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.

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.