Method of making pizza with a pizza toppings disk

A pizza toppings disk as well as a method of making a pizza toppings disk and a method of making a pizza using a toppings disk are disclosed. In accordance with the present invention a pizza toppings disk is made by combining a quantity of cheese with a plurality of pizza toppings that may include but are not limited to the following items: sliced meats, ground meats, and vegetables, as well as combinations thereof. The quantity of cheese and selected pizza toppings are combined into a layer that is appropriately shaped to be placed on a pizza shell. The cheese and the selected pizza toppings are fused together to form a pizza toppings disk that may be stored for subsequent use in assembling a pizza. In making a pizza in accordance with the present invention a pizza toppings disk is placed on a uncooked pizza shell and the pizza toppings disk and uncooked pizza shell are then baked to produce a cooked pizza.

BACKGROUND OF THE INVENTION 
The present invention relates to the field of pizzas and pizza toppings. 
More particularly, the invention relates to methods of assembling pizza 
ingredients to form pizzas. 
The preparation and cooking of pizzas in the food industry requires 
numerous labor intensive steps. For example, pizza dough is prepared and 
formed into a shell. Also, the cheese and pizza toppings are applied to 
the shell one at a time. In addition, in a pizza restaurant delivery 
and/or carryout business each ingredient that is added as a topping is 
typically measured or weighed to insure uniformity of the finished 
product. Naturally, these several steps add to the cost and the time it 
takes to prepare the products. 
Assuring uniformity of pizzas made by different employees can also be a 
challenge for the pizza restaurant, delivery, and/or carryout business. 
Products and methods have been developed attempting to reduce the cost and 
increase the speed and uniformity of preparing pizzas. 
For instance, U.S. Pat. No. 4,159,349 to Caiello discloses a pizza and 
method for making the same that includes using up to four geometrically 
congruent slices of pizza cheese having apertures. The slices are arranged 
to form one layer to cover the pizza shell. 
U.S. Pat. No. 4,066,769 to McKee discloses a pizza coating product 
containing a water-soluble algin, preferably for use with a frozen pizza. 
The water-soluble algin is applied to the surface of the pizza dough that 
forms the pizza crust prior to the addition of any toppings or tomato 
sauce. 
U.S. Pat. No. 4,753,815 to Kielsmeier, et al., discloses a method of 
preparing and quick freezing cheese in granular form to maintain granule 
moisture. The cheese granules are then baked on the pizza in a frozen or 
partially frozen condition. 
U.S. Pat. No. 4,283,431 to Giordano, et al., discloses a method of making a 
double-layered pizza product. The method disclosed uses two layers of 
pastry dough with traditional pizza toppings placed in between the pastry 
layers before baking the pizza. 
SUMMARY OF THE INVENTION 
Briefly stated, the present invention is a pizza toppings disk, as well as 
a method of making a pizza toppings disk, and a method of making a pizza 
using a pizza toppings disk. 
In accordance with the present invention a pizza is made by combining a 
quantity of cheese with a plurality of pizza toppings that may include but 
are not limited to the following items: sliced meats, ground meats, or 
vegetables, as well as combinations thereof. The quantity of cheese and 
selected pizza toppings are combined into a layer that is appropriately 
shaped to be placed on a pizza shell. The cheese and the selected pizza 
toppings are fused together to form a pizza toppings disk that is stored 
for subsequent use in assembling a pizza. A pizza shell is provided and an 
uncooked pizza is formed by assembling the pizza toppings disk and the 
pizza shell. The toppings disk and the shell are then baked to provide a 
pizza. 
In a preferred embodiment of the present invention a quantity of cheese is 
distributed over a forming surface to form a layer of cheese. Applied on 
top of this layer of cheese are selected amounts of typically requested 
pizza toppings. The layer of cheese and the selected pizza toppings are 
then fused together to form a pizza toppings disk that is stored for 
subsequent use in assembling a pizza. 
In a more preferred embodiment of the present invention, a second quantity 
of cheese is distributed on top of a first layer of cheese and selected 
pizza toppings to form a second layer of cheese. The layers of cheese and 
the pizza toppings are then fused together to form a pizza toppings disk. 
The toppings disk may then be stored for subsequent use. 
In a most preferred embodiment of the present invention a third quantity of 
cheese is mixed with the selected plurality of pizza toppings prior to 
applying these toppings to a first layer of cheese. 
In making a pizza in accordance with the present invention a pizza shell is 
provided. An uncooked pizza is formed by assembling the toppings disk and 
the pizza shell. The toppings disk and pizza shell are then baked to 
provide a pizza. 
The present invention offers several advantages for a pizza restaurant, 
delivery and/or carryout business. Some advantages include convenience, 
better uniformity of pizzas made by different employees, and closer 
control over the final product because a pizza toppings disk can be made 
prior to when a pizza is ordered. Pizza toppings disks can be made during 
off peak hours and stored for subsequent use. By making a pizza toppings 
disk in advance, each ingredient may be weighed and measured more 
carefully during these off peak hours then is permitted during hours when 
demand for pizzas is high. 
Additionally, the present invention can reduce the amount of time required 
to prepare a pizza. When an order for a pizza is received the pizza can be 
assembled more quickly by using a pizza toppings disk that has been 
prepared in advance, than by using the present traditional methods of 
making a pizza. 
Optionally, another advantage offered by the present invention is that 
pizza restaurants, deliveries and/or carry out businesses may prepare or 
receive pizza toppings disks that have been prepared at a centralized 
location. Preparing the topping disks at a centralized location can reduce 
the preparation space necessary to make an assembled pizza on site at 
these businesses. 
The present invention, together with its attendant objects and advantages, 
will be best understood with reference to the detailed description below 
read in conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
In accordance with the present invention, the pizza toppings disk 10 of 
FIG. 1 is made by combining one or more quantities of cheese with a 
plurality of pizza toppings that may include one or more of the following 
selected items: sliced meats, ground meats, or vegetables, as well as 
combinations thereof. 
In general, any type of cheese appropriate for a pizza is used to make a 
pizza toppings disk of the present invention. Preferably cheeses which 
melt evenly and do not separate upon heating are used to form a toppings 
disk. More preferably low moisture part-skim mozzarella cheese is used. 
The cheeses used to make a pizza toppings disk of the present invention are 
preferably in the form of shredded or sliced cheeses. Shredded cheeses 
used may be of a powder consistency. Spices may be added to the cheeses 
used to form a pizza toppings disk. Such spices may include but are not 
limited to the following: oregano, italian seasoning, garlic, basil, salt 
or pepper, as well as combinations thereof. 
The amounts of the total specified quantity of cheeses to be used and the 
amounts of the selected pizza toppings to be applied vary according to the 
size and type of pizza toppings disk desired. Typically, the total 
quantity of cheese used amounts to between approximately 30% and 90% of 
the total weight of a pizza toppings disk. 
The cheese is combined with selected amounts of typically requested pizza 
toppings and is distributed as a layer on a forming surface. This layer is 
appropriately shaped to be placed on top of a pizza shell. The layer may 
be shaped by dispensing the quantity of cheese combined with the selected 
pizza toppings over a forming surface having the desired diameter of a 
finished toppings disk. Generally, the forming surface can be any flat 
surface, such as the surface of a flat conveyor belt or make table. 
Typically, the forming surface used may be one of the following surfaces: 
pans, paper, ring, mold, or similar items. Preferably the forming surface 
is made of parchment paper. 
The pizza toppings of the present invention may include but are not limited 
to selections from the following group of items: sliced meats, ground 
meats, or vegetables, as well as combinations thereof. Optionally the 
selected toppings may be pre-cooked prior to forming a toppings disk. 
Preferably, the amounts of a selected pizza topping are premeasured for 
the desired disk size and evenly distributed over the surface area of the 
pizza toppings disk. Amounts of the pizza toppings combined with the total 
specified quantity of cheese may vary according to the size and type of 
pizza toppings disk desired. Optionally, the pizza toppings disk may be 
customized to certain topping types by combining an individual pizza 
topping or a combination of pizza toppings with the total specified 
quantity of cheese. Additionally, a combination of one or more toppings 
disks may be utilized for assembling a single pizza. 
The present invention includes several embodiments for providing a pizza 
toppings disk. Generally, these embodiments include distributing one or 
more quantities of cheese over a forming surface and forming these 
quantities of cheese into one or more layers of cheese. The selected pizza 
toppings are also distributed as a layer. The components are then fused 
together to form a pizza toppings disk that is stored for subsequent use 
in assembling a pizza. 
In a preferred embodiment of the present invention a quantity of cheese is 
distributed over the forming surface to form a layer of cheese. Applied on 
top of this layer of cheese are selected amounts of typically requested 
pizza toppings. 
In a more preferred embodiment of the present invention, a first quantity 
of cheese is formed into a first layer of cheese on a forming surface. In 
accordance with this preferred embodiment between approximately 20% and 
approximately 80% of the total specified quantity of cheese of the 
toppings disk is distributed on the forming surface to form the first 
layer of cheese. Applied on top of this layer of cheese are the selected 
amounts of typically requested pizza toppings. A second quantity of cheese 
is evenly dispensed over the first layer of cheese and the selected pizza 
toppings to form a second layer of cheese. Typically this second layer of 
cheese consists of between approximately 20% and approximately 80% of the 
total specified quantity of cheese for the toppings disk. 
In the most preferred embodiment of the present invention, as shown in FIG. 
2, a first quantity of cheese is formed into a first layer of cheese 14 on 
a forming surface 16. Typically between approximately 35% and 
approximately 45% of the total specified quantity of cheese in this most 
preferred embodiment is distributed on the forming surface 16 to form the 
first layer of cheese 14. Prior to the application of selected amounts of 
typically requested pizza toppings a portion of the total specified 
quantity of cheese is combined with these selected pizza toppings. This 
combination of cheese and selected pizza toppings is depicted in FIG. 2 as 
reference numeral 18. The combination 18 of cheese and selected pizza 
toppings is deposited onto the first layer of cheese 14. In this most 
preferred embodiment, between approximately 10% and approximately 20% of 
the total specified quantity of cheese is included in the combination 18 
of cheese and pizza toppings. In accordance with this most preferred 
embodiment, a second quantity of cheese is evenly dispensed over the first 
layer 14 of cheese and the combination 18 of cheese and selected toppings. 
The second quantity of cheese is dispensed to form a second layer of 
cheese 20. In this most preferred embodiment, the second layer of cheese 
20 consists of between approximately 35% and approximately 45% of the 
total specified quantity of cheese for a pizza toppings disk. 
In accordance with the present invention, the total specified quantity of 
cheese and the selected pizza toppings are fused together to form a pizza 
toppings disk that may be stored for subsequent use. The total quantity of 
cheese and selected pizza toppings may be fused together by one of the 
following methods: chemical, mechanical, or thermal methods. Examples of 
such methods include but are not limited to partially melting the cheese; 
applying a vacuum; applying a pressure such as a roller press; applying a 
food safe adhesive such as gums, pectines, gelatins, or an edible film; or 
applying a food safe shrink wrap or a spray wrap. 
Preferably the total quantity of cheese and the selected pizza toppings are 
fused together by heating. In accordance with such a method, the 
components are subjected to a partial, minimal melt. The temperature 
necessary to accomplish this minimal melt may vary depending on the type 
of cheese used and the type of heating element employed. When the 
preferred cheese, low moisture part-skim mozzarella is used, the 
temperature at which a partial, minimal melt is achieved is approximately 
425.degree. F. The amount of time required to achieve a partial minimal 
melt varies according to the following factors: the selected heating 
temperature, the individual pizza toppings chosen, and the final size 
desired for the toppings disk. 
Under the preferred fusing method, a pizza toppings disk of the present 
invention may be increased in size by applying unmelted cheese, in a 
concentric circle, to the existing fused toppings disk and repeating 
partial, minimal melts as necessary. 
After fusing, a pizza toppings disk of the present invention may be stored 
for subsequent use in assembling a pizza. Preferably, the pizza toppings 
disk is stored under refrigeration without being frozen prior to being 
used in assembling a pizza. Optionally, the pizza toppings disk may be 
frozen for a more prolonged storage prior to being used in assembling a 
pizza. 
Referring now to FIG. 3, a pizza toppings disk 10 is most preferably used 
in assembling a pizza. Optionally, a pizza toppings disk of the present 
invention may be placed onto the uncooked shell of any size or type of 
pizza. Examples of such shells may include but are not limited to pizza 
shells for a hand-tossed traditional crust, a pan-style pizza, a 
thin-crust style pizza, or a double-crust style pizza. These styles of 
pizzas are well known in the art. In accordance with the present invention 
an uncooked shell is intended to include "par baked" shells which are 
shells that are partially baked, completely unbaked shells, or any shell 
that is frozen. Optionally, a fully baked shell or fully baked shell 
frozen in advance, may be used in assembling a pizza. 
As illustrated in FIG. 3, The toppings disk 10 is removed from storage and 
is placed on top of an uncooked pizza shell 26. The pizza toppings disk 
and uncooked pizza shell are then baked to produce a cooked pizza 28, as 
illustrated in FIG. 4. Baking may include the use of a microwave to 
produce the cooked pizza 28. Preferably tomato sauce or traditional pizza 
sauce is applied between the toppings disk and the pizza shell. 
The process of making the present invention may be automated. Automating 
the process can reduce labor and overhead expenses. The process may be 
automated by use of a conveyor means. Typically the conveyor is loaded 
with forming surfaces and the cheese and selected pizza toppings are 
dispensed automatically onto the forming surfaces. The components are then 
fused to form a toppings disk of the present invention. The toppings disk 
is then stored for subsequent use in assembling a pizza. 
Optionally, under the present invention, pizza toppings disks may be 
prepared at a central location and then shipped to individual pizza 
restaurants, deliveries, and/or carryout businesses. Making the toppings 
disks of the present invention at a centralized location can reduce 
overhead expenses. 
EXAMPLES 
The following examples and tables, set forth below for purposes of 
illustration and description, further describe and illustrate a variety of 
pizza toppings disks made in accordance with the present invention. These 
examples and tables are not intended to be exhaustive or to limit the 
invention to the precise forms disclosed. 
TABLE I illustrates by way of example the amounts of cheese and selected 
pizza toppings necessary for a variety of pizza toppings disks. 
TABLE 1 
______________________________________ 
PIZZA TOTAL QUAN- SELECTED TOPPINGS 
TOPPINGS TITY OF AND QUANTITIES 
DISK TYPE CHEESES (ounces) 
(ounces) 
______________________________________ 
SUPREME 7-8 oz. low Sliced meats 1-2 oz. 
moisture part- 
Ground meats 2-4 oz. 
skim mozzarella 
Vegetables 1-3 oz. 
PEPPERONI 3.5-4.5 oz. low 
Sliced meats 2-3 oz. 
moisture part- 
skim mozzarella 
VEGETABLE 3.5-4.5 oz. low 
Vegetables 7-9 oz. 
moisture part- 
skim mozzarella 
______________________________________ 
A SUPREME pizza is a pizza consisting of a plurality of pizza toppings. The 
typical pizza toppings placed on a SUPREME pizza include sliced meats such 
as pepperoni, ground meats such as sausage, and a variety of vegetables. 
In assembling a pizza toppings disk for a SUPREME pizza in accordance with 
the most preferred embodiment of the present invention, between 35% and 
45% of the total quantity of cheese specified is evenly distributed on a 
forming surface having the desired diameter of the finished disk. This 
first quantity of cheese is formed into a first layer of cheese. Sliced 
meats are placed over this layer. Between 10% and 20% of the total 
quantity of cheese used is mixed with vegetables and ground meats and 
deposited onto the first layer of cheese. A second quantity of cheese 
consisting of between 35% and 45% of the total quantity of cheese used in 
a SUPREME pizza is then deposited onto the previous layer of cheese and 
layer of selected pizza toppings to form a second layer of cheese. The 
components are then fused to form a pizza toppings disk. 
The other examples of various pizzas set forth in TABLE I are made in the 
same manner as described above. However the total quantities of cheese 
used and the pizza toppings selected and quantities thereof vary according 
to the amounts disclosed in TABLE I. 
TABLE II sets forth the corresponding preferred partial, minimal melt 
conditions of the preferred methods of fusing for the various toppings 
disks disclosed in TABLE I. 
TABLE II 
______________________________________ 
PIZZA TEMPERATURE TIME FOR 
TOPPINGS TIAL FOR TIAL 
DISK TYPE MELT (F.) MELT (minutes) 
______________________________________ 
SUPREME 425.degree. F. 
3.20 min. 
PEPPERONI 425.degree. F. 
2.50 min. 
VEGETABLE 425.degree. F. 
2.50 min. 
______________________________________ 
The toppings disks described above were used to assemble uncooked pizzas as 
follows: the pizza toppings disks were placed on top of uncooked pizza 
shells, and pizza sauce was applied between the toppings disks and the 
pizza shells. The pizza toppings disks and uncooked pizza shells were then 
baked to produce cooked pizzas. The appearance and texture of the cooked 
pizzas were the same as that of pizzas prepared by traditional methods. 
The foregoing description of the preferred embodiments of the present 
invention has been presented for purposes of illustration and description. 
They are not intended to be exhaustive or to limit the invention to the 
precise forms disclosed, and obviously many modifications and variations 
are possible in light of the above teachings. The embodiments were chosen 
and described in order to best explain the principles of the invention and 
various embodiments and with various modifications as are suited to the 
particular use contemplated. It is intended that the scope of the 
invention be defined by the following claims, including all equivalents.