US20140023746A1 - Dough Packaging and Method for Dough Processing - Google Patents

Dough Packaging and Method for Dough Processing Download PDF

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Publication number
US20140023746A1
US20140023746A1 US13/943,259 US201313943259A US2014023746A1 US 20140023746 A1 US20140023746 A1 US 20140023746A1 US 201313943259 A US201313943259 A US 201313943259A US 2014023746 A1 US2014023746 A1 US 2014023746A1
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US
United States
Prior art keywords
base portion
packaging
dough
top portion
baking
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/943,259
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English (en)
Inventor
Noel Galluch
Kristin Alongi
Renee LaLonde
Rohit Jalali
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rich Products Corp
Original Assignee
Rich Products Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rich Products Corp filed Critical Rich Products Corp
Priority to US13/943,259 priority Critical patent/US20140023746A1/en
Assigned to RICH PRODUCTS CORPORATION reassignment RICH PRODUCTS CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JALALI, ROHIT, ALONGI, Kristin, GALLUCH, NOEL, LALONDE, Renee
Publication of US20140023746A1 publication Critical patent/US20140023746A1/en
Priority to US14/548,506 priority patent/US9282749B2/en
Priority to US14/548,532 priority patent/US20150079229A1/en
Priority to US14/972,946 priority patent/US9820492B2/en
Abandoned legal-status Critical Current

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Classifications

    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
    • A21D8/00—Methods for preparing or baking dough
    • A21D8/02—Methods for preparing dough; Treating dough prior to baking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/34—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within the package
    • B65D81/343—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within the package specially adapted to be heated in a conventional oven, e.g. a gas or electric resistance oven
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21B—BAKERS' OVENS; MACHINES OR EQUIPMENT FOR BAKING
    • A21B3/00—Parts or accessories of ovens
    • A21B3/13—Baking-tins; Baking forms
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
    • A21D10/00—Batters, dough or mixtures before baking
    • A21D10/02—Ready-for-oven doughs
    • A21D10/025—Packaged doughs
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
    • A21D6/00—Other treatment of flour or dough before baking, e.g. cooling, irradiating, heating
    • A21D6/001—Cooling
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
    • A21D8/00—Methods for preparing or baking dough
    • A21D8/02—Methods for preparing dough; Treating dough prior to baking
    • A21D8/04—Methods for preparing dough; Treating dough prior to baking treating dough with microorganisms or enzymes
    • A—HUMAN NECESSITIES
    • A21—BAKING; EDIBLE DOUGHS
    • A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
    • A21D8/00—Methods for preparing or baking dough
    • A21D8/06—Baking processes
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47J—KITCHEN EQUIPMENT; COFFEE MILLS; SPICE MILLS; APPARATUS FOR MAKING BEVERAGES
    • A47J37/00—Baking; Roasting; Grilling; Frying
    • A47J37/01—Vessels uniquely adapted for baking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/28—Articles or materials wholly enclosed in composite wrappers, i.e. wrappers formed by associating or interconnecting two or more sheets or blanks
    • B65D75/30—Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/28—Articles or materials wholly enclosed in composite wrappers, i.e. wrappers formed by associating or interconnecting two or more sheets or blanks
    • B65D75/30—Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding
    • B65D75/32—Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding one or both sheets or blanks being recessed to accommodate contents
    • B65D75/325—Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding one or both sheets or blanks being recessed to accommodate contents one sheet being recessed, and the other being a flat not- rigid sheet, e.g. puncturable or peelable foil
    • B65D75/327—Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding one or both sheets or blanks being recessed to accommodate contents one sheet being recessed, and the other being a flat not- rigid sheet, e.g. puncturable or peelable foil and forming several compartments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2205/00—Venting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2205/00—Venting means
    • B65D2205/02—Venting holes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2581/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D2581/34—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within
    • B65D2581/3401—Cooking or heating method specially adapted to the contents of the package
    • B65D2581/3402—Cooking or heating method specially adapted to the contents of the package characterised by the type of product to be heated or cooked
    • B65D2581/3405—Cooking bakery products
    • B65D2581/3408—Cakes and the like, e.g. muffins, cupcakes

Definitions

  • the present invention relates to bakery goods, particularly to dough products, more particularly to the packaging and processing of dough products, and even more particularly to the packaging, processing and cooking of dough products.
  • the present invention is directed to a packaging and method for use in 1) packaging and/or storing unproofed dough products, 2) proofing dough products, 3) storing proofed, partially proofed or unproofed dough products, and/or 4) cooking proofed dough products.
  • dough product means any type of batter or dough.
  • the dough product can include cereal grains, seeds and/or roots.
  • the dough products as defined in the present invention can be formed of one or more of the following ingredients: maize or corn, sorghum, fonio, millet, coixseed, wheat, rice, rye, barley, oat, triticale, teff, amaranth, quinoa, buckwheat, soybean, common bean, chickpea, lima bean, runner bean, pigeon pea, lentil, field pea, lupin, mung bean, fava bean, peanuts, poppy seeds, acorns, almonds, amaranth flour, cassaya flour made from the root of the cassaya, tapioca, chestnuts, potatoes, coconut, hemp, mesquite, and/or hazelnuts.
  • the dough products can include other or additional ingredients.
  • a packaging that is formed of a material that can contain dough product without adversely reacting with the dough product.
  • materials include, but are not limited to, plastic materials.
  • plastic materials include, but are not limited to, plastic materials.
  • One non-limiting plastic material that can be used to fully or partially form the packaging is a polyester film such as, but not limited to a Mylar® material offered by DuPont under the brand Teijin FilmsTM (e.g., Mylar® 400BKFP, Mylar® 200BKFP, Mylar® 100BK5, Mylar® 200BKP5, Mylar® 100BK52, etc.).
  • Mylar® 400BKFP Mylar® 400BKFP, Mylar® 200BKFP, Mylar® 100BK5, Mylar® 200BKP5, Mylar® 100BK52, etc.
  • Mylar® products can be used and/or other types of plastic materials can be used.
  • the thickness of the plastic material that is used to partially or fully form the packaging is non-limiting.
  • the plastic material generally has a thickness of about 0.2-50 mils; however, other thicknesses can be used. In one non-limiting configuration, the plastic material has a thickness of about 0.2-20 mils. In another non-limiting configuration, the plastic material has a thickness of about 0.5-10 mils. In still another non-limiting configuration, the plastic material has a thickness of about 1-5 mils.
  • the packaging can use a uniform material thickness, or have different material thicknesses for different regions of the packaging. For example, the base portion of the packaging can have a greater thickness than the top of the packaging; however, this is not required. Different types of plastic can be used to form different portions of the packaging; however, this is not required.
  • the base portion of the packaging can be formed of a different material than the material used to form the top portion of the packaging; however, this is not required.
  • the plastic material can optionally be a transparent or semi-transparent material. Such a material, when used, can enable a user to view the dough product during the storage of the product in the packaging, the proofing of the product in the packaging, and/or the baking of the dough product in the packaging.
  • the packaging includes a base and top portion
  • the base and/or top portion can option be formed of the transparent or semi-transparent material.
  • the packaging can include a top portion that is partially or fully removable from the base portion of the packaging; however, this is not required.
  • the top portion can be partially or fully removably secured to the base portion by an adhesive, melted seam, etc.
  • the top portion and/or base portion can also or alternatively include serrations to facilitate in the removal of all or a portion of the top portion from the base portion.
  • the packaging can be designed to controllably release gas (CO 2 , water vapor, etc.) during the proofing and/or baking of the dough product; however, this is not required.
  • the gas release from the packaging can be achieved in one or more arrangements.
  • Non-limiting arrangements include 1) selecting gas-permeable materials for use in one or more portions of the packaging, 2) inserting one or more openings, slots serrations, etc. in the packaging, and/or 3) using an adhesive material that will release under certain pressures/temperatures.
  • one or more small openings can be intentionally formed in the top portion, the bottom portion and/or between the top and bottom portions. The size, number and location of the intentional openings are non-limiting.
  • the top portion of the packaging can be designed to be partially or fully disengaged from the base portion of the packaging during the proofing and/or baking of the product in the packaging.
  • An adhesive, melted seam, mechanical connection e.g., snap connection, hook and loop connection, etc.
  • the type of the adhesive, the pressure and/or temperature used to secure the top portion to the base portion via the adhesive the thickness of the adhesive, the uniformity of the adhesive, the width of the adhesive layer, etc.
  • the packaging can include one or more intentional openings and/or be designed to form one or more openings during the proofing and/or baking of the dough product; however, this is not required.
  • the one or more intentional openings and/or formed openings can be designed to maintain in size and/or change in size (e.g., increase in size, decrease in size) during the proofing and/or baking of the dough product.
  • the number of formed openings in the packaging can stay the same or change (e.g., increase in number, decrease in number) during the proofing and/or baking of the dough product.
  • the use of one or more intentional openings, the formation of one or more openings, the number of one or more intentional openings and/or formed openings, the size of the one or more intentional openings and/or formed openings, and/or the control of formation of the one or more formed openings during the proofing and/or baking of the dough product can be used to control of gas release, if any, from the packaging during the proofing and/or baking of the dough product so as to control the moisture content, CO 2 content, etc. of the dough product during the proofing and/or cooking of the dough product.
  • the packaging can be designed to not release any gas or substantially no gas during the proofing and/or cooking of the dough product.
  • the one or more intentional openings and/or one or more formed openings in the packaging when used, can be used to allow gases to more easily escape during the baking and/or proofing process; however, this is not required.
  • These one or more intentional openings and/or one or more formed openings in the packaging, when used, can also or alternatively be used to control the moisture content of the dough product during the baking and/or proofing process; however, this is not required.
  • the one or more intentional openings and/or one or more formed openings in the packaging, when used, can also or alternatively be used to facilitate the uniform baking of the dough product during the baking process.
  • the packaging can include multiple cavities or wells that each include a dough product.
  • the cavities or wells in the one or more regions of the packaging may exhibit slower baking of the dough product than dough product located in other regions of the packaging.
  • the one or more intentional openings and/or one or more formed openings in the packaging when used, can be used to cause such slower baking regions to accelerate in baking. Such acceleration can be due in part to heat being allowed to enter the cavities via the one or more openings; however, this is not required.
  • the one or more intentional openings in the packaging when used, can be used to accelerate the rate at which adjacent adhesively connected regions of the top portion release from the bottom portion during the baking and/or proofing process; however, this is not required.
  • the size and/or number of the openings can be selected to control the rate at which gas is released during the baking and/or proofing process; however, this is not required.
  • the one or more openings can also or alternatively be used to control the heating of the product during a baking process; however, this is not required.
  • the one or more openings when used, not only can allow gas to escape a product cavity, but also allow heat to enter the cavity so as to facilitate in the drying and/or baking of the product in the cavity; however, this is not required. As such, strategic control of openings and/or the formation of openings can thus be used to control the uniform proofing and/or baking of a product; however, this is not required.
  • one or more portions of the packaging can be formed of a material that shrinks, expands, changes to a new shape, reverts partially or fully back to an original shape, etc. during the freezing, proofing and/or baking of the dough product.
  • one or more portions of the packaging can be designed to expand during the proofing and/or baking of the dough product; however, this is not required. For instance, during the proofing of a dough product, CO 2 and/or water vapor is formed, resulting in an increased pressure. Likewise, when a dough product is baked, water vapor is produced.
  • the packaging can be designed to expand after a certain threshold pressure is obtained due to the formation of CO 2 and/or water vapor; however, this is not required.
  • the expansion of the packaging can allow the dough to expand and rise to form a desired shape and/size during the proofing and/or baking of the dough product; however, this is not required.
  • all of the packaging can be designed to be expandable or only a portion of the packaging can be designed to be expandable.
  • the base portion of the packaging can be designed to be non-expandable, and the top portion of the packaging can be designed to be expandable; however, this is not required.
  • the base portion of the packaging can be designed to be expandable, and the top portion of the packaging can be designed to be non-expandable; however, this is not required.
  • the top and bottom portions of the packaging can be designed to be expandable, but the top and bottom portions are designed to expand at a different amount and/or rate; however, this is not required.
  • one or more portions of the packaging can be designed to partially revert back to its original shape during the heating of the packaging while proofing and/or baking the dough product; however, this is not required.
  • the base portion of the packaging can be molded or otherwise formed into a specific shape and be designed, during the baking of the dough product, to partially or fully lose its molded shape; however, this is not required.
  • the top portion of the packaging can be molded or otherwise formed into a specific shape and be designed, during the baking of the dough product, to partially or fully lose its molded shape; however, this is not required.
  • the top portion can be designed to partially or fully release from the bottom portion prior to and/or during the base and/or top portion partially or fully losing its molded shape; however, this is not required.
  • a plastic material can be used to partially or fully form the packaging.
  • the top portion and/or base portion of the packaging can be heat formed or molded in a press, etc. to form a bottom and/or top cavity for a dough product.
  • a flat sheet of plastic material can be heated and/or pressed by a cavity mold to form a top portion and/or a base portion that has a cavity that was formed by the cavity mold.
  • the packaging can be designed to include one or more cavities that are designed to receive a dough product. Each cavity is generally designed to hold an individual dough product (e.g., cinnamon roll, muffin, roll, etc.).
  • the plastic material can be selected and formed to maintain some memory in the plastic to thereby cause the cavity to 1) maintain its shape during the baking of the dough product, or 2) partially or fully revert back to its original shape (e.g., flat sheet state) that existed prior to the molding or forming process during the baking process of the dough product.
  • Such memory feature of the plastic can be used to 1) partially flatten tops of a muffin or other type of dough products during the baking of the dough product, 2) compress the sides and/or top of the dough product during the baking of the dough product, and/or 3) maintain the base and/or top portion of a product at the beginning of a baking process and then partially or fully flatten out for the remainder of the baking process to form special types of bakery goods (e.g., muffin tops, etc.).
  • This memory feature of the plastic material can be advantageously used for different types of bakery goods (e.g., cookies, brownies, cinnamon rolls, cinnamon twists or sticks, muffins, pizza dough, bread loaf, rolls, cake, pastry, muffin tops, etc.).
  • the degree to which the plastic material shrinks and/or partially reverts back to its original shape can be at least partially controlled by the type of material, thickness of material, the parameters (e.g., temperature, pressure, time, etc.) in which the material is formed into certain shapes, and/or the heating temperature of the material during the baking of the dough product.
  • the plastic material can be designed to partially or fully revert back to its original shape during the baking process, it can be appreciated that the plastic material can be designed to partially or fully revert back to its original shape during the proofing process; however, this is not required.
  • a container or packaging that 1) increases food safety, 2) reduces food contamination, 3) results in faster proofing times for the dough product, 3) results in faster baking times for the dough product, 4) results in more uniform baking of the dough product, 5) reduces the handling of the dough product from humans during the packaging, proofing and/or baking process for the dough product, 6) simplifies the proofing of the dough product, 7) simplifies the baking of the dough product, 8) simplifies the packaging of the dough product, 9) simplifies the storage of the dough product, 10) simplifies the shipping of the dough product, 11) at least partially shapes the dough product during proofing, 12) at least partially shapes the dough product during baking, 13) changes its shape during the proofing and/or baking process, 14) at least partially controls the moisture content of the bakery product during the proofing and/or baking process, 15) at least partially controls the gas pressure of the bakery product in the cavity or well during the proofing and/or baking process, and/or 16) at
  • a method for dough processing which includes packaging unproofed dough in a container or packaging.
  • the container or packaging can be a flexible, a gas impermeable, and/or a moisture proof container; however, this is not required.
  • the container or packaging can be designed to create an airtight seal for the dough product in the container or packaging; however, this is not required.
  • the container or packaging can be designed to enable freezing of the dough product in the container or packaging without any proofing; however, this is not required.
  • the container or packaging material can be expandable; however, this is not required.
  • the container or packaging can be designed to enable the container or packaging to be removed from the freezer so that the dough product in the container can be proofed while still in the container or packaging; however, this is not required.
  • the dough product can be partially or completely removed from the container or packaging and/or unsealed in the container or packaging and baked; however, this is not required.
  • the baking of the product can be in the container or packaging, or the product can be removed from the container or packaging and placed in another container or packaging for baking.
  • the dough product can remain sealed in the container or packaging during the proofing and/or baking of the dough product.
  • the container or packaging can be designed to allow frozen dough that is sealed or partially sealed in the container or packaging to be proofed and then placed in an oven while still in the container or packaging.
  • the container or packaging can be designed to be directly transferred from the freezer to the oven while the dough product is partially or fully sealed in the container or packaging.
  • the container or packaging can be designed to allow frozen dough or non-frozen dough that is sealed or partially sealed in the container or packaging to be partially or fully proofed and then placed into a freezer.
  • the proofed or partially proofed dough can then be taken out of the freezer, thawed and then baked in the container or packaging or removed from the container or packaging and placed in another container or packaging for baking.
  • This process is an improvement over traditional yeast-based proofing processes.
  • the present process requires no special baking skill, retarders or proof boxes to achieve a quality product.
  • the packaging process is such that the extent of proofing is controlled and the use of a retarder or a proof box to produce high quality proof and bake products can be fully or partially eliminated.
  • the dough product can be packaged and frozen without any proofing prior to freezing, either before or after packaging. After removal from the freezer, proofing can be carried out in the packaging.
  • the product can be optionally frozen in the packaging after being partially or proofed.
  • the packaging material can be partially or fully moisture proof and/or gas impermeable so that, during the process of proofing, there is minimal or no loss of moisture from the packaging (and therefore from the dough) and/or the CO 2 and/or other volatile materials generated during proofing is/are restricted from escaping; however, this is not required.
  • the CO 2 , water vapor and other volatile materials help to build pressure within the packaging so that at least part of the proofing process occurs under pressure resulting from the buildup of gas and/or volatile materials.
  • a process of proofing a dough product by removing the packaged dough product from the freezer and then allowing the dough product to proof while it is still in the package.
  • the dough product is contained in a gas impermeable, moisture proof packaging, there is no need for a proof box or retarder having high humidity. Rather, all or a substantial amount of the moisture from the dough is not released outside of the packaging, thus eliminating the need for having a specific humidity in the proofing enclosure. Additionally, because little or no moisture is released, the packaged dough product can be left for proofing for a much longer time (e.g., double the standard proofing time) without the concern for drying of the dough product.
  • the present dough can be placed in a retarder for several days (e.g., 1-10 days) without affecting the quality of the dough product or the baked dough product.
  • the dough product becomes undesirable or unusable within about 48 hours.
  • the dough product, when partially or fully sealed in the packaging can be proofed at room temperature for up to about 4-10 hours without any undesirable effect on the performance of the dough product.
  • Adverse performance seen without partial or full sealing the dough product in the packaging includes dryness in the dough product and/or surface crusting.
  • the packaging allows the dough to be proofed in the packaging while the dough product is still contained in the packaging.
  • the dough product can be 1) frozen for later use, 2) partially or completely uncovered in the packaging during the baking of the dough product, or 3) partially or fully sealed during the complete or partial baking of the dough product.
  • the term “sealed” or “fully sealed” means that the product in the packaging is encapsulated in an environment that prevents at least about 95%, and typically 100%, of the moisture and/or gas from escaping the environment.
  • partially sealed means that the product in the packaging is encapsulated in an environment that can include one or more small openings that control the release of the moisture and/or gas from the encapsulated environment during the proofing and/or baking of the product.
  • the one or more small openings are formed after 1) a certain pressure within the encapsulated environment is obtained, 2) after a certain temperature within the encapsulated environment is obtained, and/or 3) after the packaging has been exposed to a certain temperature for a certain period of time.
  • uncovered means that the product in the packaging is exposed to the ambient environment and achieves pressure equilibrium with the ambient environment in less than about 0.5-1 seconds.
  • the one or more small openings that are used in a partially sealed product will also eventually allow the product in the packaging to reach pressure equilibrium with the ambient environment; however, the time period is greater than 1 second and more typically about 3 seconds to 5 minutes.
  • product can be uncovered by the top portion of the packaging being pulled back, cut or partially or fully released from the base portion of the packaging or container so as to expose the dough to the outside or ambient atmosphere (e.g., oven atmosphere, proofing atmosphere, outside atmosphere, etc.), but the dough can still remain in the packaging material. In such a situation, the uncovered product reaches pressure equilibrium with the outside or ambient atmosphere in less than one second.
  • the size and number of the one or more small openings is selected such that during at least about 10% of the proofing period of the dough product in the partially or fully sealed package the pressure in the cavity that includes the dough product is greater than the ambient pressure of the package (e.g., 700-800 mm Hg). In another non-limiting arrangement, the size and number of the one or more small openings is selected such that, during 10% to 100% of the proofing period of the dough product in the partially or fully sealed package, the pressure in the cavity that includes the dough product is greater than the ambient pressure of the package.
  • the size and number of the one or more small openings is selected such that, during at least about 20% of the proofing period of the dough product in the partially or fully sealed package, the pressure in the cavity that includes the dough product is greater than the ambient pressure of the package. In yet another non-limiting arrangement, the size and number of the one or more small openings is selected such that, during at least about 40% of the proofing period of the dough product in the partially or fully sealed package, the pressure in the cavity that includes the dough product is greater than the ambient pressure of the package.
  • the size and number of the one or more small openings is selected such that, during more than 50% of the proofing period of the dough product in the partially or fully sealed package, the pressure in the cavity that includes the dough product is greater than the ambient pressure of the package. In still yet another non-limiting arrangement, the size and number of the one or more small openings is selected such that, during at least about 60% of the proofing period of the dough product in the partially or fully sealed package, the pressure in the cavity that includes the dough product is greater than the ambient pressure of the package.
  • the size and number of the one or more small openings is selected such that, during at least about 75% of the proofing period of the dough product in the partially or fully sealed package, the pressure in the cavity that includes the dough product is greater than the ambient pressure of the package. In still another non-limiting arrangement, the size and number of the one or more small openings is selected such that, during up to 95% of the proofing period of the dough product in the partially or fully sealed package, the pressure in the cavity that includes the dough product is greater than the ambient pressure of the package.
  • the size and number of the one or more small openings is selected such that, during up to 90% of the proofing period of the dough product in the partially or fully sealed package, the pressure in the cavity that includes the dough product is greater than the ambient pressure of the package. In still yet another non-limiting arrangement, the size and number of the one or more small openings is selected such that, during up to 80% of the proofing period of the dough product in the partially or fully sealed package, the pressure in the cavity that includes the dough product is greater than the ambient pressure of the package. In another non-limiting arrangement, the cross-section area of one, or a plurality, or a majority, or all of the openings is generally no more than about 0.8 in. 2 , typically no more than about 0.6 in.
  • the size and/or shape of the openings can be the same or different.
  • one, or a plurality, or a majority, or all of the openings can be preformed openings, and/or can be formed 1) when a predefined pressure is achieved in the cavity that includes the dough product, and/or 2) when the packaging is exposed to a certain temperature for a certain period.
  • an adhesive that softens at a temperature above about 60-15° F. and typically above about 75-140° F., and more typically above about 80-120° F. is used; however, this is not required.
  • the composition of the adhesive is non-limiting.
  • the predefined pressure is generally at least about 2 mm Hg above ambient pressure, typically at least about 5 mm Hg above ambient pressure, more typically at least about 10 mm Hg above ambient pressure, and still more typically at least about 20 mm Hg. Also, when one or more of the openings are formed based partially or fully on the pressure achieved in the cavity or cell that includes the dough product, the predefined pressure is generally less than about 2000 mm Hg, typically less than about 1500 mm Hg, and more typically less than about 760 mm Hg; however, this is not required.
  • the proofing of the dough product can be carried out at a variety of temperatures (e.g., 33° F.-140° F., retarder temperature, room temperature, or proof box temperature, etc.) that will enable the yeast to produce CO 2 .
  • temperatures e.g., 33° F.-140° F., retarder temperature, room temperature, or proof box temperature, etc.
  • the proofing can be carried out from a few minutes to several days (e.g., up to 10 days, etc.).
  • the superior quality product obtained when the product is partially or fully sealed in accordance with one aspect of the present invention is due to high hydration of the dough, improved carbonic acid break-down of the gluten cell structures due to the higher CO 2 content, and/or due to pressurized proofing.
  • a high degree of hydration is achieved by having high water content and/or minimizing moisture loss during proofing.
  • High water content has been a limiting factor in the traditional manufacturing processes because high water content dough products typically stick to the processing equipment.
  • high water content dough product may be desirable in certain situations (such as for pizza dough, artisan bread, ciabatta bread, etc.).
  • the present invention allows for the processing of high water content dough products using current manufacturing equipment by eliminating contact between the dough product and the processing equipment.
  • the water content of the dough product that can be used in the packaging is non-limiting.
  • proofing of the dough product can be carried out in a fully or partially gas impermeable containment, the CO 2 , water vapor, and/or volatile materials that are generated during proofing are restricted from escaping from the package.
  • CO 2 is generated by the action of yeast in the dough forming gas cells.
  • the size of the gas cells in the dough product can increase.
  • little or no gas is released from the packaging, resulting in an increase in pressure within the dough product.
  • the packaging can be expandable to avoid buildup of excess pressure in the packaging and to maintain a pressure within a certain range.
  • the packaging can include one or more small openings (i.e., partially sealed packaging) and/or include regions that form one or more openings after a certain pressure threshold is reached to the pressure build-up in the packaging (i.e., a sealed package that is transformed into a partially sealed package after a certain pressure threshold is obtained) so that some accumulated CO 2 is released from the packaging to inhibit or prevent damage to the packaging, damage to the product, and/or undesired product shapes cause by the elevated pressure in the packaging.
  • a certain pressure threshold i.e., a sealed package that is transformed into a partially sealed package after a certain pressure threshold is obtained
  • the size and/or number of the small openings when used, can be selected to maintain the desired levels of accumulated CO 2 in the packaging during proofing and also inhibit or prevent damage to the packaging, damage to the product, and/or undesired product shapes cause by the elevated pressure in the packaging during proofing. It is believed that there are advantages to reducing the loss of CO 2 from the dough product. Because of accumulation of CO 2 in the packaging, and the redistribution of CO 2 in the dough product matrix, the pH of the dough is reduced. It is believed that the pH of the dough drops to below 5.5. Furthermore, the high amount of CO 2 in the dough is believed to act as an inhibitor of pathogens. Still further, the CO 2 that is forced back into the dough matrix is also believed to aid in producing an increased open texture in the baked products.
  • the increased CO 2 content of the dough product is also believed to break down the gluten cell structures in the dough product due to the increased carbonic acid in the dough product.
  • the reduced gas loss from the dough product will reduce or prevent the weight loss of the dough product by about 1-2% as is normally observed when the CO 2 is allowed to escape from the dough product.
  • the advantages of proofing within the packaging include: 1) reduction of loss of CO 2 ; 2) reduction of loss of volatile materials (such as fermentation alcohols, water vapor, etc.); 3) no contamination of the dough by other food materials being processed or handled in the end-user facility; and/or 4) no contamination by the dough of other food materials being processed or handled in the end-user facility. This can be particularly desirable when preparing gluten-free dough products, or other special needs dough products and baked products.
  • the packaging material can be gas impermeable, bakable, elastic, and/or flexible.
  • the present invention provides a method for obtaining a baked product from a frozen dough comprising the steps of 1) obtaining an unproofed dough product; 2) packaging the unproofed dough product in a gas and/or moisture fully or partially impermeable, flexible and/or expandable packaging; 3) partially or fully sealing the packaging; 4) freezing the packaged dough product without proofing; 5) removing the frozen dough product from a freezer; 6) allowing the dough product to partially or fully proof while still in the partially or fully sealed packaging or in an unsealed packaging; 7) optionally refreezing the partially or fully proofed dough in the packaging; 8) optionally unsealing the dough product from the packaging; 9) optionally placing toppings on the partially or fully proofed dough while the dough is in a frozen, partially frozen or unfrozen state; and 10) baking the dough.
  • the packaged dough can be partially or fully proofed before the initial freezing step.
  • the dough after packaging the dough with or without proofing prior to freezing, the dough can be subjected to alternating high and low pressures, with the low pressure being lower than ambient pressure. It is believed such vacuum exercising strengthens the structure of the dough. Details of such exercising can be found in U.S. Publication No. 2007/0160709, which is incorporated herein by reference.
  • the dough can be subjected to mechanical stresses so as to restructure the dough matrix. Such restructuring may involve reducing the number of air cells and/or shifting the air cell size distribution toward larger air cells.
  • the dough can be exercised by subjecting the dough to alternating high and low pressure such that the pressure differential between the high (a first pressure) and the low pressure (a second pressure) is between 1 to 20 inches of Hg; however, this is not required.
  • One or more cycles of alternating pressure can be used wherein each half cycle last about 5 seconds to 10 minutes.
  • the flour used for making the dough is heat-treated to increase the water absorption capacity of the flour.
  • the dough holds more water than dough prepared from flour that was not heat treated.
  • the heat treatment is carried out according to the process described in U.S. Publication No. 2010/0092639, which is incorporated herein by reference.
  • the flour can be heat treated by a) thermally dehydrating the flour such that the moisture content of the flour is reduced to 1.5 to 4.1% and the flour is not gelatinized; and b) heating the dehydrated flour such that the moisture content of the flour does not go below 1.5% to obtain a heat-treated flour.
  • the heat-treated flour can have at least 7% of the total proteins denatured.
  • the heat-treated flour can have discernible starch granules.
  • the heat-treated flour can have a particle size distribution such that greater than 80% of the flour particles are between 90 and 150 microns or greater than 80% of the flour particles are between 90 and 150 microns and greater than 7% of the flour particles are between 150 and 250 microns.
  • the dough used in the present invention can be any dough.
  • the dough comprises flour, water, yeast, one or more emulsifiers and one or more dough stabilizers as provided in U.S. Publication Nos. 2007/0160709 or 2010/0092639, which are incorporated herein by reference.
  • the ingredients of the dough can be of any type that are known to be used for making dough.
  • the thickness of the plastic film, the type of plastic film, and the parameters in which the plastic film is processed can be used to control the shape of the final bakery product.
  • Non-limiting plastics that can be used include Mylar® plastic films available from DuPont Teijin Films.
  • Mylar® plastic films available from DuPont Teijin Films.
  • the plastic sheet has a sheet thickness of at least 3 mils, and typically at least about 4 mils.
  • the forming temperature is at least about 175° C., and typically at least about 200° C.
  • the heating time of the plastic sheet during the molding process is generally at least 4 seconds and typically at least about 5 seconds.
  • the plastic sheet is typically thinner than the sheet used to form the bottom portion; however, this is not required.
  • the plastic sheet has a sheet thickness of no more than 3 mils, and typically about 1-2 mils.
  • the forming temperature is no more than 195° C., and typically about 130-160° C.
  • the heating time of the plastic sheet during the molding process is generally no more than about 4 seconds and typically about 1-3 seconds. After the plastic is heated, it is generally subjected to chilled water (e.g. 5-30° C.) to rapidly cool the molded plastic; however, this is not required.
  • the base portion and/or top portion are formed from a flat sheet-like plastic material and are molded into a packaging that includes one or more cavities that are design to partially or fully receive a dough product.
  • the molded plastic material is designed to retain its form during the baking of the dough product while the dough product is partially or fully contained in the one or more cavities of the packaging.
  • the base portion and/or top portion are formed from a flat sheet-like plastic material and are molded into a packaging that includes one or more cavities that are design to partially or fully receive a dough product.
  • the molded plastic material is designed to not retain its form during the baking of the dough product while the dough product is partially or fully contained in the one or more cavities of the packaging.
  • at least about 50% of the molded form of the plastic material reverts back to its original flat sheet-like shape, typically at least about 75% of the molded form of the plastic material reverts back to its original flat sheet-like shape, and more typically at about at least 90% of the molded form of the plastic material reverts back to its original flat sheet-like shape.
  • a packaging and a method for obtaining baked muffins that includes a base portion of a packaging that substantially retains its shape; however, other products can be obtained.
  • the packaging generally includes a top portion and a base portion; however, this is not required.
  • the base portion is at least partially formed of a plastic material.
  • One non-limiting plastic material is a Mylar® material; however, other plastic materials can be used.
  • the base portion can be molded into a shape for a sheet of plastic material; however, this is not required.
  • the thickness of the plastic material is generally at least about 4 mils and typically about 4-10 mils; however, other thicknesses can be used.
  • the sheet of plastic material can be molded into a desired shape by the use of molds in combination with certain temperatures and pressures; however, this is not required.
  • the packaging can be formed by other means.
  • the type of plastic used for the top portion and/or bottom portion of the packaging is generally a bakable and/or a cryogenic plastic.
  • a bakable plastic material is a material that can be safely heated when baking food products and which will not degrade at a temperature of at least 200° F., typically at least about 300° F., and more typically at least about 400° F.
  • the type of plastic material and the method that is used for forming the plastic material into the base portion of the packaging is selected so that during the proofing and/or baking of the one or more muffins in the packaging, the packaging maintains or substantially maintains its shape.
  • the base portion of the packaging is formed of a plastic material that maintains or substantially maintains its shape during the proofing and/or baking of the one or more muffins in the packaging.
  • the plastic material for the base portion can be selected to be a bakable and/or a cryogenic plastic.
  • the packaging includes a top portion that is formed of a plastic material.
  • the top portion can be designed to be removable prior to the baking of the one or more muffins in the packaging, or be designed to be connected to the base portion when proofing and/or baking the one or more muffins in the packaging.
  • the plastic material for the top portion can be selected to be a bakable and/or a cryogenic plastic.
  • the top portion can be connected to the base portion in a variety of ways (e.g., adhesive, melted bond, pressure bond, etc.).
  • the formed base portion of the packaging can include one or more cavities that are designed to receive a dough product (e.g., dough for the muffin, etc.).
  • the number, size and/or shape of cavities in the base portion of the packaging are non-limiting. Generally, the size and/or shape of cavities in the base portion of the packaging are the same; however, this is not required.
  • the dough product can be placed into all or a portion of the cavities in the base portion of the packaging. Generally, each of the cavities in the base portion of the packaging include a dough product; however, this is not required.
  • the dough product that is placed in the cavities in the base portion can be dough that is not proofed, partially proofed or fully proofed. After the dough product is placed in the one or more cavities in the base portion, the dough product can be 1) allowed to partially or fully proof, 2) baked, and/or 3) stored in a refrigerator or freezer.
  • a top portion can be applied to the base portion of the packaging prior to the dough product being 1) allowed to partially or fully proof, 2) baked, and/or 3) stored in a refrigerator or freezer.
  • the top portion can be used to fully or partially seal the dough product between the base portion and top portion of the packaging; however, this is not required.
  • one or more small openings are formed in the top portion or in a region between the top portion and the base portion so as to form a partially sealed packaging.
  • one or more regions in the top portion or one or more regions between the top portion and the base portion can be designed to form a small opening when a certain predefined pressure in obtained in the covered cavities that include the dough product.
  • the base portion is designed to maintain or substantially maintain its shape during the baking of the one or more dough products in the packaging.
  • the packaging when the packaging includes a top portion and the top portion is not removed from the base portion prior to the proofing and/or baking of the dough product, the packaging can include and/or form small openings to facilitate in the venting of moisture and/or gas from the packaging during the proofing and/or baking of the dough product; however, this is not required.
  • the cross-section shape of the cavity can be circular or polygonal (e.g., square, rectangular, etc.); however, other shapes can be used.
  • the cavity has a generally disc shape.
  • a lip can be designed to partially or fully encircle a recessed portion of the base portion; however, this is not required.
  • the top portion can be designed to be connected to said lip; however, this is not required.
  • the lip can include serrations, slots, depressions, etc. that can be used to separate two or more cavities from one another along the serrations, slots, depressions, etc. without compromising the connection between the top portion and the base portion that is forming at least one of the cavities; however, this is not required.
  • Toppings e.g., sugar, fruit, cheese, oil, fruits, nuts, spices, etc.
  • Toppings can be applied to the muffins 1) prior to and/or during the refrigeration or freezing of the muffins, or 2) prior to and/or during the proofing and/or baking of the muffins.
  • muffins were referenced above, it can be appreciated that many other dough products can be formed, proofed and/or baked using the above-described process (e.g., cinnamon rolls, focaccia and focaccia buns, etc.).
  • a packaging and a method for obtaining muffin tops that includes a base portion of a packaging that can at least partially revert back to its original shape during a baking process; however, other products can be obtained.
  • the packaging generally includes a top portion and a base portion; however, this is not required.
  • the base portion is at least partially formed of a plastic material.
  • One non-limiting plastic material is a Mylar® material; however, other plastic materials can be used.
  • the base portion can be molded into a shape for a sheet of plastic material; however, this is not required.
  • the thickness of the plastic material is generally no more than about 4 mils and typically about 2-3 mils; however, other thicknesses can be used.
  • the sheet of plastic material can be molded into a desired shape by the use of molds in combination with certain temperatures and pressures; however, this is not required.
  • the packaging can be formed by other means.
  • the type of plastic used for the top portion and/or bottom portion of the packaging is generally a bakable and/or a cryogenic plastic.
  • the type of plastic material and the method that is used for forming the plastic material into the base portion of the packaging is selected so that during the proofing and/or baking of the one or more muffin tops in the packaging, the packaging does not maintain its shape.
  • the base portion of the packaging is formed of a plastic material that is formed from a flat sheet of plastic material to create a packaging that includes one or more cavities for the receiving of a dough product, and during the proofing and/or baking of the one or more dough products in the base portion, the shape of the formed base portion fully or partially reverts back to its original sheet-like form, thus substantially or fully eliminating the formed cavities in the base portion.
  • the plastic material for the base portion can be selected to be a bakable and/or a cryogenic plastic.
  • the packaging includes a top portion that is formed of a plastic material.
  • the top portion can be designed to be removable prior to the baking of the one or more muffin tops in the packaging, or be designed to be connected to the base portion when proofing and/or baking the one or more muffin tops in the packaging.
  • the plastic material for the top portion can be selected to be a bakable and/or a cryogenic plastic.
  • the top portion can be connected to the base portion in a variety of ways (e.g., adhesive, melted bond, pressure bond, etc.).
  • the formed base portion of the packaging can include one or more cavities that are designed to receive a dough product (e.g., dough for the muffin tops, etc.).
  • the number, size and/or shape of cavities in the base portion of the packaging are non-limiting. Generally, the size and/or shape of cavities in the base portion of the packaging are the same; however, this is not required.
  • the dough product can be placed into all or a portion of cavities in the base portion of the packaging. Generally, each of the cavities in the base portion of the packaging include a dough product; however, this is not required.
  • the dough product that is placed in the cavities in the base portion can be dough that is not proofed, partially proofed or fully proofed. After the dough product is placed in the one or more cavities in the base portion, the dough product can be 1) allowed to partially or fully proof, 2) baked, and/or 3) stored in a refrigerator or freezer.
  • a top portion can be applied to the base portion of the packaging prior to the dough product being 1) allowed to partially or fully proof, 2) baked, and/or 3) stored in a refrigerator or freezer.
  • the top portion can be used to fully or partially seal the dough product between the base portion and top portion of the packaging; however, this is not required.
  • one or more small openings are formed in the top portion or in a region between the top portion and the base portion so as to form a partially sealed packaging.
  • one or more regions in the top portion or one or more regions between the top portion and the base portion can be designed to form a small opening when a certain predefined pressure in obtained in the covered cavities that include the dough product.
  • the base portion is designed to not maintain or substantially maintain its shape during the baking of the one or more dough products in the packaging.
  • the base portion can be designed to maintain or substantially maintain it shape during at least a portion of the baking time or process while the base portion is in the oven (e.g., 2% of the total baking process, 5% of the total baking process, 10% of the total baking process, 15% of the total baking process, 20% of the total baking process, 25% of the total baking process, 30% of the total baking process, 35% of the total baking process, 40% of the total baking process, 45% of the total baking process, 50% of the total baking process, 55% of the total baking process, 60% of the total baking process, 65% of the total baking process, 70% of the total baking process, etc.) so that at least a portion of the dough product sets (e.g., the upper region or top portion of the dough product) prior to the base portion of the packaging reverting back to its original shape.
  • the dough product sets e.g., the upper region or top portion of the dough product
  • the base portion can begin to revert back to its original flat sheet-like shape.
  • the base portion of the packaging can be design to begin reverting back to its original sheet-like shape after the partial or full setting of the top portion of the muffin, but prior to the full setting of the bottom portion of the muffin.
  • the base portion of the packaging begins to revert back to its original sheet-like shape
  • the non-fully set bottom portion of the muffin begins to flatten due to the weight of the top portion of the muffin and thus partially or fully reforms and merges with the top portion of the muffin to create a muffin top product.
  • the flattened base portion of the packaging after the baking process makes it convenient to remove the baked muffin tops from the flattened base portion (e.g., by use of a spatula, etc.).
  • the packaging when the packaging includes a top portion and the top portion is not removed from the base portion prior to the proofing and/or baking of the dough product, can include and/or form small openings to facilitate in the venting of moisture and/or gas from the packaging during the proofing and/or baking of the dough product; however, this is not required.
  • the cross-section shape of the cavity can be circular or polygonal (e.g., square, rectangular, etc.); however, other shapes can be used. In one non-limiting arrangement, the cavity has a generally disc shape.
  • a lip can be designed to partially or fully encircle a recessed portion of the base portion; however, this is not required.
  • the top portion can be designed to be connected to said lip; however, this is not required.
  • the lip can include serrations, slots, depressions, etc. that can be used to separate two or more cavities from one another along the serrations, slots, depressions, etc. without compromising the connection between the top portion and the base portion that is forming at least one of the cavities; however, this is not required.
  • Toppings e.g., sugar, fruit, cheese, oil, fruits, nuts, spices, etc.
  • muffin tops were made reference to above, it can be appreciated that many other dough products can be formed, proofed and/or baked using the above described process (e.g., cinnamon rolls, focaccia and focaccia buns, etc.).
  • a packaging and a method for obtaining self-sheeting pizza crust there is provided a packaging and a method for obtaining self-sheeting pizza crust; however, other products can be obtained (e.g. pita bread, etc.).
  • the packaging includes a top portion and a base portion.
  • the base portion is at least partially formed of a plastic material.
  • One non-limiting plastic material is a Mylar® material; however, other plastic materials can be used.
  • the base portion can be molded into a shape for a sheet of plastic material; however, this is not required.
  • the thickness of the plastic material is generally no more than about 10 mils and typically about 2-6 mils; however, other thicknesses can be used.
  • the sheet of plastic material can be molded into a desired shape by the use of molds in combination with certain temperatures and pressures; however, this is not required.
  • the packaging can be formed by other means.
  • the type of plastic used for the top portion and/or bottom portion of the packaging is generally a bakable and/or a cryogenic plastic.
  • the type of plastic material and the method that is used for forming the plastic material into the base portion of the packaging is selected so that during the proofing and/or baking of the one or more pizza dough products in the packaging, the packaging may or may not maintain its shape.
  • the base portion and top portion of the packaging is formed of a plastic material that is formed from a flat sheet of plastic material to create a packaging that includes one or more cavities for the receiving of a pizza dough product when the top and bottom portion are connected together, and during the proofing of the one or more pizza dough products in the base portion, the shape of the formed base portion and top portion is such that it causes the pizza dough product to expand and form more laterally than vertically to form the desired shape of the pizza dough crust; however, this is not required.
  • the base portion and top portion of the packaging is formed of a plastic material that is formed from a flat sheet of plastic material to create a packaging that includes one or more cavities for the receiving of a pizza dough product, and during the proofing and/or baking of the one or more pizza dough products in the base portion, the shape of the formed base portion and/or top portion fully or partially reverts back to its original sheet-like form; however, this is not required.
  • the plastic material for the base portion can be a bakable and/or a cryogenic plastic.
  • the top portion can be designed to be removable prior to the baking of the one or more pizza dough crusts, or be designed to be connected to the base portion when proofing and/or baking the one or more pizza dough crusts in the packaging.
  • the plastic material for the top portion can be a bakable and/or a cryogenic plastic.
  • the top portion can be connected to the base portion in a variety of ways (e.g., adhesive, melted bond, pressure bond, etc.).
  • the number, size and/or shape of cavities in the base portion of the packaging are non-limiting.
  • the size and/or shape of cavities in the base portion of the packaging are the same; however, this is not required.
  • the dough product can be placed into all or a portion of cavities in the base portion of the packaging.
  • each of the cavities in the base portion of the packaging include a pizza dough product; however, this is not required.
  • the pizza dough product that is placed in the cavities in the base portion can be dough that is not proofed, partially proofed or fully proofed.
  • the dough product can be 1) allowed to partially or fully proof, 2) baked, and/or 3) stored in a refrigerator or freezer.
  • a top portion is applied to the base portion of the packaging prior to the dough product being 1) allowed to partially or fully proof, 2) baked, and/or 3) stored in a refrigerator or freezer.
  • the top portion can be used to fully or partially seal the dough product between the base portion and top portion of the packaging; however, this is not required.
  • one or more small openings are formed in the top portion or in a region between the top portion and the base portion so as to form a partially sealed packaging.
  • one or more regions in the top portion or one or more regions between the top portion and the base portion can be designed to form a small opening when a certain predefined pressure in obtained in the covered cavities that include the pizza dough product. After the pizza dough product is placed in the one or more cavities in the base portion, the pizza dough product can be further processed in various ways:
  • the base portion may or may not be designed to maintain or substantially maintain its shape during the baking of the one or more dough products in the packaging.
  • the packaging when the packaging includes a top portion and the top portion is not removed from the base portion prior to the proofing and/or baking of the dough product, the packaging can include and/or form small openings to facilitate in the venting of moisture and/or gas from the packaging during the proofing and/or baking of the dough product; however, this is not required.
  • pizza crust was referenced above, it can be appreciated that many other dough products can be formed, proofed and/or baked using the above described process (e.g., pita bread, etc.).
  • One or more portions of the packaging e.g., base portion, etc.
  • Another and/or alternative objective of the invention is to provide a method for manufacturing a container or packaging that includes the steps of 1) providing a film from a roll of plastic film, and 2) forming the plastic film into a container or packaging by the use of presses, cavity molds, tension, heat and/or pressure, which container or packaging can include one or more cavities designed to receive an individual dough product in each cavity or well.
  • One or more portions of the packaging e.g., base portion, etc.
  • It is still yet another and/or alternative objective of the invention is to provide a method for sealing a dough product in a formed container or packaging that includes the steps of 1) providing a film from a roll of plastic film, 2) forming the plastic film into a base portion of a container or packaging by the use of presses, cavity molds, tension, heat and/or pressure, which container or packaging can include one or more cavities or wells designed to receive an individual dough product in each cavity or well (e.g., forming process generally taking about 1-60 seconds), 3) depositing a dough product (e.g., hand, robotics, etc.) into the one or more cavities of the base portion of the container or packaging, wherein a single dough product is generally inserted into a single cavity or well, and 4) sealing the one or more dough products in the container or packaging by placing and securing a film (e.g., plastic film, etc.) on the top of the base portion of the container or packaging by use of a securing arrangement (e.g., adhesive, melted seam, pressure
  • It is another and/or alternative objective of the invention is to provide a method for sealing a dough product in a formed container or packaging and then proofing and baking the dough product that includes the steps of 1) providing a film from a roll of plastic film, 2) forming the plastic film into a base portion of a container or packaging by the use of presses, cavity molds, tension, heat and/or pressure, which container or packaging can include one or more cavities designed to receive an individual dough product in each cavity or well (e.g., forming process generally taking about 1-60 seconds), 3) depositing a dough product (e.g., hand, robotics, etc.) into the one or more cavities of the base portion of the container or packaging, wherein a single dough product is generally inserted into a single cavity or well, 4) sealing the one or more dough products in the container or packaging by placing and securing a top film (e.g., plastic film, etc.), that may or may not be formed into a shape other than a planar sheet of material, on the top of the base portion of the
  • FIG. 1 is a front elevation view of a container in accordance with the present invention illustrating an exploded view of the top portion and base portion of the container;
  • FIG. 2 is a cross-sectional view along lines 2 - 2 of FIG. 1 ;
  • FIG. 3 is a similar view as of FIG. 1 but also illustrating a food product positioned in the cavity of the base portion;
  • FIG. 4 is similar view as of FIG. 3 but also illustrating the top portion of the container being secured to an upper surface of the base portion;
  • FIG. 5 illustrates the container of FIG. 1 in a freezer or refrigerator wherein the container includes food product positioned in the cavities of the base portion and the top portion of the container is secured to the base portion;
  • FIG. 6 illustrates the container of FIG. 1 on a proofing or oven rack and wherein the container includes food product positioned in the cavities of the base portion and the top portion is partially removed from the base portion;
  • FIG. 7 illustrates the container of FIG. 1 on an oven rack and wherein the container includes food product positioned in the cavities of the base portion and the top portion is fully removed from the base portion;
  • FIG. 8 illustrates the container of FIG. 7 wherein after a certain time of baking the base portion of the container at least partially reverts back to its original shape
  • FIG. 9 illustrates a non-limiting food product that is formed by the container of FIG. 1 after the food product has been baked
  • FIG. 10 is a front elevation view of another non-limiting container in accordance with the present invention wherein the container includes a top portion and a base portion of the container;
  • FIG. 11 is a cross-sectional view along lines 11 - 11 of FIG. 10 ;
  • FIG. 12 illustrates the container of FIG. 10 that includes food product positioned in the cavities of the base portion and the top portion of the container is secured to an upper surface of the base portion;
  • FIG. 13 is a cross-sectional view along lines 13 - 13 of FIG. 12 but absent the top portion of the container;
  • FIG. 14 is similar view as of FIG. 13 but includes the top portion of the container
  • FIG. 15 illustrates the container of FIG. 10 in a freezer or refrigerator wherein the container includes food product positioned in the cavities of the base portion and the top portion of the container secured to the base portion;
  • FIG. 16 illustrates the container of FIG. 10 on a proofing or oven rack and wherein the container includes food product positioned in the cavities of the base portion and the top portion is secured to the base portion;
  • FIG. 17 illustrates the container of FIG. 10 on an oven rack and wherein the container includes food product positioned in the cavities of the base portion and the top portion is secured to the base portion;
  • FIG. 18 illustrates the container of FIG. 10 removed from the oven and the top portion is partially removed from the base portion
  • FIG. 19 is a top view of another non-limiting container in accordance with the present invention.
  • FIG. 20 is a cross-sectional view along lines 20 - 20 of FIG. 19 ;
  • FIG. 21 illustrates the container of FIG. 19 that includes food product positioned in the cavity of the container between the top and base portion of the cavities as the food product expands in the cavity during the proofing of the food product;
  • FIG. 22 is a cross-sectional of the container of FIG. 21 ;
  • FIG. 23 is a top view of the container after the proofing of the food product in container and the pressing of the proofed food product to further form the food product in the container;
  • FIG. 24 is a cross-sectional view of the container of FIG. 23 wherein the top portion is removed from the base portion as illustrated by the arrow;
  • FIG. 25 illustrates a cooking sheet placed on the side of the food product that the formerly covered by the top portion of the container
  • FIG. 26 illustrates the food product being flipped over on the cooking sheet and the base portion of the container being removed from the food product as illustrated by the arrow;
  • FIG. 27 illustrates the manual forming of a crust rim on the food product
  • FIG. 28 illustrates the addition of one or more toppings on the upper surface of the food product
  • FIG. 29 illustrates the baking of the food product in an oven
  • FIG. 30 is a cross-sectional view of the food product in the container of FIG. 19 prior to the food product being fully proofed and the container being placed in a freezer or refrigerator for storage;
  • FIGS. 31 and 32 illustrate an alternative method of pressing the proofed food product in the container by the use of a pressing machine
  • FIG. 33 illustrated the removal of the top portion of the container after the pressing process as indicated by the arrow.
  • FIGS. 1-9 illustrate one non-limiting container in accordance with the present invention and a non-limiting method for packaging, proofing and/or baking dough products in the container of the present invention.
  • the present invention describes a novel dough processing approach and a novel process for forming and using packaging for a dough product.
  • a container 100 that includes a top portion 110 and a base portion 120 .
  • the base portion and top portion are generally formed of a plastic material.
  • the type of plastic material used for the top portion and the base portion can be the same or different.
  • the color, transparency, and/or thickness of the top portion and the base portion can be the same or different.
  • the base portion is formed of a bakable plastic material; however, this is not required.
  • the top portion may or may not be a bakable plastic material.
  • the top portion and bottom portion are generally formed of a cryogenic plastic material; however, this is not required.
  • the top portion is illustrated as being a generally flat, planar sheet of material that has a generally uniform thickness; however, this is not required.
  • the base portion is illustrated as having one or more cavities or wells 122 .
  • the number, size and/or shape of the cavities in the base portion are non-limiting. As illustrated in FIGS. 1 and 2 , the size and shape of the cavities in the base portion are generally the same; however, this is not required.
  • the base portion is generally formed from a generally flat, planar sheet of plastic material that has been subjected to a forming process to the one or more cavities in the base portion.
  • the type of forming process used to form the base portion is non-limiting.
  • the base portion is formed with a certain type of material under certain forming parameters such that during the baking of the food product in the one or more cavities, the base portion reverts partially or fully back to its original generally flat, planar shape, thereby resulting in the partial or full elimination of the formed cavities on the base portion after the baking process has been completed.
  • a food product F is illustrated by the arrow as being inserted into the one or more cavities 122 of the base portion.
  • the type of food product is non-limiting.
  • the food product is a dough product.
  • the dough product when inserted into the cavity, may be in a state prior to proofed, may be a partially proofed or may be a fully proofed.
  • the food product is a dough product that has not been fully proofed when inserted into the one or more cavities of the base portion.
  • the same amount and/or type of product is inserted into each cavity of the base portion; however, this is not required.
  • the process for inserting the food product into the one or more cavities can be manual, semi-automated or fully automated.
  • the ambient temperature can be maintained at a cool temperature (e.g., less than 60° F., less than 50° F., less than 40° F., etc.) to limit or prevent the food product from proofing; however, this is not required.
  • a cool temperature e.g., less than 60° F., less than 50° F., less than 40° F., etc.
  • the top portion 110 is applied onto and secured to an upper surface 124 of the base portion as illustrated in FIG. 3 .
  • the manner in which the top portion is connected to the base portion is non-limiting.
  • an adhesive 130 or pressed or melted seam is used to secure the top portion to the base portion.
  • the top portion can be secured to the base portion such that the top portion fully prevents gas and/or moisture from entering and/or escaping the cavity that includes the food product while the top portion is secured to the base portion; however, this is not required.
  • the top portion can be secured to the base portion such that the top portion allows the controlled release of gas and/or moisture from escaping the cavity that includes the food product while the top portion is secured to the base portion during the proofing and/or baking of the food product; however, this is not required.
  • 1) the top portion and/or the base portion can include one or more small opening, 2) one or more small openings exist between the top portion and the base portion, and/or 3) one or more small openings are formed between the top portion and the base portion during the proofing and/or baking of the food product once a certain pressure within the cavity is obtained. Further explanation of such small openings that can be optionally used in the container of FIGS. 1-8 will be discussed below with respect to the other embodiments of the invention as illustrated in FIGS. 10-18 .
  • the container 100 that includes the food product F is illustrated as being positioned in a refrigerator or freezer R to either cool or freeze the food product in the container.
  • the refrigerator or freezer can include a refrigerated vehicle (e.g., truck, train, ship, etc.), a refrigerator or freezer located a particular facility, etc.
  • the food product in the container that is placed in the refrigerator or freezer can be stored in the refrigerator or freezer for later processing (e.g., proofing and/or baking) or to be shipped to a bakery, store, restaurant, etc.
  • the step of refrigerating or freezing the food product in the container is an optional step.
  • the time period that the food product in the container is refrigerated or frozen is non-limiting.
  • the food product after it has been partially or fully proofed can be refrigerated or frozen; however, this is not required.
  • the food product in the container can be 1) refrigerated or frozen after the top portion has been secured to the bottom portion, 2) refrigerated or frozen after the food product has been partially or fully proofed, or 3) refrigerated or frozen after the top portion has been secured to the bottom portion, then taken out of the refrigerator or freezer to be partially or fully proofed, and then again refrigerated or frozen.
  • the number of times that the food product is refrigerated or frozen after the top portion has been secured to the bottom portion is non-limiting.
  • the food product in the container can be moved from the freezer to a refrigerator, moved between different freezers, moved between different refrigerator and number of times.
  • the top portion 110 is illustrated by the arrow as being partially or fully removed from the base portion.
  • the top portion is partially or fully removed from the base portion during the proofing and/or baking of the food product; however, this is not required.
  • the top portion is partially or fully removed from the base portion during the proofing and/or baking of the food product.
  • the top portion remains on the base portion during the proofing of the food product and then is partially or fully removed from the base portion during the baking of the food product.
  • the food product can be 1) sealed in the cavity so as to prevent gas and/or liquid form entering and/or exiting the cavity during the proofing process while the top portion is secured to the base portion, and 2) partially sealed wherein gas and/or liquid is controllably released during the proofing process from the cavity through one or more pre-existing and/or formed small openings.
  • the container 100 that includes food product P in the one or more cavities of the base portion 120 is illustrated as being positioned on a baking rack or tray T and being placed in an oven O to bake the food product.
  • the top portion 110 is illustrated as being fully removed from the base portion during the baking process; however, this is not required.
  • base portion 120 substantially retains its shape.
  • the base portion is designed to retain its shape for at least about 2% of the total baking time of the food product, and typically at least about 5% total baking time of the food product. After a certain amount of time in the oven, the base portion begins to lose its form and revert back to its original shape that existed prior to the forming of the base portion.
  • the base portion has completed the shape reversion process by at least 99% of the total baking time of the food product, typically by at least 95% of the total baking time of the food product, more typically by at least 90% of the total baking time of the food product, and still more typically by at least 85% of the total baking time of the food product.
  • the base portion has substantially reverted back to its original flat, planar shape and the cavities 122 are 80-100% non-existent.
  • This novel feature of the base portion during the baking process of the food product can have the non-limiting advantages of 1) simplifying the removal of the food product from the base portion after the baking process, 2) providing for more uniform baking of the food product, 3) provide for more uniform cooling of the food product after baking, and/or 4) creating novel shaped food products.
  • bakery goods that resemble the top of a muffin can be formed by the novel container of the present invention. Muffins typically include a muffin top portion that is crispier than the softer bottom portion. The top portion also commonly includes added sugar and/or other types of toppings added prior to, during and/or after the baking process of the muffin. Many consumers only desire to consume the top portion or muffin top portion of the muffin and then dispose of the bottom portion.
  • the base portion of the present invention can be used to form a bakery good that looks very similar to just the top portion TP of a muffin M as illustrated in FIG. 9 .
  • the bottom portion BP of the muffin is eliminated or substantially eliminated by the use of the container of the present invention.
  • the absence of the bottom portion of the muffin is the result of the base portion of the container reverting back to its original flat shape during the baking process.
  • the reversion of the base portion back to its original shape can be designed such that the top portion of the muffin at least partially sets in its shape prior to the reversion of the base portion back to its original shape.
  • the bottom portion of a muffin typically cooks slower that the top surface of the top portion of the muffin, the bottom portion of the muffin slowly gets absorbed into the top portion of the muffin as the base portion reverts back to its original shape.
  • the typically bottom portion of the muffin has been fully or substantially been incorporated into the top portion of the muffin and the final baked food product resembles only the top portion of a standard muffin.
  • the dashed line illustrated in FIG. 9 represents that muffin as lacking a bottom portion at the completion of the baking process.
  • one or more toppings can be optionally added to the top portion of the muffin prior to, during and/or after the baking process of the muffin.
  • many other food products can be baked in the container of FIGS. 1-8 .
  • Container 200 includes a top portion 210 and a base portion 220 .
  • the base portion and top portion are generally formed of a plastic material.
  • the type of plastic material used for the top portion and the base portion can be the same or different.
  • the color, transparency, and/or thickness of the top portion and the base portion can be the same or different.
  • the base portion is formed of a bakable plastic material; however, this is not required.
  • the top portion may or may not be a bakable plastic material.
  • the top portion and bottom portion are generally formed of a cryogenic plastic material; however, this is not required.
  • the top portion is illustrated as being a generally flat, planar sheet of material that has a generally uniform thickness; however, this is not required.
  • the base portion is illustrated as having one or more cavities or wells 222 .
  • the number, size and/or shape of the cavities in the base portion are non-limiting. As illustrated in FIGS. 10 , 12 , 15 - 18 , the size and shape of the cavities in the base portion are generally the same; however, this is not required.
  • the base portion is generally formed from a generally flat, planar sheet of plastic material that has been subjected to a forming process to the one or more cavities in the base portion.
  • the type of forming process used to form the base portion is non-limiting.
  • a food product F is illustrated by the arrow as being inserted into the one or more cavities 222 of the base portion.
  • the type of food product is non-limiting.
  • the food product is a dough product.
  • the dough product when inserted into the cavity, may be in a state prior to proofed, may be a partially proofed or may be a fully proofed.
  • the food product is a dough product that has not been fully proofed when inserted into the one or more cavities of the base portion.
  • the same amount and/or type of product is inserted into each cavity of the base portion; however, this is not required.
  • the process for inserting the food product into the one or more cavities can be manual, semi-automated or fully automated.
  • the ambient temperature can be maintained at a cool temperature (e.g., less than 60° F., less than 50° F., less than 40° F., etc.) to limit or prevent the food product from proofing; however, this is not required.
  • a cool temperature e.g., less than 60° F., less than 50° F., less than 40° F., etc.
  • the top portion 210 is applied onto and secured to an upper surface 224 of the base portion as illustrated in FIG. 14 .
  • the manner in which the top portion is connected to the base portion is non-limiting.
  • an adhesive 230 or pressed or melted seam is used to secure the top portion to the base portion.
  • the top portion can be secured to the base portion such that the top portion fully prevents gas and/or moisture from entering and/or escaping the cavity that includes the food product while the top portion is secured to the base portion; however, this is not required.
  • the top portion can be secured to the base portion such that the top portion allows the controlled release of gas and/or moisture from escaping the cavity that includes the food product while the top portion is secured to the base portion during the proofing and/or baking of the food product; however, this is not required.
  • 1) the top portion and/or the base portion can include one or more small opening, 2) one or more small openings exist between the top portion and the base portion, and/or 3) one or more small openings are formed between the top portion and the base portion during the proofing and/or baking of the food product once a certain pressure within the cavity is obtained.
  • an adhesive 230 can be used to secure the top portion to the base portion.
  • the adhesive can be non-continuously applied about one or more cavities; however, this is not required.
  • one or more gaps 232 in the adhesive layer can be intentionally formed such that when the top portion is applied to the base portion, an opening or gap 226 exists between the top portion and the base portion of the container to allow the controlled release of gas and/or liquid from one or more cavities during the proofing and/or baking of the food product.
  • all or less than all of the cavities can include one or more gaps or spaces.
  • the top portion can optionally include one or more small openings 212 as an alternative to or in addition to the use of one or more gaps 226 .
  • small openings 212 allows for the controlled release of gas and/or liquid from one or more cavities during the proofing and/or baking of the food product.
  • all or less than all of the cavities can be covered by a section of the top portion that includes one or more of the small openings 212 .
  • the one or more small openings, when used are preformed in the top portion prior to the top portion being connected to the base portion and/or preformed between the top and/or base portion when the top portion is connected to the base portion; however, this is not required.
  • a breakable bond between the top portion and the base portion can optionally be formed so that after a predefined level of pressure is obtained in a cavity during the proofing and/or baking of a food product, a small space or gap is formed between the top portion and the base portion.
  • the use of a breakable bond can be used as an alternative to or in addition to the use of one or more gaps 226 and/or small openings 212 .
  • the breakable bond when used, can be formed by a variety of ways: 1) use of different adhesives, 2) use of different thickness and/or widths of adhesive in different regions about the perimeter of one or more cavities, 3) the use of release agents, and/or 4) use of heat release agents.
  • the use of one or more openings can be used to control the moisture content of the food product during the proofing and/or baking process, the pH of the food product during the proofing and/or baking process, the size and/or structure of the gas cells in the food product, the rate and/or degree to which the baking product rises during the proofing process, the rate at which the food product bakes, and/or the shape of the product that is formed during the proofing and/or baking process.
  • the container 200 that includes the food product F is illustrated as being positioned in a refrigerator or freezer R to either cool or freeze the food product in the container.
  • the refrigerator or freezer can include a refrigerated vehicle (e.g., truck, train, ship, etc.), a refrigerator or freezer located a particular facility, etc.
  • the food product in the container that is placed in the refrigerator or freezer can be stored in the refrigerator or freezer for later processing (e.g., proofing and/or baking) or to be shipped to a bakery, store, restaurant, etc.
  • the step of refrigerating or freezing the food product in the container is an optional step.
  • the time period that the food product is in the container refrigerated or frozen is non-limiting.
  • the food product after it has been partially or fully proofed, can be refrigerated or frozen; however, this is not required.
  • the food product in the container can be 1) refrigerated or frozen after the top portion has been secured to the bottom portion, 2) refrigerated or frozen after the food product has been partially or fully proofed, or 3) refrigerated or frozen after the top portion has been secured to the bottom portion, then taken out of the refrigerator or freezer to be partially or fully proofed, and then again refrigerated or frozen.
  • the number of times that the food product is refrigerated or frozen after the top portion has been secured to the bottom portion is non-limiting.
  • the food product in the container can be moved from the freezer to a refrigerator, moved between different freezers, moved between different refrigerators any number of times.
  • gas and/or liquid is illustrated as escaping from the one or more cavities 222 through the small openings 212 during the proofing of the food product.
  • gas and/or liquid can also or alternatively escape through one or more gaps 226 .
  • the food product generally expands in the cavity as illustrated by the arrows; however, this is not required.
  • the size and number of small openings and/or gaps 226 are generally selected such that gas and/or liquid only or substantially only exits the cavity, and little if any gas and/or liquid enters the one or more cavities during proofing and/or baking process.
  • the size and number of small openings and/or gaps 226 are selected such that during at least 40% of the proofing process, there is a pressure in the cavities that is greater than the ambient pressure (e.g., 1 atm, 740-780 torr). In another and/or alternative non-limiting arrangement, the size and number of small openings and/or gaps 226 are selected such that during at least 40% of the baking process, there is a pressure in the cavities that is greater than the ambient pressure (e.g., 1 atm, 740-780 torr).
  • the container 200 that includes food product P in the one or more cavities of the base portion 220 is illustrated as being positioned on a baking rack or tray T and being placed in an oven O to bake the food product.
  • the top portion 210 is illustrated as remaining connected to the base portion; however, it can be appreciated that during the baking process, the top portion can be partially or fully removed from the base portion.
  • the base portion of container 220 is designed to substantially retain its shape throughout the baking process; however, this is not required. Generally, the base portion is designed to retain its shape for at least about 70% of the total baking time of the food product, typically at least about 80% total baking time of the food product, and more typically at least about 90% total baking time of the food product.
  • the top portion if the top portion remains partially or fully secured to the base portion during the baking process, the top portion is removed from the base portion as indicated by the arrow after the completion of the baking process so that the baked product can be removed from the one or more cavities 222 in the base portion.
  • Many different types of food products can be baked in container 200 .
  • the top of the food product can optionally have added sugar and/or other types of toppings added prior to, during and/or after the baking process of the food product.
  • Container 300 includes a top portion 310 and a base portion 320 .
  • the base portion and top portion are generally formed of a plastic material.
  • the type of plastic material used for the top portion and the base portion can be the same or different.
  • the color, transparency, and/or thickness of the top portion and the base portion can be the same or different.
  • the base portion is formed of a bakable plastic material; however, this is not required.
  • the top portion may or may not be a bakable plastic material.
  • the top portion and bottom portion are generally formed of a cryogenic plastic material; however, this is not required.
  • the top portion and base portion are illustrated as being a generally flat, planar sheet of material that has a generally uniform thickness; however, this is not required.
  • the top portion and the base portion are formed together to form a single cavity for a food product F.
  • the number, size and/or shape of the cavities that are formed by the top and base portions are non-limiting. As illustrated in FIG. 19 , the shape of the cavity is generally disc-shaped; however, this is not required.
  • the type of food product that can be inserted into cavity 312 is non-limiting.
  • the food product is a dough product, such as a pizza dough, that is used to form a pizza crust; however, this is not required.
  • the dough product when inserted into the cavity may be in a state prior to being proofed, may be partially proofed or may be fully proofed.
  • the food product is a dough product that has not been fully proofed when inserted into the cavity.
  • the process for inserting the food product into the cavity can be manual, semi-automated or fully automated.
  • the ambient temperature can be maintained at a cool temperature (e.g., less than 60° F., less than 50° F., less than 40° F., etc.) to limit or prevent the food product from proofing; however, this is not required.
  • a cool temperature e.g., less than 60° F., less than 50° F., less than 40° F., etc.
  • top portion and base portion are fully connected together.
  • the manner in which the top portion is connected to the base portion is non-limiting.
  • an adhesive 330 or pressed or melted seam is used to secure the top portion to the base portion.
  • the top portion can be secured to the base portion such that the top portion fully prevents gas and/or moisture from entering and/or escaping the cavity that includes the food product while the top portion is secured to the base portion; however, this is not required.
  • the top portion can be secured to the base portion such that the top portion allows the controlled release of gas and/or moisture from escaping the cavity that includes the food product while the top portion is secured to the base portion during the proofing and/or baking of the food product as illustrated in FIGS.
  • the top portion and/or the base portion can include one or more small opening
  • one or more small openings are formed between the top portion and the base portion during the proofing and/or baking of the food product once a certain pressure within the cavity is obtained.
  • one or more small openings 326 between the top portion and the base portion of the container to allow the controlled release of gas and/or liquid from the cavity during the proofing and/or baking of the food product.
  • the use of small openings 326 allows for the controlled release of gas and/or liquid from the cavity during the proofing and/or baking of the food product.
  • the one or more small openings when used, are preformed in the top portion prior to the top portion being connected to the base portion and/or preformed between the top and/or base portion when the top portion is connected to the base portion; however, this is not required.
  • a breakable bond between the top portion and the base portion can optionally be formed so that after a predefined level of pressure is obtained in a cavity during the proofing and/or baking of a food product, a small space or gap is formed between the top portion and the base portion.
  • the use of a breakable bond can be used as an alternative to or in addition to the use of one or more gaps 326 .
  • the breakable bond when used, can be formed by a variety of ways: 1) use of different adhesives, 2) use of different thickness and/or widths of adhesive in different regions about the perimeter of one or more cavities, 3) the use of release agents, and/or 4) use of heat release agents.
  • the use of one or more openings can be used to control the moisture content of the food product during the proofing and/or baking process, the pH of the food product during the proofing and/or baking process, the size and/or structure of the gas cells in the food product, the rate and/or degree to which the baking product rises during the proofing process, the rate at which the food product bakes, and/or the shape of the product that is formed during the proofing and/or baking process.
  • the food product is illustrated as being proofed in the container and gas and/or liquid formed during the proofing process is allowed to escape from the cavity through gaps 326 as indicated by the arrows.
  • the controlled release of the gas and/or liquid from the cavity limits or presents the ballooning of the cavity during the proofing process so that the dough can form into the desired shape as the dough expands in the cavity during the proofing process.
  • the cavity can be generally disc-shaped and, as the pizza dough expands during the proofing process in the cavity as indicated by the arrows of FIGS.
  • the pizza dough partially or fully self-sheets in the cavity of the container during the proofing process as the gas and/or liquid formed during the proofing process is controllably released from the container as indicated by the arrows of FIGS. 21 and 22 .
  • the food product generally expands in the cavity as illustrated by the arrows; however, this is not required.
  • the size and number of small openings and/or gaps 326 are generally selected such that gas and/or liquid only or substantially only exits the cavity, and little if any gas and/or liquid enters the one or more cavities during proofing and/or baking process.
  • the size and number of small openings and/or gaps 326 are selected such that during at least 40% of the proofing process, there is a pressure in the cavities that is greater than the ambient pressure (e.g., 1 atm, 740-780 torr).
  • the ambient pressure e.g. 1 atm, 740-780 torr.
  • the size and number of openings results in the pressure inside the packaging not reaching equilibrium with the ambient pressure during at least 80%, typically 90%, more typically 95%, and still more typically 100% of the proofing process.
  • the food product prior to, during and/or after the food product has been proofed in the container, the food product can be manually pressed by hands H so as to facilitate in the sheeting of the food product in the cavity of the container as indicated by the arrows.
  • the optional pressing process can be by a machine 400 as indicated by FIGS. 31 and 32 .
  • the pressing of the food product by machine 400 can be, a manual, an automated or semi-automated process. Any conventional processing machine can be used.
  • the dough product can be removed from the container prior to baking the food product.
  • the food product can be partially or fully baked in the container; however, this is not required.
  • the top portion of the container is generally removed from the container as indicated by the arrow so that the dough can be further processed and/or removed from the container.
  • FIGS. 25-28 Non-limiting examples of further processing steps are illustrated in FIGS. 25-28 .
  • FIG. 25 illustrates that after the top portion of the container is removed, a cooking and/or prepping sheet 500 is placed on the exposed food product.
  • the food product can be flipped over and placed on a cooking and/or prepping sheet 500 .
  • FIG. 25 illustrates that after the top portion of the container is removed, a cooking and/or prepping sheet 500 is placed on the exposed food product.
  • the food product can be flipped over and placed on a cooking and/or prepping sheet 500 .
  • the food product on the cooking sheet is flipped over and the base portion of the container is removed from the food product as indicated by the arrow.
  • the base portion is a bakable material
  • the food product can remain in the base portion during the further processing and/or baking of the food product; however, this is not required.
  • a crust rim is manually formed by fingers I on the sheeted pizza crust; however, this is not required.
  • the crust rim can be formed by a machine; however, this is not required.
  • FIG. 28 illustrates that one or more optional toppings T (e.g., sauce, sheet, meat, cheese, vegetables, fruit, oil, seasonings, etc.) can be applied to the sheeted food product.
  • optional toppings T e.g., sauce, sheet, meat, cheese, vegetables, fruit, oil, seasonings, etc.
  • the food product can be optionally placed in a refrigerator or freezer for later processing (e.g., proofing, baking, topping, pressing, etc.).
  • the food product can be optionally placed in a refrigerator or freezer after the food product has been partially or fully proofed, pressed, one or more toppings applied to the food product, and/or the food product is partially or fully baked.
  • FIG. 30 illustrates the food product in the container being placed in a refrigerator or freezer R prior to the food product being fully proofed in the container to either cool or freeze the food product in the container.
  • the refrigerator or freezer can include a refrigerated vehicle (e.g., truck, train, ship, etc.), a refrigerator or freezer located a particular facility, etc.
  • the food product in the container that is placed in the refrigerator or freezer can be stored in the refrigerator or freezer for later processing (e.g., proofing and/or baking) or be shipped to a bakery, store, restaurant, etc.
  • the step of refrigerating or freezing the food product in the container is an optional step.
  • the time period that the food product in the container is refrigerated or frozen is non-limiting. As can be appreciated, the food product after it has been partially or fully proofed can be refrigerated or frozen; however, this is not required.
  • the food product in the container can be 1) refrigerated or frozen after the top portion has been secured to the bottom portion, 2) refrigerated or frozen after the food product has been partially or fully proofed, 3) refrigerated or frozen after the top portion has been secured to the bottom portion, then taken out of the refrigerator or freezer to be partially or fully proofed, and then again refrigerated or frozen.
  • the number of times that the food product is refrigerated or frozen after the top portion has been secured to the bottom portion is non-limiting.
  • the food product in the container can be moved from the freezer to a refrigerator, moved between different freezers, moved between different refrigerators any number of times.
  • the food product is illustrated as being placed in an oven O for the partial or full baking of the food product F.
  • the food product can be baked directly after removing the food product from a refrigerator or freezer, or after the food product has been proofed and optionally topped.
  • the top portion and base portion of the container can be removed from the food product prior to the food product being baked; however, it can be appreciated that the base portion and/or top portion of the container can remain on the food product during the partial or full baking of the food product.
  • the design of the container for the pizza crust as illustrated in FIG. 19 is designed to cause the pizza crust to expand out laterally during the proofing process.
  • the venting feature of the packaging when used, results in the pizza dough expanding laterally as opposed to the packaging ballooning into a ball if no pressure result arrangement existed.
  • the bottom portion of the packaging is generally designed to lose all or a portion of its molded form and partially or fully revert back to a flat sheet during baking; however, this is not required.
  • the top and/or bottom portion of the packaging for the pizza dough does not require forming.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Food Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Microbiology (AREA)
  • Bakery Products And Manufacturing Methods Therefor (AREA)
US13/943,259 2012-07-17 2013-07-16 Dough Packaging and Method for Dough Processing Abandoned US20140023746A1 (en)

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US13/943,259 US20140023746A1 (en) 2012-07-17 2013-07-16 Dough Packaging and Method for Dough Processing
US14/548,506 US9282749B2 (en) 2012-07-17 2014-11-20 Dough packaging and method for dough processing
US14/548,532 US20150079229A1 (en) 2012-07-17 2014-11-20 Dough packaging and method for dough processing
US14/972,946 US9820492B2 (en) 2012-07-17 2015-12-17 Dough packaging and method of dough processing

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US201261672408P 2012-07-17 2012-07-17
US201361827300P 2013-05-24 2013-05-24
US13/943,259 US20140023746A1 (en) 2012-07-17 2013-07-16 Dough Packaging and Method for Dough Processing

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US13/943,276 Abandoned US20140023747A1 (en) 2012-07-17 2013-07-16 Dough Packaging and Method for Dough Processing
US14/548,506 Active US9282749B2 (en) 2012-07-17 2014-11-20 Dough packaging and method for dough processing
US14/548,532 Abandoned US20150079229A1 (en) 2012-07-17 2014-11-20 Dough packaging and method for dough processing
US14/972,946 Active 2033-10-08 US9820492B2 (en) 2012-07-17 2015-12-17 Dough packaging and method of dough processing

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US14/548,532 Abandoned US20150079229A1 (en) 2012-07-17 2014-11-20 Dough packaging and method for dough processing
US14/972,946 Active 2033-10-08 US9820492B2 (en) 2012-07-17 2015-12-17 Dough packaging and method of dough processing

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WO2014014917A2 (en) 2014-01-23
US20160100592A1 (en) 2016-04-14
US20150079228A1 (en) 2015-03-19
EP2874498A2 (de) 2015-05-27
US9820492B2 (en) 2017-11-21
US20140023745A1 (en) 2014-01-23
US9282749B2 (en) 2016-03-15
EP2874498A4 (de) 2016-01-06
WO2014014917A3 (en) 2014-05-01
US20140023747A1 (en) 2014-01-23
EP2874498B1 (de) 2017-03-22
US20150079229A1 (en) 2015-03-19

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