especially dough with a low moisture content: below 40% or even below 34% of the tasks of shaping). Optimal dough preparation can occur much more efficiently, since, as it turned out, the number of the mechanical cutting process is possible only when the cut pieces are separated from each other in space or are able to move. One piece must be able to move away from the other, which is impossible in the case of a compact, high-pressure dough. With a compact dough mass, you can rather talk about a viscous flowing form, but you can’t cut the liquid. However, the comprehensive relationship of the protein skeleton causes a multiple mechanical shift of individual sections of the test and at the same time the most uniform distribution of moisture.

 Raw dough is transferred from the first stage to the second, preferably without pressure. Most preferably, the portioned ejection of the dough from the first stage and its hit by its own weight directly into the second stage for the formation of a monolithic homogeneous mass.

Preferably, a vacuum is created in the transfer zone by connecting the appropriate space in which the transfer takes place to the vacuum pump, which prevents the presence of air inclusions in the prepared dough. Thus, the product can be processed continuously in less than 50 seconds at a product temperature of ^about 40-70 C, preferably 40-50 ^{° C,} and translate it into finished form.

 It is most preferable to make working bodies from two interacting shafts, each of which contains kneading screws and cutting elements alternating in the direction of product passage, the discharge tip being made without a mold. In this case, the kneading augers preferably have a forced feeding effect, and the cutting elements have a self-braking effect. This creates a self-cleaning effect. The product moves even in case of idling. In addition, the cutting elements preferably have a shape that is effective over the entire section. This allows an ideal kneading action at low power consumption and without a significant increase in pressure. The effect of rolling with a screw pair and the effect of cutting or breaking dough are used. With good mixing of the loaded components and their uniform distribution, only what is needed for the dough preparation, especially for creating a good protein skeleton, is done. In numerous tests, only once was a slight increase in the temperature of the product established, that is, the claimed solution allows you to create a technology in which no shortcomings have yet been discovered. Production tests showed that the power spent on dough preparation is approximately the same as was required so far on the drive of the kneading rolls of a bowl. The minimum consumption ensures the creation of a good protein skeleton without any local temperature increase. In the preparation of dough, the product does not have the opportunity to get into any "dead zone", so that every grain or particle of flour is used in the dough. The finished product does not have unprocessed areas. All this allows us to conclude that the claimed solution can still ensure high quality of dough preparation, which has not yet been achieved; high pressure is not required. The cutting elements cut the dough into pieces. This could not be achieved at high pressure. The dough preparation process is sharply reduced in time and in terms of design costs, which could not be achieved when preparing a relatively dry dough containing 25-40% moisture, more precisely 28-32%, despite the fact that research has been carried out for at least ten years direction.

 In FIG. 1 shows a kneading device, partially in section; in FIG. 2 - interaction of the working elements of FIG. 1, in plan; in FIG. 3 is a section AA in FIG. 2; in FIG. 4 is a diagram of an embodiment of FIG. 1; in FIG. 5 is a side view of FIG. 4; in FIG. 6 - preferred use of a kneading device for the production of pasta; in FIG. 7 is a device similar to FIG. 6, but for the production of products such as cannelloni or ravioli; in FIG. 8 - connection of the kneading device with dough rolling rollers; in FIG. 9 is another embodiment of a kneading device with direct transfer of raw dough to a single roll extruder; in FIG. 10 is a diagram of the angular docking of a kneading device with a single-roll extruder; in FIG. 11 is an embodiment of FIG. 9.

 In FIG. 1 shows a kneading device 1, the upper part of the closed housing 2 of which is not shown for clarity of position of the working bodies 3 and 4. Bodies 3 and 4 contain two clockwise rotating shafts 5 and 6. Shafts 5 and 6 are equipped with an alternately alternating set of kneading screws 7, 8 and 9 or 7 ', 8' and 9 'and a set of cutting elements 10 and 11 or 10 ', 11', mounted on shafts 5, 6, made as splined shafts. The components are fed into the kneading device through the feed opening 12. Liquid components, such as water or protein suspension, enter through a nozzle 13 located immediately adjacent to the feed opening 12. Both the hole 12 and the nozzle 13 are placed in the region of the first screw 7 or 7 'made in the form of a screw pair 14, simplified shown in FIG. 4.

 In FIG. 2 shows, in an enlarged section, two screw pairs 8, 8 ′ and 9, 9 ′, as well as a kneading screw pair 11, 11 ′ located between them. The dough is forcibly advanced by screws 8, 8 ', 9, 9' and in the housing 2. At the same time, it passes through a pair of cutting elements 11, 11 '. Each set of cutting elements 11, 11 'consists in the shown example of three polygonal disks 15, which, rotating like a gear with three teeth, but in one direction, cut through the entire cross section of the body, which has the shape of a lying eight. Threefold repetition of polygonal disks 15 and their transverse movement in one direction creates a sequential effect of cutting and dividing into pieces the product originally moved by the screws in the direction of the axes. This turned out to be most preferable in the case when the section not filled with the product consists only of thin-walled “cylindrical segments”, that is, the screw line of the screw has a small “T” value.

 In FIG. 3 shows the discharge end of the kneading device 1. In this case, the product, divided into pieces by the cutting elements 11, 11 ', is pushed out by pieces using the ejector screw pair 9, 9' through the free discharge opening 16. The drive 17 of the shafts 5 and 6 not shown is mounted on the side loading hole, so that in the shown example, the shafts 5, 6 are cantilevered on the drive side. This allows you to simplify the installation and dismantling of the working bodies, especially for cleaning the entire working volume, removing, for example, the working body in the direction of the discharge opening 16.

 In FIG. 4 and 5 show the same kneading device as in FIG. 1, 2 and 3, but with a heat exchange system 20, in which, for example, heated water enters through the inlet pipe 21 and is discharged through the outlet pipe 22.

 In FIG. 6 schematically shows the most preferred embodiment of the invention for the production of pasta such as spaghetti, vermicelli, pasta, etc. Dry components, grains or flour are fed through a funnel 30 with a dispenser 31 and are fed by a feeding screw 32 to the feed opening 12 and to the initial section of the input screw pair 14 or directly to this screw pair. Precisely calculated on the performance of the dispenser for the dry component, the amount of water is discharged from the reservoir 33, made in the form of weights, and is pumped to the dry components or to the inlet screw pair with a pump 34. Depending on the variety of the target product, for example, protein suspension from the second reservoir 34 ′ can be added to the mixture. One can imagine, however, that these tanks store water with different temperatures, which allows you to adjust the downloadable components to a strictly defined water temperature. This is one of the measures to maintain control of the processing temperature in extreme situations, for example, after interruptions in work, changes in productivity or at the initial start-up of the machine. In FIG. 6 shows a fourfold alternation of mixing, stirring and cutting. From the free discharge opening 16, the raw dough, divided into pieces, falls in the shaft 35 to the beginning of the single-roll screw extruder 36. This extruder contains a pressing screw 37 in a cooled casing 38. At the end of the pressing channel there is a forming head 39 with a mold 40 installed in it The single-screw screw extruder is a special design designed for extrusion, in which immediately before the mold in the distribution tip 41 the pressure should increase, for example, from 80 to 120 bar, so that that still has a large vyazkotekuchestyu could forced through a shaped hole. In contrast to this extrusion action of a single-roll screw extruder, the kneading device is not an extruder. All elements of the working unit, as shown in FIG. 6 are adjusted and coordinated by a common program control unit 42. In FIG. 7, the active working length of a kneading device and a single-roll screw extruder can be compared.

It can be seen that the homogenization of the dough is best achieved by raising the pressure with a relatively long single-roll extruder. On the contrary, as shown by tests with long working bodies of the kneading device, this does not give any positive effect, but only increases power consumption and promotes heating of the product. The best results are achieved with a ratio of L _e / L _m = = 2: 1. From general design considerations, this ratio is selected at least 2.5: 1.

The best performance is achieved when the kneading device active length L _m refers to the inner diameter D _i with a value of about 3-7.

 In FIG. 7 also shows the possibility of manufacturing products with filling, such as cannelloni 52 or ravioli 53. The filling, which may be meat, vegetable or sweet, is fed from the tank 50 by a special pump 51 through the corresponding channel directly into the product located in the forming head.

 In FIG. Figure 8 shows another interesting embodiment of the invention for rolled pasta. Pieces of dough falling from the kneading device 1 fall into the pre-calibration rollers 60 and the resulting tape is fed to the calibrating rollers 61. The dough tape is cut first with a longitudinal knife 62 and then with a transverse knife 63 into plates, the moisture content of which is then brought to a value in the dryer at which the product can be stored.

 The invention can also be applied to the manufacture of a number of other products, for example puff pastry or bread flour.

 In FIG. 9 it is shown that water is dispensed through the pipe 70 directly into the kneading device 11. The dry components are uniformly fed through the feed tip 71. They are moistened already in the inlet section, mixed together and enter the multiple kneading zones. Here you get a loose dough. If the outlet end 73 of the kneading device 11 is freely open, slices of such a dough are 1-5 cm in size, sometimes almost from the palm, and a structure similar to a bread crumb. If this outlet end is narrowed, a “sausage” of the same structure but infinite shape is formed. In both cases, however, the loose dough does not yet have the structure of a compact, uniform dough. If you break a piece of such a test, you can easily establish that we can talk about a real test with its inherent non-stickiness and plastic-elastic properties. Microscopic analysis shows that the loose dough at the outlet end of the kneading device 11 actually already has a fully formed protein composition. Since, however, we are talking about dry dough, to which molding pressure of about 80-100 bar and higher was still applied, such a dough gives the impression of friable.

Preparation of loose dough is as follows. The starting components — water and grits or flour — are fed to the inlet of the kneading device 11. In FIG. 9 and 10 kneading bodies are shown horizontally in a plan view. The side entrance is shown vertically. In other words, the kneading bodies are rotated by 90 ^about a vertical image plane, as indicated by the cut lines 73. The starting material the gripping elements 74 in the entry area 75 of the two drive shafts 76, 77 and fed to the right along arrow 78 into the first zone 79 mashing.

 In the kneading zone 79, a pair of rotating kneading augers 79 is installed on each working shaft 76, 77. Both working shafts 76, 77 rotate in the same direction (arrow 80) and engage with each other like a worm with a worm gear. This creates a twofold action, product transportation (arrow 78) and a seal, in which a compacted mass is formed. This mass undergoes preliminary kneading in the first kneading zone using kneading augers 79.

 Kneading augers 79 'can be designed to easily create both a backwater and a feed. The mass leaving the kneading zone 79 through the cutting zone 81 is pressed in the second kneading zone 82, also with forced translational movement. In the next cutting zone 83, the formation of the protein skeleton is completed. Moreover, in the kneading zone 79, the same or different kneading elements can be used alternately. In general, the impact of mechanical pressing forces occurs deliberately on very small sections of the dough, due to which unnecessary efforts of general compression and the resulting friction are not created.

 This is the reason for the very small temperature increase compared to existing kneading devices. At the end of the kneading zone, the dough mass falls onto the ejector screw 84 or passes through the corresponding outlet zone 85 and is fed from the end 72 for further processing. The two-roll kneading device shown has a particular advantage in that it operates with a high degree of self-cleaning. Ejection of the dough can be carried out, depending on the design of the outlet end, either in pieces or, with a certain narrowing of the hole and a corresponding increase in pressure, in the form of a continuous sausage.

 The working bodies operating in separate working areas can, of course, have a different shape, for example, in the form of disks with holes, have protrusions or pins directed from the outside to the inside, etc.

 In the embodiment shown in FIG. 9 and 11, the friable dough is directly transferred to the screw 86. This screw may already be the extrusion screw 87 itself, as shown in FIG. 10. However, it is important, however, that this screw 86 has a higher conveying capacity than the kneading device 11, which prevents an uncontrolled increase in pressure in the kneading device and, thus, the danger of an uncontrolled increase in temperature. The transfer of friable dough from the kneading device 11 to the screw 86 is carried out by cutting off the test cast coming to the screw 87.

 FIG. 10 should be considered in view of the fact that individual shafts, shown as single, may in reality be three or more shafts.

 PRI me R 1. Spaghetti, diameter 1.75 mm.

 Starting materials - 100% Durum Dunst grains, particle size less than 0.350 mm protein 14.1% / dry.

 things. ash 0.90% / dry.

things. crude gluten 34% water at a temperature of 40 ^about
The starting materials are continuously charged using a batcher with a capacity of 500 kg / h to the mixer. Number of revolutions of screw 42 rev / min, the cylinder temperature was set ^to 35 C. After 16 hours of operation the dough pieces fed into the pressing extruder.

Press Parameters:
screw rotation speed of 20 r / min Cylinder temperature 28 ^{° C} head temperature 35 ^{° C} pressure 110 bar 0.85 bar vacuum
The formed spaghetti at the end of pressing is hung up on a stick and dried in a dryer to an H ₂ O content of 11.5%.

 Definition of quality. Spaghetti made by the proposed method, externally do not differ from ordinary ones. Achieve the usual transparency for products from "Durum" after boiling. No insoluble white inclusions were found. The quality of the welded product is very high. After 12 minutes of cooking, the quality of "readiness for taste" is achieved. The stickiness and loss on boiling range within comparable mass-produced products.

 PRI me R 2. Pasta with a diameter of 5 x x 3.2 mm

Raw materials 50% Kibble "Durum Dunst"
50% wheat flour
water Quality of the initial mixture: particle size less than 0.350 mm protein 13.0% / dry. things. ash 0.70% / dry. things. product humidity 12.5% H ₂ O
The initial mixture of 50% "Durum" and 50% wheat flour is continuously loaded using a batcher with a capacity of 1000 kg / h into the mixer and knead for 6 s in a homogeneous raw dough. Unlike Example 1, the raw dough does not fall freely on the pressing screw, but tears off when it is rotated in accordance with FIG. 9.

 Placement of the mixer and the press screw can be any. The transfer of raw dough to the pressing screw takes place in the rarefaction zone without mold pressure and therefore does not exceed 50 bar.

Press Parameters:
- dispenser - productivity 1000 kg / h of dry matter
dough humidity 31% H ₂ O
- mixer rotation speed 60 rpm cylinder temperature 30 ^about With the ratio of DL. / diam. 1: 7
- pressing screw rotation speed of 28 rev / min Cylinder temperature 28 ^{° C} head temperature: 45 ^{° C} pressure 105 bar 0.9 bar vacuum
The pasta is dried analogously to example 1.

 Evaluation of product quality. Appearance during storage: transparent, smooth, without inclusions of grains, color yellow, as with products of this type.

 After cooking: the water remains transparent, the shape remains, do not coagulate, the surface is not slippery, do not stick together.

 PRI me R 3. Egg horns with a diameter of 5x3 mm, a length of 25 mm

Raw materials - 100% wheat flour protein 12.5% dry. things. ash 0.48 dry. things. humidity 13.1% Н ₂ О number of eggs 3 per 1 kg of flour
The starting materials are fed with a dispenser with a capacity of 700 kg of dry matter per 1 h to the mixer and processed to obtain a raw dough similarly to examples 1 and 2.

 At the mixer output a granulator is installed for falling pieces of dough. Transfer to the press auger is carried out by free fall during rarefaction.

Preparation parameters - dispenser capacity 700 kg / h dough humidity 31% Н ₂ О
- mixer, screw rotation speed of 50 rpm cylinder temperature 40 ^about With the ratio of DL. / diam. 1: 7
Screw composition
a) inlet screw
b) cutting and feed elements
c) kneading auger as a pushing pair
- pressing screw, screw speed 24 rev / min Cylinder temperature 28 ^{° C} head temperature 40 ^{° C} pressure 110 bar 0.9 bar vacuum
The horns cut on the mold are dried in a vibratory pre and outlet dryer.

Assessment results: during storage: horns are yellow, like products of this type, transparent without the inclusion of grains, smooth surface; after cooking: cooking time 10 minutes water absorption 210% cooking loss less than 5
non-sticky, smooth surface, preservation form, taste is standard, without taste.

 PRI me R 4. Ears, two-bladed.

Raw materials: - 100% fine-grained wheat grains, particle size less than 0.250 mm protein 13.5% dry. things. ash 1.00% dry. things. humidity 13.6% H ₂ O.

The dry matter together with water to a dough moisture of 32% H ₂ O is treated in a mixer in a raw dough. Instead of direct feeding to the auger, pieces of dough are fed by a conveyor to the built-in pasta press and from it to the feeding auger, and then pressed into ears.

Cooking options
- dispenser - dry matter productivity 800 kg / h - dough humidity 32% N ₂ O
- mixer analogously to Example 3 - molding unit feed screw 31 rev / min - pressing screw 24 rev / min - barrel temperature 25 ° ^C - head temperature 35 ^{° C} - pressure 110 bar - 0.9 bar vacuum
Final drying is carried out analogously to example 3.

 Evaluation results. When comparing with standard products obtained results similar to example 3. The resulting product is not inferior to standard. (56) U.S. Patent No. 3,819,837, cl. A 21 C 1/06, 1972.

 U.S. Patent No. 4,296,582, cl. A 21 C 3/04, published. 1981.

Claims (12)

 1. A kneading device for preparing raw dough, comprising a closed housing with an opening for supplying components and an unloading nozzle, continuous working bodies mounted on the shafts on the shafts, configured to force feed over the entire working section of the housing, characterized in that each of them contains kneading screws and cutting elements alternating in the direction of product supply, the first pair of screws being the feeding pair, and the last pair of screws being the pushing pair, while in the case Execute additional holes for separately supplying the components, all the holes are placed on the feeding screw portion of the pair.  2. The device according to p. 1, characterized in that the working bodies include at least three consecutively installed screw pairs, between which pairs of cutting elements are installed.  3. The device according to paragraphs. 1 and 2, characterized in that the shafts of the working bodies are mounted for rotation in one direction and have a common drive, the rotation speed of which is less than 200 rpm. / min  4. The device according to p. 3, characterized in that the rotation speed of the drive is 20 - 100 rpm. / min  5. The device according to p. 3, characterized in that the rotation speed of the drive is 40 - 70 about. / min  6. The device according to paragraphs. 1 -5, characterized in that the ratio of the length of the working body to the inner diameter of the housing is 3 -7.  7. The device according to paragraphs. 1 to 6, characterized in that it is equipped with a single-shaft screw extruder connected in series with the kneading device, the active screw length of which is at least two times the length of the working body of the kneading device.  8. The device according to p. 7, characterized in that the length of the screw of the screw extruder is not less than 2.5 times the length of the working body of the kneading device.  9. The device according to paragraphs. 7 and 8, characterized in that it is equipped with a pump connected to a screw extruder in the area of the mold for the manufacture of products such as canneloni or ravnoli.  10. The device according to claim 1, characterized in that it is equipped with several pairs of rolling rollers installed at the discharge pipe. 11. The method of preparation of pasta from dough with a moisture content of 25 to 40 wt. %, providing for the mixing of the components in the working chamber using two kneading bodies mounted on parallel shafts, extrusion and cutting, characterized in that, in order to improve the quality of the products obtained by preventing the dough from heating when kneading above 50 ^o C, the kneading components are forcibly moved along the working chamber without creating additional pressure with periodic exposure to the cutting elements, and the extrusion is carried out in a screw extruder or on rollers.  12. The method according to p. 11, characterized in that the kneading is carried out for 6 to 60 seconds