Method for heating a layered pasta product

Abstract: A method of preparing an alimentary product with pasta layers, in particular suitable for the preparation of lasagne. The method comprising the steps of providing a plurality of disconnected segments of an alimentary product, each segment comprising layers of pasta, arranging the segments in a pan, adding a cooking liquid to said pan, and heating the segments and the cooking liquid.

Description: The present invention relates to the preparation of lasagne. The invention is especially suitable for the preparation of frozen lasagne. Conventionally, lasagne are made from sheets of pasta, which, cooked or un-cooked, raw or dehydrated, are layered with sauce between the layers, in a baking tray. Depending on the size of the tray, each pasta layer may be constituted of one or more sheets of pasta abutting or slightly overlapping. Normally, the sauce is tomato, béchamel or cheese sauce, meat and tomato sauce or a combination thereof. The layered product is then baked in an oven. Ravioli or tortellini are e.g. described in L'art Culinaire Français (1976), pp. 633-634. An alternative way of securing filling in a pasta product is described in US-A-3798343. In this patent the filling is rolled into a pasta sheet. Frozen lasagne are available as a ready meal. Such products are prepared in a tray in a conventional oven or by microwave heating in a microwave oven. Re-heating time for a 600 g lasagne is approximately 40 min. in a conventional oven and 20 min in a microwave oven. It has surprisingly been found that the disadvantages of previous lasagne preparation methods are overcome by the present inventive method of preparation. The invention provides a substantially reduced heating time in order to provide ready-to-eat lasagne from a frozen product. Accordingly, the invention relates to a method of preparing a united alimentary product with pasta layers, said method comprising the steps of providing a plurality of disconnected segments of lasagne, each segment comprising at least 3 layers of pasta, arranging the segments in a pan, adding a cooking liquid to said pan, and heating the segments and the cooking liquid so that after cooking the segments stick together and form a united lasagne. It has surprisingly been observed that the individual segments of lasagne after re-heating may form one unit of lasagne. The amount of cooking liquid is adjusted to the volume of the lasagne segments and the heating temperature used. To this, it is preferred that during the heating of the lasagne segments and the cooking liquid, substantially all the cooking liquid is either absorbed or evaporated in the lasagne segments. As the cooking liquid evaporates or is absorbed during the cooking, the pasta in the lasagne segments will tend to stick together and form a united lasagne. In the present context the cooking liquid is a cooking or heating medium e.g. water, milk, bouillon, stock etc. which is added separately from the alimentary product with pasta layers. It will be appreciated that the present invention distinguishes alimentary products wherein the segments comprising pasta layers are provided in a liquid sauce, e.g. canned ravioli in sauce, the heating of which is done by pouring the sauce with segments in a pan and heating it. In the present invention the segments are disconnected i.e. they are not joined in a liquid sauce. The lasagne segments and the cooking liquid may be heated to at least 50°C in the pan, however, the lasagne and the cooking liquid are preferably heated to at least 70°C. In the present context a pan is a cooking tool which is to be placed on hot-plates. Thus a pan may for instance be a conventional pan, saucepan, a pot with a flat base, a casserole etc. Advantageously, a non-sticking pan such as a Teflon(TM) pan may be used. Furthermore, it has surprisingly been observed that frozen lasagne can be prepared in a pan with the layers of pasta and meat filling between remaining substantially between said layers after re-heating. It has also been found that if the lasagne are provided with sauce as a top layer with the right viscosity of the sauce, it will remain as topping. The lasagne of the invention are easily portionable for serving which is generally not the case for conventional lasagne due to the sheets of lasagne extending throughout the whole width of the lasagne. In addition, the consumer is free to choose to prepare a desired size of lasagne. While it is inconvenient to divide conventional frozen lasagne as they are frozen in a block. The sauce may for instance be a sauce or other conventional filling for lasagne, e.g. using a meat fish, vegetable base. Advantageously, the filling sauce, such as tomato sauce e.g. with meat or vegetable pieces, for the lasagne according to the invention, has a viscosity of max 2 cgr. Bostwick (60 sec at 15°C). A preferred cheese sauce has a viscosity of 10 cgr Bostwick (60 sec at 60°C). An additional advantage of the lasagne segments of the invention is that, if desired, they may be arranged to give an untraditional presentation shape of the lasagne. For example they may be arranged in a star or in other patterns. However, they may also be arranged in a traditional block formation. Shape variation is not possible with the conventional type of lasagne due to their being one big block. Furthermore, the lasagne segments may be heated in a microwave oven with a good result. The method according to the invention may optionally be used for preparing alimentary products that have not been frozen or are thawed. However, the invention is particularly suitable for the preparing or reconstituting of frozen lasagne. I will be understood that the various shapes of lasagne segments can be used. Nevertheless, it has been found that if lasagne segments are rhomboid-shaped, they are particularly appropriate for arranging within a pan with a round heating surface due to their ability to in combination, substantially fill out the whole of the heating surface. Furthermore, the cross-section of such segments allows for a quick heating. Advantageously, the segments are arranged with gaps between them. This allow for a quicker heating of segments as a result of the side of the lasagne segments being in direct contact with the cooking liquid. It is preferred that the alimentary product comprises blanched pasta sheets. However, it is possible that the pasta sheets may be raw or dehydrated. The cooking time of the lasagne segments and the added cooking liquid will, however, have to be adjusted accordingly. The size of the segments may vary. Nevertheless, it is preferred that the segments are not shorter than 2 cm. If the segments are too small, arranging them in a pan is too laborious. However, if the segments are too big they may be difficult to arrange in the pan in a suitable manner and the heating time will be increased. Consequently, it is preferred that the largest dimension is not longer than 15 cm, preferably not more than 12 cm. Conveniently, the unit weight of a segment is from 20 to 80 grams, preferably from 40 to 60 grams. In order to provide a good heating of the lasagne to be heated, it is preferred that the lasagne segments are 2 to 3 cm thick, most preferably about 2 cm. It may be desirable to provide the upper surface of the segments with a browning or gratin. For this, the upper layer of lasagne is e.g. coated with a cheese or cheese sauce and passed beneath a grill or another type of heating element. Instead of such an upper cheese sauce or as a compliment thereto, a grated cheese topping may be provided. Furthermore, colouring agents may be used to enhance the colour of the top surface of the lasagne. When the consumer arranges such segments in the pan, the browned or gratined surface should consequently be facing upwards. In a particular preferred embodiment of the invention the lasagne are prepared in accordance with the method described in our co-pending European patent application EP 97201717 with the title "Encapsulated Alimentary Product Comprising Pasta and Filling" filed on the same date as the present European patent application. In this method the alimentary product production comprises the steps of providing the lasagne segment with an edible coating encapsulation, preferably a sauce encapsulation. In this embodiment of the invention the lasagne has a coating of sauce on all surface and thus also on the side and at the base of the lasagne segments. This allows for a cooking in a pan on a hot plate which may result in an easy release of the lasagne from the pan after heating. Depending on the meal to be prepared, the amount of cooking liquid and the degree of evaporation of the cooking liquid required in the preparation may vary. The invention will now be explained in further detail by example only, with reference to the accompanying drawing and the examples below, in which Fig. 1 illustrates frozen lasagne segments, Fig. 2 illustrates frozen lasagne segment encapsulated in an edible coating in accordance with a preferred embodiment of the invention, Fig. 3 illustrates lasagne segment provided with a top browning, Fig. 4 illustrates lasagne segment being arranged in a pan and the addition of cooking liquid is shown in Fig. 5, Fig. 6 shows the lasagne according to the invention prepared in a pan and Fig. 7 shows the serving of a lasagne on a plate. Fig. 1 shows lasagne segment 1 cut out of a lasagne. The lasagne segments are composed by three layers of pasta with a filling between the layers. The lasagne segments 1 are in a preferred embodiment encapsulated in a sauce 2, in accordance with our co-pending patent application referred to above, see Fig. 2. The lasagne segments are browned on the upper surface 3 to obtain a attractive appearance and flavouring of the browning, and frozen into individually frozen segments. A surface browned lasagne segment is shown in Fig. 3. Fig. 4 to 7 illustrate the steps taken in the preparation of the lasagne 7 in a frying pan 4. The lasagne segments 1 are arranged in the frying pan 4. The individual segments preferably positioned adjacent to but not abutting neighbouring segments. Advantageously, there are gaps 5 between the segments. In a particularly advantageously embodiment of the invention the lasagne segments are rhomboid shaped. This makes the segments specifically suitable for arranging in a circular frying pan and due to the geometry of the lasagne segments allows the majority of the heating surface of the pan to be covered. Optionally other geometry of lasagne segments may be used. For example, the shape of the base surface of the lasagne segments 1 may be that of a figure, animal or other shapes that makes it attractive for a children's meal. In the example illustrated in Fig. 3 the upper browning of the lasagne segments requires that the person preparing the pan lasagne positions the lasagne segments 1 with the browned surface 3 upwards to present the most attractive appearance of the lasagne. Once the frozen lasagne segments 1 are arranged in the frying pan 4, cooking liquid 6 is added, see Fig. 5. The frying pan 4 is then posed onto a hot plate, conveniently at the highest possible heat. During the heating the cooking liquid 6 evaporates and is absorbed in the lasagne segments. The result is lasagne segments 1 which tend to adhere to each other creating a united lasagne 7, see Fig. 6. On example of a lasagne 7 prepared by pan cooking in accordance with the innovation is shown in Fig. 7. EXAMPLE 1 - Manufacturing of Lasagne Segments The lasagne segments having 3 layers of pasta may conveniently be produced in the following way: The lowermost pasta sheets are blanched in a continuous blancher and forwarded on a belt conveyor, each sheet having the width of the final lasagne segments. A string of Bolognaise sauce is extruded continuously lengthwise on each sheet. The middle pasta sheets are blanched in a continuous blancher and positioned on the Bolognaise sauce. On top of the middle pasta sheet another layer of sauce is extruded and onto this a top pasta sheet is being deposited. Also the middle and top pasta sheets are of the same width as the final lasagne segments. The lasagne are cut lengthwise, e.g. by guillotine cutter in desired pieces or segments. The lasagne segments are subsequently covered with cheese sauce in accordance with the method described in our co-pending European patent application. If desired, the top of the lasagne segments are browned by passing the segments beneath a heating or grill element. The lasagne segments are then transferred to a freezer e.g. a surface contact freezer for deep-freezing. The frozen lasagne segments are finally packed e.g. with a number of lasagne segments in each pack corresponding to what is needed for one lasagne portion. The pasta, Bolognese and cheese sauces are as described in the examples below. Other types of sauce may also be suitable. EXAMPLE 2 - Pasta A suitable pasta dough may e.g. comprise 70 to 80% flour, 15 to 20% whole egg by weight and water. The flour preferably being semolina flour. The past dough is mixed and passed through a kneader and sheeter and calibrated e.g. to a thickness of about 1,5 mm. The sheeted pasta is then preferably blanched. EXAMPLE 3 - Cheese Sauce Cheese sauce may be prepared from the following ingredients (by weight): Fat 6 to 8% Flour and starch 5 to 6% Milk powder 7 to 9% Cheese 4 to 8% Salt, pepper, spices and water. EXAMPLE 4 - Sauce Bolognese Bolognese sauce may be prepared in a conventional way by cooking beef, onion, tomato puré, tomato, cheese, carrots, celeriac and herbs together. EXAMPLE 5 - Preparation of Lasagne Segments of lasagne were heated in a pan in accordance with the invention. A block of lasagne of a similar recipe was heated in a conventional oven. The prepared lasagne were tested and the taste and texture found to be the same. The lasagne is easily releasable from the pan heating surface. EXAMPLE 6 - Heating times. A 600 grams block of frozen lasagne is heated in a conventional oven at 225°C. For heating throughout at a temperature of 70°C it is found to take approximately 40 min. Frozen lasagne segments of the same recipe are prepared. 12 rhomboid-shaped frozen lasagne segments of 50 gram each are arranged in a pan. Each segment has the following dimensions: 90 * 50 * 17 mm. 150 ml water is used as cooking liquid. The cooking plate is set at high heat. The cooking liquid is evaporated or absorbed in the lasagne segments during the cooking and a joint lasagne constituted by the 12 segments is provided. Heating throughout is found to take approximately 10 to 12 min.

Claims: A method of preparing a united alimentary product with pasta layers, said method comprising the steps of providing a plurality of disconnected segments of lasagne, each segment comprising at least 3 layers of pasta, arranging the segments in a pan, adding a cooking liquid to said pan, and heating the segments and the cooking liquid so that after cooking the segments stick together and form a united lasagne. A method according to claim 1, wherein the alimentary segments are individually frozen. A method according to either of claims 1 or 2, wherein the alimentary segments are rhomboid-shaped. A method according to any of claims 1 to 3, wherein the alimentary segments and the cooking liquid are heated to at least 50°C. A method according to any of claims 1 to 4, wherein the alimentary segments are arranged in the pan with gaps between them. A method according to any of claims 1 to 5, wherein the alimentary segments comprise blanched pasta sheets. A method according to any of claims 1 to 6, wherein the alimentary segments have a length or width from 2 to 12 cm. A method according to any of claims 2 to 7, wherein the unit weight of lasagne segment is from 20 to 80 grams, preferably from 40 to 60 grams. A method according to any of claims 2 to 8, wherein the lasagne segments are 2 to 3 cm thick. A method according to any of claims 2 to 9, wherein the lasagne segments have an upper surface which is browned. A method according to any of claims 1 to 10, wherein during the heating of the lasagne segments and the cooking liquid, substantially all the cooking liquid is either absorbed or evaporated. A method according to any of claims 1 to 11, wherein the segments of the alimentary product are substantially encapsulated in an edible coating, the 5 coating preferably being a sauce coating.

Inventors: NILSSON GORAN, NILSSON, GORAN
Applicants: NESTLE SA, SOCIETE DES PRODUITS NESTLE S.A.
Application year: 1997
Main classification: A23L1
IPC codes: A23P1, A23L1