U.S. patent number RE33,508 [Application Number 07/428,491] was granted by the patent office on 1990-12-25 for pizza preparation from comminuted cheese.
This patent grant is currently assigned to Leprino Foods Company. Invention is credited to Wesley J. Allen, Richard L. Barz, Lester O. Kielsmeier.
United States Patent |
RE33,508 |
Kielsmeier , et al. |
December 25, 1990 |
Pizza preparation from comminuted cheese
Abstract
Cheese of the kind used on pizzas is prepared in granular form,
and frozen by an individual quick freezing method to maintain
granule moisture and distribution. The resulting free-flowing
granules can be baked on pizzas in frozen or partially frozen
condition while obtaining as good quality baked pizzas as when
fully thawed granule cheese is used. The problem of undue browning
and blistering heretofore associated with the use of frozen cheese
is avoided.
Inventors: |
Kielsmeier; Lester O.
(Lakewood, CO), Barz; Richard L. (Longmont, CO), Allen;
Wesley J. (Littleton, CO) |
Assignee: |
Leprino Foods Company (Denver,
CO)
|
Family
ID: |
26712723 |
Appl.
No.: |
07/428,491 |
Filed: |
October 27, 1989 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
36022 |
Apr 8, 1987 |
04753815 |
Jun 28, 1988 |
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Current U.S.
Class: |
426/582; 426/296;
426/302; 426/524; 426/96 |
Current CPC
Class: |
A23C
19/0976 (20130101); A21D 13/41 (20170101) |
Current International
Class: |
A23C
19/00 (20060101); A23C 19/097 (20060101); A21D
13/00 (20060101); A23C 019/00 (); A23C 001/08 ();
A23C 019/068 (); A23C 019/08 () |
Field of
Search: |
;426/582,293,302,305,296,524,68,89,98,100,291,92,289 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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561821 |
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Aug 1984 |
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AU |
|
578432 |
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Oct 1988 |
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AU |
|
2075326 |
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Nov 1981 |
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GB |
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Other References
Potter, N. Food Science, 1933, Avi Publishing Co., Inc., pp.
223-224..
|
Primary Examiner: Cintins; Marianne
Assistant Examiner: Pratt; H.
Attorney, Agent or Firm: Tilton, Fallon, Lungmus &
Chestnut
Claims
We claim:
1. The method of producing baked pizza, comprising the steps
of:
(a) preparing cheese .Iadd.at a cheese processing plant .Iaddend.in
the form of fresh cheese granules, said cheese consisting of at
least one variety of mozzarella, or a blend of mozzarella with
other cheese, said blend being adapted for use on baked pizza;
(b) freezing said cheese granules by individual quick freezing
thereof, the cheese granules being frozen at a temperature below
-10.degree. F. which freezes the granules so rapidly that the
individual granules retain essentially the same moisture content
and distribution as before freezing, the resulting frozen granules
being in free-flowing condition;
(c) maintaining said granules .Iadd.during storage and shipment
.Iaddend.in frozen free-flowing condition with said moisture
substantially unchanged until the granules are used;
(d) .Iadd.in a retail pizza outlet or restaurant .Iaddend.applying
the granules so maintained to pizzas being prepared .[.for.].
.Iadd.just prior to .Iaddend.baking without complete thawing of the
granules, at least the interiors thereof being frozen; and
(e) baking the pizzas with the applied unthawed granules and
obtaining baked pizzas of good appearance and quality.
2. The method of claim 1 in which said granules are applied to the
pizza in an essentially fully frozen condition and are baked
thereon from said frozen state.
3. The method of claim 1 in which an aqueous carrier containing one
or more cheese additives is applied to the frozen granules prepared
in step (b) and frozen surface coatings of said carrier are formed
thereon, the resulting coated granules being used in steps (c), (d)
and (e).
4. The method of claims 1, 2, or 3 in which said cheese granules
are prepared entirely from varieties of mozzarella.
5. The method of producing baked pizza, comprising the steps
of:
(a) preparing cheese .Iadd.at a cheese processing plant .Iaddend.in
the form of fresh cheese granules, said cheese consisting of at
least one variety of mozzarella, or a blend of mozzarella with
other cheese, said blend being adapted for use on baked pizza;
(b) freezing said cheese granules by blowing air at a temperature
below -20.degree. F. through a fluidized bed of the granules, said
granules being frozen so rapidly that the individual granules
retain essentially the same moisture content and distribution as
before freezing, the resulting frozen granules being in
free-flowing condition;
(c) maintaining said granules .Iadd.during storage and shipment
.Iaddend.in frozen free-flowing condition with said moisture
substantially unchanged until the granules are used;
(d) .Iadd.in a retail pizza outlet or restaurant .Iaddend.applying
the granules so maintained to pizzas being prepared .[.for.].
.Iadd.just prior to .Iaddend.baking without complete thawing of the
granules, at least the interiors thereof being frozen; and
(e) baking the pizzas with the applied unthawed granules and
obtaining baked pizzas of good appearance and quality.
6. The method of claim 5 in which an aqueous carrier containing a
flavor additive, or a cheese emulsifier additive, or both of said
additives is applied to the frozen granules prepared in step (b)
and frozen surface coatings of said carrier are formed thereon, the
resulting coated granules being used in steps (c), (d) and (e).
7. The method of claim 5 in which granules of mozzarella and
granules of at least one of said other cheese are separately
prepared in step (a), separately frozen in step (b), and then mixed
to provide the granules used in steps (c), (d) and (e).
8. The method of claim 5 in which said cheese granules are prepared
entirely from varieties of mozzarella.
9. The method of claim 1 or claim 5 in which said frozen granules
in step (c) are maintained by storage at a freezing temperature no
lower than the temperature at which the granules were originally
frozen.
10. The method of claim 1 or claim 5 in which said frozen granules
in step (c) are maintained by storage at a series of freezing
temperatures higher than the temperature at which they were
originally frozen, the freezing temperatures of said series being
progressively higher temperatures. .[.
11. The method of preparing and baking pizza, comprising the steps
of:
(a) preparing cheese in the form of fresh cheese granules, said
cheese consisting of at least one variety of mozzarella, or a blend
of mozzarella with other cheese, said blend being adapted for use
on baked pizza;
(b) freezing said cheese granules by individual quick freezing
thereof, the cheese granules being frozen at a temperature below
-10.degree. F. which freezes the granules so rapidly that the
individual granules retain essentially the same moisture content
and distribution as before freezing, the resulting frozen granules
being in free-flowing condition;
(c) applying the frozen cheese granules as a topping to unbaked,
unfrozen pizza;
(d) freezing the pizzas with the frozen cheese granules thereon;
and thereafter
(e) baking the pizzas in frozen or partially frozen condition while
the cheese granules have essentially the same moisture content and
distribution, at least the interiors of the cheese granules being
frozen at the start of said baking..]. .[.
12. The method of claim 11 in which an aqueous carrier containing
one or more cheese additives is applied to the frozen granules
prepared in step (b) and frozen surface coatings of said carrier
are formed thereon, the resulting coated granules being applied to
the pizzas in step (c)..]. .[.13. The method of claim 11 or claim
12 in which said cheese granules are prepared entirely from
varieties of mozzarella..].
Description
FIELD OF INVENTION
The field of this invention is the use of comminuted cheese on
baked pizza.
BACKGROUND OF INVENTION
In the United States, many retail operations engaged in preparation
and baking of pizzas desire to use cheese in a comminuted form.
Consequently, producers of mozzarella and other cheese used on
pizzas shred or dice block cheese for delivery to the pizza
restaurants. To provide improved storage and keeping qualities,
comminuted cheese for use on pizzas can be frozen and delivered in
frozen or semi-frozen condition. However, the cheese must at least
be thawed to the extent that the shreds or granules can be
separated. Moreover, further thawing is needed to improve
functionality.
The use of comminuted cheese in frozen or partially frozen
condition on pizzas frequently results in baked products showing
excessive browning and blistering. Not only is this appearance
unattractive to the consumer, but the flavor and eating quality can
also be adversely affected.
The recommended practice involves slow thawing of the frozen
cheese. Where thawing is carried out during non-freezing
refrigerated storage, as is a common practice, a minimum of two to
three days of thawing-holding is usually required. Moreover, the
best practice involves holding of the granular cheese for four to
five days, until thawing is completed.
Because of the problems associated with the use of frozen
comminuted cheese for preparing pizza, certain franchised cheese
restaurants require that the comminuted cheese be packaged
non-frozen in specially designed packages. This adds considerably
to packaging and distribution expenses, although it does avoid the
necessity of slow thawing.
As far as is known, no one heretofore has produced frozen
comminuted cheese which can be applied to pizzas in frozen or
partially frozen condition and baked to produce a pizza product of
as good quality as with fully thawed cheese. The high standards of
appearance, quality and taste for large scale pizza preparation
have not been satisfied by the use of comminuted cheese which has
not been completely thawed.
SUMMARY OF INVENTION
The development of this invention has required a better
understanding of the problems associated with the use of comminuted
cheese on pizzas. It was observed that the frozen granules of
comminuted cheese usually had visible ice coatings on their outer
surfaces. Examination disclosed that this ice is formed as the
granules are frozen-moisture being exuded and freezing around the
granules. Consequently, when thawing was commenced the outer
surfaces became wet, but by holding of the granules for several
days, the free moisture was reabsorbed. With holding periods of
four to five days, substantial equilibration of moisture
distribution was obtained, although this had not been previously
recognized. In effect, the interior moisture of the cheese
particles redistributed substantially as it was before freezing.
Without such holding and equilibration, the ice coatings melted and
the water flashed off as the pizzas were baked. This invention
involves a recognition that such water loss can aggravate
undesirable browning and blistering.
It was found that to produce pizza of the most pleasing appearance
and taste, it is important to fully maintain the moisture content
of the applied cheese. As the moisture flashes off, the resulting
steam can raise blisters. In blistering, the protein layers are
lifted from the surface of the baking pizzas. Such blisters tend to
burn and discolor.
This invention provides for the first time frozen comminuted cheese
which can be used on pizzas without any prethawing. The resulting
baked pizzas have as good or better appearance and quality as when
prepared from fully thawed and equilibrated cheese. To achieve this
result it is necessary to freeze the granules very rapidly, so that
the frozen granules have essentially the same moisture content and
distribution as before freezing. Rapid freezing prevents moisture
migration to the surface of the cheese particles. The frozen
particles are free from visible ice coatings, and the moisture
within the particles is in the form of very fine crystalline
ice.
When the frozen cheese of this invention is thawed during baking,
it immediately has the optimum moisture distribution for baking. No
holding time is needed for moisture equilibration. Moreover, during
baking the contacting surfaces of the cheese particles thaw first,
becoming softened with particle-to-particle fusing. In fact, the
particulate cheese can begin to fuse into smoothly melted layers
while the interiors of the individual particles are still partially
frozen. Using frozen cheese of the kind prepared by the method of
this invention does not interfere with normal melting of the cheese
on pizzas baked very rapidly. In the practice of using convection
ovens through which the pizzas pass on conveyor belts, baking times
are usually less than ten minutes for both "thick" and "thin" crust
type pizzas. Nevertheless, by using the method of this invention,
the baked cheese appears smooth and non-lumpy. Separate cheese
particles are not apparent. The melted cheese exhibits an
appearance comparable to that obtained with fully thawed
cheese.
Since the frozen cheese produced in accordance with this invention
is in a particulate free-flowing condition, it can be subjected to
new processing operations. Where blends of two or more kinds of
cheese are desired for use on pizzas, each of the cheeses may be
prepared separately and mixed to provide the blend. Modification of
taste and functional properties of the cheese can be obtained by
applying coatings to the outsides of the cheese particles.
The method of this invention for preparing baked pizzas and the
frozen cheese for use therewith greatly improves the production,
storage, distribution, and use of comminuted cheese. After the
frozen cheese has been prepared by the method of this invention, it
can be stored for many months without deterioration in quality. The
moisture is locked into the cheese in the form of very finely
distributed ice crystals, and there is substantially no moisture
loss during frozen storage. The cheese therefore maintains its
capacity for use in frozen condition to produce fully acceptable
pizza products.
DETAILED DESCRIPTION
The term "comminuted cheese" as used herein refers to shredded or
diced cheese of the kind which heretofore has been sold for use in
producing pizza products. The term "granule" is used generically as
referring to the particulate form of such shredded or diced cheese.
The granules are usually of cubical or an elongated rectilinear
shape. However, the granules may also be slivers of irregular
shape.
In practicing the method of this invention, any cheese may be
employed of the kind used on pizzas. In the United States,
varieties of mozzarella are the most common type cheese for pizza
use, and are used alone or in cheese blends. The term "pizza
cheese" usually refers to a semi-soft part skim milk cheese which
is similar to but not the same as mozzarella. Other varieties of
cheeses used on pizza include cheddar, Muenster, Swiss, and
Provoline. Such cheeses are usually produced in block form. For
purpose of this invention, the cheese blocks are comminuted to
shreds or granules. For example, the block cheese can be sliced and
then diced to form cubical or elongated granules. Alternatively,
cheese shredding equipment can be used. The granules may have
dimensions in inches of from 0.1.times.0.1.times.0.5 up to
0.25.times.0.25.times.1.5. Examples of representative granule
shapes are: (1) 1/8.times.3/16.times.3/4 inches; and (2)
1/8.times.1/8.times.1/8 inches.
The cheese used on pizzas has relatively large moisture content,
containing at least 30% water by weight and usually higher.
Applicable federal moisture standards are illustrative. In the case
of cheese which is classified as "low-moisture mozzarella" or
Scamorza, the federal standard specifies a moisture content in the
range of 45 to 52%; Muenster (munster) cheese can contain up to 46%
moisture, etc. Despite these high moisture contents, it is
undesirable to process the cheese in such a way that moisture
content of the frozen particles is substantially lower. For
protection of functionality, the frozen cheese of the present
invention can be prepared with less than 1% weight reduction due to
moisture loss. Optimally, the weight reduction of the cheese due to
moisture loss can be limited to 0.3 to 0.5 wt. %. In carrying out
the method of this invention, the comminuted cheese is rapidly
frozen by direct contact with low temperature air. The freezing air
should be at a temperature below -10.degree. F. and preferably
below -20.degree. F. For example, the optimum air temperature is as
low as -35.degree. to -45.degree. F.
To accomplish rapid freezing of the comminuted cheese, a bed of the
granules can be directly contacted by freezing air. For example,
the cheese granules may be contacted in a fluidized bed, or in an
agitated bed for rapidly exposing all exterior surfaces of the
granules to the freezing air. By passing the freezing air upwardly
through beds in which the cheese particles are agitated, or
preferably fluidized, the air flow can contact all of the exterior
surfaces of the particles. With air at a sufficiently low
temperature, suface crusts will rapidly form on the granules,
thereby locking in the moisture.
Commercially available equipment can be used for the freezing of
the comminuted cheese. This equipment is of the kind sold for
individual quick freezing (IQF) of granular food products.
Heretofore, "IQG" equipment has been employed primarily for
freezing vegetables, and the freezing step has usually been
accompanied by partial drying of the product. In preparing the
frozen cheese for the purpose of this invention, as explained
above, it is desirable to avoid moisture loss from the cheese as it
is being frozen.
In one preferred method of freezing the comminuted cheese,
fluidized bed-type IQF equipment is employed. Such fluidized bed
equipment is described in U.S. Pat. Nos. 3,169,381, 4,265,095, and
4,478,141. Commercially, suitable IQF fluidized bed equipment is
available from Frigoscandia (Frigoscandia Contracting, Inc.,
Bellevue, Wash.). Expanded bed-type freezing equipment is available
from several suppliers, including Cloud & Britton, Inc.,
Mountlake Terrace, Wash.
In preparing the comminuted cheese for freezing, precooling of the
cheese is not required, that is, the cheese may be at temperatures
substantially above 32.degree. F. For example, temperatures in the
range of 35.degree.-55.degree. F. can be used, up to ambient room
temperature. After the comminuted cheese is completely frozen,
typically requiring from five to ten minutes, the cheese granules
will be at very cold temperatures, but somewhat above the
temperature of the freezing air. For example, the temperature of
the frozen cheese will usually be below 0.degree. F., such as at a
temperature of from about -10.degree. to -20.degree. F.
After the cheese is frozen as described, the shreds or granules
should be in an individual free-flowing form. The particulate
cheese can then be further processed on a conveyor belt, or other
equipment, as desired. For example, frozen cheese of two different
kinds can be mixed to provide a blend for use on pizzas, or the
cheese particles may be sprayed with an aqueous carrier containing
one or more cheese additives, such as flavor modifiers,
emulsifiers, etc. Any GRAS-approved additive can be used. The
additive may be in an aqueous solution, dispersion, or emulsion.
The carrier should contain sufficient water so that it will freeze
on the cheese particles.
It is desirable to mix or agitate the cheese while the coatings are
being applied. This can be done in a fluidized bed, such as near
the discharge end of the fluidized bed IQF freezer. Alternatively,
a conveyor belt can be equipped with devices for mixing the cheese
particles as they are coated. Spray application of the coatings
will usually be most convenient. As the aqueous carrier is
distributed over the outer surfaces of the cheese granules, the
carrier can be rapidly converted to frozen layers. At the same
time, the coated granules can remain free-flowing.
When the coated frozen cheese is applied to pizzas and baked
thereon, the coatings will liquify first. This permits the flavor
additive and/or emulsifier to spread over and into the cheese
particles as their outer surfaces become thawed. The water in the
coating will then flash off. In this way, special flavor
characteristics can be imparted with relative uniformity to the
melted cheese layer on the pizza. Cheese emulsifiers applied in
this way can function to soften the outer portions of the cheese
granules. This will improve melting and fusing of the granules.
To assure that the moisture distribution in the cheese particles
during frozen storage remains essentially unchanged, it has been
found desirable to store the cheese at freezing temperatures no
lower than the one at which it was originally prepared. Migration
of ice and enlargement of ice crystals an occur if the cheese is
stored at lower freezing temperatures after it has been held at a
higher temperature. A series of storages at successively higher
freezing temperatures is a convenient practice. For example, when
the cheese is originally frozen at a temperature below -10.degree.
F., it can be stored first at -10.degree. to 0.degree. F., and next
at 0.degree. F. to 10.degree. F.
The frozen granules may be packed in plastic bags and the bags
placed in cartons for shipment or storage. In prior practice,
frozen storage of granular cheese was limited to about six months
without loss of quality. It is surprising therefore that the frozen
cheese granules of this invention can be stored for periods of over
12 months without any quality deterioration. This storability
feature facilitates production by the cheese manufacturer in the
seasons of the year when milk is abundant. As stated above, to
maintain the cheese in optimum condition, it has been found
desirable to utilize successively higher ranges of storage
temperatures. This avoids storage holding in which the granules are
stored at a lower temperature than the initial frozen storage
temperature.
When the frozen product reaches the retail pizza outlets, it is not
necessary to completely thaw the cheese prior to use. For example,
the cheese may be taken directly from frozen storage and applied to
pizzas just prior to baking. However, handling practices and
available cheese storage facilities vary considerably. Some
restaurants may not be equipped for frozen storage, and/or the
cheese may have been permitted to become partially thawed before it
reaches the restaurant. These differences are not matters for
concern when employing the frozen comminuted cheese of this
invention. Excellent results can be obtained without regard to
whether the cheese is in fully frozen or partially frozen condition
as used on the pizzas. The baked pizzas will have as good or better
appearance when prepared by the method of this invention as those
prepared from thawed and equilibrated cheese. Of course, the degree
of browning of the cheese on the baked pizzas depends in part on
the baking equipment and temperatures used. But on a comparative
basis the pizzas prepared from the frozen granules will exhibit no
more browning or blistering than pizzas prepared from fully thawed
and equilibrated granules.
PROCESS EXAMPLE
Shredded mozzarella cheese is prepared in a granule size of about
1/8.times.3/16+3/4 inches. The granules are subjected to IQF
fluidized bed freezing in a "FLo-FREEZE" Model 300 WS-ADF supplied
by Frigoscandia Contracting, Inc., Bellevue, Wash. The freezing and
fluidizing air which is blown upwardly through the bed of granules
can have a velocity of around 400 ft/min. and a temperature of
about -40.degree. F. Frozen crusts form rapidly around the outside
of the granules, viz. in one to two minutes or less. The time
required for completion of the freezing is of the order of 7
minutes. The frozen granules leaving the fluidized bed have a
temperature of around -20.degree. F. Weight loss due to moisture
evaporation during the freezing process is less than 0.5%. Baffles
along the sides and over the fluidized bed to minimize loss of
cheese fines are provided. The frozen granules are packed in bags
and boxed for storage, for example, at a temperature from
-10.degree. to 0.degree. F.
COATING EXAMPLES
Coatings for the frozen cheese can include one or more of the
following flavor additives: lactose, glucose, diacetyl, free fatty
acids (i.e., butyric, propionic, capric, caproic acids), cheese
flavors (cheddar, Swiss, Provolone, etc.), meat flavors (bacon,
pepperoni, sausage, etc.), spices (basil, oregano, garlic, dill,
cinnamon, fennel, etc.), vegetable flavors (tomato, onion,
pimiento, pepper, etc.), and fruit flavors (strawberry, pineapple,
cherry, lemon, etc.). Emulsifer additives, which may be used either
alone or with the flavor additives, include: surfactants, disodium
phosphate, silicone, emulsifiers, and other GRAS-approved
emulsifiers.
The following formulations are illustrative.
Emulsifier Coating Solution
A silicone emulsifier (Dow Corning FG-10) is mixed with water to
form a 0.05% emulsifier solution. This solution is sprayed on the
frozen cheese granules at a rate of 1.75 parts of solution per 100
parts by weight of cheese. This should achieve a final content of
around 0.09% emulsifier on the cheese.
Smoke Flavor Coating Solution
A smoke flavor (Red Arrow P-50 Hickory Smoke) is mixed with water
to form a 4.5% solution thereof. The solution is sprayed on the
frozen cheese granules at a rate of 2.2 parts by weight of solution
per 100 parts of cheese. This should achieve a final content of
about 0.1% smoke on the cheese.
Swiss Flavor Solution
A Swiss cheese flavor (Naarden International Cheese Flavor Swiss
Type) is mixed with water to form a 50% by weight solution. The
solution is sprayed on the frozen cheese granules at a rate of 0.5
parts of solution per 100 parts by weight of cheese. This should
achieve a final content of about 2.5% Swiss flavor on the
cheese.
The above solutions should be applied gradually while the frozen
cheese granules are being mixed to distribute the solution over the
outer surfaces of the granules. This produces thin frozen coatings
around the outside of the granules while the granules remain in
individual free-flowing condition.
Other Uses
In addition to commercial pizza preparation for sale in
restaurants, the method of the present invention is also applicable
to the home baking of pizzas sold in frozen condition. A
manufacturer preparing pizzas for sale through retail outlets to
home consumers can apply the comminuted frozen cheese of this
invention to unbaked, unfrozen pizza, then without thawing the
cheese the rest of the pizza is frozen by any suitable procedure.
The unbaked frozen pizzas are distributed and sold in frozen
condition. When a frozen pizza is purchased and baked at home
without thawing, the advantages of this invention for baking the
cheese in frozen or partially frozen condition will be obtained. By
applying the frozen cheese granules to unbaked, unfrozen pizzas, a
further advantage is provided. The frozen granules do not absorb
the tomato or other liquid sauces. This protects the baking
properties of the cheese granules against deterioration by
absorption of an acidic sauce.
In still another application of the method of this invention, the
comminuted frozen cheese may be packaged for sale to home users. As
with commercial pizza manufacturers, the home user may apply the
frozen or partially frozen cheese granules to pizza, and then bake
the pizza without further holding. The frozen cheese granules may
also be used as toppings on other food products which can be baked
without thawing of the cheese. It should be understood that these
alternative uses of the present invention are included within the
scope of this application.
* * * * *