Patent Publication Number: US-2005123659-A1

Title: Pizza making method and system

Description:
RELATED APPLICATIONS  
      The present application is a continuation-in-part of applicant&#39;s co-pending U.S. patent application Ser. No. 09/832,409, filed 11 Apr. 2001, entitled “Method and Device for Producing Pizza”, which application is a divisional application of U.S. patent application Ser. No. 09/294,702, filed 19 Apr. 1999 (now U.S. Pat. No. 6,245,370), which application is a continuation-in-part of Patent Cooperation Treaty Application No. PCT/EP98/05093, filed 12 Aug. 1998, which application claims priority to Italian Patent Application No. BZ97A000044, filed 19 Aug. 1997.  
      The present application is a continuation-in-part of Patent Cooperation Treaty Application No. PCT/EP01/04656, filed 25 Apr. 2001, entitled “Dough Mixer with Metering Device”, which application claims priority to European Patent Application No. 00109611.4, filed 5 May 2000.  
      The present application claims priority under 35 USC § 119(a) to Italian Patent Application No. BZ2001A000033, filed 7 Jun. 2001, entitled “Pizza Cutting and Transfer Device”.  
      The present application claims priority under 35 USC § 119(a) to European Patent Application No. 01113720.5, filed 5 Jun. 2001, entitled “Metering Device for Liquid or Cream-like Components for Garnishing Food Products”.  
      The present application claims priority under 35 USC § 119(e) to U.S. Provisional Patent Application No. 60/297,160, filed 8 Jun. 2001, entitled “An Automatic Pizza Making Method and System”. U.S. Provisional Patent Application No. 60/297,160 is incorporated in its entirety by this reference. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates generally to pizza making, and more particularly to an automated method and system for making pizza from fresh ingredients according to individual orders.  
     BACKGROUND OF THE INVENTION  
      Methods and systems are known for the automatic industrial production-line and mass-produced production of pizzas. These methods and systems essentially include the following work phases: preparation of dough including rising of the dough, extruding the dough creating a dough strand, cutting the dough strand into individual dough portions, processing the dough portions to flattened pizza bases, adding seasonings and toppings, baking, packaging for consumption within the expiration date or, respectively, for deep freezing.  
      Systems employing the above-referenced methods are numerous for mass-production. Existing automated systems have accelerated pizza production by employing pre-treated dried granulate with seasonings and toppings applied to a pre-determined, large number of pizzas of the same variety on a continuous belt with baking in a tunnel oven. Some existing systems accelerate production by employing pre-produced, precooked and/or frozen dough portions and toppings.  
      For the foregoing reasons, there is a need for an automatic pizza making method and system that provides fast, individual and completely fresh pizza preparation according to individual order placement.  
      Dough Mixer  
      Dough mixers for producing dough used in preparing foods are known which use one or two screw conveyors, or rotating mixing arms within fixed or rotating containers with vertical or angled axis or kneading elements rotating within a closed housing with a horizontal axis. Also known are smaller mechanical devices for preparing dough in the household; generally these include a cylindrical container with a vertical axis within which one or more agitator blades operate on a single drive shaft attached coaxially to the container axis.  
      Information relevant to attempts to address dough mixers can be found in U.S. Pat. Nos. 5,486,049; 4,630,930; and 5,322,388. However, each of these references suffers from one or more disadvantages.  
      The known devices are not designed for preparing individual dough portions per work cycle within relatively short periods of time and by charging with ingredients in individual portions; further, known devices do not provide that each dough portion prepared and discharged for shaping leaves no ingredients or dough residue inside the device. The known devices are also not designed to perform a periodic, completely automatic sterilization of the kneading chamber and elements.  
      Also known in the art is the problem of charging kneading devices with relatively exact volumetric amounts of flour or flour-like ingredients which are hydroscopic. Such problems result from the tendency of flour-like materials to form accumulations or agglomerates inside the container, that varying the material volume above the metering mechanism strongly affects the metering process and that it is difficult to achieve an even filling and/or emptying of the metering chamber.  
      For the foregoing reasons, there is a need for a dough mixer of simple, compact design which can be automatically sterilized, has an essentially cylindrical chamber with kneading rotation occurring about a horizontal axis to accommodate direct charging of consistently accurate and pre-metered amounts of material per work cycle while preventing accumulation of material in the container and/or metering chamber, the dough mixer quickly preparing, on demand, one individual dough portion suitable for preparation of one pizza by subsequent shaping, garnishing and baking.  
      Tomato Sauce Dispenser  
      Systems are known for mechanical metering and garnishing of pizza with tomato sauce or other liquid components. Most of these devices supply the sauce by tube, under pressure generated by a pump. Generally these systems are mounted on a production line above a passage area of the dough base to be garnished, the garnishing process occurring by free fall. Accordingly, uniform distribution of the sauce to the dough base requires several tubes or nozzles and air jets evenly spaced above the garnishing area to evenly distribute the sauce on the dough base.  
      Known liquid dispensing systems have several disadvantages. Systems with a plurality of tubes and nozzles are unsuitable for liquids such as tomato sauce as tomato sauces are rarely homogenous in fluidity and texture. As such, the individual nozzles fed from one single supply tube rarely dispense equal quantities of the sauces. In addition, dispensing sauce from a plurality of tubes and nozzles creates cleaning and sanitation problems as the sauce often drips from the nozzles after product flow ceases. To prevent the product from spoiling, mold from forming and bacteria from breeding during downtimes, tubes must be exchanged often, resulting in increased production costs.  
      Known liquid dispensing systems using air jets require high product homogeneity, accurate product metering and precise jet calibration based upon texture and volume of the liquid to be distributed. Air jet systems often distribute excessive product, insufficient product or provide intermittent distribution while continually experiencing cleaning problems.  
      Other existing free falling systems require that the underlying dough base rotate about a vertical axis with sauce distributed in a spiral manner. These systems allot all movement to the dough base, whereas dispensing nozzles remain stationary. One disadvantage of these systems, if integrated into a production line for pizza, is the complication or exclusion to using traditional conveying systems to transport the dough base through the production line due to the requirement of rotating the dough base during sauce application. Thus, conveying systems must provide the additional capability of rotating the dough base over a portion of the production line. Or, the conveying system must transfer the dough base to a separate device to spin the dough base. Further complications arise when the production line requires that the dough base be heated during conveying and/or garnishing.  
      For the foregoing reasons, there is a need for a tomato sauce dispenser that provides even sauce distribution on a dough base (regardless of sauce homogeneity), that performs in a production line having traditional conveying systems and/or conveying systems applying heat to the dough base during transport thereof through the production line, and also facilitates easy cleaning and maintenance.  
      Oven  
      Electric ovens employing electrical resistance, microwave generators (magnetrons), infrared lamps or induction units as a heat source for cooking relatively thin cakes, such as pizza and focaccia, are known, as are ovens employing one or more such heat sources in combination, such as ray or wave sources. These ovens are designed to cook or heat fresh or frozen foods, which may be precooked, in a relatively short time.  
      Cooking time is important for industrial food-production processes and for automated machines that heat or cook food on the spot. Such machines commonly use cooking systems employing microwaves and/or infrared rays, sometimes in combination with electrical resistance. However, it takes approximately 80 seconds to cook and brown pizzas having a diameter of about 270 mm and total weight of about 320 g to 360 g.  
      For the foregoing reasons, there is a need for an oven that can fully cook and brown fresh (not precooked) food in a shorter time period, without sacrificing the organoleptic and nutritional properties associated with traditional cooking.  
      Automatic Cutting Device  
      A number of devices exist for automatically cutting pizza or focaccia into slices, using plates provided with blades which operate vertically like a dinking die on the pizza being cut. The existing devices only cut the pizza, requiring specific devices to then transfer the cut pizza to the take-out box or other packaging.  
      Furthermore, the known devices are not designed for easy cleaning and/or replacement of the parts that come into repeated contact with the pizza, thereby creating cleanliness and hygiene problems with both the cutting device and the transfer device.  
      For the foregoing reasons, there is a need for a simple, combination cutting and transfer device which is easy to clean and uses some of the cutting movements to transfer the pizza, thereby expediting the pizza making process.  
     SUMMARY OF THE INVENTION  
      The present invention is an automatic pizza making method and apparatus providing fast, individual and completely fresh pizza preparation according to individual order placement. The pizza making system is innovatively designed for production of fresh pizza by turn-key operation. The pizza making system comprises multiple processing stations that combine ingredients, namely, flour, water, salt, leveling agent, tomato sauce, cheese and assorted toppings such as sausage and pepperoni, to prepare and bake a pizza.  
      Accordingly, it is an object of the present invention to furnish an automated method and a system for pizza production according to individual orders placed by selections from a list, the production employing only fresh ingredients (no pre-cooked and/or deep-frozen ingredients for the dough or toppings) with each pizza individually seasoned, spiced, garnished and baked in a short time and provided ready to eat.  
      It is another object of the present invention to furnish the method and system such that the production process is performed hygienically, without human intervention and where periodic and automated washing and sterilization cycles are provided to maintain the system in a suitable hygienic state.  
      It is a further object of the present invention to simply and periodically exchange system components that contact foodstuffs and are not otherwise subjected to the germicidal effect of elevated temperature.  
      Dough Mixer  
      The dough mixer of the automatic pizza making method and system of the present invention satisfies the need described above for dough mixers. The dough mixer has a simple, compact design providing automatic sterilization. The dough mixer has an essentially cylindrical chamber with kneading rotation occurring about a horizontal axis to accommodate direct charging of consistently accurate and pre-metered amounts of material per work cycle while preventing accumulation of material in the container and/or metering chamber. The dough mixer quickly prepares, on demand, one individual dough portion suitable for preparation of one pizza by subsequent shaping, garnishing and baking.  
      Tomato Sauce Dispenser  
      The tomato sauce dispenser of the automatic pizza making method and system of the present invention satisfies the need described above for liquid dispensers. The tomato sauce dispenser provides even sauce distribution on the dough base (regardless of sauce homogeneity), performs in a production line having traditional conveying systems and/or conveying systems which apply heat to the dough base during transport thereof through the production line, and facilitates easy cleaning and maintenance.  
      Oven  
      The oven of the automatic pizza making method and system of the present invention satisfies the need described above for ovens. The ovens of the present invention use infrared rays emitted in two different wavelength ranges by separate and specific sources, each differing in design, to produce specific heat within the top surface (toppings) of the pizza and within the thin cake (dough). The infrared rays are programmably cycled on and off, with wavelengths in a visible and near-infrared range penetrating deep into the dough, propagating in accordance with the laws of optics (especially in the presence of water molecules), while wavelengths in a far-infrared range are absorbed in the top surface of the pizza, to fully cook and brown a typical pizza in approximately 55 seconds.  
      Automatic Cutting Device  
      The automatic cutting device of the present invention provides a simple, easy-to-clean cutting and transfer device that uses some of its cutting movements to transfer the pizza. The present invention attaches a sheet that slides vertically by its own weight or by spring action to a side of a plate provided with blades. After cutting the pizza, the sheet holds the cut pizza in the cutting position as the plate that supports the pizza during cutting moves horizontally to drop the pizza onto a top box of a stack of take-out boxes disposed below. Alternatively, the sheet assists the transfer of the pizza onto a take-out box to one side as the entire cutting device moves laterally, lifting the plate provided with blades once the pizza is placed on the box.  
      The present invention also provides blades that are easily detached from the supporting plate for replacement and cleaning, regardless of whether the blades are single-use or coated with a sheath or layer that can be removed easily at the end of a predetermined cutting cycle, thereby making the cutting device as hygienic as possible. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      For the purpose of illustrating the invention, there is shown in the drawings a form that is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.  
       FIG. 1  illustrates a front elevation of the automatic pizza making system according to the present invention;  
       FIG. 2  illustrates a top plan of the automatic pizza making system shown in  FIG. 1 ;  
       FIGS. 3   a  and  3   b  illustrate a left side elevation of the automatic pizza making system shown in  FIG. 1 ,  FIG. 3   a  showing a dough punching device in an extended, non-operating position and  FIG. 3   b  showing the dough punching device in a retracted, operating position;  
       FIG. 4  illustrates an elevation of the automatic pizza making system according to the plane  4 - 4  in  FIG. 1 ,  FIG. 4  viewing through a refrigerator to a cutting device, two ovens and a tray conveying system;  
       FIG. 5  illustrates a right side, partial sectional elevation of a flour container and dough mixer of the automatic pizza making system shown in  FIG. 1 ;  
       FIG. 6  illustrates a front sectional elevation of the flour container and the dough mixer shown in  FIG. 5 ;  
       FIGS. 7   a  through  7   c  illustrate a front sectional, a left side sectional and a top plan, respectfully, of a pre-former of the automatic pizza making system shown in  FIG. 1 ;  
       FIGS. 8   a  and  8   b  illustrate a left side, partial sectional elevation of a hot press of the automatic pizza making system shown in  FIG. 1 ,  FIG. 8   a  showing an upper press portion and  FIG. 8   b  showing a lower press portion of the hot press;  
       FIGS. 9   a  and  9   b  illustrate a left side, partial sectional and a top plan, respectfully, of the dough punching device of the automatic pizza making system shown in  FIG. 1  (and detailed in  FIGS. 3   a  and  3   b ),  FIG. 9   a  showing the dough punching device in a retracted, operating position and  FIG. 9   b  showing the dough punching device in an extended, non-operating position;  
       FIG. 10   a  illustrates a top plan of a tomato sauce dispenser of the automatic pizza making system shown in  FIG. 1 ;  
       FIG. 10   b  illustrates a front section of the tomato sauce dispenser according to the plane II-II in  FIG. 10   a;    
       FIG. 10   c  illustrates a side, partial section of the tomato sauce dispenser according to the plane III-III in  FIG. 10   b ,  FIG. 10   c  detailing a carriage driven by a threaded spindle;  
       FIG. 10   d  illustrates a top plan of a tomato sauce dispenser shown in  FIG. 1  (without the case),  FIG. 10   d  showing a mounting for the threaded spindle and the carriage;  
       FIGS. 11   a  through  11   c  illustrate a left side sectional, a front sectional and a bottom plan, respectfully, of a cheese or sausage dispenser of the automatic pizza making system shown in  FIG. 1 ;  
       FIGS. 12   a  through  12   d  illustrate a front partial sectional, a left side partial sectional, a top plan and a left side sectional detailing internal mechanisms, respectfully, of a pepperoni dispenser of the automatic pizza making system shown in  FIG. 1 ;  
       FIGS. 13   a  through  13   d  illustrate various side and front elevations of each of two ovens included in the automatic pizza making system shown in  FIG. 1  with  FIGS. 13   e  and  13   f  detailing the cooking method employed by the ovens;  
       FIGS. 14   a  through  14   c  illustrate front views of one embodiment of an automatic cutting and transfer device of the present invention where a movable transfer plate is responsible for transferring a cut pizza into a box for packaging;  
       FIGS. 14   d  through  14   f  illustrate front, top and left side views, respectively, of another embodiment of an automatic cutting and transfer device of the present invention (and the embodiment shown in the automatic pizza making system of  FIG. 1 ), where the entire cutting device moves to transfer the cut pizza from a cutting position to a packaging position; and  
       FIGS. 15   a  through  15   f  are left side elevations of the automatic pizza making system shown in  FIG. 1  (close-up views of  FIGS. 3   a  and  3   b ) illustrating, step by step, a dough shaping and dough punching process according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      Referring now to the drawings, wherein like numerals indicate like elements, there is shown in  FIGS. 1 through 4  an illustration of an automatic pizza making system  20 . The pizza making system includes a flour container  22 , a dough mixer  24 , a water and leveling agent container  26 , a pre-former  28 , a hot press  30 , a dough punching device  32 , a receiving rack  34 , a conveying tray  36 , a tray conveying system  38 , a tomato sauce dispenser  40 , a cheese dispenser  42 , a pepperoni dispenser  44 , a sausage dispenser  46 , a refrigerator  48 , a first oven  50 , a second oven  52  and a cutting device  54 .  
      Flour Container and Dough Mixer ( FIGS. 5 &amp; 6 )  
      The dough mixer of the present invention is designed for preparing individual dough portions per each work cycle within relatively short periods of time and by charging with ingredients in individual portions. The dough mixer provides that every individual mixed dough portion that is rolled into a ball and is ready for shaping and baking can be discharged without leaving ingredients or dough residue inside the device. The dough mixer also performs a periodic, completely automatic sterilization of the kneading chamber and its kneading elements.  
      The object of the flour container and dough mixer of the present invention is to create a dough mixer that has a simple and compact design, can be automatically sterilized, has an essentially cylindrical chamber with horizontal axis in which a kneading element operates with horizontally rotating axis, due to direct charging of the chamber with pre-metered ingredients per work cycle, to create in a short period of time a portion of dough which then is finally discharged as a mixed individual portion in the form of a ball and ready-made for subsequent shaping, garnishing, and baking or deep-freezing.  
      To attain the flour container and dough mixer described above, a housing is designed having an inner chamber that is essentially cylindrical and has in its upper section, which corresponds to the charging region for the flour-like and possibly also liquid ingredients, as well as in the lower section, which corresponds to the discharge region, a surface area that runs parallel to the chamber axis and turns into the chamber casing surface. Within this chamber operates a rotating kneading element according to an axis that runs coaxially or parallel to the chamber axis. The rotating kneading element comprises at least one arm formed with one end attached radially to the end of a drive shaft, and on the other end of which at least one fixed bearing pin is attached cantilever with an axis running parallel to the rotational axis of the drive shaft; a freely turning sleeve is placed by means of a recessed hole on top of this bearing pin with rounded terminal ends on both sides. As an advantageous feature are two arms extending radially from the same drive shaft, which are oriented to each other longitudinally or are in the same level but are at a certain angle to each other, and each of these arms carries a bearing pin with a rotating sleeve placed on top parallel to the rotational axis, preferably with a different distance to the rotational axis of the drive shaft. While these bearing pins, which are equipped with rotating sleeves, are in motion, the dough is compressed, rolled and rolled thin repeatedly in particular in the lower region of the chamber with the level surface section that turns into the curved casing surface. If a plurality of these sleeves are operated, they can have varying outside diameters, cross-sections, and shapes depending on the consistency of the dough being produced and/or the properties of the ingredients and/or the percentage of liquid ingredients. The invention provides further for the interchangeability and/or the change in the number of the sleeves mentioned, depending on the properties of the ingredients and/or the dough that is being prepared.  
      Due to the charging of the chamber with dry flour-like ingredients, the kneading element carries out the work phase with the purpose of homogenizing and aerating the dried ingredients by rotating at a relatively high speed in order to achieve a thorough mixing of the ingredients introduced, and their preparation for the subsequent introduction of liquid ingredients, which ensures that they are evenly absorbed, and the dough agglomerate is then created with a markedly reduced rotational speed; by further reducing the speed, a mixing and homogenization of the dough mass is achieved, which then, upon further reduction in rotation speed, is compressed and rolled into balls, which as such are discharged in part due to gravity by opening the discharge opening in the region corresponding to the lower level surface section of the chamber.  
      The individual inner surfaces and surface areas of the dough mixer chamber have surface transitions with rounded areas with the largest possible radius, including the rotating arms or the sleeves of the kneading elements, all have rounded forms, and thus the chamber space is free of edges or recesses on which dough residue could stick that is not discharged along with the individual portion, due to the process by which the dough is kneaded and rolled into balls. After rolling into balls and discharging, the chamber and the kneading elements are thus free of any residue from the dough and ingredients. This form further allows them to be sterilized by means of hot air, through which small amounts of sticky dough residue are removed in the air current due to the drying process and the application of pressure.  
      The front surface of the chamber, which is across from the second front surface from which the drive shaft for the kneading element projects, can have a level, conical, more or less rounded form that protrudes against the drive shaft, with its axis extending coaxially to the rotational axis of the drive shaft or parallel to it preferably in the upper level of the chamber. By means of a distinctive conical or nose cone form, the rotating sleeves of the kneading element can roll the dough thin even with this shape. Further, the housing wall corresponding to this front interior surface with more or less distinctive shape can be replaced by another housing wall, in order to change the volume of the chamber by changing the distance between the front circular surfaces; in this case, the sleeves on the kneading element are also replaced by sleeves with the appropriate longitudinal extension.  
      Preferably, the liquid ingredient(s) for preparing the dough are introduced through one or more openings in the central region at the front wall across from the wall with the drive shaft.  
      In terms of the volumetric metering of the dry, flour-like ingredients, the invention proposes that a metering device be located in the region of the charging opening that is equipped e.g., with sliding blades, which essentially comprises a cylindrical container with vertical axis for the flour, and this container is equipped with a volumetric metering mechanism at its bottom. The container has inside in its lower region an annular, funnel-like partition, and the point of a distribution cone extends through the partition&#39;s central, circular opening so that an annular passageway is free for the flour. The container has at the bottom a metering sieve above which beaters move during the rotation of the distribution cone, which is driven by means of a vertical central shaft by a motor, in order to transport the flour through the metering sieve and through the holes which are positioned equidistant to the rotational axis on the metering disk located beneath it. The metering disk is located on the bottom disk, which is connected to the cylindrical wall of the container and which has a hole in the region of the charging opening of the dough mixer attached beneath it, through which the flour falls from the metering holes at the rotating metering disk and through the charging opening into the chamber of the dough mixer.  
      The present invention does not exclude the possibility that the dough mixer is fed from a metering device that has features other than those proposed by the invention, or from a device which charges with a pre-measured portion.  
      One embodiment of the flour container and dough mixer described above is illustrated in  FIGS. 5 and 6 . This embodiment is capable of preparing individual portions of 130-260 g within 10-15 seconds, which is suitable for the automatic pizza making system of the present invention.  
       FIG. 5  illustrates a section of a dough mixer  24  according to the invention during the charging phase and linked to a metering device  80 , showing a sectional view according to the plane of section I:I in  FIG. 6 , which plane runs through the axis of the drive shaft of the metering device  80 .  
       FIG. 6  shows the dough mixer  24  according to the invention and as shown in  FIG. 5  together with a metering device  80  in section according to the plane of section II-II in  FIG. 5 .  
      The dough mixer  24  for preparing individual portions comprises a housing  81  with an inner chamber and a kneading element  84 ,  84   c ,  84   d , containing a charging opening  82   a  and a discharging opening  83   a ,  81   d , with corresponding blades  82 ,  83 . The essentially cylindrical chamber with horizontal axis is delimited by a level, circular surface  81   e  from which a shaft  92   a  extends coaxially, by a circular surface  81   f  corresponding to the aforementioned but with a conical form projecting slightly into the chamber, by two curved surfaces  81   a  with a casing line equidistant from the chamber axis, by an upper level surface section  81   c  that essentially corresponds to the region of the charging opening  82   a , and by a lower level surface section  81   b , which is larger than the upper one and corresponds to the region of the discharging opening  81   d ,  83   a.    
      The kneading element comprises an arm  84  which is fastened on its front side at the end of the drive shaft  92   a  that extends into the chamber; at each of the ends of arm  84  a pin  84   c  is fastened having an axis running parallel to the rotational axis of the drive shaft  92   a , and a freely turning  84   b  sleeve  84   d  with a rounded, hemispherical or nose cone-shaped terminal area is placed on each of pins  84   c  by means of a recessed hole. Arm  84  of the kneading element is fastened to drive shaft  92   a , off-center relative to the center line of the transverse-extending arm, such that two pins  84   c  with sleeves  84   d  attached to it turn with varying radius about the rotational axis of drive shaft  92   a , which is driven by the electric motor  92  at varying rotational speeds and changing rotation directions.  
      Charging opening  82   a  for the introduction  94   b  of the flour-like ingredients in the upper region and discharging opening  83   a ,  81   d  for the individual portions of dough balls in the lower region, are provided with sliding blades  82 ,  83 , which for example are moved  82   b ,  83   b  by pneumatic cylinders  82   c ,  83   c  without excluding the use of rotating blades and other drives.  
      Liquid ingredients are charged via a single hole  93  or via specific holes for each of the liquid ingredients, which holes are conical and all preferably disposed on the disc-shaped wall  91  in the region within the track of sleeve  84   d , which turns with smaller radius about shaft  84   a . Same hole  93  can be used for blowing in hot air to clean and/or sterilize the chamber and rotating kneading elements  84 ,  84   c ,  84   d . The method for preparing dough with the dough mixer  24  according to this invention, has essentially the following phases: 
          Charging  94   b  with flour- or dust-like ingredients,     Homogenization and aeration of the flour- and/or dust-like ingredients,     Charging  93   a  with liquid ingredients,     Preparing the dough,     Rolling the dough thin,     Compacting and rolling the dough into balls     Discharging the individual dough portions        

      Following production of a pre-programmed number of dough portions and based on the production intervals, the chamber of the dough mixer  24  is cleaned and sterilized with hot air. 
          Charging  94   b  with flour-like and/or dust-like ingredients is by free fall through charging opening  82   a  equipped with sliding blades  82 , which is driven  82   b  by pneumatic cylinder  82   c . The construction and operation of the metering device  80 , in accordance with the invention, with discharging opening  85   e , corresponding to charging opening  82   a  of the dough mixer  24  with which it is connected, will be explained later.     The flour-like and dust-like ingredients are homogenized and aerated by rotating kneading element  84 ,  84   c ,  84   d  at a relatively high speed (approx. 2,500-3,000 rpm) that creates a favorable dispersion of the ingredients due to the special form of the chamber and kneading elements, wherein the particles of the dry ingredients are prepared for even absorption of the liquid ingredients following charging  93   a.       The dough mixture is prepared by rotating  84   a  kneading element  84 ,  84   c ,  84   d  at a lower rotation speed (approx. 950-1,400 rpm); this phase is followed initially by the formation of little dough clumps, which are then rolled together by the repeated action of rotating  84   b  sleeves  84   d.       The dough is then prepared by rotating kneading element  84 ,  84   c ,  84   d  at an even lower rotation speed (approx. 850-920 rpm); especially in this phase, the dough is repeatedly and intensely rolled out and rolled thin by the turning  84   b  sleeves  84   d , particularly at lower level surface section  81   b . The formation of a compact, balled together dough mass follows at an even lower rotation speed (approx. 700-820 rpm), thus taking on the form of a “dough ball” at the end of this phase.     The “dough ball” is discharged by centrifugal force via the rotating kneading element and by gravity through discharging opening  83   a , which is opened by activating  83   b  blade  83  by means of pneumatic cylinder  83   c.          

      During the various work stages, in particular during compacting, rolling out, and balling together the dough, it can be advantageous to make one or more changes in rotational direction  84   a  of kneading element  84 ,  84   c ,  84   d . Liquid ingredients can be charged  93   a  more or less in stages and while kneading element  84 ,  84   c ,  84   d  is rotating. For cleaning and/or sterilization of the chamber by injecting hot air, the cool air of motor  92  that drives  92   a  the kneading element or the air that is diverted from the pneumatic system can be used, the air being heated prior to its injection into the chamber.  
      The volumetric metering device  80  for the dry flour-like ingredients according to the invention comprises a cylindrical container  85 ,  85   a ,  85   b  with vertical axis, a distribution cone  87  with beaters  87   a ,  87   b  rotating  88   a  coaxially to the container axis, and a metering disk  89  with metering holes  89   a  on the rim which form the volume units for creating a total portion of flour  94  to be charged  94   b  into the dough mixer  24  in order to generate a single portion of dough.  
      Cylindrical vertical wall  85  is sealed with bottom plate  85   b , which provides a seating  85   c  for the bottom end of a vertically rotating  88   a  shaft  88  that is centrally seated  85   d  in cover plate  85   a . The upper end of shaft  88 , which extends beyond the cover plate  85   a , is equipped with a pulley  88   a  driven by the belt  88   b  of a motor  91  attached to the container. Shaft  88  can naturally be driven in other ways and by other sources of power. Inside, in the lower region, the container is equipped with an annular, funnel-like partition  86  for directing flour  94  in the direction of the container axis. The upper region of a distribution cone  87 , which is connected to drive shaft  88 , extends through the central opening in partition  86  such that an annular duct  86   c  results for flour; beaters  87   b  that extend down from the cone  86  and move closely above partition  86  cause flour  94  to pass through  94   a . Partition  86  and cone  87  prevent variations in the fill level of flour  94  and thus the weight above partition  86  from having an affect on the metering mechanism disposed beneath. This mechanism comprises metering disk  89  with holes  89   a  on rim that rotates together distribution cone  87  and drive shaft  88 ; individual holes  89   a , which are equidistant to the axis of rotation of the disk, represent with their volume the metering unit for creating the charging amount. Above metering disk  89  is a sieve  90  equipped with ducts  90   a  through which the flour is moved through at least one beater  87   c  which sticks out from cone  87 , and turns with drive shaft  89 , and moves above sieve  90 . On the underside, metering disk  89  lies on top of bottom disk  85   b  of the container. Bottom disk  85   b  has an outflow through hole  85   e  that corresponds in diameter to holes  89   a  on metering disk  89  or is of a greater diameter and in the region of the passage of these holes. Practice has shown that the construction described here allows volumetric metering that is independent of the fill level in the container, the moisture level and other physical properties of the contents, which metering is sufficiently constant and can be varied by one or more volume units that are determined by individual holes  89   a  on metering disk  89 . This feature of the metering device  80  is fundamental for achieving homogeneity in the individual dough portions, which requires charging with calibrated, homogeneous ingredients and attains this above all by assuring that the mixture does not put weight on the metering mechanism in a single casing  85 ,  85   a ,  85  which is fed via a relatively narrow annular duct  86   c  and, affected by simultaneous mixing motions in the container region above the partition  86  and in the emptying region of the metering holes  89   a  and at the metering disk  89 . Naturally, the amount of flour  94 , which moves through annular duct  86   c , must be at least as great, preferably somewhat greater than the amount which is fed to the dough mixer  24  for the purpose of maintaining the individual portion of dough.  
      The present invention does not exclude the possibility of linking the metering device  80  according to the invention to a dough mixer or another device that does not correspond to the dough mixer according to the invention.  
      Pre-Former ( FIGS. 7   a  Through  7   c )  
       FIGS. 7   a  through  7   c  illustrate various views of a pre-former  28 . The pre-former  28  receives the “dough ball” discharged by centrifugal force via the rotating kneading element and by gravity through the discharging opening  83   a  of the dough mixer  24 , which is opened by activating blade  83   b  by pneumatic cylinder  83   b.    
      The pre-former  28  is the first step of a process of shaping the “dough ball” into a flat cake for pizza preparation.  
      Referring to  FIGS. 7   a  through  7   c , the pre-former  28  includes a funnel housing  102  and a disc press  104 , which includes a disk plate  106 , a pneumatic cylinder  108  and a guide bar  110 .  
      Opening  113   a  at the top of funnel housing  102  is positioned below discharge opening  83   a ,  81   b  of the dough mixer  24 . The funnel housing  102  is fixedly connected to the underside of the housing  81  of the dough mixer  24 .  
      The “dough ball” enters opening  113   a , falls by gravity and comes to rest within the funnel housing  102  in the vicinity of a discharge opening  113   b  of the funnel housing  102 , as shown in  FIG. 7   a  by simulated “dough ball”  114 . The dough ball  114  is prevented from exiting the discharge opening  113   b  by a lower press plate  131  of the hot press  30  which has been movably positioned in two dimensions against the bottom of the funnel housing  102  at the discharge opening  113   b . The positioning of the lower press plate  131  against the bottom of the funnel housing  102 , covering the discharge opening  113   b , is timed to coincide with the activation  83   b  of the blade  83  which opens discharge opening  81   d ,  83   a  of the dough mixer  24 , which discharges the dough ball into the pre-former  28 .  
      The disk plate  106  is shaped as an inverted cup so that activation of the pneumatic cylinder  108 , lowering the disk plate  106  until contact with the lower press plate  131  shapes the dough ball  114  into a disc or puck. The disk plate  106  and the lower press plate  131  can be preheated to warm the dough ball  113  during shaping to expedite dough baking later in the pizza making process.  
      Hot Press ( FIGS. 8   a  and  8   b )  
       FIGS. 8   a  and  8   b  illustrate an upper press portion  125  and a lower press portion  127  of the hot press  30 . The upper press portion  125  includes an upper press plate  129  which is fixedly connected  130  to structure of the pizza making system  20 . The lower press portion  127  includes a lower press plate  131 , a support plate  132 , a buffer plate  133  and a pneumatic cylinder  134 . The lower press plate  131  is fixedly connected to the support plate  132  and separated therefrom by the one or more buffer plates  133 . As the lower press plate  131  is electrically heated to precook the dough during shaping, the one or more buffer plates  133  prevent the transfer of heat from the lower press plate  131  to the support plate  132  and the pneumatic cylinder  134 .  
      Referring to  FIG. 3 , the lower press portion  127  of the hot press  30  is slidable in one dimension due to connection to lateral track  136  and lateral conveyance system  138 . The lateral conveyance system  138  is pneumatically operated and programmed to slidably move the lower press portion  127  under the pre-former  28  with the pneumatic cylinder  134  raising the lower press plate  131  into contact with the underside of the funnel housing  102  to receive the dough ball discharged from the dough mixer  24 . After the pre-former  28  shapes the dough ball into a disk, the lower press plate  131  is lowered by pneumatic cylinder  134  and the lateral conveyance system  138  slides the lower press portion  127  to the position shown in  FIG. 3 . The pneumatic cylinder  134  than raises the lower press plate  131  against the upper press plate  129  to shape the dough into flat cake for pizza preparation.  
      Again, the upper press plate  129  and the lower press plate  131  are electrically heated to precook the dough during the shaping process.  
      Dough Punching Device ( FIGS. 9   a  and  9   b )  
       FIGS. 9   a  and  9   b  illustrate a side elevation and top plan, respectfully, of the dough punching device  32 . The dough punching device  32  includes a toothed punching plate  152 , a slidable housing  154 , a slidable support bracket  156  and two guide bars  158 .  
      Referring to  FIG. 3   a , the dough punching device is shown in its non-operating position. The guide bars  158  are fixedly supported to structure of the pizza making system  20 .  FIG. 9   b  is a top plan of the dough punching device  32  in this non-operating position. The slidable support bracket  156  is slidably attached to the guide bars  158  and fixedly attached to the slidable housing  154  which supports the two punching plates  152 . A dough punching conveyance system (not shown) is programmed to timely operate the dough punching device  32  after operation of the hot press  30  (shaping the dough into flat cake).  
      Upon completion of the hot press  30  operation, shaping the dough into flat cake, the pneumatic cylinder  134  lowers the lower press plate  131  back to the position shown in  FIG. 3   a . At this time, flattened pizza dough rests upon the lower press plate  131 . The dough punching conveyance system initiates slidable movements of the dough punching device  32  to an operable position shown in  FIG. 3   b . This operable position is also illustrated in  FIG. 9   a.    
      The pneumatic cylinder  134  raises the lower press plate  131  against a toothed underside of the punching plate  152  thereby dimpling the flattened pizza dough to facilitate uniform and expedited dough baking at a later stage of the automatic pizza making process.  
      The pneumatic cylinder  134  then lowers the lower press plate  131  to the position shown in  FIG. 3   a  and the dough punching device  32  returns to the non-operable position also illustrated in  FIG. 3   a.    
      Referring to  FIG. 1 , a pneumatic tilting stem  160  is then actuated to lift a distal end of the lower press plate  131  away from the support plate  132 , tilting the lower press plate  131  about a hinged attachment point  162  between the lower press plate  131  and the support plate  132  whereby the flattened, perforated pizza dough slides from the lower press plate  131  to a conveying tray  36  positioned under the tomato sauce dispenser  40 .  
      Summary of Dough Shaping and Dough Punching Process ( FIGS. 15   a  Through  15   f )—Includes Pre-Former, Hot Press and Dough Punching Device  
      The entire dough shaping and punching process is summarized below in conjunction with  FIGS. 15   a  through  15   f:  
           FIG. 15   a —the lower press portion  127  is slidably positioned along the lateral track  136  with the lower press plate  131  raised to contact the underside of the pre-former  28  to receive the dough ball and shape same into disc form.      FIG. 15   b —the lower press portion  127  is lowered away from the pre-former  28  and transports the disc-shaped dough along the lateral track  136  to a position for flattening under the upper press portion  125 .      FIG. 15   c —the lower press plate  131  is raised by the pneumatic cylinder  134  into contact with the upper press plate  129  to flatten the disc-shaped dough into flat cake for pizza preparation. The upper and the lower press plates  129 ,  131  are electrically heated to preheat the dough during the dough shaping to expedite the later baking of the pizza.      FIG. 15   d —after flattening, the lower press plate  131  is lowered and the dough punching device  32  slides along the guide bars  158  into an operating position under the upper press plate  129 .      FIG. 15   e —the lower press plate  131  is raised into contact with the toothed punching plate  152  thereby dimpling the flattened pizza dough to facilitate uniform and expeditious later baking of the pizza.      FIG. 15   f —upon completion of dough shaping and punching, the pneumatic cylinder  134  lowers the lower press plate  131 . The pneumatic tilting stem  160  then raises a distal end of the lower press plate  131  tiling same about a hinged attachment point  160  connecting the lower press plate  131  to the support plate  132 . The flattened and perforated pizza dough then slides from the lower press plate onto a conveying tray (not shown) under the tomato sauce dispenser  40  (also not shown). 
 
 Tray Conveying System ( FIGS. 1 and 2 ) 
       

      Referring to  FIGS. 1 and 2 , the tray conveyor system  38  operates horizontally at level  173  to transport one or more conveying trays  36  at level  172  from the tomato sauce dispenser  40  through cheese dispenser  42 , pepperoni dispenser  44  and sausage dispenser  46  to one of two ovens  50 ,  52 .  
      After dough shaping and punching is complete, and the lower press plate  131  is tilted by the pneumatic tilting stem  160  (as shown in  FIG. 1 ), the receiving rack  34  (tilted as shown in  FIG. 1 ) receives the flattened and perforated dough released by the tilted lower press plate  131 . A pneumatic cylinder  171  raises a distal end of the receiving rack  34 , tilting the receiving rack about a hinged or pinned attachment point  170  between the receiving rack  34  and structure of the pizza making system  20  until the receiving rack is horizontal as illustrated by position  34   a  of  FIG. 1 . The conveying tray  36  is positioned within the receiving rack  34  and is transported by the tray conveyor system  38  away from the receiving rack  34  and aligned precisely below the tomato sauce dispenser for liquid garnishment.  
      After application by the tomato sauce dispenser  40 , the tray conveyor system  38  transports the conveying tray  36  below the various dispensers  42 ,  44 ,  46  stopping if programmed below one or more of the dispensers  42 ,  44 ,  46  for respective topping application. The tray conveyor system  38  stops the conveying tray  36  at position  174  (shown in  FIG. 2 ) and directs the conveying tray  36  into one of the ovens  50 ,  52 .  
      The conveying tray  36  remains with the pizza during baking in the oven and returns the pizza to position  174  upon completion of baking. The cutting device  54  transports the prepared pizza from position  174  to a packaging position  175 . The conveying tray  36  is transported back and into the receiving rack  34  to receive the next flattened and perforated dough portion for pizza preparation.  
      The automatic pizza making system  20  as generally illustrated in  FIGS. 1 through 4 , can accommodate two conveying trays  36  operating simultaneously. As one conveying tray is positioned in one of the ovens  50 ,  52 , a second conveying tray is transporting a flattened and perforated dough portion along the various preparation stations. As the second conveying tray  36  enters the vacant oven, the first conveying tray  36  removes a completed pizza to position  174  and returns to the receiving rack  34  to repeat the preparation process while the second conveying tray  36  remains in the other oven. Accordingly, the automatic pizza making system  20  can accommodate the same number of conveying trays  36  as ovens included in the respective system. Although the automatic pizza making system  20  illustrated in  FIGS. 1 through 4 , includes two ovens and two conveying trays, the spirit of the present invention envisions various and multiple alternatives in oven and conveying tray design to accommodate the needs of any user.  
      Tomato Sauce Dispenser ( FIGS. 10   a  Through  10   d )  
      The object of the tomato sauce dispenser of the present invention is to meter and apply an even distribution of the tomato sauce on the flattened pizza dough, regardless of the inconsistency in homogeneity of some tomato sauces. The tomato sauce dispenser shall also facilitate easy cleaning and maintenance for good sanitation.  
      To achieve this object, the tomato sauce dispenser of the present invention equips a nozzle and/or end of a tube through which the sauce supplied with all the motions that are necessary to achieve the even distribution on the sauce without using special conveying means for the sauce through the tube.  
      The present invention uses a system of the spiral distribution, where the sauce falls onto the flattened pizza dough through a device that rotates about a vertical rotational axis. The rotating device has a threaded spindle that radially shifts the end of the tube or nozzle to dispense the sauce in a horizontal plane above the flattened pizza dough during rotation. Accordingly, the sauce is distributed in a spiral with constant gradient without moving the flattened pizza dough. In order to achieve a homogenous distribution, the speed of rotation (creating the spiral) is constant during the entire garnishing process. The spiral rotation preferably starts at the periphery of the flattened pizza dough and ends at the center. The number of revolutions of the device is increased in relation to the reduction of the radius of the spiral so that the sauce is always deposited onto the pizza at the same speed.  
      The even and regular distribution in spiral-shape is guaranteed, if it is ensured that the spiral has a constant gradient, the garnishing product is dispensed without interruption and evenly, and in particular that the speed with which the garnishing product touches the basic product is uniform. As an alternative, the even distribution of the garnishing product can also be achieved by adjusting the volume (dispensed volume) in relation to the changed speed with which the garnishing product touches the basic product below.  
      The tomato sauce dispenser includes a fixed basic frame with two horizontal plates; a friction ring or annular gear is mounted to the bottom plate in the region of a central bore, whereas on the top plate, a bushing is pivoted coaxially to this ring and this bore, which bushing is driven by an electric motor and permanently mounted to bearing plates for a threaded spindle; the rotation of this threaded spindle moves a carriage in the direction of the axis and to radially shift the end of the tube for supplying the sauce. The threaded spindle is driven via a friction disk which is in contact with the friction ring, or via an annular gear that engages the gear ring.  
      By rotating the bushing and thus the bearing of the threaded spindle in one direction, the radial shifting of the carriage via the threaded spindle in one direction is achieved, for instance, outwardly to the rotational axis of the bushing, whereas the friction disk or toothed gear that is connected with the threaded spindle rolls off the friction ring or annular gear which is mounted to the stationary frame. Reversing the rotational direction of the bushing results in the shifting of the carriage from the area of the rotational axis of the bushing outward, that is, into the margin area of the flattened dough underneath.  
      The flexible tube for supplying the sauce is routed freely through the rotating bushing. The tube is pivoted in the radially shiftable carriage so that the dispensed sauce can fall freely onto the pizza.  
      The positioning of the end of the tube prevents the tube from twisting or becoming entangled while the various motions of the device are performed and also allows easy disassembly and replacement of the tube for cleaning and maintenance. The tube is preferably one piece using a peristaltic pump for sauce supply. The invention does not exclude employing a constant rotational speed for the end of the tube dispensing the sauce, whereas the decreased radius of the spiral would result in a reduced volume of sauce being delivered so that the sauce is evenly deposited onto the pizza. In order to limit the required cleaning and to maintain good sanitation, the tomato sauce dispenser allows easy exchange of the tube, using a single exchange part with a single tube coupling.  
       FIG. 10   a  illustrates a top plan view of the tomato sauce dispenser according to the present invention.  FIG. 10   b  illustrates a front elevation section according to the plane II-II of  FIG. 10   a , the plane II-II comprising a vertical axis of the tomato sauce dispenser shown in  FIG. 10   a .  FIG. 10   c  illustrates a lateral view according to the plane III-III, partly in section, showing the carriage driven by the threaded spindle.  FIG. 10   d  illustrates the top plan view shown in  FIG. 10   a , without the case, exposing a mounting for the threaded spindle and the carriage.  
      Lateral carriers  181  are mounted to a frame  190  of a conveyor belt or conveyor chain  191  by clamps  181   a , the carriers  181  supporting at their top a plate  181   b  with central bore  181   c.    
      Above central bore  181   c  and coaxial to it, a second plate  183  is supported by arms  182 , the second plate  183  being spaced parallel to the first plate  181   b  and centered, in which the second plate  183  has a bushing  184  seated therein such that the bushing  184  can be rotated  183   r  via ball bearings  183   a . On an outer surface of the bushing  184 , a pulley or groove  184   a  is supported for a belt  188  that is used to transfer movement of a pulley  185   a  of an electric motor  185  to the bushing  184 . Two arms  183   e  are mounted to the bottom of the bushing  184 , which arms  183   e  extend downward and at the end of which vertical parallel bearing plates  186  are mounted for a rotatable  186   r  threaded spindle  186   c , a leading spindle  186   b  and a connecting element  186   a . The threaded spindle  186   c  is fitted with a friction disk  186   e  at one of its ends that protrudes over the bearing plates  186 , which friction disk  186   e  rolls off a friction ring  181   f  with its rubber-coated periphery  186   f . The friction ring  181   f  is mounted to the edge region of the central bore  181   c  of the plate  181   b  via rings  181   e ,  181   d . In order to ensure good contact between the periphery  186   f  of the friction disk  186   e  and the stationary friction ring  181   f , a ball bearing  186   d  is provided (seated at the same bearing plate  186 ), which ball bearing  186   d  provides a friction disk  186   e , parallel and perpendicular to the rotational axis above, in order to form a thrust bearing on top of the friction ring  181   f.    
      In accordance with rotation  183   r  of the bushing  184 , the arms  183   e  and the bearing plates  186  rotate together with the threaded spindle  186   c , the spindles  186   a ,  186   b  and a movable  189   t  carriage  189  connected thereto. The rotation  183   r  occurs when the friction disk  186   e  rolls on the stationary friction ring  181   f , the friction ring  181   f  being permanently mounted to the plate  181   b . The rolling friction disk  186   e  causes rotation  186   r  of the threaded spindle  186   c , the rotation  186   r  causing movement  189   t  in the carriage  189  due to an internally threaded nut  189   b  within the carriage  189  which engages the rotating threaded spindle  186   c . The carriage  189  provides a guide part  189   c , the guide part  189   c  including a seat  189   g  which glides along the stationary leading spindle  186   b . The rotation  186   r  of the threaded spindle  186   c  causes the carriage  189  to move  189   t  along the axis of the threaded spindle  186   c , whereas the guide part  189   c  slides along the stationary leading spindle  186   b  to prevent the carriage  189  from twisting. This mechanism allows for movement  189   t  of the carriage  189  to be linked to rotational movement  183   r , resulting in a spiral  193  distribution of the tomato sauce S with constant gradient. To ensure that the distribution of the sauce S on the flattened dough  192  is performed with uniform speed and independently of the distance of end  187   a  of tube  187  from the rotational axis of the bushing  184 , and thus from the center of the flattened dough  12  underneath, the number of revolutions of motor  185  during movement  189   t  of the carriage  189  from the outward area to the center area of the flattened dough  192  increases in relation to the decrease of the radius of the spiral  193 .  
      Tomato Sauce S is supplied under pressure, which pressure can be generated by a peristaltic pump. The sauce S is routed axially via the flexible hose  187  through passage  184   c  of the rotating bushing  184 , which bushing  184  has an internal ball bearing  184   b  to prevent friction with the tube  187  during rotation  183   r . The end  187   a  of the tube  187  for dispensing the sauce S is pivoted on ball bearing  189   d , which is mounted to the carriage  189 . The end  187   a  of the tube  187  is additionally routed through a ring element  189   e , which is also mounted to the carriage  189 .  
      The present invention does not exclude that the threaded spindle  186   c  only extends over an area that is slightly longer than the radius of the flattened dough  192  and that the threaded spindle  186   c  is driven by a toothed gear, which derives motion from a gear ring, which is connected to stationary structure of the system  20 . Furthermore, the invention does not exclude that the tomato sauce dispenser  40  is seated moveably so that it accompanies the flattened dough  192  while it is conveyed on conveying tray  36 , without stopping the conveying tray  36 , with the tomato sauce dispenser  40  returning to its initial position after the garnishing process is complete.  
      To achieve a uniform distribution, apart from the above described process which provides a change of rotational speed  183   r  with a constant supply of sauce S, a process can be used that maintains a constant rotational speed  183   r  while changing the supply of sauce S delivered in proportion to the change in the radius of the spiral (reducing the radius results in an increased supply capacity of the pump feeding the sauce).  
      Furthermore, the present invention does not exclude that the bushing  184  is seated within a single plate that covers the height of plate  181   b  and that has a friction ring  181   f  or an annular gear. In this alternative embodiment, axial passage  184   c  of the bushing  184  has a diameter that roughly corresponds to twice the movement distance of the carriage  189 . The threaded spindle  186   c  can also be seated within the passage  184   c  of the bushing  184 . The bushing  184  can also be replaced by a circular plate that is rotatably  183   r  seated on the stationary plate  181   b  and has a diametrically or simply radially arranged passage, within which or in the region of which the threaded spindle  186   c  and the carriage  9  are seated.  
      Cheese Dispenser/Sausage Dispenser ( FIGS. 11   a  Through  11   c )  
      Cheese and sausage dispenser  42 ,  46  of the automatic pizza making system  20  suitably applies any type of solid toppings, namely cheese, sausage, mushrooms pepperoni, etc., to the dough base prior to baking the pizza. Accordingly, cheese and sausage dispenser  42 ,  46  shown in  FIGS. 11   a  through  11   c  can also be used for the pepperoni dispenser  44  of the automatic pizza making system  20  shown in  FIGS. 1 and 2 . The cheese and sausage dispenser  42 ,  46  includes bulk portion control devices.  
      Cheese and sausage dispenser  42 ,  46  has a chamber  202  for holding bulk solid topping, a doser  204  attached to the chamber  202  and a motorized stirring device  206  attached to the doser  204  and used to feed the doser  204 . The doser  204  includes a slidable plate  210  fitted between two fixed plates  211 ,  212 . One of the fixed plates  211  is attached to the chamber  202  and the second fixed plate  212  is positioned above the pizza. The slidable plate  210  includes a number of openings  214  that are fed with a predetermined amount of solid topping from the chamber  202 . As the slidable plate  210  is moved, the openings  215  of the fixed plate  211  (attached to the chamber  202 ) are closed and the openings  216  of the fixed plate  212  (above the pizza) are opened, allowing portion of solid topping held within the openings  214  of the slidable plate  210  to fall onto the pizza.  
      Pepperoni Dispenser ( FIGS. 12   a  Through  12   d )  
      Pepperoni dispenser  44  of the automatic pizza making system  20  suitably applies any type of solid toppings, namely cheese, sausage, mushrooms pepperoni, etc., to the dough base prior to baking the pizza. Accordingly, pepperoni dispenser  44  as shown in  FIGS. 12   a  through  12   d  can also be used for the cheese dispenser  42  and the sausage dispenser  46  of the automatic pizza making system  20  shown in  FIGS. 1 and 2 . The pepperoni dispenser  44  includes mono-dose portion control devices.  
      The pepperoni dispenser  44  (mono-dose portion device) includes a number of stackable trays  255  having a number of dosing compartments  257  used to hold a solid topping  259 . The trays  255  are disposable and have registration features such as a dimple to maintain the trays  255  in alignment when stacked. The trays  255  are preloaded, stacked and stored with toppings  259  and may be held in place by a retainer  261 , such as a string, tape or plastic wrap. The trays  255  may be stored in a suitable modified atmosphere  263  for preserving freshness of the solid topping  259 .  
      The toppings  259  are dispensed from the stack of trays  255  as one is removed from the bottom of the stack. This is achieved by the use of the individually spaced dosing compartments  257  that are maintained in a closed position by the bottom most tray in the stack. As each tray  255  is slidably removed  265  from the bottom of the stack, the openings of the tray above it are opened to a pizza maintained below it and the solid topping  259  free fall  267  to the pizza below.  
      Ovens ( FIGS. 13   a  Through  13   f )  
      As shown in  FIGS. 1 through 4 , and detailed in  FIGS. 13   a  through  13   d , the automatic pizza making system  20  includes two ovens  50 , 52  for baking the freshly made pizza  1  transported to one of the two ovens  50 , 52  by means of ovenproof plate  302 . Each oven  50 , 52  includes a heat retaining housing, a pneumatic cylinder  312 , an opening  304   c , and a number of heating elements  307 ,  308 ,  310 . The electric components of the ovens  50 , 52  are powered and controlled by a controller.  
      As the pizza  1  approaches one of the ovens  50 , 52 , the controller activates the pneumatic cylinder  312 , which opens the opening  304   c  allowing the pizza  1  to enter the selected oven  50 , 52 . Once in the oven  50 , 52 , the pizza  1  is baked until done in stages maintained by the controller. The cooking method is determined by many factors, including the intensity, frequency, and duration of heat applied by one or more of the heating elements  307 ,  308 ,  310 , and the distance between the pizza  1  and the heating elements  307 ,  308 ,  310 . The intensity, frequency, and duration of the applied heat are set by the controller to achieve desired cooking qualities, such as surface browning, dough texture and crust crispness, each of which can be varied to accommodate consumer preferences.  
      In one embodiment of the invention, the heating elements include two arrays of infrared heating devices, one set of heating elements  308  including rays in the visible and near-infrared range and the other set of heating elements  307  including rays in the far-infrared range. Infrared rays in the visible and near-infrared range with wavelengths of 0.75 μm to 3 μm propagate in accordance with the laws of optics during transmission. Specifically, these rays pass through water molecules, and therefore steam, with little or no absorption. Infrared rays in the far-infrared range with wavelengths of 6 μm to 1,000 μm, on the other hand, propagate through space in accordance with the laws of electromagnetics, and are absorbed and converted into radiant energy (i.e., heat) as they pass through matter.  
      The invention employs a cooking method employing infrared wavelengths in the visible and near-infrared range concurrently or staggered with infrared wavelengths in the far-infrared range. When pizza cooking, the infrared rays with wavelengths in the visible and near-infrared range penetrate the pizza, in the presence of water (in the form of water vapor), to a depth of about 10 mm to 15 mm. Infrared rays in the far-infrared range penetrate about 0.5 mm to 0.8 mm.  
      To maintain the depth of penetration of the infrared rays in the visible and near-infrared range, the outer layer of the pizza or thin cake should remain moist during cooking, as that would maintain a layer capable of absorbing all or most of the visible and near-infrared radiation, preventing the rays from failing to penetrate the pizza and excessively overheating the outer layer with respect to the rest of the dough. It is an object of the present invention, therefore, for infrared rays in the visible and near-infrared range to predominate initially, and for rays in the far-infrared range to be applied at the very end of the cooking process for surface browning. The cooking method of the present invention also calls for an initial heating cycle of a given duration, which raises the temperature of the thin cake very rapidly, quickly overcoming the thermal inertia of the dough and compensating for heat energy lost to the dispersal of fermentation gases, the evaporation of ethyl alcohol produced as the dough rises and the formation of water vapor.  
      The cooking method then calls for a programmed series of heating cycles of decreasing duration with intervals between them that can be varied to prevent too much moisture from evaporating quickly from the thin cake, thereby sustaining deep penetration of the rays in the visible and near-infrared range for as long as possible. In a final stage the thin cake is heated for approximately the same amount of time as the initial heating period. This forms dextrins in the crust, which browns to form a thin textured layer, and imparts aroma and crispness through dextrinization and pyrolysis of starch.  
      An oven built according to the invention and operating according to the disclosed cooking method can cook and brown a topped pizza in approximately 55 seconds. In addition, the thermal inertia of the housing of the oven is as low as possible, since its internal surfaces are shaped to reflect the rays onto the thin cake. In another embodiment of the invention, some or all of the radiation sources are mounted to move (with or without reflectors), thereby varying the distance from the source to the surface of the thin cake during the cooking process.  
      The present invention could also include the use of a microwave generating magnetron, in addition to the sources of infrared rays. For fast cooking, a radiation or heat source could also be positioned below the pizza. In such an event, lamps emitting infrared rays in the far-infrared range could be used as a radiation source, and the thin cake could be supported on a perforated plate or grille such that at least some of the rays act directly on the thin cake while some heat the support which transfers heat to the thin cake by contact. If an induction unit is included in the oven, the plate is made of metal and provided with slits, or spiral or concentric circular openings, to transfer the heat by contact.  
      The cooking method of the present invention may call for programming of the radiation and/or heat sources depending upon the toppings on the pizza to accordingly vary the heating times, the number and duration of heating cycles, the intensity (e.g., heating using a larger or smaller number of units), the distance between the sources and the pizza and/or the position or shape of the reflectors, if any.  
      The oven of the present invention could be a bell-type oven having a stationary lower part and a moveable upper part to facilitate oven feeding using a mechanical transport means and to limit the cooking volume of the oven by completely shielding the radiation. However, the invention does not preclude application of the cooking method to other types of ovens, such as tunnel or muffle ovens. Also, the radiation sources, specifically the induction unit, may act independently of the infrared lamps or partially in conjunction with the radiation sources.  
       FIG. 13   a  illustrates a sectional view of ovens  50 ,  52  along a vertical plane parallel to the longitudinal axis of the transport mechanism of the system  20  and transverse to the lamps. The upper part of the oven is provided with lamps emitting infrared rays in the visible and near-infrared range and lamps emitting infrared rays in the far-infrared range. The upper part of the oven moves vertically, and is shown in a raised position with the transport plate and pizza in the cooking position. The stationary lower part of the oven is provided solely with lamps emitting infrared rays in the far-infrared range.  
       FIG. 13   b  illustrates a sectional view of the oven in  FIG. 13   a  along a vertical plane parallel to the arrangement of the lamps.  
       FIG. 13   c  illustrates a sectional view of an oven built and equipped similar to the oven shown in  FIG. 13   b , the upper part additionally provided with a microwave emitting magnetron.  
       FIG. 13   d  illustrates a sectional view of the oven in  FIG. 13   c  in a closed position, and replacing the infrared lamps in the lower part with an induction unit.  
       FIG. 13   e  illustrates a schematic diagram of the penetration of infrared rays and transmission of heat into the thin cake being cooked.  
       FIG. 13   f  illustrates a simplified diagram of the cooking method according to the invention.  
      The ovens  50 , 52  are bell-type ovens attached to a known horizontal transport mechanism  303  for a plate  302  supporting the pizza  1 . The lower part  304  of the ovens  50 , 52  is mounted stationary on the frame of the transport mechanism  303  with a pan  306  at the bottom that can be removed for cleaning. The frame  305  of the lower part  304  can be made from sheet metal with heat retaining internal surfaces, or the frame  305  could be provided with reflectors. The lower part  304  of the ovens  50 , 52  can include lamps  307  emitting infrared rays in the far-infrared range ( FIGS. 13   a ,  13   b , and  13   c ) or an induction unit  310  ( FIG. 13   d ). If the lower part  304  includes infrared lamps  307 , the lamps may be mounted stationary with respect to the pizza  1 , or mounted such that the distance from the pizza  1  could be vertically adjusted during various cooking cycles. In such event, the plate  302  is perforated or grille-shaped. If the lower part  304  includes an induction unit  310  ( FIG. 13   d ), the transport plate  302  is metal and provided with slits, or spiral or concentric circular openings.  
      The upper part  304   a  of the oven  50 , 52  can be moved vertically  304   b  by a pneumatic cylinder  312  anchored to a stationary frame  311  of the transport mechanism, whose piston acts upon a reinforced top  304   c  of the bell  305   a . The inside of the bell  305   a  is provided with an array of lamps  307  emitting infrared rays in the far-infrared range and, above them, lamps  308  emitting infrared rays in the visible and near-infrared range.  
      The two sets of lamps  307 , 308  may be mounted at a given fixed distance from the pizza  1  being cooked, or one or both sets of lamps  307 , 308  may be mounted so that the distance can be adjusted prior to or during the individual cooking cycles. Of course, the invention does not preclude using lamps  307 , 308  that are ring-shaped or shaped differently than as shown in the drawings.  
      Lamps  308  emitting infrared rays in the visible and near-infrared range are normally provided with internal reflectors. However, the invention does not preclude the use of special reflectors for one or both types of the lamps  307 , 308 . The reflectors can be mounted stationary so that they can be adjusted along with the lamps, and/or the reflectors may be mounted so that they can be adjusted and/or reshaped independently of the lamps, in order to vary the concentration of rays on the pizza  1  being cooked.  
      The upper part  304   a  of the oven  50 , 52  may also be provided with magnetrons  309  to assist the lamps  307 , 308  in overcoming the thermal inertia of the thin cake, and/or for cooking toppings with little or no moisture content, and/or decreasing the duration of the final surface browning cycle.  
      In one embodiment of the invention, the lower part  304  and the upper part  304   a  of the oven  50 , 52  are made from a thin material with low thermal resistance, having a double wall  305   b  providing protection and safety, and thermal insulation having no significant influence on cooking time or energy consumption.  
      The cooking method of the present invention is based on the specific penetration properties of infrared wavelengths in the visible and near-infrared range emitted by lamps  308 , and the infrared wavelengths in the far-infrared range emitted by lamps  307 . Referring now to  FIG. 13   e , in the presence of water molecules (and water vapor as well) infrared wavelengths in the visible and near-infrared range “Iv” penetrate “P” through the top surface “S” and into the dough “M” of the pizza or thin cake. These wavelengths are absorbed and converted into heat energy as they pass through (nontransparent) matter, transferring the heat “T” to the surrounding dough. By contrast, the infrared wavelengths in the far-infrared range “If” emitted by the lamps  307  only penetrate to a depth of 0.4 mm to 0.8 mm. As a result, these wavelengths only act on the top surface “S” of the pizza being cooked.  
      Referring now to  FIG. 13   f , to fully and quickly cook the pizza or thin cake  1 , the invention employs an initial heating cycle “A”, including exposure to infrared rays in both the “Iv” and “If” ranges, during which the mass of dough “M” and top surface “S” are preheated without excessively drying the top surface “S”. The initial cycle “A” is followed by a series of cycles “C” of varying but generally decreasing duration, during which infrared rays in the “Iv” and “If” ranges alternate with intervals “I” between the cycles to allow water molecules to diffuse into the top surface “S” in the form of steam, so that the “Iv” wavelengths can penetrate “P” into the dough “M”. Such penetration “P” naturally decreases as the moisture decreases and water vapor evaporates. The top surface “S” is browned during the extended final cycle “G”, using “Iv” and “If” wavelengths, since the “Iv” wavelengths now concentrate in the top surface “S” due to the decreasing moisture content in the top surface “S”, thereby reinforcing the “If” wavelengths to heat, dry, and brown the top surface “S”.  
      The cooking method of the present invention also modulates the energy emitted in the form of “Iv” and “If” wavelengths for the various cycles “A”, “C” and “G” by differentiating the time the two types of infrared lamps  307 , 308  are lit, and/or by varying the number of lamps lit, and/or by varying the position of the lit lamps in relation to the pizza or thin cake  1 , and/or by the position or shape of the reflectors.  
      In addition, the cooking method could include the combined action of a microwave generator (magnetron)  309  and/or an induction unit  310  in conjunction with the infrared lamps  307 , 308 . The additional devices  309 , 310  can emit energy during all or part of the cycles “A”, “C” and “G” described above, including all or part of the intervals “i” between the cycles, or solely during the intervals “i”.  
      Automatic Cutting Device ( FIGS. 14   a  Through  14   f )  
      The automatic cutting device of the present invention provides a simple, easy-to-clean cutting and transfer device that uses some of its cutting movements to transfer the pizza. The cutting device attaches a sheet that slides vertically by its own weight or by spring action to a side of a plate provided with blades. After cutting the pizza, the sheet holds the cut pizza in the cutting position as the plate that supports the pizza during cutting moves horizontally, dropping the pizza onto the top box of a stack of take-out boxes disposed below. Alternatively, the sheet assists the transfer of the pizza onto a take-out box to one side as the entire cutting device moves laterally, lifting the plate provided with blades once the pizza is placed on the box.  
      The cutting device also provides blades that can easily be detached from the plate that holds them for replacement and cleaning, regardless of whether said blades are interchangeable with single-use blades or coated with a sheath or layer that can be removed easily at the end of a predetermined cutting cycle, thereby making the cutting device as hygienic as possible.  
      For an embodiment of the present invention having mechanisms that move laterally, the cutting device is mounted to move in the direction of transfer of the pizza, providing a support for the take-out box or other packaging. To transfer the cut pizza from the cutting position to the packaging position, the plate provided with blades and vertically sliding sheet remains in the lowered, cutting position, or lifts slightly, as it moves toward the packaging position, dragging the pizza and sliding it off the transport plate onto the box positioned alongside. Once properly positioned over the box, the plate provided with blades lifts and moves back into position over the cutting area.  
      A threaded rod and nut screw can advantageously be used to move the cutting device. The cutting mechanism is mounted on a carriage assembly that rolls on tracks. Rotating the threaded rod mounted on a stationary frame moves a nut screw attached to the carriage assembly. However, the invention does not rule out using a pneumatic or hydraulic cylinder, or mechanical means such as chains, belts or rackwork to move the cutting mechanism.  
      Two embodiments of the pizza cutting and transfer device according to the present invention are illustrated in the accompanying drawings, which are not intended to limit the scope of the invention.  
       FIG. 14   a  illustrates a front view of one embodiment of the automatic cutting and transfer device, showing a plate provided with interchangeable blades and a vertically sliding sheet in a raised position over the pizza, the pizza resting on a movable transport plate in a position above a stack of take-out boxes.  
       FIG. 14   b  illustrates a front view of the cutting and transfer device of  FIG. 1 , showing the plate provided with interchangeable blades in a lowered, cutting position with a lower edge of the vertically sliding sheet resting on a top surface of the movable transport plate.  
       FIG. 14   c  illustrates a front view of the cutting and transfer device of  FIG. 1 , showing the transport plate after it has moved from the cutting position with the plate provided with blades in a lowered position and the pizza resting on the top take-out box in the stack of boxes underneath.  
       FIG. 14   d  illustrates a front view of another embodiment of the automatic cutting and transfer device, where the cutting device transfers the pizza by dragging the pizza as it moves. The plate provided with stationary blades and a vertically sliding sheet is shown in a lowered, cutting position, while dotted lines show the cutting device in a raised position after moving to a packaging position.  
       FIG. 14   e  illustrates a top view of the cutting and transfer device of  FIG. 14   d.    
       FIG. 14   f  is a left side view of the cutting and transfer device of  FIG. 14   d.    
      The cutting and transfer device  54  for pizza  1  or focaccia according to the present invention includes a circular plate  404 , having fixed or interchangeable vertical blades  404   b  attached to the bottom thereof, and a sheet  404   e  that slides vertically by its own weight or by spring action on stationary pins  404   g  on the edge of the plate  404 . The pins  404   g  engage in corresponding vertical slots  404   f  in the vertical sliding sheet  404   e.    
      If interchangeable blades  404   b  are used (as shown in  FIGS. 14   a ,  14   b ,  14   c ), the plate  404  is provided with a series of radial cuts for insertion of upper tabs  404   d  of the interchangeable blades  404   b , the tabs  404   d  being provided with a hole into which small pins or cotters  404   c  are inserted transversely to hold the tabs  404   d  in place. Specifically, the fixed blades (as shown in  FIGS. 14   c ,  14   d ,  14   e ) or interchangeable blades can be coated with a layer (e.g., applied by immersion, spraying on, or as a preformed sheath made from paper or plastic) that can be removed for easy cleaning of the blades. The plate  404 , together with the blades  404   b  and vertical sliding sheet  404   e , can be moved vertically  404   a  by a pneumatic cylinder  405  with a rod  405   a  and piston.  
      The cutting device of the present invention is substantially identical for the two embodiments illustrated in the figures, whereby the transport plate  402  transfers the pizza  1  to the take-out box  403  or other packaging. The sliding sheet  404   e  mounted laterally on the plate  404  provided with blades  404   b  performs one of two functions. The sliding sheet  404   e  may act simply as a projection to catch the edge of the pizza  1  and hold it while the transport plate  402  moves  402   a  from the cutting position, leaving the pizza  1  resting on the top take-out box in the stack  403  of boxes disposed below the cutting position ( FIG. 14   c ). Alternatively, the sliding sheet  404   e  may act as a transfer means to push  405   b  the pizza  1 , sliding the pizza  1  off the transport plate  402  in the cutting position onto the box  403  in a packaging position ( FIG. 14   d ). In the latter case, the transfer plate  402  may be replaced by a conveyor belt or other known transport means.  
      In the embodiment ( FIGS. 14   d ,  14   e ,  14   f ) where the sliding sheet  404   e  acts as a transfer means (this embodiment is also shown in  FIGS. 1, 2  and  4 ), the cutting device  54  includes the plate  404  provided with blades  404   b  and vertically sliding sheet  404   e , and includes a cylinder  405  with a rod  405   a  and piston mounted to move horizontally  405   b  by a plate  410  fastened to the cylinder  405  and provided with four wheels  409  which roll on parallel, horizontal tracks  407  mounted on a stationary frame  408 . A nut screw  407   a  is anchored to the plate  410  and receives a threaded rod  406   b  driven  406   c  by a motor  406  provided with a reduction unit  406   a , all forming a single piece with the stationary frame  408 . As the threaded rod  406   b  is rotated in one direction or the other  406   c , the nut screw  407   a  (along with the plate  410  and the cutting device  404 ,  404   b ,  405 ) moves  405   b  between the cutting position ( 174  in  FIG. 2 ) and the packaging position ( 175  in  FIG. 2 ), where a take-out box  403  or other packaging is predisposed on a support  403   a.    
      For the  FIG. 14   d ,  14   e ,  14   f  embodiment, where the cutting mechanism moves horizontally, the pizza  1  is cut and transferred to the take-out box  403  or other packaging in the following stages: 
          The cooked pizza  1  on the transport plate  402  is moved into the cutting position by transfer means  402   b.       The pizza  1  is cut by lowering  404   a  the plate  404  provided with blades  404   b . The sheet  404   e  rests on the top surface of the transport plate  402 .     The blades  404   b  lift almost imperceptibly from the surface of the transport plate  402 . The sliding sheet  404   e  continues to rest on the surface by its own weight.     The threaded rod  406   b  rotates  406   c , moving  405   b  the cutting device  404 ,  404   b ,  405 ,  405   a  toward the packaging position. The blades  404   b  and sheet  404   e  drag the cut pizza  1  off the plate  402  onto the box  403  that rests on support  403   a.       The plate  404  and blades  404   b  lift  404   a.       The cutting device  404 ,  404   b ,  405 ,  405   a  moves  405   b  to the cutting position for the next cooked pizza  1 .        

      An advantage of the pizza cutting and transfer device  54  of the present invention is that it can be employed independently of the type of discontinuous or continuous mechanism used to transport the pizza  1  into the cutting position (single plate, chain-driven series of plates, belt) or the method used to stock the packaging position (packaging disposed in stacks or individually).  
      These and other advantages of the present invention will be apparent to those skilled in the art from the foregoing specification. Accordingly, it will be recognized by those skilled in the art that changes or modifications may be made to the above-described embodiments without departing from the broad inventive concepts of the invention. It should therefore be understood that this invention is not limited to the particular embodiments described herein, but is intended to include all changes and modifications that are within the scope and spirit of the invention.