METHOD FOR MAKING AN ARTISANAL LOOKING PIZZA DOUGH CRUST

Abstract

The present invention relates to a method for making an artisanal looking pizza dough crust comprising the step of placing a bread-type dough ball onto a flat surface and pressing said dough ball with a heating plate, wherein the flat surface and the heating plate do not form a cavity or contained area under the press, wherein the flat surface and the heating plate do not have a groove, gutter, indentation or protrusion for forming a rim of the dough upon pressing, and wherein the surface area of the heating plate is smaller than the surface area of the dough after pressing. A further aspect of the invention pertains to the pizza obtained by said method.

Claims

1. A method for making an artisanal looking pizza dough crust comprising the step of placing a bread-type dough ball onto a flat surface and pressing the dough ball with a heating plate, wherein the flat surface and the heating plate do not form a cavity or contained area under the press, wherein the flat surface and the heating plate does not have a groove, gutter, indentation or protrusion for forming a rim of the dough upon pressing, and wherein the surface area of the heating plate is smaller than the surface area of the dough after pressing.

2. The method according to claim 1, wherein the bread-type dough ball is raw pizza dough.

3. The method according to claim 1, wherein the heating plate is flat or convex.

4. The method according to claim 1, wherein the surface area of the heating plate is 95% or less of the surface area of the dough after pressing.

5. The method according to claim 1, wherein the surface area of the heating plate is 90% or less of the surface area of the dough after pressing.

6. The method according to claim 1, wherein the surface area of the heating plate is at least 70% or more of the surface area of the dough after pressing.

7. The method according to claim 1, wherein the surface area of the heating plate is round or oval.

8. The method according to claim 1, wherein the bread-type dough ball comprises 55-70 wt % flour, water and salt.

9. The method according to claim 1, wherein the bread-type dough ball comprises active yeast.

10. The method according to claim 1, wherein the heating plate is heated to a temperature from 60° C. to 125° C.

11. The method according to claim 1, wherein the flat surface is heated.

12. The method according to claim 11, wherein the flat surface is heated to a temperature of at least 120° C.

13. A pizza dough crust obtainable by the method according to claim 1.

14. A pizza product comprising a pizza dough crust comprising the step of placing a bread-type dough ball onto a flat surface and pressing the dough ball with a heating plate, wherein the flat surface and the heating plate do not form a cavity or contained area under the press, wherein the flat surface and the heating plate does not have a groove, gutter, indentation or protrusion for forming a rim of the dough upon pressing, and wherein the surface area of the heating plate is smaller than the surface area of the dough after pressing.

15. The pizza product according to claim 14, which is a frozen prepared pizza product.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0016] FIG. 1: Artisanal looking pizza dough crust made according to the present invention with a dough ball of Formula A. A) and B) show the dough crust after pressing and before baking; C) shows the dough crust after application of tomato sauce as topping and after baking.

[0017] FIG. 2: Artisanal looking pizza dough crust made according to the present invention with a dough ball of Formula B. A) and B) show the dough crust after pressing and before baking; C) shows the dough crust after application of tomato sauce as topping and after baking.

[0018] FIG. 3: Artisanal looking pizza dough crust made according to the present invention with a dough ball of Formula B under industrial conditions. A) shows the dough crust after application of tomato sauce as topping and after baking.

DETAILED DESCRIPTION OF THE INVENTION

[0019] The present invention provides in a first aspect a method for making an artisanal looking pizza dough crust comprising the step of placing a bread-type dough ball onto a flat surface and pressing said dough ball with a heating plate, wherein the flat surface and the heating plate do not form a cavity or contained area under the press, wherein the flat surface and the heating plate do not have a groove, gutter, indentation or protrusion for forming a rim of the dough upon pressing, and wherein the surface area of the heating plate is smaller than the surface area of the dough after pressing.

[0020] The method of the present invention pertains to press forming the bread-type dough ball with a heating plate into a flat dough disk, wherein the surface area of the dough disk is larger than the surface area of the heating plate after the pressing step, and wherein thereby an elevated rim is formed at the edge of the dough disk. Consequently, after the pressing, the surface area of the heating plate is smaller than the surface area of the dough, respectively the dough disk.

[0021] Furthermore, the method of the present invention pertains to press forming the bread-type dough ball with a heating plate into a flat dough disk, wherein the dough texture, the dough rheology, the gas cell structure of the dough and/or the dough matrix is not or only minimally compromised, destroyed and/or reduced.

[0022] The advantage of the method of the present invention is that a pizza dough disk can industrially be produced which has the aspect of a hand-made artisanal looking pizza crust after baking. There are no edge marks, equipment indents, rim marks or other traces from press machinery left on the pizza dough or rim crust, which would evoke the impression of an industrially machine made pizza dough crust with the consumer.

[0023] Furthermore, the pizza crust and rim is less compact and more aerated, what a consumer would expect from an artisanal hand-made pizza crust and not from an industrially produced pizza crust. The less stress on the dough during the manufacturing process provided the resulting crust with a superior rim and crust volume after baking, and with a lighter texture to the bite. It has a hand-made like aspect, pertaining to the visual appearance as well as to the taste.

[0024] Typically the “bread-type dough” used in the method for making an artisanal looking pizza dough crust of the present invention is raw pizza dough. Preferably, the dough is proofed dough which has been prepared fresh and/or which was kept refrigerated before use in the method of the present invention.

[0025] A “dough ball” of the present invention is a portioned part of the bread-type dough. It is a block, lump or chunk of the bread-type dough. Preferably it is in a cube-like or a rounded ball or flattened ball-like form, as for example typically formed by hand as a handful of dough.

[0026] Preferably, the bread-type dough ball used in the method of the present invention is portioned for a regular size or family size pizza product. Preferably, the dough ball is portioned to a wet-weight before use from 100 g to about 600 g, preferably from 150 g to 450 g, more preferably from 200 g to 300 g, per dough ball.

[0027] In a preferred embodiment, the heating plate of the present invention is either flat or convex. This form of the heating plate has the advantage that it first flattens the dough ball sufficiently into a flat dough disk for most of the dough surface after the pressing step. The flat or convex form of the heating plate also makes sure that there is no formation of a contained or closed space under the press giving rise to a compression of the dough under the pressure. Furthermore, a convex or slightly convex form of the heating plate facilitates an equal distribution of the dough under the heating plate when pressed and thereby facilitates a regular evacuation of the excess dough mass from under the press and allows it to form an elevated rim naturally around the edge of the dough disk.

[0028] Preferably, in the method of the present invention, the surface area of the heating plate is 95% or less of the surface area of the dough after pressing, i.e. of the surface area of the dough disk after the pressing step. Thereby, the surface area of the dough disk after the pressing step is defined as 100%. This method advantageously allows to form a natural elevated rim of about 5% or more of the surface area of the dough disk around the edge of that dough disk. In a more preferred embodiment, the surface area of the heating plate is 90% or less of the surface area of the dough after pressing. This method would allow to form a natural elevated rim at the edge of the dough disk of about 10% or more of the surface area of the dough after being pressed.

[0029] Preferably, in the method of the present invention, the surface area of the heating plate is at least 70%, more preferably at least 75%, even more preferably at least 80%, or more of the surface area of the dough after pressing. This assures that there is still a sufficient large surface space on the pizza crust for applying toppings and/or decorations.

[0030] The surface area of the heating plate of the present invention can have any form. It can be round, oval, rectangular, square, rectangular or square with rounded edges, triangular or any other irregular form. In a preferred embodiment, however, the surface area of the heating plate of the present invention is round or oval. This allows the preparation of a typical handmade artisanal type pizza product.

[0031] Preferably, the method of the present invention processes a bread-type dough ball which comprises about 55-70 wt % flour, water and salt. Preferably, the dough used in the present method comprises about 60-65 wt % flour. Preferably, the salt content of the dough used in the present invention comprises from about 1 to 3 wt % salt.

[0032] In a preferred embodiment of the present invention, the bread-type dough ball comprises an active yeast. Preferably the active yeast is present in the dough from about 0.05 to 0.2 wt % of the total wet-based dough mass. The presence of active yeast facilitates fermenting and proofing of the dough and thereby generates a nice aerated structure of the dough mass, a typical aspect of yeast-rising artisan dough products.

[0033] In one embodiment of the present invention, the heating plate is heated. Preferably, the heating place is heated to a temperature from 60° C. to 125° C., preferably from 80° C. to 120° C., more preferably from 90° C. to 115° C. Active heating of the heating plate for the present method allows to accelerate the industrial process of manufacturing pizza dough crusts. The process can be run much faster and the dough disks readily detach much better from the heating plate without sticking to that plate, than when the heating plate is not actively heated.

[0034] In another embodiment of the present invention, the flat surface, onto which the bread-like dough ball is placed in the method of the present invention, is heated. This advantageously allows to already start to pre-bake the dough crust during its processing and thereafter also to better detach it again from the flat surface after the pressing process is terminated. Preferably, the flat surface is heated to a temperature of at least 120° C., preferably of at least 160° C., more preferably at least 180° C.

[0035] A further aspect of the present invention is a pizza dough crust obtainable by the present method.

[0036] A still further aspect of the present invention is a pizza product comprising the pizza dough crust of the present invention. The pizza product may further comprise toppings such as tomato sauce and/or mozzarella cheese. In a preferred embodiment, the pizza product of the present invention is a frozen prepared pizza product.

[0037] Those skilled in the art will understand that they can freely combine all features of the present invention disclosed herein. In particular, features described for the method of the present invention may be combined with the product of the present invention and vice versa. Further, features described for different embodiments of the present invention may be combined.

[0038] Further advantages and features of the present invention are apparent from the figures and examples.

EXAMPLES

[0039] Control and understanding of the pressing process and use of the equipment for pressing of the dough balls for Pizzas is critical. How and with what kind of equipment the dough is pressed and formed in the shape of the pizza before topping and baking is directly related to how the final pizza, especially the crust appears after baking in shape, height, diameter, texture, and even colour to the consumer. In addition, the pressed dough has an important impact on how evenly the tomato sauce can be applied or spread on the pizza. Last but not least, the pressed dough has an effect on how the final pizza yields through loss topping and packaging.

[0040] The main experimental equipment used to pizza dough press testing according to the present invention was a pilot plant pizza press testing machine. The test machine was able to press dough between a heated top press moving downward and a stationary heated bottom surface. The machine allowed for the testing of top press heads of various diameter, shape, and surface treatment. The machine allowed for adjustment in press head temperature. The machine could be adjusted for the amount of force to the dough. The machine could be adjusted for the final distance from the flat surface the dough is placed on to the heating plate to determine the resulting dough thickness during the pressing process. The machine could be adjusted for the time that the press head is held at its lowest position. The machine could be adjusted for the speed and acceleration/deceleration in the downward and upward motion of the press head. The machine had an air pressure release that could be applied during the release action after the pressing step. The machine, tests and process were scalable to test on industrial equipment and to apply to industrial production.

[0041] The two following dough compositions were tested as formula A and formula B.

[0042] Formula A:

[0043] 61 kg Flour Wheat Soft

[0044] 1.2 kg Salt (NaCl)

[0045] 1.2 kg sunflower oil

[0046] 0.15 kg active baker's yeast crumble

[0047] Water added to 100 kg final dough mass

[0048] Formula B:

[0049] 65 kg Flour Wheat Soft

[0050] 1.4 kg Salt (NaCl)

[0051] 1.9 kg sunflower oil [0052] 0.15 kg active baker's yeast crumble [0053] Water added to 100 kg final dough mass

Example 1

[0054] Raw dough balls made with Formula A were tested on the experimental pilot plant pizza press as outlined above.

TABLE-US-00001 Settings with formula A. Flat press head used having no grooves, indentions or protrusions capable of forming a rim. Head Pressing Duration (Sec) 6.0 Poppet (ds.) 70 to 80 Total Down (mm) 92.0 Go down fast to (mm) 92 Motor torque limit (Nm) 40 Temperture Head (° C.) 60 Temperature Convey Flat Surface Base (° C.) 170 Brushless Settings -Offset quota (mm) 10 Head Speed (mm/sec) 120 Result is shown in FIG. 1

[0055] As can be seen in FIG. 1, the pressed dough disk extended outside of the surface area which was directly pressed by the heating plate of the pizza press, and formed there a slightly elevated rim. Upon baking (see FIG. 1C), formation of this rim became clearer and has a complete natural appearance only known from artisanal handmade pizza crusts.

Example 2

[0056] Raw dough balls made with Formula B were tested on the same experimental pilot plant pizza press as outlined above.

TABLE-US-00002 Settings with formula B. Flat press head used having no grooves, indentions or protrusions capable of forming a rim. Head Pressing Duration (Sec) 6.0 Poppet (ds.) 65 to 80 Total Down (mm) 92.0 Go down fast to (mm) 92 Motor torque limit (Nm) 40 Temperture Head (° C.) 70 Temperature Convey Flat Surface Base (° C.) 180 Brushless Settings -Offset quota (mm) 10 Head Speed (mm/sec) 120 Result is shown in FIG. 2

[0057] As can be seen in FIG. 2, the pressed dough disk extended outside of the surface area which was directly pressed by the heating plate of the pizza press, and formed there a slightly elevated rim. Upon baking (see FIG. 2C), formation of this rim became clearer and has a complete natural appearance only known from artisanal handmade pizza crusts.

Example 3

[0058] Raw dough balls made with Formula B were tested on an industrial pizza line using a similar press as outlined above.

TABLE-US-00003 Settings with formula B. Flat press head used having no grooves, indentions or protrusions capable of forming a rim. Head Pressing Duration (Sec) 5.2 Poppet (ds.) 50 to 60 Total Down (mm) 92.0 Go down fast to (mm) 92 Motor torque limit (Nm) 50 Temperture Head (° C.) 80 Temperature Convey Flat Surface Base (° C.) 220 Brushless Settings -Offset quota (mm) 10 Head Speed (mm/sec) 120 Result is shown in FIG. 3

[0059] As can be seen in FIG. 3, the pressed dough disk extended outside of the surface area which was directly pressed by the heating plate of the pizza press, and formed there a slightly elevated rim. Upon baking (see FIG. 3A), formation of this rim became clearer and has a complete natural appearance only known from artisanal handmade pizza crusts.