Pizzas which are baked in a stone oven are generally regarded to have good physical appearance and properties of taste and mouth feel. While it is known to produce such pizzas on a small restaurant scale there are major problems to be overcome in producing pizzas of this type on a large scale with a high quality of physical appearance and organoleptic properties. By their nature pizzas of this type are difficult to manufacture as the dough required must be developed to several times its original volume with a high gas content. The dough is extremely difficult to handle as any significant pressure applied to the developed dough leads to the escape of gas with consequent flattening and resulting inferior physical and organoleptic properties of the cooked pizza.

This invention is directed towards providing a process for manufacturing stone baked pizzas which will overcome at least some of these difficulties.

Statements of Invention According to the invention there is provided a process for manufacturing stone baked pizzas comprising the steps of : preparing a pizza dough; fermenting the dough thus formed for a period of more than 1 hour at a temperature of about 20°C

dividing the dough into pizza sized portions; rounding the dough portions ; loading a rounded dough portion into a receiving cup; applying oil to the rounded dough portion in the cup; proofing the dough portion in the cup; removing the proofed dough portion from the cup; oiling the proofed dough portion; pressing the proofed dough portion to form a pizza shaped base; proofing the pressed pizza base; and baking the pizza base in a stone oven at a temperature of from 300 to 400°C for a period of up to 2 minutes.

In a preferred embodiment oil is applied to the dough portion in the cup by spraying through a nozzle.

In a particularly preferred embodiment the process comprises the step of applying oil to the cup prior to loading of a rounded dough portion into the cup.

Preferably oil is applied to the cup by spraying through a nozzle.

In a preferred embodiment the process comprises the step of monitoring the flow of oil to the or each nozzle and providing a control signal if the flow of oil is less than a preset flow.

Preferably the cup has a rim around an opening therein and the proofed dough is removed from the cup by engaging the rim of the cup against a conveyor and transferring the removed dough pieces along the conveyor away from the cup.

In a preferred embodiment the dough portion is heated during pressing.

Typically the dough portion is pressed between a lower plate and an upper press head, the press head being movable towards the plate to press the dough.

Preferably the process comprises heating the plate and/or the press head.

In a preferred embodiment the head is heated to a temperature at which the upper surface of the dough is not gelatinised. Ideally the press head is heated to a temperature of from 55° to 70°C.

In a preferred embodiment the plate is heated to a temperature at which the dough is gelatinised. Ideally the plate is heated to a temperature of from 130° to 180°C.

In a preferred embodiment the process comprises the step of disengaging the dough from the press head after pressing. Ideally the dough is disengaged from the press head by actuating an air assisted valving member forming part of the press head.

In one embodiment the dough portion is proofed at a temperature of from 28 to 36°C and a relative humidity of from 70 to 85% for a period of from 40 to 60 minutes.

In another embodiment the pressed pizza base is proofed at a temperature of from 24 to 34°C and a relative humidity of from 70 to 85% for a period of from 20 to 30 minutes.

Another aspect of the invention provides a process for manufacturing a pizza comprising the steps of :- loading a portion of fermented dough into a receiving cup; spraying oil onto the dough portion in the cup; proofing the dough portion in the cup; and removing the proofed dough portion from the cup.

Preferably oil is sprayed onto the dough portion through a nozzle and the process comprises the step of monitoring the flow of oil to the nozzle and providing a control signal if the flow of oil is less than a preset flow.

In one embodiment the process comprises applying oil to the cup prior to loading of a dough portion into the cup. Ideally oil is sprayed into the cup through a nozzle.

In a preferred embodiment the process comprises the step of monitoring the flow of oil to the nozzle and providing a control signal if the flow of oil is less than a preset flow.

In another aspect the invention provides a process for manufacturing stone baked pizza comprising the steps of pressing a proofed fermented dough portion

between a lower plate and an upper press head, and heating the upper press head to a temperature that does not gelatinise an upper portion of the dough.

Preferably the process comprises the step of heating the lower plate to a temperature to gelatinise a lower portion of the dough. Preferably the upper press head is heated to a temperature of from 55° to 70°C. Ideally the lower plate is heated to a temperature of from 130°C to 180°C.

In a preferred embodiment the process comprises disengaging the dough from the press head after pressing.

Preferably the dough is disengaged from the press head by actuating an air assisted valving member forming part of the press head.

The invention also provides apparatus for manufacturing a pizza comprising a plurality of receiving cups mounted on a support, each cup being sized to receive a portion of fermented dough for roofing; and a plurality of nozzles for spraying oil into a cup.

Preferably the apparatus comprises monitoring means to monitor the flow of oil to a nozzle and control means connected to the monitoring means to provide a control signal if the flow of oil is less than a preset flow.

The invention further provides apparatus for manufacturing a stone baked pizza comprising an upper press head and a lower plate between which a fermented proofed dough portion is pressed first heating means for heating the upper press head, to a temperature below the gelatinisation temperature of an upper portion of the dough and second heating means for heating the lower plate to a temperature at which a lower portion of the dough is gelatinised.

In one embodiment the apparatus comprises disengaging means for disengaging the upper press head from the pressed dough. Preferably the disengaging means comprises a valving member forming part of the press head, the valving member being movable to disengage the pressed dough from the press head.

The invention also provides stone baked pizzas whenever manufactured by a process of the invention.

Brief Description of the Drawings The invention will be more clearly understood from the following description thereof given by way of example only with reference to the accompanying drawings, in which: Fig. 1 is a flowchart of the process of the invention ; Fig. 2 is a perspective view of a dough receiving cup used in the process of the invention; Fig. 3 is a top plan view of the cup of Fig. 2; Fig. 4 is a transverse cross sectional view of the cup; Fig. 5 is a schematic elevational view of various steps in the process using the cup of Figs. 1 to 3; Fig. 6 is a cross sectional view of part of a cup oiling station used in the process of the invention;

Fig. 6A is a side, partially cross sectional view of a cup mounted in a holder; Fig. 6B is a top plan view of a holder with a number of cups in position.

Fig. 7 is a cross sectional view of a pressing system used in the process of the invention; Fig. 8 is a cross sectional view on an enlarged scale of portion of the pressing system of Fig. 7; Fig. 9 is a cross sectional view of the pressing system of Figs. 7 and 8 in operation; Fig. 10 is a plan view of a dough pressing station used in the process of the invention; and Fig. 11 is a side view of the dough pressing station of Fig. 10.

Detailed Description Referring to the drawings and initially to Fig. 1 thereof pizza dough is prepared in a large batch by mixing in step 1 wheat flour, vegetable oil, yeast, salt, an improver and water. After mixing the batch of dough is divided in step 2 into smaller batches which are fermented in step 3 for a period of more than one hour, typically two hours at a temperature of about 20°C. During the fermentation process the dough is developed to typically three to four times the original volume. The fermented dough is then transferred to a divider which divides the dough in step 4 into pizza sized portions which are rounded in step 5 to provide a generally spherical shaped dough portion.

Each dough portion is loaded in step 6 into a receiver for use in handling the dough portion during proofing. A receiver cup 7 is first oiled in step 8 before the dough is loaded 6 into the cup. Oil is then applied to the dough in the cup in step 9 and the dough is then proofed in step 10 in a proofing system for a period of from 40 to 60 minutes at a temperature of from 28°C to 36°C and a relative humidity of from 70 to 85%. The proofed dough portion is then removed from the cup in step 11 and all surfaces of the proofed dough portion are oiled in step 12. The oiled dough portion is then pressed flat in step 13 while being heated and without being confined in a tray. The pressed dough is then proofed again in step 14 for a period of from 20 to 30 minutes at a temperature of from 28°C to 34°C and a relative humidity of from 70 to 85%. In a baking step 15 the proofed and pressed dough base is baked in a stone oven at a temperature of from 300 to 400°C for a period of from 1 to 2 minutes. The stone baked pizza bases thus formed are then frozen in step 16 and, as required, are coated with a pizza sauce 17 and topping (s) 18 prior to packaging and freezing 19.

A receiver cup used to hold the dough portion during proofing is illustrated in particular in Figs. 2 to 4 and comprises a generally hemispherically shaped cup 21 having a curved'sidewall 23 with a rim 24 defining an opening for insertion of a dough portion 25 to be proofed and for removal of a proofed dough portion 26.

The cup 1 also includes a flange 28 extending outwardly of the rim 24 for mounting to a carrier holder 29 as illustrated partially in Figs. 6A and 6B. It will be noted that gaps 29A are maintained between the cups 21 and the holder 20 to facilitate cleaning.

Referring to Figs. 5 and 6 oil forming a release agent is applied to the empty cup 21 through at least one nozzle 30. This is important in minimising the amount of oil applied to that required for handling and efficient proofing. There is no excess oil which could cause uncontrolled movement of the dough portion

and/or problems of collecting excess oil. After loading of the dough portion 25 into the cup 21 further oil is applied to the dough portion 5 in the cup 1 through at least one nozzle 31. This is also important in ensuring that the minimum amount of oil is applied to the dough portion, thus avoiding uncontrolled movement of the dough portion and/or problems of excess oil collection.

The process includes the step of monitoring the flow of oil at both the first and second oiling stations to provide a control signal if the flow of oil is less than a preset flow indicating a nozzle blockage. This is especially important in ensuring that an adequate supply of oil is provided both to the cup and to the dough portion in the cup.

A plurality (typically 12) of empty receiver cups 21 on a carrier 36 are sprayed with a release oil agent at a first spraying station 41 (Fig. 6). Dough portions are loaded into the cups 21 and release agent is applied to the dough portions in the cups 21 at a second spraying station. After proofing, the dough portions are removed from the cups 21 at an unloading station. Unloaded proofed dough portions 26 are discharged onto a conveyor from which the dough portions 26 are transferred for oiling and then to a pressing station. Empty cups are returned to the first oiling station.

In more detail and referring particularly to Figs. 6 to 11 proofed dough portions 26 are delivered onto a conveyor belt 42 of non-stick material and passed to a pressing station 50 at which the dough portion 26 which is not confined by a tray is pressed out into a pizza base 51. The dough 26 is pressed between a lower plate 52 and an upper press head 53, the press head 53 being moved towards the lower plate 52 to press the dough as illustrated. Either the plate 52 and/or the press head 53 are heated through heating conduits 55 to heat at least an outer face of the dough portion. The plate 52 is heated to 130 to 180°C and the press head 43 is heated to a temperature of from 55°C to 70°C. The dough 51 is

disengaged from the press head 52 by actuating an air assisted valving member 55 which forms part of the press head 52. For enhanced physical and organoleptic properties the upper part of the dough is heated to a temperature at which the dough does not gelatinise. This ensures that the dough can rise and expand on cooking which is important in providing a pizza with the appearance of being hand made. In contrast, the lower portion of the pizza is heated to a temperature such that gelatinisation does occur. This seals the base of the pizza and provides a crisp texture.

Referring to Figs. 10 and 11 the pressing station may have an array of pressing heads for in-line pressing of a plurality of dough portions 26 travelling along conveyor 42.

The dough portions 26 discharged from the cups 21 vary in shape and the shape may be altered in the process of the invention by varying the forces applied at the feed conveyor 42 to the pressing station 50. The speed of rotation of some of the conveyor rollers may, for example, be varied to shape the dough portions travelling along the conveyor 42.

The invention provides an integrated large scale process for producing stone baked pizzas with excellent organoleptic and physical properties.

The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail.