WO2003096813A1

WO2003096813A1 - Method and installation for automated production of basic pizza crust and pizza pie crust obtained using said method and installation

Info

Publication number: WO2003096813A1
Application number: PCT/FR2003/001491
Authority: WO
Inventors: Joël GUILLET
Original assignee: Guillet Joel
Priority date: 2002-05-17
Filing date: 2003-05-16
Publication date: 2003-11-27
Also published as: FR2839615A1; AU2003260550A1

Abstract

The invention concerns a method for automated production of ready-to-fill basic pizza crust (3) based on pizza pastry from a pre-leavened raw pizza dough. Said method comprises at least one step which consists in shaping the pizza paste in the form of a layer (2) or sheet. The method is characterized in that it consists, after the shaping step, in incompletely pre-cooking the layer (2) or sheet, cutting out the layer (2) or sheet in the form of one or several individual pieces respectively constituting a basic pizza crust and in conditioning the or said pieces for subsequent filling and baking.

Description

Method and installation for the automated manufacture of pizza tart bottom and tart bottom obtained from such process and installation

The present invention relates to a method and an installation for the automated manufacture of pie base made from ready-to-fill pizza dough and a pizza pie base obtained in particular by means of the aforementioned method and installation.

The manufacture of pizza, in particular in pizzerias, is traditionally carried out as follows. The dough is prepared in advance and stored in the form of a calibrated raw dough dough. The pizzas are then produced on demand and require the spreading of a dough in the form of a sheet generally in the form of a disc, the filling of this sheet and then the cooking of the whole. Due to the very elastic nature of the dough, the tart bases thus produced have a large thickness to allow their handling once filled. Furthermore, the bottom of the pie is always, for reasons of handling and due to the shrinking of the dough at the time of baking, partially garnished so that it results, after baking, a rim or "sidewalk" of the pie shell which is often not eaten. In addition, this rim constitutes a limit on the cooking time since it tends to burn during cooking. Consequently, traditional manufacture has significant drawbacks in terms of time for preparing a pie shell, filling the pie shell and the resulting product is a product whose pie shell has a significant thickness and a generally non-flanged rim. consumed.

At the same time, industrial manufacturing processes for garnished pizzas have been developed in recent years, as illustrated in particular by international applications WO 99/44429 or WO 00/42857. However, such processes do not meet the demand of pizzerias who wish to have the choice of ingredients for the filling. An alternative method consists in industrially manufacturing semi-cooked pizza pie bottoms, as illustrated in particular by international application WO 00/60946, American patent US-A-6,126,977 or patent FR-A-2,776,166. . These manufacturing methods each time include a step of shaping by molding or cutting a portion of dough to the final dimensions of a pizza pie base before baking said base. These processes require, in the case of a molding, a release from the bottom of the pie. In the case of cutting before baking, as illustrated in patent FR-A-2,776,166, there is a heterogeneity in the shapes and dimensions of the tart bases obtained due to a shrinkage.

Manufacturing processes similar to those described above are also known, in particular in the field of manufacturing bakery items. Thus, patent EP-A-0.056.346 describes a method of manufacturing a flat industrial bakery article which comprises the steps of rolling the dough, cutting out in the dough strip articles, passing these articles cut in a fermentation tunnel followed by pre-cooking of the cut items thus fermented. Consequently, the order of the steps is: 1) a cut,

2) fermentation,

3) cutting of the articles,

4) pre-cooking of the cut items.

In addition to the order of the steps which automatically generates a shrinking of the cut products, it can be seen that the pre-cooking of the products at a temperature of 90 to 150 ° C for a period of the order of 7 to 12 minutes is not compatible with industrial production of pizza dough base.

At the same time, document FR-A-2,685,608 very clearly describes, in particular in FIG. 4, a pre-cooking step followed by a cooking step before proceeding to a cutting step. The cutting operation is therefore carried out after cooking the product. This is confirmed by the passage page 3 - lines 10 and following where it is specified that the continuous cooking of the dough is done in two very precise stages:

- pre-cooking the dough in an oven,

- making a continuous sheet using two cylinders rotating in opposite directions,

- spreading on a baking mat until advancement to the cutting station after optical cooking control.

This therefore supposes that the pre-cooking and the cooking have taken place before cutting the material. The product obtained is a fully cooked finished product since it has undergone a pre-cooking step and a cooking step before being cut.

Again, in addition to the fact that the pre-cooking step is followed by a complete cooking step before cutting, the fact that the pre-cooking takes place in an oven shows that this process is not applicable to manufacturing. pizza dough base.

The document FR-A-2,720,900 describes a process for manufacturing a bread-type product which consists in subjecting the dough obtained after kneading to an extrusion step in order to obtain a strip of dough and then cutting the strip transversely into sections of given length before baking each section and then re-cutting these sections in the transverse direction to produce, from each section, a plurality of elongated finished products. In this document, as illustrated in particular on page 8 - lines 11 and following, in which it is specified: "the fact of baking the dough before cutting makes it possible to increase the share of crumb, the product thus produced is ready in use ", the process implements a complete cooking of the product in order to obtain a finished product. This product undergoes two cutting stages: one implemented before cooking, the other after cooking. The products obtained have absolutely nothing to do with pizza bottoms since they are constantly in the form of elongated products, in particular in the form of mouillettes. An object of the present invention is therefore to propose an automated manufacturing process for pie base made from ready-to-fill pizza dough, the design of which allows the production of tart bases of reduced thickness less than 2.5 mm, not requiring no pricking before cooking and the entire surface of which can be covered with a filling.

Another object of the present invention is to provide a method of the aforementioned type, the implementation of which makes it possible to obtain a base of an easy-to-handle pie having a long shelf life and allowing a reduction in the time for preparing a pizza.

Another object of the present invention is to provide an installation for the automated manufacture of pie base made from ready-to-fill pizza dough, the design of which enables high production yields to be obtained.

To this end, the subject of the invention is an automated manufacturing process for a pastry base based on pizza dough ready to garnish from a raw pizza dough having previously risen, this process comprising at least one shaping step. pizza dough in the form of a tablecloth or a sheet, characterized in that it consists, after shaping, of pre-baking the tablecloth or sheet in an incomplete manner, of cutting the tablecloth or sheet in the form of one or more individual pieces respectively constituting a bottom of the pizza pie and in conditioning the said piece or pieces for subsequent filling and cooking.

The implementation of an incomplete pre-baking step of the pizza dough sheet or sheet before cutting said sheet to the dimensions of one or more pizza pie bases makes it possible to obtain pie bases. pizza whose shapes and dimensions are similar from one base of pie to another.

Furthermore, the pre-baking of these tart bases makes it possible to produce tart bases with extremely reduced thicknesses because the pre-baking increases the mechanical resistance of such tart bases.

Finally, this pre-cooking makes it possible to reduce the cooking time which will be necessary for the cooking of such a filled pie shell.

Finally, because of this pre-baking, it is possible to subsequently coat the entire surface of the pie shell with a filling without having to provide edges or sidewalks.

Furthermore, during this incomplete pre-cooking, there is a swelling of the dough which disappears at the end of cooking and allows a bottom to be obtained, the visible face of which remains soft. Such swelling will not recur during baking so that the filling will be held in place in the absence of any prior pricking of the dough.

The invention also relates to an installation for the automated manufacture of pie base made from ready-to-fill pizza dough of the type comprising at least one station for shaping pizza dough in the form of a tablecloth or a sheet. , characterized in that it comprises, downstream of said shaping station, an incomplete pre-baking station for the web, followed by a station for cutting the web in the form of one or more individual pieces respectively constituting a base of pizza pie and a station for packaging the said piece or pieces from the cutting station for garnishing and subsequent cooking.

The subject of the invention is also a tart shell in the form of a pizza dough ready to fill, characterized in that it is in the form of a sheet of pizza dough, free of rim, precooked so incomplete and cut out after pre-cooking.

The pizza base thus produced has an extremely small thickness, less than 2.5 mm, the entire surface of which can be coated with a filling. The bottom of the pizza pie thus obtained by means of the aforementioned method and installation does not stick to the work surface or to the oven, does not require any chalking to be used so that the cleaning time, for example in a pizzeria after pizza making is reduced. In the same way, it is no longer necessary, in pizzerias, to store the dough pieces or to have a dough preparation facility. Such pizza pie bases can be kept for several days or even weeks depending on their packaging, inventory management is facilitated and profitability increased.

The invention will be clearly understood on reading the following description of examples of embodiments, with reference to the appended drawings in which:

Figure 1 shows a schematic side view of an installation according to the invention;

FIG. 2 represents a schematic top view of the installation shown in FIG. 1 and

Figure 3 shows a schematic top view of another embodiment of an installation according to the invention.

As mentioned above, the subject of the invention is in particular an automated manufacturing process for the bottom 3 of pie in the form of pizza dough ready to be filled. This pastry base 3 can also be called semi-cooked pizza crust or pizza base. The pizza dough used for making such a pizza base is a dough of the bread dough type. This dough comprises, as main ingredients, at least flour, water, oil, fats such as butter, salt and yeast for the fermentation and raising of the dough . Traditionally, the preparation of a pizza dough requires a kneading, kneading or milling operation of a few minutes during which the ingredients are mixed and then a step of dividing the dough into dough portions also called dough 1 calibrated dough pieces, this operation generally being carried out by means of a divider before subjecting the dough pieces 1 thus calibrated to a lifting step which is carried out in particular in temperature-controlled chambers. Thus, starting from a raw pizza dough having previously risen, the process which is the subject of the invention consists in shaping said dough in the form of a tablecloth 2 or a sheet, in pre-baking the tablecloth 2 or sheet and to cut the tablecloth or sheet in the form of one or more individual pieces respectively constituting a bottom of pizza pie before conditioning the said piece or pieces for subsequent filling and cooking.

The shaping step can be carried out in different ways. In the examples shown in Figures 1 and 2, each sheet is shaped by rolling from a dough piece 1 running on at least one conveyor belt until a sheet with a thickness of between 1 and 3 mm is obtained. , preferably between 1.5 and 2 mm. To obtain a pizza base with a diameter equal to 30 cm, each dough 1 has a weight of between 100 and 130 g. During the shaping step, each mass of dough of the dough type 1 positioned on a conveyor belt is therefore subjected to two successive rolling operations and, between two rolling operations, the dough resulting from the first rolling operation is oriented transversely to said conveyor belt to carry out a second rolling of the roll in a direction substantially perpendicular to the direction of the first rolling. This orientation step can be carried out on the same conveyor belt 5 by rotation of the quarter of the lowering by means of a suitable orientation device 7 as illustrated in FIG. 2 or by passing d '' a first conveyor belt to a second conveyor belt, the removal being carried out in such a way that the lowering positioned on the second conveyor belt is offset by 90 ° relative to its positioning on the first conveyor belt by reference to the longitudinal axis of travel of the conveyor belt. The rolling mills 6 are for their part formed from rotary rolling rollers disposed above a conveyor belt and cooperating with a roller of the conveyor belt moving at a generally predetermined constant speed. Thus, in the example shown in Figure 2, a first rolling mill 6 is disposed at the end of a first belt 4 of conveying while a second rolling mill 6 is arranged at the end of a second conveyor belt 5.

In the example shown in FIG. 3, a mass of raised dough is shaped in the form of a continuous sheet by means of at least one lamination. In this case, the orientation step can be omitted because a single rolling is carried out by means of a rolling mill 6.

At the end of the shaping step, the tablecloth 2 resulting from the shaping step is directly deposited on a heated conveyor belt 8 scrolling inside a pre-baking tunnel 9. The incomplete pre-cooking step is carried out at a temperature in the range of 170 ° C - 350 ° C, for a period of time between 5 and 60 seconds, preferably between 20 and 40 seconds. The term "incomplete pre-cooking" means cooking requiring a new cooking of the bottom 3 of the pie after filling the bottom 3 of the pie for consumption, this new cooking generally taking place at a temperature of between 250 ° C. and 350 °. C for a period of 3 to 6 minutes.

At the end of the cooking tunnel 9, each part constituting a bottom 3 of a pizza pie is cut, generally with a cookie cutter, and the scraps 11 from the cut are collected and subjected to it. to a new cooking before grinding so as to form a ground type of breadcrumbs. To allow this separation of the falls 11, each device 10 for cutting with a cookie cutter consisting of a circular plate with a rim can be equipped with a knife 10A radial ensuring simultaneously with the cutting of the bottom of the pie the cutting of the strip drop 11 extending around said bottom 3. This strip can then be removed by means of a suitable removal device 10B and brought by means of a conveyor belt to an oven 12 to complete the cooking of said drops 11. These scraps 11 are then introduced into a crusher 13 so as to recover a crumb of the breadcrumb type at the outlet. The cut pie bottoms 3 are optionally sorted by means of a sorter 18 in the case where the cutters 10 equipping the station 16 cutting allow the cutting of two types of pie shell size, in particular two types of diameter such as a diameter of 25 cm and a diameter of 30 cm. The tart bases 3 thus obtained can then be packaged.

To optimize the packaging, immediately after cutting the tablecloth or sheet into several individual pieces respectively constituting a bottom 3 of pizza pie and before packaging, said pieces are still hot to avoid crusting or drying phenomena. . The stacked parts are then kept until cooled before packaging. For cooling, these stacks of parts are placed on any support, such as a trolley, and the assembly is filmed in order to keep the stacks of parts inside a closed enclosure during their cooling. Again, this step prevents any drying out of the products. Thus, immediately after cutting, the individual pieces which are still hot are stacked and then enclosed inside a delimited enclosure, for example by means of a film, until cooling to a temperature generally close to 5 ° C., at which the packaging itself can take place. This step of stacking and imprisoning the products until they are cooled to a temperature generally close to 50 ° C. can be carried out in line, the stacks then being placed on a tray before being filmed and then cooled in a tunnel. . This step can also be carried out by interrupting the production line, the stacks of filmed products then being cooled in a cold room.

In a preferred embodiment of the invention, the bottom 3 of pizza pie is conditioned in the form of a stack. This stack can be stored inside a tray or directly coated with a film. The packaging can take place under vacuum inside an enclosure 17A or in a controlled atmosphere. These pie bottoms 3 can also be subjected to a freezing or deep-freezing step. Vacuum packaging keeps the tart bases in the fridge for several weeks. Once the packaging has been opened, the bottoms 3 can still, after opening, keep for several days. In the case where the tart bases 3 are simply coated with a film, the shelf life of such tart bases is of the order of 5 to 6 days. It is also possible, in an equivalent manner, to condition the tart bases individually. In this case, a part is extracted from the stack of parts 3 produced after cutting, which is conditioned alone or in combination with ingredients used to garnish the bottom.

For the subsequent manufacture of pizza or similar products such as flambé pie, it will suffice to coat the bottom 3 of pie with a filling and to cook the whole by means of a traditional pizza oven. This results in a lower investment in terms of equipment for the pizzerias. In fact, due to the production of these ready-to-fill pie bottoms 3, it is no longer necessary for pizzeria operators to have in particular kneading or kneading equipment for the dough. The preparation time of a pizza is considerably reduced since the bottom 3 of the pie is ready to garnish. Furthermore, due to the pre-baking and cutting, the entire base of the pie can be coated with a filling. It follows that such a pie shell allows the production of pizza without rim.

The installation allowing the implementation of the aforementioned process can be in accordance with that shown in the figures. Such an installation comprises, downstream of the shaping station 14, a station 15 for incomplete pre-baking of the sheet 2 followed by a station 16 for cutting the sheet in the form of one or more individual pieces respectively constituting a bottom 3 of pizza pie and a station 17 for packaging the part or parts from the cutting station.

The shaping station 14 is thus equipped with two successive rolling mills 6 made up of rotary rollers or cylinders positioned above at least one conveyor belt. As mentioned above, a device 7 for reorienting the lowering between the first rolling mill 6 and the second rolling mill 6 can be provided. It allows the longitudinal axis of the lowering to be offset by 90 ° relative to the longitudinal axis of the conveyor belt 5. These means of orientation may be formed by the cooperation and the particular positioning of two conveyor belts forming an angle between them or by a pivoting flap capable of reorienting the lower formed at the outlet of the first rolling mill 6.

The incomplete pre-cooking station 15 is itself equipped with a conveyor belt 8 scrolling inside a cooking tunnel 9, heated to a temperature between 170 ° C. and 350 ° C., preferably close 300 ° C. The conveyor belt 8 may have heating means independent of those of the enclosure of the tunnel 9. These heating means may for example consist of electrical resistances heating refractory materials or metal plates constituting the transport surface of the belt 8 conveyor.

The cutting station 16 is itself made up of a conveyor belt 19 surmounted by die cutting organs 10 animated by an upward and downward movement controlled in synchronism with the rate of removal of at at least one sheet 2 of pizza dough partially pre-cooked on the conveyor belt 19. As mentioned above, these cutting members 10 may further comprise radially a knife 10A capable of cutting the drop strip 11 arranged around the cut pie bottom so as to allow the opening of said strip, facilitating its gripping by means of a member 10B for any sampling such as a needle or a clamp, then in positioning this drop 11 on a conveyor belt bringing said drop to an enclosure 12 for cooking the scraps, this enclosure 12 for cooking the scraps being followed by 'a grinding device 13. The product obtained is in the form of a ground breadcrumb type. Consequently, the cutting station further comprises means for separating off the scraps from the cutting and for transferring the scraps to a scraps processing station, this scraps processing station 11 being constituted by a cooking chamber 12 followed by of a grinding device 13.

The tart bases 3 are, after cutting, packaged. The packaging station 17 is a function of the packaging mode selected. Contrary to what is illustrated in the figures, there may be an interruption of the production line between the cutting station 16 and the packaging station 17. This interruption has not been shown for reasons of simplification. Indeed, in general, and as mentioned above, the still hot products from the cutting station 16 are stacked and then generally placed on a carriage which is filmed to conserve the humidity inside the enclosure thus formed. . Once cooled, the products are finally packaged. The packaging station 17 can thus be made up of an installation 17A for evacuating the tart bases 3 stored in a stacked state or of a station for freezing these tart bases or else of a laying station. a film around the tart bases 3 obtained, these tart bases 3 then being packaged in a controlled atmosphere. The tart bottoms 3 are then stored, as a function of their packaging, in cold rooms brought to temperatures which depend on the packaging method chosen. Such tart bases are then ready to be filled. The operators in the pizzeria therefore simply have to eliminate or open the packaging, remove the bottom of the pie, garnish the entire surface of this bottom 3 with pie before proceeding to traditional cooking of the bottom 3 of the pie thus garnished. Normally, the cooking time will be slightly reduced compared to the cooking time of a pizza made with a raw pie shell. The preparation of a pizza can be done in a few minutes, the operations of spreading the dough and preparing the bottom of the pie are no longer necessary. In addition, the workstation for pizza preparation no longer needs to be cleaned as frequently because, at no time, chalking is necessary. This results in a simplification of the operator's work. Furthermore, the pie shell obtained being of very small thickness, generally between 1.5 and 2 mm, this results in a product appreciated by the consumer. Finally, the absence of a ledge or sidewalk makes it possible to consume the entire product. The dough used to make such a tart shell can be free of any preservative. The tart bottom obtained is a soft tart bottom, tasty and fragrant. This pie shell allows, because of its elasticity, the production of "calzone" type turnovers.

Claims

1. Process for the automated production of a base (3) of a pizza dough tart ready to fill with a raw pizza dough having previously risen, this process comprising at least one step of shaping the pizza dough under form of a tablecloth (2) or a sheet, characterized in that it consists, after shaping, of pre-baking the tablecloth (2) or sheet in an incomplete manner, of cutting the tablecloth (2) or sheet under form of one or more individual pieces respectively constituting a bottom (3) of pizza pie and to condition the said piece or pieces for subsequent filling and cooking.

2. Method according to claim 1, characterized in that it consists, immediately after cutting the tablecloth or sheet in several individual pieces respectively constituting a bottom (3) of pizza pie, stacking said pieces still hot in sight avoid crusting or drying phenomena and the parts are kept in a stacked state until cooling before packaging.

3. Method according to one of claims 1 and 2, characterized in that the incomplete pre-cooking step is carried out at a temperature in the range 170 - 350 ° C for a period of time between 5 and 60 seconds, preferably between 20 and 40 seconds.

4. Method according to one of claims 1 to 3, characterized in that each sheet (2) is shaped, by rolling, from a dough piece (1) running on at least one carpet (4, 5) of conveying, until a sheet (2) of thickness between 1 and 3 mm, preferably between 1, 5 and 2 mm, is obtained.

5. Method according to one of claims 1 to 4, characterized in that during the shaping step, each mass of dough of the dough type (1) positioned on at least one conveyor belt (4, 5) for two successive rolling operations and in that, between two rolling operations, the dough resulting from the first rolling operation is oriented transversely to said conveyor belt in order to carry out a second rolling of the roll in a direction substantially perpendicular to the direction of the first rolling.

6. Method according to one of claims 1 to 5, characterized in that the web (2) coming from the shaping step is directly deposited on a heated conveyor belt (8) scrolling inside a pre-cooking tunnel (9).

7. Method according to one of claims 1 to 6, characterized in that, after cutting, generally with a cookie cutter, in the sheet (2), of each piece (3) constituting a pie shell pizza, the scraps (11) from the cut are collected and subjected to a new cooking process before grinding so as to form a breadcrumb type.

8. Method according to one of claims 1 to 7, characterized in that, prior to the shaping step, the ingredients necessary for the preparation of a pizza dough are subjected to kneading or kneading, in that the dough is divided into the form of a plurality of calibrated dough pieces (1) which are left to rise before shaping.

9. Method according to one of claims 1 to 8, characterized in that conditions, preferably under a controlled atmosphere, the funds (3) of pizza pie in the form of a stack.

10. Installation for the automated production of bottom (3) of pizza dough base ready to fill of the type comprising at least one station (14) for shaping pizza dough in the form of a tablecloth (2) or d '' a sheet, characterized in that it comprises, downstream of said shaping station (14), a station (15) for incomplete pre-baking of the web (2), followed by a station (16) for cutting the tablecloth (2) in the form of one or more individual pieces respectively constituting a bottom (3) of pizza pie and a station (17) for packaging the said piece or pieces from the cutting station for garnishing and subsequent cooking.

11. Installation according to claim 10, characterized in that the pre-baking station (15) is equipped with a conveyor belt (8) scrolling inside a tunnel (9) for incomplete pre-baking, heated to a temperature between 170 ° C and 350 ° C.

12. Installation according to one of claims 10 and 11, characterized in that the station (16) for cutting consists of a conveyor belt (19) surmounted by organs (10) for cutting with a punch. animated by an upward and downward movement controlled in synchronism with the rate of deposition of at least one sheet (2) of pizza dough partially pre-cooked on said mat (19).

13. Installation according to claim 12, characterized in that the cutting station (16) further comprises means (10A, 10B) for separating the scraps (11) from the cutting and transferring the scraps (11) to a fall treatment station.

14. Installation according to claim 13, characterized in that the waste treatment station consists of an enclosure (12) for cooking the waste followed by a device (13) for grinding.

15. Base (3) of pie in the form of a pizza dough ready to fill, characterized in that it is in the form of a sheet of pizza dough, free of rim, partially pre-cooked and cut after precooking.