Device and method for making an irregular dough product

A press assembly for forming a food product, the press assembly comprising:

• a cutting dye including a body that extends from a proximal end to a distal end, the proximal end having an irregular shape and a sharp edge configured to cut the food product into the irregular shape, the body having an interior surface surrounding an interior space;
• and
• a pressure plate arranged within the interior space, the pressure plate including a pressing surface including a first zone and a second zone surrounding and extending from the first zone at a taper angle such that an outer end of the second zone is recessed from an inner end adjacent the first zone,
• wherein the cutting dye and the pressure plate cooperate to press and cut the food product.

A method of making a sheet dough comprising:

• formulating the bread-type dough;
• fermenting the bread-type dough;
• forming the bread-type dough into sheet form;
• proofing the bread-type dough;
• applying random embossings to the bread-type dough using a knuckle docking device, the knuckle docking device configured and arranged with various lengths and diameters;
• cutting the bread-type dough to form an irregular shaped edge using a cutting dye, the cutting dye having an irregular peripheral cutting pattern to impart irregularity to the bread-type dough;
• pressing the bread-type dough using a pressure plate having an identical irregular peripheral cutting pattern as the cutting dye, the pressure plate having a first zone and a second zone to create a dough having a thin center that gradually thickens toward edge of the bread-type dough;
• and
• par baking the bread-type dough to set the structure.

A dough-based food product comprising:

• a crust having an irregular shape and texture, the crust defining a center portion and an edge portion surrounding the center portion, a top side, and a bottom side, wherein the crust comprises a dough matrix and a plurality of air pockets dispersed throughout the dough matrix,
• wherein the center portion of the crust comprises a plurality of indentations,
• wherein the air pockets and the indentations are randomly dispersed throughout the crust resulting in a variable thickness of the center portion of the crust, the thickness having a standard deviation of between about 10-40%, and
• wherein the food product is manufactured using an automated system.