Abstract: An improved low shear extrusion and dehydrating apparatus (10) and method is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is at least about 2, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: An improved low shear extrusion and dehydrating apparatus (10) and method is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is at least about 2, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: A continuous mixer (32) is disclosed which can be used for mixing of incoming product streams (22, 24) of different characteristics respectively to yield a final product stream (26) of predetermined, consistent characteristics. The mixer (32) includes an elongated housing (42) having a pair of product input ports (50, 52) and an output (64), with a pair of elongated, axially rotatable, mixing screws (44, 46) located within the housing (42). The screws (44, 46) include a series of outwardly projecting mixing elements (114) preferably of pyramidal design and arrayed in a helical pattern along the length of the screws (44,46). The mixer (32) may be used in a processing system (20,200) having individual product lines (28, 30, 204, 206) coupled to the mixer (32), and is especially useful for processing of incoming meat streams (22,24) of different fat/lean ratios, to give a final comminuted output stream (26) of an intermediate and essentially constant fat/lean ratio.

Abstract: A continuous mixer (32) is disclosed which can be used for mixing of incoming product streams (22, 24) of different characteristics respectively to yield a final product stream (26) of predetermined, consistent characteristics. The mixer (32) includes an elongated housing (42) having a pair of product input ports (50,52) and an output (64), with a pair of elongated, axially rotatable, mixing screws (44,46) located within the housing (42). The screws (44, 46) include a series of outwardly projecting mixing elements (114) preferably of pyramidal design and arrayed in a helical pattern along the length ofthe screws (44,46). The mixer (32) may be used in a processing system (10) having individual product lines (28, 30) coupled to the mixer (32), and is especially useful for processing of incoming meat streams (22,24) of different fat/lean ratios, to give a final comminuted output stream (26) of an intermediate and essentially constant fat/lean ratio.

Abstract: Combined extrusion/sonolation apparatus (10) which is designed to continuously and efficiently incorporate components (e.g., liquid lipids or fats or meltable solids) into heterogeneous materials in order to form stable products. The apparatus (10) includes an extruder (12) having a barrel (27) and restricted orifice outlet (38); a sonolation device (14) is directly coupled to the outlet (38). Preferably a monitoring unit (50) is located downstream of the sonolation device (14) and is connected via a controller (18) with the extruder (12) and device (14) so as to control the operation of the latter. In use, starting materials are fed into the extruder (12) and are initially mixed, whereupon a component is injected through a barrel-mounted injector pipe (41). The composite extrudate is treated within device (14) by subjecting it to acoustic vibrations.

Abstract: An improved low shear extrusion and dehydrating apparatus (10) and method is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is at least about 2, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: An improved low shear extrusion and dehydrating apparatus (10) and method is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is at least about 2, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: Combined extrusion/sonolation apparatus (10) which is designed to continuously and efficiently incorporate components (e.g., liquid lipids or fats or meltable solids) into heterogeneous materials in order to form stable products. The apparatus (10) includes an extruder (12) having a barrel (27) and restricted orifice outlet (38); a sonolation device (14) is directly coupled to the outlet (38). Preferably a monitoring unit (50) is located downstream of the sonolation device (14) and is connected via a controller (18) with the extruder (12) and device (14) so as to control the operation of the latter. In use, starting materials are fed into the extruder (12) and are initially mixed, whereupon a component is injected through a barrel-mounted injector pipe (41). The composite extrudate is treated within device (14) by subjecting it to acoustic vibrations.

Abstract: An improved low shear extrusion and dehydrating apparatus (10) and method is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is at least about 2, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: An improved low shear extrusion and dehydrating apparatus (10) is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is from about 3-20, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: An improved extrusion processing system (10) for sticky extrudates such as candy products is provided which includes an extruder (12) equipped with a die (16) presenting an outlet face (23) and a knife assembly (19) and a knife hood (18). The system (10) further has a particulate delivery unit (20) which serves to direct a stream of particulate substance under positive pressure onto the outlet face (23) of extrusion die (16). The delivery unit (20) includes a container (42) for holding a supply of a particulate substance such as starch or sugar together with conduits (52, 56) adapted for coupling with a source of pressurized air and connected with container (42); a stream of the particulate substance under pressure is created and delivered via conduit (56) to hood (18) where it passes through delivery tube (60) for application onto outlet face (23).

Abstract: Highly palatable, shelf-stable, moist, pasta-type extruded food products are provided which can be formulated as a human food (e.g., a confection) or as a pet food. The extruded products of the invention include a substantially completely gelatinized matrix including therein from about 35-70% by weight starch, dry basis, together with quantities of protein and sugar. The extruded products should have a moisture content of from about 15-30% by weight, and a water activity of from about 0.6-0.9. The products are made by forming a mixture of ingredients followed by preconditioning, extrusion and drying and/or cooling to achieve the final desired moisture.

Abstract: A high protein, shelf-stable, meat-containing snack product is provided which is in the form of a cellular, expanded extrudate which can be dried and flavored to yield nutritional snacks having excellent organoleptic properties. The final snack contains at least about 5% by weight meat (most preferably mechanically deboned poultry meat), and at least about 50% by weight wheat. The invention also comprehends a fabrication method wherein an initial mixture containing at least about 15% by weight meat and at least about 50% by weight wheat flour are mixed and passed through an extruder under time and temperature conditions to yield an expanded, cellular extrudate having the general appearance of a bread stick.

Abstract: A crisp, palatable, reduced calorie whole grain snack food is produced by subjecting initially tempering whole grains such as wheat, barley, corn, oats, rice and sorghum to a micronizing process wherein the whole grain(s) are partially precooked through application of near infrared radiation. Thereafter, the micronized grain is mixed with water and other optional ingredients and preconditioned with agitation and steam/water addition. After preconditioning, the mixture is directed to a twin screw extruder in order to form an extrudate of desired shape and size. The extrudate is then heat treated to crisp the outer surface thereof, typically through the use of oven heating and/or frying. The resultant snack product preferably has a whole grain content of at least about 50% by weight and a low total fat content on the order of about 20% by weight or less.

Abstract: An improved, low cost, energy efficient extrusion device and method for processing of cellulose, hemicellulose, and like fiber-bearing materials is described which includes a pretreatment extrusion zone and a reaction extrusion zone separated by a pressure sensitive variable die. The method hereof includes the steps of extruding cellulosic material through the pretreatment zone at an elevated pressure and temperature, passing the material into the reaction zone where it is mixed with an acid and is processed at a lower pressure and temperature than in the pretreatment zone, and extruding the material through a final extrusion die. The surging and blowing usually experienced with extrusion of fibrous material is drastically reduced by the unique construction of the extruder die members. The cellulosic material may be hydrolyzed to simple sugars in accordance with the method and apparatus hereof with a minimum of acid degradation of the extrusion equipment.

Abstract: Quick cooking pasta products are extruded in a low temperature process by advancing a partially pre-cooked mixture of pasta flour and water prepared in a preconditioner along the length of a screw extruder through a cooking zone, then through a venting zone and a forming zone, and finally through an extrusion die to yield an extruded product. The mixture has a maximum temperature of 215.degree. F. in the cooking zone in order to substantially eliminate the formation of darkened specks in the final extruded product which would otherwise represent portions of the mixture that are burned during cooking. Limiting the mixaimum temperature of the mixture in the extruder also greatly enhances the extruded pasta quality by increasing product resistance to overcooking and improving the retention characteristics of the original product integrity.

Abstract: A texturized sinking shrimp and fish food is produced in the form of an extrusion cooked, cellular produce which is self-sustaining in ambient temperature water for a period of at least four hours and is made up of a mixture of at least 8 percent marine meal with up to 60% vegetable protein flour. The product is prepared by mixing and then partially cooking the starting materials in a preconditioner and then introducing the precooked mixture into an extruder (preferably of the twin screw variety) for texturization. During extrusion, the protein within the mixture is developed into laminar striations, which ultimately yields a layered, open-celled, high protein product having a specific gravity greater than 1.00 which will not readily decompose in water during consumption by the shrimp and fish.

Abstract: An extruder for processing wood particles, shavings or sawdust is particularly useful for the production of a refined product exhibiting a large number of separated, individual fibers each of a relatively long length as is desirable in the production of a fiber core for a composite particle board. The extrusion apparatus comprises an elongated barrel and a flighted screw rotatable within the barrel, with the final downstream section of the screw being of a configuration to sequentially present three processing zones each having a compression region, a restricted region and a decompression region. The three processing zones of the final screw section cooperate with a compression region and restricted region formed in the final head section to choke the advancement of wood materials through the extruder sufficiently to enable satisfactory processing of the same without the use of a final die or restricted orifice disposed on the outlet of the extruder barrel.

Abstract: Quick cooking rice products are manufactured in a low mechanical shear extrusion process by first pre-cooking a rice and water mixture in a preconditioner and then advancing the mixture along the length of an extruder sequentially presenting a cooking zone, a venting zone, a forming zone, and finally an extrusion die to yield an extruded product. Venting of gaseous products removes a significant amount of moisture from the mixture during the time that the latter passes between the cooking zone and the forming zone, and consequently the moisture content of the mixture within the cooking zone can be increased in order to reduce the total mechanical shear imposed on the mixture during the cooking process. The extruded product, once dried, closely resembles rice grain and readily rehydrates without exhibiting slimy or sticky characteristics, and has an increased tolerance to overcooking.

Abstract: Quick cooking pasta products are extruded in a low temperature process by advancing a partially pre-cooked mixture of pasta flour and water prepared in a preconditioner along the length of a screw extruder through a cooking zone, then through a venting zone and a forming zone, and finally through an extrusion die to yield an extruded product. The mixture has a maximum temperature of 215.degree. F. in the cooking zone in order to substantially eliminate the formation of darkened specks in the final extruded product which would otherwise represent portions of the mixture that are burned during cooking. Limiting the maximum temperature of the mixture in the extruder also greatly enhances the extruded pasta quality by increasing product resistance to overcooking and improving the retention characteristics of the original product integrity.