Note: Descriptions are shown in the official language in which they were submitted.
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~ROZE~ G ~ULAR CHEESE PRODUC~
FOR BAKED p~ZZ~$
This application is a division of our application
no 563,034 filed March 31, 1988
~IELD OF INVENTION
The field o~ th~s inrention ~5 the use of comminuted
cheese on baked pizza.
BACKGROUND OF INVENTION
In the United States, many retail operations engaged
in preparation and baking of pizzas desire to use cheese in a
comminuted form. Consequentlv, producers of mozzarella and
other cheese used on pizzas shred or dice block cheese for de-
livery to the pizza restaurants. To provide improved storage
and keeping aualities, comminuted cheese ~or use on pizzas can
be frozen and delivered in frozen or semi-frozen condition.
However, the cheese must at least be thawed to the extent that
the shreds or granules can be separated. Moreover, further
thawing is needed to improve functionalitv.
The use of comminuted cheese in frozen or partially
frozen condition on pizzas frequently results in baked products
showing excessive browning and blistering. Not only is this
appearance unattractive to the consumer, but the flavor and
eating quality can also be adversely affected.
The recommended practice involves slow thawing of the
frozen cheese. Where thawing is carried out during non-freez-
ing refrigerated storage, as is a common practice, a minimum of
two to three days of thawing-holding is usuallv required.
Moreover, the best practice involves holding of the granular
cheese for four to five days, until thawing is completed.
Because of the problems associated with the use of
frozen comminuted cheese for preparing pizza, certain fran-
chised cheese restaurants require that the comminuted cheese
be packaged non-frozen in specially designed packages. This
adds considerably to packaging and distribution expenses, al-
though it does avoid the necessity of slo~ thawing.
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As far as is known, no one heretofore has produced
frozen comminuted cheese which can be applied to pizzas in
frozen or partially frozen condition and baked to produce a
pizza product of as good quality as with fully thawed cheese.
The high standards of appearance, quality and taste for large
scale pizza preparation have not been satisfied by the use of
comminuted cheese which has not been completely thawed.
It has also been desired to modify the properties of
granular cheese for use on pizzas and as toppings or
ingredients in other baked food products. Such modifications
include the incorporation of emulsifiers and flavor additives.
Heretofore, however, no method or product has been provided in
which such additives are provided as components of frozen
comminuted cheese.
The coated frozen cheese produced in accordance with
this invention is in a particulate free-flowing condition.
Modification of taste and functional properties of the cheese
can be obtained by applying coatings to the outsides of the
cheese particles. The coatings can be applied so as to
encapsulate the individual granules.
1335057
More specifically, it has been found that a new kind
of frozen granular cheese product can be prepared by coating
frozen free-flowing cheese granules with an aqueous carrier
containing one or more cheese additives, such as flavor
modifiers, emulsifiers, etc. The additive can be distributed
in an aqueous carrier in the form of a solution, dispersion,
or emulsion. The carrier containing the additive is applied
as a thin coating to the granules. On contact with the
granules, the coating freezes, thereby fixing the additive in
distributed form around the outer surfaces of the granules.
The coated frozen granules have a variety of uses in
addition to application to pizzas. They can be used as
toppings or ingredients in other food products. By
application in frozen or semi-frozen condition, the coatings
remain distributed on the granules. When the food product is
baked, the coatings will liquify and the additive will be
spread over and into the cheese granules or into and through
the food product. In other words, the desired modification
occurs during baking use of the coated frozen granules. A
method and product are thereby provided which achieve
efficient and uniform modification of granular cheese for use
in baked food products.
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DETAILED DESCRIPTION
The term "comminuted cheese" as used herein refers
to shredded or diced cheese of the kind which heretofore has
been sold for use in producing pizza products. The term
"granule" is used generically as referring to the particulate
form of such shredded or diced cheese. The granules are
usually of cubical or an elongated rectilinear shape.
However, the granules may also be slivers of irregular shape.
In practicing the method of this invention, any
cheese blend may be employed of the kind used on pizzas or in
other baked food products. In the United States, varieties of
mozzarella are the most common type cheese for pizza use, and
are used alone or in cheese blends. Other varieties of
cheeses used on pizzas in minor proportions of mozzarella
blends include cheddar, Muenster, Swiss, Monterey Jack,
Provolone, and the semi-soft part skim-milk cheese sometimes
called "pizza cheesen. Cheeses are usually produced in block
form. For purpose of this invention, the cheese blocks are
comminuted to shreds or
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granules. For example, the block cheese can be sliced and
then diced to form cubical or elongated granules.
Alternatively, cheese shredding equipment can be used. The
granules may have dimensions in inches of from 0.1 x 0.1 x 0.5
up to 0.25 x 0.25 x 1.5. Examples of representative granule
shapes are: (1) 1/8 x 3/16 x 3/4 inches; and (2) 1/8 x 1/8 x
1/8 inches.
In carrying out,the method of this invention, the
comminuted cheese is rapidly frozen, by contact with a
freezing medium, preferably by direct contact with low
temperature air. The freezing air should be at a temperature
below -lO-F and preferably below -20-F. For example, the
optimum air temperature is as low as -35 to -45-F.
To accomplish rapid freezing of the comminuted
cheese, a bed of the granules can be directly contacted by
freezing air.
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For example, the cheese granules ~ay be contacted in a fluidized
bed, or in an agitated bed foF rapi~L~ exposing all exterior
surfaces of the granules to the fxeezing air. B~ passing the
freezing air upw~rdl~ ~hrough beds in wh~ch the cheese par-
ticles are agitated, o~ preferably fl~dized, the air flow can
contact all of the exterior surfaces of the particles. With
air at a sufficiently lo~-temperature, su~face c~usts will
rapidly for~ on t~e granule~, thereby locking in the moisture.
Commerc~ally a~aIlable e~uipme~t can be used for the
freezing of the com~inuted cheese. This equipment is of the
kind sold for individual quick freezing (IQFl o granular food
products. Heretofore, "IQF~ equipment has been employed pri-
marily for freezing vegetables, and the freezing step has usual-
ly been accompanied b~ partial drying of the product. In pre-
paring the frozen cheese for the purpose of this invention, as
explained above, it IS desirable to avoid moisture loss from
the cheese as it is being frozen.
In one preferred method of freezing the comminuted
cheese, fluidized bed-type IQF equipment is employed. Such
fluidized bed equip~ent is described in United States Patents
3,169,381, 4,265,096, and 4,478,141. Commercially, suitable
IQF fluidized bed equipment is available from Prigoscandia
(Frigoscandia Contracting, Inc., ~ellevue, ~A). Expanded bed-
type freezing equipment is available from several suppliers,
including Cloud & Britton, Inc., Mountlake Terrace, Washington.
In preparing the comminuted cheese for freezing, pre-
cooling of the cheese is not required, that is, the cheese may
be at temperatures substantially above 32F. For example, tem-
peratures in the range of 35-55~ can be used, up to ambient
room temperature, ~fter the comminuted cheese is completely
frozen, typically requiring fro~ fivè to ten minutes, the cheese
granules will ~e a~ Vexy cold tempex~tu~es, but somewhat abo~e
the tempera~uxe of the freez~n~ aiX. For example, the tempera-
tuxe of the ~o~zen cheese will usua~ e ~e~ow oP, s-uch a$ at
a te~perature of fro~ a~out -10 to -20~P,
~ fter the cheese is frozen as-described, the shreds or
granules will be In an indivId~ai free-flo~ing form. The par-
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ticulate cheese iS then furthex processed in accordance with
this invention~ For ex~mple, a conVeyor belt, ox rotating drum,
or other e~uip~ent m~y be used, In one e~bod~ent, the cheese
particles may be sprayed with an aqueous ca~rier containing one
ore more cheese additi~es, such as flavor modifiers, emulsi-
fiers, surfactants, de~oamers, preser~tives~ etc. Any GRAS-
appro~ed food additive can be used~ The add~tive may be in an
aqueous solution, dispersion, or emuision, and a plurality of
additIves may be applied in a single laver or a plurality of
layers. The carrier should contain suffIcient water so that it
will freeze on the cheese particles. Granules of d~fferent
kinds of cheese may be mixed in frozen condition, either before
or after coating.
It is desirable to mix or agit~te the cheese while the
coatings are being applied. When properly applied, the in-
dividual granules become encapsulated by the frozen coating.
This can be done in a fluidized ~ed, such as near the discharge
end of the fluidized bed IQF freezer. Alternati~ely, a conveyor
blet can be equipped with devices for mixing the cheese par-
ticles as they are coated. Spray appllcation of the coatings
will usually be most convenient. As the aqueous carrier is
distributed over the outer surfaces of the cheese granules, the
carrier can be rapidly converted to frozen layers. At the same
time, the coated granules can remain free-flowing. In a pre-
ferred embodiment, the coatings are in the form of thin con-
tinuous layers and comprise from 0.5 to 4.0~ by weight based on
the uncoated cheese granules, that is, from 0.5 to 4 parts of
the aaueous coating are used per 100 parts b~ weight of the
cheese. Thorough distribution of the coatings IS enhanced be-
cause the aqueous carriex is not absorbed by the frozen gran-
ules. A sexies o~ coat~ngs, such ~s a two-layer coating may be
applied, each la~er cont~ining one OX more di~erent additives,
The use of such ~ozen coatings can be in add~tion to ap~ica-
tion of a ~xeseXY~tiye or other agent to the granules be~ore
~xeez~ng, when ~medi~te granule penetration ~s desired. For
example, an aqueous so~ution o sodium citrate may be sprayed
on the granules prlor to fxeezinq.
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W~en the coated frozen cheese is applied to pizzas and
baked thereon, the co~tin~s will liauify first. This ~ermits
the fla~or additiye and/or emulsifier to spread over and into
the cheese particles as their outer sur~aces become thawed.
The water in the coat~ng will then flash off. In this way,
special fla~or characte~istics can be im~arted with relative
uniformity to the melted cheese layex on the pizza. Cheese
emulsifiers apPlted ln this way can function to soften the out-
er portions of the cheese granules. This will improve melting
and fusing of the granules. The features are also of importance
in toppings for other baked food products. Further, the im-
proved melting and fla~or distrihution are generally advantages
where the frozen granules are mized into food oroducts prior to
baking. Some of the advantages of the present invention can
also be achie~ed in other uses of the coated frozen granules,
such as in the home preparation of salads or salad dressings.
Coated frozen granules may be mixed into a dressing or applied
to a salae. They will rapidly thaw, and as they thaw the sur-
face coating containing the flavor additive will become distri-
buted and impart the desired flavor characteristics to the
dressing, salad, etc.
T~e f~ozen granules, co~ted or uncoated, may be packed
in plastic bags-and the bags ~aced in caFtons for shipment or
storage. In prior practice, frozen storage of granular cheese
was limited to about six months without loss-of quality. It is
surprising therefore that the frozen cheese granules of this in-
~ention can be stored for Periods of over 12 months without any
quality deterioration. This storability feature facilitates
production by the c~eese manufacturer in the seasons of the year
when milk is abundant. As stated above, to maintain the cheese
in optimum condition, it has been found desirable to utilize
successively higher ranges of storage temperatures. This avoids
storage holding in which the granules are stored at a lower
temperature than the initial frozen storage tempçrature.
1335057
When the frozen product reaches the retail pizza out-
lets, it is not necessary to completely thaw the cheese prior to
use. For exam~le, teh cheese may be taken directly from frozen
storage and applied to pizzas ~ust prior to baking. However,
handling practices and a~ailable cheese storage facilities vary
considerably. Some restaurants may not be eouipped for frozen
storage, and/or the cheese may have been permitted to become
partially thawed before it reaches the restaurant. These differ-
ences are not matters for concern when employing the frozen com-
minuted cheese of this invention. Excellent results can be ob-
tained without regard to whether the cheese is in fully frozen
or partially frozen cond~tion as used on the pizzas. The baked
pizzas will ha~e ~s good or better appearance when prepared by
the method o~ this inyention as those prepaxed ~om thawed and
equilibrated cheese, Of course, the degree of browning o~ the
cheese on the b~ked p~zzas depends In part on t~he baking equip-
ment and te~pe~atures used~ ~ut on a comparat~e basIs the
pizzas prepared from the frozen granules will exhibit no more
browning or blistering than pizzas prepared from fully thawed
133~57
--10-- -
equilibrated granules,
P~C~SS EXAMP~E
Shredded mozzaFella cheese IS p~epared in a granule
size of ~bout ~8 x 3~16 x 3/4 inches~ The gr~nules are sub-
~ected to IQF fluidIzed bed freezing in a "FloFREEZE" Model 300
WS-ADF supplied ~ Frigos-candia Contracting, Inc., Bellevue,
Washington. The ~reezing and fluidiztng air which is blown up-
wardly through the bed o~ granules-can have a ~elocity of around
400 ft/min. and a temperature of about -40~. Frozen crusts
form rapidly around the outside of the granules, viz. in one to
two mlnutes or less. The time required for completIon of the
freezing is of the order of 7 minutes. The frozen granules
lea~ing the fluidized bed have a temperature of around -20~F.
Weight loss due to moisture evaporation durlng the freezing
process is less than 0.5%. Baffles alon~ the sides and over the
fluidized bed to minimize loss of cheese fines are provided.
The frozen granules are packed in bags and boxed for storage,
for example, at a temperature from -10 to 0F.
COATING EXAMPLES
Coatings for the frozen cheese can include one or more
of the following flavor additIves: lactose, glucose, diace~yl,
free fatty acids (i.e., butyric, propionic, capric, caproic
acids), cheese flavors (cheddar, Swiss, Provolone, etc.), meat
flavors (bacon, pepperoni, sausage, etc.), spices (basil, oreg-
ano, garlic, dill, cinnamon, fennel, etc.), vegetable flavors
(tomato, onion, pimiento, pepper, etc.), and fruit flavors
(strawberry, pineapple, cherry, lemon, etc.). Emsulsifier
additives, which may be used eithe~ alone or with the flavor
additives, include: surfactants, disodium phosphate, silicon
emulsifiers~ and other GRA~-approved emul~ifiexs.
The ~ol~owing fox~ulat~ons ~e ~lu~strat~ye,
- Emulsifier Coating Solut~on
~ silicone emulsifier (~Dow~Corning FG-107 is m~xed
with water to form a 0.05% emulsIfier solution. This solutIon
*Trade-mark
11- 13~5057
is sprayed on the frozen cheese granules at a rate of 1.75
parts of solution per loo parts by weight of cheese. This
should achieve a final content of around 0.09% emulsifier on
the cheese.
Smoke Flavor Coatinq Solution
A smoke flavor (Red Arrow* P-50 Hickory Smoke) is
mixed with water to form a 4.5% solution thereof. The
solution is sprayed on the frozen cheese granules at a rate of
2.2 parts by weight of solution per 100 parts of cheese. This
should achieve a final content of about 0.1~ smoke on the
cheese, which will provide a smoked flavor when the cheese is
cooked.
Swiss Flavor Solution
A Swiss cheese flavor (Naarden International Cheese
Flavor Swiss Type) is mixed with water to form a 50% by weight
solution. The solution is sprayed on the frozen cheese
granules at a rate of 0.5 parts of solution per 100 parts by
weight of cheese. This should achieve a final content of
about 2.5% Swiss flavor on the cheese, to provide cheese with
this flavor on cooking.
Provolone Flavoring of Mozzarella
A cheese having the flavor characteristics of
provolone on cooking is prepared from mozzarella cheese as
follows. Mozzarella cheese is first shredded or diced to a
granular form, as previously described. For example, two
different kinds of mozzarella cheese may be combined in equal
parts by weight, such as 70% skim mozzarella and 30% low
moisture mozzarella to provide the granular cheese mixture
which is subjected to rapid freezing as described above. After
the granules are frozen, a series of two coatings is applied.
*Trade Mark
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The first comprises a 1~ coating (based on the weight of the
cheese granules) of an 0.85~ solution of liquid smoke (Arrow
P-50). After the first coating has been distributed in the
form of a frozen layer around the cheese granules, a second
coating is applied comprising a 1 to 1.5~ application of an
aqueous solution containing 2~ defoamer and 1~ sodium citrate
dehydrate. A suitable defoamer is Union Carbide SAG 710* Food
Grade, which is a silicone (dimethylpolysiloxane) emulsion.
Cheddar Flavoring of Mozzarella
A cheese having flavor characteristics similar to
cheddar cheese on cooking is prepared from mozzarella-cheese.
In one embodiment, 100~ part skim mozzarella cheese is
converted to comminuted form. These granules after freezing
are coated with two layers. The first layer comprises a 1 to
1.5~ application af an aqueous solution containing 2% defoamer
(Mazu*) and 1~ sodium citrate dehydrate. The same defoamer
may be used as in the Provolone substitute. The second layer
comprises a 2~ application of a 50~ solution of a cheddar
cheese flavor including Annatto coloring. Suitable flavor
ingredients include the following obtainable from H&R Corp.,
Springfield, N.J.: (1) R-9219, National Cheddar Cheese Flavor
(Mild Type), and/or (2) R-9217, National Cheddar Cheese Flavor
(Sharp Type).
The above solutions should be applied gradually while the
frozen cheese granules are being mixed to distribute the
solution over the outer surfaces of the granules. This
produces thin frozen coatings around the outside of the
granules while the granules remain in individual free-flowing
condition. The silicone antifoamers tend to minimize blister
formation and to increase oiling off in the baking of pizzas
from the coated cheese granules.
*Trade Mark
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Other Uses
In addition to commercial pizza preparation for sale in
restaurants, the method of this invention is also applicable
to the home baking of pizzas sold in frozen condition. A
manufacturer preparing pizzas for sale through retail outlets
to home consumers can apply the comminuted frozen cheese of
this invention to unbaked, unfrozen pizza, then without
thawing the cheese ~he rest of the pizza is frozen by any
suitable procedure. The unbaked frozen pizzas are distributed
and sold in frozen condition. When a frozen pizza is
purchased and baked at home without thawing, the advantages of
this invention for baking the cheese in frozen or partially
frozen condition will be obtained. By applying the frozen
cheese granules to unbaked, unfrozen pizzas, a further
advantage is provided. The frozen granules do not absorb the
tomato or other liquid sauces. This protects the baking
properties of the cheese granules against deterioration by
adsorption of an acidic sauce;--
In still another application of the method of thisinvention, the comminuted frozen cheese, coated or uncoated,
may be packaged for sale to home users. As with commercial
pizza manufacturers, the home-user may apply the frozen or
partially frozen cheese granules to pizza, and then bake the
pizza without further holding. The frozen cheese granules may
also be used as toppings on other food products which can be
baked without thawing of the cheese. It should be understood
that these alternative uses of the present invention are
included within the scope of this application.
