WO2000059317A2

WO2000059317A2 - Food dispenser

Info

Publication number: WO2000059317A2
Application number: PCT/GB2000/001255
Authority: WO
Inventors: Hans Christian Wiedemann
Original assignee: Schloss Limited
Priority date: 1999-04-01
Filing date: 2000-04-03
Publication date: 2000-10-12
Also published as: AU3569500A; WO2000059317A3; GB9907528D0

Abstract

The present invention relates to a dispenser for dispensing hot food. The dispenser includes a storage facility for storing the food, and heating means for heating the food. A method of dispensing hot food is also disclosed. A method of preparing food particularly for use with the dispenser of the invention is also disclosed.

Description

"Food Dispenser"

The present invention relates to a food dispenser and more particularly, but not exclusively, to a food dispenser for dispensing cooked hot food such as hot pizzas.

A variety of food and/or drink dispensers exist which dispense a number of different products. Such dispensers include hot and cold drinks machines, and confectionery dispensers that dispense various types of confectionery, such as sweets, biscuits, crisps and the like. These dispensers can be found in many different locations such as hospitals, cafeterias, factories, offices, sports centres and the like.

Conventional dispensing machines do not dispense hot food that is ready to eat without further intervention by a user of the machine. There are no dispensing machines available that are capable of dispensing hot food such as pizzas or the like without the user having to manually place the food in a heating means.

According to a first aspect of the present invention there is provided a food dispenser comprising a casing, a storage facility within the casing for storing food, heating means within the casing for heating the food, and a conveying system for transporting food within the casing and/or to an outlet in the casing.

The food typically comprises solid food such as pizzas. Alternatively, the food may comprise burgers, chips or other types of fast food.

The casing typically includes an access door to allow the dispenser to be re-stocked and/or serviced.

The food is preferably at least partly cooked before being stored in the storage facility. The food is preferably a pizza that is prepared in accordance with the third aspect of the present invention. The food is typically individually sealed in a strip of packaging material. The packaging material typically comprises upper and lower sheets of plastics material.

The dispenser typically includes a feeder and unwrapper unit located within the storage facility. This unit retrieves the food from the storage facility and removes the outer packaging. The feeder and unwrapper unit typically comprises two pairs of rollers, one roller of each pair disposed above the strip, and the other roller in the pair being disposed below the strip. In one specific embodiment, the feeder and unwrapper unit comprises a pair of collector rollers, a pair of driven rollers, and a pair of guide rollers. One roller from each pair is typically disposed above the strip and the other roller from each pair is typically disposed below the strip. The collector rollers are typically driven by an electric motor and are preferably used to collect the unwrapped packaging material. The driven rollers are typically driven by an electric motor and preferably pull the strip through the unit. Alternatively, or additionally, the collector rollers may be used to pull the strip through the unit.

The strip of wrapped food is typically dispensed from a storage box. The storage facility typically includes a number of (eg four) storage boxes. Thus, for example, four different types of food may be dispensed.

The storage facility typically comprises a cold store. The cold store typically comprises a deep freeze unit. The storage facility is typically insulated to prevent heat entering the storage facility from within and/or outwith the casing. The storage facility maintains the quality of the food until it is required.

The heating means typically comprises a microwave oven and/or an infra-red (IR) oven. Optionally, the microwave oven and the IR oven may comprise a single unit .

The microwave oven typically defrosts the food. The IR oven typically cooks the food.

In one specific embodiment, the heating means comprises a microwave oven, a hot plate and a hot air blower. The microwave oven typically defrosts the food. The hot plate is typically used to heat the underside of the food. The hot air blower typically dispenses hot air onto the food so that the food becomes crispy. The microwave oven, hot air blower and hot plate are preferably in one unit, and may be actuated simultaneously.

Optionally, the dispenser may include an exhaust system to remove vapours, smells and the like from within the dispenser. The exhaust system can also be used to extract heat generated by the heating means so that the interior of the dispenser remains substantially cool, thus not adversely affecting the temperature of the storage facility. The exhaust system typically includes an extractor fan and optionally a filter. The filter typically comprises a filter paper. The filter may be periodically changed.

The conveying means typically comprises a first chute for transporting the food from the storage facility to the microwave oven; and a second chute for transporting the food from the microwave oven to the IR oven. Optionally, a paper plate feeder is disposed at or near a lower end of the first chute. Thus, the food slides down the first chute and lands on a paper plate dispensed by the paper plate feeder before being inserted into the microwave.

The conveying means typically includes a first feeder disposed at or near the lower end of the first chute. The first feeder typically moves the paper plate containing the food into the microwave oven. The conveyor typically includes a second feeder disposed at or near the microwave oven. The second feeder typically moves the paper plate containing the food out of the microwave oven to the top of the second chute. The conveying means typically includes a third feeder disposed at or near the lower end of the second chute. The third feeder typically moves the food from the IR oven to the outlet in the casing.

In one specific embodiment, the conveying means comprises a conveyor belt located within the storage facility at or near the feeder and unwrapper unit. The conveyor belt is preferably driven at a relatively high speed. The conveying means includes a chute, preferably angled downwardly. One end of the chute is located at or near one end of the conveyor belt and the other end of the chute is located at or near the heating means. The conveying means typically further includes a first feeder located at or near the heating means for feeding the food into the heating means. The conveying means typically further includes a second feeder for retrieving the food from the heating means. Preferably, the second feeder may also be used to feed the food into the outlet in the casing.

The outlet typically comprises a compartment within the casing wherein the food may be retrieved by a user.

The food dispenser typically includes a selection panel wherein the user can select which food is required. The selection panel typically comprises a plurality of buttons, each button corresponding to a respective type of food stored in the casing.

The food dispenser typically includes at least one display panel for displaying instructions and/or information to users of the dispenser.

Optionally, the food dispenser includes a diagnostic system. This allows an engineer or the like to check the status of each component within the machine when servicing or refilling.

According to a second aspect of the present invention, there is provided a method of dispensing hot food, the method comprising the steps of providing a food dispenser comprising a casing, a storage facility within the casing for storing food, heating means within the casing for heating the food, and a conveying system for transporting food within the casing and/or to an outlet in the casing; retrieving the food from the storage facility; heating the food using the heating means; and dispensing the food to a consumer via the outlet.

The method typically includes the additional step of removing packaging material from the food before heating.

The dispenser may have one, some or all of the dependent features of the food dispenser according to the first aspect of the present invention.

According to a third aspect of the present invention, there is provided a method of producing a pizza for use in a food dispenser, the method comprising the steps of making a pizza base; making a tomato layer; making a cheese layer; and binding the cheese layer and/or the tomato layer to the base.

The method for making a pizza base typically comprises the steps of preparing a dough; allowing the dough to grow; rolling out the dough; shaping the dough in a mould; allowing the dough to grow in the mould; and baking the dough in the mould. Optionally, the method of making the pizza includes removing the dough from the mould and baking for a further period. The mould preferably includes a number of concentric annular ribs so that in use, the mould creates a number of concentric annular recesses in the pizza base.

The method for making the tomato layer typically includes the steps of preparing a tomato juice mixture; and rolling out the mixture to form the tomato layer. The method preferably further includes stamping the mixture into a desired size and shape. The shape of the layer is preferably substantially circular. The diameter of the layer is preferably substantially the same as or at least similar to that of the base. It is understood that a tomato juice mixture comprises a number of different ingredients that include tomatoes and/or tomato juice or a substitute thereof.

The method of making the cheese layer typically comprises the steps of preparing a cheese mix; and rolling out the cheese mix to form the cheese layer. The method preferably further includes stamping the cheese layer into a desired size and shape. The shape of the layer is preferably substantially circular. The diameter of the layer is preferably substantially the same or at least similar to that of the base. Optionally, the cheese layer may be provided with a plurality of apertures therein. It will be understood that a cheese mixture comprises a number of ingredients that include cheese or a substitute thereof.

Optionally, the method of making a pizza includes the additional step of bonding the cheese layer and the tomato layer together. This typically comprises pressing the cheese layer and the tomato layer together. Where the cheese layer is provided with a number of apertures, at least a portion of the tomato layer enters the apertures . A stronger bond between the cheese layer and the tomato layers is thus created. Optionally, the cheese layer and the tomato layer are preheated to enhance the bond therebetween.

The method of making a pizza typically includes the additional step of pressing the bonded cheese layer and the tomato layer into the base. Preferably, at least a portion of the cheese layer and/or the tomato layer enters the recesses in the base. This provides a stronger bond between the layers and the base. Optionally, the pizza may then be pre-cooked.

The method typically includes the additional step of freezing the pizza. Optionally, the method includes the additional step of packaging the pizza. The method of packaging the pizza typically includes the steps of placing the pizza on a plate, preferably a paper plate; positioning the pizza (and plate) between an upper and a lower sheet of plastics material; and bonding the sheets together to form an air-tight seal around the pizza and the plate.

The pizzas (and plates) are preferably packaged in a continuous strip. The strip is then inserted into a storage box. The pizzas are typically stored within the box in a vertical orientation. Embodiments of the present invention shall now be described, by way of example only, with reference to the accompanying drawings, in which: - Fig. 1 is a flow chart illustrating the stages of operation and main components of a food dispenser according to the present invention; Figs 2a, b and c show front, side and plan views of a casing for the food dispenser; Fig. 3 is an isometric view of the casing of Figs 2a to 2c; Figs 4a to 4d are front, side, rear and plan views respectively, of a storage facility for use with the present invention; Figs 5a and 5b are side and plan elevations respectively, of a packaged pizza for use with the present invention; Fig. 6 is a plan view of a plurality of the pizzas of Figs 5a and 5b; Figs 7a, b and c are front, side and plan views respectively, of a storage box for storing the pizzas of Figs 5 and 6; Figs 8a, b and c are front, side and plan views respectively, of the storage box of Fig. 7 showing the storage of pizzas within the box; Fig. 9 is an isometric view of the food dispenser of the present invention; Fig. 10 is a plan view of the food dispenser according to the present invention; Figs 11a and lib are front and side elevations respectively, of the food dispenser of Fig. 9; Figs 12a, b and c are front, side and plan elevations respectively, of a first chute for transporting the pizzas from the storage facility to a paper plate feeder; Figs 13a and 13b are side and plan elevations respectively, of part of the food dispenser of Fi . 9 ; Figs 14a and 14b are side and plan elevations respectively, of part of the food dispenser of Fig. 9; Figs 15a, b and c are front, side and plan elevations respectively, of a second chute for transporting the pizzas from a microwave oven to an infra-red oven; Figs 16a to 16c show a feeder and feeder and unwrapping mechanism for use with the food dispenser; Fig. 17 is an illustration of a selection panel for use with the food dispenser; Fig. 18 is an illustration of a diagnostic panel for use with the food dispenser; Fig. 19 is a flowchart depicting the steps for preparing a frozen pizza; Fig. 20a is a cross-sectional elevation of a pizza base for use with third aspect of the present invention; Fig. 20b is a plan view of the pizza base of Fig. 20a; Fig. 21 is a cross-sectional elevation of a mould for use in preparing frozen pizzas; Fig. 22 is a side elevation of a tomato layer forming part of a pizza; Fig. 23 is a cross-sectional elevation of a stamp for use in preparing the tomato layer of Fig. 21; Fig. 24a is a cross-sectional elevation of a cheese layer forming part of a pizza; Fig. 24b is a plan view of the cheese layer of Fig. 24a; Fig. 25 is a cross-sectional view of a stamp for use in making the cheese layer of Figs 24a and 24b; Fig. 26a is a cross-sectional elevation showing the cheese layer and the tomato juice layer joined together; Fig. 26b is a plan view of the cheese layer and the tomato juice layer joined together; Fig. 27 is a cross-sectional elevation of a pizza; Fig. 28a is a cross-sectional elevation of a paper plate; Fig. 28b is a plan view of the plate of Fig. 28a; Fig. 29a is a cross-sectional elevation of the pizza of Fig. 27 on the plate of Figs 28a and 28b; Fig. 29b is a plan view of the pizza of Fig. 27 on the plate of Figs 28a and 28b; Fig. 30a is a cross-sectional elevation of the pizza of Fig. 27 on the plate of Figs 28a and 28b packaged in a packaging material; Fig. 30b is a plan view of the pizza of Fig. 27 on the plate of Figs 28a and 28b packaged in the packing material; Fig. 31a is an elevational view of the packaging material of Figs 30a and 30b; Fig. 31b is a plan view of the packaging material of Fig. 31a; Fig. 31c is an enlarged view of a portion of the packaging material of Fig. 31a depicted by the circle in Fig. 31a; Fig. 32a is a side elevation of view of a strip of pizzas; Fig. 32b is a plan view of the strip of pizzas of Fig. 32a; Fig. 33a is a side elevation of a storage box; Fig. 33b is a plan view of the box of Fig. 33a; Fig. 34a is a cross-sectional side elevation of the box of Figs 33a and 33b with the strip of pizzas of Figs 32a and 32b therein; Fig. 34b is a plan view of the box of Fig. 34a; Fig. 35a is a side elevation of two storage boxes located on shelves; Fig. 35b is an enlarged view showing a join between strips of pizzas in the boxes of Fig. 35a; Fig. 36 is a flowchart depicting the stages of a pizza dispenser process; Fig. 37a is a side elevation of the casing of a food dispenser; Fig. 37b is a rear elevation of the casing of Fig. 37a; Fig. 37c is a plan view of the casing of Figs 37a and 37b; Fig. 38a is an end elevation of a storage facility forming part of one embodiment of a food dispenser; Fig. 38b is a side elevation of the storage facility of Fig. 38a; Fig. 39 is an enlarged view of a part of the storage facility of Figs 38a and 38b; Fig. 40 is an enlarged view of a part of the storage facility of Figs 38a and 38b; Fig. 41a is an end elevation of a heating means for use in a food dispenser; Fig. 41b is a plan view of the heating means of Fig. 41a; Fig. 42 is a cross-sectional elevation of one embodiment of a food dispenser; Fig. 43 is a front elevation of the food dispenser of Fig. 42; Fig. 44 is a front elevation of the casing of Figs 37a, 37b and 37c; Fig. 45 is an isometric view of the casing of Fig. 44; Fig. 46 is a schematic illustration of a display panel, a selector panel and a control panel forming part of one embodiment of a food dispenser; Fig. 47 is a schematic representation of a microprocessor for controlling the operation of the food dispenser; and Fig. 48 is a flowchart showing the process for re- stocking the food dispenser. Referring to the drawings, Fig. 1 shows a flowchart illustrating the stages of operation and main components of a first embodiment of a food dispenser. Reference will be made to the food dispenser dispensing pizzas 2, but it will be appreciated that the food dispenser may be used with any other types of fast food, such as burgers, chips or the like.

The pizzas 2 are typically stored in a storage facility 100 provided within a casing 50 of the dispenser (Figs 2 and 3) . The storage facility 100 typically comprises a deep freeze unit, as can be best seen in Figs 4a to 4d, and typically includes a main storage compartment 110 in which a number of pizzas 2 are stored until required.

The pizzas 2 are generally pre-cooked before being frozen and sealed into a continuous strip 20. Figs 5a and 5b show an individual pizza 2 that is sealed within an air-tight packaging 4. The packaging 4 typically comprises two parallel sheets of plastic foil or the like, that are sealed together around the edge of the pizzas 2 at a sealing area 6 extending around the outer edge of the pizza 2. Any suitable material may be used to seal the pizzas 2 providing that the pizzas 2 are sealed within the strip 20 in an air-tight manner. In this embodiment, the seal is made by conventional ultrasonic or heat welding equipment.

Referring to Fig. 6, the pizzas 2 are individually sealed within the strip 20, typically in a continuous strip of, for example, one hundred pizzas. The strip 20 of pizzas 2 is then folded and stored within a box 8 , as shown in Fig. 7. The box 8 is provided with an opening 10 that allows the strip 20 of pizzas 2 to be removed from the box 8 as required.

Figs 8a to 8c show how the strip 20 of pizzas 2 is folded and stored within the box 8 for easy removal . A first layer 14a of four pizzas (Fig. 8c) is placed on the bottom of the box 8. The strip 20 of pizzas 2 is then folded back on itself to allow a second layer 14b of four pizzas to be placed on top of the first layer 14a. Again, the strip 20 is then folded back on itself to allow a third layer 14c to be positioned on top of the second layer 14b etc. In this way, the box 8 is substantially filled with, for example, twenty-five folded layers (14a, 14b,... etc) of pizzas 2 making a total of one hundred pizzas 2 within the box 8. Box 8 includes a space 16 that allows the strips 14a, 14b etc. to be removed from the box 8.

Referring to Figs 4a to 4c, the storage facility 100 extends upward from the storage compartment 110 into a neck portion 112 and a top portion 114. The neck portion 112 and top portion 114 are both insulated to ensure that the temperature within the storage facility 100 remains at a suitable level, for example at -22°C. The storage compartment 110 typically allows for up to four boxes 8 to be stored therein. Thus, the pizza dispenser can store and dispense four hundred pizzas of up to four different types. The number of pizzas and the number of different types thereof that the dispenser can store may vary depending upon the dimensions of the dispenser and/or storage facility 110.

In use, a user of the food dispenser inserts money and selects which type of pizza 2 is required by pressing the appropriate button at a selection panel 200 (see Fig. 17) . Once the selection has been made, a feeder and feeder and unwrapping mechanism 120 is activated. The feeder and feeder and unwrapping mechanism 120 is located within top portion 114 of the storage facility 100 (see Figs 16a to 16c) , and is used to pull the strip 20 of pizzas 2 through the opening 10 in the box 8 , up the neck portion 112 of the storage facility 100 and into the top portion 114. It should be noted that each box 8 within the storage compartment 110 typically has a feeder and feeder and unwrapping mechanism 120 associated with it.

Referring now to Figs 16a to 16c, there is shown in detail the feeder and feeder and unwrapping mechanism 120. Mechanism 120 includes a first roller 122 positioned above the strip 20, and a second roller 124 positioned below the strip 20. The first and second rollers 122, 124 are driven by, for example, electric motors (not shown) . Third and fourth rollers 126, 128 are provided above and below the strip 20, respectively, and are in contact with the strip 20. A door 134 allows access to the storage facility 100 so that the boxes 8 stored therein may be replaced when necessary. Door 134 may be locked using any conventional lock 136 to prevent any unauthorised access to the dispenser. When the boxes 8 are placed within the storage compartment 110 (for example when servicing or re-stocking) , the strip 20 is manually pulled out of the box 8 through the opening 10 and up the neck portion 112 into the top portion 114. The entire storage facility 100, including the compartment 110, neck 112 and top portion 114 are all refrigerated and insulated to ensure that the pizzas 2 are kept frozen until required. Loose ends of the parallel strips of packaging 4 are attached to the first and second rollers 122, 124 respectively by any conventional means.

In use, when the user of the food dispenser makes a selection on the selection panel 200, the feeder and feeder and unwrapping mechanism 120 associated with that particular choice is activated and the rollers 122, 124 are activated to pull the strip 20 upwards. In addition, the parallel strips of the packaging 4 are pulled apart and a pizza 2 is dispensed onto a first chute 130. Simultaneous with the activation of the rollers, a door 132 which seals the storage facility 100 moves upwards to allow the pizza 2 to exit the storage facility 100. The pizza 2 then slides down the chute 130 to the next stage. Referring now to Figs 9 to 12, the pizza 2 exits the door 132 to the storage facility 110 and slides down an upper chute 140, best shown in Figs 12a to 12c. Upper chute 140 is provided with a number of entry points 142a to 142d corresponding to each of the storage boxes 8.

The pizza 2 slides down the upper chute 140 and falls onto a paper plate 144 dispensed from a paper plate feeder 150. The paper plate feeder 150 holds a plurality of paper plates 144 in a vertical stack and dispenses one at a time when required.

Referring now to Figs 13a and 13b, a pushing feeder 160 pushes the paper plate 144 containing the pizza 2 into a microwave oven 162. The pushing feeder 162 may be of any suitable type, such as electric, hydraulic or the like. The microwave oven 162 is typically a conventional microwave oven and may be rated at, for example, 800 Watts. The microwave oven 162 is activated for approximately 30 seconds, or until the frozen pizza is substantially defrosted.

Once the microwave 162 is deactivated, a pulling mechanism 164 (Fig. 13b) is activated to pull the paper plate 144 containing the pizza 2 onto a lower chute 166, best shown in Figs 15a to 15c. The pulling mechanism 164 may be of any suitable type, such as electric, hydraulic or the like. The plate 144 slides down the lower chute 166 and into an infra-red (IR) oven 168. The IR oven 168 is then activated for approximately 30 seconds at 200°C, or until the pizza 2 becomes hot and crispy. Once the oven 168 is deactivated, a second pushing mechanism 170 (Fig. 14b) pushes the pizza 2 on the plate 144 out of the oven 168, through an upwardly sliding door 176, and into a dispensing portion 172, where the pizza 2 can be removed from the dispenser and consumed. Door 176 seals the interior of casing 50, and prevents access to the casing 50 from the dispensing portion 172.

It should be noted that the microwave oven 162 and the IR oven 168 could be combined into one unit for convenience.

Operation of the food dispenser is typically controlled by a microprocessor. The microprocessor is typically software-controlled, the software controlling the sequence of operations.

Optionally, the food processor may include a diagnostics panel 220 shown in Fig. 18. The diagnostics panel 220 has four displays 222 that show the number of each type of pizza that has been sold. Panel 220 also includes a number of fault lights 224, for example light-emitting diodes (LEDs) , which indicate if a particular component has a fault. The fault lights 224 may comprise dual -colour LEDs, wherein a green light indicates that the component is operating correctly, and a red light indicates that the component is faulty. This would allow an engineer or the like to check on the status of the food dispenser when the boxes 8 containing the pizzas are replaced or replenished, or when the dispenser is being serviced.

It is preferred that the pizzas are at least partly- cooked before being frozen and stored within the dispenser. Conventional methods of preparing partly- cooked, pre-frozen pizzas do not provide a consistent binding of the various ingredients. For example, the cheese that is placed on top of the tomato layer does not always stay bound thereto. Thus, the pizzas are not always delivered to the consumer in a consistent and aesthetically pleasing way.

Fig. 19 shows a flowchart illustrating the steps for making a frozen pizza primarily for use with the dispenser of the invention. The steps will be described in detail below.

Referring now to Figs 20a and 20b, there is shown an end elevation and plan view respectively of a pizza base 300. Base 300 is provided with a plurality of concentric circular recesses 300r, and an annular upwardly projecting lip 3001. Base 300 is prepared using conventional pizza base dough that is left to grow. The dough is then rolled out to the required thickness (in the order of around 4 to 7 mm) , and is then stamped or pressed into the shape shown in Figs 20a and 20b. Fig. 21 is a cross-sectional elevation of a mould 304 that can be used to provide the necessary shape for the base 300. Mould 304 comprises an upper portion 306 that is hingedly or otherwise coupled to a lower portion 308. In the embodiment shown in Fig. 21, the upper portion 306 is provided with a forked portion 310. Each fork of the forked portion 310 is provided with a slot 312. The forked portion 310 straddles a shoulder 314 on the lower portion 308. A pin 316 passes through an aperture (not shown) in the shoulder 314 and through the slots 312. Thus, the upper portion 306 is hingedly coupled to the lower portion 308 so that the upper portion 306 can pivot about pin 316.

The lower face of the upper portion 306 is provided with a plurality of concentric ribs 318 that are used to produce the concentric recesses 300r in the base 300. In use, the rolled-out dough is placed in the lower portion 308. The upper portion 306 is then brought down into contact with the dough and the lower portion 308. The ribs 318 press into the dough thus forming the recesses 300r.

Once the base 300 has been formed in the mould 304, it is left to grow a second time in the mould 304 to help keep the shape of the base 300 consistent. The base 300 is then baked between the mould plates for around fifteen minutes at a temperature of around 150°C. The mould 304 is then opened and the base 300 is baked for a further period of around fifteen minutes at around the same temperature. It should be noted that the dough of the base 300 should preferably not be fully cooked and should preferably not be fully crisped at this stage.

A tomato layer 320, shown in Fig. 22, is prepared from a tomato juice mixture. The tomato layer 320 is preferably fairly rigid so that the layer 320 does not bend significantly during production of the frozen pizza. Layer 320 is typically rolled out so that it is in the order of 2 to 2.5mm in depth and has a diameter approximately the same as base 300. It should be noted that the tomato layer 320 is intended to fit into the bottom of the base 300 within the annular lip 3001.

Referring to Fig. 23, the shape of the tomato layer 320 can be kept consistent by stamping the shape using a stamp, generally designated 322. Stamp 322 includes a housing 324 that is provided with a moveable piston 326. The piston 326 can be manually or hydraulically operated, but could equally be actuated using any conventional means. The piston 326 is provided at the lower end with a cutter 328 that is used to cut out or stamp the preferred shape (typically circular) of the tomato layer 320 from a continuous strip of the rolled out tomato juice mixture.

Referring to Figs 24a and 24b, a cheese layer 330 is shown in side elevation and plan views respectively. The mixture that forms the cheese layer 330 can be produced using any conventional method, but it is preferred that the cheese layer 330 should not contain too much water. It is preferred that the cheese layer 330 is fairly rigid so that it does not bend or flex during production of the pizza.

As can be seen from Figs 24a and 24b, the cheese layer 330 is typically circular and is provided with a plurality of apertures 332. It will be appreciated that although the apertures 332 are illustrated as being square in shape, they could equally be of any convenient shape such as circular, triangular etc. The diameter of the cheese layer 330 is typically of the same order as that of the base 300 and the tomato layer 320. The cheese layer 330 is also intended to fit in the base 300 within the annular lips 3001. A stamp 334 (Fig. 25) is typically used to cut out the apertures 332 in the cheese layer 330 and the overall shape of the layer 330. Stamp 334 is provided with a plurality of downward projections or cutters 336 that have the approximate shape and dimensions of the apertures 332. The stamp 334 is brought downwards, either manually, hydraulically or otherwise so that the cutters 336 cut into and pass through the cheese layer 330 thus cutting-out the apertures 332 and the overall (circular) shape of the cheese layer 330.

It should be noted that moulds may be used to produce the shape of the cheese layer 330 and/or the tomato layer 320. The cheese mix and the tomato juice mix could be poured into an appropriately shaped mould, thus obviating the use of a stamp or cutter and may also obviate having to roll out the mixes before they are stamped or cut. This would also reduce the wastage from the process.

Referring now to Figs 26a and 26b, once the tomato layer 320 and the cheese layer 330 have been prepared as described above, they are then pressed together to form a pre-jointed layer. As shown in Fig. 26a, a portion of the tomato layer 320 is pressed into the apertures 332 in the cheese layer 320 to make an improved bond and joint between the two layers 320, 330. In this way, the two layers 320, 330 are more reliably joined together. To further join the two layers 320, 330 together, they can be preheated so that they become softer, thus allowing the tomato layer 320 to flow into the apertures 332 in the cheese layer 330.

It should be noted that additional toppings such as pepperoni, peppers, chicken, sweetcorn etc can be added on top of the cheese layer 330, preferably before the cheese layer 330 and the tomato layer 320 are heated. Thus, when the cheese layer 330 melts, the toppings where used will melt into the cheese layer 330.

Referring now to Fig. 27, the bonded cheese layer 330 and tomato layer 320 are then pressed into the base 300 to form a pizza 350. As the tomato layer 320 is pressed into the base 300, a portion of the tomato layer 320 is pressed into the recesses 300r, thus providing an improved bond and joint between the base 300 and the tomato layer 320. The pizza 350 is then preheated at a high temperature for a short period so that both the cheese layer 330 and the tomato juice layer 320 melt and thus the tomato layer 320, the cheese layer 330 and the base 300 bond together. The pizza 350 is typically lightly crisped at this stage.

The annular lips 3001 of the base 300 serve to keep the cheese layer 330 and the tomato layer 320 within the base 300.

The pizza 350 is then deep-frozen immediately preferably . using a very fast deep freezing process. The deep freezing process typically involves the use of liquid gases (e.g. nitrogen or hydrogen) or the like, and avoids a change in the structure of the pizza 350 as it cools. Any conventional deep freezing process may be used.

The pizzas 350 can be stored in a refrigeration unit until they are required to be packaged. When the pizzas 350 are frozen they are packaged for use with the dispenser of the invention. Unlike the previous embodiment of dispenser, the second embodiment of dispenser does not include a paper plate feeder, as will be described. Thus, the pizza 350 is packaged on a paper plate 351. Plate 351 is illustrated in Fig. 28. The bottom surface of the plate 351 may have an aluminium sheet located therein. The sheet of aluminium provides increased rigidity to the plate 351 and also helps to heat the bottom of the pizza 350. Referring now to Figs 29a and 29b, there is shown the pizza 350 on the paper plate 351 before being sealed in an air-tight manner. For convenience, the pizza 350 placed on a paper plate 351 will be referred to as "pizza/plate 356", but it should be noted that this is intended to encompass the pizza 350 whether on a plate 351 or not. If the dispenser is provided with a paper plate feeder, as in the previous embodiment, the pizza need not be placed on a paper plate 351 before being packaged. The plate 351 is preferably manufactured from a material that is microwave compatible.

Referring to Figs 30a and 30b, the pizza/plate 356 is positioned between an upper sheet 352 and a lower sheet 354 of plastic material. Figs 31a and 31b illustrate a polyester film that is used as the upper and lower sheets 352, 354. The polyester film is suitable for packaging food and is typically in the order of around 190mm in width. As best seen in Fig. 31c, one surface of the upper and lower sheets 352, 354 may be treated so that the two sheets 352, 354 can be joined in use more easily.

Referring to Figs 30a and 30b, the pizza/plate 356 is positioned between the upper and lower sheets 352, 354. Thereafter, the sheets 352, 354 are joined together using any conventional means such as glue, heat or ultrasonic welding, or the like to create a continuous air-tight seal 358 around the pizza/plate 356.

As can be seen from Figs 32a and 32b, the upper and lower sheets 352, 354 are in a continuous form. This allows a number of pizzas/plates 356 to be spaced apart along the length of the plastic sheets 352, 354, with around 250mm between the centres of the pizzas/plates 356. Thus, a strip, generally designated 360 in Fig. 28, of pizzas/plates 356 is created.

To facilitate transportation of the strips 360 of pizzas/plates 356 to the dispenser, and also storage therein, the strips 360 are placed into cardboard boxes 362. Referring to Figs 33a and 33b, there is shown a side elevation and plan view of a storage box 362, respectively. To allow the strips 360 to be retrieved from the box 362, the box is provided with upper and lower doors 364u, 3641. Doors 364u, 3641 are typically square portions of the box 362 that can be removed as and when required, as will be described. For example, the edges around the doors 364u, 3641 may be perforated to facilitate easy removal.

Referring to Figs 34a and 34b, the strips 360 of pizzas/plates 356 are stored within the boxes 362 so that the pizzas/plates 356 are generally in a vertical orientation. The box 362 is dimensioned to accommodate a number of pizzas/plates 356 therein, typically in the order of 30 to 40 pizzas/plates 356 per box.

In use, the boxes 362 are typically disposed on shelves within the dispenser. As shown schematically illustrated in Fig. 35a, the boxes 362 are typically placed on upper and lower shelves 366u, 3661 within the dispenser. Although Fig. 35a shows only two shelves 366u, 3661 (and thus only two boxes 362) , it will be appreciated that any number of shelves 366 may be used within the dispenser.

Referring to Fig 35a and 35b, the strip 3601 in the lower box 3621 is coupled to the strip 360u in the upper box 362u. As can be seen more clearly in Fig. 35b, the upper and lower sheets 3521, 3541 that make up the lower strip 3601 are coupled, for example by gluing, heat welding or other conventional means, to the upper and lower sheets 352u, 354u that make up the upper strip 360u. It should be noted that the upper and lower doors 364u, 3641 in each box 362 are removed before the strips 360 can be extracted from the boxes 362u, 3621 and joined. This forms a continuous strip of pizzas between successive boxes and thus the dispenser requires less maintenance and re-stocking.

Fig. 36 is a flowchart illustrating a pizza dispenser process for use in the second embodiment of dispenser. As with the previous embodiment, the dispenser includes an outer casing 400 as shown in Figs 37a to 37c. Casing 400 is provided with an access door 402 that is used to re-stock and maintain the dispenser.

A storage facility, typically in the form of a deep freeze unit 404 is located within the casing 400, as illustrated in Figs 38a and 38b. A number of boxes 362 with the frozen pizzas/plates 356 therein are stored within the deep freeze unit 404. In the embodiment shown in Figs 38a and 38b, three boxes 362u, 362m, 3621 are stored within the deep freeze unit 404. The upper and middle boxes 362u, 362m are located on shelves 406 within the dispenser, and the lower box 3621 is located on the base of the freezer unit 404. As can be seen particularly in Fig. 38a, the freezer unit 404 in this embodiment is capable of storing nine boxes in total; three stacks of the three boxes 362u, 362m, 3621. Consequently, the dispenser is capable of dispensing upto three different types of pizza. It will be appreciated that the number of boxes and the number of different types of pizzas that can be dispensed by the dispenser are dependent upon the dimensions of the dispenser and/or the freezer unit 404.

The strips 360 contained within the boxes 362u, 362m, 3621 are joined together to form one continuous strip 360 between the boxes 362u, 362m, 3621 in the stack, as described with reference to Figs 35a and 35b. The strips 360 are typically joined together to form a continuous strip when the dispenser is re-stocked.

Located within the deep freeze unit 404 is a feeder and unwrapping mechanism 408, as best shown in Fig. 39. The feeder and unwrapping mechanism 408 comprises upper and lower collector rollers 410u, 4101, upper and lower driven rollers 412u, 4121 and upper and lower guide rollers 414u, 4141. The collector rollers 410u, 4101 are used to collect the unwrapped upper and lower sheets 352, 354 that are used to package the pizza/plate 356, as previously described. The driven rollers 412u, 4121 are driven by a respective electric motor (not shown) and are used to pull the strips 360 through the feeder and unwrapping mechanism 408. The strip 360 is in friction contact with the surface of the rollers 412u, 4121 so that when the rollers 412u, 4121 are rotated by the motor, the strip 360 is pulled through the mechanism 408. The collector rollers 410u, 4101 are also motor-driven (not shown) as these are required to be rotated so that the upper and lower sheets 352, 354 can be collected thereon. The collector rollers 410u, 4101 may also be used to assist in pulling the strip 360 through the feeder and unwrapping mechanism 408.

As can be seen from Fig. 38a, three feeder and unwrapping mechanisms 408 are used, one for each different type of pizza.

In use, when the dispenser is re-stocked, the strip 360 in the upper box 362u is pulled out of the box 362u. The ends of the upper and lower sheets 352, 354 of plastics material are fed through the guide and driven rollers 414, 412 and are attached, for example using tape, glue or the like to the collector rollers 410. It will be appreciated that at least one end, and preferably both ends, of the sheets 352, 354 that make up the strips 360 are left loose so that they can be easily fed through the guide and driven rollers 414, 412 and attached to the collector rollers 410. Upon actuation of the driven rollers 412 and/or the collector rollers 410, the strip 360 is pulled upwardly through the feeder and unwrapping mechanism 408. As the strip 360 is pulled therethrough, the upper and lower sheets 352, 354 are pulled apart thus breaking the air-tight seal 358 and allowing the pizza/plate 356 to fall onto a conveyor belt 416. The conveyor belt 416 is set on an axis that is perpendicular to the feeder and unwrapping mechanisms 408 so that the pizza/plate 356 from any of the (three) mechanisms 408 falls onto the conveyor belt 416 for transportation out of the freezer unit 404. The conveyor belt 416 is driven in a conventional manner by a conveyor wheel 418 at either end thereof. The belt 416 is preferably driven at a relatively high speed.

Referring to Fig. 40, as the pizza/plate 356 comes to the end of the conveyor belt 416, it is propelled off the conveyor belt 416 by the speed at which the conveyor belt 416 is travelling. A door 422 in the freezer unit 404 moves upwards to allow the pizza/plate 356 to exit the freezer unit 404. The pizza/plate 356 then falls onto a chute 424 that is angled slightly downwardly so that the pizza/plate 356 slides down the chute 424 and is aligned with a rear door 426 in a heating means, generally designated 428 and shown more clearly in Figs 41a and 41b.

The heating means 428 comprises a microwave oven 430 that is used to defrost and heat the pizza 350 on the plate 351. The microwave 430 is typically rated at around 1000 Watts output power. A hot plate 431 is located just below the microwave oven 430 so that the bottom of the pizza 350 is also heated. The aluminium sheet within the paper plate 351 is used to transfer the heat from the hot plate 431 to the pizza 350 more efficiently.

Located above the microwave 430 is a hot-air blower 432 that works on a similar principle to an electric hair dryer. Electricity is passed through a heating element (not shown) , and the heat produced by the heating element is blown onto the pizza 350 using a fan (not shown) . The hot air is thus used to make the pizza 350 crispy.

Located above the hot-air blower 432 is an exhaust system that is used to extract the smells and vapour from the hot pizza 351. As the dispenser will generally be in a closed room or other such enclosed environment, the exhaust system is used to extract the smell and vapours out of the dispenser. These can then be vented outside in any conventional manner, or can be vented outwith the dispenser so that the smell remains around the dispenser, thus tempting any passer-by to use the dispenser. A paper filter 434 or the like forms part of the exhaust system and is used to trap the smell and other particles from within the microwave 430. An extractor fan 436 is used to extract the vapour etc through the filter paper 434 and to the outside of the dispenser. Referring in particular to Fig. 42, a rear feeder 438 is used to either push or pull the pizza/plate 356 into the heating means 428. The rear feeder 438 typically includes an extendable piston or a telescopic member or the like, that has a projection 440 on one end thereof. Projection 440 is used to engage an edge of the plate 351 so that when the piston is extended, the plate 351 is pushed (or alternatively pulled) into the heating means 428.

Once in the heating means 428, the microwave oven 430 is actuated for around fifteen seconds, typically together with the hot plate 431. Hot air at around 350°C is blown onto the pizza 350 for around thirty- five seconds to make it crispy. Thereafter, the exhaust system is actuated to extract the vapour and smell from within the microwave oven 430.

When the pizza 350 has been defrosted and heated as described above, it is then ready to be served to a consumer. Referring again to Figs 41b and 42 in particular, a front feeder 442 is used to push the pizza/plate 356 out of the microwave 430. The front feeder 442 has a similar structure to the rear feeder 438 and includes a piston or telescopic member (not shown) that is provided with a projection 444. Projection 444 can be retracted so that the pizza/plate 356 is not obstructed as it is being pushed into the microwave oven 430 by the rear feeder 438. In use, the piston within the front feeder 442 is actuated and the projection 444 pushes the pizza/plate 356 out of the microwave oven 430. The microwave 430 is provided with a front door 446 that opens to allow the pizza/plate to be pushed onto an outlet 448. Thereafter, an outer door 450 that allows access to the outlet 448 opens (typically by sliding upwards) so that the consumer can remove the hot pizza 350 on the plate 351. It should be noted that to avoid any unauthorised access to the dispenser, the front door 446 is opened briefly to allow the pizza/plate 356 to be pushed out of the microwave 430. Once the pizza/plate 356 is out of the microwave 430, the front door 446 of the microwave 430 is then closed. Thereafter the outer door 450 is opened to allow the consumer to retrieve the pizza 350.

Figs 44 and 45 illustrate the casing 400 of the dispenser in front elevation and isometric views respectively. The access door 402 is provided with the outer door 450 so that a customer can retrieve the hot pizzas 350. As can be seen from Fig. 44, the customer door 450 is moveable within a slot 452 wherein the door 450 is moved upwards to allow access to the outlet 448.

Additionally, the access door 402 is provided with a conventional coin acceptor 454 that is used by customers to insert the requisite amount of money for the pizza 350. Change (if any) can be collected at a separate collection point 456. The coin acceptor 454 and collection point 456 may be of any conventional design that recognises coins and their value, and can give any change .

A display panel 458, best shown in Fig. 46 is located at or near the coin acceptor 454. The display panel 458 includes a selection unit 460. The display panel 458 is used to display instructions and information to the customer. Thus, the display panel 458 displays information and instructions such as the types of pizza that are available, the price thereof, amount of money to be inserted, the amount of change to be given in return and the approximate time to deliver the pizza 350.

The customer can select which type of pizza 350 is required using buttons 462 on the selection unit 460. The display 458 indicates (typically using an arrow) which button relates to which type of pizza.

Instructions for the use of the dispenser, together with information regarding the status thereof (e.g. "heating pizza"), can be displayed to the customer so that they can operate the dispenser correctly and will be informed of progress whilst they are waiting for the pizza 350.

The display panel 458 and/or selector unit 460 are typically electrically coupled to a control panel 464 (Fig. 46) located within the casing 400 of the dispenser, typically inside the access door 402. The control panel 464 houses a microprocessor 466 that is used to control the operation and process sequence of the dispenser using bespoke software. Fig. 47 schematically illustrates a microprocessor 466 and the functions of the dispenser that it controls.

The control panel 464 is also used to monitor the status of the dispenser and can be interrogated to determine information such as the number of pizzas sold, whether the dispenser requires to be restocked etc. An engineer or the like who re-stocks the dispenser for example, can enter an identification number (e.g. 12) into a numerical keypad 468 that typically forms a part of the control panel 464 (although it may be independent thereof) . Entering the identification number instructs the microprocessor to display (for example on the display panel 458 or another display unit located within the dispenser) information such as temperatures (e.g. of the freezer unit 404), process times, number of pizzas sold, number of pizzas remaining, whether re-stocking is required and the like. This information could also be downloaded via a suitable connection (e.g. a serial port) to a laptop computer or the like so that all the information can be displayed at once on the screen of the laptop. The display 458 and/or the control unit 464 may also provide status information in the event of a system failure (e.g. the microwave becomes inoperable due to a malfunction) . Alternatively, or additionally, the dispenser may be provided with a fault panel 200 similar to that of the previous embodiment. Additionally, the control panel 464 may include a modem or other form of communication so that the information stored within the control panel 464 can be remotely accessed using, for example, a telephone line, satellite link or other telemetry system. Thus, each dispenser can be monitored from a central distribution and/or maintenance centre to ensure efficient maintenance and re-stocking. Thus, it is possible to remotely monitor the status of the dispenser and acquire any of the aforementioned information without having to physically inspect the dispenser.

Fig. 47 is a flowchart illustrating the steps for re- stocking the dispenser. Firstly, the access door 402 is opened, the door 402 typically being locked using any conventional locking means. The engineer re- stocking the dispenser would then check the display 458 (or other display where used) to determine whether there was any fault with the dispenser, whether it needed servicing or whether it needed re-stocking. If no faults within the dispenser are noted and it does not require to be re-stocked, the access door 402 is then closed.

However, if the dispenser does require to be re- stocked, replacement boxes 362 are retrieved from, for example, a cold storage van or the like. A door (not shown) that permits access to the freezer unit 404 is opened and any empty boxes 362 removed. New boxes 362 can then be placed within the dispenser and the strips 360 from each box attached together, as described above. The collector rollers 410 are then either emptied or replaced and the ends of the strip 360 attached thereto, as described above.

The door to the freezer is then closed and the engineer re-stocking the machine can then reset the control panel 464 using an appropriate identification code. The keypad 468 may also be used to enter a personal identification number (PIN) to help prevent any unauthorised access to the information in the dispenser. The access door 402 is then closed and secured.

Thus, there is provided a food dispenser that in certain embodiments automatically retrieves the food from a cold storage area, unseals the food, heats it and then dispenses it for consumption. The dispenser in certain embodiments is easy to operate and relatively quick to deliver a hot pizza.

Modifications and improvements may be made to the foregoing without departing from the scope of the present invention.

Claims

CLAIMS 1. A food dispenser for dispensing hot food comprising a casing, a storage facility within the casing for storing food, heating means within the casing for heating the food, and a conveying system for transporting food within the casing and/or to an outlet in the casing.

2. A food dispenser according to claim 1, further comprising food portions wherein the food is preferably at least partly cooked before being stored in the storage facility.

3. A food dispenser according to any preceding claim, further comprising food portions that are individually sealed in a strip of packaging material.

4. A food dispenser according to claim 3, wherein the dispenser includes a feeder and unwrapper unit.

5. A food dispenser according to claim 4, wherein the feeder and unwrapping unit is located within the storage facility.

6. A food dispenser according to either claim 4 or claim 5, wherein the unit retrieves the food from the storage facility and removes the outer packaging thereof.

7. A food dispenser according to any one of claims 4 to 6 , wherein the feeder and unwrapper unit comprises two pairs of rollers, one roller of each pair disposed above the strip, and the other roller in the pair being disposed below the strip.

8. A food dispenser according to any one of claims 4 to 7, wherein the feeder and unwrapper unit comprises a pair of collector rollers, a pair of driven rollers, and a pair of guide rollers.

9. A food dispenser according to claim 8, wherein the collector rollers are driven by an electric motor and are used to collect unwrapped packaging material.

10. A food dispenser according to claim 9, wherein the driven rollers are driven by an electric motor and pull the strip through the unit.

11. A food dispenser according to any one of claims 3 to 10, wherein the strip of wrapped food is dispensed from a storage box.

12. A food dispenser according to any preceding claim, wherein the storage facility comprises a deep freeze unit.

13. A food dispenser according to any preceding claim, wherein the heating means comprises a microwave oven and/or an infra-red (IR) oven.

14. A food dispenser according to claim 13, wherein the microwave oven and the IR oven comprise a single unit .

15. A food dispenser according either claim 13 or claim 14, wherein the conveying means comprises a first chute for transporting the food from the storage facility to the microwave over; and a second chute for transporting the food from the microwave oven to the IR oven .

16. A food dispenser according to claim 15, wherein the conveying means includes a first feeder disposed at or near the lower end of the first chute.

17. A food dispenser according to claim 16, wherein the first feeder moves the food into the microwave oven.

18. A food dispenser according to any one of claims 15 to 17, wherein the conveyor includes a second feeder disposed at or near the microwave oven.

19. A food dispenser according to claim 18, wherein the second feeder moves the food out of the microwave oven to the top of the second chute.

20. A food dispenser according to any one of claims 15 to 19, wherein the conveying means includes a third feeder disposed at or near the lower end of the second chute.

21. A food dispenser according to claim 20, wherein the third feeder moves the food from the IR oven to the outlet in the casing.

22. A food dispenser according to any one of claims 15 to 21, wherein a paper plate feeder is disposed at or near a lower end of the first chute.

23. A food dispenser according to any one of claims 1 to 12, wherein the heating means comprises a microwave oven, a hot plate, and a hot air blower.

24. A food dispenser according to claim 23, wherein the microwave oven, hot air blower and the hot plate comprise one unit.

25. A food dispenser according to either claim 23 or claim 24, wherein the conveying means comprises a conveyor belt located within the storage facility.

26. A food dispenser according to any one of claims 23 to 25, wherein the conveying means includes a chute.

27. A food dispenser according to claim 26, wherein one end of the chute is located at or near one end of the conveyor belt and the other end of the chute is located at or near the heating means.

28. A food dispenser according to any one of claims 23 to 27, wherein the conveying means further includes a first feeder located at or near the heating means for feeding the food into the heating means.

29. A food dispenser according to any one of claims 23 to 28, wherein the conveying means further includes a second feeder for retrieving the food from the heating means .

30. A food dispenser according to claim 29, wherein the second feeder is also used to feed the food into the outlet in the casing.

31. A food dispenser according to any preceding claim, wherein the outlet comprises a compartment within the casing whereby the food may be retrieved by a user.

32. A method of dispensing hot food, the method comprising the steps of providing a food dispenser comprising a casing, a storage facility within the casing for storing food, heating means within the casing for heating the food, and a conveying system for transporting food within the casing and/or to an outlet in the casing; retrieving the food from the storage facility; heating the food using the heating means; and dispensing the food to a consumer via the outlet.

33. A method according to claim 32, wherein the method includes the additional step of removing packaging material from the food before heating.

34. A method according to claim 32 or claim 33, wherein the food is preferably at least partly cooked before being stored in the storage facility.

35. A method of producing a pizza for use in a food dispenser, the method comprising the steps of making a pizza base; making a tomato layer; making a cheese layer; and binding the cheese layer and/or the tomato layer to the base.

36. A method according to claim 35, wherein the method for making a pizza base comprises the steps of preparing a dough; allowing the dough to grow; rolling out the dough; shaping the dough in a mould; allowing the dough to grow in the mould; and baking the dough in the mould.

37. A method according to claim 36, wherein the method of making the pizza includes removing the dough from the mould and baking for a further period.

38. A method according to claim 37, wherein the mould includes a number of concentric annular ribs so that in use, the mould creates a number of concentric annular recesses in the pizza base.

39. A method according to any one of claims 35 to 38, wherein the method for making the tomato layer includes the steps of preparing a tomato juice mixture; and rolling out the mixture to form the tomato layer.

40. A method according to claim 39, wherein the method for making the tomato layer further includes cutting the mixture into a desired size and shape.

41. A method according to any one of claims 35 to 40, wherein the method of making the cheese layer comprises the steps of preparing a cheese mix; and rolling out the cheese mix to form the cheese layer.

42. A method according to claim 41, wherein the method of making a cheese layer further includes cutting the cheese layer into a desired size and shape.

43. A method according to claim 42, wherein the method of making a cheese layer includes providing the cheese layer with a plurality of apertures therein.

44. A method according to any one of claims 35 to 43, wherein the method of making a pizza includes the additional step of bonding the cheese layer and the tomato layer together.

45. A method according to claim 44, wherein the method of making a pizza includes the additional step of preheating the cheese layer and the tomato layer.

46. A method according to either claim 42 or claim 43, wherein the method of making a pizza includes the additional step of pressing the bonded cheese layer and the tomato layer into the base.

47. A method according to claim 46, wherein at least a portion of the cheese layer and/or the tomato layer enters the recesses in the base.

48. A method according to claims 46 or claim 47, wherein the method includes the additional step of pre- cooking the pizza.

49. A method according to any one of claims 35 to 48, wherein the method includes the additional step of freezing the pizza.

50. A method according to any one of claims 35 to 49, wherein the method includes the additional step of packaging the pizza.

51. A method according to claim 50, wherein the method of packaging the pizza includes the steps of placing the pizza on a plate; positioning the pizza between an upper and a lower sheet of plastics material; and bonding the sheets together to form an air-tight seal around the pizza and the plate.