GB2340023A

GB2340023A - Moulding of pizza bases with raised side edges

Info

Publication number: GB2340023A
Application number: GB9915145A
Authority: GB
Inventors: Jacinta Darmon; Gene Mcgillicuddy
Original assignee: BILLCREST PROD Ltd
Current assignee: BILLCREST PROD Ltd
Priority date: 1998-06-29
Filing date: 1999-06-29
Publication date: 2000-02-16
Anticipated expiration: 2019-06-29
Also published as: GB9915145D0; EP1094714A1; IE990542A1; GB2340023B; IES990544A2; WO2000000035A1; AU4642899A; IES990543A2

Description

20340023 "A product" latroduction

The invention reUtes to pizzas and in particular to a niethod and apparatus for manufacturing rimmed pizzas. Various processes for manufacturing pizzas are known. One such process is descn'bed in our UK 2284738-A. 10 There is a need for an apparatus and Process fbr manufacturing rinuned pizzas in which the side edge of the pizza is raised and defines a well for receiving sauce, cheese, tc)ppings and the J&e. 15 Statements of Inventio

According to the invention &= is provided a method for forming a pizza dough into a rimmed pizza shape having a raised side edge, the method induding the steps of-20 placing a single portion of dough onto a pizza tray; tamping the dough to spread the dough partiany on the tray; initW proving the dough after tamping, first pressing the tamped dough to finther spread the dough on the tray; intermediate proving the dough after first pressing; 30 final pressing the dough into a rimmed pizza shape; and 4 1 -2 final proving the dough after final pressing.

In a preferred embodiment of the invention the final proving of the dough is carried out in two stages.

In one embodiment of the invention the single portion of dough is formed into a ball of dough prior to placing onto a pizza tray.

Preferably the method includes the step of applying a release agent onto the dough prior to one or more of tarnpin g, first pressing and final pressing of the dough. Most preferably the method includes the step of applying a release agent onto the dough prior to tamping, prior to first pressing and prior to final pressing of the 15 dough. In a preferred embodiment of the invention the pizza tray comprises a number of recesses for receiving separate single portions of dough and die tamping, initial proving, first pressing, intermediate pressing, final pressing and final proving are 20 carried out when the single dough portions are positioned in the tray.

In a particularly preferred embodiment of the invention the final pressing comprises:

engaging a lower portion of a damming ring in flat scaling engagement with a tray rim; and advancing a plug me ans including a dough engaging lower face and a side wall extending upwardly from the dough engaging lower face into the pre30 pressed dough to form the dough into a pizza shape with a raised side edge.

I In this case preferably the lower portion of the damming ring has an inner cut away to define together with the dough engaging lower section of the plug side wall a dough rim receiving recess and the method includes the step of at least partially filling the recess with dough on pressing the plug into the tray.

In a particularly preferred embodiment on forming, the rim ratio of the height of the tray sidewall to the rim thickness defined between the dough engaging lower section of the side wall of the plug means and the side wall of the tray is at least 3: 1, preferably at least 4: 1, and ideally about 4:1 to 5: 1.

In another preferred arrangement, on fbrming, the base Tatio of the height of the tray sidewall to the base thickness defined between the dough engaging lower face of the plug means and the base of the tray section is at least 4.- 1, preferably at least 5: 1, and ideally is approximately 6: 1.

In another aspect the invention provides an apparatus for forming a pizza dough into a rimmed pizza shape having a raised side edge, the apparatus comprising a tray to receive a pre-pressed pizza dough and a forming means to form the pre pressed dough into a rimmed pizza shape; the tray having at least one section with a base, a side wall extending upwardly from the base and defining a central recess, the tray having an upper outwardly extending rim; the dough forming means comprising a damming ring for engaging the rim of the tray and a plug means which is slidably movable relative to the damming ring; I I the tray and plug means being of complementary shape to provide a pathway for pressed dough to form into a pizza shape with a raised side edge; the plug means including a dough engaging lower face and a side wall extending upwardly from the dough engaging lower face, the side wall having a dough engaging lower section and an upper damming ring engaging secdon for scaling engagement with the damming ring; and the damming ring having a flat tray rim engaging lower portion for flat sealing engagement wiih the tray rim.

In one embodiment of this aspect of the invention, on forming, the rim ratio of the height of the tray sidewall to the rim thickness defined between the dough engaging lower section of the side wall of the plug means and the side wall of the tray is at least 3: 1, preferably at least 4: 1, and ideally about from 4: 1 to 5: 1.

In another embodiment of this aspect of die invention, on forming, the base ratio of the height of the tray sidewall to the base thickness defined between the dough engaging lower face of the plug means and the base of the tray section is at least 4: 1, preferably at least 5: 1, and ideally approximately 6:1.

Tn a preferred embodiment of the invention the lower portion of the damming ring has an inner cut-away to define together with the dough engaging lower section of the plug side wall, a dough rim receiving recess which is at least partially filled with dough on pressing of the plug into the tray Preferably the inner cut-away of the damming ring is of curvilinear shape to define a portion of the dough rim receiving recess. Ideally, the inner cut-away of the damming ring is of arcuate shape extending upwardly from the tray rim engaging face.

-5.

In one arrangement the dough engaging lower section of the plug side wall comprises an outwardly and upwardly inclined portion leading into a transition portion to the upper damming ring engagement portion. Preferably the transition portion defines a portion of the dough rim receiving recess. Most preferably the transition portion defines together with the cut-away of the damming ring a substantially continuous arcuate dough receiving recess for receiving an upper edge of the pizza dough rim.

In another embodiment of the invention the tray comprises a plurality of tray sections, each for receiving dough for forming into a rimmed pizza shape.

Preferably the tray comprises a planar upper wall in which the central recesses are formed, the upper wall defining the rim for each recess. Ideally, the tray includes a side wall extending downwardly from the upper wall.

In a preferred embodiment the apparatus includes a tray support for supporting the tray, the tray and tray support having locator means for accurately locating the tray relative to the tray support. Preferably, the locator means comprises at least two spaced-apart locator pins on one or other of the tray and tray support for engagement with a corre5ponding recess in the other of the tray and tray support.

Ideally, the locator pins are tapered to facilitate aligrunent with the locator holes.

Preferably the locator holes are provided in the tray and the locator pins are provided in the tray support.

In another embodiment of the invention the plug means has a plurality of air outlets in a lower dough engaging face thereof Preferably the lower face of the plug is at least partially of porous metal. In a preferred arrangement the porous metal has an average pore size of from 10 to 50 microns.

I 6.

in a further aspect the invention provides an apparatus for forming a pizza dough into a rimmed pizza shape having a raised side edge, the apparatus comprising a tray to receive pizza dough, a tray support for supporting the tray and a dough forming means to form the dough into a rimmed pizza shape. 5 the tray comprising a plurality of tray sections, each section having a base, a sidewall extending upwardly from the base and defining a central dough receiving recess, each tray section having an upper outwardly extending rim; the dough forming means comprising a damming ring for engaging the rim of the tray section and a plug means which is slidably movable relative to the damming ring, each tray section and plug means being of complementary shape to provide a pathway for pressed dough to form into a pizza shape with a raised side edge-, and the tray and tray support having locator means for accurately locating the tray relative to the tray support.

In one embodiment of the invention the locator means comprises at least CWo spaced-apart locator pins on one or other of the tray and tray support for engagement with a corresponding recess in the other of the tray and tray support.

Preferably the locator pins are tapered to facilitate alignment with die locator holes. Ideally the locator holes are provided in the tray and the locator pins are provided in the tray support.

The invention also provides rimmed pizzas whenever made using the method and/or apparatus of the invention.

Brief Descri on of the Drawinga PW-- The invention will be more clearly understood from the following description thereof given by way of example only with refuence to the accompanying drawings, in which:- Fig. 1 is a block diagram illustrating a method for prepwing pizzas according to the invention, Fig. 2 is a perspective view of a tray forming part of a pizza forming apparatus of the invention; Fig. 3 is a perspective view of part of the tray of Fi& 2, in use; Fig. 4 is a perspective partially cut-away view of a detail of the tray; Fig. 5 is a cross sectional view of the detail of Fig. 4; Fig. 6 is a diagrammatic side view of a pizza dough forming apparatus of 20 the invention; Fig. 7 is an exploded penpcctive view of a detail of part of the apparatus of Fig, 6; Fig. 8 is a cross sectional view of a final dough press apparatus; Fig. 9 is a cross sectional view of part of the dough press of Fig 8 on an enlarged scale; Figs. 10(a) to 10(g) are cross sectional views of the apparatus in different positions of use; Fig. 11 is a cross sectional view of an alternative damming ring, plug and tray of the apparatus; and Fig, 12 is an underneath plan view of the plug offig. I I Dctakd -D-eSCdRI-I!QR p,derring to the drawings there is illustrated a method and an apparatus for forming a rimmed pizza 3 with a raised side edge which defines a well for receiving sauce, cheese and various toppings.

The apparatus includes a tray I to receive pizza dough and a dough fbrming means 2 to form the dough into a rimmed pizza shape 3.

in this case the tray 1 which is shown in detail in Figs. 2 and 3 comprises a plurality, in this case six tray sections 5, each for receiving pizza dougJb to be formed into a rimmed pizza shape. Each tray section 5 has a base 6 and an inclined side wall 7 which ex ds upwardly and outwardly from the base 6 to defte a central dough receiving recess 8. The tray sections 5 are fbrmed from a sheet having a planar upper wall 10 and downturned side edge walls, 11. Ile planar upper wall 10 surrounding each recess 8 defines an upper outwardly extending flat rim 15.

The tray 1 is mounted on a tray support 20 which supports the tray 1, especiall:y during dough prcssm& The tray 1 and tray support 20 have locator meam far accurately locating the tray relative to the tray support. ne locator means comprises at least two spaced-apart locator pins 21'which in this case extend upwardly from the tray support 20 to engage with corresponding locator holes 22 in the planar wall 10 of the tray 1. The locator pins 21 are tapered at an upper end thereof to facilitate accurate alignment with the locator holes 22.

A dough fbrmm-g means in this case is provided for each tray section 5. Each dough forming means comprises a damming ring 30 for engaging the rim 15 of a tray section 5 and a plug means 40 which is slidably movable in the vertical direction relative to the damming ring 30. The plug 40 includes air inlet means dosed by a valve plate 42 which is movable by air pressure through ports 43 from a dosed position to an open position illustrated to release the dough from the plug as the plug 40 is lifted out of engagement with the dough. Typically locimuts 41 are used to limit the travel of the air release valve plate 42.

Referring in Particular to Fig. 6 a number of pressing head 40/damming ring 30 combinations are mounted - on a common support 45 for substantially simultaneous pressing of a number of dough portions, especially for pressing dough portions in each of the six tray sections 5. The support is movable by main rams 46- Each pressing head 40/darnming ring 30 combination 2 is independently movable of the main support 45 by separate rams 47. This is important in ensuring that opfumum final pressing is achieved and in particular to provide additional tolerance to cater for any small variation in the amount of dough located in the tray recesses 8.

Referring in Particular to Fig. I there is illustrated the method for forming rimmed pizzas according to the invention using the tray and Pressing system as described above.

In a first step 100 the dough receiving recesses 8 of the tray I has a release agent such as a vegetable oil applied. A pizn dough is mixed and divided into single portions which are formed into balls of dough. A ball of dough is placed in each tray recess 8 in step 10 1 - A release agent is applied to the dough ball in step 102.

Optionally the release agent may be further sPread over the dough ball in a huther Step. In SteP 104 the ball of dough is tamped into a partially flattened configuration 105 which is typically about 50% of the final dough diameter. The tamped dough is proved in step 106. Further release agent is applied to the dough prior to first stage pressing 108. In the first stage pressing the dough is Rather spread into the configuration 109 which is typically about 80% of the final dough diameter. The first pressed dough is then proved 110 prior to final pressing 111.

The final pressing vnU be described in more detaA below.

The rimmed pizza dough thus formed then undergoes final proving in two stages 112, 113 prior to baldng 114 and de-pannimg 115. Each proving st;age 106, 110, 112, 113 is typically carried out at 300 to 40'C for up to 15 minutes at greater than 50% humidity. After de-panning the base is frozen, then a sauce is applied to the rimmed pizza base, toppingS are applied to the sauce, the finished pizza is packaged and frozen.

We have found that the preliminary tamping fbllowed by first pressing prior to final pressing is important in producing rimmed pizzas to a high level of efficiency. The presentation of the dough in the pre-pressed configuration fbr final pressmg greatly increases the efficiency and speed at which the final pressmg may be effected.

In more detail, and referring especially to Figs. 8 and 9, for final pressing the plug includes a dough engaging lower face 44 and a side wall extending upwardly from the dough engaging face 44. Tbe side wall has a dough engaging lower section 55 and an upper damming ring engaging section 56 fbr sealing engagement with the damming ring 30. The side wall sections 55, 56 are interconnected by a transition 57. The dough enga&g lower side wall section 44 is outwardly and upwardly inclined to match the profile of the tray side wall and thereby define a dough run receiving space therebetween. The transition 57 is of curvilinear arcuate shape curving upwardly and outwardly towards the damming ring 30.

Tie dainming ring 30 has a tray rim engaging lower portion 35 which mgages, in meta to metal sealing contact with the rim 15 of the tray section 5. The lower portion 35 also has an inner cut-away 36 to defte, together with the dough engaging lower section of the plug side wall 55 a dough rim receiving recess 38 which is filled with dough on prmmg of the plug into the tray.

The inner cut-away portion 36 of the dararriing ring is of curvilinear arcuate shape extending upwardly and inwardly from the tray rim engaghig face. The transition portion 57 of the plug side wall defines together with the cut-away 36 of the darnming ring a substantally arcuate dough receiving recess 50 for receiving an upper edge of the pizza dough nm. We have fbund that this is a very unportant feature fbr a number of reasons. The extra volume defined by the recess 50 above the level of the tray rim 15 greatly fkcilitates efficient pressing of dough into the desired shape. This extra volume introduces a tolerance to cater for any slight variation in dough location and/or amount Such a slight variation is taken up by the excess volume. In addition, the damming ring and plug arc effm-tively sealed at the junction therebetween. However, this seal is effectively stepped back from the rim of the pizza dough and is less critical than in other arrangements.

We have found that the run ratio of the height of the tray sidewall 7 to the rim thicImess tR defined between the dough engaging lower section 55 of the si&-wall of the plug means 40 and the side wall 7 of the tray I is preferably at least 3:1, ideally greater than 4: 1, and most preferably from approximately 4:1 to 5: 1. This is important in ensuring that a rimmed sidewall of the pizza dough is fbrmed which is relatively thin and crispy while maintdning the required integrity in manufacture and -in use.

We have also found that the base ratio of the height of the tray sidewall 7 to the base thickness to defined between the dough engaging lower face 44 of the plug 40 and the base 6 of the tray I is prefi=bly at least 4: 1, most pre&rably at least 5: 1, and ideally approximately 6: 1. This is important in ensuring that the base of the final rimmed pizza has good organoleptic properties of thinness and crispiness wbile maint6ning the required integrity in manufacture and -in use.

in use, and referring particularly to Figs. I O(a) to 10(g), in a first step a tray I with the pre-pressed dough 60 in place is supported on the tray support 20 and presented under the plug 40 (Fig. 10(a)). In this position the damming ring 30 is evended to engage the tray rim 15. The damming ring 30 may be advanced (Fig.

10(b)). Ihe damming ring is typically pneumatically actuated. Ihe plug 40 is then advanced typically by hydraulic action through the configuration of Fig.

10(c) to the engaged pressing position of Fig. 10(d) in which the dough is pressed into a rimmed shape 61. The valve 42 is operated to dislodge the centre of the dough from the plug 40 as illustrated in Fig. 10(e). Air is then introduced through the valve across the faces of the dough and plug 40 to assist in release of the plug from the dough as the plug 40 and damming ring 30 are retracted (Fig. 10(o). Air supply is continued until the plug 40 and damming ring 30 have been raised (Fig IOW) and the tray 1 with the formed rimmed pizza dough shape 61 is led away ftom the pressing.

Referring now to Figs. I I and 12 there is Mustrated another apparatus for fbrming a runined pizza winch is simila to that described above and like parts are assigned the same reference numerals. In this case at least portion of the dough engaging face is air pervious to deliver a stream of air across substantially all of the upper surface of the dough. The air pervious portion is provided by a plate 70 of a sintered porous metal with pores of a size of typically 20 microns, Such a porous metal is available from Mott Corporation. The air film thus apphed provides a dough release which extends over a substantial paxt of the top of the formed dough to allow ease of release of the plug 40 from the dough 61, after forming.

The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail.

(MAM L A method for forming a pizza dough into a rimmed pizza shape having a raised side edge, the method including the steps ofi placing a single portion of dough onto a pizza tray-, tamping the dough to spread the dough partially on the tray; initial proving the dough after tamping; first pressing the tamped dough to Ruer spread the dough on the tray; intermediate proving the dough after first pressing-, final pressing the dough into a rimmed pizza shape; and final proving the dough after final pressing 2. A method as claimed in claim 1 wherein the final proving of the dough is carried out in two stages.

3. A method as claimed in claim 1 or 2 wherein the single portion of dough is formed into a ball of dough prior to placing onto a pizza tray.

4. A method as claimed in any preceding claim including the step of applying a release agent onto the dough prior to one or more of tamping, first pressing and final pressing of the dough.

5. A method as claimed in any preceding claim induding the step of applying a release agent onto the dough prior to tamping, prior to fint pressing and prior to final pressing of the dough.

6. A method as claimed in any preceding claim wherein the pizza tray comprises a number of recesses for receiving separate single portions of dough and the tamping, initial proving, ffnt pressing, intermediate pressing, final pressing and final proving are carried out when the single dough portions are positioned in the tray.

7. A method as claimed in any preceding claim wherein the final pressing comprises:

- engaging a lower portion of a damming ring in flat scaling engagement with a tray rim, and advancing a plug means incluffing a dough engaging lower face and a side wall extending upwardly from the dough engaging lower face into the pre- pressed dough to form the dough into a pizza shape with a raised side edge.

8. A method as claimed in claim 7 wherein the lower portion of the damming ring has an inner cut-away to define together with the dough engaging lower section of the plng side wall a dough rim receiving recess and the 25 method includes the step of at least partially filling the recess with dough on pressing the plug into the tray. 9. A method as claimed in claim 7 or 8 wherein on ffirming the rim ratio of the height of the tray sidewall to the rim thickness defined between the 30 dough engaging lower section of the side wall of the plug means and the side wall of the tray is at least 3:1.

10. A method as claimed in claim 9 wherein the rim ratio is at least 4: 1.

11. A method as claimed in claim 10 wherein the rim ratio is from 4:1 to 5: 1.

12. A method as claimed in any of claims 7 to 11 wherein, on fbrm the base ratio of the height of the tray sidewall to the base thicimess defined between the dough enga&g lower face of the plug means and the base of the tray section is at least 4: 1. 10 13. A medwd as claimed in claim 12 wherein the base ratio is at least 5: 1.

14. A method as claftned in claim 13 wherein the base ratio is approximately 6:1.

15. Apparatus for forming a pizza dough into a rimmed pizza shape having a raised side edge, the apparatus comprising a tray to receive a prepressed pizza dough and a forming means to form the pre-pressed dough into a rimmed pizza shape; the tray having at least one section with a base, a side wall extending upwardly from the base and defining a central recess, the tray having an upper outwardly Wending rim; the dough forming means comprising a damming ring for engaging the rim of the tray and a plug means which is slidably movable relative to the damming ring; the tray and plug means being of complementary shape to provide a 30 pathway for pressed dough to form into a pizza shape with a raised side edge; the plug means including a dough engaging lower face and a side wall extendmg upwardly from the dough engagmg lower face, the side wau havmg a dough engaging lower section and an upper dammmg ring engaging section for sealing engagement with the damming ring; and the daraming ring bavmg a flat tray rim engaging lower portion for flat sealing engagement with the tray run.

16. Apparatus as claimed in claim 15 wherein, on forming, the rim ratio of the height of the tray sidewall to the rim thickness defted between the dough engaging lower section of the side wall of the plug means and the side wan of the tray is at least 3:1.

17. Apparatus as claimed in claim 16 wherein the rim ratio is at least 4: 1.

18. Apparatus as claimed in claim 17 wherein the rim ratio is from 4:1 to 5: 1 19. Apparatus as claimed in any of claims 15 to 18 wherein, on forming, the base ratio of the height of the tray sidewall to the base thickness defined between the dough engaging lower face of the Iug means and the base of the tray section is at least 4:1.

20. Apparatus as claimed in claim 19 wherein the base ratio is at least 5: 1.

21. Apparatus as claimed in clairn 20 wherein the base ratio is approximately 6:1.

22. Apparatus as claimed in any of claims 15 to 21 wherein the lower portion of the damming ring has an inner cut-away to define together with the dough engaging lower section of the plug side wall, a dough rim receiving recess which is at least partially filled with dough on pressmg of the plug into the tray.

23. Apparatus as claimed in any of claim 15 to 22 wherein the inner cutaway of the damming ring is of curvilinear shape to define a portion of the dough rim receiving recess.

24. Apparatus as claimed in claim 23 wherein the inner cut-away of the danuning, ring is of arcuate shape extending upwardly from the tray rim engaging face.

25. Apparatus as claimed in any of claims 15 to 24 wherein the dough engaging lower section of the plug side wall comprises an outwardly and upwardly inclined portion leading into a transition portion to the upper damming ring engagement portion.

26. Apparatus as claimed in claim 25 wherein the transition portion defines a portion of the dough rim receiving rec:ess.

27. Apparatus as claimed in claim 26 wherein the transition portion defines together with the cut-away of the damming ring a substantially continuous arcuate dough receiving recess for receiving an upper edge of the pizza dough rim.

28. Apparatus as claimed in any of claims 15 to 27 wherein the tray comprises a plurality of tray sections, each for receiving dough fbr forming into a rimmed pizza shape.

29. Apparatus as claimed in claim 28 wherein the tray comprises a planar upper wall in which the central recesses are fbrmed, the upper. wall defining the rim fbr each recess.

30. Apparatus as claimed in claim 29 wherein the tray includes a side wall extending downwardly from the upper wall.

31. Apparatus as claimed in any of claims 28 to 30 including a tray support fbr supporting the tray, the tray and tray support having locator means for accurately locating the tray relative to the tray support.

32. Apparann as claimed in claim 31 wherein the locator means comprises at least two spaced-apart locator pins on one or other of the tray and tray support fbr engagement with a corresponding recess in the other of the tray and tray support- 33. Apparatus as claimed in claim 32 wherein the. locator pins are tapered to facffitate ahgament with the locator holes.

34. Apparatus as claimed in clairn 32 or 33 wherein the locator holes are provided in the tray and the locator pins are provided in the tray support.

35. Apparatus as claimed in any of claims 15 to 34 wherein the plug means has a plurality of air outlets in a lower dough engaging face thereoE 36. Apparatus as claimed in claim 35 wherein the lower face of the plug is at least partially of porous metal.

37. Apparatus as claimed in claim 36 wherein the porous metal has an average pore size of from 10 to 50 microns.

38. Apparatus for forming a pizza dough into a rimmed pizza shape having a raised side edge, the apparatus comprising a tray to receive pizza dough, a tray support fbr supporting the tray and a dough forming means to fbrm, the dough into a rimmed pizza shape. 5 the tray comprising a plurality of tray sections, each section having a base, a sidewall extending upwardly from the base and defining a central dough receiving recess, each tray section having an upper outwardly extending rim; 10 the dough forming means comprising a damming ring for engaging the ran of the tray section and a plug means which is slidably movable relative ti) the darnming ring; each tray section and plug means being of complementary shape to provide apathway fbr pressed dough to form into a pizza shape with a raised side edge; and the tray and tray support having locator means for accurately locating the tray relative to the tray support.

39. Apparams as claimed in claim 38 wherein the locator means comprises at least two spaced-apart locator pins on one or other of the tray and tray support for engagement vnth a corresponding recess in the other of the tray and tray support- 40. Apparatus as claimed in claim 39 wherein the locator pins are tapered to facilitate alignment with the locator holes.

41. Apparatus as claimed in claim 39 or 40 wherein the locator holes are Provided in the tray and the locator pins are provided in die tray support.

42. A method for fbrming a pizza dougb into a rimmed pizza shape substaDtiaUy as hereinbefore described with reference to the accompanyiag drawings- 43. Apparatus fbr fonnM a pizza dough into a rimmed pizza shape substannay as hcrcinbefore dcscn-bed with reference to the accompanying drawings.

44. Rimmed pizzas whenever prepared by a method daimed in any of claim 1 to 14 and 42 and/or using an apparatus as claimed in any of daims 15 to 41 and 43.