WO2017207930A1

WO2017207930A1 - Method and device for producing and cooking rusks

Info

Publication number: WO2017207930A1
Application number: PCT/FR2017/051367
Authority: WO
Inventors: Olivier Sergent
Original assignee: Mecatherm
Priority date: 2016-06-01
Filing date: 2017-05-31
Publication date: 2017-12-07
Also published as: FR3052022B1; FR3052022A1

Abstract

The present invention concerns a method for producing and cooking rusks (1) comprising at least the following steps: - cooking a loaf of bread in a loaf pan; - removing said loaf from the pan; - cutting said loaf into slices (2); said method being characterised in that, following the step of cutting the loaf into slices (2), it involves: - arranging said slices (2) on a cooking support (3, 3a), in a vertical or substantially vertical position at a maximum tilt angle (B) of 45° from the vertical, parallel to each other and in at least one row (4, 41, 42), with a spacing pitch (A) of a few millimetres between two slices (2) and, - cooking said slices (2) by convection under the influence of a vertical and/or horizontal flow of heat-transfer fluid in order to obtain the rusks (1). The invention also relates to a device (10, 100) designed specifically for implementing the method.

Description

Method and apparatus for making and baking rusks

The present invention relates to the manufacture of bakery products, pastries or the like.

More specifically, the present invention is in the field of the production of rusks.

The invention relates more particularly to a novel method of making rusks.

Traditionally, in the state of the art, for the manufacture of rusks, is first baked a bread, generally rectangular section, in a closed mold or not, which gives shape to the bread.

The bread thus baked is then removed from the mold and then deposited on perforated supports to undergo a cooling operation, followed by refilling.

These operations are intended to allow a homogenization of moisture on the bread section.

Indeed, if the moisture is not evenly distributed, stains and mottling may appear on the finished rusk.

The bread thus obtained is then cut into slices, and these are placed horizontally, flat on the carpet of an oven, often referred to as "roasting oven" or "toasting oven".

This is the case, for example, in the documents

FR 2 573 736 and FR 985 117 where the rusks are cooked horizontally.

The bread thus generally undergoes a second cooking, or toasting, resulting in the dehydration of the product, and we obtain rusks having a golden and crispy appearance.

In the end, it leads to a product called "dry bread", whose main characteristic is to keep for a long time, because physicochemical reactions related to aging (evaporation, degradation of glutens, etc.) are completed. A traditional line of rusks production generally allows the manufacture of 400 to 800 kg of rusks, which corresponds to several thousand slices to handle.

In the state of the art, the slices of bread are placed individually flat, horizontally, on the carpet of the roasting oven which will allow obtaining the rusks.

This removal operation can be performed by a machine called "binder" which automatically de-stains the breads at the output of the slicer.

However, slices of bread may have a random shape, surface irregularities, and be sticky. It follows that the separation and removal of said slices horizontally on the carpet of the roasting furnace is an extremely delicate operation, and which generates frequent jams, the consequences of which are considerable, especially in terms of loss of products, stop lines, need to set up cleaning operations of said lines, etc.

Regarding the step of toasting slices, it is currently carried out, as already mentioned above, by maintaining said slices of bread flat in the oven.

Consequently, the surface charge per m ² is relatively low, since a slice of bread has a thickness of a few millimeters, of the order of 7 to 16 mm. It is therefore understood that for a large roasting oven surface, only a few products are finally grated.

Then, at the level of the collection of the products, the thousands of rusks that come out of the oven appear on a vast width. This is due to the fact that it seeks to reduce the length of an oven, which must still have a large cooking surface, increasing its width. At the outlet, therefore, the products are separated into several streams of lesser width, to allow batching operations of rusks, which feeds the packaging lines. This is again, particularly delicate operations, because it is necessary to straighten the rusks and pass them in a vertical position to stack them to facilitate the collection.

For example, in the patent document FR 2,573,736 of the state of the art, there is described an apparatus for collecting rusks and straighten them in a vertical position before filling a food store with a wrapper. This device, complicated design, includes a vibrating inclined slide to route the rusks flat and down to the store of the wrapper.

In addition, a shoe is freely movable on the slide. This shoe comprises, on the one hand, means for collecting the rusks sliding flat on the slide and bring them one by one in an oblique position and, on the other hand, means for successively straighten oblique rusks and arrange them vertically the against each other, and continuously, at the entrance to the store.

Here, besides the complicated design of the apparatus, a simple defect or a deteriorated, irregular or broken product can destroy hundreds or thousands of rusks, which is a waste and a loss for the producer.

It follows from the many disadvantages of the current process that the rusks are still difficult to manufacture products, requiring the realization of high investments (large oven area) for a low performance rate (sensitivity of plating operations and collection) which inevitably results in a high cost for the final consumer.

The invention offers the possibility of overcoming the various drawbacks of the state of the art by proposing a new method of manufacturing and baking rusks by means for example of a convection oven in which both sides of the products are exposed to a coolant flow, including sole and vault, said furnace. To this end, the present invention relates to a method of manufacturing and cooking rusks comprising at least the following steps:

- One bakes a bread in a mold;

Said bread is demolded;

- said slice is cut into slices;

Said method is characterized in that, following the step of cutting bread into slices:

- in a vertical or substantially vertical position is arranged at an angle (B) of maximum inclination of

45 ° with respect to the vertical, on a cooking support, said slices parallel and in at least one row with a spacing pitch (A) of a few millimeters between two slices and,

said slices are subjected to convection cooking under the influence of a vertical and / or horizontal heat transfer fluid stream to obtain the rusks. Due to this vertical or substantially vertical position of the rusks, the two faces thereof are exposed to the coolant flows that are generated by the radiators, especially the floor and crown radiators of an oven, for example convection, when roasting of products for the manufacture of rusks.

These flows of heat transfer fluid, arriving at a high speed, come into contact with both sides of all the crackers positioned in the oven, since two crackers that follow in a row are separated by a distance of a few millimeters.

By the implementation of this method, toasting qualities of rusks similar to those obtained by means of the traditional method of producing rusks, when the slices are positioned horizontally, flat, on the carpet of the roasting oven.

In particular, the rusks produced by the present process show a particularly interesting cooking regularity. Positioning the products vertically also causes a reduction in the area of the furnace used for roasting, since said products take up less space than when they are roasted in a horizontal position.

The dimensions are reduced in considerable proportions compared to the oven dimensions that are currently required. Thus, for example, an oven for the implementation of the present process has a size equivalent to half or even third of that of a traditional oven currently used for toasting rusks.

Finally, following the toasting step, the rusks are already stored vertically, for example on cooking media, such as grids, which facilitates subsequent operations, including cooling, gripping, or feeding of packaging lines.

In a most preferred exemplary embodiment, said slices are disposed in a spacing pitch (A) greater than or equal to 5 millimeters between two slices, said spacing pitch (A) being preferably between 5 and 30 millimeters, plus preferably between 8 and 20 millimeters and more preferably between 10 and 12 millimeters.

Such a spacing step between two slices of bread that follow in a row can further improve the quality and especially the uniformity of the crackers.

Preferably, when said slices are subjected to a flow of vertical heat transfer fluid for their firing, the spacing pitch (A) between two slices is substantially proportional, or even more preferably proportional, to the value of the angle (B) d inclination with respect to the vertical.

Such a feature promotes optimal contact between the flow of vertical heat transfer fluid and each point of the two surfaces of the slices of bread to be cooked.

The present invention also relates to a device for manufacturing and cooking rusks specially designed for the implementation of the method of the invention, and characterized in that it comprises at least one cooking support comprising means for holding the slices of bread baked in a vertical or substantially vertical position at an angle (B) of maximum inclination of 45 ° with respect to the vertical, parallel and according to at least one row with a spacing pitch (A) of a few millimeters between two slices.

Advantageously, at the level of said cooking support of the device of the invention, said spacing pitch (A) between two slices is greater than or equal to 5 millimeters, preferably between 5 and 30 millimeters, more preferably between 8 and 20 millimeters. and more preferably between 10 and 12 millimeters.

In a particular embodiment, said cooking support consists of a plate comprising said slice holding means.

In another embodiment, said cooking support constitutes a conveyor belt passing through a cooking chamber and comprising said means for holding the slices in the vertical or substantially vertical position as defined above.

The present device also comprises at least one means for cooking said slices positioned on said cooking support, by convection of a vertical and / or horizontal heat transfer fluid stream and possibly means for loading slices of bread baked on said cooking support. and unloading means at which cooked rusks are removed from the device.

Other characteristics and advantages of the invention will emerge from the following detailed description of non-limiting embodiments of the invention, with reference to the appended figures in which:

FIG. 1 schematically illustrates a longitudinal sectional view of a first embodiment of a biscuit baking device, in the present case an upward and downward vertical air convection tunnel oven, designed for the implementation of the method of the invention and the conveyor belt, or the belt, is directly equipped with a plurality of bread slices holding means able to allow said slices to bake in a substantially vertical position;

FIG. 2 schematically illustrates a longitudinal sectional view of a second embodiment of a biscuit baking device, in the form of an upward and downward vertical airflow convection convection oven and comprising a conveyor belt. standard transport, or conveyor belt, on which is positioned at the input of the device, a cooking support in the form of a plate having a plurality of means for holding bread slices in a substantially vertical position, and removing said plate at the output of said device;

Figure 3 schematically shows in detail and in perspective, a cooking support in the form of a plate that can be implemented in the biscuit baking device shown in Figure 2;

Figure 4 shows a side view illustrating the positioning, either vertically (bottom illustration) or substantially vertical (top illustration) that can take the slices of bread during cooking for the manufacture of rusks, said slices which follow in a row being parallel and spaced apart by a spacing pitch A, said slices being furthermore inclined, with respect to the vertical, by an angle B (top illustration) having a maximum value of 45 °;

Figure 5 schematically shows a side elevational view of another embodiment of a biscuit baking device adapted for carrying out the present process, in the form of a vertical convection oven. by airflow transverse bar equipped with a plurality of cooking supports able to allow vertical maintenance of the slices for making rusks;

- Figure 6 schematically illustrates a longitudinal sectional view of an embodiment of loading means slices crackers on a baking support having means for maintaining said slices in a substantially vertical position.

As shown in the figures of the accompanying drawings, the present invention relates, in particular, to a process for the manufacture and baking of rusks 1, in which, in a usual manner, at least the following steps are found:

- Baking a bread in a mold, the latter can be indifferently open or closed, and advantageously having, but not limited to, a generally rectangular section, round or square;

when cooked, said bread is demolded;

- Optionally and advantageously, one proceeds to a staling step of said molded bread, for example by removing it on a perforated support;

- the bread is cut into slices 2.

In this step of slicing bread 2, the process of the invention implements, in a particularly original manner, the steps described in more detail below.

In a first step, the bread slices 2 are disposed on a cooking support 3, 3a in parallel and in at least one row 4, preferably in a plurality of rows 4, 41, 42, etc., as is visible. more specifically in Figure 3 attached.

Thus, and as illustrated in FIG. 3, it is understood that each of the rows 4, 41, 42, etc., comprises a plurality of slices 2 arranged in parallel, one behind the other, and with a spacing pitch (A). a few millimeters between two slices of bread. According to an essential characteristic of the process of the invention, said slices 2 are arranged, on the cooking supports 3, 3a, in a vertical position, shown in FIG. 4 (bottom illustration) and in FIG. 5, or in FIG. a substantially vertical position, visible in Figures 1, 2, 3 and 4 (top illustration).

Such a feature of the process of the invention is particularly interesting because it allows, in particular, a considerable space saving at the time of the firing step, or roasting, slices 2 to ultimately lead to the production of rusks 1, and this in comparison with the usual processes where the slices are toasted flat.

Another significant advantage of the process of the invention lies in the fact that the rusks 1, after baking slices 2, may already be in a vertical or substantially vertical orientation, for subsequent operations to cooking, including operations packaging and packaging.

In an advantageous embodiment of the process of the invention, slices 2 of bread are provided, for their baking for making rusks 1, on a cooking support 3, 3a, and in a substantially vertical position respecting a angle (B) of maximum inclination of 45 ° to the vertical, as shown in Figure 4 attached.

Such a position, substantially vertical, is advantageous insofar as it makes it possible to prevent deformation or slumping of the slice 2 of bread under its own weight during the disposition of said slice 2 on said cooking support 3, 3a.

Returning now to the arrangement of slices 2 in rows 4, 41, 42, etc., and with reference to FIG. 4, it is particularly advantageous for two successive slices 2 in a row to be spaced apart by one step. spacing (A) of a few millimeters.

Advantageously, this spacing pitch (A) between two slices 2 is greater than or equal to 5 millimeters. Preferably, said spacing pitch (A) between two wafers 2 is between 5 and 30 millimeters, more preferably between 8 and 20 mm and, even more preferably, this pitch (A) is between 10 and 12 mm.

Such a spacing pitch (A) between two slices 2 of bread within a row 4, 41, 42, etc., is particularly interesting because it promotes a contact of the coolant flow on the entire surfaces of the slices 2 for a uniform toasting of said slices 2 to result in a production of rusks 1 of optimal quality.

In a particular embodiment of the method of manufacturing and toasting rusks 1 of the invention, when the slices 2 of bread are fired under the influence of a vertical heat transfer fluid flow, shown in Figures 1 and 2 , the spacing pitch (A) between two slices 2 of bread is proportional, or substantially proportional, to the angle of inclination (B), this angle being always at most 45 ° with respect to the vertical.

In other words, the greater the angle of inclination (B) is and approaches the value of 45 °, the greater the spacing pitch (A), and this to allow optimal contact between the flow vertical heat transfer fluid and the entirety of the two surfaces of the slices 2, during the convection baking step which provides, in the end, the rusks 1 in question.

Indeed, in a second step of the process of the invention, following the step of removing the slices 2 of bread in a vertical or substantially vertical position, these slices 2 are preferentially subjected to convection baking under the influence of a coolant flow substantially vertical and / or horizontal, preferably perpendicular or substantially perpendicular to the direction of movement of the slices 2.

Preferably, the heat transfer fluid flow consists of a hot air flow, and is represented, in particular in FIGS. 1, 2 and 5, by solid arrows, while the direction of displacement of the slices 2 is illustrated, in these same figures, by means of a thick arrow in dashed lines.

When the coolant flow is vertical, it can be upward and / or downward. Thus, in the embodiments shown in FIGS. 1 and 2, in a convection tunnel furnace, for example, this flow may be vertical up and down at a time.

In another embodiment, shown in FIG. 5 illustrating a vertical convection oven, the slices 2 of bread are placed in a vertical position, parallel and in rows, in a plurality of cooking supports 3a, then said slices 2 are submitted. to a flow of horizontal heat transfer fluid while said cooking supports 3a move in a vertical direction within the furnace.

The present invention also relates to a device 10, 100 for the manufacture and baking of rusks 1, specially designed for the implementation of the method of the invention which has been described above.

Said device 10, 100 of the invention comprises at least one cooking support 3, 3a, the latter itself comprising a plurality of holding means 5, 5a respectively, slices 2 of bread in a position that is vertical, or substantially vertical at an angle B of maximum inclination of 45 ° relative to the vertical, parallel and in at least one row 4, 41, 42 with a spacing pitch A of a few millimeters between two slices 2 which follow within 'a row .

Most preferably, in the device 10, 100 of the invention, the spacing pitch A between two bread slices is greater than or equal to 5 millimeters, preferably between 5 and 30 millimeters, more preferably between 8 and 20 millimeters and more preferably still between 10 and 12 millimeters.

With reference to FIG. 1 attached, the cooking support 3 of the device 10 of the invention may constitute a conveyor belt 13, or a conveyor belt, passing through an enclosure cooking a linear tunnel furnace 10 by describing a looped circuit, said conveyor belt 13 itself itself, directly, a plurality of means 5 for maintaining the slices 2 in vertical or substantially vertical position, as defined above. In this case, in FIG. 1, said means 5 for holding slices 2 of bread allow a substantially inclined position thereof.

Most preferably, this conveyor belt 13 is mobile and permeable to the flow of coolant fluid so as to allow the crackling of rusks 1 and, as such, said conveyor belt 13 can be designed openwork with a very open mesh, to allow toasting the rusks by convection, and while allowing assembly of the holding means 5 of the slices 2.

These holding means are configured to maintain said slices 2 parallel and in rows, in a vertical position or, more preferably, substantially vertically and at an angle B of maximum inclination of 45 ° with respect to the vertical, with a pitch of spacing A of a few millimeters between two slices 2.

In another embodiment of the invention, equally advantageous, described with reference to FIGS. 2 and 3 in particular, the device 10 of the invention comprises at least one cooking support 3a in the form of a plate comprising a plurality holding means 5a slices 2 bread in the particular and advantageous position which has been defined in detail above.

In this example, said plate 3a comprising the holding means 5a of the slices 2 in vertical or substantially vertical position is intended to rest on a conveyor belt 13 passing through a cooking chamber of the device 10, for example a linear tunnel furnace, by describing here too a looped circuit.

Whatever the embodiment chosen, said cooking supports 3, 3a and the holding means 5, 5a slices in a vertical or substantially vertical position preferably have a low inertia and are advantageously designed permeable by perforations or openings.

The baking supports 3a, as shown in Figures 2 and 3 for example, may thus consist, for example, grids, grids mesh or perforated plates.

Such cooking supports 3, 3a and holding means 5, 5a are intended to let a coolant flow flow, for example a flow of air, and thus allow toasting or toasting optimal slices of bread 2 to obtain, in the end, rusks 1.

For this purpose, preferably, said device 10, 100 for making and cooking rusks 1 of the invention further comprises at least one means of cooking said slices 2 held in position on their cooking support 3, 3a, said means cooking being by convection of an upward and / or downward vertical heat transfer fluid flow, in FIGS. 1 and 2, and / or a flow of horizontal heat transfer fluid, visible in FIG.

The heat transfer fluid flow is illustrated in the figures mentioned by the solid arrows. To this convection cooking means may also be added a radiation cooking means, not shown.

The means for convection cooking of an ascending and / or descending vertical heat transfer fluid flow, for example a flow of hot air, is implemented for example in a linear tunnel furnace 10 while the horizontal heat transfer fluid flow is used for cooking slices 2 and making rusks 1 in a vertical convection oven 100, shown in FIG. 5, in which the cooking supports, preferably in the form of plates 3a, comprise means for holding slices 2 in a position vertical.

The device 10, 100 for making and cooking rusks 1 also comprises, optionally: - Loading means 11, visible in Figures 1 and 6, slices 2 of bread baked on at least one cooking support 3, 3a, and in the appropriate position described above. An example of such loading means 11 is illustrated in greater detail in FIG. 6 and these loading means 11 may be in the form of a belt conveyor 111 bringing steps 2 of rusk step by step to introduce them at the same time. holding means 5a of the cooking supports 3a advancing step by step also, under said conveyor belt 111;

- Unloading means 12 of the slices 2 once they cooked in the form of crackers 1, and at which the biscuits 1 cooked out of the device 10, 100.

As can be seen in FIG. 1, representing a linear tunnel furnace 10, between the loading means 11 and the unloading means 12 of the slices 2, these are preferably conveyed, through said furnace 10, via the conveyor belt. transport 13, or conveyor belt, mobile and describing a looped circuit.

In the embodiment of Figure 5 illustrating a vertical furnace 100, these loading and unloading means are not visible but they may however be present.

In general, the elements that have been described for the method of the invention can be applied to the device of the invention, and vice versa.

The method and the device 10, 100 according to the present invention, in which the rusks 1 undergo the step of roasting in a vertical or substantially vertical position, for example on grilling plates or grids, make it possible to meet the drawbacks of the traditional methods and especially :

- Securing considerably the post-slicing and pre-cooking preparation operations; - Drastically reduce the surface of the roaster and be able to use, for example, a vertical convection oven 100;

- To secure the cooling, batch preparation and feeding operations of packaging machines.

As a result, the investment required for the production of rusks 1 on an industrial scale is substantially reduced. In addition, the efficiency of the production lines is greatly improved by several percent, the latter being able to finally have, thanks to the process and the device of the invention, much larger capacities than what exists today.

Of course, the invention is not limited to the examples illustrated and described above which may have variants and modifications without departing from the scope of the invention.

Claims

1. Process for manufacturing and cooking rusks (1) comprising at least the following steps:

- We bake a loaf in a mold;

- We unmold said bread;

- Said bread is cut into slices (2);

said method being characterized in that, following the step of cutting the bread into slices (2)

- we place, in a vertical or substantially vertical position at a maximum angle (B) of inclination of 45° relative to the vertical, on a cooking support (3, 3a), said slices (2) parallel and at least a row (4, 41, 42) with a spacing pitch (A) of a few millimeters between two slices (2) and,

- said slices (2) are subjected to convection cooking under the influence of a vertical and/or horizontal flow of heat transfer fluid to obtain the rusks (1).

2. Method for manufacturing and cooking rusks (1) according to claim 1 characterized in that said slices (2) are arranged at a spacing pitch (A) greater than or equal to 5 millimeters between two slices (2). ), said spacing pitch (A) preferably being between 5 and 30 millimeters, more preferably between 8 and 20 millimeters and even more preferably between 10 and 12 millimeters.

3. Method for manufacturing and cooking rusks (1) according to any one of claims 1 or 2 characterized in that, when said slices (2) are subjected to a flow of vertical heat transfer fluid for their cooking, the step d The spacing (A) between two slices (2) is substantially proportional to the value of the angle (B) of inclination relative to the vertical.

4. Device (10,100) for manufacturing and cooking rusks (1) specially designed for the implementation of method according to any one of claims 1 to 3 characterized in that it comprises at least one cooking support (3, 3a) comprising means (5, 5a) for holding the slices (2) of cooked bread in a position vertical or substantially vertical at a maximum inclination angle (B) of 45° relative to the vertical, parallel and in at least one row (4, 41, 42) with a spacing step (A) of a few millimeters between two slices (2).

5. Device (10,100) for manufacturing and cooking rusks (1) according to claim 4, characterized in that said spacing pitch (A) between two slices (2) is greater than or equal to 5 millimeters, preferably included between 5 and 30 millimeters, more preferably between 8 and 20 millimeters and even more preferably between 10 and 12 millimeters.

6. Device (10) for manufacturing and cooking rusks (1) according to any one of claims 4 or 5 characterized in that said cooking support (3a) consists of a plate comprising said holding means (5a) of slices (2).

7. Device (10) for manufacturing and cooking rusks (1) according to any one of claims 4 or 5 characterized in that said cooking support (3) constitutes a transport belt (13) passing through a cooking enclosure and comprising said means (5) for holding the slices (2).

8. Device (10,100) for manufacturing and cooking rusks (1) according to any one of claims 4 to 7 characterized in that it also comprises at least one means for cooking said slices (2) positioned on said support of cooking (3, 3a), by convection of a flow of vertical and/or horizontal heat transfer fluid.

9. Device (10,100) for manufacturing and cooking rusks (1) according to any one of claims 4 to 8 characterized in that it comprises means (11) for loading slices (2) of bread cooked on said cooking support (3, 3a) and unloading means (12) at which the cooked rusks (1) exit the device (10, 100).