Food or edible material: processes – compositions – and products – Processes – Treatment or preparation of farinaceous dough – batter – or...
Reexamination Certificate
2000-01-26
2001-09-18
Yeung, George C. (Department: 1761)
Food or edible material: processes, compositions, and products
Processes
Treatment or preparation of farinaceous dough, batter, or...
C426S138000, C426S502000, C426S523000
Reexamination Certificate
active
06291002
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to flatbreads and more particularly to a method and apparatus for preparing an elongated, substantially continuous pita bread.
2. Description of the Related Art
Flatbread is a common staple in Middle Eastern countries and, in recent years, has enjoyed considerably increasing popularity in other areas of the world. There are several types of flatbread, including lavash and pita bread. Pita bread, also known as pocket bread, has found a special popularity due in part to the convenience of using pita bread for making sandwiches. This is because the bread, when torn, forms a pocket which may be filled with meat, vegetables, cheese and other sandwich fixings. The pocket is formed between two outer layers which are easily separated by the user. The relative thinness of the layers is another attractive aspect of the bread.
The double layer form characteristic of pita bread results from its baking process. In this process, a rolled, flat dough disk is baked in an extremely hot oven, typically in excess of 500° F., on a flat support surface. The extreme heat initially sears the top, bottom and edge surfaces of the dough disk, thus creating a crust that at least partially seals these surfaces. As the dough between the surfaces heats up and bakes, gas and steam are liberated from the dough. This gas and steam is generated faster than it can escape through the crust; thus, pressure is created within the dough disk and the disk inflates. The inflation process separates the upper and lower surfaces of the bread so that the upper and lower layers bake separate from each other.
The popularity of pita bread has prompted a demand for additional flatbread products. For example, the relatively thin outer layers of baked pita bread can be used to manufacture a low-fat, yet pleasing chip-type snack food. One approach for creating such pita chips is to feed baked pita bread through a chopper, which chops the bread into snack-sized portions. This process involves extensive labor because individual baked pita bread loaves must be fed into the chopper. Additionally, the outer layers of each pita bread portion are joined to each other along an edge of the pita bread portion. A great deal of waste results from feeding individual pita bread portions through a chopper because the edges create incomplete snack portions that must be disposed of.
SUMMARY OF THE INVENTION
Accordingly, there is a need in the art for a method for preparing a two-layered pita bread that minimizes the amount of edge portions relative to the rest of the pita bread. Additionally, there is a need in the art for an apparatus and method for preparing pita chips in a manner that minimizes both waste and the labor required to manufacture the chips. Further, there is a need in the art for an apparatus and method for preparing an elongated, continuous pita bread.
In accordance with one aspect, the present invention comprises a method for making an elongated pita bread. The method includes forming dough into an elongated flat dough form and conveying the dough along a conveyor through an oven such that baking-induced gases inflate the dough, forming an upper bread layer and a lower bread layer. The layers are connected at first and second edges. The baked dough is cut adjacent the first edge so that the upper and lower layers are unattached at the first edge.
In accordance with another aspect, the present invention comprises an apparatus for manufacturing an elongated pita bread. A dough mixer is included and is adapted to supply dough to a conveyor system. A proofer is also provided. A plurality of rollers shape the dough into an elongated, substantially rectangular shape. An oven is provided and is adapted to bake the dough so that baking-induced gases inflate the dough, at least partially dividing the dough into upper and lower layers. An edge cutter is provided and is adapted to cut the baked dough between the upper and lower layers. In further embodiments, a chopper is provided to cut at least one of the layers into snack-sized portions.
In accordance with a still further aspect, the present invention comprises an apparatus for manufacturing pita bread. The apparatus includes a conveyor system, a proofer, means for forming a substantially continuous elongated sheet of dough, an oven for baking the dough so that the dough inflates during baking, and means for cutting the baked dough along opposing edges.
In accordance with yet another aspect, the present invention provides a method for making snack-sized portions of pita bread. A continuous elongated strip of pita dough is provided, along with a conveyor system and a proofing apparatus. An oven is provided and is adapted to bake the elongated pita dough strip to form an elongated pita bread strip having upper and lower bread layers. A chopper apparatus is provided and is adapted to cut the pita bread strip into snack-sized portions. The elongated pita strip is advanced along the conveyor system through the proofing apparatus, oven and chopper apparatus.
In accordance with another aspect, the present invention provides a method for making an elongated pita bread loaf. Pita dough is continuously extruded onto a conveyor system and continuously advanced through a first proofing apparatus, a rolling apparatus, and a second proofing apparatus. An oven is provided and is adapted to bake the pita dough so that the dough separates into upper and lower layers that are connected at opposing edges. The pita dough is continuously advanced along the conveyor system through the oven.
In accordance with yet another aspect, the present invention provides an elongated rectangular pita bread having a substantially uniform width, an upper and lower layer that are connected along first and second edges, and a length greater than its width.
For purposes of summarizing the invention and the advantages achieved over the prior art, certain objects and advantages of the invention have been described herein above. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed.
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Goglanian Asgdhig
Knobbe Martens & Olson Bear LLP.
Yeung George C.
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