FR2839615A1 - Pizza base automated manufacturing procedure consists of cutting portions from partly pre-cooked layer and packaging for subsequent garnishing and cooking - Google Patents

Abstract

The procedure consists of forming a layer or sheet (2) from raw and risen pizza dough, partly cooking the layer and cutting it into individual portions before packaging for subsequent garnishing and cooking. The initial layers or sheets and made from portions of dough (1) rolled as they pass along at least one conveyor (4, 5) to achieve a preferable thickness of 1.5 - 2 mm; the partial cooking is carried out at a temperature of 220 to 350 deg C for a period of 15 - 25 sec on a heated conveyor (8) passing through a tunnel oven (9). The leftovers (11) from the dough after cutting out are cooked and ground to make crumbs, while the cut-out portions are stacked and packed.

Description

parasite chosen from Plathelminths and Nemathelminths and

Arthropods.

  The process and installation for the automated manufacture of a pizza pie base and a pie base obtained from such a method and installation. The present invention relates to a method and an installation for the automated production of a pizza dough base. ready to garnish as well as a pizza pie base obtained in particular by means of the process and

the aforementioned installation.

  2s The manufacture of pizza, in particular in pizzerias, is traditionally carried out as follows. The dough is prepared in advance and stored in the form of a sized raw dough paton. The pizzas are then made on demand and require spreading a paton in the form of a sheet generally in the form of a disc, garnishing this sheet and then cooking the whole. Due to the very elastic nature of the dough, the tart bases thus produced have a significant thickness to allow their handling once filled. Furthermore, the bottom of the pie is always, for reasons of handling and due to the shrinking of the dough at the time of cooking, partially garnished so that it results, after cooking, a rim or "sidewalk" of the pastry base which is often not eaten. In addition, this rim constitutes a limit on the cooking time because it tends to burn during cooking. Consequently, traditional manufacture has significant drawbacks in terms of time for preparing a base of pie, filling of the base of pie and the resulting product is a product whose base of pie has a significant thickness and a rim generally not consumes. At the same time, processes for the industrial manufacture of garnished pizzas have been developed in recent years, as illustrated in particular by international applications WO 99/44429 or WO 00/42857. However, such procedures do not meet the demand of pizzerias who wish to have a choice of ingredients.

the garnish.

  An alternative method consists in industrially manufacturing semi-finished pizza tart bases, as illustrated in particular by international application WO 00/60946 or American patent US-A-6,126,977. These manufacturing methods each time include a step of shaping by molding or cutting a portion of dough to the final dimensions of a pizza pie base before cooking at said base. These methods require, in the case of a molding, a demolding of the bottom of the pie. In the case of a cut before cooking, there is a heterogeneity in the shapes and dimensions of the bottoms

  of pie obtained due to a shrinkage.

  3s An object of the present invention is therefore to propose an automated manufacturing process for pie base made from ready-to-fill pizza dough, the design of which allows the manufacture of pie base with a thickness reduced to less than 2.5 mm and whose entire surface can be covered with a trim. Another object of the present invention is to provide a process of the precise type, the implementation of which makes it possible to obtain a base of easy handling pie having a long shelf life and allowing a reduction in the preparation time of a pizza. Another object of the present invention is to provide an installation for the automated manufacture of pie base made from ready-to-fill pizza dough, the design of which enables high production yields to be obtained. To this end, the invention has for ob] and a process for the automated manufacture of pie base based on pizza dough ready to fill, characterized in that it consists, from a raw pizza dough having previously riser, to shape the pizza dough in the form of a tablecloth or a sheet, to pre-cook the tablecloth or sheet in an incomplete manner, to cut the tablecloth or sheet in the form of one or more individual pieces respectively constituting a bottom of pizza pie and to condition the said one or more

  pieces for later filling and cooking.

  The implementation of an incomplete pre-baking step of the sheet or tablecloth of pizza dough before cutting said sheet to the dimensions of one or more pizza pie bases makes it possible to obtain pie bases. pizza with similar shapes and dimensions of a

another pie shell.

  Furthermore, the precooking of these tart bases makes it possible to produce tart bases with extremely reduced thicknesses because the precooking increases the resistance.

mechanics of such pie crusts.

  Finally, this pre-cooking makes it possible to reduce the cooking time which will be necessary for the cooking of such a bottom.

of garnished pie.

  Finally, because of this pre-baking, it is possible to subsequently coat the entire surface of the pie shell with a filling without having to arrange edges or

sidewalks.

  Furthermore, during this incomplete pre-cooking, there is a swelling of the dough which disappears at the end of cooking and allows a bottom to be obtained, the visible face of which remains soft. Such swelling will not recur during cooking so that the

trim will be held in place.

  The invention also relates to an installation for the 2s automated manufacture of pie base based on pizza dough ready to fill of the type comprising at least one posse for shaping pizza dough in the form of a tablecloth or a sheet, characterized in that it comprises, downstream of said shaping position, an incomplete pre-baking position of the web, followed by a cutting position of the web in the form of one or more individual pieces respectively constituting a base of pizza pie and a packaging posse of the said piece or pieces from the cutting posse for filling and

3s subsequent cooking.

  s The invention also relates to a tart shell in the form of a pizza dough ready to garnish, characterized in that it is in the form of a sheet of pizza dough, free of rim, precooked in an incomplete manner. and

cut after pre-cooking.

  The pizza base thus produced has an extremely small thickness, less than 2.5 mm, the totality of which

  of the surface can be covered with a gasket.

  The bottom of the pizza pie thus obtained by means of the above process and installation does not stick to the work surface or to the oven, does not require any chalking to be used so that the cleaning time, for example in a pizzeria after pizza making is reduced. In the same way, it is no longer necessary, in pizzerias, to store the patons or to have a dough preparation facility. As such pizza pie bases can be kept for several days or even weeks depending on their packaging, inventory management is

  facilitated and increased profitability.

  The invention will be clearly understood on reading the

  2s following description of examples of realization, in

  reference to the accompanying drawings in which: FIG. 1 represents a schematic side view of an installation according to the invention; FIG. 2 represents a schematic view from above of the installation represented in FIG. 1 and FIG. 3 represents a schematic view from above of another embodiment of an installation.

in accordance with the invention.

  As mentioned above, the subject of the invention is in particular an automated manufacturing process for the bottom 3 of pie in the form of pizza dough ready to garnish. This background

  3 pie can also be called semi-pizza crust

  cooked or even pizza base. The pizza dough used for the production of such a pizza base is a dough of the bread dough type. This dough includes, as main ingredients, at least flour, water, oil, fats such as butter, salt and yeast for the fermentation and the lifting of the dough . Traditionally, the preparation of a pizza dough requires a kneading or kneading operation during which the ingredients are mixed and then a step of dividing the dough in the form of dough portions, also called 1-caliber patons, this operation generally carried out by means of a divider before subjecting the patons 1 thus calibrated to a lifting step which is carried out in particular in temperature-controlled chambers. Thus, starting from a raw pizza dough having previously risen, the process which is the subject of the invention consists in shaping said dough in the form of a tablecloth 2 or of a sheet, to pre-bake in an incomplete manner the tablecloth 2 2s or sheet and to cut the tablecloth or sheet in the form of one or more individual pieces respectively constituting a bottom of pizza pie before packaging the said piece or pieces for filling

and subsequent cooking.

  The shaping step can be done in different ways. In the examples represented in FIGS. 1 and 2, each sheet is shaped, by rolling, from a pad 1 running on at least one conveyor belt until a sheet of thickness between 1 and 2.5 mm is obtained. , preferably between 1.5 and 2 mm. To obtain a pizza base with a diameter equal to 30 cm, each paton 1 has a weight of between 100 and 130 g. During the shaping step, each mass of paton type dough 1 positioned on a conveyor belt is therefore subjected to two successive rolling operations and, between two rolling operations, the lowering resulting from the first rolling operation is oriented transversely of said conveyor belt to carry out a second rolling of the roll in a direction substantially perpendicular to the direction of the first rolling. This orientation step can be carried out on the same conveyor belt 5 by rotation of a quarter turn of the lower using an appropriate orientation device 7 as illustrated in FIG. 2 or by passing through a first conveyor belt to a second conveyor belt, the deposition being carried out in such a way that the lowering positioned on the second conveyor belt is offset by 90 relative to its positioning on the first conveyor belt by reference to the longitudinal axis of travel of the conveyor belt. The rolling mills, for their part, are in the form of rotary rolling cylinders arranged above a conveyor belt and cooperating with a roller of the conveyor belt moving at a generally predetermined constant speed. Thus, in the example represented in FIG. 2, a first rolling mill 6 is placed at the end of a first conveyor belt 4 while a second rolling mill 6 is arranged at the end of a second

conveyor belt 5.

  In the example shown in FIG. 3, a mass of raised dough is shaped in the form of a continuous sheet by means of at least one lamination. In this case, the orientation step can be omitted because a

  single rolling by means of a rolling mill 6.

  3s At the end of the shaping step, the tablecloth 2 after the shaping step is directly deposited on a heated conveyor belt 8 passing through inside a pre-baking tunnel 9. The incomplete pre-baking step is performed at a temperature in the range of 220 C 350 C, for a period of time between 5 and 45

  seconds, preferably between 15 and 25 seconds.

  By incomplete pre-cooking means cooking requiring a new cooking of the bottom of the pie 3 after

  filling the bottom 3 of pie for consumption.

  At the end of the cooking tunnel 9, cut out

  piece in the tablecloth each piece constituting a bottom 3 of pizza pie and the scraps 11 are collected from the cut which is subjected to a new baking before

  grinding so as to form a ground type of breadcrumbs.

  To allow this separation of the scraps 11, each device 10 for cutting the cookie cutter constituted by a circular plate with a rim can be fitted with a radial LOA knife ensuring simultaneously with the cutting of the bottom of the pie the cutting of the drop strip 11 extending around said bottom 3. This strip can then be removed by means of an appropriate lOB device for removal and brought by means of a conveyor belt to an oven 12 to complete the cooking of said falls 11. These falls 11 wind then introduced into a grinder 13 so as to recover a crushed breadcrumbs at the outlet. The bottom 3 of the cut pie may be sorted by means of a sorter 18 in the case where the cutting members 10 equipping the cutting posse 16 allow the cutting of two types of size of the bottom of the pie, in particular two types of diameter such as a diameter of 25 cm and a diameter of 30 cm. The pie crust 3 thus obtained

can then be conditioned.

  3s In a preferred embodiment of the invention, the bottom 3 of pizza pie is conditioned in the form of a stack. This stack can be stored inside a tray or directly coated with a film. The conditioning can operate under vice inside a chamber 17A or in a controlled atmosphere. These pie bottoms 3 may still be subjected to a freezing or deep-freezing stage. The packaging under defect keeps the pie base in the refrigerator for several weeks. Once the packaging has been opened, the bottoms 3 can still, after opening, keep several days. In the case where the tart bases 3 are simply coated with a film, the shelf life of

  such tart bases is around 5 to 6 days.

  For the subsequent manufacture of pizza or similar products such as flambé pie, it will suffice to coat the bottom 3 of the pie with a garnish and to cook the whole by means of a traditional pizza oven. The result for pizzerias is a lower investment in terms of equipment. Indeed, due to the realization of these funds 3 of pie press to garnish, it is no longer necessary for the operators in pizzeria to have in particular equipment for kneading or kneading the dough. The time to prepare a pizza is considerably reduced since the bottom 3 of the pie is ready to garnish. Furthermore, due to the pre-baking and the cutting, the entire base of the pie can be coated with a filling. It follows that such a base of pie allows the

  rimless pizza making.

  The installation allowing the implementation of the process

  precise may conform to that shown in the figures.

  Such an installation comprises, downstream of the shaping posse 14, a posse 15 for incomplete pre-baking of the sheet 2 followed by a posse 16 for cutting the sheet in the form of a dune or several individual pieces respectively constituting a bottom 3 pizza pie and a posse 17 for packaging the piece (s)

s from the cutting posse.

  The posse 14 of fa, connage is thus equipped with two successive rolling mills 6 made up of rotary rollers or cylinders

  positioned above at least one conveyor belt.

  As mentioned above, a device 7 for reorientation of the lowering between the first rolling mill 6 and the second rolling mill 6 can be provided. I1 allows the longitudinal axis of the lowering to be offset by 90 relative to the longitudinal axis of the conveyor belt 5. These 1S orientation means can be constituted by the cooperation and the particular positioning of two conveyor belts forming an angle between them or by a pivoting flight capable of reorienting the lower formed at the outlet of the first rolling mill 6. The posse 15 of pre -incomplete cooking is in turn equipped with a conveyor belt 8 scrolling inside a cooking tunnel 9, heated to a temperature between 220 C and 350 C, preferably close to 2s 300 C. 8 conveyor presents means of

  heating independent of those of the tunnel enclosure 9.

  These heating means can for example consist of electrical resistances heating refractory materials constitute the transport surface of the mat 8

conveyor.

  The cutting posse 16 is itself made up of a conveyor belt 19 surmounted by die-cutting cutters 10 animated by an up and down movement controlled in synchronism with the rate of removal of at at least one sheet 2 of pizza dough partially pre-cooked on the conveyor belt 19. As mentioned above, these cutting members 10 may further comprise radially a knife LOA capable of cutting the drop strip 11 disposed around the bottom of the cut pie so as to allow the opening of said strip, facilitating its gripping by means of a member any sample lob such as a needle or a piece, then to position this drop 11 on a conveyor belt bringing said drop to an enclosure 12 for cooking the scraps, this enclosure 12 for cooking the scraps being followed by a device 13 grinding. The product obtained is in the form of a breadcrumb type. Consequently, the cutting posse further comprises means for separating the falls from the cutting and for transferring the falls to a falling treatment posse, this falling treatment posse 11 being constituted by a cooking chamber 12 followed by a

grinding device 13.

  As for the tart bottoms 3, after cutting, packaged. The packaging posse 17 depends on the packaging mode selected. This packaging posse 17 can thus be made up of an installation 17A for placing the tart bottoms 3 stored in the empire state under a vice or a freezing posse for these tart bottoms or else a laying posse of a film around the pie crust 3 obtained. The tart bottoms 3 are then stored, as a function of their packaging, in cold rooms brought to temperatures which depend on the packaging method chosen. Such tart bases are then pressed to be filled. The interveners in pizzeria therefore simply have to eliminate or open the packaging, remove the bottom of the pie, garnish the entire surface of this bottom 3 with pie before proceeding to a traditional baking of the bottom 3 of pie thus garnished. Normally, the cooking time will be slightly reduced compared to the cooking time of a pizza made using a raw pie shell. The preparation of a pizza can be done in a few minutes, the operations of spreading the dough and preparing the bottom of the pie are no longer necessary. In addition, the work station for the preparation of pizza no longer needs to be cleaned as frequently because, at no time, flouring is necessary. The result is a simplification of the operator's work. Furthermore, the pie shell obtained being very thin, generally between 1.5 and 2 mm, the result is a product appreciated by the consumer. Finally, the absence of a ledge or sidewalk makes it possible to consume the entire product. The dough used to make such a pie shell may be free from any preservative. The pie shell obtained is a soft pie shell with

palate, taste and fragrant.

Claims (14)

REVENDI CATI ONS   1. Process for the automated production of bottom (3) of a pizza dough base ready to fill, S characterized in that it consists, from a raw pizza dough having previously risen, to shape the dough   pizza in the form of a tablecloth (2) or a sheet, pre-   bake the tablecloth (2) or sheet in an incomplete manner, to cut the tablecloth (2) or sheet in the form of one or more individual pieces respectively constituting a bottom (3) of pizza pie and to condition the said piece or pieces with a view to subsequent filling and cooking. 2. Method according to claim 1, characterized in that the incomplete pre-cooking step   takes place at a temperature in the range 220 -   350 C for a period of time between 5 and 45   seconds, preferably between 15 and 25 seconds.   3. Method according to one of claims 1 and 2,   characterized in that each sheet (2) is shaped, by rolling, from a pattern (1) running on at least one conveyor belt (4, 5), until a sheet (2) of thickness between 1 and 2.5 mm, preferably between 1.5 and 2 mm.   4. Method according to one of claims 1 to 3,   characterized in that during the shaping step, each mass of dough of the paton type (1) positioned on at least one conveyor belt (4, 5) is subjected to two successive rolling operations and in that, between two rolling operations, the bar from the first rolling is oriented transversely to said belt in order to carry out a second rolling of the bar in a direction substantially perpendicular to the direction of the first rolling.   5. Method according to one of claims 1 to 4,   characterized in that the web (2) from the shaping step is directly deposited on a conveyor belt (8)   scrolling heater inside dinn tunnel (9) pre- cooking.   6. Method according to one of claims 1 to 5,   characterized in that it is cut with a cookie cutter in the tablecloth (2) each piece (3) constituting a bottom of the pizza pie and in that quton collects the scraps (11) from the cut that we re-cook before   grinding so as to form a ground type of breadcrumbs.   7. Method according to one of claims 1 to 6,   characterized in that, prior to the shaping step, the ingredients necessary for the preparation of a pizza dough are subjected to kneading or kneading, in that the dough is divided in the form of a plurality of patons ( 1) sizes that are left to rise before shaping.   8. Method according to one of claims 1 to 7,   2s characterizes in that it conditions the funds (3) of pie pizza in stack form.   9. Installation for the automated manufacture of bottom (3) of pizza dough base ready to fill of the type comprising at least one posse (14) for shaping pizza dough in the form of a tablecloth (2) or diune sheet, characterized in that it comprises, downstream of said shaping posse (14), a posse (15) for incomplete pre-baking of the tablecloth (2), followed by a posse (16) for cutting the tablecloth (2 ) in the form of one or more individual pieces respectively constituting a bottom (3) of pizza pie and a posse (17) for packaging the said piece or pieces from the cutting posse for a   later garnish and cooking.   10. Installation according to claim 3, characterized in that the pre-cooking posse (15) is fitted with a conveyor belt (8) running inside a tunnel (9) for incomplete pre-cooking, heats to a temperature between 250 C and 350 C, the conveyor belt (8) having independent heating means   those of the tunnel enclosure (9).   11. Installation according to one of claims 9 and 10,   1S characterized in that the cutting posse (16) consists of a conveyor belt (19) surmounted by diorganes (10) of die cut (10) animated by an up and down movement controlled in synchronism with the rate of depositing at least one sheet (2) of precooked pizza dough   incomplete on said mat (19).   12. Installation according to claim 11, characterized in that the cutting posse (16) further comprises means (1OA, lOB) for separating the scraps (11) from the cutting and transferring the scraps (11) to a fall treatment posse.   13. Installation according to claim 12, characterized in that the drop treatment posse consists of an enclosure (12) for cooking the falls   followed by a grinding device (13).   14. Pie base (3) in the form of a ready-to-fill pizza dough, 3s characterized in that it is in the form of a sheet of pizza dough, free of record, precooked with