Apparatus and method for continuous rework fermentation

Abstract

A method and system for the reclamation and re-use of rework dough created in the process of forming a final good. Initially, the reworks are formed into a batter into which a catalyst is placed. Subsequently the batter is cooled and stored until it is added to a new batch of dough. Through this method and system there may be a nearly total re-use of rework dough.

What is claimed is:  
     
         1 . A method for the reclamation and use of rework dough created in the process of forming a final good comprising the steps of: 
 providing a rework dough;    adding water at a first temperature above ambient temperature and a catalyst to said rework dough;    mixing together said rework, said catalyst, and said water to form a reprocessed dough batter, thereby raising the temperature of said reprocessed batter to a temperature which is substantially equal to that of said first temperature;    cooling said reprocessed batter to a second temperature; and    adding said reprocessed batter to a new batch of batter.    
     
     
         2 . The method of  claim 1 , wherein said cooling to said second temperature is done in a controlled manner with regards to time and rate.  
     
     
         3 . The method of  claim 2 , wherein said reprocessed dough batter is held at said second temperature until said reprocessed dough batter is added to said new batch of dough in a ratio of approximately 1.3:1.  
     
     
         4 . The method of  claim 1 , wherein said hot water is added to said dough reworks at a temperature in the range of about 80 degrees Fahrenheit to about 110 degrees Fahrenheit.  
     
     
         5 . The method of  claim 4 , wherein the temperature of said hot water is between approximately 90 and 105 degrees Fahrenheit.  
     
     
         6 . The method  claim 1 , wherein said catalyst comprises dextrose, sugar, wheat gluten, an enzyme and a carrier.  
     
     
         7 . The method of  claim 6 , wherein said enzyme is L-cystine.  
     
     
         8 . The method of  claim 6 , wherein said carrier is selected from the group consisting of flour and soy.  
     
     
         9 . The method of  claim 8 , wherein said catalyst preferably comprises about 58-62% of sugar, 18-22% of dextrose, 8-12% of wheat gluten, 0.75-1.50% of L-cystine; and 8-12% of flour by weight.  
     
     
         10 . The method of  claim 1 , wherein said batch of reprocessed batter includes approximately 33-38% said water, 58-62% said rework dough and 3-6% of said catalyst by weight.  
     
     
         11 . The method of  claim 1 , wherein said second temperature is in a range of 38 to 54 degrees Fahrenheit.  
     
     
         12 . The method of  claim 11 , wherein said second temperature is preferably about 40 to 50 degrees Fahrenheit.  
     
     
         13 . The method of  claim 12 , wherein said second temperature is achieved by the steps of: 
 pumping said reprocessed dough batter to a heat exchanger;    cooling said reprocessed dough batter in a controlled manner from said initial temperature to said second temperature in approximately 30 minutes.    
     
     
         14 . A catalyst for the reuse of rework dough produced during the production of baked goods to produce a reprocessed batter comprising dextrose, sugar, wheat gluten, an enzyme and a carrier.  
     
     
         15 . The catalyst of  claim 14 , wherein said enzyme is L-cystine.  
     
     
         16 . The catalyst of  claim 14 , wherein said carrier is selected from the group consisting of flour and soy.  
     
     
         17 . The catalyst of  claim 16 , wherein said catalyst preferably comprises about 58-62% of sugar, 18-22% of dextrose, 8-12% of wheat gluten, 0.75-1.50% of L-cystine, and 8-12% of flour by weight.  
     
     
         18 . The catalyst of  claim 16 , wherein about 20 pounds of said catalyst preferably comprises about 12 pounds of sugar, 4 pounds of dextrose, 2 pounds of wheat gluten, 4 ounces of L-cystine, and 2 pounds of flour.  
     
     
         19 . A system to reclaim rework for use in producing a dough comprising: 
 a mixer adapted to mix a rework, hot water and a catalyst into a reprocessed batter;    a heat exchanger adapted to cool said reprocessed batter;    a first transport system to move said reprocessed batter from said mixer to said heat exchanger;    a holding tank adapted to store said reprocessed batter at a given temperature; and    a second transport system to move said reprocessed batter from said heat exchanger to said holding tank.    
     
     
         20 . The system of  claim 19 , wherein said mixer includes a mixing vat capable of mixing said rework, said hot water and said catalyst into a homogenous mixture in a mixing time period of about 90 seconds or less.