Abstract: A method of producing extrudates such as high protein, high fat sinking aquatic feeds is provided wherein a high protein starting material is initially preconditioned and passed through an extruder; in the extruder barrel a zone of reduced pressure is created upstream of the die for densifying the final extrudate. Fat may be added to the starting mixture at any desired point in the process, and/or may be added as a surface coating to the final extrudate. Preferably, the method further involves measuring a density value of the extrudate such as bulk density, and adjusting the magnitude of the reduced pressure conditions in the barrel in response to such measurement.

Abstract: A pellet conditioning device (10) for the cooling and/or drying of preformed discrete pellets (148) is provided which includes an upright pellet-receiving bin (12) with a dual grate assembly (18) therein. The assembly (18) includes a stationary first grate comprising a plurality of upright, apertured grate wall members (86), and a shiftable second grate including a plurality of elongated, obliquely oriented plates (106) located between and in spanning relationship to adjacent pairs of the wall members (86). Shifting structure (20) is provided for selective and sequential translational, rectilinear shifting movement of the lower margins (110) of the plates (106) so as to successively open and close a pellet passageway (117) adjacent each lower margin (110). A duct and fan arrangement (38) is also provided with the bin (12) so as to draw cooling air currents through the grate assembly (18) and pellets (148) therein.

Abstract: An extrusion die apparatus adapted for coupling to the outlet end of an extruder barrel and corresponding methods of use are described. The die apparatus, when so coupled to the extruder barrel, has 1) an inlet-end chamber downstream of and in communication with the interior of the extruder barrel, 2) a secondary chamber downstream of and in communication with the inlet-end chamber, and 3) a plurality of individual, spaced die-outlet orifices downstream of and in communication with the secondary chamber. The die apparatus includes manually or automatically controllable inserts for controlling the operating pressures within the chambers and outlet orifices. These operating pressures are adjusted so that the pressure within the inlet-end chamber, which controls cooking, is greater than the pressure within the secondary chamber, and the pressure within the secondary chamber is greater than the pressure within each outlet orifice. In operation, the die apparatus receives product from the extruder barrel.

Abstract: Improved short length extrusion cooking devices (10) are provided which can achieve product throughput and quality characteristics of conventional long-barrel extruders. The short length extruders (10) of the invention include a relatively short barrel (14) having an inlet (18) and an endmost extrusion die (20). An elongated, helically flighted axially, rotatable screw assembly (22) is positioned within the barrel (14) and is coupled to motive means (39, 39a) for rotation of the assembly (22) at a speed of at least about 500 rpm. The device (10) includes an internal, apertured flow-restricting device (60, 110) which defines a mid-barrel choke point for the material being processed. Preferably, the barrel (14) has an internal bore of generally frustoconical configuration with an effective length to maximum diameter ratio (L/D) of at least about 6.

Abstract: Improved sea urchin feeds are provided which are very efficiently utilized by sea urchins and significantly increase gonadal development. The feeds are semi-moist, stable, extruded solid pellets or bodies which sink in sea water and have protein and carbohydrate fractions as well as a moisture content of from about 12-40% by weight. The feed bodies have an as manufactured water activity of up to about 0.8, are storable at ambient temperature for a period of at least two months, and are self-sustaining in sea water for a period of at least about 24 hours. Preferred feeds include kelp, fish oil and humectant.

Abstract: A short-time low-pollution method for preparing masa flour is provided wherein whole grain is first partially cooked in a hot alkaline treating solution to achieve at least about 15% gelatinization and loosening of the bran fraction of the grain. The partially cooked grain is then debranned and is subjected to a flash dehydration for quickly subdividing and reducing the moisture content of the grain. The dehydrated grain is then milled to create an acceptable masa flour.

Abstract: An improved extrusion conditioning apparatus (10) includes an extrusion and cooker (12) and a closed loop pneumatic conditioning system (14) operatively coupled with the cooker (12). The closed loop system (14) includes a hood (16) disposed about the extruder outlet, together with first and second conduits (20, 22) operatively coupled with the hood and a cyclone separator (18); and a fan (24) and a heater (26) are operatively interposed within the conduit (22). In use, extrudate from extruder (12) is picked up by positive pressure air currents created by the fan (24), and such product is then conveyed to the separator (18) for separation thereof. The separated air then returns to the hood (16) via the conduit (22), and is heated during such return passage. Use of a largely positive pressure, heated air conveying system (14) minimizes product contamination by airborne microorganisms, while at least partially sterilizing the product prior to drying thereof.

Abstract: An extrusion process for the production of animal feeds having high soluble protein contents is provided wherein respective starch-bearing and proteinaceous ingredient fractions are differentially processed so as to obtain an extruded final product containing soluble protein. In the process, a starch-bearing fraction is preferably preconditioned and introduced into an extruder; a proteinaceous fraction is introduced into the extruder barrel, preferably adjacent the extrusion die, for mixture and extrusion with the starch-bearing fraction. This yields an extruded feed having a starchy matrix with protein of high solubility carried by the matrix.

Abstract: An improved fried snack product is provided which is fabricated by a two step process including initial extrusion followed by frying, preferably in a wet condition wherein the extrudate has a moisture content of from about 16-40% by weight. The starting mixture fed to the extruder preferably includes an amount of low protein flour (e.g., cake flour) in order to increase the expansion of the product upon frying. Fried snacks in accordance with the invention exhibit a smooth, even appearance, and have excellent organoleptic properties. Extrusion is advantageously carried out using an initial preconditioner and a co-rotating twin screw extruder equipped with a venting apparatus along the length thereof.

Abstract: An improved extrusion process is provided for the production of freezeable breadings which can be applied to frozen food products and which essentially eliminates the problem of "frosty tips", i.e., the tendency of prior extruded breadings to exhibit an unappealing whitish color when breaded products were fried or baked. The process of the invention involves first preparing a moisturized breading mixture containing a major proportion of wheat flour, together with water and active yeast; this mixture is then passed into and through an extruder under moderate conditions of temperature, pressure and shear, followed by shredding and drying of the extrudate to a moisture content of from about 8-12% by weight.

Abstract: An apparatus (10) and method for the production of sterile, pelleted feed products is provided which includes an extruder device (12) equipped with a pelleting head (14) adjacent the outlet end of the extruder barrel (17). The pelleting head (14) includes an annular die section (52) having die openings (58) therethrough which is secured to the extruder barrel (17), forming an extension thereof; a rotatable, multiple-vane plate (66) is secured to the screw (42) of the device (12) and cooperates with the die section (52) to form final pellets. A rotatable knife (16) serves to cut emerging extrudate so as to size the pellets. In an alternative embodiment, the plate (66) is separately powered for rotation independent of the extruder screw (17), preferably by means of a prime mover (102) coupled with a short extruder screw section (100) which supports the plate (66). Preferably, the extruder device (12) is equipped with an upstream preconditioner (40) serving to moisturize and uniformly mix dry feed ingredients.

Abstract: A short-time, low-pollution method of preparing masa flour is provided which yields flour equivalent to conventionally fabricated masas with a total processing time significantly less than prior techniques. The procedure preferably comprises subjecting alkali-treated, debranned and moisturized grain (e.g., corn) to near infrared radiation in order to partially cook the grain. The grain can then be milled to desired particle size specifications. Masa prepared in accordance with the invention may be produced in as little as one-half hour, as compared with prior methods involving many hours of preparation time. The preferred alkali treatment of the grain prior to infrared processing substantially reduces pollution inherent in prior art methods.

Abstract: A preferred preconditioning device for use with an extruder includes two juxtaposed, frustocylindrical, intercommunicated chambers one of which presents a greater cross-sectional area than the other. A respective pair of rotatably driven mixing shafts extend axially through corresponding chambers with each mixing shaft having a plurality of mixing elements coupled therewith. The mixing elements are arranged, in order to present in cooperation with the chambers, a plurality of conditioning zones preferably including a mixing zone for initially mixing the material, an intermediate retention zone providing increased retention time for enhancing equilibration between solid and liquid portions of the material, and a final tertiary zone for comminuting clumps of material.

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: An apparatus for drying and coating a food product is provided which enables a uniform coating to be sprayed on the product without adversely affecting the product moisture content. The apparatus includes a reel which includes at least one and preferably a series of perforate zones in the sidewall for circulating air around the product during passage of the product therealong. Spray nozzles are arranged at intervals along the reel to deposit sugar, salt or other food coatings in slurry form on the food product. The reel rotates during coating and drying of the product to prevent aggregation of the individual food products and uneven coating, as well as providing for uniform drying of the coated product.

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: An improved diverter apparatus (18) is provided for use in pneumatic conveying systems (16), in order to permit selective diversion of product to waste or recycle. The apparatus (18) includes an elongate tubular body (42) having at least one opening (48) therein; a gate (52) is situated adjacent the opening (48) for normally closing the same. A piston and cylinder assembly (62) is operatively coupled with the gate (52) for selective, remote operation of the gate (52). When the gate (52) is opened, product is diverted and does not pass the gate (52).

Abstract: A material enrobing apparatus includes an elongated enrobing chamber, a material inlet adapted to receive material to be treated into the enrobing chamber, a material outlet adapted to deliver material from the enrobing chamber, and suspension means for creating and maintaining a circulating suspending flow of fluid within the enrobing chamber in a direction circumferential to the axis of the enrobing chamber. The fluid is adapted to suspend material in the enrobing chamber while the material is submitted to a treatment operation. The enrobing chamber includes an opening extending in a direction generally parallel to the axis along substantially the entire length of the enrobing chamber. The opening permits access to the enrobing chamber from outside the apparatus during operation thereof.

Abstract: Flaking roll apparatus (10) for the processing of cereal products or the like is provided which includes a pair of counterrotating, nip-defining flaking rolls (76, 78) which are obliquely oriented with the rotational axes thereof lying in a plane situated at an angle between about 15.degree. and 70.degree. with respect to the horizontal. In this manner, the apparatus (10) uses less floor space and can more readily be serviced and cleaned. The overall flaking apparatus (10) preferably includes threadably adjustable devices (136) for maintaining proper nip clearance between the flaking rolls (76, 78) and for precise adjustment thereof. Additionally, end-to-end adjustment of the flaking roll assembly (10) is afforded by means of an eccentric mount (108) for one of the flaking rolls (76).