IE20020485U1 - A method and facility for the production of pizza - Google Patents

Abstract

ABSTRACT Pizza is produced by preparing dough for a pizza base, providing the dough and pressing the dough to form the pizza base with the application of heat to at least partially set the base into the formed shape. The pizza is assembled by placing toppings of choice on the pizza base. The quantity of each topping is per—determined using a portion control method, with utensils which measure the required quantity of each topping for the size of the pizza being made. The pizza is then baked in an oven, which has an entry side and an exit side and includes at least one conveyor belt for conveying the pizza from the entry side through the oven to the exit side. The temperature of the oven and the speed with which the conveyor belt travels can be pre- programmed so that the heat applied and residence time of the pizza in the oven are sufficient to cook the pizza. ).

Description

A Method and Facility for the Production of Pizza This invention relates generally to the field of food production and in particular to the production of bread products such as pizza for a retail outlet.

The first pizza originated thousands of years ago, as a type of bread baked by hunters on hot stones. The modern pizza with tomato based sauce, cheese and various toppings was created in Naples around the 17”‘ century. The popularity of pizza has grown significantly since the creation of the modern pizza. In America alone, it is estimated that approximately 166 acres of pizza are consumed each day. Currently there are many different types of pizza, each type being determined by the choice of toppings on the pizza.

A large quantity of the pizza produced for daily consumption is made available for purchase at fast food outlets, sandwich bars and so forth. These pizzas are of standard size and type. Generally the pizza’s are cooked in bulk, sliced and kept warm throughout the day in a warming oven. More popular types of pizza will be sold more frequently, thus may not be kept in the warming oven for the same length of time as the less popular types of pizza. Regardless, a pizza produced in this way is unable to maintain quality or flavour if left to stand for long periods of time once cooked. The base, sauce and toppings dry out, the cheese becomes hard and rubbery, resulting in a visually unappealing unpalatable pizza.

Furthermore when a person orders pizza in one of these retail outlets, they are restricted to the pre-deterrnined pizza types on the menu. A person is unable to create their own pizza, by choosing a selection of toppings. Alternatively if a person wishes to choose a basic pizza on the menu, but wishes to add an extra topping for example extra cheese or olives, they are unable to do so.

It is the object of the present invention to seek to alleviate the aforementioned problems. fovenmvuaucmsvecnou 'umensEcnou2sANoRut£23 _ 'E020485 Accordingly the present invention provides a method for producing pizza, the method comprising the steps of: (a) preparing the dough for the pizza base; (b) proving the dough; (c) pressing the dough to form the pizza base with the application of heat to at least partially set the base into the formed shape; (d) assembling the pizza by placing toppings of choice on the pizza base, where the quantity of each topping is pre—determined using a portion control method, the portion control method optionally using utensils which measure the required quantity of each topping, the required quantity of each topping being determined by the size of the pizza being made; and (e) baking the pizza in an oven, optionally where the oven has an entry side and an exit side and includes at least one conveying device for conveying the pizza from the entry side through the oven to the exit side.

In another aspect of the invention, there is also provided an oven having an entry side and an exit side, an upper and lower heating element, a temperature control device so that in use the temperature of the upper and lower element can be controlled and including at least one conveying device for conveying a food product from the entry side of the container to the exit side of the container.

Preferably, the conveying device comprises a conveyor belt.

Advantageously, the temperature of the upper and lower element and the speed with which the conveyor belt travels can be pre-pro gramme so that the heat applied and residence time of the pizza in the oven are sufficient to cook the pizza.

|E020485 In a further aspect, the invention also provides a facility for carrying out the process of the invention comprising; means for preparing the pizza dough; means for storing the prepared pizza dough; means for pressing the pizza dough with the application of heat to produce an at least partially set pizza base, means for measuring out pre—determined quantities of toppings when assembling the pizza; means for cooking the assembled pizza, and means for keeping the pizza warm once cooked.

The invention also provides a pizza press for forming a pizza base from a dough portion, the press comprising a lower plate for receiving the dough portion and an upper plate, the plates being displaceable toward one another to press the dough into a flattened pizza base and at least one of the plates being heated so as to at least partially set the formed pizza base into its shape.

Ideally the pizza dough is produced by combining a set of ingredients together to form a thick mixture. It is preferable to produce the pizza dough using the following ingredients: Soft Wheat Flour Wheatgerm Soya Flour (Preferably GM Free) Extra Virgin Olive Oil Salt Yeast |EIl20485 Ideally, the pizza dough recipe produces a pizza base that has good mouth-feel characteristics. Advantageously, the distinctive texture and tenderness of the pizza base is maintained if the pizza is kept warm for a period of time not exceeding 2.5 hours.

Ideally, the pizza dough once formed is divided into smaller dough balls or portions, where the size of the dough ball relates directly to the size of pizza. Advantageously once the Ideally It is preferable to dough balls are formed they can be frozen until required to form the pizza base. the dough should be kept frozen at temperatures lower than -18° C. remove the dough balls from the freezer twenty-four hours prior to forming the pizza base.

A dough ball generally makes a circular pizza base, but other shapes may also be produced and the dough pressing of the invention is not limited to the production of circular pizza bases.

It is preferable when either defrosting the frozen dough balls or storing freshly formed dough balls to place the dough balls on trays. Ideally space is left between each dough ball in order to allow the dough ball to expand without touching a neighbouring dough ball.

Preferably each tray of dough balls is covered preventing a skin from forming on the surface of the dough. The covered trays are then placed in a refrigerator or a cold room for storage at temperatures between 0°C-4°C. This allows the frozen dough balls to defrost slowly whilst in cold storage. Advantageously dough balls can be stored in a chilled environment for approximately four days.

It is preferable to label each tray indicating the day, date and time the dough balls on the tray were placed in the refrigerator/cold room.

Ideally the oldest dough balls are removed from the chilled environment first. It is preferable for the dough balls once removed from the chilled environment to be brought to room temperature at least four hours before forming the pizza base to prove the dough.

Advantageously any dough balls that have been brought to room temperature and are unused at the end of the day can be placed back into the chilled environment overnight and used again on the following day.

|E020485 Preferably the pizza base is formed by pressing the proved dough balls into a circular disk using a pizza press. Ideally the pizza press comprises two plates, an upper and lower plate respectively. In operation it is preferable for the pizza press to be heated. Ideally the upper plate of the pizza press is heated to about 140°C whilst the lower plate is heated to about 150°C. The temperature of the plates is not limited to these temperatures, any suitable temperature known to a person skilled in the art can be used. The application of heat to the dough at this stage is advantages in that it “sets” or partially cooks or initiates crusting at the surface of the pizza base, thereby fixing or partially fixing the base into the shape imparted to it by the press. This renders it easier to handle the formed pizza base in subsequent steps.

Ideally prior to pressing the proved dough balls, the plates of the pizza press are cleaned with olive oil. This removes any pieces of pizza dough which may have stuck to them from previous use and leaves a coating of oil on the plates of the pizza press, which help to prevent the pizza dough from sticking during future use. The coating of oil will deplete with prolonged use, therefore it is desirable to re-clean the plates at regular intervals.

Once cleaned the pizza press is switched on and heated to the required temperature. It is preferable to prepare the plates by pressing the first dough ball two or three times until the plates resemble mirrors. This base will be discarded.

Preferably the proved dough balls are dusted with flour prior to being pressed by the pizza press. Ideally the entire surface of the proved dough ball is dusted with flour.

A floured dough ball is placed into the centre of the pizza press and pressed it into a circular disk forming the pizza base.

Advantageously in operation, the preferred embodiment of the pizza press has a safety switch, which is engaged prior to any movement of the plates. Once the safety switch is engaged, an operator can press the floured dough ball between the heated plates for a required length of time. The length of time is determined by the size of the pizza base and the temperature of the plates. As described above, the heat of the plates causes the dough |Efl20485 to partially set providing better consistency once the pizza press is disengaged. Next the pizza base is removed from the press and ideally placed on a grid which has been pre- dusted with flour.

Ideally the pizza base is then rolled with a bubble burster device, which pricks the surface of the dough to enable air to escape from within the dough, preventing the formation of air bubbles while the pizza is cooking Advantageously, the pizza is then assembled by placing pre-determined quantities of a selection of toppings on the pizza base. It is preferable to initially place a pre-determined amount of tomato sauce and cheese on the pizza base and then a selection of further toppings. Ideally the pizza toppings include the following; Mozzarella Cheese Mushrooms Pineapple Peppers Ham Extra Cheese Pepperoni Sweetcom Bacon Tuna Olives Onions Sauces — Tomato Pesto Garlic The extra cheese is selected from any one or more hard cheeses which brown when melted, including but not limited to mozzarelle, chedder, Cheshire, monterey jack, emmental, edam, parmesan and gouda cheeses. One or more of the cheeses may be used, for example a mixture of four cheeses.

It is of course understood that the toppings are not limited to the above list and that any additional toppings known to a person skilled in the art may be used.

|EU2fl485 Advantageously, the quantity of each topping required is pre-determined. Ideally a measuring chart is provided which lists the various toppings and the quantity of each topping required to make up the pizza. Advantageously in the preferred embodiment of the invention the measuring chart provided relates the pre-deterrnined quantity of each topping to a series of utensils that have been formed to measure and hold exact quantities.

For example, in the preferred embodiment of the invention, if a person is assembling any type of pizza, the measuring chart tells them to use one spoon of tomato sauce for a regular pizza and two spoons of tomato sauce for a large pizza. The person then uses the spoon allocated to tomato sauce to measure out the appropriate amount of tomato sauce. In the preferred embodiment the quantity of each dry topping, such as cheese, mushrooms and so forth, is measured using scoops. Advantageously, the scoops are a set of different colours.

Ideally the measuring chart displays the quantity of dry topping required as a colour which directly corresponds to the colour of the appropriately sized scoop.

Once the pizza is assembled, it is cooked. It is preferable for the pizza to be cooked in an oven where the pizza is conveyed by means of a conveying device from the entry side of the oven to the exit side of the oven.

Preferably, the conveying device comprises a conveyor belt.

Advantageously, the speed at which the conveyor belt travels can be varied to accommodate different cooking periods required by different pizza sizes. Ideally the oven includes an upper and lower heating element and a temperature control device so that in use the temperature of the upper and lower element can be controlled.

Ideally, the temperature of the upper and lower element and the speed with which the conveyor belt travels are pre-programmed, for example, Programme 1 contains the temperature settings and conveyor belt speed required to cook a large pizza, Programme 2, contains the same information relating to a medium pizza and so on.

|E020485 It is preferable to remove any air pockets from the oven after long periods of non-use for example if the oven has been unused overnight. Ideally this can be done by passing an empty grid through the oven on one of the preset programmes.

Advantageously, once the pizza is cooked, the pizza can be sliced. If the pizza is being sold immediately, it is preferable to slice the pizza into slices equivalent to one-eighth the size of the pizza. If the pizza is being stored in a pizza warmer, it is preferable to cut the pizza into quarters.

Ideally if the pizza is being sold immediately, the sliced pizza is presented to the customer packaged in an appropriately sized pizza box.

Advantageously, the method of producing pizza can be readily adapted to produce speciality breads, where the floured bread dough is pressed to form a bread loaf of desired thickness. for example pesto sauce.

Ideally ingredients to form the speciality bread are placed on top of the bread, Advantageously the bread is cooked in the same way as the pizza using the appropriate pre-set programme.

The method and facility of the invention will now be described by way of example only and with reference to the accompanying drawings in which, Figure 1 is a flow diagram outlining the stages involved in the method of pizza production; Figure 2 is a measuring chart for a regular sized pizza; Figure 3 is a measuring chart for a large sized pizza; Figure 4 is a measuring chart for speciality breads; and Figure 5 is an outline of the facility used to produce a pizza according to the method provided by the invention. l&aZ@@35 Figure 1 shows a flow diagram outlining the method of the invention as follows: . Making the Pizza Dough (10) The pizza dough is prepared using the following exemplary ingredients, which are combined together forming a thick mixture Soft Wheat Flour Wheatgerm Soya Flour (Preferably GMO Free) Extra Virgin Olive Oil Salt Yeast Once the pizza dough is formed it is divided into smaller circular portions or dough balls.

The dough balls are then frozen 10a at temperatures lower than -18°C. If the retail outlet which will sell the cooked pizza does not have facilities to prepare and freeze large quantities of pizza dough, the pizza dough can be prepared at a secondary location.

Freezing the dough balls is convenient for the transportation of pizza dough from the secondary location to the retail outlet.

The dough balls are defrosted and stored 10b in a chilled environment (O°C-4°C) at least twenty-four hours prior to use. A refrigerator or a cold storage room can provide the chilled environment. The frozen dough balls are placed on plastic trays with space left between each dough ball enabling them to expand without touching a neighbour. A second tray or a sheet of plastic covers the tray of dough balls, preventing the formation of Each tray is labelled with the day, date and time The dough balls can be kept a skin on the surface of the dough ball. the tray was placed for storage in the chilled environment. for approximately four days in this environment.

|Et]20435 . Proving the Pizza Dough (20) dough balls are brought to room temperature at least four hours before forming the pizza The oldest trays of dough balls are removed from the chilled environment first. base. Any dough balls that are unused at the end of the day are returned to the chilled environment and are used on the following day.

. Pressing the Pizza Dough (30) A pizza press presses the proved dough balls into a circular disk forming a pizza base.

The pizza press comprises means to operate the press and an upper and lower plate, each plate having a temperature control.

At the start of the day prior to pressing any proved dough balls, the plates of the pizza press are cleaned with olive oil removing any pieces of pizza dough which may have stuck from previous use. Furthermore a coating of oil is left on the plates of the pizza press to help prevent the pizza dough from sticking throughout the day.

Once cleaned, the pizza press is switched on and heated to the required temperature. The upper plate of the pizza press is heated to about 140°C whilst the lower plate is heated to about 150°C.

The first dough ball of the day is pressed two or three times until the plates resemble mirrors. This also helps prevent pieces of pizza dough sticking during use. This pizza base is not suitable for further use and is discarded.

Initially when forming the pizza base, the entire surface of a proved dough ball is dusted with flour. The floured dough ball is placed in a central position intermediate the upper and lower plates. The pizza press is engaged, causing the plates to press together. In the preferred embodiment of the invention a safety switch must also be engaged on order for |EU2U485. the pizza press to operate. The plates remain pressed together for a period of time causing the floured dough ball to flatten into a circular disk, which is the pizza base. The length of time the plates remain pressed together is determined by the size of the pizza. The heat of the plates cause the dough to partially set providing better consistency once the pizza press is disengaged.

Once the pizza base has been pressed for the correct period of time, the safety switch is disengaged and the upper and lower plates are separated. The pizza base is carefully removed by sliding it off the lower plate onto a predusted grid.

The thickness of the pizza base is determined by the distance between the upper and lower plates and can be easily adjusted as required.

The pizza base is then rolled with a bubble burster device, which pricks the surface of the base to enable air to escape from within the dough, preventing the formation of air bubbles while the pizza is cooking The pizza press is readily adapted to press floured dough balls for other purposes, for example, a floured dough ball can be pressed, producing a circular disk of greater thickness than that of the pizza base for use as a bread.

. Assembling the Pizza (40) The pizza is assembled by placing pre-deterrnined quantities of various toppings on top of the pizza base. In the preferred embodiment of the invention, a measuring chart and specialist utensils are provided to assist when assembling the pizza.

This process is described in detail with reference to Figures 2 and 3, which show a measuring chart for a regular 400 and a large (Gigante) 401 pizza respectively. Each measuring chart comprises a table, which has a defining colurrm of ingredients (toppings) 420 at one side of the table and a defining row of different pizza types 410 at the top of the table. The quantity of each ingredient required for the different pizza types is written on \Efl20435 the chart beneath each pizza type in a position that corresponds to the position of that ingredient in the defining column 420.

The measuring chart provided relates the pre-determined quantity of each ingredient to a series of specialist utensils, such as spoons, scoops and perforated scoops that have been formed to measure and hold exact quantities.

Each different type of pizza has two basic ingredients, tomato sauce 419 and mozzarella cheese 429. A spoon is used to measure out the tomato sauce. It can be seen from the measuring charts 400 and 401 respectively that one spoon of tomato sauce is required for a regular pizza 411, while two spoons of tomato sauce are required for a larger pizza 421.

The same spoon can be used to measure out tomato sauce for both types of pizza.

The quantity of each dry ingredient, such as cheese, mushrooms and so forth, is measured using scoops of different colours. The measuring chart displays the quantity of dry topping required as a colour 414 and 424 on Figures 2 and 3 respectively which directly corresponds to the colour of the appropriately sized scoop. In this example each colour is the same, however this is not always desirable, as the quantity of some ingredients relative to other ingredients may be greater or lesser. In this instance it is desirable to incorporate more utensils measuring greater or lesser amounts, this is turn is reflected in the measuring chart by introducing the colours of the measuring scoops onto the measuring chart in the appropriate position.

Other ingredients such as pineapple and ham are more easily measured and do not require the use of utensils. Pineapple is measured in cut rings. For a regular pizza 1.5 rings of pineapple are required 412, Figure 2 while a large pizza requires 3 rings 422, Figure 3.

Ham is measured in the number of slices used 413 and 423, Figures 2 and 3 respectively.

The measuring chart also incorporates extra toppings. If ordering an extra portion of tuna, onions or olives a blue scoop is used 415. A blue scoop is also if ordering an extra portion of onion or pesto sauce 416.

|Ell20485 When assembling the pizza, the amount of tomato sauce specified in the measuring chart is placed on the centre of the base. Using the bottom of the spoon, the tomato sauce is gradually spread over the base in a circular design until the sauce covers the base to approximately 5mm from the edge. The quantity of mozzarella cheese specified on the measuring chart is then spread evenly over the tomato sauce to the edge of the pizza base.

The remaining ingredients are spread evenly over the cheese on top of the pizza, using the amounts specified in the make up sheet. Any ingredients that have been soaked in oil are drained carefully before placing on the pizza.

Figure 4 is a measuring chart 402 showing the quantity of ingredients 430 required by the bread if making speciality breads. For example, a cheese and garlic bread requires, 1 grey spoon of garlic sauce and 1 grey spoon of the four cheese mix.

. Cooking the assembled Pizza (50) Once the pizza is assembled, it is cooked. The pizza is cooked in an oven where the pizza is conveyed on a conveyor belt from the entry side of the oven to the exit side of the oven.

The speed at which the conveyor belt conveys the pizza through the oven is equal to the length of time required to cook the pizza. The rate of the conveyor belt for a regular and a large sized pizza ore outlined below. The speed of the conveyor belt can be altered to accommodate different cooking periods required by different pizza sizes.

The oven has an upper and lower heating element and a temperature control device so that in use the temperature of the upper and lower element can be controlled. The desired temperature of the oven is 160°C and in order to achieve this, it has been found that the upper element is at 30% of it’s heating capacity whilst the lower element is at 60% of it’s heating capacity.

OVEN RATE OF BELT Size of Oven Upper Lower Pizza Temperature / “C Element Element |Eu20485 Large 160 Regular 160 % % % 60% min 30 sec min 30 sec The temperatures of the upper and lower element and the speed with which the conveyor belt travels are pre-programmed into the oven. For example, Programme 1 contains information regarding a large pizza, the temperature settings, i.e. Oven Temperature = 160°C, Upper Element = 30%, Lower Element = 60% and the conveyor belt is set to take 5 min 30 sec to convey a large pizza from the entry side of the oven to the exit side of the oven. Similar programmes are installed relating to regular sized pizza, speciality breads ands so forth.

Any air pockets are removed from the oven after long periods of non-use for example if the oven has been unused overnight. Passing an empty grid through the oven on one of the pre-set programmes does this. & 7. Storing (50a) and Selling (60) the cooked Pizza Once the pizza is cooked, the pizza can be sliced. If the pizza is being sold immediately, it is preferable to slice the pizza into slices equivalent to one-eighth the size of the pizza.

Alternatively, the pizza can be stored in a pizza warmer. If the pizza is being stored it is preferable to cut the pizza into quarters.

There is shown is Figure 5 an outline 100 of the facility used to produce a pizza according to the method provided by the invention. An order for a pizza can be taken at the front counter 108. The order may also be taken by telephone 111. The order is keyed into the till 110 and a receipt is issued 114. The proved dough ball is removed from storage area A (not shown), dusted with flour and pressed on the pizza press 102. Once the pizza base is formed the pizza is assembled at assembly counter 101. The assembled pizza is cooked in placed on the conveyor belt at 103a and is conveyed through oven 103, exiting the oven 103 at lO3b. The cooked pizza is sliced and packaged at finishing counter 104 ready to serve to the customer at front counter 108. If the pizza needs to be kept warm, it can be placed in warming oven 107.

|Eu2n4 Additional features such as a drinks dispenser 112, menu advertising displays 109a — 109c and 113 and a microwave 105 are also present. A sink 106 has been incorporated into the design for health and safety reasons.

It is to be understood that the invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible without departing form the scope of the invention.

MACLACHLAN & DONALDSON Applicant’s Agents Merrion Square DUBLIN 2

Claims (5)

CLAIMS:

1. A method for producing pizza, the method comprising the steps of: (a) preparing dough for a pizza base; (b) proving the dough; (c) pressing the dough to form the pizza base with the application of heat to at least partially set the base into the formed shape; ((1) assembling the pizza by placing toppings of choice on the pizza base, where the quantity of each topping is pre—determined using a portion control method, the portion control method optionally using utensils which measure the required quantity of each topping, the required quantity of each topping being determined by the size of the pizza being made; and (e) baking the pizza in an oven, optionally where the oven has an entry side and an exit side and includes at least one conveying device for conveying the pizza from the entry side through the oven to the exit side.

2. Apparatus for producing pizza including an oven having an entry side and an exit side, an upper and lower heating element, a temperature control device so that in use the temperature of the upper and lower element can be controlled and including at least one conveying device for conveying a food product from the entry side of the container to the exit side of the container; optionally the conveying device comprises a conveyor belt; and optionally the temperature of the upper and lower element and the speed with which the conveyor belt travels can be pre-programmed so that the heat applied and residence time of the pizza in the oven are sufficient to cook the pizza. |ED204

3. Apparatus for producing pizza as claimed in Claim 2, further comprising; means for preparing the pizza dough; means for storing the prepared pizza dough; means for pressing the pizza dough with the application of heat to produce an at least partially set pizza base, means for measuring out pre-determined quantities of toppings when assembling the pizza; means for cooking the assembled pizza, and means for keeping the pizza warm once cooked.

4. Apparatus for producing pizza as claimed in Claim 2 or Claim 3, further comprising a pizza press for forming a pizza base from a dough portion, the press comprising a lower plate for receiving the dough portion and an upper plate, the plates being displaceable toward one another to press the dough into a flattened pizza base and at least one of the plates being heated so as to at least partially set the formed pizza base into its shape.

5. A method for producing pizza substantially as herein described with reference to the accompanying drawings. MACLACHLAN & DONALDSON Applicants’ Agents 47 Merrion Square