Title of Invention

A PROCESS FOR THE MANUFACTURE OF A COMPOSITE BISCUIT WITH MULTIPLE LAYERS

Abstract A process for the manufacture of a composite biscuit with multiple layers having different taste, bite, color and flavor, in said multiple layers, said process comprising the steps of: preparing, in a manner known per se, doughs with different formulations in different mixers to be made into separate layers of dough sheets, each sheet having a desired thickness and different taste, color and flavor; combining the separate layers of dough sheets by merging to form a multiple layer single dough sheet and gauging to reduce the thickness of said multiple layer single dough sheet to the thickness desired in the final biscuit product; cutting the multiple layer single dough sheet into biscuits of desired shapes such that the inner layers are camouflaged and not visible ; incorporating the scrap dough generated in the cutting step, in one or other dough layer at the appropriate position so that it does not alter the visual appearance of said multiple layer single dough sheet of desired shape; and baking said multiple layer single dough sheet of desired shape to form said composite biscuit with multiple layers.
Full Text The present invention relates to a process for the manufacture of a
composite biscuit with multiple layers.
Only two forms of biscuit are conventionally known, namely a single
biscuit comprising (a single layer) and a cream biscuit in the form of a
sandwich comprising two separate biscuits sandwiching creams having
different flavors and colors.
People are always on the look out for products that are different from
classical ones. To cater to such a need a new biscuit with multiple layers
having different taste, bite, color and flavor in a composite biscuit has been
developed in the present invention.
Accordingly, the present invention provides a process for the
manufacture of a composite biscuit with multiple layers having different taste,
bite, color and flavor, in said multiple layers, said process comprising the
steps of:
preparing in a manner known per se, doughs with different formulations
in different mixers to be made into separate layers of dough sheets, each
sheet having a desired thickness and different taste, color and flavor;
combining the separate layers of dough sheets by merging to form a
multiple layer single dough sheet and gauging to reduce the thickness of said
multiple layer single dough sheet to form a multiple layer single dough sheet
to the thickness desired in the final biscuit product;


cutting the multiple layer single dough sheet into biscuits of desired
shapes such that the inner layers are camouflaged and not visible;
incorporating the scrap dough generated in the cutting step, in one or
other dough layer at the appropriate position so that it does not alter the
visual appearance of the said multiple layer single dough sheet of desired
shape; and
baking said multiple layer single dough sheet of desired shape to form
said composite biscuit with multiple layers.
In the biscuits of the present invention, the layers will have different
formulations with different ingredients to create variations in terms of taste,
bite, flavor, color, etc. Different formulations will be processed simultaneously
in different mixers wherein mixing parameters like mixing time, mixer speed,
temperature, etc. will vary depending on the desired layer characteristics.
Quantity of dough to be put in different layers will also vary depending on end
product characteristics.
During processing, dough with different formulations will be made into
sheets of specific thickness separately which will be combined subsequently
by a physical process of merging and gauging. By this process the inner
layer(s) which is(are) camouflaged and not visible as such after baking, in the
final product, will be visible only after breaking the composite biscuit.
Cutting of biscuit dough using a rotary cutter into specific shapes after
sheeting will be accompanied by generation of scrap dough. This dough is
incorporated in one or the other dough layer (in an appropriate position) so
that this blending does not alter the visual appearance of the composite
biscuit.


The final product, on baking will have an unique aesthetic appeal in
terms of taste, flavor, bite, etc. simultaneously catering to different taste
profiles, thus satisfying a vast majority of population who are on the look out
for different and new products.
The invention will be described with reference to preferred non-limiting
embodiments and with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
In the accompanying drawings -
Fig. 1 : Process flow chart for the manufacture of a conventional single
biscuit comprising a single layer; and
Fig. 2 : Process flow chart for the manufacture of a composite biscuit
having multiple layers according to a preferred embodiment of the instant
invention.
In the prior art process as shown in Fig. 1, sugar, invert syrup, fat,
skimmed milk powder, salt, leavening agents, colors and flavors together with
optional ingredients comprising cocoa and cocoa products, are mixed at high
speed in the creaming stage and then blended at a slower speed with wheat
flour and dough conditioner in a mixing stage to form a dough. The dough is
allowed to rest for not more than 1 hour. Thereafter the dough is made into a
layer of dough sheet in the sheeting stage and cutting of the dough sheet into
a desired shape is carried out before baking to form the final product.


According to the present invention, as shown in Fig. 2, sugar and
sugar products (1 to 32%), invert syrup (0 to 8%), fat (2 to 25%), skimmed
whole milk powder (0 to 8%), salt (.025 to 3%), leavening agents (0.1 to 6%),
colors and flavors together with optional ingredients comprising: cocoa,
coffee and their products, fruits, vegetables and their products, gelling agents
(0.5 to 15%), emulsifiers (0.2 to 1.0%), are creamed by mixing at high/low
speed for 2 to 10 minutes and subsequently wheat flour (50-89%) together
with enzymes or dough conditioners (0.025 to 1.0%) are added and mixed at
slow/fast speed for 3 to 20 minutes to form doughs with different taste, color
and flavor, in a conventional manner, which is well known in the art. The
dough is given a rest time of 0 to 1 hour and then charged into separate
hoppers. The doughs from different hoppers are made into separate dough
sheets. The separate dough sheets are combined by merging to form a
multiple layer single dough sheet and gauging to reduce the thickness of the
said multiple layer single dough sheet having the thickness desired in the
final biscuit product by passing through sets of gauge rollers. The multiple
layer single dough sheet is cut into dough of desired shapes using a rotary
cutter such that the inner layers are camouflaged and not visible and scrap
dough is generated. The scrap dough is incorporated in one or other layer of
the biscuit dough at the appropriate position so that it does not alter the visual
appearance of the final product. The shaped dough is then baked to form
composite biscuits with multiple layers. During merging of the layers, the ratio
of the top layer, middle layer(s) and bottom layer is maintained in the range of
1 to 3:1 to 3:1 to 3. During gauging, the ratio is maintained in the range of 1
to 3:1 to 3:1 to 3 depending on the end product characteristics.


EXAMPLE 1
(Top and bottom of biscuit is chocolate colored/flavored and the middle layer
with orange color/flavor)
A first dough comprising sugar (32%), invert syrup (4%), fat (13%),
special ingredients such as cocoa and cocoa products (13%), skimmed milk
powder (4%), salt (0.6%), leavening agents (3.5%), colors and flavors is
formed by mixing the ingredients at high speed for 5 to 10 minutes. Wheat
flour is then added, followed by addition of enzymes or dough conditioners.
The mixture is then mixed at a slow speed for 8 to 10 minutes.
A second dough comprising sugar (25%), invert syrup (2%), fat (16%),
skimmed milk powder (2%), salt (0.6%), leavening agents (3.5%), color and
flavors as required are mixed at high speed for 5 to 10 minutes. Thereafter,
wheat flour is first added and then enzymes or dough conditioners are
added and the mixture is mixed at a slow speed for 8 to 10 minutes.
The first dough is allowed to rest for 0 to 1 hour and then charged into
two hoppers of the 2 extreme sheeters. The second dough is also allowed to
rest for 0 to 1 hour and then charged into the hopper of the middle layer

sheeter.
The first dough from the two hoppers is formed separately into a top
layer sheet and a bottom layer sheet during sheeting. Similarly, the second
dough from respective hopper is formed into the middle layer sheet and laid
between the top layer and bottom layer. The top layer sheet, middle layer
sheet and bottom layer sheet are merged to form a single layer. It is
preferable to maintain the ratio of the top layer, middle layers and bottom
layer at 1 : 2 : 1.


The merged layer is gauged or reduced in thickness by passing it
through a set of gauge rollers. After gauging the thickness of the merged
layer will have the final thickness of the biscuits. From this merged and
gauged layer, dough of desired shape is cut in a rotary cutter. Any scrap
dough that generated by cutting is either incorporated in one or other layer at
appropriate position so that it does not alter the visual appearance of the final
product or is carried by a conveyor and mixed with the dough in the
appropriate hoppers.
EXAMPLE-2
(biscuits with orange color/flavored top layer, chocolate colored flavored
middle layer and brown colored bottom layer)
Three different doughs with different colors and/or flavors are prepared
separately as described in Example 1. The three doughs are fed into three
hoppers. Doughs from the respective hoppers are drawn in the form of
separate sheets.
The three sheets are laid one over the other and then merged to form
a single layer as described in Example 1. The merged layer is then gauged
so that the thickness of the layer gets reduced. In this step, it is preferred to
reduce the thickness such that the thicknesses of the top, bottom and middle
layers are in the ratio of 1:1:1. Thereafter, biscuit shapes are produced by
cutting by means of a rotary cutter. Some of the scrap dough produced is
used for covering the edges of the biscuits. Rest of the scrap dough is fed to
one of the hoppers. The dough is then baked to obtain the final product,
namely, composite biscuit with multiple layers of different taste, bite and
colors.


Although the invention has been described with reference to preferred
embodiments, this invention extends to all modifications falling within the
scope of the invention as hereinafter defined.

WE CLAIM :
1. A process for the manufacture of a composite biscuit with multiple layers
having different taste, bite, color and flavor, in said multiple layers, said process
comprising the steps of:
preparing, in a manner known per se, doughs with different formulations in
different mixers to be made into separate layers of dough sheets, each sheet
having a desired thickness and different taste (sweet, salt, spicy, etc.), color
(differentiating colors across layers) and different flavors;
combining the separate layers of dough sheets by merging (converging
the different layers at one point) to form a multiple layer single dough sheet and
gauging to reduce the thickness of said multiple layer single dough sheet to the
thickness desired in the final biscuit product;
cutting the multiple layer single dough sheet into biscuits if desired shapes
such that the inner layers are camouflaged and not visible;
incorporating the scrap dough generated in the cutting step, in one of or
other dough layer at the appropriate position so that it does not alter the visual
appearance of said multiple layer single dough sheet of desired shape by
modification of the dough through addition of the requisite food colors and
flavors, and

baking the said multiple layer single dough sheet of the desired shape
(round, rectangle, hexagonal or square or other irregular shapes based on
marketing requirements) to form said composite biscuit with multiple layers.
2. The process as claimed in claim 1, wherein, in said step of combining,
three separate layers of dough sheets having different taste, bite, color and flavor
are merged to form a multiple layer single dough sheet such that the thickness of
top, middle and bottom layers are in the ratio of 1 to 3:1 to 3:1 to 3.
3. The process as claimed in claim 1 or 2, wherein, in said step of combining,
after merging, grouping is carried out such that the thickness of the top, middle
and bottom layers are maintained in these ratio of 1 to 3:1 to 3:1 to 3 depending
on the variability required in end product attributes like taste, flavor and bite.
4. A process for the manufacture of a composite biscuit with multiple layers ,
said process comprising the steps of:
preparing a first dough comprising
sugar (1 - 32%), invert syrup (0 - 8%), fat (2 - 25%), special ingredients such as
cocoa, coffee and their product (0 -13%), skimmed whole milk powder (0 - 8%),
salt (0.025 - 3%), leavening agents (0.1 - 6%), food colors and flavors as
required, by mixing the ingredients at high/low speed for 2 to 10 minutes; and
thereafter mixing the flour followed by enzymes or dough conditioners
(sulphites, etc.), at a slow/fast speed for 3 to 20 minutes;

preparing at least one second dough comprising:
sugar (2 -30%), Invert syrup (1 - 7%), fat (3 - 23%), skimmed whole milk powder
(0 - 6%), salt (0.04 - 25%), leavening agents (0.5 - 7%), food colors, flavors and
other optional ingredients as required, by mixing the ingredients as required by
mixing the ingredients at a high/slow speed for 2 to 10 minutes, and
thereafter, mixing at least flour followed by enzymes or dough conditioners
(sulphites, etc.), at a slow/fast speed for 3 to 18 minutes;
allowing the first and second doughs to rest for almost 15 minutes to 1.0
hour;
feeding the first dough into two hoppers of the two extreme sheeters;
feeding the said second dough to a third hopper of the middle sheeter;
forming a top layer sheet from the first dough almost a bottom layer sheet
from the first dough;
forming at least one middle layer sheet from the second dough;
positioning said at least one middle layer sheet between the top layer
sheet and bottom layer sheet;
merging the layers to forma single layer;
gauging the merged layer to reduce its thickness to the desired thickness
and cutting the gauged layer into a desired shape; and
baking to produce said composite biscuit with multiple layers.

5. A process for the manufacture of a composite biscuit with multiple layers,
as claimed in claim 4, wherein the scrap dough obtained during the cutting step
is fed to the appropriate hopper for bending with the dough, contained therein.
6. A process for the manufacture of a composite biscuit with multiple layers,
as claimed in claim 4 or 5, wherein the scrap dough obtained during the cutting
step is used to cover the external edges of the biscuit.
7. A process for the manufacture of a composite biscuit with multiple layers,
as claimed in any of claims 4 to 6, wherein during merging, the thickness of the
top, middle and bottom layers are maintained in the ratio range of 1 to 3:1 to 3:1
to 3.
8. A process for the manufacture of a composite biscuit with multiple layers,
as claimed in any one of claims 4 to 7, wherein during gauging, the thickness of
the top, middle and bottom layers is maintained in the ratio range of 1 to 3:1 to
3:1 to 3 depending on the desired end product characteristics like taste, bite,
color and flavor.


A process for the manufacture of a composite biscuit with multiple
layers having different taste, bite, color and flavor, in said multiple layers, said
process comprising the steps of:
preparing, in a manner known per se, doughs with different
formulations in different mixers to be made into separate layers of dough
sheets, each sheet having a desired thickness and different taste, color and
flavor;
combining the separate layers of dough sheets by merging to form a
multiple layer single dough sheet and gauging to reduce the thickness of said
multiple layer single dough sheet to the thickness desired in the final biscuit
product;
cutting the multiple layer single dough sheet into biscuits of desired
shapes such that the inner layers are camouflaged and not visible ;
incorporating the scrap dough generated in the cutting step, in one or
other dough layer at the appropriate position so that it does not alter the
visual appearance of said multiple layer single dough sheet of desired shape;
and
baking said multiple layer single dough sheet of desired shape to form
said composite biscuit with multiple layers.

Documents:

195-KOL-2004-ABSTRACT-1.1.pdf

195-kol-2004-abstract.pdf

195-KOL-2004-AMANDED CLAIMS.pdf

195-kol-2004-assignment.pdf

195-kol-2004-assignment1.1.pdf

195-kol-2004-claims.pdf

195-KOL-2004-CORRESPONDENCE 1.2.pdf

195-KOL-2004-CORRESPONDENCE-1.1.pdf

195-KOL-2004-CORRESPONDENCE-1.3.pdf

195-KOL-2004-CORRESPONDENCE.pdf

195-kol-2004-correspondence1.4.pdf

195-KOL-2004-DESCRIPTION (COMPLETE)-1.1.pdf

195-kol-2004-description (complete).pdf

195-KOL-2004-DRAWINGS-1.1.pdf

195-kol-2004-drawings.pdf

195-KOL-2004-EXAMINATION REPORT REPLY RECIEVED.pdf

195-kol-2004-examination report.pdf

195-KOL-2004-FORM 1-1.1.pdf

195-kol-2004-form 1.pdf

195-kol-2004-form 18.pdf

195-KOL-2004-FORM 2-1.1.pdf

195-kol-2004-form 2.pdf

195-kol-2004-form 3.1.pdf

195-kol-2004-form 3.pdf

195-kol-2004-gpa.pdf

195-kol-2004-gpa1.1.pdf

195-kol-2004-granted-abstract.pdf

195-kol-2004-granted-claims.pdf

195-kol-2004-granted-description (complete).pdf

195-kol-2004-granted-drawings.pdf

195-kol-2004-granted-form 1.pdf

195-kol-2004-granted-form 2.pdf

195-kol-2004-granted-specification.pdf

195-KOL-2004-OTHERS-1.1.pdf

195-KOL-2004-PA.pdf

195-kol-2004-reply to examination report.pdf

195-kol-2004-specification.pdf


Patent Number 248994
Indian Patent Application Number 195/KOL/2004
PG Journal Number 38/2011
Publication Date 23-Sep-2011
Grant Date 20-Sep-2011
Date of Filing 20-Apr-2004
Name of Patentee BRITANNIA INDUSTRIES LIMITED
Applicant Address 5/1A, HUNGERFORD STREET, CALCUTTA
Inventors:
# Inventor's Name Inventor's Address
1 KAUL VIJAY 2B, DEODAR, BRITANNIA GARDENS, AIRPORT ROAD, VIMANAPURA, BANGALORE-560017, KARNATAKA
PCT International Classification Number A21B 5/02
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 NA