Frozen pizzas have always been ideal for a quick, savory product, and their popularity has kept on growing for decades. And while the final consumer might not be able to tell it, the technology that goes into creating that perfect slice is highly complex. For each and every topping, manufacturers need to use precise cutting machines, so companies that bring these machines to the market need to be at the forefront of innovation.
From Urschel’s perspective, the frozen food market, including pizza, continues to be one of the fastest growing market sectors in food processing. Advances in freezing methods intersect with consumer trends. Consumers are seeking healthier, convenient options. These trends include increased choices of vegetables and plant-based proteins. Traditional toppings remain popular while niche pizza toppings and styles of crusts are ever expanding. Research and development teams continue to build on new flavors and toppings.
According to Urschel, Brussel sprouts, beets, arugula, spinach, zucchini, and yellow squash are just a few on-trend toppings. Cauliflower crusts are also at the forefront. Alternative textured plant proteins take center stage and appear on pizzas as shreds, crumbles, or dices in place of traditional meat selections. The category of cheese toppings is ever growing including goat cheese, feta, and non-dairy, plant-based options. Challenges in cutting are relative to the input and desired output of the ingredient which are also dependent on the characteristics of the ingredient itself, Urschel examines factors such as compressibility, denseness, percentage of fat, hardness, acidity, etc. Certain products may require temperature adjustments.
The right cut
“Every ingredient cut on an Urschel dicer or slicer that goes into a pizza should impact the precise size and shape to deliver maximum profitability and to deter and wasted product,” according to Mike Jacko, vice president of Applications & Product Development at Urschel. “The size and shape of each topping component is an important consideration. This will determine the visual appeal, coverage, taste, and texture which are key in SKU success. A processor must then identify the proper cutting machinery to deliver just the right cut for each ingredient. A cut should be identified for each ingredient that will also result in the highest usable product from a profit standpoint.”
Urschel technology delivers precision and expertise to pizza manufacturers. With the extensive ability to effectively cut a gamut of shapes to provide precision cuts within the targeted specifications. Many ingredients go into creating different styles of frozen pizza and ingredients vary depending on product characteristics. For toppings, fruits and vegetables rely on gentle cutting methods, whereas alternative proteins require more aggressive cutting methods. In addition, reduction of ingredients for sauces and crusts down to micro-dimensions is necessary to produce the ideal frozen pizza. “As a powerhouse developer of cutting solutions, Urschel identifies the proper machine to pair with the desired outcome. With slicers, dicers, milling equipment, and all types of cuts, Urschel offers boundless reduction opportunities to frozen pizza processors. This may translate into a new beet sauce or cauliflower flour crust. Urschel size reduction equipment paves the way for processing capabilities,” Mike Jacko goes on to say.
“Urschel partners with customers to optimize their productivity. Test lab technicians identify new cuts that bring true benefits to the processors that work with Urschel. From half-moon zucchini slices to bow-tie beet cuts, unique looks abound to help processors standout in the competitive frozen pizza industry.”
Identifying the right solution
There are very few machines and food manufacturers out there that can truly cut items when fully frozen. Urschel customers cut products in a fresh, cooked, or frozen-tempered state. Decreasing temperature tends to stiffen or create a frozen crust on a chicken breast, harden a strawberry or soft cheese, so that slicer/dicer with sharp knives can cut without damaging the knives or other parts. The products may then get fully frozen. Tempering requires the customer to have good systems for controlled freezing, warming-up slowly to specific temperatures maybe as accurate as +/- 1° C on some products.
Urschel identifies machine set-up depending on the types of components available for the machine. Specific to cutting, some machines operate using a 3-dimensional cut incorporating different styles of spindles, feeding discs, and a slicing knife area. Depending on the targeted style of cut, not all the 3 designated cutting stations may be equipped with knives. After determining the cutting station set-up, concentrating on the knives at each related station is another important step. Knife edges and types should be paired with specific products to deliver optimum results. Details matter in the set-up of the machine. Power and gearing options also need to be clearly defined. Some products require more power or higher gearing than others.
To read the entire article, please access your complimentary e-copy of Frozen Food Europe May-June, 2024 issue here.