IE83923B1 - A process for manufacturing a food product - Google Patents
A process for manufacturing a food product Download PDFInfo
- Publication number
- IE83923B1 IE83923B1 IE2000/1030A IE20001030A IE83923B1 IE 83923 B1 IE83923 B1 IE 83923B1 IE 2000/1030 A IE2000/1030 A IE 2000/1030A IE 20001030 A IE20001030 A IE 20001030A IE 83923 B1 IE83923 B1 IE 83923B1
- Authority
- IE
- Ireland
- Prior art keywords
- dough sheet
- pockets
- sheet portion
- base
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims description 19
- 238000004519 manufacturing process Methods 0.000 title claims description 9
- 235000013305 food Nutrition 0.000 title description 4
- 235000014594 pastries Nutrition 0.000 claims description 26
- 238000002788 crimping Methods 0.000 claims description 11
- 235000013372 meat Nutrition 0.000 claims description 10
- 235000015067 sauces Nutrition 0.000 claims description 9
- 235000013311 vegetables Nutrition 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 5
- 238000002156 mixing Methods 0.000 claims description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 4
- 108010068370 Glutens Proteins 0.000 claims description 3
- 238000010411 cooking Methods 0.000 claims description 3
- 235000021312 gluten Nutrition 0.000 claims description 3
- 238000003032 molecular docking Methods 0.000 claims description 3
- 238000001816 cooling Methods 0.000 claims description 2
- 238000005520 cutting process Methods 0.000 claims description 2
- 238000007710 freezing Methods 0.000 claims description 2
- 238000010030 laminating Methods 0.000 claims description 2
- 238000007789 sealing Methods 0.000 claims description 2
- 238000005507 spraying Methods 0.000 claims description 2
- 239000003795 chemical substances by application Substances 0.000 claims 1
- 235000013312 flour Nutrition 0.000 description 2
- 240000004808 Saccharomyces cerevisiae Species 0.000 description 1
- 240000002057 Secale cereale Species 0.000 description 1
- 235000007238 Secale cereale Nutrition 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 210000001138 Tears Anatomy 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- 230000002452 interceptive Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000011780 sodium chloride Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
Description
PATENTS ACT, 1992
2000/1030
A PROCESS FOR MANUFACTURING A FOOD PRODUCT
RYE DEVELOPMENTS LIMITED
“A PROCESS FOR MANUFACTURING A FOOD PRODUCT”
Introduction
The invention relates to a process for manufacturing a food product and in
particular to a process for manufacturing a filled pastry product, especially a
pastry pocket.
Pastry pockets comprising a pastry outer filled with various fillings are known.
There is however, a need for a process for producing such pastry pockets on a
factory scale while providing a product which can be easily cooked by the user
and which has good 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 a process for manufacturing a filled
pastry product comprising the stepsof: -
preparing a pastry dough;
forming the dough into a sheet;
laminating the dough sheet;
docking the dough sheet;
splitting the dough sheet longitudinally to form a base dough sheet
portion and a top dough sheet portion;
leading the base dough sheet portion along a conveyor;
leading the top dough sheet portion along a conveyor;
spraying the base dough sheet with water;
applying gluten to the sprayed base dough sheet;
preparing a filing comprising a mixture of sauce and frozen cooked meat
and/ or vegetables, the filling being at a temperature of from 2°C to —3°C;
forming the filing into a desired form shape;
applying the formed filing to the floured base dough sheet;
placing the top dough sheet portion over the base dough sheet portion
and filling;
sealing the top sheet portion to the base dough sheet portion to form a
pocket between the base and top dough sheets housing the filling;
crimping the edges of the pocket;
cutting away excess dough between the pockets;
applying a glaze to the individual pockets;
cooking the pastry pockets;
cooling the cooked pockets; and
freezing the cooled pockets.
In a preferred embodiment of the invention the pastry pockets are cooked in an
oven at a temperature of from 275°C to 300°C for a period of from 12 to 16
minutes
In a particularly preferred embodiment the filling, on application to the base
dough sheet, is at a temperature of from -1 °C to —2°C.
Preferably the filling is prepared by mixing sauce with cooked frozen meat pieces
and subsequently adding blanched frozen vegetables to the sauce/ meat mixture.
In a preferred embodiment the filling includes rusk in an amount of from 1% to
% by weight.
In a preferred embodiment the edges of the pocket are crirnped by aligning a
pocket-shaped crimping tool with the side edges of a pocket, applying a support
to the body of the pocket and advancing the crimping tool relative to the support
to crimp the side edges of the pocket.
The invention also provides a filled pastry product 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 pastry dough of flour, water, yeast, starch, salt, sugar, baking powder, relaxer
and fat is prepared in a mixer and, after mixing, the dough is fonned into a
sheet, and laminated in several stages to achieve a suitable laminated dough
sheet. The laminated sheet is docked and then split longitudinally as it travels
along a conveyor to form a base dough sheet portion and a top dough sheet
portion which are separated. Docking involves impregnating the dough with a
plurality of small (generally about lmm) holes.
The base dough sheet portion is led along a conveyor and the upper surface of
the sheet portion is sprayed with water. Gluten flour is then sprinkled over the
sprayed base dough sheet portion. The base dough sheet portion is then ready
to receive a filling.
A filling is prepared by mixing a sauce with frozen cooked meat and/ or
vegetables. The frozen cooked meat is at a temperature of from -10 to —15°C,
which is also the temperature at which the blanched frozen vegetables are stored.
The sauce is generally at about 10°C. We have found that for optimum filling
characteristics the filling mixture when applied to the pastry base sheet portion
should be from +2°C to —3°C, ideally from about —l°C to about —2°C. To
provide enhanced flow characteristics while avoiding break—up of the meat and
vegetable pieces ideally the sauce is first mixed with the meat prior to addition of
the vegetable pieces. The filling also includes rusk in an amount of from 1 to 5%
by weight.
The filling is formed into a desired shape which is then deposited on the base
sheet portion as it is moving along the conveyor. Several such forms are applied
spaced—apart across the width of the base sheet. The top sheet portion is then
placed over the base dough sheet and formed fillings. Rollers are then applied to
the top sheet between the form fillings to seal the top sheet to the bottom sheet
longitudinally and thereby defining a pocket containing the form fillings between
the top and bottom sheet portions. A glaze is applied to the top sheet.
The edges of the pocket are then crimped in-line using a crimping tool shaped to
the desired pocket shape. Each crimping tool comprises a central support of or
coated with a release material such as Teflon (RTM) which is engagable against the
main body of the pocket and a serrated crimping blade which is movable relative
to the support from an aligned position in which the support is engaged with the
pocket and the blade is retracted, to a crimping position in which the blade is
advanced downwardly of the support. The blade is in the desired shape of the
pockets and individual pockets are fonned across the width of the dough using
several such crimping tools. The excess dough between the pockets is separated
from the pockets, removed from the line and recycled for‘ use in dough
preparation.
The individual pastry pockets are deposited directly onto hot balcing trays which
are at a typical temperature of from 50 to 60°C. The pastry pockets are cooked
in an oven at a temperature of from 270°C to 300°C for a period of from 12 to 16
minutes. After cooking, the pastry pockets are cooled to about 20°C, wrapped
and frozen.
The pastry pockets are ideally inserted into a sleeve to be heated from frozen.
The sleeve includes an internal microwave interactive layer for browning and
toasting the pastry surface during microwaving. The sleeve may have a tear tab
to open the sleeve allowing the pastry pocket to be eaten directly from the sleeve.
The invention provides a highly eflicient process for manufacturing pastry
pockets on a large factory scale with excellent organoleptic and physical
properties.
The invention is not limited to the embodiments hereinbefore described which
may be varied in detail without departing from the scope of the invention as defined by
the appended claims.
Claims (1)
1. A process for manufacturing a filled pastry product comprising the steps of: - preparing a pastry dough; forming the dough into a sheet; laminating the dough sheet; docking the dough sheet; splitting the dough sheet longitudinally to form a base dough sheet portion and a top dough sheet portion; leading the base dough sheet portion along a conveyor; leading the top dough sheet portion along a conveyor; spraying the base dough sheet portion with water; applying gluten to the sprayed base dough portion sheet; preparing a filing comprising a mixture of sauce and frozen cooked meat and/ or vegetables, the filling being at a temperature of from +2°C to —3°C; forming the filing into a desired form shape; applying the formed filing to the floured base dough sheet portion; placing the top dough sheet portion over the base dough sheet portion and filling; sealing the top sheet portion to the base dough sheet portion to form a pocket between the base and top dough sheet portions housing the filling; crimping the edges of the pocket; cutting away excess dough between the pockets; applying a glaze to the individual pockets; cooking the pastry pockets; cooling the cooked pockets; and freezing the cooled pockets. A process as claimed in claim 1 wherein the glazed pastry pockets are deposited directly onto baking trays which are at a typical temperature of from 50 to 60°C. A process as claimed in claim 1 or 2 wherein the pastry pockets are cooked in an oven at a temperature of form 270°C to 300°C for a period of from 12 to 16 minutes. A process as claimed in any preceding claim Where the filling, on application to the base dough sheet, is at a temperature of from —l “C to — 2°C. A process as claimed in any preceding claim wherein the filling is prepared by mixing sauce with cooked frozen meat pieces and subsequently adding blanched frozen vegetables to the sauce/ meat mixture. A process as claimed in any preceding claim wherein the filling includes rusk in an amount of from 1% to 5% by weight. A process as claimed in any preceding claim wherein the edges of the pocket are crimped by aligning a pocket—shaped crimping tool with the side edges of a pocket, applying a support to the body of the pocket and advancing the crimping tool relative to the support to crimp the side edges of the pocket. A process for manufacturing a filled pastry product substantially as hereinbefore described. A filled pastry product whenever manufactured by a process as claimed in any preceding claim. F. R. KELLY & CO., AGENTS FOR THE APPLICANTS
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| IE2000/1030A IE83923B1 (en) | 2000-12-18 | A process for manufacturing a food product |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| IE2000/1030A IE83923B1 (en) | 2000-12-18 | A process for manufacturing a food product |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| IE20001030A1 IE20001030A1 (en) | 2002-06-26 |
| IE83923B1 true IE83923B1 (en) | 2005-06-29 |
Family
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