Apparatus for making a pizza topping disk

An apparatus for making a pizza toppings disk is disclosed. An apparatus, made in accordance with the present invention includes a conveyor means for transporting forming surfaces, and a plurality of depositing means for depositing onto forming surfaces a quantity of cheese and 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. A fusing means is also included which fuses the quantity of cheese and plurality of pizza toppings to form a pizza toppings disk that may be frozen for storage and subsequent use in assembling a pizza.

BACKGROUND OF THE INVENTION 
The present invention relates to the field of pizzas and pizza toppings. 
More particularly, the invention relates to methods and apparatus for 
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. In 
addition, lack of uniformity affects cost control. Even small additional 
amounts of ingredients over the specified quantity add up over time to 
large additional expenses for a 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 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. 4,753,8I5 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 provides an apparatus for making a 
pizza toppings disk. 
In one aspect, the present invention is an apparatus for depositing onto 
forming surfaces a quantity of cheese and 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 the plurality of pizza toppings are deposited onto a 
conveyor having a forming surface. A fusing means fuses the quantity of 
cheese and plurality of pizza toppings 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 conveyor means 
transports a plurality of forming surfaces under a plurality of depositing 
means. The depositing means deposit cheeses and selected amounts of 
typically requested pizza toppings onto the forming surfaces. As the 
components of cheese and typically requested pizza toppings are deposited 
onto the forming surfaces from the depositing means they cascade through a 
template conveyor means. The template conveyor means is configured such 
that as the components fall onto the forming surfaces a specific pattern 
is formed. The components are then fused together to form a pizza toppings 
disk that is frozen for storage and subsequent use in assembling a pizza. 
In another preferred embodiment of the present invention a quantity of 
cheese is deposited onto a forming surface to form a layer of cheese. 
Deposited on top of this layer of cheese are selected amounts of typically 
requested pizza toppings. The layer of cheese and the selected pizza 
toppings fall through a template conveyor means and form a specific 
pattern on the forming surfaces as they are deposited. The components are 
then fused together to form a pizza toppings disk that is frozen for 
storage and subsequent use in assembling a pizza. 
In a more preferred embodiment of the present invention, a second quantity 
of cheese is deposited 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 deposited from a depositing means through a 
template conveyor means such that a specific pattern is formed as they are 
deposited on the forming surfaces. The components are then fused together 
to form a pizza toppings disk. The toppings disk is frozen for storage and 
subsequent use. 
In another preferred embodiment of the present invention a sliced meat 
depositing means deposits on the forming surfaces a quantity of sliced 
meats. The sliced meats deposited are deposited in a predetermined pattern 
on the forming surfaces. 
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 greater cost 
control, increased labor savings, 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 at a centralized location. 
Preparing the toppings disks at a centralized location can reduce the 
preparation space necessary to make an assembled pizza on site at pizza 
restaurants, deliveries and/or carry out businesses. 
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. 
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, an apparatus for making a pizza 
toppings disk includes generally a conveyor means, at least one forming 
surface, at least one depositing means, a fusing means, and a freezing 
means, wherein the components of the pizza toppings disk are deposited 
from at least one depositing means onto a forming surface as the forming 
surface travels along a conveyor or automated traveling means to a fusing 
means, where the components are then fused together to form a pizza 
toppings disk that is stored for subsequent use in assembling a pizza. 
Typically, a pizza toppings disk 10 of FIG. 1 is 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. 1, a toppings disk 10, made in accordance with 
present invention, is removed from storage and is placed on top of an 
uncooked pizza shell 20. The pizza toppings disk and uncooked pizza shell 
are then baked to produce a cooked pizza 25, as illustrated in FIG. 1a. 
Baking may include the use of a microwave to produce the cooked pizza 25. 
Preferably tomato sauce or traditional pizza sauce is applied between the 
toppings disk and the pizza shell. 
Automating the process of making a pizza toppings disk reduces labor and 
overhead expenses and results in cost control savings. In a preferred 
embodiment of the present invention, the apparatus for automating the 
process of making a pizza toppings disk includes a conveyor means which 
transport forming surfaces, a depositing means from which cheese and 
selected pizza toppings are deposited automatically onto the forming 
surfaces as they travel on the conveyor means, a fusing means which fuses 
the components to form a toppings disk, an a freezing means for freezing 
the toppings disk for storage and subsequent use in assembling a pizza. 
In a preferred embodiment, the apparatus for making a pizza toppings disk 
includes a conveyor which continuously transports a forming surface. At 
predetermined intervals a depositing means deposits a quantity of cheese 
onto the forming surface to form a first layer of cheese. The forming 
surface continues along the conveyor or other automated traveling surface 
to a second depositing means where selected amounts of typically requested 
pizza toppings are deposited onto the layer of cheese and the forming 
surface. The forming surface with the first layer of cheese and the layer 
of selected pizza toppings continues along the conveyor to a fusing means 
where the quantity of cheese and selected pizza toppings are fused 
together to form a pizza toppings disk. A freezing means freezes the fused 
pizza toppings disk which then may be stored for subsequent use in 
assembling a pizza. 
In another preferred embodiment, a forming surface is placed on a conveyor 
means or other automated traveling means. Preferably, the forming surface 
has the profile shape and diameter of the desired finished toppings disk. 
Generally, the forming surface placed on the conveyor can be any flat 
surface, such as the following surfaces: pans, paper, ring, mold, 
plastics, metallic materials or similar items. Optionally, the conveyor 
belt may be used as the forming surface. Preferably, the forming surface 
is made of parchment paper having a high tensile strength and a flash 
point that is greater than 500.degree. F. More preferably, the forming 
surface is coated with a mixture of vegetable oil and silicon. The mixture 
aids in better separation of the forming surfaces from various finished 
pizza toppings disk combinations. Optionally, other materials having a 
slick surface may be used as forming surfaces. The forming surfaces may be 
delivered to the conveyor means or other automated means by a standard 
paper carrier such as the type manufactured by The James River Co. of 
Virginia. The forming surfaces are arranged on the conveyor means in a 
single file with a predetermined spacing between surfaces. 
In a preferred embodiment, the forming surfaces are transported by a 
conveyor or other automated traveling means under a depositing means where 
a quantity of cheese or a selected quantity of a typically requested pizza 
topping is deposited onto the forming surface in a shape substantially 
similar to that of the forming surface. Preferably, the component is 
deposited onto the forming surface in a manner wherein the component falls 
onto the forming surface and forms a specific shape on the forming 
surface. More preferably, a quantity of cheese is used as the first 
component to be deposited onto the forming surface and forms a first layer 
of cheese on the forming surface when deposited. 
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. Optionally, the total quantity 
of cheese used may amount to approximately 100% of the total weight of a 
pizza toppings disk if a "cheese only" toppings disk is desired. 
In accordance with the present invention, upon depositing the first 
component onto the forming surface, the forming surface is transported 
through a plurality of depositing means wherein a quantity of cheese or 
other edible binding agent and typically requested pizza toppings are 
deposited onto the first component. The pizza toppings which are deposited 
may include, but are not limited to, the following items: sliced meats, 
ground meats, or vegetables as well as combinations thereof. 
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. 
Preferably a quantity of cheese or other edible binding agent is deposited 
as the first component on the forming surface to form a first layer of 
cheese. Preferably, deposited on top of this first quantity of cheese are 
one or more typically requested pizza toppings, depending on the finished 
toppings disk desired. Upon depositing the selected pizza toppings, an 
additional amount of cheese or other binding agent is deposited onto the 
toppings. 
In a more preferred embodiment of the present invention, a first quantity 
of cheese is deposited as 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 deposited on the forming surface to form the first layer 
of cheese. Deposited on top of this layer of cheese are selected amounts 
of typically requested pizza toppings. A second quantity of cheese is 
evenly deposited 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 another more preferred embodiment of the present invention, a first 
quantity of cheese is deposited as a first layer of cheese on a forming 
surface. Typically between approximately 35% and approximately 45% of the 
total specified quantity of cheese in this more preferred embodiment is 
deposited on the forming surface to form the first layer of cheese. 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. The combination of cheese and selected 
pizza toppings is deposited onto the first layer of cheese. In this more 
preferred embodiment, between approximately 10% and approximately 20% of 
the total specified quantity of cheese is included in the combination of 
cheese and pizza toppings. In accordance with this more preferred 
embodiment, a second quantity of cheese is evenly dispensed over the first 
layer of cheese and the combination of cheese and selected toppings. The 
second quantity of cheese is dispensed to form a second layer of cheese. 
In this more preferred embodiment, the second layer of cheese consists of 
between approximately 35% and approximately 45% of the total specified 
quantity of cheese for a pizza toppings disk. 
A preferred means for depositing the components of a toppings disk is a 
waterfall depositing means. A waterfall depositing means, made in 
accordance with the present invention incorporates a unique template 
conveyor means. The template conveyor means enables the components of the 
toppings disk to be deposited onto the forming surface in a specific shape 
while recycling excess amounts. The template conveyor means removes excess 
collected amounts of the binding agent to a reclaim feed system that 
resupplies the waterfall depositing means. 
Preferably, the template conveyor means is configured and shaped to deposit 
the desired amount of a component onto the forming surface in a 
predetermined profile. Preferably, the template conveyor means is 
configured and shaped such that the component being deposited falls onto 
the forming surface and forms a specific shape on the forming surface 
which thereby avoids having to recycle excess amounts. Preferably, the 
template conveyor is configured such that a loop having a series of 
templates is formed which encompasses the automated traveling means upon 
which the forming surfaces are transported. Additionally, the template 
conveyor includes a drive means which synchronizes each individual 
template with a forming surface such that the template travels a 
predetermined distance above and is in synchronized correspondence with a 
forming surface. 
Another preferred means for depositing the components of a toppings disk is 
a weighbelt depositing means. This preferred depositing means is also 
designed and configured to incorporate a template conveyor means which is 
substantially similar to the template conveyor means described above. The 
weighbelt depositing means and template conveyor means will be described 
in greater detail in connection with FIGS. 4 and 5. 
Once all the components are deposited on the forming surface, they are 
transported along the conveyor or automated traveling means to a fusing 
means. The fusing means fuses the components together to thereby form a 
pizza toppings disk. 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 and an impingement of steam air. In accordance 
with such a method, the components are subjected to a partial, minimal 
melt. The temperature and amount of humidity necessary to accomplish this 
minimal melt may vary depending on the type of cheese used and the type of 
heating element employed. The amount of time required to achieve a partial 
minimal melt varies according to the following factors: the selected 
heating temperature, the percentage of humidity, the individual pizza 
toppings chosen, and the final size desired for the toppings disk. 
Once fused together, the pizza toppings disk is transported to a freezing 
means where the temperature of the disk is cooled until frozen. Preferably 
the disk is frozen for use at a subsequent date in assembling a pizza. 
Optionally, the pizza toppings disk is stored under refrigeration without 
being frozen prior to being used in assembling a pizza. 
Referring now to FIGS. 2 and 3, a more preferred embodiment 100 of the 
apparatus for making a pizza toppings disk is illustrated. In this 
preferred embodiment 100, the forming surfaces 135 are fed from a 
continuous unwind source 130 onto an automated conveyor belt 140. 
preferably, the forming surfaces are constructed from paper 132 having a 
high tensile strength and a flash point greater than approximately 
300.degree. F. More preferably, the forming surfaces 135 have a flash 
point greater than approximately 500.degree. F. The paper 132 is guided in 
roll form from the unwind source 130 to the conveyor belt 140, which is 
traveling between approximately 45 feet per minute to 110 feet per minute. 
As the paper 132 is guided to the conveyor belt 140 it is sheared into 
individual segments or forming surfaces 135. Preferably, the forming 
surfaces 135 are coated with a mixture of vegetable oil and silicon. The 
coating aids in separating the various finished toppings disks from the 
forming surface. Preferably, the forming surfaces 135 are arranged in 
single file at predetermined space intervals on the conveyor belt 140. 
Optionally, plastic, metallic, and other materials may be used as forming 
surfaces in place of paper. In addition, the conveyor belt 140 may be 
configured to incorporate internal forming surfaces within the traveling 
means. 
The forming surface 135 is transported along the conveyor means 140 to a 
depositing means 150. The depositing means 150 deposits layer of a 
selected component onto the forming surface 135 to form a base layer upon 
which additional components of the pizza toppings disk are deposited. 
Preferably, the depositing means 150 is configured to deposit the correct 
specification of shape, volume, and density of the pizza toppings disk 
component within a predetermined profile space in a continuous manner. 
Preferably, the depositing means is used in conjunction with a template 
conveyor means 160 which is synchronized to deposit the components of a 
pizza toppings disk onto the forming surfaces 135 in a predetermined 
profile shape. The depositing means 150 and template conveyor means 160 
will be described in greater detail with respect to FIGS. 4 and 5. 
In a preferred embodiment of the present invention, the base layer upon 
which the additional pizza toppings components are deposited is formed of 
cheese or another similar edible binding agent. Preferably, the cheese is 
deposited in a continuous flow onto the forming surface 135 to for a base 
layer. More preferably, pre-shredded frozen mozzarella or other typical 
pizza cheese is deposited. 
Upon depositing a base layer of a selected component, the forming surface 
135 is then transported along the conveyor 140 to a check weighing means 
170. Preferably, the check weighing means 170 checks the amount of the 
first component deposited by the depositing means 150. The check weighing 
means 170 aids in regulating the performance of the depositing means 150. 
Additionally, the check weighing means 170 is capable of discharging and 
reclaiming amounts of the deposited component which are not within the 
specification desired for the finished pizza toppings disk. Preferably, 
the forming surfaces are presented to the check weighing means 170 in a 
single file manner. Preferably, the check weighing means 170 is a standard 
in line high speed check weighing system of the type manufactured by 
Hi-Check Weigher Company of Ithaca, New York. 
From the check weighing means 170, the forming surface 135 and the first 
deposited component are transported to a depositing means designed to 
deposit sliced meats in a specific predetermined pattern. The sliced meats 
depositing means 180 deposits components of the pizza toppings disk such 
as pepperoni in a predetermined pattern that corresponds to the size and 
shape of the first component deposited on the forming surface 135. 
Preferably, forming surfaces are presented to the sliced meats depositing 
means 180 in a single file manner. Preferably, a standard pizza 
manufacturer slicer such as the Pepp-o-matic, manufactured by Grote, Inc. 
of Ohio is used to deposit the sliced meats. 
Upon depositing the sliced meats on the forming surface 135 and the first 
deposited component, the forming surface is transported through a 
plurality of depositing means which are substantially similar to the 
depositing means 150 described previously. As the forming surface is 
guided through these depositing means, additional pizza toppings 
components are deposited. Preferably, typically requested pizza topping 
items such as vegetables and ground meats are deposited individually or in 
a combined mixture on top of the sliced meats. 
As illustrated in FIGS. 2 and 3, the forming surface 135 is transported 
through a plurality of depositing means 150 after traveling through the 
sliced meats depositing means. In the preferred embodiment illustrated in 
FIGS. 2 and 3 separate depositing means 150 are arranged to deposit the 
remaining components of the pizza toppings disk onto the forming surface 
135. Preferably the forming surface 135 is passed through a depositing 
means 150 for depositing vegetables and a depositing means 150 for 
depositing ground meats. Optionally, a single depositing means 150 may be 
used to deposit a preblended combination of ground meats and vegetables. 
Preferably, an additional depositing means 150 is used to deposit an 
additional layer of cheese or other binding agent. More preferably, the 
additional layer of cheese is deposited as the final pizza toppings disk 
component on the forming surface 135. 
Optionally, upon deposit of the various components of the pizza toppings 
disk, the forming surface 135 containing these components is guided 
through an inline metal detector 175. The metal detector 175 indicates if 
an individual forming surface contains an excessive amount of metal. If 
this occurs the contaminated forming surface is disposed of before 
continuing along the conveyor belt means 140. Preferably, an inline 
standard metal detector of the type known in the art is used which is able 
to detect particle size greater than accepted safety standards for the 
various types of pizza toppings disks. 
Preferably, as the forming surfaces 135 pass the metal detector 175 they 
are diverted from a single feed loading along the conveyor 140 to a triple 
feed loading before entering the fusing means 185. The triple feed loading 
provides a more efficient presentation of forming the surfaces as they 
enter the fusing means 185. Preferably a standard lane diverter 178 of the 
type known in the art is used. 
After being rearranged by the lane diverter 178 the forming surfaces 135 
containing the assembled components of a pizza toppings disk enter a 
fusing means 185. The fusing means 185 fuses together the selected pizza 
toppings and cheeses to form a pizza toppings disk. Preferably, the 
components are fused together by being subjected to a partial minimal melt 
combined with an impingement of steam, preferably, the impingement of 
steam is enough that a nominal amount of free standing water remains on 
the surface of the toppings disk as the disk exits the fusing means. The 
free standing water prevents dehydration of the components of the toppings 
disk during chilling and freezing. More preferably the forming surfaces 
135 and the assembled components are exposed to a temperature between 
approximately 100.degree. F. and 450.degree. F. with an impingement of 
steam having approximately 2% to 50% humidity for approximately 15 seconds 
to approximately 60 seconds. Most preferably, the forming surfaces 135 and 
assembled components are exposed to a temperature between approximately 
200.degree. F. and approximately 350.degree. F. with an impingement of 
steam having approximately 4% to approximately 10% for approximately 25 
seconds to approximately 40 seconds. In the preferred embodiment 
illustrated in FIGS. 2 and 3 the fusing means 185 is modular in design and 
has independent temperature, humidity, and air velocity controls. The 
modules of the fusing means are designed to meet the United States 
Department of Agriculture requirements. Preferably, the fusing means 185 
may be one of several models of high velocity convection ovens such as 
those manufactured by Stein Inc., of Sandusky, Ohio. 
Optionally, upon exiting the fusing means 185, the forming surfaces 135 and 
the fused toppings disks 110 are transported through a chilling means 190. 
The chilling means 190 chills the temperature of the fused toppings disks 
110 and sets the surface of the fused toppings disks prior to freezing. 
Preferably, a chilling means is used prior to freezing the fused toppings 
disks to prevent moisture transfer during the freezing process. In 
addition, chilling the fused toppings disks 110 prior to freezing aids in 
preventing surface deformation. Preferably, the fused toppings disks are 
subjected to an impingement of air containing carbon dioxide. More 
preferably, the fused toppings disks are exposed to an impingement of 
carbon dioxide for approximately 5 seconds to approximately 25 seconds as 
the fused toppings disks 110 are being transported. The amount of exposure 
time is dependant on the type of fused toppings disk and the rate of flow 
of the carbon dioxide. Preferably, an air-blast freezer or cryogenic 
freezer may be used as the chilling means 190. Optionally, alternative 
chilling means or prefreezing cool down options may be employed. A 
chilling means chamber may be used where the forming surfaces 135 and 
assembled components travel the length of a housing chamber in which 
ambient air is passed. 
Upon exiting the chilling means 190, or if no chilling means has been 
employed, upon being rearranged by the lane diverter 178, the fused 
toppings disks 110 are frozen. Prior to packaging, the fused toppings 
disks 110 pass through a freezing means 195. The fused toppings disks are 
frozen to allow for prolonged storage periods and to prevent bacterial 
growth. Preferably, a fast freezer or a freezing means which freezes 
rapidly is used to avoid dehydration of the fused components. More 
preferably a standard spiral freezer is used. Preferably, the fused pizza 
toppings disks 110, are subjected to temperatures of approximately 
-40.degree. F. to approximately -10.degree. F. for approximately five 
minutes to approximately ten minutes. Preferably, a spiral freezer of the 
type manufactured by the Frigoscandia Company, of Sweden is used. Other 
freezing means 195 may be used which will vary the parameters of the time 
and temperature necessary to freeze a fused toppings disk made in 
accordance with the present invention. 
Optionally, upon exiting the chilling means, or if no chilling means has 
been employed, upon being rearranged by the lane diverter, the fused 
toppings disks may be refrigerated. Preferably, prior to being 
refrigerated the fused toppings disks are packaged in a modified 
atmosphere package to prevent bacterial growth. 
After the fused toppings disks are frozen, the forming surfaces 135 are 
separated from the toppings disk 110. Various separation methods may be 
used which do not affect the integrity of the toppings disk 110. 
Preferably, a vacuum belt means 198 is used which pulls the forming 
surface taught against the belt's surface causing the frozen toppings disk 
110 to be peeled away automatically. Preferably, a standard vacuum belt 
such of the type known in the art is used. Once the forming surfaces are 
separated from the toppings disks, the toppings disks may be stored for 
subsequent use in assembling a pizza. 
Referring now to FIGS. 4 and 5 a weighbelt depositing means 150 and a 
template conveyor means 160 are shown. The weighbelt depositing means 150, 
as described previously, may be used for depositing various components of 
a pizza toppings disk onto the forming surfaces. A template conveyor means 
160 is used to disperse the components into a predetermined shape as they 
are being deposited. Typically, when a weighbelt feed device is used as 
the depositing means 150, the component being deposited is feed into a 
hopper 151. Contained within the hopper is an agitator bar 152 which aids 
in depositing the component evenly. Additionally, the hopper 151 contains 
and orifice or window 153 which can be adjusted to change the flow rate of 
the component being deposited. The component is then feed into a weighbelt 
chamber 155. The weighbelt chamber is supported by a series of load cells 
157. Preferably, the weighbelt depositing means is configured such that 
the load cells 157 communicate with the orifice 153 to ensure the proper 
amount of component is deposited. Within the weighbelt chamber is a 
weighbelt 156 which weighs the amount of component to be deposited. After 
the component is weighed it is passed through an opening and onto a 
vibratory plate 158. The vibratory plate 158 permits the component being 
deposited to be continuously deposited onto the forming surfaces without 
having to stop the conveyor belt 140 on an intermittent basis. Preferably, 
the weighbelt depositing means 150 is made of stainless steel construction 
and is approved by the United States Department of Agriculture. 
As the component is dispensed from the vibratory plate 158 onto the forming 
surfaces 135, it is passed through a template conveyor means 160. The 
template conveyor means 160 disperses the component onto the forming 
surfaces 135 in a predetermined shape. The template conveyor means 160 is 
shaped and configured such that the entire amount of component being 
deposited is dispersed onto the forming surface in a specific shape 
without having to recycle excess amounts. The template conveyor means 
removes excess collected amounts of the component being deposited to a 
reclaim feed system that resupplies the waterfall or weighbelt depositing 
means 150. Preferably, the template conveyor means 160 is independent of 
the conveyor belt 140 and the depositing means 150 but is positioned to 
encompass the conveyor belt 140 in proximity of the depositing means. 
Preferably, the template conveyor is configured such that a loop having a 
series of templates 162 is formed which encompasses the automated 
traveling means or conveyor belt 140 upon which the forming surfaces 135 
are transported. 
Preferably, the loop having a series of templates is affixed such that the 
templates orientation is guided by a stationary cam track. Preferably, 
each template is affixed to the loop individually and have a hinged 
support bracket. The hinged support bracket permits the template to be 
adjusted to travel in parallel with the forming surfaces. Additionally, 
the template conveyor 160 includes a drive means 164 which allows each 
individual template 162 to travel over a forming surface 135 such that the 
template travels a predetermined distance above the forming surface 135. 
Optionally, the templates may be synchronized to be aligned with a forming 
surface 135 such that the template travels a predetermined distance above 
and is in synchronized correspondence with a forming surface 135. 
Optionally, the template conveyor means 160 may be configured to have a 
single template which encompasses the automated traveling means or 
conveyor belt 140. 
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 SELECTED TOPPINGS 
TOPPINGS QUANTITY 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 4-9 oz. 
moisture part- 
skim mozzarella 
______________________________________ 
TABLE IA illustrates by way of example the amounts of cheese and selected 
pizza toppings necessary for a variety of pizza toppings disks made in 
accordance with the preferred apparatus disclosed herewithin. 
TABLE IA 
__________________________________________________________________________ 
AUTOMATED PIZZA TOPPINGS DISK 
__________________________________________________________________________ 
AUTOMATED 6" PIZZA TOPPINGS 
TOTAL QUANTITY OF CHEESES 
SELECTED TOPPINGS AND QUANTITIES 
DISK TYPE (ounces) (ounces) 
__________________________________________________________________________ 
SUPREME 2-2.5 oz. low moisture 
Sliced meats .25-1 oz. 
part-skim mozzarella 
Ground meats .75-1 oz. 
Vegetables 1-2 oz. 
PEPPERONI 2-2.5 oz. low moisture 
Sliced meats .50-1 oz. 
part-skim mozzarella 
CHEESE-LOW COUNT 1-2 oz. low moisture 
Sliced meats .25-1 oz. 
PEPPERONI part-skim mozzarella 
CHEESE 3-3.5 oz. low moisture 
None 
part-skim mozzarella 
MEAT LOVERS .RTM. 2-2.5 oz. low moisture 
Pepperoni .25-1 oz. 
part-skim mozzarella 
Ground meats 2.5-5 oz. 
__________________________________________________________________________ 
AUTOMATED 12" PIZZA TOPPINGS 
TOTAL QUANTITY OF CHEESES 
SELECTED TOPPINGS AND QUANTITIES 
DISK TYPE (ounces) (ounces) 
__________________________________________________________________________ 
SUPREME 3.5-4 oz. low moisture 
Sliced meats 1-2 oz. 
part-skim mozzarella 
Ground Meat 6-7 oz. 
Vegetables 3-4 oz. 
PEPPERONI 7-8 oz. low moisture 
Sliced meats 2-3 oz. 
part-skim mozzarella 
CHEESE-LOW COUNT 3.5-4 oz. low moisture 
Sliced meats 1-2 oz. 
PEPPERONI part-skim mozzarella 
CHEESE 10.5-11 oz. low moisture 
None 
part-skim mozzarella 
MEAT LOVERS .RTM. 7-8 oz. low moisture 
Pepperoni 1-2 oz. 
part-skim mozzarella 
Ground meats 7-11 oz. 
__________________________________________________________________________ 
AUTOMATED 15" PIZZA TOPPINGS 
TOTAL QUANTITY OF CHEESES 
SELECTED TOPPINGS AND QUANTITIES 
DISK TYPE (ounces) (ounces) 
__________________________________________________________________________ 
SUPREME 10-11 oz. low moisture 
Sliced meats 1.5-2 oz. 
part-skim mozzarella 
Ground Meat 9-10 oz. 
Vegetables 4.5-5 
oz. 
PEPPERONI 10.5-11 oz. low moisture 
Sliced meats 3-4 oz. 
part-skim mozzarella 
CHEESE-LOW COUNT 5.25-6 oz. low moisture 
Sliced meats 1.5-2.5 
oz. 
PEPPERONI part-skim mozzarella 
CHEESE 15.75-16 oz. low moisture 
None 
part-skim mozzarella 
MEAT LOVERS .RTM. 10-11 oz. low moisture 
Pepperoni 1.5-2 oz. 
part-skim mozzarella 
Ground meats 10-13 oz. 
__________________________________________________________________________ 
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 and TABLE IA 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 and TABLE IA. 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 TIME 
TOPPINGS TEMPERATURE FOR FOR TIAL 
DISK TYPE TIAL 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. 
______________________________________ 
TABLE IIA sets forth the corresponding preferred partial, minimal melt 
conditions of a preferred fusing means with an impingement of steam for 
the various toppings disks disclosed in TABLE IA. 
TABLE IIA 
______________________________________ 
PIZZA TIME 
TOPPINGS TEMPERATURE FOR FOR TIAL 
DISK TYPE TIAL MELT (F.) 
MELT (seconds) 
______________________________________ 
SUPREME 280.degree. F. 25 sec. 
PEPPERONI 280.degree. F. 25 sec. 
CHEESE-LOW 280.degree. F. 20 sec. 
COUNT 
PEPPERONI 
CHEESE 280.degree. F. 20 sec. 
MEAT 280.degree. F. 25 sec. 
LOVERS .RTM. 
______________________________________ 
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 descriptions of the preferred embodiments of the present 
invention have 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.