This invention is in the field of pre-made sandwiches which are produced in a factory and sold either to the consumer or a food preparation outlet to be heated or cooked immediately prior to being consumed. BACKGROUND ART

DISCLOSURE OF THE INVENTION

In a first aspect the invention consists in a sandwich comprising: a first slice from a loaf of bread, a second slice from a loaf of bread with a cut face thereof inwardly directed and substantially parallel to the proximate cut face of said first slice, the perimeters of each slice being substantially aligned, an edible filling or fillings positioned between said slices of bread and an edible adhesive material which holds the structure together by either or both

(a) holding outer regions of each said slice one to the other and/or

(b) holding each slice to the filling or fillings and such filling or fillings to the other slice.

Preferably said adhesive material is applied as a melted material and sets to a gel or solid which provides the bonding properties.

Preferably said adhesive material is a viscous liquid.

Preferably said edible filling(s) is embedded or partially embedded into said slice(s) by means of the compression of the assembled sandwich.

Preferably said sandwich, slices and/or filling(s) are/is chilled to speed the set of the adhesive material.

Preferably said adhesive material is selected from gelatine, food gum, a starch solution, butter fat, a simulated butter fat and/or any mixture thereof.

Preferably there are three slices from a loaf of bread and a filling between each of the two proximate pairs of slices. Preferably said sandwich is individually wrapped.

In a further aspect the invention consists in, as a stack, a plurality of sandwiches in accordance with the present invention wherein the adhesion between individual preformed sandwiches is less than that caused by said edible adhesive material providing

the integrity of each preformed sandwich.

Preferably said stack is packaged as a commodity.

Preferably separation sheets are provided between individual preformed sandwiches. In a further aspect the invention consists in, as a marketable commodity for toasting, a wrapped sandwich as previously defined and/or a wrapped stack of preformed sandwiches as previously defined.

In still a further aspect the invention consists in a method of providing a factory assembled sandwich for supply to an end user which comprises providing to an assembly zone a serially useable supply of slices from a loaf or loaves of bread and at least one filling for the sandwich to be interposed between two proximate such slices, the method being characterised in that an adhesive material selected from gelatine, food gum, a starch solution, butter fat, a simulated butter fat and/or any mixture thereof is applied to one or both (i) the at least one filling and (ii) a slice or the slices, and thereafter, the material is allowed or caused to set under sufficient pressure to achieve a lasting bond. Preferably the sandwich produced is as previously defined.

The invention also consists in, for toasting and/or heating as a sandwich, a sandwich as previously defined or from a stack as previously defined.

Preferably the outer faces of said slices have been impregnated with a material selected from one or more of the group consisting of: (i) butter;

(ii) a butter substitute;

(iii) a blend of (i) with any other ingredient(s); and

(iv) a blend of (ii) with any other ingredient.

In yet another aspect the present invention consists in a marked sandwich comprising: a sandwich assembled from: a first slice from a loaf or bread, a second slice from a loaf of bread and edible fillings positioned between the slices of bread, the sandwich being characterised in that at least part of the outer surface(s) of one or both of said first and second slices of bread are marked by means of a colouring agent which is applied to the surface thereof.

Preferably said markings are in the form of a series of parallel lines arranged

diagonally across the surface of the slice(s).

Alternatively said markings are in the form of a series of parallel lines arranged parallel to an outer edge of the said slice(s).

Preferably said colouring agent is a food grade dye. In yet another aspect the present invention consists in a marked sandwich comprising: a sandwich assembled from: a first slice from a loaf or bread, a second slice from a loaf of bread and edible fillings positioned between the slices of bread, the sandwich being characterised in that at least part of the outer surface(s) of one or both of said first and second slices of bread are marked by means of a heated brand which is applied to the surface thereof.

Preferably said markings are in the form of a series of parallel lines arranged diagonally across the surface of the slice(s).

Alternatively said markings are in the form of a series of parallel lines arranged parallel to an outer edge of the said slice(s).

In yet another aspect the invention consists in a method of marking bread products (whether in the form of a slice from a loaf of bread or an assembled sandwich) comprising providing bread product, applying to at least part of at least one surface of said bread product a colouring agent by means of a rotary branding cylinder, said rotary branding cylinder having a raised pattern or profile on the outer surface thereof so that when the rotary branding cylinder overrides the surface of the bread product the colouring agent is transferred onto the surface of the said bread product. Preferably said colouring agent is a food grade dye.

Preferably said raised portions are in the form of transversely spaced ridges so that a series of parallel lines are formed on the surface of the bread product.

Alternatively said raised portions are substantially in the form of helical ridges on the surface of said rotary branding cylinder. In yet another aspect the invention consists in a method of marking bread products

(whether in the form of a slice from a loaf of bread or an assembled sandwich) comprising providing bread product, applying to at least part of at least one surface of said bread product a colouring agent by means of a rotary branding cylinder, said rotary

branding cylinder having a raised pattern or profile on the outer surface thereof said pattern or profile being heated so that when the rotary branding cylinder overrides the surface of the bread product the surface of said bread product has its colour altered by branding. Preferably said colouring agent is a food grade dye.

Preferably said raised portions are in the form of transversely spaced ridges so that a series of parallel lines are formed on the surface of the bread product.

Alternatively said raised portions are substantially in the form of helical ridges on the surface of said rotary branding cylinder. BRIEF DESCRIPTION OF THE DRAWINGS

Preferred forms of the present invention will now be described with reference to the accompanying drawings in which;

Figure 1 is a side elevation of a bread slice,

Figure 2 shows a side view of one form of the application of the food glue by means of spray,

Figure 3 shows a side elevation of another form of the application of the food glue by means of drops,

Figure 4 is a plan view of the bread slice after the application of the food glue, Figure 5 shows the side elevation of the assembly of a food sandwich according to one form of the present invention,

Figure 6 shows a side elevation of the assembled food sandwich before it is compressed,

Figure 7 shows a side elevation of the assembled and compressed food sandwich, Figure 8 shows a belt positioned over a conveying means to apply pressure to an assembled sandwich preferably prior to "glue" set,

Figure 9 shows a form of apparatus to "grill mark" a bread product, Figure 10 shows the surface of a bread product which has been "grill marked" with a series of parallel lines which run parallel to the side of said surface, and

Figure 11 shows a bread product which has been "grill marked" with a series of parallel diagonal lines.

BEST MODES FOR CARRYING OUT THE INVENTION

This invention is specifically directed to the making of such sandwiches from sliced bread and the need to hold the sandwich together in proper alignment between the bread

slices and the slices of food after the sandwich is assembled in the factory. The invention uses a "glue" to hold the sandwich together. The glue is placed between the bread and the ingredient or ingredients in the sandwich in the sandwich assembly process. More specifically, the glue is a heat sensitive liquid which is in a liquid state when applied warm but quickly cools in the assembled sandwich becoming a gel or solid. When the glue solidifies it holds the sandwich together. The sandwich can then be handled, packaged and handled again when it is placed in the heating appliance without danger of the bread slices and the ingredients becoming misaligned or the sandwich falling apart.

The glue may be any edible product such as gelatine, food gum, starch solution or combination of same but is preferably heat sensitive. It may also contain a thickening agent such as starch or food gum to provide the optimum viscosity for applying the glue in the proper amounts. The glue may also be a fat such as butterfat. An example of the invention is a sandwich made up of the following: 2 slices of bread (preferably chilled) sliced cheese (preferably chilled)

Several drops of warmed glue made of starch, gelatin and water are applied in liquid form to each slice of chilled bread, the chilled cheese is placed on one slice of bread and the other slice of bread placed over the cheese. This assembly is completed and compressed before the glue gels or solidifies. When chilled, the glue sets up, holding the sandwich together.

The warmed glue may be dropped or sprayed onto the surface and may be applied so that it forms a pattern of drops or stripes.

Although the preferred method is to place drops of glue on the bread, glue may also be applied as a spray or included in a sauce or other liquid inserted into the sandwich. The glue may also alternatively be applied to the ingredient such as the slice of cheese instead of the bread or a combination of applying part of the glue to the bread and part of it to the ingredient. The glue may also be the ingredient such as hot cheese.

In this invention the word "ingredient" refers to any food product placed between the bread and can consist of one or more ingredients such as sliced ham and cheese. When two or more ingredients are inserted into the sandwich, the glue may also be placed between the ingredients if the natural adhesion is not sufficient to hold them together.

The method of making the sandwich includes the steps of placing the bread on a

flat surface, applying the glue, placing the ingredient(s) on the bread, placing one slice of bread over the ingredients and compressing the sandwich to provide contact between the bread and the ingredients so as to cause the glue to contact both the bread and the ingredients. It is also a part of the method to use bread and ingredients which are at a temperature below the solidifying point of the glue to obtain quick holding of the components together. The compressing of the completed sandwich is preferably a roller or set of rolls but may consist of manual pressure on the sandwich or a pair of conveyors or a belt over a conveying means. (See Figure 8). An additional feature of the rolling of the completed sandwich is the compressing of the sandwich to bed the ingredients into the bread, thereby reducing the overall thickness of the sandwich for placing in a vertical toaster for heating. It also buries the ingredients in the sandwich reducing the chances of melted ingredients in the sandwich running out when the sandwich is heated.

In one form of the invention the sandwiches are compressed by means of an idle conveyor 12 the driven main conveyor 10 draws the sandwiches 11 under the angled idle conveyor 12 which has the effect of progressively compressing the sandwiches 11. This compression has the effect of embedding or partially embedding the ingredients into the bread of the sandwich.

Apparatus for providing "grill marks" on the surface of a bread product as per one form of the invention are illustrated in Figure 9. In this form a marking roller 20 has a helical spiral 22 mounted on the surface thereof. The helical spiral 22 is held off the surface of the marking roller 20 by a series of rods or pegs 23. The marking roller 20 is arranged so that the helical spiral 22 abuts against a colouring agent supply roller 21. This colouring agent supply roller may for example comprise a roller made from an absorbent material. The colouring agent supply roller is supplied with colouring agent by means of a drip feed or other similar means. In use a bread product 1 is transported beneath the rollers 20 and 21 by for example means of a conveyor. As the bread product 1 travels under the roller 20 the helical spiral 22 transfers colouring agent from the colouring agent supply roller onto the upper surface of the said bread product.

The colouring agent may consist of caramel or carbon based colouring products or other suitable food grade dyes. The "grill lines" may be arranged in a series of parallel lines which run parallel to one side of the surface of the said bread product or may consist of a series of parallel lines which run diagonal to the sides of the bread product. In other forms only one line is provided on the surface of the bread product.

In one aspect the present invention provides a method of producing premade sandwiches. In particular, the invention relates to sandwiches which are cooked or toasted or at least heated before consumption.

The sandwiches are made from sliced bread 1. The invention uses a food glue to hold the sandwiches together. This glue 3 is sprayed onto the bread through a nozzle 2. The food glue 3 consists of a heat sensitive liquid which is solid at room temperature but which becomes a liquid at higher temperatures or non heat sensitive viscous solution. The glue 3 comprises an edible substance such as gelatine, food gum, starch solution or a combination of the three. In other forms of the invention the food glue comprises fat.

The bread 1 may be passed under the dispensing nozzle 2 of the food glue 3 by means of a conveyor. In other forms of the invention the bread moves down a chute or slide by force of gravity. In other less preferred forms of the invention the food glue dispensing nozzle is moved over the bread. In other forms of the invention the bread product 1 comprises a flattened or unleavened bread such as pita or pizza bread. The bread product 1 may be plain or may be spread or coated with such spreads as butter margarine or other such dairy fats or substitutes. The bread itself 1 may be plain or flavoured with natural or artificial flavouring substances such as garlic powder or garlic oil. The bread 1 may also be of a type that has solid substances such as raisins, grains, olives, cheese, onions, or garlic cloves embedded in it. In forms of the invention the bread product 1 is cut so as to remove the crusts from the sides of the said bread product.

The bread product is preferably square or rectangular when viewed from above as shown in Figure 4. In other forms of the invention the bread product 1 is round or triangular. In other less preferred forms of the invention the bread products are cut to more complex shapes such as stars or hexagons etc. In other forms of the invention the bread product 1 comprises a long strip of sliced or flattened bread. The long strip of bread is used to produce a long strip of sandwiches which may be then cut into individual sandwiches. In some forms of the invention the bread product 1 is decrumbed before the food glue is applied. This decrumbing can be achieved by vacuuming, brushing or shaking the bread product.

The made up food sandwiches may be packaged individually, i.e. a sandwich unit

comprising the two outlined slices of bread and the inner ingredients may be over wrapped with wrapping such as wax paper, plastic sheeting or less preferably foil or laminated materials. In other forms several premade sandwiches may be packaged together in the form of a loaf. In other forms of the invention the made up sandwich is compressed simultaneously with and/or subsequent to the hardening of the food glue. This pressure is sufficient to cause defamation of the bread and/or filling ingredients and thus lessen the overall thickness of the made up sandwich. In forms of the invention the pressure causes the ingredients to be bedded into one or both of the slices of bread. This causes the slices of bread which extend beyond the periphery of the filling ingredients to be bonded together by the food glue. This bonding by the food glue produces a sandwich which is substantially sealed around its perimeter and the filling ingredients are thus less likely to drip or fall out when the sandwich is heated vertically, for example, in a vertical slot toaster. The compression of the sandwich may be achieved by means of rollers or plates. Examples of the thicknesses of bread and filling ingredients both before and after compressing are given in the table below. A specific example of this is using bread 10mm thick adding a 3mm slice of cheese, a lV_*mm slice of meat product and compressing the completed sandwich so that its final thickness is 20mm to 22mm thick. This size of sandwich fits easily into standard vertical slot domestic toasters.

TABLE ONE