FIELD OF INVENTION
The invention relates to a baking oven for making bread. More particularly, the
invention relates to a bake-oven system for producing crustless bread.
BACKGROUND OF INVENTION
Baking ovens for producing breads are known. However, the known baking
ovens are capable to produce breads normally having puncture force of 6.00 to
6.50 Newton. The moisture content on the top surface of the breads produced
by known baking ovens is substantially high. In absence of a suitable
temperature control mechanism in the conventional ovens, the dough
gets either overheated or under-heated. In case of over-heating, and in absence
of a provision for injecting any cooling medium on the over-heated dough, the
produced bread does not have requisite softness, and forms crust particularly on
the top surface. In case of under-heating of the dough, the formed bread lacks
test and preservation becomes difficult. Further, the conventional bake ovens are
incapacitating to produce crustless bread. The known oven takes substantially
higher baking time, and requires high baking temperature.

OBJECTS OF THE INVENTION
It is therefore an object of the invention to propose a bake-oven system for
producing crustless bread.
Another object of the invention is to propose a bake-oven system for producing
crustless bread, which is capable to produce breads having a puncture force
between 0.12 to 0.15 Newton.
A still another object of the invention is to propose a bake-oven system for
producing crustless bread, which is enabled to produce crustless bread with
lower moisture content on the top surface of the bread.
A further object of the invention is to propose a bake-oven system for producing
crustless bread, which reduces the baking time due to innovative configuration of
the baking chamber including adaptation of spray pulses during baking
operation.
A still further object of the invention is to propose a bake-oven system for
producing crustless bread, which requires less baking temperature, and ensures
less energy consumption owing to provision of temperature control means.

Another object of the invention is to propose a bake-oven system for producing
crustless bread without any carcinogenic compound like acrylamide.
SUMMARY OF INVENTION
The present invention discloses a crustless bread baking oven capable of making
crustless bread by gently baking the bread in controlled temperature and
spraying water at predetermined time interval during baking which ensures that
the surface of the bread does not get very hot which eliminates crust forming.
The inventive baking oven comprises:
(a) a Baking Chamber,
(b) a Spraying device,
(c) a Water Storage tank,
(d) a Flow controller, and
(e) an Instrumentation panel
After completion of the proofing stage, the dough is kept under the spraying
nozzle at the preheated baking oven. Water is sprayed from the water storage
tank on the surface of the bread at a predetermined time interval. After
completion of the normal baking time, the crustless bread is produced.

The baking chamber is configured with glass wool filled dual wall construction
with the outer wall being formed of hammer tone painted mild steel and the
inner wall is made of SS316. The outside and inside dimensions of the outer wall
and the inner wall can be 0.625 m x 0.53 m x 0.47 m and 0.37 m x 0.36 m x 0.3
m respectively which allows baking of four bread loaves of 25-35 g each.
A Stanner type sprayer brass nozzle insulated with mica tape having diameter of
6.35 mm and distance between the nozzles of 0.103 m x 0.086 m with water
spraying rate of 300-325 ml/m2 /stroke/nozzle/bread is provided.
Accordingly, there is provided A bake-oven system for producing crustless
bread, comprising a main baking oven having a hollow internal space forming an
inside surface, and an external surface, insulating materials disposed between
the inside and outside surfaces to prevent heat leakage, a plurality of holes
configured on the internal rear wall to allow ingress of atmospheric air, a blower
being interposed inside the oven for uniform heat distribution, and a holding
tray with baking cup provided for accommodating the dough; a spraying device
comprising a plurality of nozzles provided inside the main chamber for
intermittent spraying of water on the dough by adapting a lever main , the
device being connected to a water storage tank via an insulated pipeline ; the

water storage tank disposed outside the chamber , and connected to the
spraying device via a flow controller ; the flow controller comprising a non-
return valve and connected to the storage tank via a piping network ; and an
instrumentation panel externally disposed over the main chamber , and
comprising a digital controller with a sensor to indicate the temperature of the
chamber , a heating element for supplying heat to the oven , the power being
supplied to the heating element via a rotary switch .
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig. 1- shows an isometric view of the baking chamber of the bake-oven system
according to the invention
Fig. 2- shows a front view of an inner chamber of the baking oven of Fig. 1
Fig. 3- shows an isometric view of the storage tank of the bake-oven system of
the invention.
Fig. 4- shows isometric views of the various piston positions including water
displacement during operation of the storage tank.

Fig. 5- shows a schematic view of the flow controller of the inventive system
Fig. 6- shows a block diagram of the inventive system including the
instrumentation panel
Fig. 7- shows a spraying device of the system according to the invention.
DETAIL DESCRIPTION OF THE INVENTION
An isometric view of the Bake-oven system has been shown in Fig. 1. Different
features of the oven system is discussed for example, the baking chamber the
water spraying device, water storage tank, the flow controller, and the
instrumentation panel.
Baking Oven (1)
A Baking chamber is the most important unit of a baking oven (1) where all the
operations are done. In this baking oven (1) two sides (i.e. inside and outside) of
the main baking chamber are made with two different materials. Outer wall of
the baking chamber is made with MS sheet with paint. Inner wall of the chamber

is made with SS sheet of 316 grade. Insulation is another important criterion of a
baking chamber. It is necessary for preventing the heat leakage. In this baking
oven (1), glass wool is used as the insulating material which is placed between
the inner and outer wall (1A,1B). A blower (6) is used for simultaneous heat
distribution in the chamber, which is placed at the rear wall of the chamber.
There are at least four holes for adequate air movement in the chamber. A
holding tray (not shown) is kept in the chamber for holding a baking cup (not
shown). Front view of the inside of the chamber is shown in Fig. 2.
Spraying device (7)
One of the most important features of the baking oven (1) is a spraying device
(7). The main object of the invention, i.e. making of crustless bread is achieved
by spraying water on the top surface of the dough. As shown in Fig. 7, there are
at least four brass-made stanner type nozzles (8) which are used for spraying
water at different time intervals. Distance between any two nozzles (8) at length
wise and width wise are respectively between 10 to 11 cm, and 8 to 9 cm. Water
spraying rate of these nozzles (8) is 300-325 ml/m2/stroke/nozzle/bread. All the
nozzles (8) and pipelines (9) are insulated with mica tape (10).

Water Storage tank (3)
Isometric view of the water storage (3) tank is shown in Fig. 3. An outside
cylinder (3c) of the tank (3) is made of aluminium which is used for storing
water. Inside the outer cylinder (3c) there is another brass made cylinder (3d). A
piston (3a) is fitted inside the inner cylinder (3d) for linear motion within its bore.
There is air hole (3e) on the top and a nonreturn valve (3f) on the bottom of
piston cylinder attachment. A mechanical pressure gauge is connected with outer
cylinder (3c) to measure the spraying pressure of water. As the piston (3a) is
withdrawn the volume increases, causing a reduction in pressure—commonly
known as suction. So atmospheric pressure will cause air to flow into the
cylinder. At the end of the suction stroke, the maximum quantity of air will have
been inducted to the outer cylinder (3c) which is filled with water through the
nonreturn valve (3f) which in turn increases pressure on the water. This
increased pressure forces water to flow through an attached pipe (3g). Water
displacement in the tank (3) according to piston position is shown in Fig. 4.
Flow controller (5)
A manually operated lever means (11) is attached to the water storage tank (3)
via a connecting pipe (3g) for spraying water at predetermined time interval. A
non return valve (13) is placed in the pipeline (3g) for controlling water spraying

system. When time comes for spraying water on the dough, the valve (13) opens
and water is sprayed on the dough by pressing the lever means (11). After
releasing the lever (11), the non return valve (13) closes so that more water can
not pass through the pipeline (3g). It is shown in Fig. 5.
Instrumentation Panel
Fig.-6 shows that there are two types of instrument in the machine (1) viz., a
digital temperature controller cum indicator (2), a heating element (14). The
digital controller cum indicator (2) with a sensor indicates the temperature of the
chamber (1). Power is supplied by a three way rotary switch (15).
Inside the main baking chamber (1), the doughs are placed on a baking cup, the
baking cup being held by a tray. The spraying device (7) is disposed inside the
baking chamber (1). The storage tank (3) is placed outside the baking chamber.
Water from the storage tank (3) is supplied through a flow-controller (5) to the
spraying device (7). The water storage tank (3) is providd with a pressure gauge
to measure the spraying pressure of the water. The flow controller (5) is
provided with a non-return valve (13) which controls the supply of water from
the storage tank (3) to the spraying device (7) via a pipe (9).

The system is provided with a digital controller cum a sensor (2), and a heating
element (14) which is disposed over the inner chamber. The temperature
controller (2) controls the heat to be supplied to the baking chamber (1)
depending on the requirement. The power is supplied externally to the heating
element (14) via a rotary switch (15).
Advantages of the invention
1. Process of making crustless bread is a novel concept.
2. Reduction of baking time to the extent of 20-30% is achieved.
3. Reduction of baking temperature to the extent of 15-25% is achieved.
4. Reduction in energy usage to the extent of 20-30% is achieved.
5. Softness of the bread baked in this oven is greater than bread baked by
conventional mean as puncture force of crustless bread is 0.13 Newton
wherein, it is 6.4 Newton for unsliced bread. But softness of crustless
bread is almost same as that of bun bread having puncture force around
0.12 Newton.
6. Moisture content on wet basis of the top surface of the crustless bread is
19.94 % lower than the bread baked by conventional method.

We Claim:
1. A bake-oven system for producing crustless bread, comprising:
- a main baking oven (1) having a hollow internal space forming an
inside surface, and an external surface, insulating materials
disposed between the inside and outside surfaces to prevent heat
leakage, a plurality of holes configured on the internal rear surface
to allow ingress of atmospheric air, a blower being interposed
inside the oven (1) for uniform heat distribution, and a holding tray
with baking cup provided for accommodating the dough;
- a spraying device (7) comprising a plurality of nozzles (8) provided
inside the main chamber (1) for intermittent spraying of water on
the dough by adapting a lever main (11), the device (7) being
connected to a water storage tank (3) via an insulated pipeline (9);
- the water storage tank (3) disposed outside the chamber (1), and
connected to the spraying device (7) via a flow controller (5);
- the flow controller (5) comprising a non-return valve (13) and
connected to the storage tank (3) via a piping network (3g); and
- an instrumentation panel (2,14,15) externally disposed over the
main chamber (1), and comprising a digital controller with a sensor
(2) to indicate the temperature of the chamber (1), a heating
element (14) for supplying heat to the oven (1), the power being
supplied to the heating element (14) via a rotary switch (15).

2. The system as claimed in claim 1, wherein the water-storage tank (3)
comprises a piston (3a), an outer cylinder (3c), an inner cylinder (3d), a
non-return valve (3f), and a pressure gauge.
3. The system as claimed in claim 2, wherein the outer cylinder (cC), and the
inner cylinder (3d) are made of different metal.
4. A bake-oven system for producing crustless bread, as substantially described
and illustrated herein with reference to the accompanying drawings.

The invention relates to a bake-oven system for producing crustless bread,
comprising a main baking oven (1) having a hollow internal space forming an
inside surface, and an external surface, insulating materials disposed between
the inside and outside surfaces to prevent heat leakage, a plurality of holes
configured on the internal rear surface to allow ingress of atmospheric air, a
blower being interposed inside the oven (1) for uniform heat distribution, and a
holding tray with baking cup provided for accommodating the dough; a spraying
device (7) comprising a plurality of nozzles (8) provided inside the main chamber
(1) for intermittent spraying of water on the dough by adapting a lever main
(11), the device (7) being connected to a water storage tank (3) via an
insulated pipeline (9); the water storage tank (3) disposed outside the chamber
(1), and connected to the spraying device (7) via a flow controller (5); the flow
controller (5) comprising a non-return valve (13) and connected to the storage
tank (3) via a piping network (3g); and an instrumentation panel (2,14,15)
externally disposed over the main chamber (1), and comprising a digital
controller with a sensor (2) to indicate the temperature of the chamber (1), a
heating element (14) for supplying heat to the oven (1), the power being
supplied to the heating element (14) via a rotary switch (15).