MULTI-LAYERED FOOD PRODUCT AND METHOD FOR FORMING

Abstract

A multi-layered food product comprises a filling encapsulated by a dough layer, and the multi-layered food product can optionally include one or more toppings atop the dough layer.

Claims

1. A method for forming a plurality of filled food products on an automated assembly line system; said method comprising the steps of: a) providing an automated assembly line; said automated assembly line including I) a plurality of plate assemblies, and wherein each plate assembly a first plate and a second plate, and wherein said first plate includes a) a plurality of spaced apart teeth extending upwardly from a top surface of said first plate, and wherein a plurality of said teeth have a different upwardly extending height from said top surface and/or b) said second plate includes a plurality of spaced apart teeth extending downwardly from a bottom surface of said second plate, and wherein a plurality of said teeth have a different downwardly extending height from said bottom surface, II) a drive arrangement to cause said plurality of plate assemblies to continuously move through various regions of said automated assembly line, III) an automated food insert feeder arrangement, IV) an automated mating arrangement, V) an optional preheat heating system, and VI) an oven system; each of said plate assemblies includes a first plate and a second plate; said first plate is configured to at least partially receive a food insert; said second plate is configured to be inserted over said first plate to form a closed cavity that at least partially encapsulates said food insert when said food insert is positioned in said closed cavity; said food insert includes a filling and a dough layer; said dough layer encapsulates at least 80% of said filling; said food insert is at least partially formed by a coextrusion process wherein said filling and said dough layer are coextruded; at least 70% of an outer perimeter of said food insert is absent crimping; a composition of said filling and dough layer is different; b. causing said automated food insert feeder arrangement to place said food insert onto said first plate of each of said plate assemblies; c. causing said automating mating arrangement to mate said second plate with said first plate to form a closed cavity for each of said plate assemblies while said plate assemblies are moved through said automated assembly line assembly so that said food insert in each of said plate assemblies is at least partially encapsulated in said closed cavity; d. moving said plurality of said plate assemblies by said drive arrangement into said oven system while said food insert in each of said plate assemblies is at least partially encapsulated in said closed cavity; e. baking said food insert in each of said plate assemblies for a period of time as said plate assemblies are moved by said drive arrangement through said oven system to form a baked food insert; f. moving said plurality of plate assemblies by said drive arrangement so as to cause said plurality of plate assemblies to be removed from said oven system after said period of time; and g. causing said baked food insert in each of said cavities of said plate assemblies to be automatically removed from said plate assembly.

2. The method as defined in claim 1, wherein said first plate includes a) said plurality of spaced apart teeth extending upwardly from said top surface of said first plate, and wherein said plurality of said teeth have a different upwardly extending height from said top surface and b) said second plate includes said plurality of spaced apart teeth extending downwardly from said bottom surface of said second plate, and wherein said plurality of said teeth have a different downwardly extending height from said bottom surface.

3. The method as defined in claim 2, wherein said first plate and said second plate forms a waffle-shaped baked food insert.

4. The method as defined in claim 2, wherein said plurality of said teeth on said first plate and said plurality of said teeth on said second plate are spaced apart from one another when said second plate and said first plate are mated together to form said closed cavity.

5. The method as defined in claim 3, wherein said plurality of said teeth on said first plate and said plurality of said teeth on said second plate are spaced apart from one another when said second plate and said first plate are mated together to form said closed cavity.

6. The method as defined in claim 2, wherein an enhanced sized food pocket is formed in said closed cavity which reduces an amount of compressive force on said food insert in said first plate includes a) a plurality of said spaced apart teeth extending upwardly from said top surface of said first plate and which are located in a central region of said first plate extend upwardly from said top surface a less amount than a plurality of said spaced apart teeth extending upwardly from said top surface of said first plate and which are located at or adjacent to an outer perimeter of said first plate, and/or b) a plurality of said spaced apart teeth extending downwardly from said bottom surface of said second plate and which are located in a central region of said second plate extend downwardly from said bottom surface a less amount than a plurality of said spaced apart teeth extending downwardly from said bottom surface of said second plate and which are located at or adjacent to an outer perimeter of said second plate.

7. The method as defined in claim 5, wherein an enhanced sized food pocket is formed in said closed cavity which reduces an amount of compressive force on said food insert in said first plate includes a) a plurality of said spaced apart teeth extending upwardly from said top surface of said first plate and which are located in a central region of said first plate extend upwardly from said top surface a less amount than a plurality of said spaced apart teeth extending upwardly from said top surface of said first plate and which are located at or adjacent to an outer perimeter of said first plate, and/or b) a plurality of said spaced apart teeth extending downwardly from said bottom surface of said second plate and which are located in a central region of said second plate extend downwardly from said bottom surface a less amount than a plurality of said spaced apart teeth extending downwardly from said bottom surface of said second plate and which are located at or adjacent to an outer perimeter of said second plate.

8. The method as defined in claim 2, wherein a) a plurality of said spaced apart teeth extending upwardly from said top surface of said first plate have a rounded bottom surface, and/or b) a plurality of said spaced apart teeth extending downwardly from said bottom surface of said second plate have a rounded top surface.

9. The method as defined in claim 7, wherein a) a plurality of said spaced apart teeth extending upwardly from said top surface of said first plate have a rounded bottom surface, and/or b) a plurality of said spaced apart teeth extending downwardly from said bottom surface of said second plate have a rounded top surface.

10. The method as defined in claim 1, wherein said automating mating arrangement causes said mated first and second plates to move away from one another to open said cavity as said plate assemblies are moved through said automated assembly line assembly.

11. The method as defined in claim 9, wherein said automating mating arrangement causes said mated first and second plates to move away from one another to open said cavity as said plate assemblies are moved through said automated assembly line assembly.

12. The method as defined in claim 1, wherein said dough layer of said food insert is a) proofed prior to being inserted on said first plate, and/or b) baked for a period before being inverted and baked for a second period.

13. The method as defined in claim 11, wherein said dough layer of said food insert is a) proofed prior to being inserted on said first plate, and/or b) baked for a period before being inverted and baked for a second period.

14. The method as defined in claim 1, further including the step of inserting one or more toppings on said food insert; said topping having a different composition from said filling and said dough layer.

15. The method as defined in claim 13, further including the step of inserting one or more toppings on said food insert; said topping having a different composition from said filling and said dough layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0102] Non-limiting and non-exhaustive embodiments are described with reference to the following drawings, wherein like labels refer to like parts throughout the various views unless otherwise specified. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements are selected, enlarged, and positioned to improve drawing legibility. The particular shapes of the elements as drawn have been selected for case of recognition in the drawings. Reference may now be made to the drawings, which illustrate various embodiments that the disclosure may take in physical form and in certain parts and arrangement of parts wherein:

[0103] FIG. 1A is a perspective view of a multi-layered food product in accordance with another aspect of the present disclosure;

[0104] FIG. 1B is a cross-sectional view taken along Line 1B-1B in FIG. 1A;

[0105] FIG. 1C is a cross-sectional view taken along Line 1B-1B in FIG. 1A, but the multi-layered food product further includes a topping;

[0106] FIG. 1D is a cross-sectional view of a stuffed waffle-shaped product;

[0107] FIG. 2 is a schematic diagram showing an automated assembly line system used to form the multi-layered food product of the present disclosure;

[0108] FIG. 3 is a schematic diagram showing an alternative configuration of the automated assembly line system in FIG. 2;

[0109] FIG. 4A is a perspective view of a second bi-molded plate assembly for forming the multi-layered food product, the second bi-molded plate assembly comprising a lid member and a receptacle member;

[0110] FIG. 4B is a side view of the second bi-molded plate assembly in FIG. 4A;

[0111] FIG. 5A is a side view of the lid member shown in FIG. 4A;

[0112] FIG. 5B is a top view of the lid member shown in FIG. 5A;

[0113] FIG. 6A is a side view of the receptacle member shown in FIG. 4A;

[0114] FIG. 6B is a top view of the receptacle member shown in FIG. 6A;

[0115] FIG. 6C is another side view of another non-limiting configuration of a bi-molded plate assembly reflecting another aspect of the present disclosure reflecting a waffle grid pattern on the surface of the lid and receptacle members of the bi-molded plate assemble as well as a baking pocket created by having an additional recessed pockets, or filling pocket, space to accommodate and maintain the integrity of the filling within the bi-molded baking plate assembly, and wherein the grid (in this case a waffle grid) can have the grid (teeth) optionally softened or rounded to further protect the integrity of the filling from sharp edges;

[0116] FIG. 7 is a process flow diagram illustrating a further aspect of the method for forming a multi-layered food product;

[0117] FIG. 8 is a process flow diagram illustrating a method for forming a multi-layered food product according to another aspect of the present disclosure; and

[0118] FIG. 9 is a schematic diagram showing an alternative configuration of the automated assembly line system in FIG. 3.

DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0119] A more complete understanding of the articles/devices, processes and components disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the case of demonstrating the present disclosure, and are, therefore, not intended to indicate relative size and dimensions of the devices or components thereof and/or to define or limit the scope of the exemplary embodiments.

[0120] Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.

[0121] The singular forms a, an, and the include plural referents unless the context clearly dictates otherwise.

[0122] As used in the specification and in the claims, the term comprising may include the embodiments consisting of and consisting essentially of. The terms comprise(s), include(s), having, has, can, contain(s), and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that require the presence of the named ingredients/steps and permit the presence of other ingredients/steps. However, such description should be construed as also describing compositions or processes as consisting of and consisting essentially of the enumerated ingredients/steps, which allows the presence of only the named ingredients/steps, along with any unavoidable impurities that might result therefrom, and excludes other ingredients/steps.

[0123] Numerical values in the specification and claims of this application should be understood to include numerical values which are the same when reduced to the same number of significant figures and numerical values which differ from the stated value by less than the experimental error of conventional measurement technique of the type described in the present application to determine the value.

[0124] All ranges disclosed herein are inclusive of the recited endpoint and independently combinable (for example, the range of from 2 grams to 10 grams is inclusive of the endpoints, 2 grams and 10 grams, and all the intermediate values).

[0125] The terms about and approximately can be used to include any numerical value that can vary without changing the basic function of that value. When used with a range, about and approximately also disclose the range defined by the absolute values of the two endpoints, e.g., about 2 to about 4 also discloses the range from 2 to 4. Generally, the terms about and approximately may refer to plus or minus 10% of the indicated number.

[0126] Percentages of elements should be assumed to be percent by weight of the stated element, unless expressly stated otherwise.

[0127] Although the operations of exemplary embodiments of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that disclosed embodiments can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular embodiment are not limited to that embodiment, and may be applied to any embodiment disclosed.

[0128] For the sake of simplicity, the attached figures may not show the various ways (readily discernable, based on this disclosure, by one of ordinary skill in the art) in which the disclosed system, method and apparatus can be used in combination with other systems, methods and apparatuses. Additionally, the description sometimes uses terms such as produce and provide to describe the disclosed method. These terms are abstractions of the actual operations that can be performed. The actual operations that correspond to these terms can vary depending on the particular implementation and are, based on this disclosure, readily discernible by one of ordinary skill in the art.

[0129] Referring now to the drawings wherein the showings are for the purpose of illustrating non-limiting embodiments of the disclosure only and not for the purpose of limiting same, the figures illustrate various non-limiting embodiments of the multi-layered food product and a method for manufacturing the same in accordance with the present disclosure.

[0130] The present disclosure relates generally to filled food products, and more particularly to a multi-layered food product and method for forming the multi-layered food product. The multi-layered food product can be optionally initially warmed in a microwave and then heated in an oven, or toaster, or air fryer.

[0131] Although a puck-shaped and waffle shaped configuration is shown, the multi-layered food product can have other shapes, such as rectangular, circular, ovoid, square, triangular, cylindrical, star, or any other polygonal shape. As can also be appreciated, the multilayered food product does not need to be molded. The shaped configuration of the multi-layered food product gives the multi-layered food product the appearance of a home-baked meal or snack that has been prepared on a griddle, pan or panini. Although the multi-layered food product is shown as having a puck-shaped or waffle-shaped configuration, it will be appreciated that the product can have any desirable shape and size that makes the multi-layered food product versatile and easy to consume. For example, the multi-layered food product can have any shape and size that enables a consumer to easily eat the multi-layered food product at home or on-the-go without any mess. The molded configuration of the multi-layered food product also allows the product to be quickly and easily heated for consumption in a microwave and/or toaster, or simply in an oven.

[0132] The multi-layered food product comprises a partially or fully baked insert that includes a filling, which filling is substantially (e.g., more than 50%, at least about 60%, at least about 70%, at least about 80% or at least about 90%) or typically completely enveloped or encapsulated by a dough. The dough is at least partially fully baked (baked 50-99% of full baked) or fully baked. The dough layer can include one or more fillings and/or be topped by one or more toppings. The one or more toppings can include flavored powders, seasonings, crumbs or clusters, grated cheeses, meats, sugars, vegetables, fruits, eggs, and/or any other food topping and/or filling. Butter and/or oil can be optionally applied to the one or more toppings (e.g., spray coating, brush coating, etc.) to facilitate in the partial or full caramelization of one or more of the toppings during the baking process, and to help prevent the toppings from sticking to the baking cavity. The butter and/or oil can be applied prior to, during or after the one or more toppings are applied to the dough layer.

[0133] The multi-layered food product can have a molded configuration (e.g., a puck-like shape, cylindrical-shaped, cube-shaped, waffle-shape, etc.). As noted above, the baked insert optionally includes a filling that is substantially or completely enveloped or encapsulated by the dough. The filling 16, when used, can comprise any desired solid or semi-solid food product that is typically included as part of a meal or snack. Non-limiting examples of fillings can include, but are not limited to, fruit, cheese, eggs, meat (e.g., ham, bacon, sausage, hamburger, chicken, turkey, etc.), plant-based meat, tofu, vegetables, sauces, gravy, nuts, seeds, caramel, butterscotch, chocolate, fudge, confectionary, custard, pudding, marshmallow filling, etc. and/or a combination thereof.

[0134] The weight percent of the optional topping, the filling, and the dough can be varied to impart the multi-layered food product with the desired structural, appearance, and/or taste characteristics. In one non-limiting example of the present disclosure, the filling can be about 15-75 wt. % of the total weight of the multi-layered food product, the dough 18 can be about 10-60 wt. % of the total weight of the multi-layered food product, and the optional topping layer can be about 2-15 wt. % of the total weight of the multi-layered food product.

[0135] Referring now to FIGS. 1A-1D, there is illustrated a multi-layered food product 10 according to one aspect of the present disclosure. The multi-layered food product 10 can have a molded configuration (e.g., puck-shaped, waffle-shaped, etc.). Although the multi-layered food product 10 is shown as having a puck-shaped configuration or square waffle-shaped configuration, it will be appreciated that the product can have any desirable shape and size that makes the product versatile and easy to consume (e.g., star-shaped waffle, flower-shaped waffle, circular-shaped waffle, square-shaped puck, etc.). For example, the multi-layered food product 10 can have any shape and size that enables a consumer to easily eat the multi-layered food product at home or on-the-go without any mess. The molded configuration of the multi-layered food product 10 also allows the product to be quickly and easily reconstituted for consumption in a microwave and/or toaster, air-fryer, or simply heated in an oven.

[0136] As shown in FIG. 1B, 1C, 1D, the multi-layered food product 10 can comprise an insert 12 including a filling 16 that is substantially (e.g., 70-99.99% encapsulated and all values and ranges therebetween) or completely enveloped or encapsulated by a dough 18 (which can optionally include additional dough ingredients 15), and optionally include one or more toppings 13 as illustrated in FIG. 1C that can include flavored powders, seasonings, crumbs or clusters, grated cheeses, meats, sugars, sauces, vegetables, fruits, eggs or any other food toppings. As described above, the filling 16 can include any desired solid or semi-solid food product that is typically included as part of a meal or snack. The multi-layered food product 10 illustrated in FIGS. 1A-1D only includes a single dough layer (e.g., yeast-leavened dough layer or chemically-leavened dough layer, batter, dough that is absent leavened agent, etc.), a filling 16 that is partially or fully encapsulated by the dough layer, and an optional topping on the outer surface of the dough layer. As illustrated in FIGS. 1A-1C, the shape of the multi-layered food product 10 is a generally pucked-shaped. As illustrated in FIG. 1D, the shape of the multi-layered food product 10 is has a waffle-shaped appearance.

[0137] The weight percent of the filling 16, the dough 18, and the optional topping layer 13 can be varied to impart the multi-layered food product 10 with desired structural and taste characteristics. In one example of the present disclosure, the filling 16 can be about 15-75 wt. % of the total weight of the multi-layered food product 10 and the dough layer 18 can be about 25-75 wt. % of the total weight of the multi-layered food product, and the optional topping layer 13 can be about 1-11 wt. % of the total weight of the multi-layered food product. In another non-limiting example of the present disclosure, the filling layer 16 in the multi-layered food product 10 can be about 55-65 wt. % of the multi-layered food product, the dough layer 16 of the multi-layered food product 10 can be about 30-40 wt. % of the multi-layered food product, and the optional topping 13 of the multi-layered food product 10 can be 0-10 wt. % of the multi-layered food product.

[0138] As illustrated in FIGS. 2, 3, 6C, 7, 8, and 9, another aspect of the present disclosure includes a method 30 and apparatus for forming a multi-layered food product 10. The method 30 can be performed using an automated assembly line system (FIGS. 2, 3, and 9) comprising an automated assembly line 52, and automated line 200, and optional automated line 50.

[0139] Referring now to FIG. 2, the automated assembly line 52 for preparing the multi layered food product 10 comprises a series of upper and lower loop-shaped tracts 54 and 56, a portion of each of which is disposed within an oven 58. The upper and lower tracts 54 and 56 of the automated assembly line 52 include a plurality of baking plates 60 securely mounted thereto that can be securely mated together to form a plurality of bi-molded plate assemblies 62.

[0140] Each of the bi-molded plate assemblies formed by each of the baking plates have a shaped configuration and form a cavity therebetween. As can be appreciated, the cavity can have any shape (e.g., cylindrical shaped, waffle-shaped, disc or saucer-shaped body, star-shaped, cube-shaped, box-shaped, etc.). The cavity is defined by first and second plates. The dimensions (e.g., height, width, length, cavity depth, etc.) of the first and second plates can be about equal so that the dimensions of the multi-layered food product 10 formed by the method are also about equal or they can be split with any percentage being apportioned to the top or bottom plate and the remainder apportioned to the opposing plate (e.g., 5-100% (and all values and ranges therebetween) of the cavity is formed by the first plate and 5-100% (and all values and ranges therebetween) of the cavity is formed by the bottom plate; 30-70% of cavity formed by the first plate and 30-70% of the cavity formed by the second plate.

[0141] All or only a portion of each of the bi-molded plate assemblies can be made of a rigid, heat-conductive material (e.g., a metal or metal alloy), and the baking surface can optionally be coated with a non-stick baking surface such as Teflon or silicone.

[0142] During the partial or full baking of the dough layer 18 of the multi-layered food product 10, the cavity formed by the heated first and/or second plates partially or fully entraps gasses (e.g., CO2, water vapor, etc.) in the cavity, thereby increasing the pressure in the cavity during the partial or full baking of the dough layer, which can 1) dramatically increase the rate of baking of the dough layer, 2) enhance the properties of the dough layer (e.g., dough strength, flavor, color), and/or 3) increase or maintain the moisture content of the partially or fully baked dough layer. The cavity also is used to create and maintain the shape of the multi-layered food product 10 during the partial or full baking of the dough layer. The closed cavity can also result in a portion of the inner surface of the cavity pressing the one or more toppings 13 partially or fully into the dough layer, thereby facilitating in the securing of the one or more toppings to the dough layer; however, this is not required.

[0143] When the multi-layered food product 10 is to be formed as illustrated in FIGS. 1A-1D, cither the first automated assembly line 50 or the automated assembly line 52 or 200 is used to form the multi-layered food product 10. As can be appreciated, for various multi-layered food products, automated assembly lines 50, 52 and 200 can optionally be used to individually partially or fully bake each of the various dough layers during different time periods.

[0144] As shown in FIGS. 2 and 3, the automated assembly line 52 is for preparing the multi-layered food product 10 and comprises a continuous, loop-shaped tract 74 having an upper portion 76 and a lower portion 78. A portion of the assembly line 52 is seated within an oven 80. The tract 74 of the assembly line 52 is operably mated to opposing rotation members 82, each of which is separately or jointly powered by a power source (not shown). As described in greater detail below, the assembly line 52 also includes an automatic removing system 84, a filled dough feeding system 88, and can optionally include a topping applicator 91 (See FIG. 2).

[0145] The assembly line 52 also includes a plurality of baking plates 92, each of which includes at least one of a bi-molded plate assembly 94 (FIGS. 4A-4B). As shown in FIG. 2, the assembly line 52 includes fourteen second baking plates 92 having six of the bi-molded plate assemblies 94 in each. It will be appreciated that the number of the baking plates 92, as well as the number of the bi-molded plate assemblies 94 comprising each of the baking plates, can be varied depending upon production needs and the configuration of the assembly line 52.

[0146] As shown in FIGS. 4A-4B, the bi-molded plate assemblies 94 comprises a receptacle member 96 and a lid member 98. All or only a portion of each of the bi-molded plate assemblies 94 can be made of a rigid, heat-conductive material (e.g., a metal or metal alloy). The receptacle member 96 (e.g., first plate) and the lid member 98 (e.g., second plate) are shown to have a generally circular or oval-shaped configuration and include a cavity 100 (FIGS. 5A and 6A). When the receptacle member 96 (FIG. 4B) and the lid member 98 are securely mated with one another, the cavities 100 of the lid member and the receptacle member form a molded, closed baking cavity 102. The shape of the closed cavity is non-limiting (e.g., puck-shaped, cylindrical-shaped, waffle-shaped, disc-shaped, saucer-shaped, star-shaped, cube-shaped, box-shaped, etc.). The molded, closed baking cavity 102 can have a diameter of 4 cm to about 25 cm (and all values and ranges therebetween), and a depth of about 1 cm to 10 cm (and all values and ranges therebetween); however, it can be appreciated that other sizes can be used. As illustrated in FIGS. 5A and 6A, receptacle member 96 has a larger cavity 100 and receptacle member 98 has a smaller cavity 100 such the majority of closed baking cavity 102 is formed by cavity 100 of receptacle 96. However, it can be appreciated that cavities 100 can be generally the same size as illustrated in the closed baking cavity 102 that is formed by first and second plates 96 and 98. The closed baking cavity 102 can optionally be configured to be larger (e.g., 0.1-200% larger in volume and all values and ranges therebetween) or the same size than the multi-layered dough product when the multi-layered dough product is contained with the closed baking cavity 102.

[0147] The molded, closed baking cavity 102 is designed to hold and bake the components of the multi-layered food product 10 concurrently. Accordingly, the flavor of the multi-layered food product 10 is enhanced through the process of baking the product components within the molded baking cavity 102. In addition to the leavening power that the multi-layered food product 10 receives from the yeast or chemically leavened dough 18, the multi-layered food product receives further leavening from the steam generated within the scaled molded baking cavity 102 during the baking process. Also, the increased pressure generated in the closed cavity due to the generation of gasses (e.g., steam, CO.sub.2, etc.) during the partial or full baking of the multi-layered food product in the closed baking cavity 102 can facilitate in the bonding of one or more optional toppings 13 to the top surface of the dough layer (See FIG. 1Cmulti-layered food product 10). The closed cavity baking container or vessel can also result in a portion of the inner surface of the cavity pressing the one or more toppings partially or fully into the dough layer, thereby facilitating in the securing of the one or more toppings to the dough layer; however, this is not required. As can be appreciated, the dough can be absent yeast and chemical leavening agent.

[0148] The lid member 98 (FIG. 5A) (e.g., second plate) of each of the second bi-molded plate (e.g., first plate) assemblies 96 has a disc-like shape and is defined by oppositely disposed first and second major surfaces 104 and 106. As can be appreciated, the lid member 98 (e.g., second plate) of each of the second bi-molded plate (e.g., first plate) assemblies 96 can form other shaped cavities (e.g., cylindrical-shaped, waffle-shaped, saucer-shaped, star-shaped, cube-shaped, box-shaped, etc.). The first major surface 104 has a generally smooth, flat configuration that gradually tapers around the edge 108 towards the second major surface 106; however, this is not required. The second major surface 106 is adapted for mating with the receptacle member 96. As shown in FIG. 5A, the cavity 100 of the lid member 98 extends from the second major surface 106 towards the first major surface 104 such that the cavity is recessed within the second major surface. The cavity 100 of the lid member 98 defines a volume capable of holding up to about 100 vol. % (e.g., 0-100% and all values and ranges therebetween) of the multi layered food product 10 during the baking process. In one non-limiting arrangement, the cavity 100 of the lid member 98 defines a volume capable of holding up to about 0-70 vol. % of the multi layered food product 10 during the baking process. In another non-limiting arrangement, the cavity 100 of the lid member 98 defines a volume capable of holding up to about 5-30 vol. % of the multi-layered food product 10 during the baking process.

[0149] As shown in FIGS. 6A-6B, the receptacle member 96 (e.g., first plate) has a rounded, pan-shaped configuration; however, this is not required. The receptacle member 96 includes oppositely disposed first and second major surfaces 110 and 112 and an annular side wall 114 that extends between the first and second major surfaces. The cavity 100 of the receptacle member 96 extends between the first major surface 110 and the bottom surface 116 of the receptacle member. The cavity 100 of the receptacle member 96 defines a volume that can be equal to or greater than the volume of cavity 100 of lid member 98. The cavity 100 of the receptacle member 96 is capable of holding about 0-100 vol. % (and all values and ranges therebetween) of the multi-layered food product 10 during the baking process.

[0150] Referring now to FIG. 6C, another non-limiting receptacle member 94 is illustrated. The receptacle member 94 has a waffle-shape configuration. The lid member or second plate 98 has a bottom surface that include a plurality of spaced apart teeth 97. The receptacle member or first plate 96 includes a top surface that include a plurality of spaced apart teeth 99. As illustrated in FIG. 6C, when the lid member or second plate 98 and the receptacle member or first plate 96 are positioned together to form the closed baking cavity 102, the bottom surface of teeth 97 and the top surface of teeth 99 are spaced apart. Such spacing between the teeth 97, 99 allows the dough to flow between the teeth 97, 99 when the closed baking cavity 102 is formed so that the formed and baked waffle-shaped multi-layered food product does not have holes through the multi-layered food product. However, if it is desirable to form one or more openings through the baked waffle-shaped multi-layered food product, no spaced can be formed between one or more sets of bottom surface 105 of teeth 97 and the top surface 107 of teeth 99 are spaced apart when the closed baking cavity 102. Although not shown, the sides of the closed baking cavity 102 can be closed so that the little (e.g., 0-10% of the volume of the waffle-shaped multi-layered food product and all values and ranges therebetween) or no portion of the waffle-shaped multi-layered food product escapes or flows from the closed baking cavity 102 during the baking of the waffle-shaped multi-layered food product. As illustrated in FIG. 6C, there can be multiple different spacings between the teeth. As illustrated in FIG. 6C, the spacing between the teeth about the outer edge of the closed baking cavity 102 are the smallest. The spacing of the teeth that are spaced from the outer edge of teeth of the closed baking cavity 102 is larger than the spacing of the teeth about the outer edge of the closed baking cavity 102, but less than the spacing between the teeth in the central region of the closed baking cavity 102. As can be appreciated, other teeth spacing arrangement can be used.

[0151] As illustrated in FIG. 6C, a portion of all of the bottom surface of teeth 97 and/or the top surface of teeth 99 can be rounded or otherwise softened surfaces 121 so that the formed and/or baked waffle-shaped multi-layered food product are not cut, tear, damaged or sheared so as to adversely affect the appearance baked waffle-shaped multi-layered food product and to protect the integrity of the filling.

[0152] Referring again to FIG. 6C, the central portion of the closed baking cavity 102 has the largest spacing between the teeth of the bottom surface of teeth 97 and the top surface of teeth 99. Such spacing forms a filling pocket 103 such that when the lid member or second plate 98 receptacle member and the receptacle member or first plate 96 are positioned together to form the closed baking cavity 102, additional spacing is formed between the teeth so as to accommodate the filling in the multi-layered food product. For example, when the multi-layered food product (which is generally a coextruded multi-layered food product) is inserted onto receptacle member or first plate 96, and thereafter the lid member or second plate 98 is moved toward the receptacle member or first plate 96, or the lid member or second plate 98 receptacle member is otherwise moved together with the receptacle member or first plate 96, the multi-layered food product is squeezed between the lid member or second plate 98 and the receptacle member or first plate 96 and the filling pocket provides added spacing between the teeth so as to inhibit or prevent the filling from being pressured outside the outer perimeter of the dough layer and flow into the closed baking cavity 102, thus causing a) sticking of the baked multi-layered food product to the lid member or second plate 98 receptacle member and/or the receptacle member or first plate 96, b) adversely affecting the appearance of the baked multi-layered food product, c) damaging the multi-layered food product when being removed from the lid member or second plate 98 receptacle member and/or the receptacle member or first plate 96, d) over-cooking and/or under-cooking the filling, the dough material, and/or the optional one or more toppings, and/or c) interfere with the proper and desired application of the optional one or more toppings. Generally the spacing between the bottom surface 105 of teeth 97 and the top surface 107 of teeth 99 is 5-90% (and all values and ranges therebetween) of the spacing between the bottom surface 111 of lid member or second plate 98 and the top surface 113 of the receptacle member or first plate 96. In one non-limiting configuration, the spacing between the bottom surface 105 of teeth 97 and the top surface 107 of teeth 99 of the teeth that located at or nearest to the outer perimeter of the lid member or second plate 98 and the receptacle member or first plate 96 is 5-20% (and all values and ranges therebetween) of the spacing between the bottom surface 111 of lid member or second plate 98 and the top surface 113 of the receptacle member or first plate 96, and the spacing between the bottom surface 105 of teeth 97 and the top surface 107 of teeth 99 of the teeth that are located at or near the center of the lid member or second plate 98 and the receptacle member or first plate 96 is 20%-80% (and all values and ranges therebetween) of the spacing between the bottom surface 111 of lid member or second plate 98 and the top surface 113 of the receptacle member or first plate 96, and the spacing between the teeth of the bottom surface 105 of teeth 97 and the top surface 107 of teeth 99 that are located at or near the center of the lid member or second plate 98 and the receptacle member or first plate 96 is greater (e.g., 5-200% and all values and ranges therebetween) than the spacing between the bottom surface 111 of lid member or second plate 98 and the top surface 113 of the receptacle member or first plate 96, and the spacing between the teeth of the bottom surface 105 of teeth 97 and the top surface 107 of teeth 99 are located at or near the perimeter of the lid member or second plate 98 and the receptacle member or first plate 96. In another non-limiting embodiment, 10-80% (and all values or ranges therebetween) of teeth 97 and 99 are used to form the filling pocket 103, and which teeth that are used to form the filling pocket 103 are the teeth wherein the spacing between the bottom surface 105 of teeth 97 and the top surface 107 of teeth 99 of the teeth 20-90% (and all values and ranges therebetween) of the spacing between the bottom surface 111 of lid member or second plate 98 and the top surface 113 of the receptacle member or first plate 96. In another non-limiting configuration, the volume of one or more or all of the teeth 97 and 99 are used to form the filling pocket 103 is less (5-60% and all values and ranges therebetween) than a) the volume of the teeth that are located at or near the perimeter of the lid member or second plate 98 and the receptacle member or first plate 96, and/or b) the volume of the teeth that are located adjacent to the teeth that are located at or near the perimeter of the lid member or second plate 98 and the receptacle member or first plate 96.

[0153] It will be appreciated that one or more of the bi-molded plate assemblies 94 can optionally include an imprinting surface (as shown by example a waffle grid surface) for imparting all or only a portion of a surface of the multi-layered food product 10 with a decorative design. For example, one or more surfaces defining the cavity 100 of the bi-molded plate assembly 94 can include at least one depressed and/or raised imprinting surface having a decorative or aesthetically pleasing design.

[0154] The method can begin by heating the baking plates 60 to a predetermined temperature (e.g., about 180-450 F.). Either prior to, contemporaneous with, or subsequent to Step 36, the raw components of the multi-layered food product 10 are prepared. For example, the dough 18 can be formed by scaling (e.g., measuring out) the needed ingredients, which may include flour (e.g., about 27% to about 68% of the total batch weight), water (e.g., about 21% to about 57% of the total batch weight), milk powder (e.g., about 0% to about 28% of the total batch weight), eggs (e.g., about 2% to about 40% of the total batch weight), gluten (e.g., about 2% to about 5% of the total batch weight), sugar (e.g., about 2% to about 35% of the total batch weight), oil (e.g., about 0% to 20% of the total batch weight), leavening agent [yeast and/or chemical leavening agent] (e.g., about 1% to about 5% of the total batch weight), and salt (e.g., about 0.5% to about 2% of the total batch weight). As can be appreciated, the dough can have other formulations.

[0155] It will be appreciated that other ingredients may be added to adjust the flavor or improve the functionality of the dough 18. Examples of ingredients that can be added to adjust the flavor of the dough 18 can include butter, cheese, meats, spices, natural flavorings, and fruit or nut inclusions. Examples of ingredients that may be added to improve the functionality of the dough 18 can include protein powders for nutrition, baking enzymes, mono and diglycerides, fats, and oils. After the ingredients are scaled, the ingredients are then mixed and kneaded together for a period of time sufficient to develop the gluten structure of the dough if the dough is gluten containing 18. The fully developed dough 18 is then ready for subsequent use.

[0156] After preparing the dough 18, a measured amount of one or more fillings 16 is encrusted inside a measured amount of the dough to form the multi-layered food product 10. The measured amount of filling 16 may range from about 15 grams to about 112 grams, and the measured amount of the dough 18 may range from 12 grams to about 128 grams. After the filling 16 is encrusted inside the dough 18, the formed product generally comprises a ball-shaped multi-layered food product 10 that is substantially or completely enveloped or encapsulated by the dough and includes the filling at its center. Generally, the dough and filling are co-extruded through any industrial process. As such, a separate top and bottom layer of dough are not used wherein the filling is placed on a top layer of the bottom layer of dough and thereafter the top layer of dough is overlaid the filling and bottom layer of dough and then the edges of the top and bottom layer of dough are crimped together around 70-100% of the perimeter of the top and bottom dough layers to encapsulate the filling between the top and bottom dough layers. The present disclosure typically uses a single layer of dough to partially or fully encapsulate the filling by use of a co-extrusion process, and less than 20% (0-19.99% and all values and ranges therebetween) of the perimeter of the co-extruded dough includes a crimped region. Such co-extruded dough and filling food product in accordance with the present disclosure results in a superior baked product as to a) appearance of the multi-layered food product, b) the reduction of filling leaking from the dough layer prior to and/or during the baking of the multi-layered food product, c) the near (80-99.99% and all values and ranges therebetween) or full encapsulation of the filling in the dough layer prior to the baking of any portion of the dough layer, and/or d) includes a seamless or borderless outer perimeter (e.g., no crimped edge region). It should be appreciated that any industrial filling process, such as a sheeting of the dough 18, topping with filling 16, and then folding over a top layer of sheeted dough 18, before crimping and cutting the individual multi-layered dough product can also be used to create the multi layered dough product 10.

[0157] The multi-layered food product 10 can optionally be passed through a molding or shaping device (not shown) so that upper and/or lower portions of the insert or multi-layered food product are partially flattened. The molded multi-layered food product 10 is optionally placed into a bakery proofing chamber 118 (FIG. 2) for a period of time sufficient to adequately rise or proof the insert prior to baking. If multi-layered food product 10 includes a chemically-leavened dough, then the proofing chamber may not be used. For example, the proofing time can vary depending upon the type and size of the dough 18 and the filling 16. Generally, the proofing time is at least five minutes and typically about 10-60 minutes; however, longer proofing times can be used.

[0158] As discussed above, multi-layered food product 10 can either be formed in an automated assembly line 50 or automated assembly line 52 or 200.

[0159] If I the multi-layered food product 10 is formed by automated assembly line 50, one or more toppings can optionally be deposited on the outer surface of multi-layered food product 10 by optional topping depositor(s) 91 (FIG. 2) to form a topping layer 13 as illustrated in FIG. IC. As can be appreciated, one or more topping layers 13 or dough ingredient inclusions 15 can be applied to multi-layered food product 10 as illustrated in FIG. 1D. As illustrated in FIG. 2, the one or more toppings are applied to the outer surface of the dough layer after the dough layer has been proofed in proofing chamber 118 and prior to the dough being partially or fully baked in oven 58. The one or more toppings that are dispensed from the optional topping depositor(s) 91 result in 1-100% (and all values and ranges therebetween), typically 10-100%, and more typically 50-100% of the top surface of the dough layer 18 being covered by the one or more toppings 13. Generally, 0-50% (and all values and ranges therebetween) of the one or more toppings that are applied to the dough layer become partially or fully embedded in the dough layer prior to the baking of the dough layer.

[0160] If the multi-layered food product 10 is formed by automated assembly line 52, one or more toppings can optionally be deposited on the outer surface of multi-layered food product 10 by optional topping depositor(s) 91 (FIG. 2) to form a topping layer 13 as illustrated in FIG. 1C. As can be appreciated, one or more topping layers 13 can be applied to multi-layered food product 10 as illustrated in FIG. 1D. As illustrated in FIG. 2, the one or more toppings are applied to the outer surface of the dough layer prior to the dough layer being partially or fully baked in the oven. As can be appreciated, one of automated assembly line 50 or automated assembly line 52 can be eliminated.

[0161] Referring again to FIG. 2, the baking plates 60 move through an oven 52 (e.g., a tunnel oven) for a time and at a temperature sufficient to partially or fully bake the multi-layered food product 10. The term partially baked means that the multi-layered food product 10 is baked to at least about 10% of being fully baked, and typically 40-85% of being fully baked. The term substantially baked means that the multi-layered food product 10 is baked to at least about 80% of being fully baked, and typically 80-99.9% of being fully baked. Fully baked means the multi-layered food product 10 is completely baked (100% baked).

[0162] In one non-limiting arrangement, the baking plates 60 can move through oven 52 so that the multi-layered food product 10 is partially or fully baked (i.e., 100% baked). For instance, the first baking plates 60 can move through oven 52 for a time of about 20-2000 seconds, typically 25-1000 second, and more typically 45-360 seconds and at a temperature of about 250-450 F. to partially or fully bake the multi-layered food product 10.

[0163] As the baking plates 92 continue to advance further along the assembly line 52, the optional topping depositor(s) 91 can then be activated to optionally deposit one or more toppings 13 (e.g., 1-4 toppings) onto or atop the multi-layered food product 10 such that 1-100% (and all values and ranges therebetween), typically 10-100%, and more typically 50-100% of the top surface of the multi-layered food product 10 that is exposed in cavity 110 is covered by the one or more toppings 13. Generally, about 5-100% (and all values and ranges therebetween) of the one or more toppings that are applied to the top, sides or bottom of the multi-layered food product 10 become partially or fully embedded in the dough layer prior to the baking of the dough layer, and typically about 20-100% of the one or more toppings that are applied to the dough layer become partially or fully embedded in the dough layer.

[0164] Each of the second bi-molded plate assemblies 94 is arranged to form the molded baking cavity 102. For example, the second major surface 106 of each of the lid members 98 is securely mated with the first major surface 110 of each of the receptacle members 96 to form a heated and sealed molded baking cavity 102. By sealed it is understood that the baking cavity 102 can include holes, gaps, vents, or other apertures that permit the release of steam, CO.sub.2, and other gasses from the baking cavity while preventing leakage of product components. The baking time for Step 46 can occur in one or more baking periods. If the baking time for Step 46 is a single baking period, the dough layer is baked until it is substantially or fully baked. If the baking time occurs in two baking periods, in the first period of time of baking, the dough layer is baked 5-60% of the time of fully baking the dough layer, and typically 5-49 of the time of fully baking the dough layer. After baking for the first period of time, the second baking plates 92 can be optionally rotated about the rotation members 82 (indicated by arrows) so that the second bi-molded plate assemblies 94 is inverted (FIG. 7). Inverting the second bi-molded plate assemblies 94 facilitates in more even baking throughout the multi-layered food product. After optionally inverting the second baking plates 92, the second baking plates are heated for a second period of time. The second period of time can be about 40% to about 95% of the total time needed to bake the multi-layered food product, and typically 51-95% of the time needed to fully bake the dough layer. The second period of time can optionally be the same or greater than the first period of time. It should be understood that if the baking plates 92 are not inverted, then the entire baking process (first and second periods of time) is combined into one baking period. By baking components (e.g., all of the components) of the multi-layered food product under pressure and at a uniform temperature, the dough layer 18 and the optional topping(s) 13, the filling 16 can be combined to form a substantially seamless, borderless product (e.g., little or no crimped region). It should be appreciated that there can optionally be a 3.sup.rd or even 4.sup.th baking period in addition to a first and second baking period which can further increase the baking quality and functionality of the baking process.

[0165] The automatic removing system 84 separates the lid member 98 and the receptacle member 96 of each of the second bi-molded plate assemblies 94 after the multi-layered food product has been sufficiently baked. Since each of the receptacle members 96 is inverted, separation of the lid members 98 from the receptacle members allows the multi-layered food product to be easily removed from the second bi-molded plate assemblies 94 via gravity since the larger volume cavity is on top. Alternatively, the multi-layer food product can be removed by a suction mechanism or needles (not shown) once the bi-molded plate assemblies 94 are opened. For example, if the receptacle members 96 are not inverted during the baking process, suction or needles can be used to remove the multi-layer food product from the opened bi-molded plate assemblies 94; however, other removal processes can be used.

[0166] After removing the multi-layered food product from the bi-molded plate assemblies 94, the multi-layered food product is cooled for an appropriate period of time before freezing, wrapping, and packaging. The packaged multi-layered food product can be boxed and further frozen ahead of distribution to the marketplace.

[0167] As illustrated in FIG. 8, another aspect of the present disclosure includes a method 130 for forming a multi-layered food product 10. As discussed above, multi-layered food product 10 can be formed an automated assembly line 50 or in automated assembly line 52, depending on the type of dough layer used to form multi-layered food product 10. For example, the method 130 can be performed using an automated assembly line that is identical or similar to the automated assembly line 50 described above. Additionally, the method 130 can be performed using bi-molded plate assemblies (not shown) that are similar to the bi-molded plate assemblies described above or bi-molded plate assemblies 94 as described above.

[0168] Method 130 can begin by heating the bi-molded plate assemblies to a predetermined temperature (e.g., about 300-450 F.). Either prior to, contemporaneous with, or subsequent to Step 36, the raw components of the multi-layered food product 10 can be prepared. For example, the dough 18 can be formed by scaling (e.g., measuring out) the needed ingredients (as described above). As also described above, it will be appreciated that other ingredients, such as inclusion ingredients 15, may be added to adjust the flavor or improve the functionality of the dough 18. Additionally, the filling layer 16 and the optional topping(s) layer 13 ingredients are prepared.

[0169] After the ingredients are scaled, the ingredients can be mixed and kneaded together for a period of time. When the dough 18 is a yeast-leavened dough, the ingredients are mixed and kneaded together for a period of time sufficient to develop the gluten structure of the yeast leavened dough 18. Next, a measured amount of one or more fillings 16 can be encrusted inside a measured amount of the dough 18 using a known bakery machining process, such as co-extrusion or sheeting and crimping. In one non-limiting embodiment, the measured amount of filling 16 can be about 15-99 grams, and the measured amount of the dough 18 can be about 12-128 grams. After the filling 16 is encrusted inside the dough 18, the formed product comprises a ball-shaped insert 12 that is substantially or completely enveloped or encapsulated by the dough and includes the filling at its center.

[0170] The insert 12 can optionally be passed through a molding or shaping device (not shown) so that upper and lower portions of the insert are partially flattened. The molded insert 12 is then optionally placed into a bakery proofing chamber 118 for a period of time sufficient to adequately rise or proof the insert prior to baking. For example, the proofing time can vary from about 10-60 minutes, depending upon the type and size of the dough 18 and the filling 16. After the insert 12 is adequately proofed, it is ready for subsequent use.

[0171] Upon heating each of the bi-molded plate assemblies to the predetermined temperature and forming the raw components of the multi-layered food product 10, the insert 12 can be placed into a receptacle member of a bi-molded plate assembly (Step 132). At Step 43, optionally one or more toppings 13 can be sprinkled or poured atop the insert 12 before the lid member is mated with the receptacle member to form a sealed baking cavity (Step 44). The one or more optional toppings 13 typically cover about 50-100% of the top half of insert 12 prior to closing the lid member and baking and forming the food product 10 as illustrated in FIGS. 1A-1D.

[0172] Following formation of the sealed baking cavity, the insert 12 can be partially or fully baked at Step 46. As described above, an insert 12 is taken from the proofing chamber 118 and deposited into the receptacle member of a bi-molded plate assembly. It will be appreciated that the insert 12 can be deposited into the receptacle member by any one or combination of mechanisms known in the art, such as via a robotic arm, conveyor belt system 140 (FIG. 3), or by hand. Once the insert 12 is deposited into the receptacle member and the optional topping(s) 13 are deposited below or atop insert 12, the receptacle members and the lid members move about the tracts of an oven 52 (e.g., a tunnel oven) to securely mate with another and thereby form a plurality of bi-molded plate assemblies.

[0173] The bi-molded plate assemblies then move through the oven 52 for a time and at a temperature sufficient to partially or fully bake the insert 12 and the optional topping(s) 13. For example, the bi-molded plate assemblies can move through oven 52 so that the insert 12 and the topping(s) are baked to completion (100% baked). For instance, the first bi-molded plate assemblies can move through the oven 52 for a time of about 1-4 minutes and at a temperature of about 300-450 F. to completely bake the insert 12 and the optional topping(s) 13.

[0174] After the bi-molded plate assemblies pass through the oven 52, the receptacle members and the lid members are separated as shown in FIG. 2 so that the multi-layered food product 10 can be removed from the plates and cooled for an appropriate period of time before freezing, wrapping, and packaging. The packaged multi-layered food product 10 can be boxed and further frozen ahead of distribution to the marketplace.

[0175] It will be appreciated that the present disclosure can include an alternative assembly line system 200 (FIG. 9) for forming a multi-layered food product. As illustrated in FIG. 9, the assembly line system 200 includes a series of upper and lower loop-shaped tracts 202 and 204, a portion of each of which is disposed within an oven 206. The upper and lower tracts 202 and 204 include a plurality of baking plates 208 (not shown in detail) securely mounted thereto that can be mated together to form a plurality of bi-molded plate assemblies (not shown) (as described above). The lower tract 204 has a greater length than the upper tract 202, which allows the components of the multi-layered food product 10 to be supplied to the baking plates 208 as shown in FIG. 9. Other components of the assembly line system 200 are similar or identical to those shown in FIG. 3 and described above, such as an optional bakery proofing chamber 212, a conveyor belt system 214, an oven 206, a transfer machine 214, an insert feeding system 222, an optional topping device 226, and an optional automatic removing system 225. For example, the oven 206 is different from the oven 52 described above because there is no inversion or flipping of plates during operation.

[0176] In operation, the baking plates are heated to a pre-determined temperature (as described above). The baking plates 208 are then advanced along the lower tract 204 (e.g., clockwise) to the insert feeding system 222, which is activated to place a substantially baked insert in each of the baking plates 208. As the baking plates 208 continue to advance along the lower tract 204, and the optional topping device 226 is then activated to sprinkle one or more toppings 13 below or atop the insert. Once the optional one or more toppings layers 13 are deposited in the insert, the baking plates of the upper tract 202 rotate (e.g., counter-clockwise) to securely mate with the baking plates of the lower tract 204, thereby forming the plurality of bi-molded plate assemblies. When one or more toppings are applied to the surfaces of the insert, about 5-100% of the toppings are partially or fully embedded in the dough layer prior to the full baking of the dough layer.

[0177] Next, the bi-molded plate assemblies move through the oven 206 for a time and at a temperature sufficient to substantially or completely bake the multi-layered food product (as described above). The total bake time is about 30-360 seconds. After the bi-molded plate assemblies pass through the oven 206, the baking plates of the lower and upper tracts 204 and 202 are separated so that the partially or fully baked multi-layered food product is removed from each of the bi-molded plate assemblies (e.g., by gravity or an automatic removing system 225) and cooled for an appropriate period of time before freezing, wrapping, and packaging. The packaged multi-layered food product can be boxed and further frozen ahead of distribution to the marketplace.

[0178] Consumers of the multi-layered food products 10 can reheat or prepare the frozen product by microwave, oven, toaster, air fryer, or by a combination of a microwave and a toaster or toaster oven. The frozen multi-layered food product can be heated by a microwave for a period of time (e.g., 10-80 seconds (depending on microwave strength)) and then optionally toasted or air fried for a period of (20-250 seconds on a low-medium setting).

[0179] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the constructions set forth without departing from the spirit and scope of the disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The disclosure has been described with reference to preferred and alternate embodiments. Modifications and alterations will become apparent to those skilled in the art upon reading and understanding the detailed discussion of the disclosure provided herein. This disclosure is intended to include all such modifications and alterations insofar as they come within the scope of the present disclosure. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the disclosure herein described and all statements of the scope of the disclosure, which, as a matter of language, might be said to fall therebetween.