Patent Document

BACKGROUND 
     The present application is related to methods for producing snack foods and more particularly pita chips. 
     Pita chips have been produced for some time. Typically, pita chips are produced from a normal sized pita that is cut into triangular shapes, which results in generally flat and often irregularly shaped chips. This is problematic for the consumer in that these chips are not well suited to be used for scooping dip. Accordingly, there is a need for a method for producing pita chips that are not so limited. 
     SUMMARY 
     The present invention provides a method and a conveyorized system for slicing for slicing pita chips. The system comprises a first conveyor belt configured to transport whole pita chips from a first location of the conveyorized system to a second location of the conveyorized system and a third location of the conveyorized system, a second conveyor belt configured to transport the whole pita chips in conjunction with the first conveyor belt from the second location of the conveyorized system to the third location of the conveyorized system wherein the whole pita chips are disposed in a gap between the first conveyor belt and the second conveyor belt, the first conveyor belt is below the whole pita chips and the second conveyor belt is above the whole pita chips, and a slicing means configured to slice the whole pita chips into two halves at the third location of the conveyorized system, the slicing means including a blade and a blade guide. 
     In one embodiment, the slicing means comprises a horizontal band slicer. The whole pita chips may have a diameter between about 2 inches to about 2.5 inches. According to another embodiment, a slicing portion of the blade and the blade guide are configured in the gap approximately equidistance between the first conveyor belt and the second conveyor belt. In a further embodiment, the blade guide is configured on a back side of the slicing portion of the blade and partially around a top side and a bottom side of the slicing portion of the blade. In yet another further embodiment, the blade guide is configured to provide two channels for the two halves of the whole pita chips. 
     According to one embodiment, the blade is configured in a plane substantially parallel with the first conveyor belt and the second conveyor belt. 
     In another embodiment, the blade is operable in a rotating slicing motion. For a further embodiment, the rotating slicing motion is in a direction perpendicular to the planes of the first conveyor belt and the second conveyor belt. 
     Yet another embodiment includes wherein the first conveyor belt and the second conveyor belt are angled in a V shape at at least one of the second location of the conveyorized system and the third location of the conveyorized system. 
     The method comprises transporting whole pita chips on a first conveyor belt from a first location of the conveyorized system to a second location of the conveyorized system and a third location of the conveyorized system, wherein transporting the whole pita chips from the second location of the conveyorized system to the third location of the conveyorized system, the whole pita chips are disposed in a gap between the first conveyor belt and a second conveyor belt, the first conveyor belt is below the whole pita chips and the second conveyor belt is above the whole pita chips, and slicing the whole pita chips into two halves at the third location of the conveyorized system by a slicing means, the slicing means including a blade and a blade guide. 
     In one embodiment, the slicing means comprises a horizontal band slicer. The whole pita chips may have a diameter between about 2 inches to about 2.5 inches. According to another embodiment, a slicing portion of the blade and the blade guide are configured in the gap approximately equidistance between the first conveyor belt and the second conveyor belt. In a further embodiment, the blade guide is configured on a back side of the slicing portion of the blade and partially around a top side and a bottom side of the slicing portion of the blade. In yet another further embodiment, the blade guide is configured to provide two channels for the two halves of the whole pita chips. 
     According to one embodiment, the blade is configured in a plane substantially parallel with the first conveyor belt and the second conveyor belt. 
     In another embodiment, the blade is operable in a rotating slicing motion. For a further embodiment, the rotating slicing motion is in a direction perpendicular to the planes of the first conveyor belt and the second conveyor belt. 
     Yet another embodiment includes wherein the first conveyor belt and the second conveyor belt are angled in a V shape at at least one of the second location of the conveyorized system and the third location of the conveyorized system. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a flow diagram of a method for producing scooped shaped pita chips according to at least one embodiment. 
         FIG. 2  is a conveyorized baking system for producing scooped shaped pita chips according to at least one embodiment. 
         FIG. 3  is a conveyorized slicing system for cutting scooped shaped pita chips according to at least one embodiment. 
         FIG. 4  illustrates a back view of a cutting mechanism according to at least one embodiment. 
         FIG. 5  illustrates a front view of a cutting mechanism according to at least one embodiment. 
         FIG. 6  illustrates an overhead view of a cutting mechanism according to at least one embodiment. 
         FIG. 7  illustrates a cross section view of a portion of a cutting mechanism according to at least one embodiment. 
         FIG. 8  illustrates a cross section view of a portion of a conveyorized slicing system according to at least one embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     The present application generally provides methods and for producing scooped shaped pita chips. In certain embodiments, the chips are created using conventional pita baking equipment. That is, the chips may be formed into scoop shapes without using an appropriately shaped blank. Moreover, the chips are not necessarily cut out from larger pitas. Instead, according to one embodiment, each chip is created from a single pita appropriately sized so that no cutting is required. 
     Referring to  FIGS. 1 and 2 , in at least one embodiment, the method of producing scooped shaped chips begins by preparing the pita dough at  102 . The pita dough is generally a mixture that includes, inter alia, flour, salt, yeast, and water that is mixed until pliable. Mixing may be accomplished by hand or preferably with a mixing machine  200  that receives ingredients from one or more tanks  202 . Once the dough is prepared, the dough is formed into appropriately sized essentially circular sheets of dough at  104 . The circular sheets of dough may be formed in a variety of ways. Preferably, the circular sheets are formed by first sheeting the dough at  106  with a dough sheeter  204  to form a continuous sheet of dough having a thickness of about 1.5 mm to about 2.0 mm. Thereafter, a dough press  206  is used to cut the circular shaped dough out of the continuous sheet of dough. The dough press  206  cuts circular shapes having a diameter of about 1 inch to about 3 inches, preferably of about 2 inches to about 2.5 inches, or more preferably of about 2.25 inches. 
     Alternatively, the circular sheets of dough may be formed by extruding and subsequently cutting the extruded dough at  108  into roughly shaped dough balls that when flattened, result in a circular sheet having the dimensions noted above. Preferably, the dough balls are between about 10 grams and about 14 grams, or preferably about 12 grams. The roughly shaped balls may then be fed into a dough balling machine  208  that shapes the chunks into essentially spherical balls with a well-developed skin. The dough balls may then be fed through a sheeting machine  204  at  110  that passes rollers over the balls in two essentially perpendicular directions to flatten the balls into the desired circular shaped dough sheets. 
     The circular sheets of dough may then be fed into a conveyorized multi-tiered proofer  210  at  112 . Preferably, the proofer  210  is maintained at a temperature of between 75° F. and 95° F. and a humidity level of between 45% and 65%, for about 10 minutes to about 25 minutes. Once proofed, the circular sheets may then be fed into a baking oven  212  for baking at  114  at a temperature of over 500° F. for a sufficient time to cause the planer surfaces of the circular sheet to sear on the outside and subsequently to cause the circular sheet to separate into layers and balloon as the steam within the pita expands. As the ballooned sheet continues to cook, the initially uncooked inside of the pita solidifies to lock in the balloon shape. That is, each of the upper and lower layers of the pita is form into a cupped shape. The baking occurs from about 25 seconds to about 90 seconds, depending on the dimensions of the pita. 
     After baking, the ballooned shaped pitas are cooled at  116  for about 20 minutes to about 40 minutes. Because of the relatively small size of the pitas, the pitas retain the ballooned shape after cooling. Once cooled, the ballooned pitas are then passed onto a horizontal band slicer  214  at  118  that is adjusted to slice the ballooned pitas at the seam, i.e., at the intersection of the upper and lower layers. Slicing of the ballooned pitas is described in further detail with respect to the description of  FIG. 3  through  FIG. 8 . Once split at  118 , an individual pita will result in two concave pita halves. The pita halves may be 2-2.5 inches round or slightly oval in dimension. The pita halves may then be sprayed with oil and seasoned at  120 , and then passed into a toasting or drying oven at  122 . The drying oven is preferably set between 275° F. to about 375° F. and the pita halves are dried for about 7 minutes to about 20 minutes depending on the temperature and airflow in the drying oven. Alternatively, the oil and seasoning may be applied to the pita halves after drying. 
       FIG. 3  presents a conveyorized slicing system for cutting scooped shaped pita chips according to at least one embodiment. As described above, the baked pitas  310  are transported to a horizontal band slicer after cooling. The baked pitas may take the form of “pocket” pitas comprising a piece of dough that blisters while baking in the oven such that a pocket is formed with a top and bottom layer. According to another embodiment, the baked pitas may be “pocketless.” The horizontal band slicer is capable of slicing both pocket and pocketless pitas. 
     A continuous feed of pitas are carried on a belt  302  by belt pulley  306  from a first location to a second location on the conveyorized system. At the second location, the pitas  310  reach belt pulley  308  and come into contact with a belt  304  that is above the belt  302  and pitas  310  such that pitas  310  are disposed between belt  302  and belt  304 . Belt  302  and belt  304  are pulled via belt pulley  306  and belt pulley  312 , respectively. According to one embodiment, the belts may be wrapped around pressing rollers to double task the pressing rollers ( 204 ) as belt pulleys. In such a configuration, the belts remain in constant contact with the pitas all the way through the pressing and slicing at the blade so there is no loss of traction. A gap is allocated between belt  302  and  304  for the pitas  310 . The gap is adjustable and is configured to a predetermined size suitable for fitting the baked pitas. 
     While disposed between belts  302  and  304 , the pitas  310  can be carried towards and fed to a blade and blade guide configuration  312  at a third location on the conveyorized system comprising the horizontal band slicer  400 , as illustrated in  FIG. 4 . Horizontal band slicer  400  includes a blade  402 , blade guide  404  and blade pulleys  406 . The horizontal band slicer  400  is capable of operating blade  402  in a circular or rotating slicing motion. According to one embodiment, the slicing motion of blade  402  moves in a direction perpendicular to the planes of belts  302  and  304 . Blade and blade guide  312  may be configured wherein a portion of blade  402  and/or blade guide  404  are configured in a gap approximately an equidistance between belts  302  and  304 . 
     The portion of the blade configured in the gap herein referred to as the “slicing portion.” The blade  402  may be configured in a plane parallel with or substantially parallel with the belts  302  and  304 . Pitas  310  approach the slicing portion of blade  402  as seen from the front view presented in  FIG. 5  and sliced with blade  402  on the front side (slicing side) of horizontal band slicer  400 .  FIG. 6  and  FIG. 7  present an overhead view and a cross section view of blade  402  and blade guide  404 , respectively. The blade guide  404  may be configured at the back side of the horizontal band slicer  400 , opposite the slicing side, and partially around the top and bottom sides of the slicing portion of the blade  402 , leaving the portion of the front side (slicing side) of the blade exposed. 
       FIG. 8  presents a cross section view of the blade  402 , blade guide  404 , belt  302 , belt  304 , and a pita  310  A. A portion of belt  302  and belt  304  (e.g., the second or third location of the conveyorized system) may be angled in a “V” shape towards blade  402  and blade guide  404  in a fashion to allow for the two pita halves to pass through between the belt pulleys  306  and  312  and the blade guide. Blade guide  404  provides two channels where a pair of pita halves (resulting from the bifurcation of a pita) may be directed by belts  302  and  304  pass the blade  402 . The two channels may vary from approximately ¼ of an inch to half an inch in width. The blade guide  404  illustrated in  FIG. 8  includes sections that follow along the top and bottom sides of the slicing portion of the blade  402  and angles or tapers towards the front side of the blade. Pita  310  A upon contacting with blade  402  is sliced into two halves. 
     The blade guide  404  is configured to stabilize and maintain blade  402  straight, prohibiting movement to occur as pita  310  A makes contact with the front side of the blade  402 . According to one embodiment, blade guide  404  is substantially thin towards the front of blade  402 , tapering in width from approximately ⅛″-¼″ in the front to approximately ½″ in the back, and includes a center gap about ⅛″-¼″ in width for configuration of blade  402 . The thin front of the blade guide  404  allows fitment of blade  402  between and allows belts  302  and  304  to be brought extremely close together. A thicker back of the blade guide  404  helps create the a respective channel for each sliced half of pita  310  A in addition to providing a backbone/support to the blade guide  404  that prevents movement of the blade  402  when pitas make contact with blade  402 , thereby ensuring each pita is slice perfectly in half. A given pita  310 A is extremely thin (about half an inch) and the top and bottom skins resulting from slicing the pita  310 A into halves, each approximately have half the thickness of pita  310 A (¼ of an inch). One pita half may be transported by belt  302  on the bottom side of the blade guide  404  while the other pita half may be transported by belt  304  on the top side of the blade guide  404 . Thereafter, the pita halves may be seasoned and toasted. By slicing the pitas in the described manner, there is a 95% success rate slicing every pita perfectly in half. 
     While the foregoing has been described in some detail for purposes of clarity and understanding, it will be appreciated by one skilled in the art, from a reading of the disclosure, that various changes in form and detail can be made without departing from the true scope of the invention.

Technology Category: 1