Abstract: An extended hold potato product comprising cut potatoes having a starch-based coating, the coating including corn starch, corn flour, and low solubility dextrin. In a preferred embodiment, the starch-based coating further includes rice flour, sodium chloride, and sodium acid pyrophosphate. After finish preparation, the potato product retains a generally crisp outer surface texture for an extended period of time. A process for preparing a potato product having an extended hold time comprises (a) washing, cutting, and blanching raw potatoes, (b) partially drying surfaces of the potatoes, (c) applying an aqueous starch-based slurry to the potatoes, the aqueous slurry including corn flour, corn starch, low solubility dextrin, and water, and then (d) parfrying and freezing the coated potatoes.

Abstract: An extended hold potato product comprising cut potatoes having a starch-based coating, the coating including corn starch, corn flour, and low solubility dextrin. In a preferred embodiment, the starch-based coating further includes rice flour, sodium chloride, and sodium acid pyrophosphate. After finish preparation, the potato product retains a generally crisp outer surface texture for an extended period of time. A process for preparing a potato product having an extended hold time comprises (a) washing, cutting, and blanching raw potatoes, (b) partially drying surfaces of the potatoes, (c) applying an aqueous starch-based slurry to the potatoes, the aqueous slurry including corn flour, corn starch, low solubility dextrin, and water, and then (d) parfrying and freezing the coated potatoes.

Abstract: A method for testing the ingredients of fabricated snack products includes the steps of; producing snack product test pieces using a test ingredient; evaluating certain characteristics of the test pieces; and then using this information to predict the characteristics of a fabricated snack product containing the test ingredient. Initially, a dough containing the test ingredient is mixed under controlled conditions. A quantity of the dough is extruded using an extrusion apparatus adapted to extrude the dough at a uniform rate regardless of the dough's consistency. The extruded dough is then cut into dough pieces having a uniform length, wall thickness and density. Next, the dough pieces are cooked at a predetermined temperature for a predetermined time to form the snack product test pieces. Characteristics of the test pieces are determined and analyzed as a predictor of similar characteristics in a fabricated snack product containing the test ingredient.

Abstract: A process for dehydrating food products particularly suited to the dehydration of potatoes for use in the preparation of hashbrown potatoes, and the product of said process. In accordance with the process of the invention, a food product is prepared into separate pieces for drying. The separate pieces are then coated with a dry mixture which includes a separation particulate which maintains separation between adjacent pieces such that the pieces may be more efficiently and effectively hot air dried. The dry mixture may also include ingredients which react with moisture on the food product surface to form the adhesive surface for adhering the dry mixture to the food product. For the preparation of hashbrown potatoes, the dry mixture may include spices, browning ingredients, and patty-binding ingredients. For the preparation of casserole potato dishes, the dry mixture may include spices, dehydrated vegetables and cheeses, and a thickening agent.

Abstract: A dough-processing system for dividing a dough sheet into multiple separate portions and transporting each portion in a predetermined direction. A rotary cutter, having a multiplicity of cutting dies affixed thereon, divides the dough sheet. The cutting dies have an exterior peripheral cutting edge for cutting the linear dough sheet into two or more linear portions for further processing on standard conveyor systems and an interior peripheral cutting edge for cutting an interior portion from the snack-piece dough. The rotary cutter includes an internal helical auger rigidly affixed to an external cylindrical mandrill having first and second ends and having a multiplicity of cutting dies affixed thereon. The rotary cutter has an ever-increasing diameter funnel path for transporting the interior cut portion of the snack-piece dough into the interior of the rotary cutter and thereupon the helical auger transports it out to the side of the rotary cutter.

Abstract: A process for forming a snack product and a snack formed therefrom with discontinuous characteristics. The process includes forming a first highly cohesive dough and a second less cohesive dough matrix, combining the first and second discrete dough components into a composite dough sheet, cutting the dough sheet into a multiplicity of dough preforms, and frying the preforms to produce a snack with discontinuous characteristics.

Abstract: A dough-processing system for dividing a dough sheet into multiple separate portions and transporting each portion in a predetermined direction. A rotary cutter, having a multiplicity of cutting dies affixed thereon, divides the dough sheet. The cutting dies have an exterior peripheral cutting edge for cutting the linear dough sheet into two or more linear portions for further processing on standard conveyor systems and an interior peripheral cutting edge for cutting an interior portion from the snack-piece dough. The rotary cutter includes an internal helical auger rigidly affixed to an external cylindrical mandrill having first and second ends and having a multiplicity of cutting dies affixed thereon. The rotary cutter has an ever-increasing diameter funnel path for transporting the interior cut portion of the snack-piece dough into the interior of the rotary cutter and thereupon the helical auger transports it out to the side of the rotary cutter.

Abstract: A process for producing expanded corn snack products. The products are preferably made in a fluted ring shape, and have an expanded, airy texture. The process for producing the products includes successive cutting steps wherein the corn is comminuted to a relatively narrow particle size distribution with most of the corn retained on a #40 or #60 mesh screen. The corn is comminuted by impelling whole cooked corn kernels against a blade and through a screen having a ratio of open area screen material of from about 1:1 to about 3:1.

Abstract: A process for producing expanded corn snack products. The products are preferably made in a fluted ring shape, and have an expanded, airy texture. The process for producing the products includes successive cutting steps wherein the corn is comminuted to a relatively narrow particle size distribution with most of the corn retained on a #40 or #60 mesh screen. The corn is comminuted by impelling whole cooked corn kernels against a blade and through a screen having a ratio of open area:screen material of from about 1:1 to about 3:1.

Abstract: A process for dehydrating food products particularly suited to the dehydration of potatoes for use in the preparation of hashbrown potatoes. In accordance with the process of the invention, a food product, e.g. a potato is prepared into separate pieces for drying. The separate pieces are then coated with a dry mixture which includes a separation particulate which maintains separation between adjacent pieces such that the pieces may be more efficiently and effectively hot air dried. The dry mixture also includes ingredients which react with moisture on the food product surface to form an adhesive surface for adhering the dry mixture to the food product. For the preparation of hashbrown potatoes, the dry mixture may include spices, browning ingredients, and patty-binding ingredients. For the preparation of casserole potato dishes, the dry mixture may include spices, dehydrated vegetables and cheeses, and a thickening agent.

Abstract: The invention comprises a dough preform which when fried, produces a snack chip product having a predetermined level of surface bubbling. The dough preform has outer dough portions having substantially less moisture than inner dough portion. The dough preform is made by a process that includes sheeting a dough having from about 30% to about 55% moisture, removing a portion of the moisture from the dough sheet, at a greater rate from the outer dough portions than from the inner dough portion and then frying the partially dried dough prior to any significant equilibration of moisture between the outer and inner dough portions. The moisture can be removed from the dough sheet or preform by heat, air movement or a combination of the two.

Abstract: Corrugated snack food pieces are fabricated from a dough directed through a pair of mated corrugated sheeting rolls. The dough is impressed with the corrugated pattern of the sheeting rolls and subsequently cut into individual snack food pieces. The dough is fed directly into the sheeting rolls so that no prior memory is imparted to the dough sheet prior to receiving its corrugated shape. The corrugated sheeting rolls may be scored transverse to the corrugations to provide transverse webs of dough between adjacent corrugations.

Abstract: The invention comprises a dough preform which when fried, produces a snack chip product having a predetermined level of surface bubbling. The dough preform has outer dough portions having substantially less moisture than inner dough portion. The dough preform is made by a process that includes sheeting a dough having from about 30% to about 55% moisture, removing a portion of the moisture from the dough sheet, at a greater rate from the outer dough portions than from the inner dough portion and then frying the partially dried dough prior to any significant equilibration of moisture between the outer and inner dough portions. The moisture can be removed from the dough sheet or preform by heat, air movement or a combination of the two.

Abstract: A method for producing fried snack products of controlled shape comprises introducing dough pieces into a shallow depth of frying oil and allowing the dough pieces to travel unsupported through the oil while frying to a set shape. The shallow depth of the oil prevents the pieces from overturning in the oil while frying, so they form a controlled shape. In one embodiment, a two-layer sheeted dough is formed from dissimilar potato-based dough layers adhered and cut into layered dough pieces introduced into the shallow oil depth. The first layer is on the bottom and the second layer is at the top of each dough piece. The layered dough pieces maintain their original orientation in the shallow oil depth as they fry to form a fried potato skin product having a convexly curved upper layer and a concavely curved bottom layer. The dough pieces are partially fried in the shallow oil depth to set the curved shape, after which the partially fried pieces are finish-fried in a greater depth of frying oil.

Abstract: A potato patty is made from cooked or blanched shredded potatoes and a natural potato binder. The binder is made from cooked or blanched potatoes in which the gelatinized starch naturally present in the potatoes is extensively retrograded either by holding the potatoes at a temperature of about 50.degree. F. for at least about 16 hours, or at lower temperatures for proportionately shorter holding times, or by freezing the potatoes. The potatoes used in preparing the binder are subdivided, preferably comminuted to a fine particle size either before or after the starch is retrograded. Between about 10 to about 50 parts of binder are mixed with about 100 parts of the potato shreds, by weight, and a potato patty is formed from the mixture, preferably in a high-speed commercial former.