RU147571U1 - MACHINE FOR CONTINUOUS CONSISTENT BREWING AND AIR-OXIDATIVE KLEISTERIZATION OF FLOUR - Google Patents

Abstract

A machine for continuous consistent brewing and air-oxidative gelatinization of flour, including a kneading trough installed on the bed with a system of baffles and dividers of mixed mass, a blade shaft, a shaft drive, a flour batcher with controlled continuous feeding of flour, an input flour channel, a continuous custard feeding unit water into the "hot zone of primary mixing and brewing", an air purge system of the custard mass, the outlet discharge unit and the outlet cooled pipe, characterized in that the flour flour channel is directed at an acute angle to the end wall of the trough, with a polished inner surface, and the flour batcher is located at the height necessary to create a sliding flow of flour in the inlet channel; - the flour batcher and the inlet flour channel are equipped externally with flat electric heating elements with thermal insulation supporting required wall temperatures; - the "hot zone of primary mixing and brewing" is separated by a partition from the blown volume of the trough, equipped with a separate lid with a rectangular cutout, and the ki and the bottom along the length of the hot zone of the trough are equipped with electric heating and thermal insulation; - for supplying flour and "boiled" water in the calculated proportions to the "hot zone of primary mixing and brewing" in the form of directed jets found at the "point of primary contact and brewing" on dry and a heated section of the bottom of the trough, the entry of “custard” water into the hot zone is made by a fitting with an adjustable head forming and directing the jet to the “point of primary contact and brewing”; - for the movement of the mixed “initial custard mass” from

Description

The inventive utility model relates to the food industry, namely to the baking industry, and is intended for the manufacture of consistent flour paste gelatin used in the preparation of bakery product tests.

It is known to use a continuous continuous kneading machine for a consistent brewing of flour, which is a kneading trough mounted on a bed in which a blade shaft rotates, with a gear drive from a gear motor with a sector flour dispenser and a drive dependent on the shaft drive. Elements and control devices of such a machine are located in a separate control cabinet [1, p. 189]. A machine of this type can be used for the manufacture of consistent tea leaves after a significant reconstruction with the manufacture of additional devices and components.

The disadvantages of such a reconstructed kneading machine when used for the manufacture of consistent welding are:

- uneven supply and disorganization of the initial contact of flour with "custard" water and further processes of brewing and gelatinization, leading to heterogeneity of the resulting custard mass, as well as increased stickiness and insufficient form-holding ability of the resulting tea leaves for use in the production of bakery products at extreme humidity tests;

- insufficient volume of the trough for preparing the tea leaves and achieving the necessary level of gelatinization, saccharification, homogeneity, as well as the strength and elasticity of gluten at different brewing and dough production rates;

- the impossibility of significant changes in machine performance;

- significant dimensions of additional devices and components that make it difficult to place them in the cramped conditions of existing industries.

The closest analogue of the claimed utility model, taken as a prototype, is the "Machine for continuous consistent brewing and air-oxidative gelatinization of flour", including

- a kneading trough installed on the bed, equipped with a blade shaft, a system of partitions dividing the working volume of the trough into zones of "primary brewing", gelatinization and saccharification, homogenization and fermentation; an output partition made with windows of variable height and cross-section for mass flow, and a system of mass dividers mounted staggered on the side walls of the trough between the shaft blades, a shaft drive made with a belt with pairs of two-strand pulleys, a continuous screw flour dispenser with an adjustable drive, equipped with a loading funnel, a feed channel for flour from the batcher to the trough "primary mixing mixture";

- a unit for introducing “custard” water, with temperature control and regulation devices and a pipe for supplying water to the primary brewing zone,

- a closed system of directed air-oxidative purging of the mass stirred in the trough, including a radial fan, a distribution pipe, inlet and outlet channels made on the side walls of the kneading trough, an expansion outlet box, as well as a separately located dust collector cabinet,

- an outlet discharge unit including an extrusion screw with a drive and an extrusion head and a cooled outlet pipe.

In practical industrial use of the prototype machine

- “primary mixing and brewing” is carried out in the total blown volume of the trough under the influence of air currents and vortices, which spray the remnants of dry flour and cool the mass of tea leaves already in the process of its formation, in connection with which, to achieve the required temperature of the “initial custard mass” and the depth of gelatinization has to further increase the temperature of the "custard" water, which leads to an increase in the stickiness of the gelatinized paste and dough with its use;

- flour and "custard" water in the calculated proportions by mass and temperature are fed into the "zone of primary mixing and brewing"; water through the fitting in the end wall of the trough flows continuously, immediately falling into a relatively cold custard mass mixed on a cold bottom; flour promoted by the auger of the flour batch through the inlet of the flour channel, pushed out of it and poured out along the end wall into a mixed mass; As a result, the primary contact and mixing occurs first between the "custard" water, the cold bottom and the custard mass, and only then with the incoming flour, therefore, the actual ratio of flour and "custard" water in the contact zone differs several times from the calculated ones, as a result of which Kleisterizate, in addition to the necessary colloid, significant amounts of agglomerates of swollen starch grains are glued together with pentose mucus, which makes the klesterizate non-uniform and additional sticky and made using it test, creating problems in the formation of dough pieces, and prevents the achievement of maximum humidity and terms of preservation of freshness of bakery products;

- a closed air purge system includes channels through which fresh air enters, and the exhaust air leaves a trough closed by a lid in a separately located overall dust collector cabinet containing a dust collector system; a separate radial fan is used to supply air and overcome the resistance of a closed system;

- fresh air coming from the fan in the closed volume of the trough mixes with the moist and reaches the surface of the blown mass already in the wet state, which reduces the efficiency of evaporation, cooling and oxidation; in addition, excess pressure and humidity leads to condensation of moisture on the surface of the trough lid window, preventing it from observing the consistency of the mass when it is mixed and quickly correcting the formation of the “initial custard mass” (when the trough lid is opened, the rotation of the shaft automatically stops and mixing stops);

an increase in the tension force leads to additional loads on the bearings, which causes their wear and failure.

- the extrusion auger is calculated and manufactured for a specific consistency and mass feed rate of the paste gel, which does not allow you to quickly change the feed rate of the mass and productivity of the machine; to change the performance of the machine, it is necessary to replace the extrusion screw and its casing; to do this, stop production, dismantle and replace the entire assembly;

- with an increase in machine productivity and paste weight being mixed in the trough, the shaft load increases and the belt drive starts slipping on the pulleys, which leads to fluctuations in the shaft rotation speed and mixing intensity and requires an increase in tension force and frequency of belt replacement;

- an increase in the tension force of the belts leads to additional loads on the bearings and causes their premature failure.

The disadvantages of the utility model of the prototype are:

- the inability to maintain optimal temperatures of flour and "custard" water necessary to achieve complete gelatinization of flour starch;

- the unevenness of the receipt of flour and the inability to ensure continuous primary contact of dry flour with "custard" water in the calculated proportions to obtain the necessary temperature and quality of the "initial custard mass" and then - pasteurized paste, dough and crumb of bakery products;

- the location of the "primary mixing and brewing zone" in the total blown volume of the trough, leading to the formation of flour dust and the need for an additional increase in the temperature of the brewed water, which leads to an increase in the stickiness of the paste gel, which prevents the maximum humidity of the dough and prolongs the freshness of the bakery products;

- excessive complexity, material consumption, dimensions and power consumption of the closed air purge system, insufficient evaporative cooling and the inability to quickly monitor the consistency of the gel paste in the process of mixing to timely make the necessary adjustments in the manufacture of "initial custard mass";

- the impossibility of operational regulation of the feed rate of the paste gel and changes in machine performance and the impossibility of rapid replacement of the working body without stopping production;

- the unreliability of the belt drive, fluctuations in the speed of rotation of the shaft and the intensity of mixing, premature failure of the thrust bearings of the shaft. The objective of the proposed utility model is

- ensuring continuous primary contact of dry flour with "custard" water in the calculated proportions necessary to achieve optimal temperatures and the quality of the initial custard mass, and then - gel paste, dough and product;

- the creation of the possibility of heating supplied to the gelatinization of flour to temperatures optimal for obtaining the "initial custard mass";

- the exclusion of air flows from the "primary mixing and brewing zone", and due to this, - lowering the temperature of the "brewed" water, eliminating the excessive stickiness of the paste and dough to achieve maximum working humidity and preserve the freshness of the crumb of products; elimination of dusting of flour and additional devices for its capture;

- simplifying the design, reducing the material consumption, dimensions and energy consumption of the air purge system, increasing the efficiency of evaporative cooling, making it possible to quickly monitor the consistency of the mixed paste and to make timely adjustments to the manufacturing process of the “initial custard mass”;

- creating the possibility of operational regulation of the feed rate of the paste and the performance of the machine and replacing the working body of the output node without stopping production;

- ensuring the reliability of the drives of the shaft and pump and the intensity of mixing in the entire range of loadings and productivity of the machine.

The task is achieved by the fact that

- in a continuous flour brewing and air-oxidative flour gelatinization machine, which is claimed to be a utility model, including a kneading trough installed on the bed with a system of baffles and dividers of the mixed mass, a blade shaft, a shaft drive, a flour dosing unit with adjustable continuous supply of flour, an input flour channel, knot of continuous supply of “brewed” water to the “hot zone of primary mixing and brewing”, air mass purge system, outlet discharge unit and cooled outlet pipe ;

- the opening flour channel is directed at an acute angle to the end wall of the trough, with a polished inner surface; and the flour batcher is located at the height necessary to create a sliding flow of flour in the inlet channel;

- the flour dispenser and the introductory flour channel are provided with flat electric heating elements and thermal insulation that maintains the required wall temperatures;

- “the hot zone of primary mixing and brewing” is separated by a partition from the blown volume of the trough, equipped with a separate lid with a rectangular cutout, and the walls and bottom along the length of the hot zone are equipped with electric heating and thermal insulation;

- for supplying flour and “scalded” water in the calculated ratios to the “hot zone of primary mixing and brewing” in the form of directed jets found at the “point of primary contact and brewing” on a dry and heated section of the bottom of the trough;

- “custard” water is introduced into the hot zone by a fitting with an adjustable head forming and directing the jet to the “point of primary contact and brewing”;

- for movement of the mixed “initial custard mass” from the “hot zone” into the blown trough volume along the heated trough bottom under the “pushing” action of the shaft blades, space is left under the lower edge of the “hot” partition;

- the rotation of the blade shaft and the pump of the machine is carried out using chain drives;

- blowing of the “initial custard mass”, converted to pasteurizer, is carried out by a directed air flow supplied from the axial fan integrated into the air pipe mounted on the trough through the inclined slot channel made along the length of the trough, and the exhaust air is drawn out freely upward through the cover grill trough;

- the output node of the machine is made up of the output hopper of the trough and the high-pressure screw pump connected to it with the planetary movement of the rotor screw in an elastic cage and frequency control of revolutions, at the output of which, using a quick-detachable connection, a rotary outlet is connected to the outlet cooled pipe supplying gelatin for kneading dough.

A schematic diagram of the machine is shown in FIG. 1 is a longitudinal section and FIG. 2 is a transverse section.

According to the circuit diagram, see FIG. 1 and 2, the pasteurizing machine contains a kneading trough 3 located on the bed 1 with a blade shaft 6 with blades 7 mounted in the bearing bearings 2, driven from the gear motor 14 by a chain gear 15, closed by a casing 16, and a transparent glass 23 for receiving flour with flour level sensors 24, a dispenser 19 with a drive 20 controlled by a frequency controller 21, and an input flour channel 22;

- a rotary fitting 33 is inserted into the wall of the hot chamber for forming and directing the jet of “custard” water; at the bottom of the trough, partitions are welded - 9, 10, 11, mass dividers 8 are located on the sides between the shaft blades; a partition 4 is made across the section of the trough, separating the “hot zone of primary mixing and brewing” from the remaining volume of the trough and leaving enough space from the lower edge to the bottom to bring out the “initial custard mass”; outside, a flexible electric heating element 13 is provided on the cylindrical bottom of the hot zone, equipped with a thermostat; the hot zone has a separate cover 5 with a rectangular cutout, and the end wall, sides and the bottom of the trough along the length of the hot zone are covered externally with a layer 17 of thermal insulation material;

- in the immediate vicinity of the "hot" partition 4, a fitting 40 is inserted for supplying prescription vegetable oil; an open system for blowing air of a mixed custard mass contains an axial fan 18 built into the end of the air pipe 36, from which the distribution channel 37 is tangentially diverted, and from it an inclined slotted directional channel 38; the upper perimeter of the blown part of the trough is covered with a protective grill 39, which prevents contact with the rotating blade shaft, but does not create obstacles for the free exit of the exhaust air and visual observation of the consistency of the mixed paste; at the end of the trough, an output hopper 12 for receiving the pasteurizer is made, to which a screw pump 42 with a drive 43 connected to the platform 30 with wedge washers 48 is connected to the bottom by flanges 41; at the outlet of the pump, a quick-release nut 44 is fixed to a rotary outlet 45, to which a lead pipe 46 is fixed with a flange connection with an upper branch 47, to which a cooled pipe is connected, which supplies the paste to knead the dough; the control panel 49 is mounted on a platform 50 mounted on a rack 51 mounted on a flange connector on a rack stop 52, rigidly welded into the frame of the bed, and includes a temperature meter-controller 28 and a control unit for feeding flour to the machine 25.

The machine works as follows:

- after turning on the machine, the control unit 25 of the remote control includes an external auger for feeding flour; flour enters the glass 23 and reaches a level in it, automatically maintained between the sensors 24;

- the dispenser 19 evenly and continuously delivers the flour with an estimated capacity through the channel 22 in the form of a jet into the hot “zone of primary mixing and brewing” when passing through the dispenser and the channel the flour is heated to the required temperature;

- "brewed" water with a design capacity and temperature is continuously and evenly fed into the zone from the nozzle 33, directing the jet to the point of contact with the flour;

- dry flour and “custard” water uniformly and continuously contact, mix and form “primary custard masses”, which are advanced by the blades 7, oriented to the maximum shift of the formed “primary custard masses”, from the point of primary contact into a single “initial custard mass”;

- the temperature ratio of dry flour and “custard” water is maintained in such a way that the temperature of the “initial custard mass” exceeds the “brewing point” of 61 ± 1 ° C, in order to maintain heat for further gelatinization, saccharification and homogenization;

- “initial custard mass” after intensive mixing in the “hot zone” is discharged into the blown volume of the trough by the “pushing” shaft blades along the heated bottom of the trough under the edge of the “hot” partition; the presence of 100% humidity in the volume of the "hot zone", intensive mixing and lower output of custard mass exclude breakthroughs of dry flour and dusting;

- gradually the trough is filled with mass up to the level set by the partition 11, and the process becomes stable: a continuous supply of flour and “custard” water at the beginning of the trough and a corresponding exit of the mass through the partition 11 to the output hopper 12, - at the end of the trough

- with vigorous stirring in the blown part of the trough under the influence of oxygen, temperature and its own enzymes of the flour in the custard mass, the stages of gelatinization, saccharification, homogenization and oxygen saturation occur;

- initially viscous and motionless “initial custard mass”, continuously subjected to mechanical stirring by the rotating blades of the shaft and stationary dividers mounted on the walls of the trough, creating a shear motion of the mass layers and accelerating heat and mass transfer; by the end of the trough, it becomes a uniform viscous consistency gelatinizing paste, which allows it to flow through the main partition of the trough into the output hopper, and from it into the inlet neck of the screw pump, the working body of which is a polished steel screw, which performs planetary rotation in an elastic holder;

- the pump of the machine, when pumping the pasteurizer, performs an additional dispersing function, - “crushing” the remaining agglomerates between the screw and the holder, and making the pasteurizer structure thinner, more uniform and fluid;

- in the output hopper of the trough a predetermined level of gel paste is maintained, which provides constant pressure for normal operation of the pump, and the feed rate of the pump with the help of a frequency governor is set so that the level in the hopper remains constant, i.e. how much paste is made and delivered to the hopper, the same amount is pumped to knead the dough;

- when the productivity of the machine changes, along with the change in the supply of flour and water, the pump speed changes and then the maintenance of a constant level of mass in the hopper is controlled;

- a rotary output branch with a quick-detachable connection allows you to quickly, without stopping production (during a normal technological pause), replace the working body, - an elastic pump cage, for this a quick-connect connection is turned off, the tap is removed, and the pump outlet becomes available for replacing the cage; after replacing the clip, the assembly is performed in the reverse order;

- during pumping under high pressure of the mass of pasteurized gel through a cooled pipe, additional mutual penetration and combination of starch colloid and swollen gluten occurs, which leads to an increase in the structural and form-holding action of pasteurizer in the dough;

- when the paste passes through the pipe, its aerobic fermentation continues (for this, the paste contains sufficient oxygen in the air involved in the purging and mixing in the trough);

- the process time (finding the mass in the machine) for constant productivity (flour and water supply) is regulated by changing the height of the partition 11 (level and volume of the mass in the trough);

As a result of the process, a homogeneous gelatinizer with a given final moisture content is continuously obtained, containing a strong and uniform hydrophilic colloid, the optimal amount of Sugars, activated enzymes, involved oxygen, and fortified gluten. The introduction of such a gel paste into the dough provides a form holding at extreme humidity, long-term preservation of the initial freshness and excellent taste of the crumb of bakery products.

Kneading the dough using the thus obtained pasteurizer is carried out in a batch or continuous manner.

The inventive machine for the continuous production of pasteurizer allows you to knead the dough both in continuous mode, simultaneously feeding paste in the mixing zone of the main dough mixer, and in a batch mode, feeding paste through dispensers in the bowl for mixing.

Examples of the manufacture of paste using a machine, as well as the characteristics of the resulting paste, tests and bakery products are shown in table 1.

As follows from the data in Tab. 1, the claimed utility model provides:

- the possibility of heating the gelatinized flour to the required temperature;

- the primary contact of dry flour with "custard" water in the calculated proportions to ensure the optimum temperature and quality of the "initial custard mass", and then - gel paste, dough, product;

- the exclusion of air flows from the "hot zone of primary mixing and brewing";

- lowering the temperature of "custard" water;

- the exclusion of excessive stickiness of pasteurization and the achievement of maximum moisture and freshness of the crumb products;

- elimination of dusting and the need to use dust collecting devices;

- simplification of design, reduction of material consumption, dimensions and energy costs of the air purge system; increasing the efficiency of air-vapor cooling of the paste;

- the possibility of operational control of the primary contact of flour and "custard" water in the hot zone and the formation of the "initial custard mass";

- the possibility of operational control of the feed rate of the paste gel when the productivity of the machine;

- non-stop operation of the machine in the entire range of productivity;

- the reliability of the drives of the shaft and pump of the machine and the intensity of mixing.

Information sources:

1. Tsyganova TB “Technology of baking production”, M. Profizdat, 2001

2. RF patent No. 73767, A21C 1/06, 2006

Claims (1)

A machine for continuous consistent brewing and air-oxidative gelatinization of flour, including a kneading trough installed on the bed with a system of baffles and dividers of mixed mass, a blade shaft, a shaft drive, a flour batcher with controlled continuous feeding of flour, an input flour channel, a continuous custard feeding unit water into the "hot zone of primary mixing and brewing", an air purge system of the custard mass, an outlet discharge unit and an outlet cooled pipe, characterized in that - the input flour channel is directed at an acute angle to the end wall of the trough, with a polished inner surface, and the flour batcher is located at the height necessary to create a sliding flow of flour in the input channel; - the flour dispenser and the inlet flour channel are provided externally with flat electric heating elements with thermal insulation that maintains the required wall temperatures; - the "hot zone of primary mixing and brewing" is separated by a partition from the blown volume of the trough, equipped with a separate cover with a rectangular cutout, and the walls and bottom along the length of the hot zone of the trough are equipped with electric heating and thermal insulation; - for supplying flour and "boiled" water in the calculated ratios to the "hot zone of primary mixing and brewing" in the form of directed jets found at the "point of primary contact and brewing" on a dry and heated section of the bottom of the trough, introducing "boiled" water into hot the zone is made by a fitting with an adjustable head, forming and directing the jet to the "point of primary contact and brewing"; - for the movement of the mixed “initial custard mass” from the “hot zone” into the blown trough volume along the heated trough bottom under the “pushing” action of the shaft blades, a space is left under the lower edge of the “hot” partition; - the rotation of the blade shaft and the pump of the machine is carried out using chain drives; - blowing the "initial custard mass", converted into pasteurized paste, is carried out by a directed air flow supplied from the axial fan integrated into the air pipe mounted on the trough through the inclined slot channel made along the length of the trough, and the exhaust air is drawn out freely upward through the cover grill trough; - the output unit of the machine is made up of the output hopper of the trough and the high-pressure screw pump connected to it with the planetary movement of the rotor screw in an elastic cage and frequency control of revolutions, at the output of which, using a quick-detachable connection, a rotary outlet is connected to the outlet cooled pipe supplying gelatin for kneading dough.

Images