U.S. patent application number 11/035198 was filed with the patent office on 2005-06-09 for pizza making method and system.
Invention is credited to Malfatti, Pierluigi, Torghele, Claudio.
Application Number | 20050123659 11/035198 |
Document ID | / |
Family ID | 27561846 |
Filed Date | 2005-06-09 |
United States Patent
Application |
20050123659 |
Kind Code |
A1 |
Torghele, Claudio ; et
al. |
June 9, 2005 |
Pizza making method and system
Abstract
The invention provides an automated method and apparatus for
pizza production which is initiated by individual order placement
and uses only fresh ingredients (no ingredients are frozen,
pre-prepared or pre-cooked). Each dough portion is individually and
mechanically prepared from flour and other fresh, pre-proportioned
ingredients. The dough portion passes through a series of shaping
and pre-heating processing stations to prepare a flattened and
partially baked pizza base. Using a preheated or continuously
heated conveying tray, the pizza base passes under a number of
metering and distribution devices for selected application of
tomato sauce and/or various other toppings according to the order.
Baking occurs in one of multiple ovens to complete pizza
preparation. Multiple ovens are provided to facilitate the
automated preparation of multiple pizzas at any given time. A tray
conveying system transports one or more trays through the various
processing stations to accommodate multiple orders at the same
time.
Inventors: |
Torghele, Claudio;
(Viganello, CH) ; Malfatti, Pierluigi; (Rovereto
(Tn), IT) |
Correspondence
Address: |
WOODCOCK WASHBURN LLP
ONE LIBERTY PLACE, 46TH FLOOR
1650 MARKET STREET
PHILADELPHIA
PA
19103
US
|
Family ID: |
27561846 |
Appl. No.: |
11/035198 |
Filed: |
January 12, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11035198 |
Jan 12, 2005 |
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10040950 |
Jan 7, 2002 |
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10040950 |
Jan 7, 2002 |
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09832409 |
Apr 11, 2001 |
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6546847 |
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09832409 |
Apr 11, 2001 |
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09294702 |
Apr 19, 1999 |
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6245370 |
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09294702 |
Apr 19, 1999 |
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PCT/EP98/05093 |
Aug 12, 1998 |
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10040950 |
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PCT/EP01/04656 |
Apr 25, 2001 |
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60297160 |
Jun 8, 2001 |
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Current U.S.
Class: |
426/289 |
Current CPC
Class: |
A21D 13/22 20170101;
G07F 17/0078 20130101; A21C 9/04 20130101; A21C 11/00 20130101;
B01F 15/00876 20130101; A21C 9/083 20130101; A21C 11/006 20130101;
A21C 1/144 20130101; A21D 13/41 20170101; A21C 1/06 20130101; A21C
15/002 20130101; B01F 15/00792 20130101; A21C 1/142 20130101; A21C
1/1425 20130101; A21D 13/40 20170101; B01F 7/145 20130101; B01F
15/0219 20130101 |
Class at
Publication: |
426/289 |
International
Class: |
A23G 003/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 19, 1997 |
IT |
BZ97A000044 |
May 5, 2000 |
EP |
00109611.4 |
Jun 7, 2000 |
IT |
BZ2001A000033 |
Jun 5, 2001 |
EP |
01113720.5 |
Claims
1. (canceled)
2. (canceled)
3. A method for automated and mechanized preparation of pizza, the
method comprising the steps of: a. receiving an order for a pizza,
the order specifying topping requirements as selected from
available offerings; b. preparing an individual dough portion from
flour and other component ingredients by: i. charging a mixing
region with flour-like or dust-like ingredients by free fall; ii.
homogenizing and aerating the flour-like or dust-like ingredients
by rotating a kneading element at a relatively high speed; iii.
introducing liquid ingredients to the flour-like or dust-like
ingredients; iv. preparing a dough mixture by rotating the kneading
element at a lower speed to form and roll together little dough
clumps; v. forming a single, compact, balled together dough mass by
rotating the kneading element at a lowest speed; and vi.
discharging the single, balled together dough mass by centrifugal
force via the rotating kneading element and by gravity; c. shaping
the dough portion to a flattened pizza base; d. metering and
applying toppings to the pizza base as received in the order; e.
cooking the pizza; and f. providing the pizza.
4. The method of claim 3, wherein charging the mixing region is by
free fall occurring through a charging opening in the mixing region
equipped with a sliding door.
5. The method of claim 3, wherein the relatively high speed is
between about 2,500 and 3,000 rpm.
6. The method of claim 3, wherein the lower speed is between about
950 and 1,400 rpm.
7. The method of claim 3, wherein the little dough clumps are
formed and rolled together by repeated action of rotating sleeves
of the kneading element.
8. The method of claim 3, wherein the lowest speed is between about
700 and 820 rpm.
9. The method of claim 3, wherein discharging the single, balled
together dough mass occurs through a discharge opening in the
mixing region equipped with a sliding door.
10. The method of claim 3, wherein the rotational direction of the
kneading element changes one or more times during various method
steps.
11. A method for automated and mechanized preparation of pizza, the
method comprising the steps of: a. receiving an order for a pizza,
the order specifying topping requirements as selected from
available offerings; b. preparing an individual dough portion from
flour and other component ingredients; c. shaping the dough portion
to a flattened pizza base by: i. pressing a dough ball into a dough
disc; ii. pressing a dough disc into a pizza base; and iii.
dimpling the pizza base to facilitate a uniform and expedited
cooking of the pizza base; d. metering and applying toppings to the
pizza base as received in the order; e. cooking the pizza; and f.
providing the pizza.
12. The method of claim 11, wherein pressing a dough ball into a
dough disc includes the steps of: a. raising a lower press plate
into contact with a preformer; b. receiving a dough ball by gravity
into the preformer; and c. lowering a disc press of the preformer
to form the dough disc by pressing the dough disc against the lower
press plate.
13. The method of claim 11, wherein pressing a dough disc into a
pizza base includes the steps of: a. lowering a lower press plate
away from a preformer while the lower press plate supports the
dough disc; b. horizontally moving the lower press plate to a
position under an upper press plate of a dough shaping press; and
c. raising the lower press plate to form the pizza base by pressing
against the upper press plate.
14. The method of claim 11, wherein dimpling the pizza base
includes the steps of: a. lowering a lower press plate away from an
upper press plate of a dough shaping press, the lower press plate
supporting the pizza base; b. horizontally sliding a toothed
punching plate to a position above the lower press plate; c.
raising the lower press plate to dimple the pizza base by pressing
the pizza base against the toothed punching plate.
15. The method of claim 11, wherein the steps to shape the dough
portion into a flattened pizza base (steps i., ii. and iii.)
involves: raising a lower press plate into contact with an
open-bottomed housing; receiving a dough ball onto the lower press
plate; lowering a disc press to form the dough disc by pressing the
dough disc against the lower press plate; lowering the lower press
plate away from the housing while the lower press plate supports
the dough disc; horizontally moving the lower press plate to a
position under an upper press plate; raising the lower press plate
to form the pizza base by pressing against the upper press plate;
lowering the lower press plate away from the upper press plate, the
lower press plate supporting the pizza base; horizontally sliding a
toothed punching plate to a position above the lower press plate;
and raising the lower press plate to dimple the pizza base by
pressing the pizza base against the toothed punching plate.
16. A method for automated and mechanized preparation of pizza, the
method comprising the steps of: a. receiving an order for a pizza,
the order specifying topping requirements as selected from
available offerings; b. preparing an individual dough portion from
flour and other component ingredients; c. shaping the dough portion
to a flattened pizza base; d. metering and applying toppings to the
pizza base as received in the order; wherein metering and applying
liquid or cream-like components includes the steps of: i.
positioning the pizza base for garnishing; ii. rotating a
dispensing device about an axis perpendicular to the pizza base;
iii. moving the dispensing device radially relative to the
perpendicular axis and parallel relative to the pizza base; and iv.
applying the liquid or cream-like component during steps (ii.) and
(iii.), whereby the component is placed on the pizza base in a
spiral. e. cooking the pizza; and f. providing the pizza.
17. The method of claim 16, wherein the pizza base is motionless
during the application of liquid or cream-like components.
18. The method of claim 16, wherein the liquid or cream-like
components are applied uniformly on the pizza base such that a time
unit of dispensed volume of component remains constant, the uniform
dispensing being achieved by altering the rotational speed of the
dispensing device in relation to a changing radius of the spiral of
component on the pizza base.
19. The method of claim 16, wherein the liquid or cream-like
components are applied uniformly on the pizza base such that the
rotational speed of the dispensing device remains constant and a
time unit of dispensed volume of component changes in proportion to
a changing radius of the spiral of component on the pizza base,
wherein a reduction of the radius causes a decrease in the time
unit of dispensed volume.
20. A method for automated and mechanized preparation of pizza, the
method comprising the steps of: a. receiving an order for a pizza,
the order specifying topping requirements as selected from
available offerings; b. preparing an individual dough portion from
flour and other component ingredients; c. shaping the dough portion
to a flattened pizza base; d. metering and applying toppings to the
pizza base as received in the order; e. cooking the pizza, which
involves; i. at least one initial heating cycle; ii. at least one
intermediate heating cycle; and iii. at least one final heating
cycle, wherein all cycles include use of infrared rays; sources of
infrared rays include infrared rays in the visible, the
near-infrared, and the far-infrared range; and a cooking effect of
the sources of infrared rays in the visible and the near-infrared
rays predominate during the initial heating cycle, while a cooking
effect of the sources of infrared rays in the far-infrared range
gradually counterbalance during subsequent heating cycles; and f.
providing the pizza.
21. The method of claim 20, wherein the initial heating cycle is
longer than the longest intermediate heating cycle, and the final
heating cycle is approximately a duration equal to the initial
heating cycle.
22. The method of claim 20, wherein the infrared rays exist in a
lower portion and in an upper portion of an oven and the sources of
infrared rays in the lower portion operate during at least some
portion of an interval between cycles of operation of the infrared
rays in the upper portion.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of
applicant's co-pending U.S. patent application Ser. No. 09/832,409,
filed 11 Apr. 2001, entitled "Method and Device for Producing
Pizza", which application is a divisional application of U.S.
patent application Ser. No. 09/294,702, filed 19 Apr. 1999 (now
U.S. Pat. No. 6,245,370), which application is a
continuation-in-part of Patent Cooperation Treaty Application No.
PCT/EP98/05093, filed 12 Aug. 1998, which application claims
priority to Italian Patent Application No. BZ97A000044, filed 19
Aug. 1997.
[0002] The present application is a continuation-in-part of Patent
Cooperation Treaty Application No. PCT/EP01/04656, filed 25 Apr.
2001, entitled "Dough Mixer with Metering Device", which
application claims priority to European Patent Application No.
00109611.4, filed 5 May 2000.
[0003] The present application claims priority under 35 USC .sctn.
119(a) to Italian Patent Application No. BZ2001A000033, filed 7
Jun. 2001, entitled "Pizza Cutting and Transfer Device".
[0004] The present application claims priority under 35 USC .sctn.
119(a) to European Patent Application No. 01113720.5, filed 5 Jun.
2001, entitled "Metering Device for Liquid or Cream-like Components
for Garnishing Food Products".
[0005] The present application claims priority under 35 USC .sctn.
119(e) to U.S. Provisional Patent Application No. 60/297,160, filed
8 Jun. 2001, entitled "An Automatic Pizza Making Method and
System". U.S. Provisional Patent Application No. 60/297,160 is
incorporated in its entirety by this reference.
FIELD OF THE INVENTION
[0006] The present invention relates generally to pizza making, and
more particularly to an automated method and system for making
pizza from fresh ingredients according to individual orders.
BACKGROUND OF THE INVENTION
[0007] Methods and systems are known for the automatic industrial
production-line and mass-produced production of pizzas. These
methods and systems essentially include the following work phases:
preparation of dough including rising of the dough, extruding the
dough creating a dough strand, cutting the dough strand into
individual dough portions, processing the dough portions to
flattened pizza bases, adding seasonings and toppings, baking,
packaging for consumption within the expiration date or,
respectively, for deep freezing.
[0008] Systems employing the above-referenced methods are numerous
for mass-production. Existing automated systems have accelerated
pizza production by employing pre-treated dried granulate with
seasonings and toppings applied to a pre-determined, large number
of pizzas of the same variety on a continuous belt with baking in a
tunnel oven. Some existing systems accelerate production by
employing pre-produced, precooked and/or frozen dough portions and
toppings.
[0009] For the foregoing reasons, there is a need for an automatic
pizza making method and system that provides fast, individual and
completely fresh pizza preparation according to individual order
placement.
[0010] Dough Mixer
[0011] Dough mixers for producing dough used in preparing foods are
known which use one or two screw conveyors, or rotating mixing arms
within fixed or rotating containers with vertical or angled axis or
kneading elements rotating within a closed housing with a
horizontal axis. Also known are smaller mechanical devices for
preparing dough in the household; generally these include a
cylindrical container with a vertical axis within which one or more
agitator blades operate on a single drive shaft attached coaxially
to the container axis.
[0012] Information relevant to attempts to address dough mixers can
be found in U.S. Pat. Nos. 5,486,049; 4,630,930; and 5,322,388.
However, each of these references suffers from one or more
disadvantages.
[0013] The known devices are not designed for preparing individual
dough portions per work cycle within relatively short periods of
time and by charging with ingredients in individual portions;
further, known devices do not provide that each dough portion
prepared and discharged for shaping leaves no ingredients or dough
residue inside the device. The known devices are also not designed
to perform a periodic, completely automatic sterilization of the
kneading chamber and elements.
[0014] Also known in the art is the problem of charging kneading
devices with relatively exact volumetric amounts of flour or
flour-like ingredients which are hydroscopic. Such problems result
from the tendency of flour-like materials to form accumulations or
agglomerates inside the container, that varying the material volume
above the metering mechanism strongly affects the metering process
and that it is difficult to achieve an even filling and/or emptying
of the metering chamber.
[0015] For the foregoing reasons, there is a need for a dough mixer
of simple, compact design which can be automatically sterilized,
has an essentially cylindrical chamber with kneading rotation
occurring about a horizontal axis to accommodate direct charging of
consistently accurate and pre-metered amounts of material per work
cycle while preventing accumulation of material in the container
and/or metering chamber, the dough mixer quickly preparing, on
demand, one individual dough portion suitable for preparation of
one pizza by subsequent shaping, garnishing and baking.
[0016] Tomato Sauce Dispenser
[0017] Systems are known for mechanical metering and garnishing of
pizza with tomato sauce or other liquid components. Most of these
devices supply the sauce by tube, under pressure generated by a
pump. Generally these systems are mounted on a production line
above a passage area of the dough base to be garnished, the
garnishing process occurring by free fall. Accordingly, uniform
distribution of the sauce to the dough base requires several tubes
or nozzles and air jets evenly spaced above the garnishing area to
evenly distribute the sauce on the dough base.
[0018] Known liquid dispensing systems have several disadvantages.
Systems with a plurality of tubes and nozzles are unsuitable for
liquids such as tomato sauce as tomato sauces are rarely homogenous
in fluidity and texture. As such, the individual nozzles fed from
one single supply tube rarely dispense equal quantities of the
sauces. In addition, dispensing sauce from a plurality of tubes and
nozzles creates cleaning and sanitation problems as the sauce often
drips from the nozzles after product flow ceases. To prevent the
product from spoiling, mold from forming and bacteria from breeding
during downtimes, tubes must be exchanged often, resulting in
increased production costs.
[0019] Known liquid dispensing systems using air jets require high
product homogeneity, accurate product metering and precise jet
calibration based upon texture and volume of the liquid to be
distributed. Air jet systems often distribute excessive product,
insufficient product or provide intermittent distribution while
continually experiencing cleaning problems.
[0020] Other existing free falling systems require that the
underlying dough base rotate about a vertical axis with sauce
distributed in a spiral manner. These systems allot all movement to
the dough base, whereas dispensing nozzles remain stationary. One
disadvantage of these systems, if integrated into a production line
for pizza, is the complication or exclusion to using traditional
conveying systems to transport the dough base through the
production line due to the requirement of rotating the dough base
during sauce application. Thus, conveying systems must provide the
additional capability of rotating the dough base over a portion of
the production line. Or, the conveying system must transfer the
dough base to a separate device to spin the dough base. Further
complications arise when the production line requires that the
dough base be heated during conveying and/or garnishing.
[0021] For the foregoing reasons, there is a need for a tomato
sauce dispenser that provides even sauce distribution on a dough
base (regardless of sauce homogeneity), that performs in a
production line having traditional conveying systems and/or
conveying systems applying heat to the dough base during transport
thereof through the production line, and also facilitates easy
cleaning and maintenance.
[0022] Oven
[0023] Electric ovens employing electrical resistance, microwave
generators (magnetrons), infrared lamps or induction units as a
heat source for cooking relatively thin cakes, such as pizza and
focaccia, are known, as are ovens employing one or more such heat
sources in combination, such as ray or wave sources. These ovens
are designed to cook or heat fresh or frozen foods, which may be
precooked, in a relatively short time.
[0024] Cooking time is important for industrial food-production
processes and for automated machines that heat or cook food on the
spot. Such machines commonly use cooking systems employing
microwaves and/or infrared rays, sometimes in combination with
electrical resistance. However, it takes approximately 80 seconds
to cook and brown pizzas having a diameter of about 270 mm and
total weight of about 320 g to 360 g.
[0025] For the foregoing reasons, there is a need for an oven that
can fully cook and brown fresh (not precooked) food in a shorter
time period, without sacrificing the organoleptic and nutritional
properties associated with traditional cooking.
[0026] Automatic Cutting Device
[0027] A number of devices exist for automatically cutting pizza or
focaccia into slices, using plates provided with blades which
operate vertically like a dinking die on the pizza being cut. The
existing devices only cut the pizza, requiring specific devices to
then transfer the cut pizza to the take-out box or other
packaging.
[0028] Furthermore, the known devices are not designed for easy
cleaning and/or replacement of the parts that come into repeated
contact with the pizza, thereby creating cleanliness and hygiene
problems with both the cutting device and the transfer device.
[0029] For the foregoing reasons, there is a need for a simple,
combination cutting and transfer device which is easy to clean and
uses some of the cutting movements to transfer the pizza, thereby
expediting the pizza making process.
SUMMARY OF THE INVENTION
[0030] The present invention is an automatic pizza making method
and apparatus providing fast, individual and completely fresh pizza
preparation according to individual order placement. The pizza
making system is innovatively designed for production of fresh
pizza by turn-key operation. The pizza making system comprises
multiple processing stations that combine ingredients, namely,
flour, water, salt, leveling agent, tomato sauce, cheese and
assorted toppings such as sausage and pepperoni, to prepare and
bake a pizza.
[0031] Accordingly, it is an object of the present invention to
furnish an automated method and a system for pizza production
according to individual orders placed by selections from a list,
the production employing only fresh ingredients (no pre-cooked
and/or deep-frozen ingredients for the dough or toppings) with each
pizza individually seasoned, spiced, garnished and baked in a short
time and provided ready to eat.
[0032] It is another object of the present invention to furnish the
method and system such that the production process is performed
hygienically, without human intervention and where periodic and
automated washing and sterilization cycles are provided to maintain
the system in a suitable hygienic state.
[0033] It is a further object of the present invention to simply
and periodically exchange system components that contact foodstuffs
and are not otherwise subjected to the germicidal effect of
elevated temperature.
[0034] Dough Mixer
[0035] The dough mixer of the automatic pizza making method and
system of the present invention satisfies the need described above
for dough mixers. The dough mixer has a simple, compact design
providing automatic sterilization. The dough mixer has an
essentially cylindrical chamber with kneading rotation occurring
about a horizontal axis to accommodate direct charging of
consistently accurate and pre-metered amounts of material per work
cycle while preventing accumulation of material in the container
and/or metering chamber. The dough mixer quickly prepares, on
demand, one individual dough portion suitable for preparation of
one pizza by subsequent shaping, garnishing and baking.
[0036] Tomato Sauce Dispenser
[0037] The tomato sauce dispenser of the automatic pizza making
method and system of the present invention satisfies the need
described above for liquid dispensers. The tomato sauce dispenser
provides even sauce distribution on the dough base (regardless of
sauce homogeneity), performs in a production line having
traditional conveying systems and/or conveying systems which apply
heat to the dough base during transport thereof through the
production line, and facilitates easy cleaning and maintenance.
[0038] Oven
[0039] The oven of the automatic pizza making method and system of
the present invention satisfies the need described above for ovens.
The ovens of the present invention use infrared rays emitted in two
different wavelength ranges by separate and specific sources, each
differing in design, to produce specific heat within the top
surface (toppings) of the pizza and within the thin cake (dough).
The infrared rays are programmably cycled on and off, with
wavelengths in a visible and near-infrared range penetrating deep
into the dough, propagating in accordance with the laws of optics
(especially in the presence of water molecules), while wavelengths
in a far-infrared range are absorbed in the top surface of the
pizza, to fully cook and brown a typical pizza in approximately 55
seconds.
[0040] Automatic Cutting Device
[0041] The automatic cutting device of the present invention
provides a simple, easy-to-clean cutting and transfer device that
uses some of its cutting movements to transfer the pizza. The
present invention attaches a sheet that slides vertically by its
own weight or by spring action to a side of a plate provided with
blades. After cutting the pizza, the sheet holds the cut pizza in
the cutting position as the plate that supports the pizza during
cutting moves horizontally to drop the pizza onto a top box of a
stack of take-out boxes disposed below. Alternatively, the sheet
assists the transfer of the pizza onto a take-out box to one side
as the entire cutting device moves laterally, lifting the plate
provided with blades once the pizza is placed on the box.
[0042] The present invention also provides blades that are easily
detached from the supporting plate for replacement and cleaning,
regardless of whether the blades are single-use or coated with a
sheath or layer that can be removed easily at the end of a
predetermined cutting cycle, thereby making the cutting device as
hygienic as possible.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] For the purpose of illustrating the invention, there is
shown in the drawings a form that is presently preferred; it being
understood, however, that this invention is not limited to the
precise arrangements and instrumentalities shown.
[0044] FIG. 1 illustrates a front elevation of the automatic pizza
making system according to the present invention;
[0045] FIG. 2 illustrates a top plan of the automatic pizza making
system shown in FIG. 1;
[0046] FIGS. 3a and 3b illustrate a left side elevation of the
automatic pizza making system shown in FIG. 1, FIG. 3a showing a
dough punching device in an extended, non-operating position and
FIG. 3b showing the dough punching device in a retracted, operating
position;
[0047] FIG. 4 illustrates an elevation of the automatic pizza
making system according to the plane 4-4 in FIG. 1, FIG. 4 viewing
through a refrigerator to a cutting device, two ovens and a tray
conveying system;
[0048] FIG. 5 illustrates a right side, partial sectional elevation
of a flour container and dough mixer of the automatic pizza making
system shown in FIG. 1;
[0049] FIG. 6 illustrates a front sectional elevation of the flour
container and the dough mixer shown in FIG. 5;
[0050] FIGS. 7a through 7c illustrate a front sectional, a left
side sectional and a top plan, respectfully, of a pre-former of the
automatic pizza making system shown in FIG. 1;
[0051] FIGS. 8a and 8b illustrate a left side, partial sectional
elevation of a hot press of the automatic pizza making system shown
in FIG. 1, FIG. 8a showing an upper press portion and FIG. 8b
showing a lower press portion of the hot press;
[0052] FIGS. 9a and 9b illustrate a left side, partial sectional
and a top plan, respectfully, of the dough punching device of the
automatic pizza making system shown in FIG. 1 (and detailed in
FIGS. 3a and 3b), FIG. 9a showing the dough punching device in a
retracted, operating position and FIG. 9b showing the dough
punching device in an extended, non-operating position;
[0053] FIG. 10a illustrates a top plan of a tomato sauce dispenser
of the automatic pizza making system shown in FIG. 1;
[0054] FIG. 10b illustrates a front section of the tomato sauce
dispenser according to the plane II-II in FIG. 10a;
[0055] FIG. 10c illustrates a side, partial section of the tomato
sauce dispenser according to the plane III-III in FIG. 10b, FIG.
10c detailing a carriage driven by a threaded spindle;
[0056] FIG. 10d illustrates a top plan of a tomato sauce dispenser
shown in FIG. 1 (without the case), FIG. 10d showing a mounting for
the threaded spindle and the carriage;
[0057] FIGS. 11a through 11c illustrate a left side sectional, a
front sectional and a bottom plan, respectfully, of a cheese or
sausage dispenser of the automatic pizza making system shown in
FIG. 1;
[0058] FIGS. 12a through 12d illustrate a front partial sectional,
a left side partial sectional, a top plan and a left side sectional
detailing internal mechanisms, respectfully, of a pepperoni
dispenser of the automatic pizza making system shown in FIG. 1;
[0059] FIGS. 13a through 13d illustrate various side and front
elevations of each of two ovens included in the automatic pizza
making system shown in FIG. 1 with FIGS. 13e and 13f detailing the
cooking method employed by the ovens;
[0060] FIGS. 14a through 14c illustrate front views of one
embodiment of an automatic cutting and transfer device of the
present invention where a movable transfer plate is responsible for
transferring a cut pizza into a box for packaging;
[0061] FIGS. 14d through 14f illustrate front, top and left side
views, respectively, of another embodiment of an automatic cutting
and transfer device of the present invention (and the embodiment
shown in the automatic pizza making system of FIG. 1), where the
entire cutting device moves to transfer the cut pizza from a
cutting position to a packaging position; and
[0062] FIGS. 15a through 15f are left side elevations of the
automatic pizza making system shown in FIG. 1 (close-up views of
FIGS. 3a and 3b) illustrating, step by step, a dough shaping and
dough punching process according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0063] Referring now to the drawings, wherein like numerals
indicate like elements, there is shown in FIGS. 1 through 4 an
illustration of an automatic pizza making system 20. The pizza
making system includes a flour container 22, a dough mixer 24, a
water and leveling agent container 26, a pre-former 28, a hot press
30, a dough punching device 32, a receiving rack 34, a conveying
tray 36, a tray conveying system 38, a tomato sauce dispenser 40, a
cheese dispenser 42, a pepperoni dispenser 44, a sausage dispenser
46, a refrigerator 48, a first oven 50, a second oven 52 and a
cutting device 54.
[0064] Flour Container and Dough Mixer (FIGS. 5 & 6)
[0065] The dough mixer of the present invention is designed for
preparing individual dough portions per each work cycle within
relatively short periods of time and by charging with ingredients
in individual portions. The dough mixer provides that every
individual mixed dough portion that is rolled into a ball and is
ready for shaping and baking can be discharged without leaving
ingredients or dough residue inside the device. The dough mixer
also performs a periodic, completely automatic sterilization of the
kneading chamber and its kneading elements.
[0066] The object of the flour container and dough mixer of the
present invention is to create a dough mixer that has a simple and
compact design, can be automatically sterilized, has an essentially
cylindrical chamber with horizontal axis in which a kneading
element operates with horizontally rotating axis, due to direct
charging of the chamber with pre-metered ingredients per work
cycle, to create in a short period of time a portion of dough which
then is finally discharged as a mixed individual portion in the
form of a ball and ready-made for subsequent shaping, garnishing,
and baking or deep-freezing.
[0067] To attain the flour container and dough mixer described
above, a housing is designed having an inner chamber that is
essentially cylindrical and has in its upper section, which
corresponds to the charging region for the flour-like and possibly
also liquid ingredients, as well as in the lower section, which
corresponds to the discharge region, a surface area that runs
parallel to the chamber axis and turns into the chamber casing
surface. Within this chamber operates a rotating kneading element
according to an axis that runs coaxially or parallel to the chamber
axis. The rotating kneading element comprises at least one arm
formed with one end attached radially to the end of a drive shaft,
and on the other end of which at least one fixed bearing pin is
attached cantilever with an axis running parallel to the rotational
axis of the drive shaft; a freely turning sleeve is placed by means
of a recessed hole on top of this bearing pin with rounded terminal
ends on both sides. As an advantageous feature are two arms
extending radially from the same drive shaft, which are oriented to
each other longitudinally or are in the same level but are at a
certain angle to each other, and each of these arms carries a
bearing pin with a rotating sleeve placed on top parallel to the
rotational axis, preferably with a different distance to the
rotational axis of the drive shaft. While these bearing pins, which
are equipped with rotating sleeves, are in motion, the dough is
compressed, rolled and rolled thin repeatedly in particular in the
lower region of the chamber with the level surface section that
turns into the curved casing surface. If a plurality of these
sleeves are operated, they can have varying outside diameters,
cross-sections, and shapes depending on the consistency of the
dough being produced and/or the properties of the ingredients
and/or the percentage of liquid ingredients. The invention provides
further for the interchangeability and/or the change in the number
of the sleeves mentioned, depending on the properties of the
ingredients and/or the dough that is being prepared.
[0068] Due to the charging of the chamber with dry flour-like
ingredients, the kneading element carries out the work phase with
the purpose of homogenizing and aerating the dried ingredients by
rotating at a relatively high speed in order to achieve a thorough
mixing of the ingredients introduced, and their preparation for the
subsequent introduction of liquid ingredients, which ensures that
they are evenly absorbed, and the dough agglomerate is then created
with a markedly reduced rotational speed; by further reducing the
speed, a mixing and homogenization of the dough mass is achieved,
which then, upon further reduction in rotation speed, is compressed
and rolled into balls, which as such are discharged in part due to
gravity by opening the discharge opening in the region
corresponding to the lower level surface section of the
chamber.
[0069] The individual inner surfaces and surface areas of the dough
mixer chamber have surface transitions with rounded areas with the
largest possible radius, including the rotating arms or the sleeves
of the kneading elements, all have rounded forms, and thus the
chamber space is free of edges or recesses on which dough residue
could stick that is not discharged along with the individual
portion, due to the process by which the dough is kneaded and
rolled into balls. After rolling into balls and discharging, the
chamber and the kneading elements are thus free of any residue from
the dough and ingredients. This form further allows them to be
sterilized by means of hot air, through which small amounts of
sticky dough residue are removed in the air current due to the
drying process and the application of pressure.
[0070] The front surface of the chamber, which is across from the
second front surface from which the drive shaft for the kneading
element projects, can have a level, conical, more or less rounded
form that protrudes against the drive shaft, with its axis
extending coaxially to the rotational axis of the drive shaft or
parallel to it preferably in the upper level of the chamber. By
means of a distinctive conical or nose cone form, the rotating
sleeves of the kneading element can roll the dough thin even with
this shape. Further, the housing wall corresponding to this front
interior surface with more or less distinctive shape can be
replaced by another housing wall, in order to change the volume of
the chamber by changing the distance between the front circular
surfaces; in this case, the sleeves on the kneading element are
also replaced by sleeves with the appropriate longitudinal
extension.
[0071] Preferably, the liquid ingredient(s) for preparing the dough
are introduced through one or more openings in the central region
at the front wall across from the wall with the drive shaft.
[0072] In terms of the volumetric metering of the dry, flour-like
ingredients, the invention proposes that a metering device be
located in the region of the charging opening that is equipped
e.g., with sliding blades, which essentially comprises a
cylindrical container with vertical axis for the flour, and this
container is equipped with a volumetric metering mechanism at its
bottom. The container has inside in its lower region an annular,
funnel-like partition, and the point of a distribution cone extends
through the partition's central, circular opening so that an
annular passageway is free for the flour. The container has at the
bottom a metering sieve above which beaters move during the
rotation of the distribution cone, which is driven by means of a
vertical central shaft by a motor, in order to transport the flour
through the metering sieve and through the holes which are
positioned equidistant to the rotational axis on the metering disk
located beneath it. The metering disk is located on the bottom
disk, which is connected to the cylindrical wall of the container
and which has a hole in the region of the charging opening of the
dough mixer attached beneath it, through which the flour falls from
the metering holes at the rotating metering disk and through the
charging opening into the chamber of the dough mixer.
[0073] The present invention does not exclude the possibility that
the dough mixer is fed from a metering device that has features
other than those proposed by the invention, or from a device which
charges with a pre-measured portion.
[0074] One embodiment of the flour container and dough mixer
described above is illustrated in FIGS. 5 and 6. This embodiment is
capable of preparing individual portions of 130-260 g within 10-15
seconds, which is suitable for the automatic pizza making system of
the present invention.
[0075] FIG. 5 illustrates a section of a dough mixer 24 according
to the invention during the charging phase and linked to a metering
device 80, showing a sectional view according to the plane of
section I:I in FIG. 6, which plane runs through the axis of the
drive shaft of the metering device 80.
[0076] FIG. 6 shows the dough mixer 24 according to the invention
and as shown in FIG. 5 together with a metering device 80 in
section according to the plane of section II-II in FIG. 5.
[0077] The dough mixer 24 for preparing individual portions
comprises a housing 81 with an inner chamber and a kneading element
84, 84c, 84d, containing a charging opening 82a and a discharging
opening 83a, 81d, with corresponding blades 82, 83. The essentially
cylindrical chamber with horizontal axis is delimited by a level,
circular surface 81e from which a shaft 92a extends coaxially, by a
circular surface 81f corresponding to the aforementioned but with a
conical form projecting slightly into the chamber, by two curved
surfaces 81a with a casing line equidistant from the chamber axis,
by an upper level surface section 81c that essentially corresponds
to the region of the charging opening 82a, and by a lower level
surface section 81b, which is larger than the upper one and
corresponds to the region of the discharging opening 81d, 83a.
[0078] The kneading element comprises an arm 84 which is fastened
on its front side at the end of the drive shaft 92a that extends
into the chamber; at each of the ends of arm 84 a pin 84c is
fastened having an axis running parallel to the rotational axis of
the drive shaft 92a, and a freely turning 84b sleeve 84d with a
rounded, hemispherical or nose cone-shaped terminal area is placed
on each of pins 84c by means of a recessed hole. Arm 84 of the
kneading element is fastened to drive shaft 92a, off-center
relative to the center line of the transverse-extending arm, such
that two pins 84c with sleeves 84d attached to it turn with varying
radius about the rotational axis of drive shaft 92a, which is
driven by the electric motor 92 at varying rotational speeds and
changing rotation directions.
[0079] Charging opening 82a for the introduction 94b of the
flour-like ingredients in the upper region and discharging opening
83a, 81d for the individual portions of dough balls in the lower
region, are provided with sliding blades 82, 83, which for example
are moved 82b, 83b by pneumatic cylinders 82c, 83c without
excluding the use of rotating blades and other drives.
[0080] Liquid ingredients are charged via a single hole 93 or via
specific holes for each of the liquid ingredients, which holes are
conical and all preferably disposed on the disc-shaped wall 91 in
the region within the track of sleeve 84d, which turns with smaller
radius about shaft 84a. Same hole 93 can be used for blowing in hot
air to clean and/or sterilize the chamber and rotating kneading
elements 84, 84c, 84d. The method for preparing dough with the
dough mixer 24 according to this invention, has essentially the
following phases:
[0081] Charging 94b with flour- or dust-like ingredients,
[0082] Homogenization and aeration of the flour- and/or dust-like
ingredients,
[0083] Charging 93a with liquid ingredients,
[0084] Preparing the dough,
[0085] Rolling the dough thin,
[0086] Compacting and rolling the dough into balls
[0087] Discharging the individual dough portions
[0088] Following production of a pre-programmed number of dough
portions and based on the production intervals, the chamber of the
dough mixer 24 is cleaned and sterilized with hot air.
[0089] Charging 94b with flour-like and/or dust-like ingredients is
by free fall through charging opening 82a equipped with sliding
blades 82, which is driven 82b by pneumatic cylinder 82c. The
construction and operation of the metering device 80, in accordance
with the invention, with discharging opening 85e, corresponding to
charging opening 82a of the dough mixer 24 with which it is
connected, will be explained later.
[0090] The flour-like and dust-like ingredients are homogenized and
aerated by rotating kneading element 84, 84c, 84d at a relatively
high speed (approx. 2,500-3,000 rpm) that creates a favorable
dispersion of the ingredients due to the special form of the
chamber and kneading elements, wherein the particles of the dry
ingredients are prepared for even absorption of the liquid
ingredients following charging 93a.
[0091] The dough mixture is prepared by rotating 84a kneading
element 84, 84c, 84d at a lower rotation speed (approx. 950-1,400
rpm); this phase is followed initially by the formation of little
dough clumps, which are then rolled together by the repeated action
of rotating 84b sleeves 84d.
[0092] The dough is then prepared by rotating kneading element 84,
84c, 84d at an even lower rotation speed (approx. 850-920 rpm);
especially in this phase, the dough is repeatedly and intensely
rolled out and rolled thin by the turning 84b sleeves 84d,
particularly at lower level surface section 81b. The formation of a
compact, balled together dough mass follows at an even lower
rotation speed (approx. 700-820 rpm), thus taking on the form of a
"dough ball" at the end of this phase.
[0093] The "dough ball" is discharged by centrifugal force via the
rotating kneading element and by gravity through discharging
opening 83a, which is opened by activating 83b blade 83 by means of
pneumatic cylinder 83c.
[0094] During the various work stages, in particular during
compacting, rolling out, and balling together the dough, it can be
advantageous to make one or more changes in rotational direction
84a of kneading element 84, 84c, 84d. Liquid ingredients can be
charged 93a more or less in stages and while kneading element 84,
84c, 84d is rotating. For cleaning and/or sterilization of the
chamber by injecting hot air, the cool air of motor 92 that drives
92a the kneading element or the air that is diverted from the
pneumatic system can be used, the air being heated prior to its
injection into the chamber.
[0095] The volumetric metering device 80 for the dry flour-like
ingredients according to the invention comprises a cylindrical
container 85, 85a, 85b with vertical axis, a distribution cone 87
with beaters 87a, 87b rotating 88a coaxially to the container axis,
and a metering disk 89 with metering holes 89a on the rim which
form the volume units for creating a total portion of flour 94 to
be charged 94b into the dough mixer 24 in order to generate a
single portion of dough.
[0096] Cylindrical vertical wall 85 is sealed with bottom plate
85b, which provides a seating 85c for the bottom end of a
vertically rotating 88a shaft 88 that is centrally seated 85d in
cover plate 85a. The upper end of shaft 88, which extends beyond
the cover plate 85a, is equipped with a pulley 88a driven by the
belt 88b of a motor 91 attached to the container. Shaft 88 can
naturally be driven in other ways and by other sources of power.
Inside, in the lower region, the container is equipped with an
annular, funnel-like partition 86 for directing flour 94 in the
direction of the container axis. The upper region of a distribution
cone 87, which is connected to drive shaft 88, extends through the
central opening in partition 86 such that an annular duct 86c
results for flour; beaters 87b that extend down from the cone 86
and move closely above partition 86 cause flour 94 to pass through
94a. Partition 86 and cone 87 prevent variations in the fill level
of flour 94 and thus the weight above partition 86 from having an
affect on the metering mechanism disposed beneath. This mechanism
comprises metering disk 89 with holes 89a on rim that rotates
together distribution cone 87 and drive shaft 88; individual holes
89a, which are equidistant to the axis of rotation of the disk,
represent with their volume the metering unit for creating the
charging amount. Above metering disk 89 is a sieve 90 equipped with
ducts 90a through which the flour is moved through at least one
beater 87c which sticks out from cone 87, and turns with drive
shaft 89, and moves above sieve 90. On the underside, metering disk
89 lies on top of bottom disk 85b of the container. Bottom disk 85b
has an outflow through hole 85e that corresponds in diameter to
holes 89a on metering disk 89 or is of a greater diameter and in
the region of the passage of these holes. Practice has shown that
the construction described here allows volumetric metering that is
independent of the fill level in the container, the moisture level
and other physical properties of the contents, which metering is
sufficiently constant and can be varied by one or more volume units
that are determined by individual holes 89a on metering disk 89.
This feature of the metering device 80 is fundamental for achieving
homogeneity in the individual dough portions, which requires
charging with calibrated, homogeneous ingredients and attains this
above all by assuring that the mixture does not put weight on the
metering mechanism in a single casing 85, 85a, 85 which is fed via
a relatively narrow annular duct 86c and, affected by simultaneous
mixing motions in the container region above the partition 86 and
in the emptying region of the metering holes 89a and at the
metering disk 89. Naturally, the amount of flour 94, which moves
through annular duct 86c, must be at least as great, preferably
somewhat greater than the amount which is fed to the dough mixer 24
for the purpose of maintaining the individual portion of dough.
[0097] The present invention does not exclude the possibility of
linking the metering device 80 according to the invention to a
dough mixer or another device that does not correspond to the dough
mixer according to the invention.
[0098] Pre-Former (FIGS. 7a Through 7c)
[0099] FIGS. 7a through 7c illustrate various views of a pre-former
28. The pre-former 28 receives the "dough ball" discharged by
centrifugal force via the rotating kneading element and by gravity
through the discharging opening 83a of the dough mixer 24, which is
opened by activating blade 83b by pneumatic cylinder 83b.
[0100] The pre-former 28 is the first step of a process of shaping
the "dough ball" into a flat cake for pizza preparation.
[0101] Referring to FIGS. 7a through 7c, the pre-former 28 includes
a funnel housing 102 and a disc press 104, which includes a disk
plate 106, a pneumatic cylinder 108 and a guide bar 110.
[0102] Opening 113a at the top of funnel housing 102 is positioned
below discharge opening 83a, 81b of the dough mixer 24. The funnel
housing 102 is fixedly connected to the underside of the housing 81
of the dough mixer 24.
[0103] The "dough ball" enters opening 113a, falls by gravity and
comes to rest within the funnel housing 102 in the vicinity of a
discharge opening 113b of the funnel housing 102, as shown in FIG.
7a by simulated "dough ball" 114. The dough ball 114 is prevented
from exiting the discharge opening 113b by a lower press plate 131
of the hot press 30 which has been movably positioned in two
dimensions against the bottom of the funnel housing 102 at the
discharge opening 113b. The positioning of the lower press plate
131 against the bottom of the funnel housing 102, covering the
discharge opening 113b, is timed to coincide with the activation
83b of the blade 83 which opens discharge opening 81d, 83a of the
dough mixer 24, which discharges the dough ball into the pre-former
28.
[0104] The disk plate 106 is shaped as an inverted cup so that
activation of the pneumatic cylinder 108, lowering the disk plate
106 until contact with the lower press plate 131 shapes the dough
ball 114 into a disc or puck. The disk plate 106 and the lower
press plate 131 can be preheated to warm the dough ball 113 during
shaping to expedite dough baking later in the pizza making
process.
[0105] Hot Press (FIGS. 8a and 8b)
[0106] FIGS. 8a and 8b illustrate an upper press portion 125 and a
lower press portion 127 of the hot press 30. The upper press
portion 125 includes an upper press plate 129 which is fixedly
connected 130 to structure of the pizza making system 20. The lower
press portion 127 includes a lower press plate 131, a support plate
132, a buffer plate 133 and a pneumatic cylinder 134. The lower
press plate 131 is fixedly connected to the support plate 132 and
separated therefrom by the one or more buffer plates 133. As the
lower press plate 131 is electrically heated to precook the dough
during shaping, the one or more buffer plates 133 prevent the
transfer of heat from the lower press plate 131 to the support
plate 132 and the pneumatic cylinder 134.
[0107] Referring to FIG. 3, the lower press portion 127 of the hot
press 30 is slidable in one dimension due to connection to lateral
track 136 and lateral conveyance system 138. The lateral conveyance
system 138 is pneumatically operated and programmed to slidably
move the lower press portion 127 under the pre-former 28 with the
pneumatic cylinder 134 raising the lower press plate 131 into
contact with the underside of the funnel housing 102 to receive the
dough ball discharged from the dough mixer 24. After the pre-former
28 shapes the dough ball into a disk, the lower press plate 131 is
lowered by pneumatic cylinder 134 and the lateral conveyance system
138 slides the lower press portion 127 to the position shown in
FIG. 3. The pneumatic cylinder 134 than raises the lower press
plate 131 against the upper press plate 129 to shape the dough into
flat cake for pizza preparation.
[0108] Again, the upper press plate 129 and the lower press plate
131 are electrically heated to precook the dough during the shaping
process.
[0109] Dough Punching Device (FIGS. 9a and 9b)
[0110] FIGS. 9a and 9b illustrate a side elevation and top plan,
respectfully, of the dough punching device 32. The dough punching
device 32 includes a toothed punching plate 152, a slidable housing
154, a slidable support bracket 156 and two guide bars 158.
[0111] Referring to FIG. 3a, the dough punching device is shown in
its non-operating position. The guide bars 158 are fixedly
supported to structure of the pizza making system 20. FIG. 9b is a
top plan of the dough punching device 32 in this non-operating
position. The slidable support bracket 156 is slidably attached to
the guide bars 158 and fixedly attached to the slidable housing 154
which supports the two punching plates 152. A dough punching
conveyance system (not shown) is programmed to timely operate the
dough punching device 32 after operation of the hot press 30
(shaping the dough into flat cake).
[0112] Upon completion of the hot press 30 operation, shaping the
dough into flat cake, the pneumatic cylinder 134 lowers the lower
press plate 131 back to the position shown in FIG. 3a. At this
time, flattened pizza dough rests upon the lower press plate 131.
The dough punching conveyance system initiates slidable movements
of the dough punching device 32 to an operable position shown in
FIG. 3b. This operable position is also illustrated in FIG. 9a.
[0113] The pneumatic cylinder 134 raises the lower press plate 131
against a toothed underside of the punching plate 152 thereby
dimpling the flattened pizza dough to facilitate uniform and
expedited dough baking at a later stage of the automatic pizza
making process.
[0114] The pneumatic cylinder 134 then lowers the lower press plate
131 to the position shown in FIG. 3a and the dough punching device
32 returns to the non-operable position also illustrated in FIG.
3a.
[0115] Referring to FIG. 1, a pneumatic tilting stem 160 is then
actuated to lift a distal end of the lower press plate 131 away
from the support plate 132, tilting the lower press plate 131 about
a hinged attachment point 162 between the lower press plate 131 and
the support plate 132 whereby the flattened, perforated pizza dough
slides from the lower press plate 131 to a conveying tray 36
positioned under the tomato sauce dispenser 40.
[0116] Summary of Dough Shaping and Dough Punching Process (FIGS.
15a Through 15f)--Includes Pre-Former, Hot Press and Dough Punching
Device
[0117] The entire dough shaping and punching process is summarized
below in conjunction with FIGS. 15a through 15f:
[0118] FIG. 15a--the lower press portion 127 is slidably positioned
along the lateral track 136 with the lower press plate 131 raised
to contact the underside of the pre-former 28 to receive the dough
ball and shape same into disc form.
[0119] FIG. 15b--the lower press portion 127 is lowered away from
the pre-former 28 and transports the disc-shaped dough along the
lateral track 136 to a position for flattening under the upper
press portion 125.
[0120] FIG. 15c--the lower press plate 131 is raised by the
pneumatic cylinder 134 into contact with the upper press plate 129
to flatten the disc-shaped dough into flat cake for pizza
preparation. The upper and the lower press plates 129, 131 are
electrically heated to preheat the dough during the dough shaping
to expedite the later baking of the pizza.
[0121] FIG. 15d--after flattening, the lower press plate 131 is
lowered and the dough punching device 32 slides along the guide
bars 158 into an operating position under the upper press plate
129.
[0122] FIG. 15e--the lower press plate 131 is raised into contact
with the toothed punching plate 152 thereby dimpling the flattened
pizza dough to facilitate uniform and expeditious later baking of
the pizza.
[0123] FIG. 15f--upon completion of dough shaping and punching, the
pneumatic cylinder 134 lowers the lower press plate 131. The
pneumatic tilting stem 160 then raises a distal end of the lower
press plate 131 tiling same about a hinged attachment point 160
connecting the lower press plate 131 to the support plate 132. The
flattened and perforated pizza dough then slides from the lower
press plate onto a conveying tray (not shown) under the tomato
sauce dispenser 40 (also not shown).
[0124] Tray Conveying System (FIGS. 1 and 2)
[0125] Referring to FIGS. 1 and 2, the tray conveyor system 38
operates horizontally at level 173 to transport one or more
conveying trays 36 at level 172 from the tomato sauce dispenser 40
through cheese dispenser 42, pepperoni dispenser 44 and sausage
dispenser 46 to one of two ovens 50, 52.
[0126] After dough shaping and punching is complete, and the lower
press plate 131 is tilted by the pneumatic tilting stem 160 (as
shown in FIG. 1), the receiving rack 34 (tilted as shown in FIG. 1)
receives the flattened and perforated dough released by the tilted
lower press plate 131. A pneumatic cylinder 171 raises a distal end
of the receiving rack 34, tilting the receiving rack about a hinged
or pinned attachment point 170 between the receiving rack 34 and
structure of the pizza making system 20 until the receiving rack is
horizontal as illustrated by position 34a of FIG. 1. The conveying
tray 36 is positioned within the receiving rack 34 and is
transported by the tray conveyor system 38 away from the receiving
rack 34 and aligned precisely below the tomato sauce dispenser for
liquid garnishment.
[0127] After application by the tomato sauce dispenser 40, the tray
conveyor system 38 transports the conveying tray 36 below the
various dispensers 42, 44, 46 stopping if programmed below one or
more of the dispensers 42, 44, 46 for respective topping
application. The tray conveyor system 38 stops the conveying tray
36 at position 174 (shown in FIG. 2) and directs the conveying tray
36 into one of the ovens 50, 52.
[0128] The conveying tray 36 remains with the pizza during baking
in the oven and returns the pizza to position 174 upon completion
of baking. The cutting device 54 transports the prepared pizza from
position 174 to a packaging position 175. The conveying tray 36 is
transported back and into the receiving rack 34 to receive the next
flattened and perforated dough portion for pizza preparation.
[0129] The automatic pizza making system 20 as generally
illustrated in FIGS. 1 through 4, can accommodate two conveying
trays 36 operating simultaneously. As one conveying tray is
positioned in one of the ovens 50, 52, a second conveying tray is
transporting a flattened and perforated dough portion along the
various preparation stations. As the second conveying tray 36
enters the vacant oven, the first conveying tray 36 removes a
completed pizza to position 174 and returns to the receiving rack
34 to repeat the preparation process while the second conveying
tray 36 remains in the other oven. Accordingly, the automatic pizza
making system 20 can accommodate the same number of conveying trays
36 as ovens included in the respective system. Although the
automatic pizza making system 20 illustrated in FIGS. 1 through 4,
includes two ovens and two conveying trays, the spirit of the
present invention envisions various and multiple alternatives in
oven and conveying tray design to accommodate the needs of any
user.
[0130] Tomato Sauce Dispenser (FIGS. 10a Through 10d)
[0131] The object of the tomato sauce dispenser of the present
invention is to meter and apply an even distribution of the tomato
sauce on the flattened pizza dough, regardless of the inconsistency
in homogeneity of some tomato sauces. The tomato sauce dispenser
shall also facilitate easy cleaning and maintenance for good
sanitation.
[0132] To achieve this object, the tomato sauce dispenser of the
present invention equips a nozzle and/or end of a tube through
which the sauce supplied with all the motions that are necessary to
achieve the even distribution on the sauce without using special
conveying means for the sauce through the tube.
[0133] The present invention uses a system of the spiral
distribution, where the sauce falls onto the flattened pizza dough
through a device that rotates about a vertical rotational axis. The
rotating device has a threaded spindle that radially shifts the end
of the tube or nozzle to dispense the sauce in a horizontal plane
above the flattened pizza dough during rotation. Accordingly, the
sauce is distributed in a spiral with constant gradient without
moving the flattened pizza dough. In order to achieve a homogenous
distribution, the speed of rotation (creating the spiral) is
constant during the entire garnishing process. The spiral rotation
preferably starts at the periphery of the flattened pizza dough and
ends at the center. The number of revolutions of the device is
increased in relation to the reduction of the radius of the spiral
so that the sauce is always deposited onto the pizza at the same
speed.
[0134] The even and regular distribution in spiral-shape is
guaranteed, if it is ensured that the spiral has a constant
gradient, the garnishing product is dispensed without interruption
and evenly, and in particular that the speed with which the
garnishing product touches the basic product is uniform. As an
alternative, the even distribution of the garnishing product can
also be achieved by adjusting the volume (dispensed volume) in
relation to the changed speed with which the garnishing product
touches the basic product below.
[0135] The tomato sauce dispenser includes a fixed basic frame with
two horizontal plates; a friction ring or annular gear is mounted
to the bottom plate in the region of a central bore, whereas on the
top plate, a bushing is pivoted coaxially to this ring and this
bore, which bushing is driven by an electric motor and permanently
mounted to bearing plates for a threaded spindle; the rotation of
this threaded spindle moves a carriage in the direction of the axis
and to radially shift the end of the tube for supplying the sauce.
The threaded spindle is driven via a friction disk which is in
contact with the friction ring, or via an annular gear that engages
the gear ring.
[0136] By rotating the bushing and thus the bearing of the threaded
spindle in one direction, the radial shifting of the carriage via
the threaded spindle in one direction is achieved, for instance,
outwardly to the rotational axis of the bushing, whereas the
friction disk or toothed gear that is connected with the threaded
spindle rolls off the friction ring or annular gear which is
mounted to the stationary frame. Reversing the rotational direction
of the bushing results in the shifting of the carriage from the
area of the rotational axis of the bushing outward, that is, into
the margin area of the flattened dough underneath.
[0137] The flexible tube for supplying the sauce is routed freely
through the rotating bushing. The tube is pivoted in the radially
shiftable carriage so that the dispensed sauce can fall freely onto
the pizza.
[0138] The positioning of the end of the tube prevents the tube
from twisting or becoming entangled while the various motions of
the device are performed and also allows easy disassembly and
replacement of the tube for cleaning and maintenance. The tube is
preferably one piece using a peristaltic pump for sauce supply. The
invention does not exclude employing a constant rotational speed
for the end of the tube dispensing the sauce, whereas the decreased
radius of the spiral would result in a reduced volume of sauce
being delivered so that the sauce is evenly deposited onto the
pizza. In order to limit the required cleaning and to maintain good
sanitation, the tomato sauce dispenser allows easy exchange of the
tube, using a single exchange part with a single tube coupling.
[0139] FIG. 10a illustrates a top plan view of the tomato sauce
dispenser according to the present invention. FIG. 10b illustrates
a front elevation section according to the plane II-II of FIG. 10a,
the plane II-II comprising a vertical axis of the tomato sauce
dispenser shown in FIG. 10a. FIG. 10c illustrates a lateral view
according to the plane III-III, partly in section, showing the
carriage driven by the threaded spindle. FIG. 10d illustrates the
top plan view shown in FIG. 10a, without the case, exposing a
mounting for the threaded spindle and the carriage.
[0140] Lateral carriers 181 are mounted to a frame 190 of a
conveyor belt or conveyor chain 191 by clamps 181a, the carriers
181 supporting at their top a plate 181b with central bore
181c.
[0141] Above central bore 181c and coaxial to it, a second plate
183 is supported by arms 182, the second plate 183 being spaced
parallel to the first plate 181b and centered, in which the second
plate 183 has a bushing 184 seated therein such that the bushing
184 can be rotated 183r via ball bearings 183a. On an outer surface
of the bushing 184, a pulley or groove 184a is supported for a belt
188 that is used to transfer movement of a pulley 185a of an
electric motor 185 to the bushing 184. Two arms 183e are mounted to
the bottom of the bushing 184, which arms 183e extend downward and
at the end of which vertical parallel bearing plates 186 are
mounted for a rotatable 186r threaded spindle 186c, a leading
spindle 186b and a connecting element 186a. The threaded spindle
186c is fitted with a friction disk 186e at one of its ends that
protrudes over the bearing plates 186, which friction disk 186e
rolls off a friction ring 181f with its rubber-coated periphery
186f. The friction ring 181f is mounted to the edge region of the
central bore 181c of the plate 181b via rings 181e, 181d. In order
to ensure good contact between the periphery 186f of the friction
disk 186e and the stationary friction ring 181f, a ball bearing
186d is provided (seated at the same bearing plate 186), which ball
bearing 186d provides a friction disk 186e, parallel and
perpendicular to the rotational axis above, in order to form a
thrust bearing on top of the friction ring 181f.
[0142] In accordance with rotation 183r of the bushing 184, the
arms 183e and the bearing plates 186 rotate together with the
threaded spindle 186c, the spindles 186a, 186b and a movable 189t
carriage 189 connected thereto. The rotation 183r occurs when the
friction disk 186e rolls on the stationary friction ring 181f, the
friction ring 181f being permanently mounted to the plate 181b. The
rolling friction disk 186e causes rotation 186r of the threaded
spindle 186c, the rotation 186r causing movement 189t in the
carriage 189 due to an internally threaded nut 189b within the
carriage 189 which engages the rotating threaded spindle 186c. The
carriage 189 provides a guide part 189c, the guide part 189c
including a seat 189g which glides along the stationary leading
spindle 186b. The rotation 186r of the threaded spindle 186c causes
the carriage 189 to move 189t along the axis of the threaded
spindle 186c, whereas the guide part 189c slides along the
stationary leading spindle 186b to prevent the carriage 189 from
twisting. This mechanism allows for movement 189t of the carriage
189 to be linked to rotational movement 183r, resulting in a spiral
193 distribution of the tomato sauce S with constant gradient. To
ensure that the distribution of the sauce S on the flattened dough
192 is performed with uniform speed and independently of the
distance of end 187a of tube 187 from the rotational axis of the
bushing 184, and thus from the center of the flattened dough 12
underneath, the number of revolutions of motor 185 during movement
189t of the carriage 189 from the outward area to the center area
of the flattened dough 192 increases in relation to the decrease of
the radius of the spiral 193.
[0143] Tomato Sauce S is supplied under pressure, which pressure
can be generated by a peristaltic pump. The sauce S is routed
axially via the flexible hose 187 through passage 184c of the
rotating bushing 184, which bushing 184 has an internal ball
bearing 184b to prevent friction with the tube 187 during rotation
183r. The end 187a of the tube 187 for dispensing the sauce S is
pivoted on ball bearing 189d, which is mounted to the carriage 189.
The end 187a of the tube 187 is additionally routed through a ring
element 189e, which is also mounted to the carriage 189.
[0144] The present invention does not exclude that the threaded
spindle 186c only extends over an area that is slightly longer than
the radius of the flattened dough 192 and that the threaded spindle
186c is driven by a toothed gear, which derives motion from a gear
ring, which is connected to stationary structure of the system 20.
Furthermore, the invention does not exclude that the tomato sauce
dispenser 40 is seated moveably so that it accompanies the
flattened dough 192 while it is conveyed on conveying tray 36,
without stopping the conveying tray 36, with the tomato sauce
dispenser 40 returning to its initial position after the garnishing
process is complete.
[0145] To achieve a uniform distribution, apart from the above
described process which provides a change of rotational speed 183r
with a constant supply of sauce S, a process can be used that
maintains a constant rotational speed 183r while changing the
supply of sauce S delivered in proportion to the change in the
radius of the spiral (reducing the radius results in an increased
supply capacity of the pump feeding the sauce).
[0146] Furthermore, the present invention does not exclude that the
bushing 184 is seated within a single plate that covers the height
of plate 181b and that has a friction ring 181f or an annular gear.
In this alternative embodiment, axial passage 184c of the bushing
184 has a diameter that roughly corresponds to twice the movement
distance of the carriage 189. The threaded spindle 186c can also be
seated within the passage 184c of the bushing 184. The bushing 184
can also be replaced by a circular plate that is rotatably 183r
seated on the stationary plate 181b and has a diametrically or
simply radially arranged passage, within which or in the region of
which the threaded spindle 186c and the carriage 9 are seated.
[0147] Cheese Dispenser/Sausage Dispenser (FIGS. 11a Through
11c)
[0148] Cheese and sausage dispenser 42, 46 of the automatic pizza
making system 20 suitably applies any type of solid toppings,
namely cheese, sausage, mushrooms pepperoni, etc., to the dough
base prior to baking the pizza. Accordingly, cheese and sausage
dispenser 42, 46 shown in FIGS. 11a through 11c can also be used
for the pepperoni dispenser 44 of the automatic pizza making system
20 shown in FIGS. 1 and 2. The cheese and sausage dispenser 42, 46
includes bulk portion control devices.
[0149] Cheese and sausage dispenser 42, 46 has a chamber 202 for
holding bulk solid topping, a doser 204 attached to the chamber 202
and a motorized stirring device 206 attached to the doser 204 and
used to feed the doser 204. The doser 204 includes a slidable plate
210 fitted between two fixed plates 211, 212. One of the fixed
plates 211 is attached to the chamber 202 and the second fixed
plate 212 is positioned above the pizza. The slidable plate 210
includes a number of openings 214 that are fed with a predetermined
amount of solid topping from the chamber 202. As the slidable plate
210 is moved, the openings 215 of the fixed plate 211 (attached to
the chamber 202) are closed and the openings 216 of the fixed plate
212 (above the pizza) are opened, allowing portion of solid topping
held within the openings 214 of the slidable plate 210 to fall onto
the pizza.
[0150] Pepperoni Dispenser (FIGS. 12a Through 12d)
[0151] Pepperoni dispenser 44 of the automatic pizza making system
20 suitably applies any type of solid toppings, namely cheese,
sausage, mushrooms pepperoni, etc., to the dough base prior to
baking the pizza. Accordingly, pepperoni dispenser 44 as shown in
FIGS. 12a through 12d can also be used for the cheese dispenser 42
and the sausage dispenser 46 of the automatic pizza making system
20 shown in FIGS. 1 and 2. The pepperoni dispenser 44 includes
mono-dose portion control devices.
[0152] The pepperoni dispenser 44 (mono-dose portion device)
includes a number of stackable trays 255 having a number of dosing
compartments 257 used to hold a solid topping 259. The trays 255
are disposable and have registration features such as a dimple to
maintain the trays 255 in alignment when stacked. The trays 255 are
preloaded, stacked and stored with toppings 259 and may be held in
place by a retainer 261, such as a string, tape or plastic wrap.
The trays 255 may be stored in a suitable modified atmosphere 263
for preserving freshness of the solid topping 259.
[0153] The toppings 259 are dispensed from the stack of trays 255
as one is removed from the bottom of the stack. This is achieved by
the use of the individually spaced dosing compartments 257 that are
maintained in a closed position by the bottom most tray in the
stack. As each tray 255 is slidably removed 265 from the bottom of
the stack, the openings of the tray above it are opened to a pizza
maintained below it and the solid topping 259 free fall 267 to the
pizza below.
[0154] Ovens (FIGS. 13a Through 13f)
[0155] As shown in FIGS. 1 through 4, and detailed in FIGS. 13a
through 13d, the automatic pizza making system 20 includes two
ovens 50,52 for baking the freshly made pizza 1 transported to one
of the two ovens 50,52 by means of ovenproof plate 302. Each oven
50,52 includes a heat retaining housing, a pneumatic cylinder 312,
an opening 304c, and a number of heating elements 307, 308, 310.
The electric components of the ovens 50,52 are powered and
controlled by a controller.
[0156] As the pizza 1 approaches one of the ovens 50,52, the
controller activates the pneumatic cylinder 312, which opens the
opening 304c allowing the pizza 1 to enter the selected oven 50,52.
Once in the oven 50,52, the pizza 1 is baked until done in stages
maintained by the controller. The cooking method is determined by
many factors, including the intensity, frequency, and duration of
heat applied by one or more of the heating elements 307, 308, 310,
and the distance between the pizza 1 and the heating elements 307,
308, 310. The intensity, frequency, and duration of the applied
heat are set by the controller to achieve desired cooking
qualities, such as surface browning, dough texture and crust
crispness, each of which can be varied to accommodate consumer
preferences.
[0157] In one embodiment of the invention, the heating elements
include two arrays of infrared heating devices, one set of heating
elements 308 including rays in the visible and near-infrared range
and the other set of heating elements 307 including rays in the
far-infrared range. Infrared rays in the visible and near-infrared
range with wavelengths of 0.75 .mu.m to 3 .mu.m propagate in
accordance with the laws of optics during transmission.
Specifically, these rays pass through water molecules, and
therefore steam, with little or no absorption. Infrared rays in the
far-infrared range with wavelengths of 6 .mu.m to 1,000 .mu.m, on
the other hand, propagate through space in accordance with the laws
of electromagnetics, and are absorbed and converted into radiant
energy (i.e., heat) as they pass through matter.
[0158] The invention employs a cooking method employing infrared
wavelengths in the visible and near-infrared range concurrently or
staggered with infrared wavelengths in the far-infrared range. When
pizza cooking, the infrared rays with wavelengths in the visible
and near-infrared range penetrate the pizza, in the presence of
water (in the form of water vapor), to a depth of about 10 mm to 15
mm. Infrared rays in the far-infrared range penetrate about 0.5 mm
to 0.8 mm.
[0159] To maintain the depth of penetration of the infrared rays in
the visible and near-infrared range, the outer layer of the pizza
or thin cake should remain moist during cooking, as that would
maintain a layer capable of absorbing all or most of the visible
and near-infrared radiation, preventing the rays from failing to
penetrate the pizza and excessively overheating the outer layer
with respect to the rest of the dough. It is an object of the
present invention, therefore, for infrared rays in the visible and
near-infrared range to predominate initially, and for rays in the
far-infrared range to be applied at the very end of the cooking
process for surface browning. The cooking method of the present
invention also calls for an initial heating cycle of a given
duration, which raises the temperature of the thin cake very
rapidly, quickly overcoming the thermal inertia of the dough and
compensating for heat energy lost to the dispersal of fermentation
gases, the evaporation of ethyl alcohol produced as the dough rises
and the formation of water vapor.
[0160] The cooking method then calls for a programmed series of
heating cycles of decreasing duration with intervals between them
that can be varied to prevent too much moisture from evaporating
quickly from the thin cake, thereby sustaining deep penetration of
the rays in the visible and near-infrared range for as long as
possible. In a final stage the thin cake is heated for
approximately the same amount of time as the initial heating
period. This forms dextrins in the crust, which browns to form a
thin textured layer, and imparts aroma and crispness through
dextrinization and pyrolysis of starch.
[0161] An oven built according to the invention and operating
according to the disclosed cooking method can cook and brown a
topped pizza in approximately 55 seconds. In addition, the thermal
inertia of the housing of the oven is as low as possible, since its
internal surfaces are shaped to reflect the rays onto the thin
cake. In another embodiment of the invention, some or all of the
radiation sources are mounted to move (with or without reflectors),
thereby varying the distance from the source to the surface of the
thin cake during the cooking process.
[0162] The present invention could also include the use of a
microwave generating magnetron, in addition to the sources of
infrared rays. For fast cooking, a radiation or heat source could
also be positioned below the pizza. In such an event, lamps
emitting infrared rays in the far-infrared range could be used as a
radiation source, and the thin cake could be supported on a
perforated plate or grille such that at least some of the rays act
directly on the thin cake while some heat the support which
transfers heat to the thin cake by contact. If an induction unit is
included in the oven, the plate is made of metal and provided with
slits, or spiral or concentric circular openings, to transfer the
heat by contact.
[0163] The cooking method of the present invention may call for
programming of the radiation and/or heat sources depending upon the
toppings on the pizza to accordingly vary the heating times, the
number and duration of heating cycles, the intensity (e.g., heating
using a larger or smaller number of units), the distance between
the sources and the pizza and/or the position or shape of the
reflectors, if any.
[0164] The oven of the present invention could be a bell-type oven
having a stationary lower part and a moveable upper part to
facilitate oven feeding using a mechanical transport means and to
limit the cooking volume of the oven by completely shielding the
radiation. However, the invention does not preclude application of
the cooking method to other types of ovens, such as tunnel or
muffle ovens. Also, the radiation sources, specifically the
induction unit, may act independently of the infrared lamps or
partially in conjunction with the radiation sources.
[0165] FIG. 13a illustrates a sectional view of ovens 50, 52 along
a vertical plane parallel to the longitudinal axis of the transport
mechanism of the system 20 and transverse to the lamps. The upper
part of the oven is provided with lamps emitting infrared rays in
the visible and near-infrared range and lamps emitting infrared
rays in the far-infrared range. The upper part of the oven moves
vertically, and is shown in a raised position with the transport
plate and pizza in the cooking position. The stationary lower part
of the oven is provided solely with lamps emitting infrared rays in
the far-infrared range.
[0166] FIG. 13b illustrates a sectional view of the oven in FIG.
13a along a vertical plane parallel to the arrangement of the
lamps.
[0167] FIG. 13c illustrates a sectional view of an oven built and
equipped similar to the oven shown in FIG. 13b, the upper part
additionally provided with a microwave emitting magnetron.
[0168] FIG. 13d illustrates a sectional view of the oven in FIG.
13c in a closed position, and replacing the infrared lamps in the
lower part with an induction unit.
[0169] FIG. 13e illustrates a schematic diagram of the penetration
of infrared rays and transmission of heat into the thin cake being
cooked.
[0170] FIG. 13f illustrates a simplified diagram of the cooking
method according to the invention.
[0171] The ovens 50,52 are bell-type ovens attached to a known
horizontal transport mechanism 303 for a plate 302 supporting the
pizza 1. The lower part 304 of the ovens 50,52 is mounted
stationary on the frame of the transport mechanism 303 with a pan
306 at the bottom that can be removed for cleaning. The frame 305
of the lower part 304 can be made from sheet metal with heat
retaining internal surfaces, or the frame 305 could be provided
with reflectors. The lower part 304 of the ovens 50,52 can include
lamps 307 emitting infrared rays in the far-infrared range (FIGS.
13a, 13b, and 13c) or an induction unit 310 (FIG. 13d). If the
lower part 304 includes infrared lamps 307, the lamps may be
mounted stationary with respect to the pizza 1, or mounted such
that the distance from the pizza 1 could be vertically adjusted
during various cooking cycles. In such event, the plate 302 is
perforated or grille-shaped. If the lower part 304 includes an
induction unit 310 (FIG. 13d), the transport plate 302 is metal and
provided with slits, or spiral or concentric circular openings.
[0172] The upper part 304a of the oven 50,52 can be moved
vertically 304b by a pneumatic cylinder 312 anchored to a
stationary frame 311 of the transport mechanism, whose piston acts
upon a reinforced top 304c of the bell 305a. The inside of the bell
305a is provided with an array of lamps 307 emitting infrared rays
in the far-infrared range and, above them, lamps 308 emitting
infrared rays in the visible and near-infrared range.
[0173] The two sets of lamps 307,308 may be mounted at a given
fixed distance from the pizza 1 being cooked, or one or both sets
of lamps 307,308 may be mounted so that the distance can be
adjusted prior to or during the individual cooking cycles. Of
course, the invention does not preclude using lamps 307,308 that
are ring-shaped or shaped differently than as shown in the
drawings.
[0174] Lamps 308 emitting infrared rays in the visible and
near-infrared range are normally provided with internal reflectors.
However, the invention does not preclude the use of special
reflectors for one or both types of the lamps 307,308. The
reflectors can be mounted stationary so that they can be adjusted
along with the lamps, and/or the reflectors may be mounted so that
they can be adjusted and/or reshaped independently of the lamps, in
order to vary the concentration of rays on the pizza 1 being
cooked.
[0175] The upper part 304a of the oven 50,52 may also be provided
with magnetrons 309 to assist the lamps 307,308 in overcoming the
thermal inertia of the thin cake, and/or for cooking toppings with
little or no moisture content, and/or decreasing the duration of
the final surface browning cycle.
[0176] In one embodiment of the invention, the lower part 304 and
the upper part 304a of the oven 50,52 are made from a thin material
with low thermal resistance, having a double wall 305b providing
protection and safety, and thermal insulation having no significant
influence on cooking time or energy consumption.
[0177] The cooking method of the present invention is based on the
specific penetration properties of infrared wavelengths in the
visible and near-infrared range emitted by lamps 308, and the
infrared wavelengths in the far-infrared range emitted by lamps
307. Referring now to FIG. 13e, in the presence of water molecules
(and water vapor as well) infrared wavelengths in the visible and
near-infrared range "Iv" penetrate "P" through the top surface "S"
and into the dough "M" of the pizza or thin cake. These wavelengths
are absorbed and converted into heat energy as they pass through
(nontransparent) matter, transferring the heat "T" to the
surrounding dough. By contrast, the infrared wavelengths in the
far-infrared range "If" emitted by the lamps 307 only penetrate to
a depth of 0.4 mm to 0.8 mm. As a result, these wavelengths only
act on the top surface "S" of the pizza being cooked.
[0178] Referring now to FIG. 13f, to fully and quickly cook the
pizza or thin cake 1, the invention employs an initial heating
cycle "A", including exposure to infrared rays in both the "Iv" and
"If" ranges, during which the mass of dough "M" and top surface "S"
are preheated without excessively drying the top surface "S". The
initial cycle "A" is followed by a series of cycles "C" of varying
but generally decreasing duration, during which infrared rays in
the "Iv" and "If" ranges alternate with intervals "I" between the
cycles to allow water molecules to diffuse into the top surface "S"
in the form of steam, so that the "Iv" wavelengths can penetrate
"P" into the dough "M". Such penetration "P" naturally decreases as
the moisture decreases and water vapor evaporates. The top surface
"S" is browned during the extended final cycle "G", using "Iv" and
"If" wavelengths, since the "Iv" wavelengths now concentrate in the
top surface "S" due to the decreasing moisture content in the top
surface "S", thereby reinforcing the "If" wavelengths to heat, dry,
and brown the top surface "S".
[0179] The cooking method of the present invention also modulates
the energy emitted in the form of "Iv" and "If" wavelengths for the
various cycles "A", "C" and "G" by differentiating the time the two
types of infrared lamps 307,308 are lit, and/or by varying the
number of lamps lit, and/or by varying the position of the lit
lamps in relation to the pizza or thin cake 1, and/or by the
position or shape of the reflectors.
[0180] In addition, the cooking method could include the combined
action of a microwave generator (magnetron) 309 and/or an induction
unit 310 in conjunction with the infrared lamps 307,308. The
additional devices 309,310 can emit energy during all or part of
the cycles "A", "C" and "G" described above, including all or part
of the intervals "i" between the cycles, or solely during the
intervals "i".
[0181] Automatic Cutting Device (FIGS. 14a Through 14f)
[0182] The automatic cutting device of the present invention
provides a simple, easy-to-clean cutting and transfer device that
uses some of its cutting movements to transfer the pizza. The
cutting device attaches a sheet that slides vertically by its own
weight or by spring action to a side of a plate provided with
blades. After cutting the pizza, the sheet holds the cut pizza in
the cutting position as the plate that supports the pizza during
cutting moves horizontally, dropping the pizza onto the top box of
a stack of take-out boxes disposed below. Alternatively, the sheet
assists the transfer of the pizza onto a take-out box to one side
as the entire cutting device moves laterally, lifting the plate
provided with blades once the pizza is placed on the box.
[0183] The cutting device also provides blades that can easily be
detached from the plate that holds them for replacement and
cleaning, regardless of whether said blades are interchangeable
with single-use blades or coated with a sheath or layer that can be
removed easily at the end of a predetermined cutting cycle, thereby
making the cutting device as hygienic as possible.
[0184] For an embodiment of the present invention having mechanisms
that move laterally, the cutting device is mounted to move in the
direction of transfer of the pizza, providing a support for the
take-out box or other packaging. To transfer the cut pizza from the
cutting position to the packaging position, the plate provided with
blades and vertically sliding sheet remains in the lowered, cutting
position, or lifts slightly, as it moves toward the packaging
position, dragging the pizza and sliding it off the transport plate
onto the box positioned alongside. Once properly positioned over
the box, the plate provided with blades lifts and moves back into
position over the cutting area.
[0185] A threaded rod and nut screw can advantageously be used to
move the cutting device. The cutting mechanism is mounted on a
carriage assembly that rolls on tracks. Rotating the threaded rod
mounted on a stationary frame moves a nut screw attached to the
carriage assembly. However, the invention does not rule out using a
pneumatic or hydraulic cylinder, or mechanical means such as
chains, belts or rackwork to move the cutting mechanism.
[0186] Two embodiments of the pizza cutting and transfer device
according to the present invention are illustrated in the
accompanying drawings, which are not intended to limit the scope of
the invention.
[0187] FIG. 14a illustrates a front view of one embodiment of the
automatic cutting and transfer device, showing a plate provided
with interchangeable blades and a vertically sliding sheet in a
raised position over the pizza, the pizza resting on a movable
transport plate in a position above a stack of take-out boxes.
[0188] FIG. 14b illustrates a front view of the cutting and
transfer device of FIG. 1, showing the plate provided with
interchangeable blades in a lowered, cutting position with a lower
edge of the vertically sliding sheet resting on a top surface of
the movable transport plate.
[0189] FIG. 14c illustrates a front view of the cutting and
transfer device of FIG. 1, showing the transport plate after it has
moved from the cutting position with the plate provided with blades
in a lowered position and the pizza resting on the top take-out box
in the stack of boxes underneath.
[0190] FIG. 14d illustrates a front view of another embodiment of
the automatic cutting and transfer device, where the cutting device
transfers the pizza by dragging the pizza as it moves. The plate
provided with stationary blades and a vertically sliding sheet is
shown in a lowered, cutting position, while dotted lines show the
cutting device in a raised position after moving to a packaging
position.
[0191] FIG. 14e illustrates a top view of the cutting and transfer
device of FIG. 14d.
[0192] FIG. 14f is a left side view of the cutting and transfer
device of FIG. 14d.
[0193] The cutting and transfer device 54 for pizza 1 or focaccia
according to the present invention includes a circular plate 404,
having fixed or interchangeable vertical blades 404b attached to
the bottom thereof, and a sheet 404e that slides vertically by its
own weight or by spring action on stationary pins 404g on the edge
of the plate 404. The pins 404g engage in corresponding vertical
slots 404f in the vertical sliding sheet 404e.
[0194] If interchangeable blades 404b are used (as shown in FIGS.
14a, 14b, 14c), the plate 404 is provided with a series of radial
cuts for insertion of upper tabs 404d of the interchangeable blades
404b, the tabs 404d being provided with a hole into which small
pins or cotters 404c are inserted transversely to hold the tabs
404d in place. Specifically, the fixed blades (as shown in FIGS.
14c, 14d, 14e) or interchangeable blades can be coated with a layer
(e.g., applied by immersion, spraying on, or as a preformed sheath
made from paper or plastic) that can be removed for easy cleaning
of the blades. The plate 404, together with the blades 404b and
vertical sliding sheet 404e, can be moved vertically 404a by a
pneumatic cylinder 405 with a rod 405a and piston.
[0195] The cutting device of the present invention is substantially
identical for the two embodiments illustrated in the figures,
whereby the transport plate 402 transfers the pizza 1 to the
take-out box 403 or other packaging. The sliding sheet 404e mounted
laterally on the plate 404 provided with blades 404b performs one
of two functions. The sliding sheet 404e may act simply as a
projection to catch the edge of the pizza 1 and hold it while the
transport plate 402 moves 402a from the cutting position, leaving
the pizza 1 resting on the top take-out box in the stack 403 of
boxes disposed below the cutting position (FIG. 14c).
Alternatively, the sliding sheet 404e may act as a transfer means
to push 405b the pizza 1, sliding the pizza 1 off the transport
plate 402 in the cutting position onto the box 403 in a packaging
position (FIG. 14d). In the latter case, the transfer plate 402 may
be replaced by a conveyor belt or other known transport means.
[0196] In the embodiment (FIGS. 14d, 14e, 14f) where the sliding
sheet 404e acts as a transfer means (this embodiment is also shown
in FIGS. 1, 2 and 4), the cutting device 54 includes the plate 404
provided with blades 404b and vertically sliding sheet 404e, and
includes a cylinder 405 with a rod 405a and piston mounted to move
horizontally 405b by a plate 410 fastened to the cylinder 405 and
provided with four wheels 409 which roll on parallel, horizontal
tracks 407 mounted on a stationary frame 408. A nut screw 407a is
anchored to the plate 410 and receives a threaded rod 406b driven
406c by a motor 406 provided with a reduction unit 406a, all
forming a single piece with the stationary frame 408. As the
threaded rod 406b is rotated in one direction or the other 406c,
the nut screw 407a (along with the plate 410 and the cutting device
404, 404b, 405) moves 405b between the cutting position (174 in
FIG. 2) and the packaging position (175 in FIG. 2), where a
take-out box 403 or other packaging is predisposed on a support
403a.
[0197] For the FIG. 14d, 14e, 14f embodiment, where the cutting
mechanism moves horizontally, the pizza 1 is cut and transferred to
the take-out box 403 or other packaging in the following
stages:
[0198] The cooked pizza 1 on the transport plate 402 is moved into
the cutting position by transfer means 402b.
[0199] The pizza 1 is cut by lowering 404a the plate 404 provided
with blades 404b. The sheet 404e rests on the top surface of the
transport plate 402.
[0200] The blades 404b lift almost imperceptibly from the surface
of the transport plate 402. The sliding sheet 404e continues to
rest on the surface by its own weight.
[0201] The threaded rod 406b rotates 406c, moving 405b the cutting
device 404, 404b, 405, 405a toward the packaging position. The
blades 404b and sheet 404e drag the cut pizza 1 off the plate 402
onto the box 403 that rests on support 403a.
[0202] The plate 404 and blades 404b lift 404a.
[0203] The cutting device 404, 404b, 405, 405a moves 405b to the
cutting position for the next cooked pizza 1.
[0204] An advantage of the pizza cutting and transfer device 54 of
the present invention is that it can be employed independently of
the type of discontinuous or continuous mechanism used to transport
the pizza 1 into the cutting position (single plate, chain-driven
series of plates, belt) or the method used to stock the packaging
position (packaging disposed in stacks or individually).
[0205] These and other advantages of the present invention will be
apparent to those skilled in the art from the foregoing
specification. Accordingly, it will be recognized by those skilled
in the art that changes or modifications may be made to the
above-described embodiments without departing from the broad
inventive concepts of the invention. It should therefore be
understood that this invention is not limited to the particular
embodiments described herein, but is intended to include all
changes and modifications that are within the scope and spirit of
the invention.
* * * * *