PIZZA PRODUCT, PACKAGING FOR A PIZZA PRODUCT, AND METHOD OF COOKING AND DISTRIBUTION FOR A PIZZA PRODUCT
20230100146 · 2023-03-30
Assignee
Inventors
Cpc classification
A21D13/11
HUMAN NECESSITIES
B65D81/3446
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
This invention relates to a pizza product that is prepared separately utilizing two types of doughs that are combined after heating. The doughs have different characteristics and are heated in combination with different ingredients. The heating process for both doughs is performed under different humidity conditions and may be performed simply with a conventional microwave oven. The present invention also includes an apparatus and method for the preparation of such pizzas, as well as an innovative delivery process, which allows delivery of the pizzas from a central delivery station—without the need of having one or more processing locations (e.g., a chain of physical stores) to prepare and/or cook the pizza product.
Claims
1.-17. (canceled)
18. A packaging container for a pizza product formed by two dough parts (Dough A and Dough B), the packaging container comprising: a lower portion arranged and configured to contain the Dough A; an upper portion arranged and configured to contain the Dough B, a moisture-rich product and additional ingredients in a closed environment, wherein the upper portion is arranged and configured to produce humid heating conditions from the moisture present in the moisture rich product when the Dough B is heated, whereby a paste-like product is formed from the ingredients; A middle section separating the upper portion with the lower portion, the middle section arranged and configured to transfer the paste-like product from the upper portion onto Dough A, whereby the pizza product is formed.
19. The packaging container according to claim 18, wherein the container is arranged and configured to enclose a third dough, wherein the third dough is edible, is a part of the microwaveable container, and acts as a separator layer between the first dough and second dough.
20. The packaging container according to claim 19, wherein the third dough corresponds to the underside of the microwaveable container, which facilitates the assembly of the final pizza product
21. The packaging container according to claim 19, wherein the assembly process comprises removing a plastic film or separator from in between both sections of the package, wherein the Dough A is placed over the Dough B in an upside-down manner, whereby the packaging container is rotated 180 degrees to place the Dough A and Dough B in position to form the assembled pizza product.
22. A delivery process for a pizza product formed by two dough parts (Dough A and Dough B), the process comprising: providing at least one preparation hub including a physical store that prepares the parts that compose the pizza product, wherein such preparation hub provides ready-to-heat pizza products to at least one distribution hub such as refrigerated trucks or physical locations located strategically for efficient distribution; distributing the ready-to-heat pizza products through the at least one distribution hub, wherein the at least one distribution hub is equipped with refrigeration equipment to maintain suitable refrigeration temperature of the pizza product; transporting the pizza product comprising the Dough A and Dough B through mobile transportation means, such as a delivery car, motorcycles, or similar means that are equipped with a portable microwave device, wherein the portable microwave device heats both parts of the pizza product, namely Dough A and a container containing Dough B, a moisture-rich product, and additional ingredients in a short period of time; performing a heating process on the mobile delivery means, on the way to the final delivery point, or upon arriving at the final destination; and delivering the heated the pizza product in a ready-to-assemble basis, wherein either the delivery person or the final consumer assembles the pizza thereby obtaining a final pizza product that maintains high crunchiness and moisture that has not been achieved by previous delivery methods; and whereby the instant pizza product is delivered in a heated state with very low costs and in a short period of time, while maintaining a high crunchiness and moisture.
23. The delivery process according to claim 22, wherein the central distribution hub is a fixed location.
24. The delivery process according to claim 22, wherein the pizza product is delivered in a ready-to-heat condition, and the final consumer is responsible for heating the two dough parts and assembling the final pizza product.
25. The packaging container according to claim 18, wherein the container is constructed of a material suitable for use in a microwave and wherein the material is a microwaveable safe material.
26. The packaging container according to claim 25, wherein the microwaveable safe material is selected from the group comprising plastic and paper.
27. The packaging container according to claim 18, wherein the container comprises a vacuum sealed package, an easy-open package including zip lock-style packages, a shrink film, a paper bag, an auto-seal bag, cardboard, or a press & seal package.
28. The packaging container according to claim 18, wherein the container includes a safety system to avoid the container from exploding from increased pressure inside the container during heating, the safety system selected from the group comprising valves, pressure relief systems, holes, or special materials that allow air to leave the container.
29. The packaging container according to claim 18, wherein a third dough is provided, where the third dough is edible and a part of the microwaveable container, and acts as a separator layer between the first dough and second dough.
30. The packaging container according to claim 29, wherein the third dough corresponds to the underside of the microwaveable container, which facilitates the assembly of the final pizza product
31. The packaging container according to claim 18, wherein the pizza product assembly process comprises removing a plastic film or separator from in between both sections of the packaging container, wherein the top Dough is placed over the bottom Dough in an upside-down manner, to then flip the complete package and obtain the final assembled pizza product.
32. The delivery process according to claim 22, wherein the distribution hub comprises mobile centers such as distribution trucks or vans that can park in different locations depending on the demand.
33. The delivery process according to claim 22, wherein the distribution hub is a fixed distribution center with a fixed location.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] Referring to the drawings, wherein like numerals represent like parts throughout the several views:
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DETAILED DESCRIPTION
[0057] The present invention relates to a high quality pizza product and a method for preparing a pizza product, wherein the pizza is heated and assembled in a manner that results in higher moisture and at the same time higher crunchiness than current fast food and retail pizzas. The present invention also optionally provides a centralized manufacture and delivery process, wherein such delivery process delivers pizzas from a central delivery hub without the need of having a local physical store to prepare and/or cook the pizza product.
[0058] Regarding the retail market of fresh and frozen pizza products for homes and offices for example, embodiments according to the present invention may be heated and assembled in less than 1 minute using a simple conventional microwave oven while achieving high moisture, and at the same time high crunchiness properties, in a short period of time. In contrast, current, conventional fresh and frozen pizza products are generally required to be heated up in conventional convection ovens that take a long time to pre-heat up to the required heating temperature, and then take an additional time to heat the pizza product, which usually takes more than 20 minutes. In addition, high crunchiness and high moisture are rarely accomplished at the same time.
[0059] Regarding the restaurant market, stores that today are not able to offer pizza products since they don't have the required equipment or space to provide these products, such as specialized ovens and preparing and processing space for the dough, may utilize pizza products in accordance with the principles of the present invention by having (or installing) a microwave oven. This would allow the stores to provide high quality pizzas as part of their menu.
[0060] Regarding the delivery market, pizza products according to the present invention provide for delivery of a high quality pizza product without requiring a local physical store to prepare and/or cook the pizza. Instead, a microwave oven that may be portable and provide for heating the pizza product in route to the delivery location may be employed. Additionally, the delivery of the ready-to-heat product can be performed where the final consumer can heat the product in a short period of time, and assemble the product themselves obtaining a high quality pizza with higher moisture and crunchiness than conventional delivery pizza products.
[0061] As used in the present application, the term “crunchiness” refers to the ability of the dough to offer resistance to chewing, presenting a tougher dough that has low flexibility and that when chewed emits a recognizable noise. Some examples of crunchy foods include croutons, crackers, shortbread cookies, potato chips, among others.
[0062] A preferred embodiment of the present invention is disclosed herein. The preferred embodiment pizza product includes two separate dough parts, wherein the first dough part (Dough A) is a crunchy dough that constitutes the base of the final pizza product, and the second dough part (Dough B) is a spongy dough that when combined with a moisture-rich product can capture the moisture, and that after heating results in a paste-like product that constitutes the upper part of the pizza product. Both dough parts are cooked under different humidity conditions, and after the heating process they are both joined together by placing Dough B along with its moisture-rich product and additional ingredients on top of Dough A, providing the final pizza product. As it will be explained later, it is important to note that both dough parts can be heated simultaneously in a microwave oven.
[0063] The first dough part, which is referred to as Dough A throughout the specification, refers to the bottom part of the pizza, which has crunchy conditions such as the dough from meat pies and tartlets. Dough A is pre-cooked in a conventional oven in order to generate the ready-to-heat product. In an embodiment of the invention, Dough A comprises different types of doughs or combinations of doughs.
[0064] When it is time to assemble and/or serve the final pizza product, the ready-to-heat Dough A product is heated in a dry environment, such as a toaster, or a conventional microwave oven with low humidity conditions that allow maintaining its crunchiness. Additionally, the heating process may include a moisture-absorbent element, such as paper, or cardboard.
[0065] The second dough part, which is referred to as Dough B throughout the specification, refers to the upper portion of the pizza, which comprises a spongy dough that is combined with a moisture-rich product and additional ingredients, and that when it's heated results in a paste-like product. As previously mentioned, Dough B is combined with a moisture-rich product that provide moisture that is able to be captured by Dough B. Such products comprise an edible gel that is flavored with different essences or flavors such as tomato paste, fresh tomatoes, scalded tomatoes, and meat concentrates, among others. In a preferred embodiment, the moisture rich product is a tomato gel, which allows to have a firm product that when heated is dissolved and produces a paste-like texture that does not get Dough B wet. Additionally, different ingredients can be added to Dough B, such as fresh tomato and fresh vegetables, or other products such as cheese and oregano. In an embodiment of the invention, Dough B comprises different types of doughs or combinations of doughs.
[0066] Dough B has a ready-to-heat preparation that comprises a container from a microwaveable safe material, such as a plastic or paper bag, which contains Dough B along with the moisture-rich product and additional ingredients, in order to be able to carry out a heating process under high humidity conditions where Dough B and the moisture-rich product obtain a paste-like texture.
[0067] The container is designed and configured to allow the heating of Dough B, the moisture rich product, and the additional ingredients altogether in the same container, which is required to be microwave-safe and includes vacuum sealed packages, easy-open packages like zip lock-type packages, shrink films, press & seal packages, and similar packages. The container includes a safety system to avoid it from exploding from increased pressure inside the container, such as valves, pressure relief systems, holes, special materials that allow air to leave the container, and similar systems.
[0068] When it is time to assemble and/or serve the final pizza product, Dough B is heated up in specific conditions so that generation of saturated vapor is allowed, where Dough B captures the humidity from the moisture-rich product. This is achieved by heating up the container that contains Dough B, the moisture rich product, and the additional ingredients, where the container includes minimal ventilation (to avoid it from exploding from high pressures) and is heated in a microwave oven.
[0069] Therefore, as previously explained, both Dough A and Dough B have different properties, can be combined with a moisture rich product and different ingredients (if any), and are heated up in different ways and under different humidity conditions.
[0070] After the heating process, both Dough A and Dough B are joined together by placing the paste-like heated Dough B with the moisture rich product and additional ingredients, on top of Dough A through the use of different types of packaging and assembly methods, generating a high quality product with high moisture and crunchiness in a shorter period of time, and requiring much less equipment and labor than other retail or fast-food pizza products.
[0071] The two dough portions, Dough A and Dough B are provided separately, where Dough A is separate from Dough B, and wherein Dough B, the moisture-rich product, and additional ingredients are packaged in a container.
[0072] The heating process for both doughs may be performed with different equipment or using common equipment or appliance at the same time.
[0073] In a first embodiment of the application, only a simple microwave oven is needed, wherein Dough A and the container comprising Dough B, the moisture rich product, and additional ingredients, are heated up in the same interior microwave space but maintaining a physical separation. For example, Dough A is heated in the microwave oven with the option of using a moisture absorbent material such as cardboard, while the separate container containing Dough B along with the moisture rich product and additional ingredients is also heated in the microwave oven at the same time. Therefore, moisture migration from the humid products inside Dough B's bag is avoided while both products are being heated within the same microwave oven interior space.
[0074] In a second embodiment of the application, Dough A is heated up in a conventional toaster, where Dough A is heated up by itself with no need of additional packaging, in order to allow dry heat to cook Dough A and provide a crunchy texture, while the container containing Dough B along with the moisture-rich product and additional ingredients is heated in a conventional microwave at the same time.
[0075] After heating both parts of the pizza product, they are joined together by incorporating the humid and moisture-rich paste-like contents from the container (including Dough B, the moisture rich product, and additional ingredients) on top of Dough A, achieving a final pizza product with excellent crunchiness and moisture conditions, and excellent quality and taste in a very short period of time, with minimal equipment, and requiring minimal labor compared to conventional pizza products.
[0076] Under specific circumstances, and depending on the type of dough B, moisture rich products, and additional ingredients that are used, which may result in a stickier product that has more difficulty sliding from a tray or separator in order to be placed on the bottom dough without affecting it's configuration and look, then different assembly methods can be used such as assembling the pizza in an upside down manner so that transferring the top part of the pizza is easier.
[0077] Embodiments of the present invention allow that the pizza components are assembled in a manner that the top portion of the pizza product is placed on top of the bottom portion in an upside down manner, then they are heated, and then the assembled pizza product is flipped before removing all packaging.
[0078] The shape of the pizza product can vary from a classic circular shape, into a more square or rectangular shape, to accommodate the heating equipment.
[0079] Embodiments of the present invention provide for a pizza product that may preferably be designed to be sold to the final customer in either a fresh state, frozen state, or already heated condition, depending on the type of market. However, as previously noted above, the pizza product may cover the needs of three different markets: (1) the fast food market, (2) the delivery market, and (3) the retail market.
[0080] The present invention also provides embodiments having suitable packaging for an efficient and simple heating of the pizza product, wherein the packaging includes containers, plastic bags, zip lock-type bags, paper bags, auto-seal bags, easy open containers, cardboard, shrink films, and similar materials, and wherein the packaging is made out of microwave-safe materials.
[0081] The packaging generally includes an upper portion, a lower portion, and a separating middle portion.
[0082] In an embodiment of the invention, the lower portion of the packaging has a hollow volume dedicated for placing and heating Dough A under dry heat conditions to maintain its crunchiness, wherein the lower portion includes a moisture-absorbent material and lower portion walls to create the hollow volume housing Dough A. The upper portion of the packaging includes a containing film that allows containing Dough B along with its moisture-rich product and additional ingredients, in order to provide a closed heating environment with high humidity and allow to maintain the moisture of the inside product. The containment film is configured so that it minimizes movement of Dough B, the moisture-rich product, and the additional ingredients as to maintain its aesthetics while transporting. Both parts of the packaging are separated through the separating tray, which after heating is easily removed to be able to place the heated Dough B with its moisture-rich product and additional ingredients, on top of Dough A and assemble the final heated pizza product.
[0083] In another embodiment, the packaging comprises a three layer film container, which houses Dough A in its lower part, and houses Dough B with its moisture-rich product and additional ingredients on the upper part, separated by a middle film layer that is easily removed after heating, as to be able to place the heated Dough B with its moisture-rich product and additional ingredients on top of heated Dough A.
[0084] In another embodiment, the packaging comprises two sections, with one section housing the container (containing Dough B, the moisture-rich product, and additional ingredients) which has an easy-tear system that can be accessed from the exterior of the package. The easy-tear system allows to open and/or separate the container in order to allow its contents to be placed on top of Dough A with a simple movement. The easy tear system may comprise an initially scored or semi-scored tear line as commonly employed on individual food packaging such as ketchup, peanuts and the like.
[0085] In another embodiment of the invention, a third dough is included within the pizza product, where the third dough acts as a separator between the first dough and the second dough, the moisture rich product, and its additional ingredients. The third dough can be used as a separating layer that can be used as part of the microwaveable container that contains the second dough, the moisture rich product, and the additional ingredients. In an embodiment, the third dough corresponds to the underside of the container, so that the other sides of the container (top and sides) are covered with a plastic or paper material that is easily removable. In this manner, if the third dough acts as the underside of the microwaveable container, the transfer process for placing the second dough, the moisture rich material, and additional ingredients, is simplified as the bottom of the container is also an edible dough that is placed directly over the first dough to assemble the pizza product. The third dough, being the underside of the microwaveable container, is able to absorb moisture from the heating process of the second dough, the moisture rich product, and the additional ingredients, at the same time minimizing moisture transfer to the first dough.
[0086] In all of these embodiments for the packaging, it is considered that the assembly process for the pizza product comprises removing a plastic film or separator from in between both sections of the package, wherein the top Dough is placed over the bottom Dough in an upside-down manner, to then flip the complete package and have the final pizza product ready to eat.
[0087] Regarding the delivery process, embodiments of the present invention allows for transformation of the pizza delivery market and processes, by minimizing the logistic requirements of preparing and cooking the pizza product, at the same time avoiding the need to having a local, physical store for preparing and cooking the pizza product. On the other hand, the present invention does not require facilities, equipment, or space for preparing and cooking the pizza product, but may employ only a small microwave oven for heating the pizza product.
[0088] The delivery process from the present invention comprises having at least one preparation hub, which cooks and prepares the pizza products. Such preparation hub distributes the ready-to-heat pizza products to a distribution hub. Such distribution hubs are equipped with refrigeration equipment to keep the frozen or fresh pizza products at a temperature of no more than 15° C. most of the time. In a preferred embodiment, the distribution hub comprises mobile centers such as distribution trucks or vans that can park in different locations depending on the demand. In another embodiment of the invention, the distribution hub is a fixed distribution center with a fixed location. Such distribution hubs, when mobile, can move to high demand locations taking in account consumer behavior.
[0089] In contrast to a conventional delivery store, which is a fixed location store that receives products to assemble the pizza and has equipment and space to prepare and cook the pizza products, the present invention only requires that the distribution hubs have small refrigeration equipment to maintain the ready-to-heat pizza products, therefore not requiring to have a physical store for preparing and/or cooking the pizza product. As a reference, in the U.S. the four largest pizza chains account for more than 19,000 physical pizza stores, which would not be needed with the innovative delivery process from the present invention.
[0090] The delivery process from the distribution hub to the final destination is then carried out by a smaller mobile transportation means, such as a delivery car, small truck, motorcycles, or similar means.
[0091] The heating process can be performed in the central distribution hub, on the way to the delivery point, or it can be done once arrived at the final destination. Preferably, the heating process is performed in-route to the final delivery point, wherein the mobile transportation means is equipped with a portable microwave device. Therefore, the portable microwave device allows to heat up both Dough A and the container containing Dough B along with the moisture rich product and additional ingredients in parallel and in the same appliance in a very short period of time, and deliver a pizza product at a hotter temperature than standard delivery pizzas.
[0092] Then, the pizza product is delivered in a heated state with very low costs and in a short period of time.
[0093] For the assembly of the pizza product, a first option is that the pizza product is delivered in a heated state but not in a ready-to-eat state, as the final consumer will assemble the pizza according to the methods described previously, to obtain the final pizza product that maintains crunchiness and moisture properties with good quality and flavor, which has not been achieved by similar delivery methods.
[0094] Another option for the assembly of the pizza upon delivery, is that the delivery person uses a simple packaging that allows to assemble the pizza before giving it to the customer. The packaging used for delivery can allow a simple assembly without requiring to manipulate each dough separately, but only manipulating the package and its easy transfer system for placing the contents of the container on top of Dough A.
[0095] The products and methods described herein can also be used for similar food preparations and different markets, taking advantage of the simplicity and efficiency of the heating, packaging, and delivery processes.
Example 1
[0096] The pizza product from the present invention was prepared in order to conduct a sensory panel and compare the crunchiness and moisture of the product compared to other products found in the market.
[0097] The first dough part, Dough A was manufactured from a mixture of flour of the 0000 type, water, margarine and salt, with food preservatives for maintaining its freshness. For the preparation of Dough A, a mix of 3 cups of flour, 1.5 tablespoons of margarine, 1 cup of warm water, and 1 teaspoon of salt was used.
[0098] The second dough, Part B, was manufactured from a white sandwich bread type cooked dough, specifically a by removing its crust and maintaining the white cooked dough as the spongy dough. Additionally, the moisture-rich product is a previously mixed and cooled gel flavored with tomato sauce.
[0099] The gel is prepared by using 500 grams of tomato sauce with a pizza flavor, and 5 grams of powered agar-agar. The tomato sauce is heated and the agar-agar powder is added to the mix while still warm, then the mixture is boiled for 3 minutes while stirring. The mix is then emptied into a container that allows to cool it down, cut it, and obtain round circles that are easy to manage in a gel state.
[0100] Then, the gel is placed over the spongy bread dough, and toppings are added on top. For example, the toppings may include Gouda cheese and oregano. Such layered product is then placed in a microwaveable-safe plastic bag, which is then sealed.
TABLE-US-00001 Listing of elements shown in the drawings: Number Description (1) Pizza Product (2) Dough A (3) Dough B (4) Moisture Rich Elements (5) Cheese and Toppings (6) Container (7) Preparation Hub (8) Distribution Hub (9) Refrigeration Equipment (10) Mobile Delivery Means (11) Microwave Equipment (12) Final Delivery Location (13) Packaging (14) Moisture-Absorbent Material (15) Lower Package Walls (16) Containment Film (17) Separation Tray (18) Three Layer Container (19) Middle Film Layer (20) Microwave Oven
[0101] It should be understood that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only and changes may be made in detail, especially in matters of the supporting hardware, components and devices, and to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.