GB2361403A

GB2361403A - A convenience food product and method of making same

Info

Publication number: GB2361403A
Application number: GB0006276A
Authority: GB
Inventors: Peter Dow
Original assignee: GEEST PLC
Current assignee: GEEST PLC
Priority date: 2000-03-15
Filing date: 2000-03-15
Publication date: 2001-10-24
Also published as: GB0006276D0

Abstract

A convenience food product 10 comprises a filling 18 sandwiched between edible layers 12, 14 which are sealed around the edges 16, each layer being of baked or partly baked pizza dough. The food product is suitable for heating in a toaster.

Description

2361403 A CONVENIENCE FOOD PRODUCT AND METHOD OF MAKING THE $AME The

invention relates to a convenience food product and a method of making the same and is primarily concerned with a convenience -food of a kind which can be heated in an electric toaster- Ready prepared convenience foods have been known for many years and are widely sold. The last ten years in particular have seen a significant rise in dernand for fresh chilled convenience foods such as sandwiches which are now sold in large numbers of retail outlets. Swidwiches are, of course, sold in a ready-to-eat condition and are eaten cold. However hot snack,,, for example toasted sandwiches, have gained in popularity and the present invention is concerned primarily with a convenience food product which can serve as a substitute for a -sandwich and which can be heated in an electric toaster by the purchaser prior to being eaten. A known convenience food which is sold for heating in a toaster comprises a filling sandwiched betwe en two thin, soft, biscuit-like layers which are scaled around the edges. However, the thin biscuit-like form of the product means that it does not lend itself as a substitute for a sandwich.

According to one aspect of the invention there is provided a convenience food product in a condition ready for heating in an electric toaster, the product comprising a filling sandwiched betwwn cdiblc layers which are sealed around the edges, each layer being of baked or partly baked pizza dough.

The layers of such a product have a bread-like character and the product is a ready substitute for a sandwich.

2 The layers are preferably of a thickness not too dissimilar to that of bread slices used to make sandwiches.

The product be of rectangular form similar to fbat of a sandwich and may be have a diagonal wea-keninly, line or zone along which the product may be cut or torn into two triangular parts.

The scaled edges may have a crimpcd appearance for aesthetic purposes as well as to provide a good seal between the layers.

Extemal surfaces, of the layers inboard of the edges may have bar marks thercon preferably formed during the dough Oaldng process, again for aesthetic purposes.

The filling may be of a savoury nature such as minced meat vegetables, cheese or a mix of suitable savoury fillings.

The product is preforably supplied to the user in fre-sh chilled condition ready for heatinger in the toaster.

According to a second aspect of the invention their, is provided a method of making a convenirmce food product comprising the stepq of taking a pizza dough, forming the dough into a base layer, placing a filling on the layer, sandwiching the filling between the base layer and a covering layer of pizza dough, sealingg together edgc of the layers to form the -product in an unbaked condition, baking the product to a desired extent and thereafter cooling the baked product.

The method prcferably compri%es controlling tho dough ternperat"C by beating water used to make the dough so as to lie within a temperature range SC to 3(FC and preferably around 24PC. The method may include using water at a 3 temperature different from that of tile flour to bring the temperature of the dough Eo its correct temperature if for any re--vson the flour temperature is incorrect.

Once Lhe dough haa been mixed, it i3 preferably made into the aforesaid layers within a time period ranging from 30 seconds to no more than 50 minutes in an V ambi enL EompeTaturc of 010C to -)OC. 'rhe preferred time period is 10 minutes.

The layers may be made by producing a sbeet of dough, cutting the dough into strips and cutting the strips into piwes to form the layers. The strips may be formed by cutting the sheet by mcans, of a plurality of spaced apart cutter,% whereby the strips are parallel.

The method may comprise maldng the layers of the dough sufficiently thin whereby the layers of the finished product will have a thickness not unlike that of bread slices used to make ordinary sandwiches. in order to ensure that the dough layers. do not rise excessively due to proving, the unbaked product is preferably transferred in a short period of time from a station at which its edges are sealed to a baking station. For example, in an ambient temperature of OPC to 200C the tr4nsfer period may rango from a few secor& to no more than 30 minutes. A preferred time period is around 10.scconds in an ambient temperature of 180C.

The method may include baking the producL at a teraperatare of around 350C (in an electric oven) or around 200C (in a gas oven). Typically, that will cause the product to leave to oven at a temperature of 80C to 95C In order to ensure optimum product life, the method preferably comprises cooling the product over a short time period, for example where the product leaves the oven a temperature around 85"C, the cooling station may be arranged to cool the product to a temperature. of about 5'C. in around 15 to 60 minutes.

^0 3 4 According to a third aspect of the invention there is provided apparatus for performing the method according to the second aspect of the invention or any of the subsidiary clauses relating thereto. The apparatus may include means for producing a sheet of dough and cutting means for cutting the sheeL into parallel strips. The apparatus may also include furthur cutting means for cutting the strips into pieces to fonn the layers of dough.

The way in which a product is presented to a purchaser can have a effect on the purchaser making a decision to buy the product.

According to a fourth aspect of the invention there is provided a pack containing convenienct,- food products in accordance with first aspect of the invention or which are made M- accordance with the second aspect of the invention, the pack compnsmc,r a carton having an upper opening through which the products can be viewed, Ehe products being an-anged in a vertically sta"gered configuration so that a product at the rear of the carton stands- higher than a product at the front of the carton.

Preferably, the, opening is formed so as to face botb upwardly and outwardly of 20 the carton so that side surfaces of both the front and rear product can be viewed when they are in the carton.

The carton preferably has a step formed on a bottom thereof which prqjects upwardly of a-v-- bottom. In such a case, the product at the front of the carton preferably rests on the bottom and the product at the rear of the canon preferably rests on the step.

A convenience food product and a method of makin"." the same will now be described by way of example with reference to the accompanying dmwincgrs in which:- Fig. I is a perspective view of a product in accordance with the invention, fig. 2 is a cross section of the product shown in Fig 1 generally in Une 11-11 in 5 Fig 1.

Fig. 3 is a diagrammatic represenmtion of apparatus used in a production scquence for the product, Fig. 4 is a perspective view of an odge scaler for the product Fig. 5 is a perspective view of a carton for the product the carton being shown partly broken away.

Fig 6 is a diagranunitic representation of alternative apparatus for forming dough layers and Fig 7 is as plan view of the apparatus shown in Fig 6.

Rcferring to Figures 1 and 2, a food product 10 comprises upper and lower layers. 12,14 respectively which are sealed together at their edges 16 and which have a filling 18 such as a mixture of meat and vegetables, sandwiched therebetween. T'ho layers 12,14 are pressed together over a diagonal line or zone 20 to divide the product into two interconnected triangular halvt;s 22,24.

Ibc praduct, 10 is preferably square in external shape and has an overall thickness T and length and width dimensions which will enable the product 10 to be heated or cooked in an electric toaster.

6 The thickness of each of the upper and lower layers 12,14 is somewhat like that of bread sliccs which would be used to make convenfional sandwiches.

Reference is now made. to Figure 3 which illustrates appan-mis used in a 5 production sequence for a product of the kind shown in Figures I and 2.

Flour, yeast and other ingredients indicated collectively at 26 and wliir;h are suitable for the production of pizza dough are blended together in a mixing bowl 28 with water from a supply 10. A mixing machine 32 is used to forin the mixture into a dough which is then deposited in the form of individual roughly formed baUs 36 on a conveyor 34. The conveyer 34 takes the balls 36 to a rolling -tation ' 37 which rolls the individual balls 36 into thin flat layers 38. The rolling station 30 produces the layer 38 to a thickness of approximately 2mm so that the upper and lower layers indicated at 12,14 of tho finished product will havo Lhickness somewhat like that of bread slices used for making conventional sandwicheq. The conveyor 34 carries the layers 38 to a fillincy station 40 where a suitable filling 18 is placed on the layer 38 (constituting the aforesaid base layer). Another layer 38 (constituting the aforesaid covering layer) is then placed on the first layer wid filling I S. In that way, the upper and lower layers 12 and 14 shown in Fig 2 are prepared with the filling 18 sandwiched betwecn them. The time period between placing the dough in the form of balls 36 on the conveyor 34 and the point at which it reacheq the fillingy station 40 is preferably around 20 seconds to contro[ proving of the dough in an ambient temperature of 180C.

0 Next, the conveyor 34 carries the partly formed product to an edge sealing station 46 at which an edge sealer 48 (shown in detail in Figure 4) is pressed on to the partly formed product to seal togtther the edgc.s of the upper and lower layers 12,14. Looking at Figure 4, the sealing device 48 shown is suitable for sealing the edges of two partly formed products 10 simultaneously. The sealing member 30 48 comprises a hollow block 50 which is divided into two identical section% 52.

7 Each section 52 has four internal peripheral walls 54, each of which has a serrated upper ed-C 55 as viewed in Fig 4- A dJagonal blade 56 extends 0 Pre between two comer-, of each section 52 and has a narrow upper edge 58. Each section 52 has ati upstanding peripheral cutting edge 60, A peripheral cutting s 0 ed&e 60 and a transverso cutting edge 61. common to both sections 52 of the block 50 project beyond the serrated upper edges 55.

0 In use, the sealing member 48 is inverted from the Figure 4 position aDd is pressed down on the partly formed product 10 so that the cutting edges 60, 61 penetrate marginal portionsor aicuppor and lower layers, 12, 14 and, at the same time, the serrated edges 55 crimp tngether the edges of the upper and lower layers 12,14 so as to seal them togetlief. To assist sealing the ed,- g ges of the layers 12,14 may be moistened immediately be-fore entering the edge sealing station 46. The diagonal blade 58 forms the Uno 20 shown in Figurcs I and 2 and the narrow edges 58 are preferably curved so that the central region thereof lies below a plane containing the cutting edges 60 so that the, blado 58 will not cut through the layers 12,14.

After leaving, the sealing station 46, the product 10 is conveyed to an oven 62 '10 which, in the example shown. is a travelling eluctric. oven. A gas oven may be used instead. It is important to keep the period from which the product 10 leaves the sealinc, -station 46 to the point at which it reaches the oven 62 as short as possible to avoid excessive proving. A time period of 10 seconds is ideal at an ambient temperature of I 8'C.

The electric oven 62 has a temperature of around 350'C and the product may spend around 5 to 10 juinutes in the oven 62. On leaving the oven, the product 10 is likely to ba at a temperature of around 850C.

After leaving the oven 62, the cooked product 10 is conveyed to a cooler 64.

9 The coolcr 64 is arranged to cool the products as quickly as possible to rainimise 0 bacteria growth. For example, cooler 64 may cool the product by means of a cold air blw,,t to a temperature of around about 5C in around 15 to 60 minutes.

After leaving the cooler 64, the product can be t2ken away and placed in suitable C) packaging. One example of a packag" for the product 10 is shown in Figure 5.

Figure 5 shows a carton folded from a blank and it will be understood that Figure 5 is merely diaggartunatic and docs not show the various flaps required in the construction of the carton. The carton will normally be supplied in a flattencd form for machine erection.

The carton comprises a front panel 66, a rear panel 68, side panels 70 and a base 72. The rear panel 68 projects upwardly from the side panels 70 and has a curved upper edge 74. In all, the carton is intended to depiet somewhat the appearance of a towter. The rear panel 69 and base 72 are formed with respective cuts 76,78 and sections 68a. 72a bounded by the cuts 76,78 are pressed inwardly to form a stop 80. In use, the carton will hold two of the, products 10. The first product will rest on the base 72 between the step 80 mid front panel 66 whilst the second product 10 will rest on the section 68a of the step RO between the first product 10 and the rear panel 68 so as to stand higher than tho first product 10 to give a staggered appearance. In that way, surfaces of both products 10 will be partly visible. Both of the products 10 in the carton will pi:oject through the open upper end (indicated at 82) of the carton but the reannost product 10 will not project above the edge. 74. Once the product 10 is placed in the. carton, the carton can be wrapped in transparent cellophane prior to shipping, to a retail sales outlet.

9 Reference is now made to the apparatus shown in Figs 6 and 7 in which parts. corresponding to parts shown in Fig 3 carry the sarne reference numerals and will not be described in detail- After the dough has been mixed in the mixing bowl 28, it is passed to a sheeter 84 -which produces a wide sheet 96 of dough having a tbiclmess of around 2mm. As it leaves the sheeter 84. the sheet 86 is laid on Lo the conveyor 34. The conveyer 34 moves tho sheet 86 to a cutting station 88 where it is cut by disc cutter-, 90 into a series of parallel strips 92. from there, the strips pass to a 10guillotining station 94 where the strips 92 are cut by a transwexse Made 96 into short longths to form the layers 38 which are then carried by the conveyor 34 to the fillin- station 40 as shown in Fi-, 3. Thus, the apparatus shown in Figs 5 and 6 can replace the section of the appitratiiq shown in Fig 3 upstream of tho filling station 40. 15 For aesthetic purposes, the external surfaces of the upper and lower layers 12, 13 may have bar marks formed thereon during the bakincyp process in the oven 62.

The use of pizza dough is particulw-ly advantageous as it provides a final product 20 having bread slice like layers 12,14 and thoreforc, the product makes an 0 acceptable substitute for sandwiche!;.

The product '10 may be fully cooked or partially cooked in the oven 62 for heating or final cooking, in a toaster.

t'

Claims

1. A convenience food product for heating in an electric toaster, the product comprising a filling sandwiched between edible layers which are sealed around the edges, each layer being of baked or partly baked pizza dough.

2. A convenience food product according to claim I in which the product is of rectangular form and has a diagonal weakening line or zone along which the product may be cut or tom into two triangular parts.

3. A convenience food product according to claim I or 2 in which the sealed edges are crimped.

4. A method of making a convenience food product comprising the steps of taking a pizza dough, forming the dough into a base layer, placing a filling on the layer, sandwiching the filling between the base layer and a covering layer of pizza dough, sealing together edges of the layers to form the product in an unbaked condition, baking the product to a desired extent and thereafter cooling the baked product.

5. A method of making a convenience food product according to claim 4 comprising supplying the product to a user in a fresh chilled condition ready for heating in a toaster.

6. A method of making a convenience food product according to claim 4 or 5 which further comprises the step of controlling the dough temperature by heating water used to make the dough so that the temperature of the dough lies within a temperature range 5T to 30T.

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7. A method of making a convenience food product according to claim 4, 5 or 6 in which the dough is made into the layers within a time period of between 30 seconds and 50 minutes.

8. A method of making a convenience food product according to any of claims 4 to 7 in which the method of making the dough into layers comprises the steps of producing a sheet of dough, cutting the dough into strips and cutting the strips into pieces to form the layers.

9. A method of making a convenience food product according to claim 8 in which the strips are formed by cutting the sheet by means of a plurality of spaced apart cutters whereby the strips are parallel.

10. A method of making a convenience food according to any of claims 4 to 9 comprising transferring the unbaked product from a station at which its edges are sealed to a baking station.

11. A method of making a convenience food according to claim 10 in which the transfer period is around 10 seconds in an ambient temperature of 18 'C.

12. A method of making a convenience food product according to any of claims 5 to 9 which further comprises the step of baking the product at a temperature of around 3 500C in an electric oven.

13. A method of making a convenience food product according to any of claims 4 to I I which further comprises the step of baking the product at a temperature of around 200T in a gas oven.

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14. A method of making a convenience food product according to any of claims 4 to 12 which ftirther comprises the step of cooling the product over a short period of time.

15. A pack containing convenience food products in accordance with any one of claims I to 3 or which are made in accordance with any one of claims 4 to 12, the pack comprising a carton having an upper opening through which the products can be viewed, the products being arranged in a vertically staggered configuration so that a product at the rear of the carton stands higher than a product at the front of the carton.

16. A pack containing convenience food products according to claim 15 in which the opening is fon-ned so as to face both upwardly and outwardly of the carton so that side surfaces of both the front and rear product can be viewed when they are in the carton.

17. A pack containing convenience food products according to claim 15 or 16 in which the carton has a step formed on a bottom thereof which projects upwardly of the bottom 18. A pack containing a convenience food product according to claim 7 in which the product at the front of the carton rests on the bottom and the product at the rear of the carton rests on the step.

18. A convenience food product substantially as herein described, with reference to the accompanying drawings.

19. A method of making a convenience food product substantially as herein described, with reference to the accompanying drawings.

20. A pack containing convenience food products substantially as herein described, with reference to the accompanying drawings.