US008304008B2 (12) United States Patent (10) Patent No.: US 8.304,008 B2 Hartmann (45) Date of Patent: * Nov. 6, 2012 (54) FROZEN FILLED YEAST-LEAVENED BREAD 3:638 A : 13 1323 M * * * * * * * * * * * * * * * * * * * * * * * * * * * 36 MY Z -- MY OIKNlCI . PRODUCT AND A METHOD FOR MAKING 4,285,979 A :k 8/1981 IZZi * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 42694 THE PRODUCT 4,297.942 A 11/1981 Benson et al. 4,784,869 A * 11/1988 Bishop .......................... 4268523 (75) Inventor: William J. Hartmann, Duluth, MN 5,044,264 A 9/1991 Forney (US) 5,951,895 A 9/1999 Green et al. 6, 192.789 B1 * 2/2001 Agcaoili et al. ................ 998349 8 8 6.210,723 B1 4/2001 Coleman et al. (73) Assignee: Belisio Foods, Inc., Duluth, MIN (US) 6.231,898 EB 1 :k 5/2001 Perrine * * * * * * * * * * * * * * * * * * * * * * * * * * * 42694 6,406,731 B1 * 6/2002 Hartman . ... 426/446 ( * ) Notice: Subject to any disclaimer, the term of this 2004/0005391 A 1 * 182004 Shim han : 426/275 patent is extended or adjusted under 35 2004/0040445 A 1 * 3/2004 Errera ............................. 998388 U.S.C. 154(b) by 722 days. 2005/028 1923 A 1 * 12/2005 Kubat et al. ................... 4268128 This patent is subject to a terminal dis- FOREIGN PATENT DOCUMENTS claimer. EP 0 053 656 A1 6/1982 EP 1 157 613 A 1 1 1200 1 (21) Appl. No.: 11/226,016 WO 9805214 A1 2, 1998 OTHER PUBLICATIONS (22) Filed: Sep. 14, 2005 European Search Report; dated Apr. 14, 2009; Application No. / (65) Prior Publication Data Patent No. 06803559, 1—1221 || 1933628 PCTUS2006035762 US 2007/0059413 A1 Mar. 15, 2007 * cited by examiner (51) Int. Cl Primary Examiner — Jyoti Chawla A2I) 3/)) (2006.01) (74) Attorney, Agent, or Firm — Ladas & Parry LLP (52) U.S. Cl. ........................................ 426/446: 426/283 (57) ABSTRACT (58) Field of Classification Search ....... 38ääsi A frozen, filled, yeast-bread product and a method for pro See application file for complete search histo 3 ducing the same, the method including coextruding an pp p ry. unrisen yeast-bread dough and a filling through an extruder (56) References Cited that is capable of at least encasing the filling with the unrisen yeast-bread dough to form a filled, unrisen yeast-bread dough; shaping the filled, unrisen yeast-bread dough into a U.S. PATENT DOCUMENTS consistent flattened shape; proofing, baking, cooling, enrob 3,065,079 A :k 1 1/1962 Elliott ........................... 426296 ing, grilling and freezing the filled, unrisen yeast-bread dough 3,589.274 A 6/1971 Murray .... ... 998346 3,611.913 A * 10/1971 McGinley ....................... 998349 to form a frozen, filled, yeast-leavened bread product that 3,615,678 A 10/1971 Tangel et al. experiences substantially no leaking of filling from out of the 3,646,880 A * 3/1972 Norris ............................. 998349 bread product. 3,659,517 A * 5/1972 Holen ... 998355 3,690,898 A * 9/1972 Partyka ......................... 4268275 12 Claims, 2 Drawing Sheets U.S. Patent Nov. 6, 2012 Sheet 1 0f2 US 8.304,008 B2 Providing a Yeast Providing a Filling 13 Bread Dough O Filling Unrisen Dough 14 12 Co-extruding the Unrisen Dough and - 10s)> Filling through an 16 stuffed Panini L. Extruder 18 ~---M---T- Shaping the Stuffed Panini into a Round Flattened Shape Shaped Stuffed Panini Proofing (Raising) the Stuffed Panini Pr??fed Stuffed Panini 26 ~M~*~--- Baking the Stuffed Panin? Baked Stuffed Panini 30 ~M~~~--- Cooling the Stuffed Panini Cooled Stuffed Panini 33 Enrobing the Stuffed Panini With Oil EnrObed Stuffed Panini 4 ~ M**~--- 3 FIG. 1 Grilling the Stuffed PaniniS 35 Grilled Stuffed Panini 37 - M*~ Freezing the Stuffed Penini Frozen Stuffed Panini 38-MT~--- Packaging the 40 Stuffed Pamini U.S. Patent Nov. 6, 2012 Sheet 2 0f2 US 8.304,008 B2 FIG. 2 FIG. 3 US 8,304,008 B2 1 2 FROZEN FILLED YEAST LEAVENED BREAD includes extruding the unrisen yeast-bread dough through a PRODUCT AND A METHOD FOR MAKING unique dual noZZle configuration with a shutter adjustment to THE PRODUCT eliminate substantially all leaking of the filling from out of the frozen, filled, yeast-leavened bread product. The configura BACKGROUND OF THE INVENTION tion of the nozzle in relation to a conveyor belt allows the filled bread product to be formed in a round, flattened shape. During the last decade, a dramatic change in consumer Further flattening is accomplished by passing the filled bread eating patterns has been observed. Longer working hours, product between two converging conveyor belts. changing family structures and the pursuit of a healthier lif In a preferred embodiment of the present invention, a bread estyle are all factors that have influenced food purchasing 1 (0) dough and filling are co-extruded through an extruder and the decisions. As a result, consumers typically seek out foods that co-extruded bread dough and filling are pinched off into dis taste fresh, require minimal preparation time, can be micro crete units in order to form a closed, filled bread dough with waved, are conveniently packaged, and/or are portable. substantially no leakage of filling from the bread dough. The The use of baking is a food process well known to food filled bread dough is proofed (raised), baked, cooled and manufacturers as a preparation Vehicle for foods that meet the 15 enrobed with an oil component in order to form a filled aforementioned characteristics. For example, the baking yeast-bread product with an extended interior and exterior industry which typically manufactures cupcakes, cookies, shelf life. Before freezing and packaging, the filled bread and bars, has experienced phenomenal growth as consumers product may be impressed with grill marks to give the bread now incorporate these baked foods during their eating occa product the appearance of being cooked on a grill. sions. In fact, the Snack food industry, which originated in the 20 baking industry, is prospering due to the sales of foods that are BRIEF DESCRIPTION OF THE DRAWINGS fresh-tasting, conveniently-packaged and portable. One area FIGURES of the baking industry that is yet to be fully developed is the creation of high quality hand-held, portable, yeast-leavened FIG. 1 is a schematic view of a process for producing a bread products, such as hand-held piZZas, sandwiches, orany 25 frozen, filled, yeast-leavened bread product in accordance bread-type product with a topping and/or filling. with the present invention. The lack of high quality products in this area is due in part FIG. 2 is a side view of the extruding and shaping appara to the fact that manufacturing hand-held, yeast-leavened tUS. bread products is typically challenging due to a number of FIG. 3 is a side view of the grilling apparatus. variables. For example, yeast-leavened bread products 30 undergo yeast leavening, which is a fermentation process that DETAILLED DESCRIPTION OF THE PREFERRED depends on factors such as yeast viability, temperature, pH, EMBODIMENTS starch concentration, and/or moisture. Controlling each of these factors is difficult, therefore, product quality often var The present invention generally relates to a frozen, filled, ies from one day to the next. Additionally, the incorporation 35 yeast-leavened bread product such as a stuffed panini and to of fillings, such as tomato sauces, cheese sauces, peanut but a method of making this yeast-leavened bread product. The ter, jams, jellies, or creams, into yeast-leavened bread prod present invention further relates to a method of extruding a ucts is also challenging since the filling may leak out from filled, unrisen, yeast bread dough. inside of the yeast-leavened bread product, and thus, destroy A process for producing a frozen, filled, yeast-leavened the overall organoleptic qualities of the yeast-leavened bread 40 bread product, which will be described with reference to a product. Inconsistent textural properties within the bread por frozen stuffed panini 38 for this embodiment, is generally tion is another hurdle that food manufacturers must over depicted at 10 in FIG. 1. In the process 10, an unrisen yeast come, especially if application of heat, particularly micro bread dough 12, hereinafter referred to as an unrisen dough wave heat, is required to complete preparation of the yeast 12, along with a filling 14 are introduced into an extruder. At leavened bread product. 45 16, the extruder co-extrudes the unrisen dough 12 and the Another challenge is to produce a high-quality food prod filling 14, encasing the filling 14 within the unrisen dough 12 uct that has a fresh and homemade feel to it, which appeals to such that substantially all leaking of the filling 14 is elimi the consumers” tastes. nated. The filled unrisen dough 18, which will be referred to In the past, food manufacturers have incorporated unleav as a stuffed panini 18 for this embodiment, is transferred from ened dough products in dough-based food products, and 50 the extruder 16 to at least one set of rollers that are capable of avoided yeast-leavened bread products. Clearly, there is a shaping the stuffed panini 18 into a round, flattened shape at need in the baking industry for the manufacture of hand-held, 20. portable, yeast-leavened bread products to meet growing con A shaped stuffed panini 22 is transferred from the rollers to sumer demand. a proofing apparatus at 24 that allows the yeast within the 55 unrisen dough to leaven the shaped stuffed panini 22. A SUMMARY proofed stuffed panini 26 is then transferred from the proofing apparatus to a baking apparatus at 28 that bakes the proofed The present invention includes a method for producing a stuffed panini 26, and transforms the dough into a bread.