Note: Descriptions are shown in the official language in which they were submitted.
CA 02588248 2007-04-20
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PROCESS AND APPARATUS FOR MAKING IMPROVED
SAMOSA-PASTRY AND PATISSERIE PRODUCTS
FIELD OF THE INVENTION
This invention relates to processes for making samosa-pastry dough and
patisserie products, particularly pastry shells and wraps for classic samosas;
and
apparatus of use in said processes; and said products.
BACKGROUND TO THE INVENTION
Samosa chapris or wraps like those for other similar foods e.g.turn-overs,
pies,
pasta etc. are characterized by unleavened, thinly sheeted dough pastry that
may be
semi-cooked, in the case of egg rolls or samosas used raw prior to cooking, in
the case
of pies, or hardened prior to boiling, in the case of pasta, and then used for
covering or
layering the product that normally consisted of meat, vegetables, spices, dry
fruits,
nuts, and the like.
Authentic, classic samosas are described as samosas originating from Gujerati
speaking enclaves of South Asia and are characterized by a single, thinly
sheeted
dough pastry that is pre-cooked to a degree, and then used for assembling
samosas.
The traditional art for doing this is slow and time consuming as the pastry
could only
be cooked one at a time. The final product was also quick to dry out,
inconsistent in
its physical and chemical compositions and, therefore, problematic to work
with in
terms of a business dedicated to industrializing and commercializing the art
of
producing authentic, classic samosas.
The other broad category of samosas is known as Punjabi samosas originating
from Punjabi speaking enclaves of South Asia that are characterized by a
single,
thickly sheeted dough pastry that is uncooked and is used for assembling
samosas.
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Unfortunately, at present, commercial pastry of use as shells and wraps for
these samosas or similar products do not measure up to the quality
characteristics
associated with traditional authentic classic samosa pastry, such as, for
example, the
degree of crunchiness, elasticity, pliability, non-porous and smooth surface,
moisture
and oil content, inter-connected as they all are, and pastries that are also
quick to peel.
Accordingly, there is a need for a new way of producing novel pastry shells to
wrap traditional, authentic, classic samosas that have the quality expected of
traditional samosas and which can be manufactured in an improved batch or
continuous process in a mass produced manner.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process for the mass-
production of a pastry used to wrap authentic, classic samosas that is made
with wheat
or other type of flour and prepared in such a manner as to accomplish a number
of the
aforesaid desirable characteristics that includes a crispy and crunchy eating
quality, a
non-porous, non-greasy appearance, that is also not crumbly or dry, but in
fact,
appears polished, and has an extended shelf life. Intermediary and final
products
made with the pastry according to the invention, whether they are stored
frozen,
refrigerated or at ambient temperatures have a utility that allows their use
in assorted
varieties of main menu, appetizers and snack food products in various forms.
It is a further object to provide apparatus of use in said aforesaid process.
It is a further object to provide pastry products of said process and
apparatus.
Accordingly, in one aspect, the invention provides an improved method of
making a cooked pastry from a pastry dough in a convection baking oven having
a
convection atmosphere, the method comprising cooking the dough in the oven at
a
cooking temperature for a cooking period of time, the improvement comprising
cooking the pastry and maintaining the convection atmosphere at a sufficiently
moist
atmosphere for the duration of the cooking time to prevent the pastry from
losing
moisture while in a semi-cooked state.
Preferably, the cooking temperature is selected from 450 F - 485 F and a
cooking time of about 90 minutes.
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The terms "baking" or "cooking" in this specification in relation to the
processes according to the invention means a heating process effected in the
presence
of a sufficiently moist atmosphere as herein defined.
It is highly desirable that the baking pastry does not become dry.
In a further aspect, the invention provides an improved method of making a
baked pastry from a pastry dough in a convection baking oven having a
convection
atmosphere, the method comprising baking the dough in the oven at a baking
temperature for a baking period of time, the improvement comprising
maintaining the
convection atmosphere having at least 50%, preferably at least 70%, humidity
for the
duration of the baking time.
The humidity may be maintained by the introduction of water vapour during
the baking step into the oven, either as a slow injection of steam, water
droplets or
vapour during the baking period.
Alternatively and preferably, the humidity is maintained by the generation of
water vapour, heated as to constitute steam, from a water reservoir within the
oven.
Preferably, the pastry dough is in the form of a sheet having a thickness
selected from 0.2 mm to 3 cm., and more preferably, the sheet is of a desired
width of
between 40 - 60 cm, and a length selected from 10 cm to 20 m, preferably 10cm
to
5m, suitably rolled on or as a spool, if appropriate and desired.
More preferably, the dough is in the form of a stack comprising a plurality of
the sheets, one upon another, wherein each of the sheets has a thickness
selection
from 0.2 mm to 3.0 mm.
In preferred embodiments, the stack is formed from a single folded sheet
wherein the sheet is folded longitudinally upon itself at least once to
produce a folded
stack.
More preferably, a process as hereinabove defined, further comprises
(i) providing a baking pan assembly comprising water-containing
reservoir means for operably releasing water vapour into said
convection atmosphere during said baking;
(ii) placing said pastry dough in said baking pan assembly; and
(iii) locating said baking pan assembly within said oven.
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The reservoir means may comprise an upper and/or lower water reservoir,
which operably contains sufficient water to provide the humidity during the
baking
period.
The processes as hereinabove defined are most valuable when preferably used
with a novel pastry, which is made, stored and treated in a manner, which
maintains
desired amounts of moisture as to not become dry.
Accordingly, the invention in a preferred aspect provides a process as
hereinabove defined wherein the baking pan assembly comprises an upper water-
containing reservoir, and a lower water-containing reservoir.
Preferably, the dough is stored at a temperature selected from about 2 to 8
C,
preferably, 2 to 6 C; and the tempering container is formed of a plastics
material, for
example, polyethylene in the form of a bag, tube or other container.
In a further aspect, the invention provides a process of making a novel pastry
dough for use as a shell or wrap for samosas, said process comprising said
stored
dough is at a temperature selected from 2 to 6 C.
Preferably, the admixture comprises 62-68% w/w flour, 1-4% w/w salt and the
balance to 100% w/w of water.
Most preferably, the admixture consists essentially of 65% flour, 33% water,
2% salt.
In a further aspect, the invention provides wherein the means for providing
the
humidity comprises water addition means.
The means for providing and maintaining the desired humidity may comprise
water addition means whereby water operably enters the oven as steam, water
droplets
or vapour, through inlet conduit means.
In a preferred embodiment, the oven comprises water reservoir means
containing sufficient water for the duration of the baking period.
In a further aspect, the invention provides an apparatus for the manufacture
of
a cooked pastry from a pastry dough, said apparatus comprising a convection
baking
oven assembly having
(i) a cooking chamber for receiving and cooking said pastry dough
operably at a cooking temperature for a cooking period of time and having a
convection atmosphere, and
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(ii) means for providing said convection atmosphere with a sufficiently
moist atmosphere for the duration of said cooking time to prevent said pastry
from
becoming dry.
Preferably, the apparatus comprises means for providing said convection
atmosphere with a humidity of at least 50% for said cooking period of time.
Preferably, said means for providing said humidity comprises water addition
means.
Preferably, said means for providing said humidity comprises water reservoir
means within said chamber.
Preferably, the apparatus comprises portable baking tray assembly means
comprising a cooking tray and said water reservoir means transportable with
said tray.
Preferably, the apparatus comprises means wherein said cooking tray has a
plurality of perforations and is disposed above a lower water-reservoir
whereby water
vapour operably passes through said perforations to maintain said humidity.
Preferably, the apparatus comprises means wherein said assembly further
comprises an upper water-reservoir above said baking tray.
Preferably, the apparatus comprises means wherein said assembly further
comprises a sheet of silicone Bakers paper upon which said pastry dough rests
during
said cooking period.
Preferably, the apparatus comprises means wherein said assembly further
comprises a sheet of silicone Bakers paper covering said pastry dough during
said
cooking period.
In a further aspect, the invention provides an apparatus for the manufacture
of a
samosa shell or wrap.
In a further aspect, the invention provides a pastry dough produced by a
process
comprising intimately mixing dough ingredients comprising an admixture
consisting
essentially of the following ingredients in said ratios 62 - 68% w/w flour, 28
- 37%
w/w water, and 1- 4% w/w salt to produce a relatively non-sticky pastry dough
of
desired consistency.
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In a further aspect, the invention provides a pastry dough wherein said
admixture consists essentially the following ingredients in said ratios of 65%
w/w
flour: 33% w/w water and 2% w/w salt.
In a further aspect, the invention provides a pastry dough wherein said flour
has
a gluten content of at least 13%.
In a further aspect, the invention provides a pastry dough as hereinabove
defined
of use in the manufacture of a samosa shell or wrap.
In a further aspect, the invention provides a sheet of pastry dough for baking
in a
convection oven for use as a samosa shell or wrap said process further
comprising
cooling said dough to a temperature selected from 4 to 12 C;
storing said dough in a sealed tempering container at a temperature of less
than
10 C for at least 8 hrs; and
rolling and cutting said tempered dough to a sheet of desired dimensions.
In a further aspect, the invention provides a baked pastry produced by a
method and having a moisture content of 25-35% w/w water.
In a further aspect, the invention provides a pastry having a moisture content
of 29-31 % w/w water.
In a further aspect, the invention provides apparatus as hereinabove defined
further comprising a baking pan assembly containing pastry dough and
comprising
water reservoir means to operably provide water vapour to produce the desired
humidity during the baking period.
In preferred embodiments, the baking pan is located above and/or below
containers containing the water such that the pastry dough is above, below or
between
the adjacent reservoir(s), in the baking pan assembly, which may be
transportable as a
whole to, within and out of the oven.
In more preferred embodiments the assembly further comprises an upper
water-reservoir above the baking tray.
In a further aspect, the invention provides a cooked pastry product produced
having a moisture content of 25-35% w/w water, preferably, 28-30% w/w water by
a
method as hereinabove defined.
In most preferred embodiments of a method according to the invention, the
surface of the dough sheet is treated with a natural edible oil, such as, for
example,
olive oil or, most preferably, a vegetable oil, such as canola oil. The oil
may be
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applied, for example, as a spray or by means of a brush. I have found that the
oil both
facilitates the separation of the layers of the stacked dough sheets after
baking and
assisting in maintaining the moisture content of the dough layers during the
baking
process.
Although the prior art teaches the admixture of oil during the dough
preparation stage, the present invention, preferably, does not have such
admixed
oil/dough for baking. Surprisingly, I have found that dough sheets coated with
oil in
the preferred embodiments of the invention, after baking provide a pastry wrap
or
shell, which when formed into a samosa with an appropriate, desired filling
does not
produce surface bubbles or a greasy product according to the prior art, but
rather a
desirable, crispy samosa, when fried.
Thus, in a further aspect the invention provides a method as hereinabove
defined comprising coating said dough with a natural edible oil prior to said
baking.
Preferably, the vegetable oil is canola oil.
In a further aspect, the invention provides a cooked pastry product produced
by a method as hereinabove defined.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be better understood, preferred embodiments
will now be described, by way of example only, with reference to the
accompanying
drawings wherein
Fig. 1 is a flow chart of the steps in manually making authentic classical
samosa shells or pastry wraps, according to the prior art;
Fig. 2 is a flow chart of the steps in a semi-mechanized method for the mass
production of pastry wraps of use in making classical samosas according to the
prior
art;
Fig. 3 is a diagrammatic representation of layered pastry folded in a baking
pan prior to baking in the process of Fig. 2;
Fig. 4 is a flow chart of the steps in a fully mechanized method of making
pastry for use in samosas and similar products, according to the prior art;
Fig. 5 is a flow chart of the steps of the process of Fig. 4 showing optional
steps in use of the pastry preparation stage; and
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Fig. 6 is a diagrammatic vertical sectional view of a baking tray assembly in
a
convection oven, according to the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to Fig. 1, this shows generally as 10 the typical eight steps
in
making classical samosa pastry.
Typical ingredients, namely, flour, water, oil and salt, herein collectively
12
are manually mixed in bowl 14 by spoon 16, to a dough 18. Dough 18 is kneaded
and
formed into a plurality of 5 cm diameter dough balls 20 which are each then
flattened
to individual 10 cm diameter "flats" 22 by rolling pin 24. Two flats 22 are
combined
and rolled together to form an approximately 20 cm diameter resultant flat 26.
Flat 26 is conditioned by a light dusting of flour 28 and sprayed with cooling
oil 30. A layered stack 32 of eight conditioned flats is formed and cooked on
a pan 32
at a low heat with periodic flipping and peeling of the layer every minute to
form
cooked stack 36. Each cooked layer of stack 36 is sliced into strips 38 and
wrapped in
a moist cloth 40 and stored.
Fig. 2 represents a semi-mechanized process for the mass production of dough
for wraps, for samosas comprising the steps of mixing aforesaid ingredients 12
in a
mixer 50 to provide prepared dough using a sheeter 52, cooking in oven 54,
and,
subsequently, suitable cutting thereof with a knife and cutting template 56.
Cooking
is done with regular baking pans and a convection oven. However, with
reference to
Fig. 3, the sheeted pastry 58 is first layered in folds 60, covered in a
muslin cloth 62,
prior to cooking in baking pan 64 having dimensions of 65cm long and 30cm
wide.
Figs. 4 and 5 represent flow charts of a prior art fully mechanized method
having the steps so-named therein.
Fig. 6 shows generally as 80 a rectangular cooking tray assembly having a
lower stainless steel reservoir 82, an upper steel reservoir 84 and
therebetween a steel
dough sheet tray 85.
Lower reservoir 82 has a base 86 and upstanding sides 88 having a pair of
upper lips 90 on opposite sides, which rests on inside frame members 92 of
oven
shown generally as 93, as hereinbelow described. On the inside and extending
the
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length of base 86 is a pair of solid steel cylindrical support bars 94 upon
which rests
dough sheet tray 85.
Dough sheet tray 85 has a tray base 96 having a plurality of water vapour vent
holes 98 and upstanding vertical sides 100. A sheet of silicone Bakers paper
101
upon which rests a stack 102 of twenty-four dough sheets of approximately 0.3
mm
thick.
Upper steel reservoir 84 comprises a planar cover base 104 having
downwardly directed sides 106 having a pair of bottom lips 108 mid-way of
opposing
sides complementary of lips 90 whereby lips 108 rest on lips 90 to support
reservoir
84.
Vertical sides 106 extend beyond lips 108 into reservoir 82 between sides 88
and 100.
Extending downwardly of the inside of cover base 104 is a rectangular
reservoir member 110 defining with sides 106 and base 104 a chamber 112 having
perforated sides 114 with a plurality of horizontal apertures 116, midway of
the height
of sides 114.
Above and resting on dough stack 102 and below reservoir 110 is an upper
sheet of silicone Bakers paper 118.
In operation, dough stack 102 is placed on paper 101 in tray 85 resting on
support bars 94. Water is poured into reservoir 82. Upper sheet of paper 118
covers
stack 102.
Each sheet of stack 102 has been sprayed or brushed with a coating of canola
oil during the building of stack 102.
Upper reservoir 84, containing water, is lowered into lower reservoir 82 over
tray 85, by means of handles 120.
The aforesaid baking tray assembly 80, is loaded onto oven support frame 122,
either as a single assembly 80, or, typically, as one of a stack of a
plurality of
assemblies.
The assembly stack may be loaded onto support frame 122 outside or inside
oven 93.
During the cooking period of generally 90 minutes at 250 C, (in the range
450 F - 485 F) water vapour (steam) is generated in both lower and upper
reservoirs,
82 and 84, respectively, to provide and maintain the humid atmosphere in the
oven
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chamber and more particularly, around and within the dough stack 102.
Notwithstanding the presence of the two sheets of Bakers paper, moisture,
surprisingly, percolates to stack 102.
In alternative embodiments, water may be introduced during the cooking
period through water conduit inlet 124.
EXAMPLE I
Dough according to the invention is made by admixing strong Bakers Flour
(20kg), salt (0.25kg) and water (10.8kg) initially at 55-60 C, and mixing
these
ingredients for 30 minutes in a standard mixing bowl to the desired
consistency.
Portions of the dough of approximately 4kg were transferred from the mixing
bowl and sealed in polyethylene bags at a temperature of about 4 C overnight.
Unfortunately, this prior art semi-mechanized process has little ability to
economically produce a stack of pastry for authentic classic samosa that is
easy to
peel, while retaining the ability to produce crunchy, non-porous and non-
greasy
samosa, consistently to achieve the quality characteristics of authentic
classical
samosa.
Each of the dough portions are initially flattened by hand, rolling pin and
subsequently fed to a sheeter assembly having a pair of adjustable sheeter
rollers for
gradually reducing the dough sheet thickness on a conveyor feed line to about
0.5 to 3
mm. The pastry is rolled into spools of about 4-20m in length and usually 40cm
to
60cm in width.
The dough sheet is fed from the spool as a single layer onto one or a
plurality
of baking pans aligned lengthwise, and cut from the spool. This process of
feeding
the sheet on the pan(s) is repeated to provide a pastry stack of 20-30 layers
on each
pan.
Each pan is part of a baking tray assembly having a perforated tray upon
which the dough sheet rests and which, itself, rests on a lower water
reservoir. An
upper reservoir rests above the tray. In operation, during the cooking, water
evaporates and circulates in the oven to maintain the humidity.
Other examples in the ranges of 62 - 68% w/w Bakers Flour; 28 - 37% w/w
water and I - 4% w/w salt were used to prepare pastry products in the form of
single
and multi-folded sheets and samosa shells or wraps.
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Although this disclosure has described and illustrated certain preferred
embodiments of the invention, it is to be understood that the invention is not
restricted
to those particular embodiments. Rather, the invention includes all
embodiments,
which are functional or mechanical equivalence of the specific embodiments and
features that have been described and illustrated.
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