METHOD AND APPARATUS FOR FORMING A PIZZA DOUGH INTO A RIMMED PIZZA SHAPE

Abstract: A ball of pizza dough is placed in each recess (5) of a tray (1). A release agent is applied and the ball is tamped into a partially flattened shape. The tamped dough is proved and then first pressed in a first stage pressing. The pressed dough is proved and finally pressed into a rimmed pizza shape in a final stage pressing. The rimmed pizza dough base thus formed then undergoes final proving in two stages prior to baking and de-panning.

Description: METHOD AND APPARATUS FOR FORMING A PIZZA DOUGH INTO A RIMMED PIZZA SHAPE Introduction The invention relates to pizzas and in particular to a method and apparatus for manufacturing rimmed pizzas. Various processes for manufacturing pizzas are known. One such process is described in our UK 2284738-A. There is a need for an apparatus and process for manufacturing rimmed pizzas in which the side edge of the pizza is raised and defines a well for receiving sauce, cheese, toppings and the like. Statements of Invention According to the invention there is provided a method for forming a pizza dough into a rimmed pizza shape having a raised side edge, the method including the steps of:- placing a single portion of dough onto a pizza tray; tamping the dough to spread the dough partially on the tray; initial proving the dough after tamping; first pressing the tamped dough to further spread the dough on the tray; intermediate proving the dough after first pressing; final pressing the dough into a rimmed pizza shape; and final proving the dough after final pressing. In a preferred embodiment of the invention the final proving of the dough is carried out in two stages. In one embodiment of the invention the single portion of dough is formed into a ball of dough prior to placing onto a pizza tray. Preferably the method includes the step of applying a release agent onto the dough prior to one or more of tamping, first pressing and final pressing of the dough. Most preferably the method includes the step of applying a release agent onto the dough prior to tamping, prior to first pressing and prior to final pressing of the dough. In a preferred embodiment of the invention the pizza tray comprises a number of recesses for receiving separate single portions of dough and the tamping, initial proving, first pressing, intermediate pressing, final pressing and final proving are carried out when the single dough portions are positioned in the tray. In a particularly preferred embodiment of the invention the final pressing comprises: engaging a lower portion of a damming ring in flat sealing engagement with a tray rim; and advancing a plug means including a dough engaging lower face and a side wall extending upwardly from the dough engaging lower face into the pre- pressed dough to form the dough into a pizza shape with a raised side edge. In this case preferably the lower portion of the damming ring has an inner cutaway to define together with the dough engaging lower section of the plug side wall a dough rim receiving recess and the method includes the step of at least partially filling the recess with dough on pressing the plug into the tray. In a particularly preferred embodiment on forming, the rim ratio of the height of the tray sidewall to the rim thickness defined between the dough engaging lower section of the side wall of the plug means and the side wall of the tray is at least 3:1, preferably at least 4:1, and ideally about 4:1 to 5:1. In another preferred arrangement, on forming, the base ratio of the height of the tray sidewall to the base thickness defined between the dough engaging lower face of the plug means and the base of the tray section is at least 4:1, preferably at least 5:1, and ideally is approximately 6:1. In another aspect the invention provides an apparatus for forming a pizza dough into a rimmed pizza shape having a raised side edge, the apparatus comprising a tray to receive a pre-pressed pizza dough and a forming means to form the pre- pressed dough into a rimmed pizza shape; the tray having at least one section with a base, a side wall extending upwardly from the base and defining a central recess, the tray having an upper outwardly extending rim; the dough forming means comprising a damming ring for engaging the rim of the tray and a plug means which is slidably movable relative to the damming ring; the tray and plug means being of complementary shape to provide a pathway for pressed dough to form into a pizza shape with a raised side edge; the plug means including a dough engaging lower face and a side wall extending upwardly from the dough engaging lower face, the side wall having a dough engaging lower section and an upper damming ring engaging section for sealing engagement with the damming ring; and the damming ring having a flat tray rim engaging lower portion for flat sealing engagement with the tray rim. In one embodiment of this aspect of the invention, on forming, the rim ratio of the height of the tray sidewall to the rim thickness defined between the dough engaging lower section of the side wall of the plug means and the side wall of the tray is at least 3:1, preferably at least 4:1, and ideally about from 4:1 to 5:1. In another embodiment of this aspect of the invention, on forming, the base ratio of the height of the tray sidewall to the base thickness defined between the dough engaging lower face of the plug means and the base of the tray section is at least 4:1, preferably at least 5:1, and ideally approximately 6:1. In a preferred embodiment of the invention the lower portion of the damming ring has an inner cut-away to define together with the dough engaging lower section of the plug side wall, a dough rim receiving recess which is at least partially filled with dough on pressing of the plug into the tray. Preferably the inner cut-away of the damming ring is of curvilinear shape to define a portion of the dough rim receiving recess. Ideally, the inner cut-away of the damming ring is of arcuate shape extending upwardly from the tray rim engaging face. In one arrangement the dough engaging lower section of the plug side w comprises an outwardly and upwardly inclined portion leading into a transitio portion to the upper damming ring engagement portion. Preferably the transitio portion defines a portion of the dough rim receiving recess. Most preferably t transition portion defines together with the cut-away of the damming ring substantially continuous arcuate dough receiving recess for receiving an upp edge of the pizza dough rim. In another embodiment of the invention the tray comprises a plurality of tr sections, each for receiving dough for forming into a rimmed pizza shape. Preferably the tray comprises a planar upper wall in which the central recesses a formed, the upper wall defining the rim for each recess. Ideally, the tray includ a side wall extending downwardly from the upper wall. In a preferred embodiment the apparatus includes a tray support for supporti the tray, the tray and tray support having locator means for accurately locating t tray relative to the tray support. Preferably, the locator means comprises at lea two spaced-apart locator pins on one or other of the tray and tray support f engagement with a corresponding recess in the other of the tray and tray suppor Ideally, the locator pins are tapered to facilitate alignment with the locator hole Preferably the locator holes are provided in the tray and the locator pins a provided in the tray support. In another embodiment of the invention the plug means has a plurality of a outlets in a lower dough engaging face thereof. Preferably the lower face of t plug is at least partially of porous metal. In a preferred arrangement the poro metal has an average pore size of from 10 to 50 microns. In a further aspect the invention provides an apparatus for forming a pizza dough into a rimmed pizza shape having a raised side edge, the apparatus comprising a tray to receive pizza dough, a tray support for supporting the tray and a dough forming means to form the dough into a rimmed pizza shape. the tray comprising a plurality of tray sections, each section having a base, a sidewall extending upwardly from the base and defining a central dough receiving recess, each tray section having an upper outwardly extending rim; the dough forming means comprising a damming ring for engaging the rim of the tray section and a plug means which is slidably movable relative to the damming ring; each tray section and plug means being of complementary shape to provide a pathway for pressed dough to form into a pizza shape with a raised side edge; and the tray and tray support having locator means for accurately locating the tray relative to the tray support. In one embodiment of the invention the locator means comprises at least two spaced-apart locator pins on one or other of the tray and tray support for engagement with a corresponding recess in the other of the tray and tray support. Preferably the locator pins are tapered to facilitate alignment with the locator holes. Ideally the locator holes are provided in the tray and the locator pins are provided in the tray support. The invention also provides rimmed pizzas whenever made using the method and/or apparatus of the invention. Brief Description of the Drawings The invention will be more clearly understood from the following description thereof given by way of example only with reference to the accompanying drawings, in which :- Fig. 1 is a block diagram illustrating a method for preparing pizzas according to the invention; Fig. 2 is a perspective view of a tray fomiing part of a pizza forming apparatus of the invention; Fig. 3 is a perspective view of part of the tray of Fig. 2, in use; Fig. 4 is a perspective partially cut-away view of a detail of the tray; Fig. 5 is a cross sectional view of the detail of Fig. 4; Fig. 6 is a diagrammatic side view of a pizza dough forming apparatus of the invention; Fig. 7 is an exploded perspective view of a detail of part of the apparatus of Fig. 6; Fig. 8 is a cross sectional view of a final dough press apparatus; Fig. 9 is a cross sectional view of part of the dough press of Fig 8 on an enlarged scale; Figs. 10(a) to 10(g) are cross sectional views of the apparatus in different positions of use; Fig. 11 is a cross sectional view of an alternative damming ring, plug and tray of the apparatus; and Fig. 12 is an underneath plan view of the plug of Fig. 11. Detailed Description Referring to the drawings there is illustrated a method and an apparatus for forming a rimmed pizza 3 with a raised side edge which defines a well for receiving sauce, cheese and various toppings. The apparatus includes a tray 1 to receive pizza dough and a dough forming means 2 to form the dough into a rimmed pizza shape 3. In this case the tray 1 which is shown in detail in Figs. 2 and 3 comprises a plurality, in this case six tray sections 5, each for receiving pizza dough to be formed into a rimmed pizza shape. Each tray section 5 has a base 6 and an inclined side wall 7 which extends upwardly and outwardly from the base 6 to define a central dough receiving recess 8. The tray sections 5 are formed from a sheet having a planar upper wall 10 and downturned side edge walls 11. The planar upper wall 10 surrounding each recess 8 defines an upper outwardly extending flat rim 15. The tray 1 is mounted on a tray support 20 which supports the tray 1, especially during dough pressing. The tray 1 and tray support 20 have locator means for accurately locating the tray relative to the tray support. The locator means comprises at least two spaced-apart locator pins 21 which in this case extend upwardly from the tray support 20 to engage with corresponding locator holes 22 in the planar wall 10 of the tray 1. The locator pins 21 are tapered at an upper end thereof to facilitate accurate alignment with the locator holes 22. A dough forming means in this case is provided for each tray section 5. Each dough forming means comprises a damming ring 30 for engaging the rim 15 of a tray section 5 and a plug means 40 which is slidably movable in the vertical direction relative to the damming ring 30. The plug 40 includes air inlet means closed by a valve plate 42 which is movable by air pressure through ports 43 from a closed position to an open position illustrated to release the dough from the plug 40 as the plug 40 is lifted out of engagement with the dough. Typically locknuts 41 are used to limit the travel of the air release valve plate 42. Referring in particular to Fig. 6 a number of pressing head 40/damming ring 30 combinations are mounted on a common support 45 for substantially simultaneous pressing of a number of dough portions, especially for pressing dough portions in each of the six tray sections 5. The support is movable by main rams 46. Each pressing head 40/damming ring 30 combination 2 is independently movable of the main support 45 by separate rams 47. This is important in ensuring that optimum final pressing is achieved and in particular to provide additional tolerance to cater for any small variation in the amount of dough located in the tray recesses 8. Referring in particular to Fig. 1 there is illustrated the method for forming rimmed pizzas according to the invention using the tray and pressing system as described above. In a first step 100 the dough receiving recesses 8 of the tray 1 has a release agent such as a vegetable oil applied. A pizza dough is mixed and divided into single portions which are formed into balls of dough. A ball of dough is placed in each tray recess 8 in step 101. A release agent is applied to the dough ball in step 102. Optionally the release agent may be further spread over the dough ball in a further step. In step 104 the ball of dough is tamped into a partially flattened configuration 105 which is typically about 50% of the final dough diameter. The tamped dough is proved in step 106. Further release agent is applied to the dough prior to first stage pressing 108. In the first stage pressing the dough is further spread into the configuration 109 which is typically about 80% of the final dough diameter. The first pressed dough is then proved 110 prior to final pressing 111. The final pressing will be described in more detail below. The rimmed pizza dough thus formed then undergoes final proving in two stages 112, 113 prior to baking 114 and de-panning 115. Each proving stage 106, 110, 112, 113 is typically carried out at 30° to 40°C for up to 15 minutes at greater than 50% humidity. After de-panning the base is frozen, then a sauce is applied to the rimmed pizza base, toppings are applied to the sauce, the finished pizza is packaged and frozen. We have found that the preliminary tamping followed by first pressing prior to final pressing is important in producing rimmed pizzas to a high level of efficiency. The presentation of the dough in the pre-pressed configuration for final pressing greatly increases the efficiency and speed at which the final pressing may be effected. In more detail, and referring especially to Figs. 8 and 9, for final pressing the plug 40 includes a dough engaging lower face 44 and a side wall extending upwardly from the dough engaging face 44. The side wall has a dough engaging lower section 55 and an upper damming ring engaging section 56 for sealing engagement with the damming ring 30. The side wall sections 55, 56 are interconnected by a transition 57. The dough engaging lower side wall section 44 is outwardly and upwardly inclined to match the profile of the tray side wall and thereby define a dough rim receiving space therebetween. The transition 57 is of curvilinear arcuate shape curving upwardly and outwardly towards the damming ring 30. The damming ring 30 has a tray rim engaging lower portion 35 which engages in metal to metal sealing contact with the rim 15 of the tray section 5. The lower portion 35 also has an inner cut-away 36 to define, together with the dough engaging lower section of the plug side wall 55 a dough rim receiving recess 38 which is filled with dough on pressing of the plug into the tray. The inner cut-away portion 36 of the damming ring is of curvilinear arcuate shape extending upwardly and inwardly from the tray rim engaging face. The transition portion 57 of the plug side wall defines together with the cut-away 36 of the damming ring a substantially arcuate dough receiving recess 50 for receiving an upper edge of the pizza dough rim. We have found that this is a very important feature for a number of reasons. The extra volume defined by the recess 50 above the level of the tray rim 15 greatly facilitates efficient pressing of dough into the desired shape. This extra volume introduces a tolerance to cater for any slight variation in dough location and/ or amount. Such a slight variation is taken up by the excess volume. In addition, the damming ring and plug are effectively sealed at the junction therebetween. However, this seal is effectively stepped back from the rim of the pizza dough and is less critical than in other arrangements. We have found that the rim ratio of the height of the tray sidewall 7 to the rim thickness t R defined between the dough engaging lower section 55 of the sidewall of the plug means 40 and the side wall 7 of the tray 1 is preferably at least 3:1, ideally greater than 4:1, and most preferably from approximately 4:1 to 5:1. This is important in ensuring that a rimmed sidewall of the pizza dough is formed which is relatively thin and crispy while maintaining the required integrity in manufacture and in use. We have also found that the base ratio of the height of the tray sidewall 7 to the base thickness t B defined between the dough engaging lower face 44 of the plug 40 and the base 6 of the tray 1 is preferably at least 4:1, most preferably at least 5:1, and ideally approximately 6:1. This is important in ensuring that the base of the final rimmed pizza has good organoleptic properties of thinness and crispiness while maintaining the required integrity in manufacture and in use. In use, and referring particularly to Figs. 10(a) to 10(g), in a first step a tray 1 with the pre-pressed dough 60 in place is supported on the tray support 20 and presented under the plug 40 (Fig. 10(a)). In this position the damming ring 30 is extended to engage the tray rim 15. The damming ring 30 may be advanced (Fig. 10(b)). The damming ring is typically pneumatically actuated. The plug 40 is then advanced typically by hydraulic action through the configuration of Fig. 10(c) to the engaged pressing position of Fig. 10(d) in which the dough is pressed into a rimmed shape 61. The valve 42 is operated to dislodge the centre of the dough from the plug 40 as illustrated in Fig. 10(e). Air is then introduced through the valve across the faces of the dough and plug 40 to assist in release of the plug from the dough as the plug 40 and damming ring 30 are retracted (Fig. 10(f)). Air supply is continued until the plug 40 and damming ring 30 have been raised (Fig. 10(g)) and the tray 1 with the formed rimmed pizza dough shape 61 is led away from the pressing. Referring now to Figs. 11 and 12 there is illustrated another apparatus for forming a rimmed pizza which is similar to that described above and like parts are assigned the same reference numerals. In this case at least portion of the dough engaging face is air pervious to deliver a stream of air across substantially all of the upper surface of the dough. The air pervious portion is provided by a plate 70 of a sintered porous metal with pores of a size of typically 20 microns. Such a porous metal is available from Mott Corporation. The air film thus applied provides a dough release which extends over a substantial part of the top of the formed dough to allow ease of release of the plug 40 from the dough 61, after forming. The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail.

Claims: CLAIMS 1. A method for forming a pizza dough into a rimmed pizza shape having a raised side edge, the method including the steps of:- placing a single portion of dough onto a pizza tray; tamping the dough to spread the dough partially on the tray; initial proving the dough after tamping; first pressing the tamped dough to further spread the dough on the tray; intermediate proving the dough after first pressing; final pressing the dough into a rimmed pizza shape; and final proving the dough after final pressing. 2. A method as claimed in claim 1 wherein the final proving of the dough is carried out in two stages. 3. A method as claimed in claim 1 or 2 wherein the single portion of dough is formed into a ball of dough prior to placing onto a pizza tray. 4. A method as claimed in any preceding claim including the step of applying a release agent onto the dough prior to one or more of tamping, first pressing and final pressing of the dough. 5. A method as claimed in any preceding claim including the step of applying a release agent onto the dough prior to tamping, prior to first pressing and prior to final pressing of the dough. i 6. A method as claimed in any preceding claim wherein the pizza tray comprises a number of recesses for receiving separate single portions of dough and the tamping, initial proving, first pressing, intermediate pressing, final pressing and final proving are carried out when the single dough portions are positioned in the tray. 7. A method as claimed in any preceding claim wherein the final pressing comprises: engaging a lower portion of a damming ring in flat sealing engagement with a tray rim; and advancing a plug means including a dough engaging lower face and a side wall extending upwardly from the dough engaging lower face into the pre-pressed dough to form the dough into a pizza shape with a raised side edge. 8. A method as claimed in claim 7 wherein the lower portion of the damming ring has an inner cut-away to define together with the dough engaging lower section of the plug side wall a dough rim receiving recess and the method includes the step of at least partially filling the recess with dough on pressing the plug into the tray. 9. A method as claimed in claim 7 or 8 wherein on forming the rim ratio of the height of the tray sidewall to the rim thickness defined between the dough engaging lower section of the side wall of the plug means and the side wall of the tray is at least 3:1. 10. A method as claimed in claim 9 wherein the rim ratio is at least 4: 1. 11. A method as claimed in claim 10 wherein the rim ratio is from 4 : 1 to 5:1. 12. A method as claimed in any of claims 7 to 11 wherein, on forming, the base ratio of the height of the tray sidewall to the base thickness defined between the dough engaging lower face of the plug means and the base of the tray section is at least 4:1. 13. A method as claimed in claim 12 wherein the base ratio is at least 5:1. 14. A method as claimed in claim 13 wherein the base ratio is approximately 6:1. 15. Apparatus for forming a pizza dough into a rimmed pizza shape having a raised side edge, the apparatus comprising a tray to receive a pre-pressed pizza dough and a forming means to form the pre-pressed dough into a rimmed pizza shape; the tray having at least one section with a base, a side wall extending upwardly from the base and defining a central recess, the tray having an upper outwardly extending rim; the dough forming means comprising a damming ring for engaging the rim of the tray and a plug means which is slidably movable relative to the damming ring; the tray and plug means being of complementary shape to provide a pathway for pressed dough to form into a pizza shape with a raised side edge; the plug means including a dough engaging lower face and a side wall extending upwardly from the dough engaging lower face, the side wall having a dough engaging lower section and an upper damming ring engaging section for sealing engagement with the damming ring; and the damming ring having a flat tray rim engaging lower portion for flat sealing engagement with the tray rim. 16. Apparatus as claimed in claim 15 wherein, on forming, the rim ratio of the height of the tray sidewall to the rim thickness defined between the dough engaging lower section of the side wall of the plug means and the side wall of the tray is at least 3:1. 17. Apparatus as claimed in claim 16 wherein the rim ratio is at least 4: 1. 18. Apparatus as claimed in claim 17 wherein the rim ratio is from 4:1 to 5:1. 19. Apparatus as claimed in any of claims 15 to 18 wherein, on forming, the base ratio of the height of the tray sidewall to the base thickness defined between the dough engaging lower face of the plug means and the base of the tray section is at least 4:1. 20. Apparatus as claimed in claim 19 wherein the base ratio is at least 5:1. 21. Apparatus as claimed in claim 20 wherein the base ratio is approximately 6:1. 22. Apparatus as claimed in any of claims 15 to 21 wherein the lower portion of the damming ring has an inner cut-away to define together with the dough engaging lower section of the plug side wall, a dough rim receiving recess which is at least partially filled with dough on pressing of the plug into the tray. 23. Apparatus as claimed in any of claims 15 to 22 wherein the inner cut-away of the damming ring is of curvilinear shape to define a portion of the dough rim receiving recess. 24. Apparatus as claimed in claim 23 wherein the inner cut-away of the damming ring is of arcuate shape extending upwardly from the tray rim engaging face. 25. Apparatus as claimed in any of claims 15 to 24 wherein the dough engaging lower section of the plug side wall comprises an outwardly and upwardly inclined portion leading into a transition portion to the upper damming ring engagement portion. 26. Apparatus as claimed in claim 25 wherein the transition portion defines a portion of the dough rim receiving recess. 27. Apparatus as claimed in claim 26 wherein the transition portion defines together with the cut-away of the damming ring a substantially continuous arcuate dough receiving recess for receiving an upper edge of the pizza dough rim. 28. Apparatus as claimed in any of claims 15 to 27 wherein the tray comprises a plurality of tray sections, each for receiving dough for forming into a rimmed pizza shape. 29. Apparatus as claimed in claim 28 wherein the tray comprises a planar upper wall in which the central recesses are formed, the upper wall defining the rim for each recess. 30. Apparatus as claimed in claim 29 wherein the tray includes a side wall extending downwardly from the upper wall. 31. Apparatus as claimed in any of claims 28 to 30 including a tray support for supporting the tray, the tray and tray support having locator means for accurately locating the tray relative to the tray support. 32. Apparatus as claimed in claim 31 wherein the locator means comprises at least two spaced-apart locator pins on one or other of the tray and tray support for engagement with a corresponding recess in the other of the tray and tray support. 33. Apparatus as claimed in claim 32 wherein the locator pins are tapered to facilitate alignment with the locator holes. 34. Apparatus as claimed in claim 32 or 33 wherein the locator holes are provided in the tray and the locator pins are provided in the tray support. 35. Apparatus as claimed in any of claims 15 to 34 wherein the plug means has a plurality of air outlets in a lower dough engaging face thereof. 36. Apparatus as claimed in claim 35 wherein the lower face of the plug is at least partially of porous metal. 37. Apparatus as claimed in claim 36 wherein the porous metal has an average pore size of from 10 to 50 microns. 38. Apparatus for forming a pizza dough into a rimmed pizza shape having a raised side edge, the apparatus comprising a tray to receive pizza dough, a tray support for supporting the tray and a dough forming means to form the dough into a rimmed pizza shape. the tray comprising a plurality of tray sections, each section having a base, a sidewall extending upwardly from the base and defining a central dough receiving recess, each tray section having an upper outwardly extending rim; the dough forming means comprising a damrning ring for engaging the rim of the tray section and a plug means which is slidably movable relative to the damming ring; each tray section and plug means being of complementary shape to provide a pathway for pressed dough to form into a pizza shape with a raised side edge; and the tray and tray support having locator means for accurately locating the tray relative to the tray support. 39. Apparatus as claimed in claim 38 wherein the locator means comprises at least two spaced-apart locator pins on one or other of the tray and tray support for engagement with a corresponding recess in the other of the tray and tray support. 40. Apparatus as claimed in claim 39 wherein the locator pins are tapered to facilitate alignment with the locator holes. 41. Apparatus as claimed in claim 39 or 40 wherein the locator holes are provided in the tray and the locator pins are provided in the tray support. 42. A method for forming a pizza dough into a rimmed pizza shape substantially as hereinbefore described with reference to the accompanying drawings. 43. Apparatus for forming a pizza dough into a rimmed pizza shape substantially as hereinbefore described with reference to the accompanying drawings. 44. Rimmed pizzas whenever prepared by a method claimed in any of claims 1 to 14 and 42 and/ or using an apparatus as claimed in any of claims 15 to 41 and 43.

Inventors: DARMON JACINTA, MCGILLICUDDY GENE, DARMON, JACINTA, MCGILLICUDDY, GENE
Applicants: BILLCREST PROD LTD, DARMON JACINTA, MCGILLICUDDY GENE, BILLCREST PRODUCTS LIMITED, DARMON, JACINTA, MCGILLICUDDY, GENE
Application year: 1999
Main classification: A21C11
IPC codes: A21C11