IES20001029A2 - A process for manufacturing a food product - Google Patents
A process for manufacturing a food productInfo
- Publication number
- IES20001029A2 IES20001029A2 IE20001029A IES20001029A IES20001029A2 IE S20001029 A2 IES20001029 A2 IE S20001029A2 IE 20001029 A IE20001029 A IE 20001029A IE S20001029 A IES20001029 A IE S20001029A IE S20001029 A2 IES20001029 A2 IE S20001029A2
- Authority
- IE
- Ireland
- Prior art keywords
- dough sheet
- dough
- sheet portion
- base
- filling
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 15
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 8
- 235000013305 food Nutrition 0.000 title description 3
- 235000014594 pastries Nutrition 0.000 claims abstract description 28
- 235000013372 meat Nutrition 0.000 claims abstract description 10
- 235000015067 sauces Nutrition 0.000 claims abstract description 10
- 235000013311 vegetables Nutrition 0.000 claims abstract description 9
- 239000000203 mixture Substances 0.000 claims abstract description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 5
- 108010068370 Glutens Proteins 0.000 claims abstract description 4
- 235000021312 gluten Nutrition 0.000 claims abstract description 4
- 238000003032 molecular docking Methods 0.000 claims abstract description 4
- 238000010030 laminating Methods 0.000 claims abstract description 3
- 238000002788 crimping Methods 0.000 claims description 11
- 238000002156 mixing Methods 0.000 claims description 4
- 238000010411 cooking Methods 0.000 claims description 2
- 238000001816 cooling Methods 0.000 claims description 2
- 238000005520 cutting process Methods 0.000 claims description 2
- 238000007710 freezing Methods 0.000 claims description 2
- 230000008014 freezing Effects 0.000 claims description 2
- 238000007789 sealing Methods 0.000 claims description 2
- 238000005507 spraying Methods 0.000 claims description 2
- 238000004806 packaging method and process Methods 0.000 abstract 1
- 235000013312 flour Nutrition 0.000 description 2
- 240000004808 Saccharomyces cerevisiae Species 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
Landscapes
- Bakery Products And Manufacturing Methods Therefor (AREA)
Abstract
A process for manufacturing a filled pastry product comprises preparing a pastry dough, forming the dough into a sheet, laminating the dough sheet, and docking the dough sheet. The dough sheet is split longitudinally to form a base dough sheet portion and a top dough sheet portion. The base dough sheet portion is sprayed with water and applying gluten to the sprayed base dough portion sheet. A filling comprising a mixture of sauce and frozen cooked meat and/or vegetables is prepared, the filling being at a temperature of from +2 degrees celcius to -3 degrees celcius. The filling is formed into a desired form shape and then applied to the floured base dough sheet portion. The top dough sheet portion is placed over the base dough sheet portion and filling. The top sheet portion is sealed to the base dough sheet portion to form a pocket between the base and top dough sheet portions housing the filling. The edges of the pocket are crimped, excess dough between the pockets is cut away and a glaze is applied to the individual pockets. The pastry pockets are cooked, cooled and subsequently frozen for packaging.
Description
-1RYE006/C/IES “A PROCESS FOR MANUFACTURING A FOOD PRODUCT”
Introduction
The invention relates to a process for manufacturing a food product and in particular to a process for manufacturing a filled pastry product, especially a pastry pocket.
Pastry pockets comprising a pastry outer filled with various fillings are known.
There is however, a need for a process for producing such pastry pockets on a factory scale while providing a product which can be easily cooked by the user and which has good organoleptic properties of taste and mouth feel.
This invention is directed towards providing such a process.
Statements of Invention
According to the invention there is provided a process for manufacturing a filled 20 pastry product comprising the steps of: preparing a pastry dough;
forming the dough into a sheet;
laminating the dough sheet;
docking the dough sheet;
INT CL T ft F i/FFL·
OPEN TO PU8UC INSPECTION UNDER SECTION 28 AND RULE 23
JNL No. fHA - .QF 23
IE001029
RYE006/C/IES
-2splitting the dough sheet longitudinally to form a base dough sheet portion and a top dough sheet portion;
leading the base dough sheet portion along a conveyor;
leading the top dough sheet portion along a conveyor;
spraying the base dough sheet with water;
applying gluten to the sprayed base dough sheet;
preparing a filing comprising a mixture of sauce and frozen cooked meat and/or vegetables, the filling being at a temperature of from 2°C to -3°C;
forming the filing into a desired form shape;
applying the formed filing to the floured base dough sheet;
placing the top dough sheet portion over the base dough sheet portion and filling;
sealing the top sheet portion to the base dough sheet portion to form a pocket between the base and top dough sheets housing the filling;
crimping the edges of the pocket;
cutting away excess dough between the pockets;
applying a glaze to the individual pockets;
IE001029
RYE006/C/IES
-3cooking the pastry pockets;
cooling the cooked pockets; and freezing the cooled pockets.
In a preferred embodiment of the invention the pastry pockets are cooked in an oven at a temperature of from 275°C to 300°C for a period of from 12 to 16 minutes
In a particularly preferred embodiment the filling, on application to the base dough sheet, is at a temperature of from -1 °C to -2°C.
Preferably the filling is prepared by mixing sauce with cooked frozen meat pieces and subsequently adding blanched frozen vegetables to the sauce/meat mixture.
In a preferred embodiment the filling includes rusk in an amount of from 1% to 5% by weight.
In a preferred embodiment the edges of the pocket are crimped by aligning a pocket-shaped crimping tool with the side edges of a pocket, applying a support to the body of the pocket and advancing the crimping tool relative to the support to crimp the side edges of the pocket.
The invention also provides a filled pastry product whenever manufactured by a process of the invention.
IE001029
RYE006/C/IES
-4Detailed Description
The invention will be more clearly understood from the following description thereof given by way of example only.
A pastry dough of flour, water, yeast, starch, salt, sugar, baking powder, relaxer and fat is prepared in a mixer and, after mixing, the dough is formed into a sheet, and laminated in several stages to achieve a suitable laminated dough sheet. The laminated sheet is docked and then split longitudinally as it travels along a conveyor to form a base dough sheet portion and a top dough sheet portion which are separated. Docking involves impregnating the dough with a plurality of small (generally about 1mm) holes.
The base dough sheet portion is led along a conveyor and the upper surface of the sheet portion is sprayed with water. Gluten flour is then sprinkled over the sprayed base dough sheet portion. The base dough sheet portion is then ready to receive a filling.
A filling is prepared by mixing a sauce with frozen cooked meat and/or vegetables. The frozen cooked meat is at a temperature of from -10 to -15°C, which is also the temperature at which the blanched frozen vegetables are stored. The sauce is generally at about 10°C. We have found that for optimum filling characteristics the filling mixture when applied to the pastry base sheet portion should be from +2°C to -3°C, ideally from about -1°C to about -2°C. To provide enhanced flow characteristics while avoiding break-up of the meat and vegetable pieces ideally the sauce is first mixed with the meat prior to addition of the vegetable pieces. The filling also includes rusk in an amount of from 1 to 5% by weight.
IE001029
RYE006/C/IES
-5The filling is formed into a desired shape which is then deposited on the base sheet portion as it is moving along the conveyor. Several such forms are applied spaced-apart across the width of the base sheet. The top sheet portion is then placed over the base dough sheet and formed fillings. Rollers are then applied to the top sheet between the form fillings to seal the top sheet to the bottom sheet longitudinally and thereby defining a pocket containing the form fillings between the top and bottom sheet portions. A glaze is applied to the top sheet.
The edges of the pocket are then crimped in-line using a crimping tool shaped to the desired pocket shape. Each crimping tool comprises a central support of or coated with a release material such as Teflon which is engagable against the main body of the pocket and a serrated crimping blade which is movable relative to the support from an aligned position in which the support is engaged with the pocket and the blade is retracted, to a crimping position in which the blade is advanced downwardly of the support. The blade is in the desired shape of the pockets and individual pockets are formed across the width of the dough using several such crimping tools. The excess dough between the pockets is separated from the pockets, removed from the line and recycled for use in dough preparation.
The individual pastry pockets are deposited directly onto hot baking trays which are at a typical temperature of from 50 to 60°C. The pastry pockets are cooked in an oven at a temperature of from 270°C to 300°C for a period of from 12 to 16 minutes. After cooking, the pastry pockets are cooled to about 20°C, wrapped and frozen.
The pastry pockets are ideally inserted into a sleeve to be heated from frozen.
The sleeve includes an internal microwave interactive layer for browning and toasting the pastry surface during microwaving. The sleeve may have a tear tab to open the sleeve allowing the pastry pocket to be eaten directly from the sleeve.
IE001029
RYE006/C/IES
-6The invention provides a highly efficient process for manufacturing pastry pockets on a large factory scale with excellent organoleptic and physical properties.
The invention is not limited to the embodiments hereinbefore described which may be varied in detail.
IE001029
RYE006/C/IES
Claims (5)
1. A process for manufacturing a filled pastry product comprising the steps of: preparing a pastry dough; forming the dough into a sheet; laminating the dough sheet; docking the dough sheet; splitting the dough sheet longitudinally to form a base dough sheet portion and a top dough sheet portion; leading the base dough sheet portion along a conveyor; leading the top dough sheet portion along a conveyor; spraying the base dough sheet portion with water; applying gluten to the sprayed base dough portion sheet; preparing a filing comprising a mixture of sauce and frozen cooked meat and/or vegetables, the filling being at a temperature of from +2°C to -3°C; forming the filing into a desired form shape; IE001029 RYE006/C/IES -8applying the formed filing to the floured base dough sheet portion; placing the top dough sheet portion over the base dough sheet portion and filling; sealing the top sheet portion to the base dough sheet portion to form a pocket between the base and top dough sheet portions housing the filling; crimping the edges of the pocket; cutting away excess dough between the pockets; applying a glaze to the individual pockets; cooking the pastry pockets; cooling the cooked pockets; and freezing the cooled pockets.
2. A process as claimed in claim 1 wherein the glazed pastry pockets are deposited directly onto baking trays which are at a typical temperature of from 50 to 60°C, preferably the pastry pockets are cooked in an oven at a temperature of form 270°C to 300°C for a period of from 12 to 16 minutes.
3. A process as claimed in any preceding claim where the filling, on application to the base dough sheet, is at a temperature of from -1 °C to 2°C, preferably the filling is prepared by mixing sauce with cooked frozen IE001029 RYE006/C/IES -9meat pieces and subsequently adding blanched frozen vegetables to the sauce/meat mixture, preferably the filling includes rusk in an amount of from 1% to 5% by weight. 5
4. A process as claimed in any preceding claim wherein the edges of the pocket are crimped by aligning a pocket-shaped crimping tool with the side edges of a pocket, applying a support to the body of the pocket and advancing the crimping tool relative to the support to crimp the side edges of the pocket.
5. A filled pastry product whenever manufactured by a process as claimed in any preceding claim.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| IE20001029A IES20001029A2 (en) | 2000-12-18 | 2000-12-18 | A process for manufacturing a food product |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| IE20001029A IES20001029A2 (en) | 2000-12-18 | 2000-12-18 | A process for manufacturing a food product |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| IES20001029A2 true IES20001029A2 (en) | 2002-01-23 |
Family
ID=27637831
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| IE20001029A IES20001029A2 (en) | 2000-12-18 | 2000-12-18 | A process for manufacturing a food product |
Country Status (1)
| Country | Link |
|---|---|
| IE (1) | IES20001029A2 (en) |
-
2000
- 2000-12-18 IE IE20001029A patent/IES20001029A2/en not_active IP Right Cessation
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FD4E | Short term patents deemed void under section 64 |