NZ237914A - Using frozen cheese granules in the preparation of pizzas - Google Patents

Description

New Zealand Paient Spedficaiion for Paient Number £37914 237 9 1 Priority "a'1 '""Vacation m«* ;omp^e -'PeMI / 0 -Q —i :laSS: (6).AX.3C.>.^./.Oq,^:: •■'21' DEC »9i' ' . I ." " der ...Bm»teions ' or''neBIS5l| PuWicafo" D^-p) ^ p n. Journal, —Mo'ORmW 1 fi* Specification h«s blTnTnie-datecJ t0 19 .jfcjJ.

Patents Form No. 5 Inlt^ls NEW ZEALAND PATENTS ACT 1953 />*%■»v 0'<\ /.A, * .*tN /0\. *<■ '< fr : '^22 APR 1991 COMPLETE SPECIFICATION METHOD OF MANUFACTURING BAKED PIZZA We, LEPRINO FOODS COMPANT, a corporation of the State of Colorado, USA located at 1830 West 38th Avenue, Denver, CO 80201, United States of America, hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: 237 9 U This invention relates to a method of manufacturing baked pizza.

In the United States, many retail operations engaged in preparation and baking of pizzas desire to use cheese in a comminuted form. Consequently, producers of mozzarella and other cheese used on pizzas shred or dice block cheese for delivery to the pizza restaurants. To provide improved storage and keeping qualities, comminuted cheese for use on pizzas can be frozen and delivered in frozen or semi-frozen condition. However, the cheese must at least be thawed to the extent that the shreds or granules can be separated. Moreover, further thawing is needed to improve functionality.

The use of comminuted cheese in frozen or partially frozen condition on pizzas frequently results in baked products showing excessive browning and blistering. Not only is this appearance unattractive to the consumer, but the flavour and eating quality can also be adversely affected.

The recommended practice involves slow thawing of the frozen cheese. Where thawing is carried out during non-freezing refrigerated storage, as is a common practice, a minimum of two to three days of thawing-holding is usually required. Moreover, the best practice involved holding of the granular cheese for four to five days, until thawing is completed. 237 9 1 4 Because of the problems associated with the use of frozen comminuted cheese for preparing pizza, certain (3) franchised cheese restaurants require that the comminuted cheese be packaged non-frozen in specially designed packages. This adds considerably to packaging and distribution expenses, although it does avoid the necessity of slow thawing.

As far as is known, no one heretofore has produced frozen comminuted cheese which can be applied to pizzas in frozen or partially frozen condition and baked to produce a pizza produce of as good quality as with fully thawed cheese. The high standards of appearance, quality and taste for large scale pizza preparation have not been satisfied by the use of comminuted cheese which has not been completely thawed.

O The development of this invention has required a better understanding of the problems associated with the use of comminuted cheese on pizzas. It was observed that the frozen granules of comminuted cheese usually had visible ice coatings on their outer surfaces. Examination disclosed that this ice is formed as the granules are frozen - moisture being exuded and freezing around the granules. Consequently, when thawing was commenced the outer surfaces became wet, but by holding of the granules for several days, the free moisture was reabsorbed. With holding periods of four to five days, substantial equilibration of moisture distribution was obtained, although this had not been previously 237 9 14 obtained, although this had not been previously recognized. In effect, the interior moisture of the cheese particles redistributed substantially as it was before freezing. Without such holding and equilibration, the ice coatings melted and the water flashed off as the pizzas were baked. This invention involves a recognition that such water loss can aggravate undesirable browning and blistering.

It was found that to produce pizza of the most pleasing appearance and taste, it is important to fully maintain the moisture content of the applied cheese. As the moisture flashes off, the resulting steam can raise blisters. In blistering, the protein layers are lifted from the surface of the baking pizzas. Such blisters tend to burn and discolor.

It is thus an object of the invention to provide an improved method for the manufacture of pizza or at least provide the public with a useful choice.

Accordingly the invention provides a method of manufacturing baked pizza comprising the steps of: (a) at a cheese manufacturing plant preparing cheese in the form of fresh cheese granules, the cheese granules consisting of at least one variety of mozzarella, or a blend of mozzarella with other cheese; (b) freezing the cheese granules so rapidly that the individual granules retain substantially the same moisture content and distribution as before freezing, the resulting frozen granules being in free-flowing '. , v • '_ ' ' ^byj, \yt." "V j o o m 237914 condition; (c) maintaining the granules in frozen free-flowing condition with said moisture substantially unchanged during distribution; (d) at a pizza outlet or restaurant applying the frozen free-flowing granules to pizzas being prepared for baking, without complete thawing of the granules, at least the interiors thereof being frozen; and (e) baking the pizzas in frozen or partially frozen condition while the cheese granules have essentially the same moisture content and distribution, at least the interiors of the cheese granules being frozen at the start of baking.

The frozen comminuted cheese described in this specification can be used on pizzas without any pre-thawing. The resulting baked pizzas have as good or better appearance and quality as when prepared from fully thawed and equilibrated cheese. To achieve this result it is necessary to freeze the granules very rapidly, so that the frozen granules have essentially the same moisture content and distribution as before freezing. Rapid freezing prevents moisture migration to the surface of the cheese particles. The frozen particles are free from visible ice coatings, and the moisture within the particles is in the form of very fine crystalline ice.

When the frozen cheese of this invention is thawed during baking, it immediately has the optimum moisture distribution for baking. No holding time is needed for /»', iBfe> o 2 3 7 9 1 ': moisture equilibration. Moreover, during baking the contacting surfaces of the cheese particles thaw first, becoming softened with particle-to-particle fusing. In fact, the particulate cheese can begin to fuse into smoothly melted layers while the interiors of the individual particles are still partially frozen. Using frozen cheese of the kind prepared by the method described in this specification does not interfere with normal melting of the cheese on pizzas baked very rapidly. In the practice of using convection ovens through which the pizzas pass on conveyor belts, baking times are usually less than ten minutes for both "thick" and "thin" crust type pizzas. Nevertheless, by using the method of this invention the baked cheese appears smooth and non-lumpy. Separate cheese particles are not apparent. The melted cheese exhibits an appearance comparable to that obtained with fully thawed cheese.

The method of this invention for preparing baked pizzas and the frozen cheese for use therewith greatly improves the production, storage, distribution and use of comminuted cheese. After the frozen cheese has been prepared by the method of this invention, it can be stored for many months without deterioration in quality. The moisture is locked into the cheese in the form of very finely distributed ice crystals, and there is substantially no moisture loss during frozen storage. The cheese therefore maintains its capacity for use in frozen condition to produce fully acceptable pizza products.

Since the coated frozen cheese produced by the method described in this specification is in particulate free-flowing condition, modification of taste and functional properties of the cheese can be obtained by applying coatings to the outsides of the cheese particles. The coatings are applied so as to encapsulate the individual granules. More specifically, it has been found that a new kind of frozen granular cheese product can be prepared by coating frozen free-flowing cheese granules with an aqueous carrier containing one or more cheese additives, such as flavor modifiers, emulsifiers, etc. The additive can be distributed in an aqueous carrier in the form of a solution, dispersion, or emulsion. The carrier containing the additive is applied as a thin coating to the granules. On contact with the granules, the coating freezes, thereby fixing the additive in distributed form around the outer surfaces of the granules. addition to application to pizzas. They can be used as toppings or ingredients in other food products. By application in frozen or semi-frozen condition, the coatings remain distributed on the granules. When the food is baked, the coatings will liquify and the additive will be spread over and into the cheese granules or into and through the food product. In other words, the desired modification occurs during baking use of the coated frozen granules. A method and product are thereby provided which achieve efficient and uniform modification of granular cheese for use The coated frozen granules have a variety of uses in in baked food products. 237914 The terra "comminuted cheese" as used herein refers to shredded or diced cheese of the kind which heretofore has been sold for use in producing pizza products. The term "granule" is used generically as referring to the particulate form of such shredded or diced cheese. The granules are usually of cubical or elongated rectilinear shape. However, the granules may also be slivers of irregular shape.

In practising the method of this invention, any cheese blend may be employed of the kind used on pizzas. In the United States, varieties of mozzarella are the most common type cheese for pizza use, and are used alone or in cheese blends. Other varieties of cheeses used on pizzas in minor proportions of mozzarella blends include cheddar, Muenster, Swiss, Monterey Jack, Provolone, and the semi-soft part skim-milk cheese sometimes called "pizza cheese".

Cheeses are usually produced in block form. For purpose of this invention, the cheese blocks are comminuted to shreds or granules. For example, the block cheese can be sliced and then diced to form cubical or elongated granules. Alternatively, cheese shredding equipment can be used. The granules may have dimensions in inches of from 0.1 x 0.1 x 0.5 up to 0.25 x 0.25 x 1.5. Examples of representative granule shapes ares (1) 1/8 x 3/16 x 3/4 inches; and ( x 1/8 x 1/8 inches. The granules of different cheese a blended by mixing, either before or after freezing.

The cheese used on pizzas has relatively large moisture content, containing at least 30% water by weig usually higher. Applicable federal moisture standards illustrative. In the case of cheese which is classified as 23 "low-moisture mozzarella" or Scamorza, the federal standard specifies a moisture content in the range of 45 to 52%; Muenster (munster) cheese can contain up to 46% moisture/ etc. Despite these high moisture contents, it is undesirable to process the cheese in such a way that moisture content of the frozen particles is substantially lower. For protection of functionality, the frozen cheese of the present invention can be prepared with less than 1% weight reduction due to moisture loss. Optimally, the weight reduction of the cheese due to moisture loss can be limited to 0.3 to 0.5 wt.%. In carrying out the method of this invention, the comminuted cheese is rapidly frozen by direct contact with low temperature air. The freezing air should be at a temperature below -10 °F and preferably below -20°F. For example, the optimum air temperature is as low as -35 to -45 °F.

To accomplish rapid freezing of the comminuted cheese, a bed of the granules can be directly contacted by freezing air. For example, the cheese granules may be contacted in a fluidized bed, or in an agitated bed for rapidly exposing all exterior surfaces of the granules to the freezing air. By passing the freezing air upwardly through beds in which the cheese particles sure agitated, or preferably fluidized, the air flow can contact all of the exterior surfaces of the particles. With air at a sufficiently low temperature, surface crusts will rapidly form on the granules, thereby locking in the moisture. 237014 Commercially available equipment can be used for the freezing of the comminuted cheese. This equipment is of the kind sold for individual quick freezing (IQF) of granular food products. Heretofore "IQF" equipment has been employed primarily for freezing vegetables, and the freezing step has usually been accompanied by partial drying of the product. In preparing the frozen cheese for the purpose of this invention, as explained above, it is desirable to avoid moisture loss from the cheese as it is being frozen.

In one preferred method of freezing the comminuted cheese, fluidized bed-type IQF equipment is employed. Such fluidized bed equipment is described in United States Patents 3,169,381, 4,265,096 and 4,478,141. Commercially, suitable IQF fluidized bed equipment is available from Frigoscandia (Frigoscandia Contracting Inc, Bellevue, WA). Expanded bed-type freezing equipment is available from several suppliers, including Cloud & Britton Inc, Mountlake Terrace, Washington.

In preparing the comminuted cheese for freezing, pre-cooling of the cheese is not required, that is, the cheese may be at temperatures substantially above 32°F. For example, temperatures in the range of 35-55°F can be used, up to ambient room temperature. After the comminuted cheese is completely frozen, typically requiring from five to ten minutes, the cheese granules will be at very cold temperatures, but somewhat above the temperature of the freezing air. For example, the temperature of the frozen cheese will usually be below 0°F, such as at a temperature of from about -10 to -20°F. •v SEP 1991 23 After the cheese is frozen as described, the shreds or granules will be in an individual free-flowing form. The particulate cheese is then further processed in accordance with this invention. For example, a conveyer belt, or rotating drum, or other equipment may be used. In one embodiment, the cheese particles may be sprayed with an aqueous carrier containing one or more cheese additives, such as flavor modifiers, emulsifiers, surfactants, defoamers, preservatives, etc. Any GRAS-approved food additive can be used. The additive may be in an aqueous solution, dispersion, or emulsion, and a plurality of additives may be applied in a single layer or a plurality of layers. The carrier should contain sufficient water so that it will freeze on the cheese particles. Granules of different kinds of cheese may be mixed in frozen condition, either before or after coating.

It is desirable to mix or agitate the cheese while the coatings are being applied. When properly applied, the individual granules become encapsulated by the frozen coating. This can be done in a fluidized bed, such as near the discharge end of the fluidized bed IQF freezer. Alternatively, a conveyer belt can be equipped with devices for mixing the cheese particles as they are coated. Spray application of the coatings will usually be most convenient. As the aqueous carrier is distributed over the outer surfaces of the cheese granules, the carrier can be rapidly converted to frozen layers. At the same time, the coated granules can remain free flowing. In a preferred embodiment, the coatings are in the form of thin continuous layers and comprise 237914 0.5 to 4.0% by weight based on the uncoated cheese granules, that is, from 0.5 to 4 parts of the aqueous coating are used per 100 parts by weight of the cheese. Thorough distribution of the coatings is enhanced because the aqueous carrier is not absorbed by the frozen granules. A series of coatings, such as a two-layer coating may be applied, each layer containing one or more different additives. The use of such frozen coatings can be in addition to application of a preservative or other agent to the granules before freezing, when immediate granule penetration is desired. For example, an aqueous solution of sodium citrate may be sprayed on the granules prior to freezing.

When the coated frozen cheese is applied to pizzas and baked thereon, the coatings will liquify first. This permits the flavor additive and/or emulsifier to spread over and into the cheese particles as their outer surfaces become thawed. The water in the coating will then flash off. In this way, special flavor characteristics can be imparted with relative uniformity to the melted cheese layer on the pizza. Cheese emulsifiers applied in this way can function to soften the outer portions of the cheese granules. This will improve melting and fusing of the granules. The features are also of importance in toppings for other baked products. Further, the improved melting and flavor distribution are generally advantages where the frozen granules are mixed into food products prior to baking. Coated frozen granules may be mixed into a dressing or applied to a salad. They will rapidly thaw, and as they thaw the surface coating cont^^mi^^ the flavor additive will become distributed and impart Jfhe desired flavor characteristics to the dressing, salad,\elP.SEPl99f»' 237914 When the coated frozen cheese is applied to pizzas and baked thereon, the coatings will liquify first. This permits the flavor additive and/or emulsifier to spread over and into the cheese particles as their outer surfaces become thawed. The water in the coating will then flash off. In this way, special flavor characteristics can be imparted with relative uniformity to the melted cheese layer on the pizza. Cheese emulsifiers applied in this way can function to soften the outer portions of the cheese granules. This will improve melting and fusing of the granules.

To assure that the moisture distribution in the cheese particles during frozen storage remains essentially unchanged, it has been found desirable to store the cheese at freezing temperatures no lower than the one at which it was originally prepared. Migration of ice and enlargement of ice crystals can occur if the cheese is stored at lower freezing temperatures after it has been held at a higher temperature. A series of storages at successively higher freezing temperatures is a convenient practice. For example, when the cheese is originally frozen at a temperature below -10°F, it can be stored first at -10 to -0°F and next at 0 to 10°F.

The frozen granules, coated or uncoated, may be packed in plastic bags and the bags placed in cartons for shipment or storage. In prior practice, frozen storage of granular cheese was limited to about six months without loss of quality. It is surprising therefore that the frozen cheese granules of this invention can be stored for periods of over 12 months without any quality deterioration.

JO SEP I99J £ storabi.li.ty feature facilitates production by the cheese manufacturer in the seasons of the year when milk is abundant. As stated above, to maintain the cheese in optimum condition, it has been found desirable to utilise successively higher ranges of storage temperatures. This avoids storage holding in which the granules are stored at a lower temperature than the initial frozen storage temperature. outlets, it is not necessary to completely thaw the cheese prior to use. For example, the cheese may be taken directly from frozen storage and applied to pizzas just prior to baking. However, handling practices and available cheese storage facilities vary considerably. Some restaurants may not be equipped for frozen storage, and/or the cheese may have been permitted to become partially thawed before it reaches the restaurant. These differences are not matters for concern when employing the frozen comminuted cheese of this invention. Excellent results can be obtained without regard to whether the cheese is in fully frozen or partially frozen condition as used on the pizzas. The baked pizzas will have as good or better appearance when prepared by the method of this invention as those prepared from thawed and equilibrated cheese. Of course, the degree of browning of the cheese on the baked pizzas depends in part on the baking equipment and temperatures used. But on a comparative basis the pizzas appeared from the frozen granules will exhibit no more browning or blistering than pizzas prepared from full: thawed equilibrated granules.

When the frozen product reaches the retail pizza //V •:Z o o o 237014 PROCESS EXAMPLE Shredded mozzarella cheese is prepared in a granule size of about 1/8 x 3/16 x 3/4 inches. The granules are subjected to IQF fluidised bed freezing in a "FloFREEZE" Model 300 WS-ADF supplied by Frigoscandia Contracting Inc, Bellevue, Washington. The freezing and fluidising air which is blown upwardly through the bed of granules can have a velocity of around 400 ft/min and a temperature of about -40°F. Frozen crusts form rapidly around the outside of the granules, viz in one to two minutes or less. The time required for completion of the freezing is of the order of 7 minutes. The frozen granules leaving the fluidised bed have a temperature of around -20°F. Weight loss due to moisture evaporation during the freezing process is less than 0.5%. Baffles along the sides and over the fluidised bed to minimise loss of cheese fines are provided. The frozen granules are packed in bags and boxed for storage, for example, at a temperature from -10 to 0°F.

COATING EXAMPLES Coatings for the frozen cheese can include one or more of the following flavor additives: lactose, glucose, diacetyl, free fatty acids (ie, butyric, propionic, capric, caproic acids), cheese flavors (Cheddar, Swiss, Provolone, etc), meat flavors (bacon, pepperoni, sausage, etc), spices (basil, oregano, garlic, dill, cinnamon, fennel, etc), vegetable flavors (tomato, onion, pimiento, pepper, etc), and fruit flavors (strawberry, pineapple, cherry, lemon, etc).

Emulsifier additives, which may be used either alone or the flavor additives, include: surfactants, disodium/! •v 237014 O o phosphate, silicon emulsifiers, and oither GRAS-approved emulsifiers.

The following formulations are illustrative.

Emulsifier Coating Solution A silicone emulsifier (Dow Corning FG-10) is mixed with water to form a 0.05% emulsifier solution. This solution is sprayed on the frozen cheese granules at a rate of 1.75 parts of solution per 100 parts by weight of cheese. This should achieve a final content of around 0.09% emulsifier on the cheese.

Smoke Flavor Coating Solution A smoke flavor (Red Arrow P-50 Hickory Smoke) is mixed with water to form a 4.5% solution thereof. The solution is sprayed on the frozen cheese granules at a rate of 2.2 parts by weight of solution per 100 parts of cheese. This should achieve a final content of about 0.1% smoke on the cheese.

Swiss Flavor Solution A Swiss cheese flavor (Naarden International Cheese Flavor Swiss Type) is mixed with water to form a 50% by weight solution. The solution is sprayed on the frozen cheese granules at a rate of 0.5 parts of solution per 100 parts by weight of cheese. This should achieve a final content of about 2.5% Swiss flavor on the cheese.

Provolone Flavoring of Mozzarella A cheese having the flavor characteristics of provolone on cooking is prepared from mozzarella cheese as follows. Mozzarella cheese is first shredded or diced to^a=r-r-granular form, as previously described. For example, two y JOSEPH? 237014 different kinds of mozzarella cheese may be combined in equal parts by weight, such as 70% skim mozzarella and 30% low moisture mozzarella to provide the granular cheese mixture which is subjected to rapid freezing as described above.

After the granules are frozen, a series of two coatings is applied. The first comprises a 1% coating (based on the weight of the cheese granules) of an 0.85% solution of liquid smoke (Arrow P-50). After the first coating has been distributed in the form of a frozen layer around the cheese granules, a second coating is applied comprising a 1 to 1.5% application of an aqueous solution containing 2% defoamer and 1% sodium citrate dehydrate. A suitable deformer is Union Carbide SAG 710 Food Grade, which is a silicone (dimethylpolysiloxane) emulsion.

Cheddar Flavoring of Mozzarella A cheese having flavor characteristics similar to cheddar cheese on cooking is prepared from mozzarella cheese.

In one embodiment, 100% part skim mozzarella cheese is converted to comminuted form. These granules after freezing are coated with two layers. The first layer comprises 1 to 1.5% application of an aqueous solution containing 2% defoamer (Mazu) and 1% sodium citrate dehydrate. The same defoamer may be used as in the Provolone substitute. The second layer comprises a 2% application of a 50% solution of a cheddar cheese flavor including Annatto coloring. Suitable flavor ingredients include the following obtainable from H&R Corp, Springfield, NJ: (1) R-9219, National Cheddar Cheese Flavor (Mild Type), and/or (2) R-9217, National Cheddar // X o / 4 Cheese Flavor (Sharp Type). ',y \ 10 SEP 1991? The above solutions should be applied generally while the frozen cheese granules are being mixed to distribute the solution over the outer surfaces of the granules. This produces thin frozen coatings around the outside of the granules while the granules remain in individual free-flowing condition.

Other Uses In addition to commercial pizza preparation for sale in restaurants, the method of this invention is also applicable to the home baking of pizzas sold in frozen condition. A manufacturer preparing pizzas for sale through retail outlets to home consumers can apply the comminuted frozen cheese of this invention to unbaked, unfrozen pizza, then without thawing the cheese the rest of the pizza is frozen by any suitable procedure. The unbaked frozen pizzas are distributed and sold in frozen condition. When a frozen pizza is purchased and baked at home without thawing, . the advantage of this invention for baking the cheese in frozen or partially frozen condition will be obtained.

By applying the frozen cheese granules to unbaked, unfrozen pizzas, a further advantage is provided. The frozen granules do not absorb the tomato or other liquid sauces.

This protects the baking properties of the cheese granules against deterioration by absorption of an acidic sauce.

It should be understood that these alternative uses of the present invention are included within the scope of this application. o -lc! - 235914 D

Claims (7)

WHAT WE CLAIM IS:

1. A method of manufacturing baked pizzas comprising the steps of: (a) at a cheese manufacturing plant preparing cheese in the form of fresh cheese granules, the cheese granules consisting of at least one variety of mozzarella, or a blend of mozzarella with other cheese; (b) freezing the cheese granules so rapidly that the individual granules retain substantially the same moisture content and distribution as before freezing, the resulting frozen granules being in free-flowing condition; (c) maintaining the granules in frozen free-flowing condition with said moisture content substantially unchanged during distribution; (d) at a pizza outlet or restaurant applying the frozen free-flowing granules to pizzas being prepared for baking, without complete thawing of the granules, at least the interiors thereof being frozen; and (e) baking the pizzas while the granules are in a frozen or partially frozen condition; the cheese granules having substantially the same moisture content and moisture distribution as before freezing and at least the interiors of the cheese granules being frozen at the start of baking.

2. A method as claimed in claim 1, wherein the granules are frozen by individual quick freezing thereof, the cheese granules being frozen at a temperature below -10°F.

3. A method as claimed in claim 1, wherein the cheese * gjr^jiules are frozen by blowing air at a temperature below -20CF thfjemgh a fluidized bed of the granules. • 5 NOV 1991 -«to- 235914

4. A method as claimed in any one of the preceding claims, in which an aqueous carrier containing a flavour additive, or a cheese emulsifier additive, or both of the additives, is applied to the frozen granules prepared in step (b), frozen surface coatings of the carrier being formed thereon.

5. A method as claimed in any one of the preceding claims wherein the frozen granules are stored at a temperature no lower than the original freezing temperature prior to distribution.

6. A method as claimed in claim 5 wherein the frozen granules are stored at successively higher temperatures prior to distribution.

7. A method of manufacturing baked pizzas as claimed in claim 1 substantially as hereinbefore described. LEPRLNO FOODS COMPANY By Thl sir Attorneys BALDWffNj_ aOjN & CAREY \ ""^0^/99/^] ..J