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(12) Patent Application Publication (10) Pub. No.: US 2011/0151052 A1 Ajmera Et Al

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(12) Patent Application Publication (10) Pub. No.: US 2011/0151052 A1 Ajmera Et Al US 2011 O151052A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2011/0151052 A1 Ajmera et al. (43) Pub. Date: Jun. 23, 2011 (54) SYSTEMAND METHOD FOR PREPARING Publication Classification NAAN BREAD (51) Int. Cl. (75) Inventors: Sam Ajmera, Maple (CA); John A2ID 8/02 (2006.01) Gordon, Markham (CA); Dragan A2ID 8/04 (2006.01) A2ID 0/02 (2006.01) Janus, Concord (CA) A2ID 3/00 (2006.01) (73) Assignee: FGF BRANDS, INC., Concord (52) U.S. Cl. .............. 426/19: 426/503; 426/87: 426/549 (CA) (21) Appl. No.: 13/040,790 (57) ABSTRACT A method and system for preparing naan bread is provided. A (22) Filed: Mar. 4, 2011 conveyor oven is used to bake flattened and pre-shaped naan bread loaves. The conveyor oven uses high temperature gas Related U.S. Application Data heat to bake the naan, imparting traditional characteristics (62) Division of application No. 12/310,827, filed on Apr. Such as the slightly Smoky or scorched appearance. The oven 27, 2010, filed as application No. PCT/CA2006/ interior is preferably lined with stone, granite, clay or porce 0.01612 on Sep. 29, 2006. lain to enhance baking and provide traditional flavour. 2222222222222222 W w atw y \s Azes arez-Azaar. Patent Application Publication Jun. 23, 2011 Sheet 1 of 9 US 2011/O151052 A1 ŽZZZZ// ZZZ$)No.ae, FIG. 1A (PRIOR ART) FIG. 1B (PRIOR ART) Patent Application Publication Jun. 23, 2011 Sheet 2 of 9 US 2011/0151052 A1 1 OO A. YA CY (Y ?y raaaaaa.rear Asaar AAAAAAs. 1 OO aa?aaaaaaaaaaaa.s SEGE FIG.2 Patent Application Publication Jun. 23, 2011 Sheet 3 of 9 US 2011/O151052 A1 Patent Application Publication Jun. 23, 2011 Sheet 4 of 9 US 2011/O151052 A1 FG4 Patent Application Publication Jun. 23, 2011 Sheet 5 of 9 US 2011/O151052 A1 15O Patent Application Publication Jun. 23, 2011 Sheet 6 of 9 US 2011/0151052 A1 Patent Application Publication Jun. 23, 2011 Sheet 7 of 9 US 2011/O151052 A1 2OO Patent Application Publication Jun. 23, 2011 Sheet 8 of 9 US 2011/O151052 A1 Maw Yaaaa. assassassistas S. 90080820| }}}}}}}}}}}}}}} s?(x)x^•N^^^ YeaNo. a WRNNNNNNNNNNNNNNNNNNNNNNNNNNNNNN sassEZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZ)¿ZZZZZZZZZZZZZZZZZZZZZZZZZZZZZa's as SYS Patent Application Publication Jun. 23, 2011 Sheet 9 of 9 US 2011/O151052 A1 240 223-22s22saaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa. S& 214412.4% AA44%aaaaaaaaaaaaaaaya Ayaaaaaaaaaaaaaaaaaaa.ea FIG.9 US 2011/O151052 A1 Jun. 23, 2011 SYSTEMAND METHOD FOR PREPARING 0010. However, these traditional naanbaking processes do NAAN BREAD not lend themselves readily to larger commercial scale pro duction. Accordingly, naan is largely considered a bread for restaurant consumption, and not a food purchased to consume 0001. This application is a divisional of U.S. Ser. No. at home. Home cooks, unless they have access to a tandoor, 12/310,827 filed Apr. 27, 2010, which is a 371 of PCT/ are not likely to be able to enjoy hot naan bread with a meal. CA2006/001612 filed Sep. 29, 2006, the disclosures of which Methods of cooking naan in an electric orgas home oven have are incorporated herein by reference. been suggested, but such methods are generally considered to produce an inferior product as home ovens are simply not hot FIELD OF THE INVENTION enough to mimic a tandoor. 0011. A need therefore exists for a method of preparing 0002. A system and method is provided for preparing naan naan that allows for commercial-scale production, using safe bread. modern equipment, without sacrificing the traditional flavour and texture of a tandoor-baked naan. BACKGROUND OF THE INVENTION 0003) Naan is a type of flatbread traditionally made in SUMMARY OF THE INVENTION Central and South Asia and now enjoyed worldwide, espe 0012. According to a first aspect of the invention, a method cially as an accompaniment to Indian foods, Such as curries. of making naan bread is provided. Naan bread is prepared by: It is made from a leavened dough that is flattened and baked 0013 (a) preparing a naan bread dough; in a cylindrical or urn-shaped oven known as a tandoor. 0.014 (b) dividing and forming the dough into balls; 0004. A traditional tandoor consisted of a clay baking 0.015 (c) rising the round balls of dough; layer encased in a masonry or earth housing. An insulating 0016 (d) flattening the round balls into generally circu layer of sand was provided between the clay layer and the lar discs; housing. The tandoor was heated by charcoal or woodburned 0017 (e) stretching each disc into an irregular non in the bottom of the baking chamber. circular shaped loaf 0005 To bake naan breads in a traditional tandoor, pieces 0.018 (f) loading the shaped loaves onto a conveyor, and of flattened dough were slapped by hand or baking pad onto 0.019 (g) running the conveyor through a high tempera the extremely hot inside walls of the oven. A hook was used to ture gas oven for a period of time sufficient to bake the remove the baked naan after a short baking time. loaves to a crisp-chewy consistency, having a visibly 0006. The basic process for baking naan has not changed bubbled surface texture and a slightly scorched top sur for centuries. Modern tandoor ovens use different materials face. (such as steel housings and ceramic interiors) and different (0020 Preferably, the oven temperature is at least 700°F. heating options (such as electric heating elements or gas Preferably, the conveyor speed is approximately 60 feet/min burners). However, the basic shape of the tandoor, and the and the resident oven time for each loaf is between approxi Vertical wall-based baking process have not changed. mately 20-50 seconds. 0007. In spite of improvements in materials, many purists 0021. At least part of the dough may be coated with an oil believe that there is no substitute for the flavour imparted by or fat prior to baking. baking naan with a traditional Stone or clay oven. However, 0022. The stretching step in step (e) is preferred for mak the traditional tandoor design has a number of drawbacks— ing a more-authentically shaped naan bread. Preferably, the material issues and poor safety. Naan must be baked at very stretching is done by hand, for instance to form the dough into high temperatures to impart the Sultry Smoky characteristic a teardrop, or oblong shape. Preferably, each loaf may be that is its signature. Clay ovens, in particular, are known to shaped into a unique shape. At step (e), other shaping or crack under prolonged exposure to high heat. Cracks can prepping may be performed, for instance, the dough may be cause the traditional sand fill that is used to insulate the oven stretched the dough and/or pressed to impart deliberate to leak into the baking chamber, potentially getting into the unevenness over areas of the Surface. food. It is seldom possible to effectively patch a clay oven 0023 Preferably, the thickness of the round discs follow once it cracks. Accordingly, it becomes necessary at regular ing step (d) is between approximately 2-5 mm. Preferably, the intervals to replace a tandoor oven. thickness of the shaped loaves following step (e) is between 0008 Traditional baking methods are also dangerous even approximately 1.5-3 mm. for skilled operators. The inside of the tandoor oven reaches 0024. Various methods may be used to rise the dough temperatures often in excess of 700° F (370°C.). In order to before the pressing and shaping steps. A steam proofer may slap the raw naan dough onto the inside walls of the tandoor, be used. Preferably, the balls of dough may be conveyed the operator must Stick a portion of his arm into the oven. Any during the rising step on a conveyor tray proofer. slight contact with the walls of the tandoor can result in severe 0025 Depending on the humidity and temperature (an burns. The top openings of the oven are often relatively small acceptable range being within the general knowledge of those (approximately 1-2 ft across, or approximately 30-60 cm). skilled in the art), the balls of dough may be left to rise for increasing the difficulty to maneuver the bread into place between approximately 45 and approximately 60 minutes. without contacting the oven Surfaces. 0026. Prior to rising, the balls of dough may be pre 0009. In a traditional tandoor, a baker can only bake a weighed for approximately even weight. Small number of naan at a time due to the Small size of most 0027 Various dough formulations are possible. The tandoor ovens and due to the quick baking process requiring dough is preferably a leavened dough, Such as a yeast-leav constant human involvement and attention. Consequently, a ened dough or a baking powder-leavened dough. Alterna tandoor operator bakes a steady stream of tiny batches of tively, the dough may comprises a Sour dough. In any of these breads for “a la minute” serving and consumption. formulations, the dough may contain a souring ingredient. US 2011/O151052 A1 Jun. 23, 2011 0028 Preferably, the dough is baked by employing heat 0049. The system is preferably adapted for preparing up to ing sources above and below the loaves. After baking, the 8000 breads per hour. loaves may be cooled and packaged to be sold as re-heatable naan bread. The cooling step may employ a cooling spiral. BRIEF DESCRIPTION OF THE FIGURES 0029. According to a second aspect of the invention, a 0050 FIG. 1A is a diagram of a traditional tandoor oven naan bread is provided, which is made by the foregoing (prior art) showing the housing in cutaway to reveal the clay method.
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