Patent EA-001153-B1 (EA)
Title: Method and device for producing pizza
Inventor: PILATI MARCO
IPC: A21D13/00
Filed: 1998-08-12
Abstract: 1. Method for a mechanized and automatic production of flat cakes and/or pizzas without using baking forms for the flat cakes and without already preshaped flat cakes, wherein the flat cake is topped with garnishing ingredients under at least one garnishing station, characterized in that each individual flat cake (16a) is prepared of individual dough ingredients or of a pre-portioned mixture of ingredients as an individual dough portion (16) in a kneading and extrusion apparatus (5) and passes in the following on a pre-heated or continuously heated transport plate (11) through a series of processing stations such as a shaping press (6), a metering and distribution device (7) for tomato pulp, sauces and the like, one or several metering stations (8, 9) for the garnishing ingredients, as well as the baking station (13), by having the flat cake (16a) produced and garnished based on individual order according to a selection list, wherein the production comprises a complete production cycle, wherein the pizza is produced also by taking into consideration a desired amount of the garnishing ingredients and/or spices starting from the individual ingredients for preparing the dough, without use of pre-produced and/or pre-cooked semi-finished products, under use of pre-proportioned garnishing ingredients or, respectively, dough ingredients, and wherein those parts of the production installation which are not already subjected to a continuous germicidal effect based on temperature influence are maintained permanently in a hygienic state corresponding to the regulations concerning foodstuffs either by a programmed cleaning and sterilization cycle employing water and hot air in connection with cleaning and germicidal agents and/or by a simple exchange of the device components (7b, 7c, 7d, 7h, 7i, 7e; 10b). 2. Method according to patent claim 1, characterized in that the production cycle starts with the pre-heating of a transport plate (11) in the baking oven (13) or by heating elements built into the transport plate (11), wherein the baking process for the pizza (16a) starts already with the shaping (5) of the flat cake (16a), and wherein the baking process continues during the complete following work phases for garnishing, stuffing, and seasoning either based on the heat dissipation of the pre-heated transport plate (11) or by the continuous heating of the transport plate (11), such that the pizza (16a) disengages without any problem from the support plate (11) upon insertion (16b) into the baking oven (13) and exhibits the necessary consistency in order to be slid into the oven (13) with a slide-in mechanism (11a) without deforming the flat cake or, respectively, to be retained in the oven (13). 3. Method according to patent claim 1, characterized in that the pre-metered dough components are mixed, kneaded, densified, homogenized and extruded as compact dough portions (16) and are ejected (5j) from two worm casings (5k, 5m) disposed successively and perpendicular to each other with corresponding worms (5a, 5b), wherein in particular in the region of the transition of the dough from the first worm (5a) to the second worm (5b) the dough experiences an intensive interspersing based on a torsion and repeated shearing, which intensive interspersing favors an incorporation of air, wherein the feed (5c) to the first worm casing (5k) and the exit opening (5i) of the second worm casing (5m) is closed upon standstill of the apparatus by a slider or, respectively, by a separating spatula for the dough portion, wherein the rotation speed of the two worms (5a, 5b) can be adapted by an independent setting to the properties and to the quantity ratio of the ingredients, and wherein the rotation speed of the worms (5a, 5b) is increased arid the direction of rotation is changed during the flushing and sterilization cycle. 4. Method according to patent claim 1, characterized in that the shaping of the flat cake is performed by a heated greasing device, wherein the dough welling up between the press f aces in the edge region is formed as an edge bead in order to form thus a barrier for the successive placing and distribution of ingredients on the surface of the flat cake and in order to form a larger rest face for the insertion mechanism (11a), which prevents a deformation of the flat cake during insertion into the oven. 5. Method according to patent claim 1, characterized in that a single transport plate (11) moves back and forth (11d) between the dough extruder station (5) and the baking oven (13) along the production line of the installation and wherein the single transport plate (11) is possibly pre-heated in the baking oven (13). 6. Method according to patent claim 1, characterized in that a single transport plate (11) moves along a plane in direction of the baking oven (13) along the production line of the installation and moves along a plane disposed below the baking oven (23) in a direction of the dough extruder station (5). 7. Method according to patent claim 1, characterized in that two or more transport plates (11) are furnished for the same production line, which transport plates (11) are moved by a common drive mechanism (15). 8. Method according to patent claim 1, characterized in that the production line is arranged in a circle, wherein one oz several transport plates (11) can be furnished. 9. Method according to patent claim 1, characterized in that several production lines feed a baking oven with several baking chambers, separated from each other, or feed a baking oven (13), which is shifted in each case to the respective production line in case of need. 10. Method according to patent claim 1, characterized in that the flat cakes (16a) are inserted and removed through a single oven opening (13a). 11. Method according to patent claim 1, characterized in that the flat cakes (16a) are inserted into the oven (13) through its own insertion opening (13a) and are removed through its own removal opening (13b), which removal opening (13b) is aligned with the respective insertion opening or is furnished staggered or, respectively, twisted relative to this insertion opening. 12. Method according to patent claim 1, which is also suitable for other methods in the production of foodstuffs, characterized in that the garnishing ingredients and spices are present in a controlled atmosphere, in form of unit portions (8, 18a) combined to bubble bands (8a) or to stacks of dishes (18d) in cooled storage containers, from which storage containers the garnishing ingredients and spices are removed in each case immediately prior to use, and wherein also the dough components are kept in storage as a mixture or in the shape of partial mixtures in such packaging, and wherein the dough components are emptied as required above the dough kneading station and extrusion station (5). 13. Method according to patent claim 1, characterized in that the garnishing ingredients possibly also of a liquid consistency are contained in dishes (18) with a cellular subdivision, and wherein the uniform distribution on the surf ace of the flat cake is performed by tilting the dish (18), by the corresponding dish diameter, without dispersing device (10) and without distribution through air beams. 14. Method according to patent claim 1, characterized in that the dishes (18) themselves are furnished with a grate or sieve for the garnishing ingredients (18a) and are emptied through vibration in a tilted position, wherein the contents is dispersed onto the surface of the flat cake. 15. Apparatus for preparing dough according to the method recited in the preceding patent claim 3, characterized in that the apparatus comprises two worms (5a, 5b), disposed relative to each other preferably at an angle of about 90 degrees, with the corresponding casings (5k, 5m), wherein the rotation speed of the two worms can be varied independently of each other and the direction of rotation can be reversed, wherein the first worn (5a) exhibits a continuous coil (5e) in the region of the input (5c) and somewhat after this region, wherein the coil is interrupted after this region and helically disposed, adjustable mixing blades (5f) acre furnished, wherein in the following region the again closed running conical evil rotates in a conical casing part (5g), wherein the conical casing (5g) joins from the side into the second worm. casing (5m), wherein the second worm (5b) exhibits a continuous coil (5h), wherein an extruder discharge (5i) can be placed at the end of the second worm casing (5m), wherein a closure flap is furnished at the input (5c), and wherein a separating spatula for the exiting strand of dough can be furnished at the discharge port (5i), wherein in case of a stoppage of the apparatus (5) the closure flap and the separating spatula close the worm casing (5k, 5m). 16. Apparatus for shaping the flat cake (16a) according to the method claimed in the preceding patent claim 4, characterized in that the dough portion (16) falls (5j) onto a pre-heated or continuously heated transport plate (11), movable (11d) under the production stations (6, 7, 8, 9) of the plant, which transport plate (11) is moved in the following under the shaping station (6), wherein a heated press plate (6e) including its outer ring (6h) is lowered (6i) toward the transport plate (11), wherein the ring (6h) initially contacts the face of the transport plate (11) and wherein the ring (6h) rests on the face of the transport plate (11) while the press plate (6e) is further lowered (6i) until the desired thickness of the flat cake has been reached, wherein the guide pins (6f), projecting upwardly from the ring (6h), slide axially in the holder (6c) and the compression springs (6g), disposed between the guide pins (6f), are compressed, and wherein upon a subsequent lifting up (6i) of the press plate (6e), the ring is further pressed by the springs (6g) to the transport plate (11) until the guide pins (6f) with their heads