Abstract: A composition and method for providing a strong dough having a substantial quantity of fresh potatoes. Fresh potatoes are made into a mash and centrifuged to reduce the water content to about 70% by weight. Such potato mash can comprise over 50% by weight of the final dough. This dough can be used to make sheeted or extruded products. Such dough results in improved, more naturally-flavored products compared to products made entirely from dehydrated or partially-dehydrated potato derivatives. The method comprises finely slicing potatoes to form a potato slurry or mash; decanting excess water from the potato slurry; heating the potato slurry to a temperature no greater than about 190 degrees Fahrenheit; cooling the slurry to under 140 degrees Fahrenheit; and imparting a low amount of work input to a mixture of the slurry and other ingredients to form a shapeable dough.

Abstract: An improved dough-rolling apparatus and method for rolling sheeted dough. The proposed invention comprises a dough-rolling apparatus having a dough sheeter that cuts a dough sheet into preforms having a concave leading edge and convex trailing edge. A rolling curtain creates a rolled preform with the leading edge on the inside and the trailing edge on the outside. The rolled preform is cooked to produce a rolled snack product with consistent thickness throughout its length and a round outer flap.

Abstract: An extruder die designed to produce a spiral corn-based snack food product with consistent, tight spiral pitch and the resultant food product. The extruder die has a center post parallel to the flow path along with three cone-shaped receiving ports arranged in a cloverleaf pattern around the center post. The die has three curved slots on the output side of the die which are in fluid communication with the cone-shaped receiving ports. At the distal end of each of these slots is a semi-circular tip. The tip has a diameter larger than the width of its associated slot. Further, the tip is located at the apex of a cone-shaped receiving port with which it is in fluid communication, thus providing for the highest flow velocity of the extrudate through the tip. The resultant flow profile produces the consistent spiral shape of the snack product produced by the die design described.

Abstract: An improved package for heating dry food products is provided. The present invention allows a dry food product to be heated in a microwave oven. The package has barrier properties and at least a portion of an outer surface that is water absorbent, so that the food package may be wetted prior to being heated in the microwave in order to prevent burning of the food products inside.

Abstract: A partially metallized packaging film and method of making is disclosed. In one aspect, at least one portion of a vaporized metal stream is shielded from contacting a sheet of packaging film during the metallization process. The shield is a rigid plate and can be shaped to provide a sharp transition from transparent film to opaque film, or it can provide a gradual transition from transparent film to opaque film. The partially metallized packaging film can be used with a form, fill and seal machine or other packaging machine to create a food package with a product viewing window. In one aspect, the barrier web comprises a bio-based film.

Abstract: A method for compacting a slug of product and apparatus for accomplishing the same. The invention describes collecting weighed product in an intermediate settling device to form a compact slug of product. The device can comprise a single settling chamber or can comprise multiple settling chambers which are axially rotatable. The slug can be compacted by jostling and/or vibrating the settling device. Thereafter, the product is discharged to a packaging apparatus. Because the product in the final package is denser, a smaller package can be utilized reducing manufacturing and shipping costs.

Abstract: The present invention discloses a washer for washing produce such as potatoes. In one aspect, a debris removal section removes debris, such as rocks, and a sloped serpentine flume is used to gravity feed the produce through a serpentine flow path to remove the surface dirt and loosen any embedded dirt. The produce can be optionally routed to a spray washer to remove embedded dirt.

Abstract: A method and apparatus for sealing films. In one embodiment the sealing device comprises a horn and an anvil. The film has a standard portion and an increased portion. Increased energy is applied to the film in the increased portion compared to the energy applied to the standard portion. Such a method allows for sealing of varying number of layers.

Abstract: A method and apparatus for sealing films. In one embodiment the sealing device comprises a horn and an anvil. The film has a standard portion and an increased portion. Increased energy is applied to the film in the increased portion compared to the energy applied to the standard portion. Such a method allows for sealing of varying number of layers.

Abstract: A continuous process and the accompanying equipment for making a chip product, such as pita chips. The process involves cutting sheeted dough into continuous longitudinal strips, and cooking them to form hollow tubes. In some embodiments, these tubes are split longitudinally. Also disclosed is a vacuum-assisted splitter. These bread tubes or strips are cured in an accelerated process. The bread tube is trimmed into chip-sized pieces. In one embodiment, the pita bread strips are cut into chip-sized pieces using a continuous, low-pressure water jet cutting system. The resulting chip-sized pieces are nearly uniform in size, shape, and texture.

Abstract: A method for compacting a slug of product and apparatus for accomplishing the same. The invention describes collecting weighed product in an intermediate settling device to form a compact slug of product. The device can comprise a single settling chamber or can comprise multiple settling chambers which are axially rotatable. The slug can be compacted by jostling and/or vibrating the settling device. Thereafter, the product is discharged to a packaging apparatus. Because the product in the final package is denser, a smaller package can be utilized reducing manufacturing and shipping costs.

Abstract: A composition and method for providing a strong dough having a substantial quantity of fresh potatoes. Fresh potatoes are made into a mash and centrifuged to reduce the water content to about 70% by weight. Such potato mash can comprise over 50% by weight of the final dough. This dough can be used to make sheeted or extruded products. Such dough results in improved, more naturally-flavored products compared to products made entirely from dehydrated or partially-dehydrated potato derivatives. The method comprises finely slicing potatoes to form a potato slurry or mash; decanting excess water from the potato slurry; heating the potato slurry to a temperature no greater than about 190 degrees Fahrenheit; cooling the slurry to under 140 degrees Fahrenheit; and imparting a low amount of work input to a mixture of the slurry and other ingredients to form a shapeable dough.

Abstract: Apparatuses for cutting food product are provided having a cutting head. The cutting head includes one or more knife assemblies. Each knife assembly includes a knife extending toward the food product and is adapter to secure the knife to the cutting head. The knife has a corrugated shape to produce a food product slice with generally parallel cuts wherein the food product slice has a periodic shape and a large-amplitude cross-section.

Abstract: Disclosed is an improved process and system for producing low oil fried food products. The process discloses frying food products at atmospheric pressure, and deoiling the fried food products using a centrifuge under vacuum pressure.

Abstract: The present invention overcomes many of the shortcomings inherent in previous containers for packaging potato chips and/or crisps, corn based chips and/or crisps, cookies and the like. The improved implosion-resistant container of the present invention utilizes flowing geometries mechanisms which allow a hermetically sealed container to smoothly change its geometric shape thereby adjusting its internal volume in response to changes in environmental conditions. These volumetric adjustments compensate for changes in environmental conditions thereby avoiding the random buckling and deformation inherent in current packaging techniques which detracts from the commercial presentation of the container. The improved container of the present invention may also include a variety of other stress dissipating mechanisms that counteract the forces causing thermo-plastic container deformation, implosion and loss of seal integrity.

Abstract: The present invention discloses a flat bottom pillow pouch that can stand upright on its bottom transverse seal. The flat bottom pillow bag can be made from the same film as a standard pillow pouch and requires less film than prior art stand up packages. The flat bottom pillow pouch disclosed herein has no gussets.

Abstract: A multi-layer bio-based composite film with a bio-based heat seal layer. The compostable bio-based film can comprise a crystalline bio-based heat seal layer and an amorphous bio-based barrier web layer. The heat seal layer has a second heat melting temperature which is lower than its first heat melting temperature.

Abstract: A continuous oil fryer used to fry food slices, such as potato chips, having an internal oil stripping capability. The fryer accumulates the steam produced by the frying process in a hood and utilizes such steam, after superheating the steam by passing it through a heat exchanger, to strip oil from product immediately upon removal from the hot oil bath by passing the superheated steam through a product bed while on an output conveyor. The superheated steam removes oil from the product on the output conveyor without increasing the moisture level of the product. The fryer therefore accomplishes the same function as a low-oil stripper without increasing the footprint of the frying unit and with less energy.

Abstract: A method for compacting a slug of product and apparatus for accomplishing the same. The invention describes collecting weighed product in an intermediate settling device to form a compact slug of product. The device can comprise a single settling chamber or can comprise multiple settling chambers which are axially rotatable. The slug can be compacted by jostling and/or vibrating the settling device. Thereafter, the product is discharged to a packaging apparatus. Because the product in the final package is denser, a smaller package can be utilized reducing manufacturing and shipping costs.

Abstract: An expandable starch-based component is extruded through a random extruder together with a colored component having a color unlike that of said starch-based component. The starch-based component may include cereal grains such as rice or corn meal or components derived therefrom. The colored component may include colored starches such as blue corn meal; seeds; and/or micropellets made from fine particle ingredients. When combined, the components form a color-comprising mixture that can be extruded into colored or colorful collets. The color-comprising mixture comprises between about 2% to about 10% colored component. The produced bi-colored collets may then be cooked, optionally seasoned and packaged for consumption.