Method for producing fresh filled pasta and filled pasta obtained by the method

Abstract

A method for producing fresh filled pasta (1), such as ravioli, cappelletti, tortelli, panzerotti, etc., comprises the steps of: a) preparing a first sheet (2) of fresh pasta and laying it on a flat support (F); b) depositing a first dose (D1) of a first food filling (3) on the first sheet (2); c) depositing a second dose (D2) of a second food filling (4), other than the first food filling (3), on the first dose (D1) of the first food filling (3); d) preparing a second sheet (5) of fresh pasta and laying it on top of the first sheet (2) and the doses (D1, D2); e) joining the sheets (2, 5) along a substantially continuous peripheral edge (C) of a predetermined shape corresponding to the shape of the finished product; and f) cutting the joined sheets (2, 5) along the peripheral edge (C) to obtain the desired type of fresh filled pasta (1). The first food filling (3) is in a shape-memory paste state, and the second food filling (4) is in a liquid or gel state. Between steps b) and c) there is provided a step g) of plastically deforming the first dose (D1) to form thereon a constantly upwardly open cavity (6) for receiving and holding the second dose (D2) without spilling or leaking from the first dose (D1). By this method, fresh filled pasta (1) can be obtained.

Description

Technical Field

[0001] The present invention generally applies to the food field, and particularly relates to a method for manufacturing fresh-filled pasta such as ravioli, cappelletti, tortellini, pansotti, etc.

[0002] The present invention also relates to fresh-filled pasta obtained by such a method.

Background Art

[0003] Definition As used herein, the terms "filling (stuffing, ingredient)" or "filler" refer to a food obtained by combining raw or cooked materials to obtain a more or less homogeneous mixture.

[0004] As used hereinafter, the terms "coextrusion", "extrusion" and their derivatives mean a process of discharging a plurality of products in a paste state through a substantially tubular nozzle or a substantially circular hole.

[0005] Background Art In the food industry, the use of pasta filled with a filling has been known for a long time. Such products are typical products of regional Italian cuisine, and the filling can be made of, for example, meat, fish, grains, vegetables, cheese, milk-derived products, fruits and fruit-derived products, protein or fat-based substances, sauces, creams, and other types of materials.

[0006] Due to their shape, they are called ravioli, tortellini, cappelletti, pansotti, etc., but there are also various shaped filled foods based on the traditions of Italian regions and overseas gourmet foods.

[0007] Foods with multiple fillers are also known, which have a first filler and a second filler, that is, a filler formed by the first and second paste-like food components.

[0008] An example of such a food product is disclosed in European Patent Application Publication No. 475911. This food product is an envelope composed of two different pockets or shells, which encloses differentiated components or ingredients, and is thus designed so that they do not contact each other.

[0009] The characteristics of these prior art products are that, in fact, two ravioli with different flavors are formed by sticking to each other, and they cannot be tasted simultaneously unless they are combined and ingested.

[0010] A further characteristic of these prior art products is that a large amount of pasta is required to form such a food product, thereby diluting the taste of the individual ingredients.

[0011] International Publication No. 2011 / 117641 discloses a food product having one or more grooves for holding food in different paste states in a crust or outer cylinder made of pasta dough.

[0012] The manufacturing method of this product manufactures, for example, a roll-shaped product by co-extruding a body of pasta containing sauce and minced meat into grooves arranged concentrically or in a staggered pattern in the radial direction.

[0013] In this product, raw pasta cannot actually be used for the body. Also, the components of the filling need to undergo heat cooking treatment before being extruded into their respective channels.

[0014] Furthermore, this method can only provide a cylindrical envelope and filling in which the first component and the second component are arranged in coaxial or parallel channels respectively. In fact, the product is eaten in a sliced state and is more similar to a sausage than a pasta product.

[0015] U.S. Patent Application Publication No. 2006 / 121169 discloses a pasta in the form of a ravioli consisting of an outer layer made of a multi-colored and multi-layered paste and an inner layer joined to the outer layer along the peripheral portion and enclosing a filling made of a single or composite component in a sealed container.

[0016] The drawback of this product is that there is only one filling and multiple fillings are not possible, so there are no variations in taste and aroma.

[0017] To solve such problems, a method for manufacturing a filled food has been developed in which a first filling and a second filling are placed on a sheet of pasta, and the sheet of pasta is closed or closed with another sheet to wrap and enclose the two fillings.

[0018] An example of such a food and its manufacturing method is disclosed in European Patent Application Publication No. 2900083 by the present applicant, in which the first and second food fillings are co-extruded in a substantially overlapping or coplanar relationship over a continuous time to form a filled food in which the two food components of the filling are separated without mixing.

[0019] Thereby, a filled food made faithfully to the original recipe can be provided, and the taste obtained by combining the respective tastes of each food component contained in the filling can be conveyed to the consumer.

[0020] Nevertheless, the common limitation of these prior art methods is that a plurality of fillers can be used to make a filled food with the food components of the filling in a paste state.

[0021] Furthermore, these known methods can provide conventional foods, but precious high-quality materials cannot be used and utilized.

[0022] Chinese Patent Application Publication No. 105432708 discloses a method for manufacturing soup dumplings consisting of a package of fresh pasta filled with a mixture of a plurality of solid and liquid fillings.

[0023] GB 2414158 A1 discloses a method for obtaining a filled pasta product that can be easily cooked in a microwave oven, with a filling consisting of a sauce in which pieces of meat are dispersed.

[0024] US Patent Application Publication No. 2018 / 064118 discloses a method for obtaining fresh filled pasta products, comprising a fresh pasta wrapper enclosing two or three doses of different types of filling in an overlapping or side-by-side relationship.

[0025] None of the above methods specifically address one or more doses of fill having a particular consistency. [Prior art documents] [Patent documents]

[0026] [Patent Document 1] European Patent Application Publication No. 475911 [Patent Document 2] International Publication No. 2011 / 117641 [Patent Document 3] US Patent Application Publication No. 2006 / 121169 [Patent Document 4] European Patent Application Publication No. 2900083 [Patent Document 5] Chinese Patent Application Publication No. 105432708 [Patent Document 6] GB Patent Application Publication No. 2414158 [Patent Document 7] US Patent Application Publication No. 2018 / 064118 Summary of the Invention [Problem to be solved by the invention]

[0027] Technical Problem In view of the known prior art, the technical problem that the present invention aims to solve is to provide a method for producing fresh filled pasta that is relatively inexpensive, allows the use of fillings of various compositions and allows the use of valuable food ingredients.

[0028] Disclosure of the Invention The object of the present invention is to overcome the above drawbacks and to provide a method for producing fresh filled pasta that is highly efficient and relatively cost-effective.

[0029] Another object of the present invention is to provide a method for producing fresh filled pasta that allows the use of food products with high organoleptic properties.

[0030] A further object of the present invention is to provide a method for producing fresh filled pasta that allows for the use of complex ingredients that are problematic in terms of quality, cost and usable quantity.

[0031] It is yet another object of the present invention to provide a method for producing fresh filled pasta that allows for different positions of the filling ingredients to accommodate a wide variety of product shapes and types.

[0032] It is yet another object of the present invention to provide a method for producing fresh filled pasta that can provide a filled product having multiple fillers.

[0033] Another object of the present invention is to provide a method for producing fresh filled pasta in which multiple filling doses can be deposited without spilling or leaking from other filling doses. [Means for solving the problem]

[0034] These and other objects are met by a method for manufacturing a fresh-filled pasta as defined in claim 1, such as ravioli, cappelletti, tortelli, pansotti, said method comprising: a) preparing a first sheet of fresh pasta and placing it on a flat support; b) depositing a first dose of a first food filling on the first sheet; c) depositing a second dose of a second food filling, different from the first food filling, on the first dose of the first food filling; and d) preparing a second sheet of fresh pasta and laying the second sheet over the first sheet and the doses of the first and second food fillings.

[0035] Preferably, e) joining the first and second sheets along a substantially continuous perimeter of a predetermined shape corresponding to the shape of the finished product; and f) cutting the sheets joined along the perimeter to obtain a fresh pasta with the desired type of cream filling.

[0036] Furthermore, according to the invention, the first food filling is in a paste state with shape memory, the second food filling is in a liquid or gel state, and a step is provided between b) depositing the first dose and c) depositing the second dose, namely: g) plastically deforming the first dose to form a cavity that is constantly open upwards over the first dose in order to receive and hold the second dose in a liquid or gel state without overflowing or leaking from the first dose.

[0037] Thanks to these features, the method for manufacturing fresh pasta according to the invention can provide a filled product in which a plurality of materials are present in the outer skin of the fresh pasta, at least one of which is in a liquid or gel state.

[0038] Thus, the method of the invention allows the addition of valuable ingredients to the liquid or gelled filling, such as fresh precious mushrooms, truffles, caviar, botago, exotic spices, fine meat or fish, fine wines and spirits, distilled spirits, fine fruits, fine fruit preparations, etc., which will characterize the taste of the filling.

[0039] Preferably, the step of g) plastically deforming the first dose to form the cavity is performed by a punch tool positioned above the first dose.

[0040] This property allows for increased production speed to the finished product without changing the physical or organoleptic properties of the raw filled pasta ingredients.

[0041] A further aspect of the present invention provides fresh filled pasta obtainable by the method as described above, as defined in claim 14.

[0042] Further embodiments of the invention are defined by the dependent claims.

[0043] Brief Description of the Drawings Further features and advantages of the present invention will become more apparent from the detailed description of a preferred, non-exclusive embodiment of a method for producing fresh filled pasta having at least two fillings, as described below by way of non-limiting example with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0044]

Figure 1

Figure 2A

Figure 2B

Figure 2C

Figure 2D

Figure 3

Figure 4

Figure 5

[0045] The attached drawing shows a method for producing fresh filled pasta, designated by the reference number 1, intended primarily for the preparation of dishes with high gastronomic quality.

[0046] In particular, the fresh filled pasta 1 produced by the method of the present invention may be ravioli, cappelletti, tortelli, panzerotti, etc., and is intended to be cooked and eaten.

[0047] If the fresh filled pasta 1 is intended for cooking, it may, i.e., be designed to be boiled in water or soup, baked, heated in a microwave oven or fried in oil.

[0048] As best shown in FIG. 1, the method comprises the steps of: a) preparing a first sheet 2 of fresh pasta and laying it down on a flat support F.

[0049] As a non-limiting example, the first sheet 2 may be made from a mixture based on common wheat flour, hard wheat, a small amount of water, and optionally eggs.

[0050] The dough may also be subjected to one or more unidirectional and / or multidirectional lamination steps to obtain continuous strips of fresh pasta of a desired thickness, preferably in the range of 0.3 mm to 2.5 mm, using known techniques used for bakery products such as bread and croissants.

[0051] Next, there are provided steps of: b) depositing a first dose D1 of a first food filling 3 on a first sheet 2; and c) depositing a second dose D2 of a second food filling 4 other than the first food filling 3 on the first dose D1 of the first food filling 3.

[0052] The first food filling 3 can be obtained by mixing a number of materials selected from the group consisting of meat, fish, eggs, cheese, milk-derived products, fruits, fruit-derived products, sausages, vegetables, grains, protein and fat-based substances, or combinations thereof, additionally adding seasonings, flavors and sauces, even if it cannot be easily combined according to traditional recipes.

[0053] As shown in FIGS. 2A, 2C, 3 and 4, it should be noted that the doses D1, D2 are deposited on the first sheet 2 over a continuous period of time by individual single-tube nozzles U’, U’’.

[0054] Following step c) of depositing the second dose D2, step d) of preparing a second sheet 5 of fresh pasta and laying it over the first sheet 2, the doses D1 of the fillings 3, 4 and the second dose D2, as best shown in FIG. 2D, is carried out.

[0055] The second sheet 5 may be formed from the same dough as the first sheet 2, or alternatively, from a different type of dough that may have different functional properties from the first dough.

[0056] Subsequent to step d) of preparation, there are provided steps of: e) joining the first sheet 2 and the second sheet 5 along a substantially continuous peripheral edge C of a predetermined shape corresponding to the shape of the finished product; and f) cutting the joined sheets 2, 5 along the periphery to obtain the desired type of fresh filled pasta 1.

[0057] Therefore, the first sheet 2 and the second sheet 5 can have a predetermined size and shape for containing the first food filling 3 and the second food filling 4 according to the specific type of finished product to be manufactured.

[0058] Furthermore, by selecting the fresh pasta and its base components, the sheets 2, 5 can optimally wrap the outer surfaces of the fillings 3, 4 with high surface adhesion, and obtain almost perfect liquid tightness necessary for cooking without losing the fillings 3, 4 even in liquid or boiling state.

[0059] Furthermore, thereby, the food 1 with a double filling having a characteristic taste is provided, and the taste of traditional regional food can be faithfully reproduced.

[0060] In the first embodiment, as shown in FIG. 3, the sheets 2, 5 may be formed from the same continuous strip of fresh pasta 2', which strip, not shown, is folded onto itself along the longitudinal line X using a special hoe-shaped blade known to those skilled in the art.

[0061] This embodiment is particularly suitable for making fresh filled pasta 1 such as tortellini, cappelletti, panserotti, etc.

[0062] Alternatively, in the second embodiment as shown in FIG. 4, the sheets 2, 5 can be separated and distinguished, and one can be stacked on top of the other. This embodiment is particularly suitable for making fresh filled pasta 1 such as ravioli and panserotti.

[0063] Furthermore, the cutting step f) can be carried out using a forming and cutting tool P adapted to join the sheets 2, 5 along the peripheral edge C and cut in proximity to the peripheral edge to form the fresh pasta 1.

[0064] In a particular aspect of the present invention, the first food filling 3 is in a paste state with shape memory, and the second food filling 4 is in a liquid state or a gel state.

[0065] Furthermore, between steps b) depositing the first dose D1 and c) depositing the second dose D2, there is step g) of plastically deforming the first dose D1 to form a constantly upwardly open cavity 6 for receiving and holding the second dose D2 without the second dose D2 spilling or leaking out of the first dose D1, as best shown in FIG. 2B.

[0066] Preferably, a first dose D1 of a first food filling 3 in a paste state may be deposited on the first sheet 2 by extrusion, while a second dose D2 of a second food filling 4 in a liquid or gel state is deposited on the cavity 6 by injection.

[0067] Additionally, a second dose D2 of second food filling 4 in a liquid or gel state may be deposited onto cavity 6 by extrusion or gravity.

[0068] It will be appreciated that the use of a second food filling 4 in liquid form in depositing step c) of the method of the present invention and the plastic deformation of the first dose D1 in step g) make it possible to provide novel fresh filled pasta 1 having high organoleptic qualities.

[0069] Furthermore, the method of the present invention allows the use of foods with high organoleptic properties and complex ingredients that are problematic in terms of quality, cost and available quantity.

[0070] That is, the type of second food filling 4 in a liquid state may be in two preparation forms depending on the quality and type of ingredients used.

[0071] In the first preparation form, the second filling 4 in a liquid state is able to maintain its fluid structure when eaten without changing the taste, even after cooking the fresh filled pasta 1.

[0072] In this first preparation form, the second food filling 4 in a liquid state may comprise a liquid or gel extract or concentrate of a food selected from the group consisting of precious mushrooms, truffles, herbs or spices, meat, fish, fine cheeses, fine wines, spirits, distilled spirits, high quality fruits or high quality fruit-based preparations.

[0073] In the second preparation form, the second food filling 4 can act as a liquid carrier or inert matrix for one or more valuable ingredients with specific properties in terms of texture, cost, quality and amount used.

[0074] In this second preparation form, the second food filling 4 in liquid state may consist of a liquid carrier in which a valuable ingredient is dispersed, selected from the group consisting of truffles, saffron threads, caviar (sturgeon, lumpfish, salmon, trout eggs), bottargo, etc.

[0075] Additionally, after the step c) of depositing the second dose D2, there is a step h) of depositing a third dose D3 of a filling 3' other than the second food filling 4 and identical to the first food filling 3 so as to completely cover the second dose D2, as shown in Figure 2E.

[0076] As shown in several figures, the step of g) plastically deforming the first dose D1 can be carried out by interacting the first dose D1 with a punch 7 whose lower end 8 has the same shape as the cavity 6 and is smaller than the planar shape size of the first dose D1.

[0077] To reduce the tendency of the punch 7 to adhere to the first doses D1 of the first food filling 3 and prevent the first doses D1 from being removed from the first sheet 2, the punch 7 can be sprayed with a convenient lubricant or non-stick liquid.

[0078] The lower end 8 of the punch 7 may also be connected to a rod 9 having a vertical axis Z and made of metal, plastic or material.

[0079] The length of the rod 9 may be a predetermined or adjustable length as required to interact with the first dose D1, and the punch 7 may be heated or rotated R about its vertical axis Z to further reduce the tendency of the punch 7 to adhere to the first dose D1.

[0080] In an alternative embodiment of the invention, the punch 7 may include a device 10 adapted to impart uniaxial or multiaxial vibrations W to the rod, as best shown in FIG.

[0081] However, it cannot be excluded that the punch 7 is equipped with a rotating device, a swinging device 10, a heating element, and a lubricating device at the same time.

[0082] In a continuous processing installation, as shown in Figures 3 and 4, the first sheet 2 and the second sheet 5 are fed substantially along a longitudinal direction L by a movable flat support F, for example a closed-loop conveyor belt N.

[0083] Preferably, the first dose D1 is deposited on the first sheet 2 at a predetermined position, and the interaction of the first dose D1 with the punch 7 occurs while the flat support F is held substantially horizontal at a constant height and while a vertical downward movement V is imparted to the punch 7 by a suitable drive device, not shown.

[0084] In an alternative embodiment, the interaction of the punch 7 with the first dose D1 may be carried out while keeping the punch 7 at a constant height and imparting an upward vertical movement to the flat support F.

[0085] Here, the punch 7 may consist of a number of weights 11 connected to the upper end 12 of the rod 9, the amount of which may be suitably adjusted depending on the required interaction with the first dose D1 of the first food filling 3.

[0086] However, it cannot be excluded that the punch 7 and the flat support F move vertically at the same time.

[0087] In a continuously processing facility, the second dose D2 of the second food filling 4 in liquid state will be deposited on top of the first dose D1 at a timing following the deposition of the first dose D1 and the formation of the cavity 6 by the punch 7.

[0088] Furthermore, a third individual single-tube nozzle U''' may be provided, aligned with the first nozzle U' and the second nozzle U'', for depositing a third dose D3 of the filling 3' on top of the second dose D2 so as to completely cover the latter.

[0089] When the doses D1, D2, and optionally the third dose D3 are deposited on the first sheet 2, the continuously processing facility folds the first sheet 2 along the longitudinal line X or stretches the second sheet 5 over the doses D1, D2, D3, thereby forming a semi-finished product 1'.

[0090] Finally, the semi-finished product 1' can be sized and cut using a shaping and cutting tool P, and the sheets 2, 5 are joined along the peripheral edge C and cut there to form a raw-filled pasta 1 that is completely liquid-tight and closed at the peripheral edge C.

[0091] From the above, it becomes clear that the method for manufacturing a raw-filled pasta according to the present invention achieves the intended purpose and is particularly highly efficient and relatively cost-effective.

[0092] Also, the method for manufacturing a raw-filled pasta and the raw-filled pasta according to the present invention can use fillings in paste state, liquid state, or gel state, and can make filled foods using precious materials.

[0093] The method and the raw-filled pasta of the present invention can be subject to many changes or modifications within the scope of the inventive concept disclosed in the appended claims.

[0094] The method of the present invention and the fresh cream pasta have been described with reference to the attached drawings. However, the reference signs mentioned in the present disclosure and the claims are used only for making the present invention easier to understand and are not intended to limit the claims in any way.

[0095] As used herein, the terms "one embodiment", "an embodiment", or "some embodiments" refer to the fact that the particular features, structures, or elements described are included in at least one embodiment of the subject matter of the present invention.

[0096] Furthermore, one or more embodiments can be provided by combining the particular features, structures, or elements in any suitable manner.

Industrial Applicability

[0097] Industrial Applicability Since the present invention can be produced on an industrial scale in the field of food processing, its application in the industry is expected.

Claims

1. A method for manufacturing a fresh-filled pasta (1), comprising: a) preparing a first sheet (2) of fresh pasta and laying it on a flat support (F); b) depositing a first dose (D1) of a first food filling (3) on the first sheet (2); c) depositing a second dose (D2) of a second food filling (4), different from the first food filling (3), on the first dose (D1) of the first food filling (3); d) preparing a second sheet (5) of fresh pasta and laying the second sheet (5) over the first sheet (2) and the first dose (D1) and the second dose (D2) of the first and second food fillings (3, 4); e) joining the first sheet (2) and the second sheet (5) along a substantially continuous peripheral edge (C) of a predetermined shape corresponding to the shape of the finished product; f) cutting the first and second sheets (2, 5) joined along the peripheral edge (C) to obtain a fresh-filled pasta (1) of the desired type; wherein: the first food filling (3) is in a paste state with shape memory properties, and the second food filling (4) is in a liquid or gel state; and between step b) of depositing the first dose (D1) and step c) of depositing the second dose (D2), step g) is provided, which comprises plastically deforming the first dose (D ​ ​ ​ ​ ​ The method according to claim 2, characterized in that the interaction is carried out while keeping the punch (7) at a constant height and giving a vertical upward movement to the substantially horizontal flat support (F).

5. The method according to claim 2, characterized in that the punch (7) is suitably lubricated or sprayed with a non-sticky liquid in order to prevent it from adhering to the first dose (D1) of the first food filling (3) and being removed from the first sheet (2).

6. The method according to claim 2, characterized in that the punch (7) is heated to reduce the tendency to adhere to the first dose (D1).

7. The method according to claim 2, characterized in that the punch (7) is rotated (R) about its vertical axis (Z) to reduce the tendency to adhere to the first dose (D1).

8. h) The method according to claim 1, characterized by including an additional step of depositing a third dose (D3) that is outside the second food filling (4) and either outside the first food filling (3) or the same filling (3') as the first food filling (1) so as to completely cover the second dose (D2).

9. The method according to claim 1, characterized in that the first dose (D1) in paste form is deposited on the first sheet (2) by extrusion.

10. The method according to claim 1, characterized in that the two doses (D2) are deposited in the cavity (6) by injection, extrusion, or gravity.

11. The method according to claim 1, characterized in that the first food filling (3) in paste form is obtained by mixing a number of materials selected from the group consisting of meat, fish, eggs, cheese, milk-derived products, sausages, vegetables, fruits and fruit-derived products, cereals, protein and fat-based substances, or combinations thereof, additionally adding seasonings, flavors and sauces.

12. The method according to claim 1, characterized in that the second food filling (4) in liquid form consists of an extract or concentrate of a liquid or gel of a food selected from the group consisting of mushrooms, truffles, herbs or spices, meat, fish, cheese, wine, spirits, distilled liquors, fruits or fruit-based preparations.

13. The method according to claim 1, characterized in that the second food filling (4) in the liquid state consists of a liquid carrier in which a component selected from the group consisting of truffles, saffron threads, caviar (shark, lamprey, salmon, masu eggs), and bottarga is dispersed.

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