DOUGH PRODUCT AND METHOD

Abstract: A dough crust (10) made by a process involving baking and then frying. The crust (10) has a fried flavor and is especially advantageous for making frozen pizzas. The crust (10) is formed from a sheeted dough piece (12) which has been docked. During the baking step the docking holes (28) bake through. A hard surface forms in them to both prevent oil absorption through the holes (28) and to prevent crust delamination. After the crust (10) has cooled pizza topping can be applied and the crust (10) frozen.

Description: DOUGH PRODUCT AND METHOD BACKGROUND OF THE INVENTION Field of the Invention This invention relates to prepared foods and more particularly to dough crusts used for fresh or frozen pizzas or the like. The Prior Art The prior art includes both baked and fried crusts for pizza and other dough products. It has long been known to either bake or fry such crusts. Examples of baked crusts are found in Groth U.S. Patent No. 3,379,141 and Ruiz U.S. Patent No. 3,451,358. Examples of fried crusts are found in Totino et al U.S. Patent No. 4,170,659 and in the many cookbooks which describe so-called "Neopolitan" pizzas. In processes described in both these patents, for example, a dough sheet is provided with "docking" holes which allow gas and moisture to be released during frying. The "docking" process also fastens top and bottom dough sheet surfaces together and prevents delamination between the upper and lower surfaces of the cooked pizza crust. SUMMARY OF THE INVENTION The present invention is embodied in an improved process for making a dough crust product and in the product itself. The crust of the present invention is particularly suited for pizzas and, even more specifically, for frozen pizzas. The improvement results primarily from carrying out the cooking process in two steps. First a docked dough piece is baked for a short period of time. Then the slightly baked dough piece or crust is deep fried for a short period of time. The initial baking step is effective to partially cook the dough crust. The crust surfaces become somewhat resistant to oil penetration. Baking also seals the interior of the docking holes against substantial oil penetration and prevents them from frying closed. The interior dough is set, delamination being resisted by the baked docking hole connection between upper and lower crust surfaces. In the sub¬ sequent frying step the crust absorbs some oil to take on a fried taste, however. It has been discovered that a lower protein flour can be used in a combined baked-fried crust than with fried crusts, for example. Low protein flour dough, when cooked, results in a crust with superior chewiness and without the toughness that results from using higher protein flour. The dough product is a delamination resistant crust of superior eating quality. It has a bready interior texture, a fried outside appear¬ ance with no noticeable blisters, and a crisp bottom. The thickness of the crust can be varied by varying proofing conditions. It can also be varied by varying the thickness of the original dough sheet. After the frying step the crust is cooled. Used in a frozen pizza, for example, it is then topped, frozen and packaged. BRIEE DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of an improved dough product embodying features of the invention; and FIG. 2 is a sectional view taken along line FIG. 3 is a flow chart illustrating the principle steps in the preferred process of the invention. DETAILED DESCRIPTION OF THE INVENTION The improved dough product of the present invention can be prepared from low protein flour con¬ taining either yeast or chemical leavening. The formula may vary. An example of a preferred dough formula will be hereinafter described. Referring now both to FIG. 1 and FIG. 2, an improved pizza crust embodying features of the present invention is illustrated generally at 10. The pizza crust 10 is nearly flat and, in this case, circular in shape. It is composed of a porous body 12 of at least partially cooked dough between top and bottom crust surfaces 14 and 15. The body 12 of dough is substantially uniform in texture throughout its extent. Its porous nature is such that a bready internal structure 13 containing innumerable small pores is formed. The height of the finished crust 10 is determined primarily by the thickness of the sheeted dough, the moisture and yeast content of the dough, and the proofing time and temperature. Higher moisture and yeast content, as well as longer proofing, produce thicker crusts, for example. The crust 10 is characterized by having a multiplicity of docking holes 28 which extend from the top surface 14 through the bottom surface 15. These holes 28 are a minimum of one-eighth of an inch (0.3175 cm. ) in diameter and are spaced about one and one-quar¬ ter inches (3.175 cm) apart. The function of the dock¬ ing process is primarily to prevent delamination of the crust during the cooking process. The docking holes 28 must be large enough so that they don't close during cooking, thereby increasing the delamination tendency of the crust. The dough sur¬ face through the docking holes 28 is exposed to direct heat during baking. It becomes cooked fairly hard. This creates a bond connecting the upper and lower sur- faces 14 and 15 and seals the holes 28 against oil pene¬ tration. The crust surfaces 14 and 15 of the fried crust 10 are quite dense and lack pores compared with the interior. It is preferred that they have a very light color but can, if desired, be fried until sub¬ stantially darker. The lighter colors are preferred for frozen pizzas since reheating can overcook or burn the crust if it is already a dark brown color. Because the dough sheet is first partially baked, the subsequent frying does not result in substan¬ tial oil absorption by the crust 10. Sufficient oil is absorbed to give a desirable fried dough taste, however. The fat which is absorbed serves as a moisture barrier to prevent absorption of moisture from the surface and tends to preserve the crisp character of the crust sur¬ aces 14 and 15. FIG. 3 is a flow chart illustrating the pre¬ ferred method for practicing the invention. In the first step dough is prepared. It has been discovered that a dough using low protein flour results in a crust having desired chewiness qualities, whereas dough made from high protein flour results in a tougher crust. The dough is next extruded and sheeted. A short proof between extrusion and sheeting is desirable. The dough is sheeted down to the desired thickness, between 2 and 10 mm. The sheet is dusted with corn starch to prevent sticking on rollers and belts used for sheeting. The dough sheet is then proofed from two and one-half to fifteen minutes at 85° to 110° F. (29.4° to 43.3°C) and ambient humidity to allow the dough to rise further. After proofing the dough sheet is docked by piercing it all the way through. The preferred spac¬ ing is one and one-quarter inches (3.175 cm.) apart in both directions throughout the width and breadth of the sheet. The dough sheet is then cut into pieces of any desired shape. Baking is then carried out in an oven of con¬ ventional design for thirty-eight to sixty seconds at 375° to 550°F (190.5° to 287.7°C). The partially cooked pizza crusts are moved from the oven immediately into a conventional submerging fryer for thirteen to eighteen and one-half seconds at 390° to 415°F (198.9° to 212.8°C) The initial baking sets the dough structure. The crust surfaces are hardened somewhat. This occurs through the docking holes also. The frying steps result in some oil absorp¬ tion. Excess oil is removed from the surface of the product after frying in any conventional manner. After frying and oil removal, the product is cooled either by letting it stand in the air or passing it through a cooler. The latter procedure is preferred for large scale production. After cooking the topping is applied in a well known manner. Toppings are then applied and the product is frozen and packaged. The invention will be understood more completely by reference to the following: EXAMPLE 1 Dough Formula Per Batch Flour 500.000 lbs. 226.799 kg Brew Slurry* 109.000 lbs. 49.442 kg Water (Variable) 225.000 lbs. 102.059 kg Salt 7.500 lbs. 3.402 kg Monocalcium Phosphate. 3.000 lbs. 1.361 kg Sodium Bicarbonate.... 2.500 lbs. 1.134 kg Dextrose 1.875 lbs. 0.850 kg Calcium Propionate.... 1.500 lbs. 0.680 kg Whey 1.400 lbs. 0.635 kg Sodium Stearoyl Lacty- late 1.250 lbs. 0.567 kg Succinylated monogly- ceride and distill¬ ed monoglyceride.... 0.250 lbs 0. .113 kg Soybean Oil 2.500 lbs 1..134 kg TOTAL: 855.775 lbs 388. .176 kg Brew Slurry Per Batch Water 60.00 lbs. 27.216 kg Yeast (fresh crumbles) 40.00 lbs. 18.144 kg Dextrose 8.50 lbs. 3.856 kg Buff r 0.39 lbs. 0.177 kg Salt 0.23 lbs. 0.104 kg Soybean Oil 0.04 lbs. 0.018 kg 109.16 lbs. 49.515 kg Raw Materials A. Flour - low protein; produces doughs with less shrinkage and crusts having desired chewiness without toughness. Farinograph - Data based on 14.0% moisture flour Absorption 56.5 + .1 MTI 35 + 5 Mixing Tolerance. 9.0 ± 1 (min) Mix Peak 6.5 +_ 1 (min) Analytical Moisture. 13.0 + .5 Protein.. 9.5 to 9.8 Ash .48 + .03 B. Yeast - the most critical ingredient in pizza crusts or bread leavened products is active in the fermentation (proof) time and initial onset of the baking. C. Salt - Enhances the flavor of the pizza crusts. D. Monocalcium Phosphate - Chemical leavener used with 80 parts of sodium bicarbonate to neutralize pH - produces C0 2 which aids in leavening during baking. E. Dextrose - Provides fermentable carbohydrates for yeast activity and aids in crust color development during baking. F. Whey - Provides fermentable carbohydrates for yeast activity and browning of the crusts. G. Sodium Stearoylate Lactylate (SSL) - Is highly functional in improving volume and more tender eating properties. H. Succinylated Monoglyceride and Distilled Monoglyceride Reducing agent, dough conditioner aids in improving volume and eating qualities. I. Soybean Oil Aids in lubrication to reduce sticking and aids in flow characteristics for uniformity of shape. J. Brew Buffer - Controls brew activity at optimum level for yeast activity (pH 4.8 to 5.3). - 3. Dough Preparation Mixer - horizontal bar mixer. Mixer time - 7 minutes ± 1 minute at high speed for developing dough after 1 minute at low speed for mixing. Dough Temperature out of mixer - 78 to 82°F (25.6° to 27.8°C). Dough extruded on to 36 inch (91.4 cm) belt where it proofs as it travels to the first sheeting roller. 4. Sheeting Dough sheeted down to desired amount of dough per square inch (6.45 cm 2 ) in a series of 3 sheet¬ ing rollers. Dough is dusted with corn starch on top and on bottom to prevent sticking on rollers and belts. 5. Proofing Variable proofing time ranges from 2.5 minutes to 15 minutes. Proof temperature - 85°F to 110°F (29.4° to 43.3°C) Humidity - Ambient 6. Docking Dough is docked with dockers which penetrate through the sheeted dough spaced IV (3.175 cm) apart - the docking holes prevent delamination of crusts during the cooking process . Dough Cutting Raw/wt. Fin¬ Finished Crust Cutter per ished Wt. per Size Size Raw Wt. Sq. In. Weight Sq. In. 12" 13.0" 10.5 Oz. 0.791 9.7 Oz. 0.805 10" 10.85" 8.0 Oz. 0.865 7.4 Oz. 0.942 9.25" 10.0" 6.25 Oz. 0.795 5.8 Oz. 0.863 8.25" 9.0" 5.5 Oz. 0.865 5.0 Oz. 0.930 2" 2.2" .292 Oz. 0.601 .229 Oz. 0.730 Dough Cutting (in metric) Raw/wt. Fin¬ Finished Crust Cutter per ished Wt. per Size Size Raw Wt. 6.45 cm 2 Weight 6.45 cm 2 cm cm 2 a 30.48 33.02 297.7 0.791 275.0 0.805 25.4 27.6 226.8 0.865 209.8 0.942 23.50 25.4 177.2 0.795 164.4 0.863 20.96 22.9 155.9 0.865 141.75 0.930 5.08 5.59 8.28 0.601 6.49 0.730 8. Baking - Jet Sweep oven - 48 feet (14.63 m) long heating area - 4 Zones - 52 feet (15.85 m) total length Bake Time - 38 to 60 seconds Oven Temperature - 374° to 550°F (190.0° to 287.8°C) 9. Frying - Deep fried in edible oil - Frying Time - 13 to 18.5 seconds - Frying Temperature - 390 to 415° F (198.9° to 212.8°C). 10. Cooling - through spiral cooler down to between 70° - 90°F (21.1° to 32.2°C). 11. Finished Product Specifications Crust dimension - size _+ .25 inches (± 0.635 cm) Crust weight - weight .2 ounces (± 5.67 g) Crust moisture - 32% + 4% Crust fat content - no higher than 10% Cooled temperature 80°F + 10°F (26.7°C ± 3.3°C) Crust Height - .475 + .025 inches (1.21 cm ± 0.063 cm) While the product and process embodiments described herein are presently preferred, it should be understood that various modifications and improvements may be made therein, and it is intended to cover in the appended claims all such modifications and improvements as fall within the true spirit and scope of the invention.

Claims: I CLAIM: 1. A process of preparing a crust comprising the steps of: a) producing a sheet of dough; b) cutting the sheet into individual dough pieces; c) baking each dough piece to partially cook the dough, forming a bready interior and harder surfaces; and d) frying the partially cooked dough piece for a short period after the baking step. 2. The process of Claim 1 further characterized by and including the step of: a) docking the dough sheet before the cutting step to provide a plurality of spaced-apart docking holes that extend through the dough sheet; b) said baking step being effective to harden the internal surface of said docking holes through the crust to fasten upper and lower surfaces of the crust together and prevent delamination. 3. The process of Claim 2 further characterized by and including the step of: a) subjecting the dough sheet to proofing at an elevated temperature; and b) docking the dough sheet after said proofing. 4. The process of Claim 1 further characterized by and including the step of: a) baking the dough piece in an oven for a minute or less at a temperature of 375° (190.6°C) to 550° F (287.8°C).; and b) submerged frying said dough piece for less than twenty seconds at a temperature of 390° (198.9°C) to 415° F (212.8°C). 5. A process of preparing a crust comprising the steps of: a) preparing a sheet of dough using a low protein wheat flour; b) proofing the dough sheet; c) docking the dough sheet to provide a plurality of spaced-apart docking holes which extend through the dough sheet; d) cutting the sheet into individual dough pieces; e) baking each dough piece to partially cook the dough and harden the dough surfaces through the holes; and f) submerging the partially cooked dough piece in heated fat to fry the baked dough. 6. The process of Claim 5 further characterized in that: a) said wheat flour has a protein content of 10% or less. 7. The process of Claim 5 further characterized in that: a) said proofing comprises resting said dough sheet before docking for from two and one-half to fifteen minutes and a temperature of 85° (29.4°C) to 110° F (43.3°C). 8. A delamination resistant pizza crust, comprising: a) a generally flat dough structure composed of cooked dough having a moist, chewy, bready interior and relatively dense upper and lower surfaces; 5 b) said crust having a plurality of spaced-apart holes therein which extend through the dough between its top and bottom surfaces; c) said crust having a baked interior and 10 an outer surface baked and then fried crisp.

Inventors: PAULUCCI JENO F, PAULUCCI, JENO, F.
Applicants: PAULUCCI JENO F, PAULUCCI, JENO, F.
Application year: 1985
Main classification: A21D6
IPC codes: A21C11, A21D6, A21D8, A21D13