First exemplary process: sealing (closing the open edge) by
means of a baking step after application of fatty-
substance-rich masses
a. Application of a fatty-substance-rich mass in aqueous
สารละลาย or สารแขวนลอย in a thin layer to the open edge. The term fatty-substance-rich mass designates a fatty substance content of 20% and more, preferably of 34% or more, particularly preferably of 40% or more. This application is preferably accomplished in one step by known methods of application of thin layers of viscous สารละลายs and สารแขวนลอยs, preferably by means
of brushing, rolling or removal in the contact
process.
b. The composition of the fatty-substance-rich masses
ranges from conventional baking masses for host wafers and wafers, optionally with the addition of colouring foodstuffs such as, for example, cocoa, colourings, pigments and increased lipid fractions such as fats and wax. The main components in addition to water are therefore starch-rich flours of all kinds as well as
food starches (native and/or modified).
c. Expressly included in the said "conventional baking
masses for host wafers and wafers" are sugar-rich
wafer baking masses such as are used for the
manufacture of cast sugar cones, rolled sugar cones, sugar wafer rolls or wafer sticks. The fractions of
sugars contained therein, optionally of sugar
replacements result in the formation of sugar glass after cooling, in the same way as is known from the technology of sugar wafers, which reduces moisture
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diffusion and increases the mechanical strength of such sealing edges in a desired manner.
d. In order to achieve two preferred properties of such
seals, gloss and increased hydrophobic properties, the masses described under b. having the same or similar viscosity masses A and/or B are mixed in the ratio 99:1 to 50:50. Masses of type A contain เดกซ์ตริน from the group starch เดกซ์ตริน, maltoเดกซ์ตริน, thin-boiling flours or starches, oxidized starches. Masses of type B contain modified starches from the group of starch
esters and starch ethers where longer-chain
hydrophobic side chains such as possibly octenyl
succinate are included. If the properties of masses A and B allow, higher fractions than 50% of A and/or B can also be used, in individual cases up to 100%.
e. The amount applied is measured in such a manner that a
through-moistening of the open edge by means of the
entrained water fraction remains below 1 mm,
preferably below 0.5 mm, particularly preferably below
0.3 mm - with a lower water fraction of the fatty-
substance-rich mass, more can therefore be applied than with a higher fraction.
f. Directly after application of the fatty-substance-rich
mass, by pressing onto a heated metal plate or baking plate the edge is sealed in a baking manner with a smooth or patterned embossing according to the plate design. The sealing temperature of the heated plates
lies in the range of 105°C to 225°C, preferably 135°C
to 205°C, particularly preferably 160°C to 205°C.
g The sealing process is accomplished in a sealing
station which directly follows the separating step of
the baking link of the hollow wafer sheet. The
separation of the baking link is made by known
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methods. The separate half-shells with open edge are mechanically guided here or held pressed onto the hot sealing plate which comes in contact below, above or optionally laterally. The pressing process can start from the half-shell guide or from the sealing plate, preferably from the former. The heating of the sealing plate is accomplished by one of the known methods for
baking moulds, but preferably electrically or
electrically inductively. Oiling or a scraping off of
baking residues or cleaning the heating sealing plate
is optionally integrated in the sealing station.
h. The duration of the sealing process lies in the range
of 1 to 60 seconds, preferably 6 to 50 seconds. This
duration will be adapted by the person skilled in the
art to the amount of supplied solids and supplied
water. The criterion is that over 50% of the supplied
water, preferably over 70%, particularly preferably
over 90% escapes from the sealing zone and that at the
sealing surface the gelatinization of the fraction of
gelatinizable starch is approximately 100%.
i. The heat sealing station is followed directly by the
following process steps such as, for example, coating, metering, brushing or inserting.
In principle, the sealing process is also applicable to conventionally baked hollow bodies or baked products having porous crumb when an open-pore structure occurs as a result of a separation of a part of the closed baking skin.
Process 1: process scheme
1 Baking a hollow body or a sheet with pluralities
of hollow bodies with baking link or baking a
baked product with porous crumb.
2 Separating the baking link by methods from the
prior art and flat holding/guiding the remaining
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baked product body or separation of a part of the
baked product with porous crumb and
holding/guiding.
3 Application of the fatty-substance-rich mass in a
thin layer by known methods. Penetration depth
below 1 mm.
4 Immediate thermal sealing by guided pressing onto
a heated surface which can optionally be oiled.
Heating temperature in the range of 105°C to
225°C.
5 Further process steps such as possibly coating,
metering, brushing, inserting etc. immediately
afterwards.
Second exemplary process: sealing (closing the open edge)
by means of a baking step after application of fat-
containing masses
a. Application of a flowable, molten fat-rich mass from
the group chocolate, compound chocolate, fat glaze, ice glaze in a thin layer to the open edge. This application is preferably made in one step by known methods of application of thin layers of viscous สารละลายs and สารแขวนลอยs, preferably by removal in the contact process, rolling, dipping or brushing. The
colour of the mass is adjusted as desired. The
optional application of several colour masses is
included.
b. The temperature of the baked product body is held so
that the flowable molten fat-rich mass does not
significantly vary its temperature and therefore the solid fat fraction until hardening.
c. The applied amount is measured by the person skilled
in the art so that a closed sealing layer without
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defects or without visually interfering overhangs is formed.
d. Directly after application of the fat-rich mass, the
smooth, shiny sealing surface is formed by pressing onto a cooled metal plate with smooth or patterned embossing according to plate design. The precautions known from the technology explained above with regard to control of the air humidity and temperature in this working area should be observed. These parameters are adapted by the person skilled in the art in the same way as the contact time to the small amount of fat-
rich mass to be solidified. In particular, the
temperature of the fat-rich mass must be brought below
the melting point of the mass, preferably quickly.
e. This cold sealing process takes place in a sealing
station which directly follows the separating step of
the baking link of the hollow wafer sheet. The
separation of the baking link is made by known
methods. The separated half-shells with open edges and
applied fat-rich mass are here guided or held
mechanically, pressed onto the cold stamp plate which
comes in contact below, above, optionally also
laterally. The pressing process can start from the half-shell guide or from the cold stamp plate, but preferably from the former.
f. Following the cold sealing station, the subsequent
processes for the edge-sealed hollow wafer half-shells can follow directly such as, for example, coating, metering, brushing or inserting.
The cold sealing process is also applicable to
conventionally baked hollow bodies or baked products having porous crumb when an open-pore structure occurs as a result of a separation of a part of the closed baking skin.
Recipe examples for fat-containing masses
Table 1: Genuine chocolates
Milk A Milk B White Dark A Dark B
Cocoa mass 12 12 0 33 48
Cocoa butter 20 23 24 15 9.5
CBE 1.5 0 3.5 0 0
Sugar 46 40.5 48 51.5 42
Full milk 20 7 22 0 0
powder
Skimmed milk 0 7 0 0 0
powder
Lactose 0 5 2 0
Whey powder 0 5 0 0 0
Small 0.5 0.5 0.5 0.5 0.5
components, approx.
Fat fraction, 33.5 33.5 33.5 33 35
approx.
FP, °C, 34 33 34 35 35
approx.
CBE ... cocoa butter equivalent fat
Small components ... emulsifiers (lecithin, PGPR), vanilla
(flavouring)
FP ... fusion point/melting point
Table 2: Genuine chocolates
Milk Milk Ice Ice Ice
dipping coating glaze, glaze, glaze,
chocolate white milk dark
Cocoa mass 13 15 0 12.5 32.5
Cocoa butter 13 18 32.5 27.5 20
CBE