Foods and beverages: apparatus – Cooking – With other treating or handling of material
Reexamination Certificate
2000-03-17
2001-12-11
Alexander, Reginald L. (Department: 1761)
Foods and beverages: apparatus
Cooking
With other treating or handling of material
C099S432000, C099S439000, C099S448000, C099SDIG014, C426S468000, C426S514000
Reexamination Certificate
active
06327968
ABSTRACT:
TECHNICAL FIELD OF THE INVENTION
This invention relates to the field of pizza preparation and more particularly to a system and method for producing par-baked pizza crusts.
BACKGROUND OF THE INVENTION
Traditionally, pizzas have been made at restaurants by mixing dough ingredients, rolling and shaping the dough into a round disc, placing various toppings on the dough, and then baking the pizza to completion. However, in many restaurants, there is a need to produce pizza in a more timely fashion due to the high volume of pizza ordered and the customers' expectations of quick service. An alternate method that has been used to speed up the pizza-making process is to obtain frozen dough from a centralized source, thus eliminating the mixing step and reducing the time required to make the pizza in the restaurant.
Baking pizza crust dough from “scratch” or frozen dough requires a relatively long baking time. This is particularly true for certain specialty pizzas, such as deep-dish style pizzas. Furthermore, due to variances in the method by which the dough is formed, the resulting pizza crusts may have an inconsistent texture and taste. Moreover, when raw dough is made or when frozen dough is thawed, the dough must be used within a relatively short period of time.
SUMMARY OF THE INVENTION
Accordingly, a need has arisen for a type of pizza crust that may be pre-made and stored for a relatively long period of time. In addition, a need also exists for a method of partially cooking a pizza crust prior to a customer's order, so that the final cooking time after the order is received will be reduced. Moreover, a need has arisen for a process of baking a pizza crust that produces pizza crusts having a consistent form, texture, and taste. The present invention provides a system and method for producing par-baked pizza crusts that addresses shortcomings of prior systems and methods.
According to one embodiment of the invention, a system for producing par-baked pizza crusts includes a pan formed from a unitary sheet of metal. The pan includes a number of recesses stamped into the sheet of metal, each recess being adapted to receive a corresponding dough portion. The pan also includes a ledge formed around a perimeter of the pan. The system for producing par-baked pizza crusts further includes a lid assembly formed from a unitary sheet of metal for use in conjunction with the pan. The lid assembly includes a number of lids stamped into the sheet of metal, each lid corresponding to one of the recesses of the pan. The lid assembly also includes a ledge formed around a perimeter of the lid assembly. The ledge is formed such that when the lid assembly is placed over and in contact with the pan, the ledge of the lid assembly aligns with and rests on the ledge of the pan to enclose dough portions in an enclosed gap between the lid assembly and the pan.
Embodiments of the present invention provide numerous technical advantages. For example, par-baking a pizza crust according to one embodiment of the invention reduces the final cooking time that is required to cook a topped pizza crust. This advantage allows a restaurant serving pizzas to deliver its product more quickly to the consumer, and allows the restaurant to produce a higher quantity of pizzas. Furthermore, par-baking pizza crusts according to teachings of the present invention produces cost savings in equipment and labor due to the centralized production of the par-baked pizza crusts. Instead of each restaurant having to prepare and cook pizza crust dough from scratch, the dough can be prepared at a few central locations, par-baked at those locations, and then shipped to individual restaurants or consumers for later use. In addition, the present invention provides an automated system that enables the par-baked crusts to be mass-produced at these central locations.
Further advantages of the present invention include the ability to create pizza crusts that may be stored for longer periods of time than raw pizza dough, thus reducing the cost of wasted pizza dough. In addition, the use of a lid assembly incorporating teachings of the present invention in the par-baking process provides pizza crusts having a consistent and optimal form. The use of the lid assembly also provides an appropriate amount of heat transfer to and from the pizza crust and moisture retention in the pizza crust to give the pizza crust a consistent, pleasing texture and taste. Furthermore, the present invention provides a system and method that produce a par-baked pizza crust that, when cooked a final time with toppings, tastes similar to or better than a pizza cooked in one step from raw dough with toppings.
Other technical advantages are readily apparent to one skilled in the art from the following figures, descriptions, and claims.
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Alexander Reginald L.
Baker & Botts L.L.P.
Pizza Hut, Inc.
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