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