IE20001027A1 - A Process for Manufacturing a Food Product - Google Patents

Abstract

A process for manufacturing a filled tortilla comprises the steps of preparing a tortilla dough, forming the tortilla dough into a sheet, laminating the tortilla dough sheet and folding the laminated dough sheet back onto itself. The folded dough sheet is further laminated, docked and the tortilla dough sheet is cut in-line into a desired shape. The tortilla shapes are baked and cooled. The cooled tortilla shapes are directed into at least two separate lanes. Water is sprayed onto the upper and/or bottom surface of the tortilla shapes in the lanes and the tortilla shapes are delivered to a filling and folding station at which a filling is applied to a portion of the tortilla shape. The tortilla is folded onto the filling to form a wrapped tortilla and the wrapped tortillas thus formed are frozen.

Description

The invention relates to a process for manufacturing a filled tortilla.

Filled tortillas are known. There is however a need for a process for producing such filled tortillas on a factory scale while providing a product which can be readily cooked by the user and which has good physical and organoleptic properties of taste and mouth feel.

This invention is directed towards providing such a process.

Statements of Invention According to the invention there is provided tortilla comprising the steps of: preparing a tortilla dough; a process for manufacturing a filled OPEN TO PUBLIC INSPECTION UNDER SECTION 28 AND RULE 23 JNL No. qf forming the tortilla dough into a sheet; laminating the tortilla dough sheet; folding the laminated dough sheet back onto itself; further laminating the folded dough sheet; docking the laminated tortilla dough sheet; BI91B2T RYE007/C -2cutting the tortilla dough sheet in-line into a desired shape; baking the tortilla shapes; cooling the tortilla shapes; directing the cooled tortilla shapes into at least two separate lanes; spraying water onto the upper and/or bottom surface of the tortilla shapes in the lanes; delivering tortilla shapes to a filling and folding station; applying a filling to a portion of a tortilla shape; folding the tortilla onto the filling to form a wrapped tortilla; and freezing the wrapped tortillas thus formed.

In a preferred embodiment of the invention the cooled tortilla shapes are directed into at least three separate spaced-apart lanes.

Preferably the process includes the step of transversely aligning the tortilla shapes of adjacent lanes to substantially simultaneously present a tortilla from each lane for filling and folding.

In one embodiment of the invention water is sprayed onto the upper and/or bottom surface of the tortilla shape from spray heads aligned with each lane.

RYE007/C -3Ιη a preferred embodiment the tortilla shapes are led over an open conveyor such as a mesh conveyor as the water is sprayed onto the upper face of the tortilla shapes, excess spray and/or run off being collected below the conveyor.

Preferably the tortilla shapes are baked in an oven at a temperature of from 235°C to 245°C.

Ideally the tortilla shapes are baked for a period of from 35 to 60 seconds.

Preferably, after baking, the tortilla shapes are cooled to a target temperature of approximately 15°C.

The invention also provides filled tortillas whenever manufactured by a process of the invention.

Detailed Description The invention will be more clearly understood from the following description thereof given by way of example only.

A tortilla dough is prepared by mixing flour, water and yeast. The dough is formed into a sheet and the sheet is laminated. The laminated tortilla dough sheet is folded back on itself and the folded sheet is further laminated. The laminated dough sheet is then docked by impregnating the dough with a plurality of small (generally about 1mm) holes. The tortilla dough sheet is cut in-line into a desired shape which is a general circular disc shape. The tortilla shapes are then baked in an oven at a temperature of from 235°C to 245°C for a period of from 35 to 60 seconds. ΙΡί 0 ί β 27’ RYE007/C -4The baked tortilla shapes are cooled in a cooler to a target temperature of about 15°C. The cooled tortilla shapes are directed into at least two and preferably three separate transversely spaced-apart lanes. The tortilla shapes are transversely aligned to present a tortilla shape substantially simultaneously from each lane. This is achieved by positioning a plurality of spacers to guide the tortilla shapes exiting randomly from the cooler into predetermined lanes at predetermined positions.

The aligned tortilla shapes are then led over a mesh conveyor and water from separate spray heads associated with each lane is sprayed onto the upper face of the tortilla shapes. Excess spray and run-off is collected below the mesh. The lower face of the tortilla shapes is also sprayed with water from below.

The arrangement is such that tortillas are available on demand by a feed conveyor for delivery to a filling and folding station. There are three such stations, one associated with each lane. At the filling station a filling is applied to a centre portion of the tortilla and the tortilla is folded over to enwrap the filling. The wrapped tortillas thus formed are led along an outfeed conveyor to a spiral freezer.

A filling typically comprises a mixture of a cooked sauce and pre-cooked particulates such as meat and/or vegetable pieces. The sauce and particulates are blended to form a homogenous mixture.

The tortilla wraps are ideally inserted into a sleeve to be heated from frozen. The sleeve may have a tear tab to open the sleeve thereby allowing the tortilla wrap to be eaten directly from the sleeve.

The invention provides a highly efficient process for manufacturing tortilla wraps on a large factory scale with excellent physical and organoleptic properties. 1F09 1027 RYE007/C -5The invention is not limited to the embodiments hereinbefore described which may be varied in detail.

Claims (10)

Claims

1. A process for manufacturing a filled tortilla comprising the steps of: preparing a tortilla dough; forming the tortilla dough into a sheet; laminating the tortilla dough sheet; folding the laminated dough sheet back onto itself; further laminating the folded dough sheet; docking the laminated tortilla dough sheet; cutting the tortilla dough sheet in-line into a desired shape; baking the tortilla shapes; cooling the tortilla shapes; directing the cooled tortilla shapes into at least two separate lanes; spraying water onto the upper and/or bottom surface of the tortilla shapes in the lanes; delivering tortilla shapes to a filling and folding station; IF0O1OT7 4 RYE007/C -7applying a filling to a portion of the tortilla shape; folding the tortilla onto the filling to form a wrapped tortilla; and freezing the wrapped tortillas thus formed.

2. A process as claimed in claim 1 wherein the cooled tortillas shapes are directed into at least three separate spaced-apart lanes.

3. A process as claimed in claim 1 or 2 including the step of transversely aligning the tortilla shapes of adjacent lanes to substantially simultaneously present a tortilla from each lane for filling and folding.

4. A process as claimed in any preceding claim wherein water is sprayed onto the upper and/or bottom surface of the tortilla shaped dough from spray heads aligned with each lane.

5. A process as claimed in any preceding claim wherein the tortilla shapes are led over an open conveyor as the water is sprayed onto the upper face of the tortilla shapes, excess spray and/or run off being collected below the conveyor.

6. A process as claimed in any preceding claim wherein the tortilla shapes are baked in an oven at a temperature of from 235°C to 245°C.

7. A process as claimed in any preceding claim wherein the tortilla shapes are baked for a period of from 35 to 60 seconds.

8. A process as claimed in any preceding claim wherein, after baking, the tortilla shapes are cooled to a target temperature of approximately 15°C.

9. Hmm* 7

10. RYE007/C -8A process for manufacturing a filled tortilla substantially as hereinbefore described. Filled tortillas whenever manufactured by a process as claimed in any preceding claim.