Abstract: Methods for the production of a variety of tortilla products involve initial extrusion of one or more grain(s) and/or legume(s) using a twin-screw extruder, followed by mixing the extrudate with water and other ingredients to form a tortilla dough. The dough is then subdivided and formed into a flat tortilla shape, followed by cooking. The grain(s) and/or legume(s) may be previously extruded as a part of a continuous process. High quality tortilla products may be produced using a wide variety of grain(s) and/or legume(s), including gluten-free ingredients.

Abstract: Improved extruded starch-bearing products (e.g., starches, starch-bearing legumes, starch-bearing grains and formulations containing any of the foregoing) are provided having relatively high cook values and low cold water viscosities. The products are prepared by initial preconditioning to partially cook the starting material(s), followed by low shear extrusion cooking, with a total STE/SME ratio of at least about 4.

Abstract: Improved extruded starch-bearing products (e.g., starches, starch-bearing legumes, starch-bearing grains and formulations containing any of the foregoing) are provided having relatively high cook values and low cold water viscosities. The products are prepared by initial preconditioning to partially cook the starting material(s), followed by low shear extrusion cooking, with a total STE/SME ratio of at least about 4.

Abstract: Improved extruded starch-bearing products (e.g., starches, starch-bearing legumes, starch-bearing grains and formulations containing any of the foregoing) are provided having relatively high cook values and low cold water viscosities. The products are prepared by initial preconditioning to partially cook the starting material(s), followed by low shear extrusion cooking, with a total STE/SME ratio of at least about 4.

Abstract: Improved extruded starch-bearing grain products (e.g., corn and wheat) are provided having relatively high cook values and low cold water viscosities. The products are prepared by initial preconditioning to partially cook the starting material(s), followed by low shear extrusion cooking, with a total STE/SME ratio of at least about 4.

Abstract: Improved extruded starch-bearing grain products (e.g., corn and wheat) are provided having relatively high cook values and low cold water viscosities. The products are prepared by initial preconditioning to partially cook the starting material(s), followed by low shear extrusion cooking, with a total STE/SME ratio of at least about 4.

Abstract: Improved processes are provided for the production of grain-based products and especially multi-grain chips. The preferred process makes use of a single mixture of dry ingredients containing respective starch fractions having different levels of gelatinization. The starting mixture is preconditioned and extruded so as to form the mixture but without any substantial additional gelatinization of the starches. Moisture is added to the mixture during both preconditioning and extruding such that the extrudate exhibits both different levels of gelatinization in the starches therein, and also has portions with different levels of moisturization.

Abstract: Improved, high Specific Mechanical Energy extrusion systems (20) are provided including a single or twin extruder (22) and an upstream preconditioner (24). The extruder (22) includes an elongated barrel (26) with at least one elongated, axially flighted, rotatable screw assembly (58) therein. The barrel (26) includes a mid-barrel variable restriction valve assembly (32), and the screw assembly (58) has a disrupting/homogenizing screw section (66) therein upstream of the valve assembly (32). The screw section (66) includes a plurality of alternating pitch screw parts (82-92). Preferably, the barrel (26) also has an atmospheric vent (36) downstream of the valve assembly (32).

Abstract: Improved, high Specific Mechanical Energy extrusion systems (20) are provided including a single or twin extruder (22) and an upstream preconditioner (24). The extruder (22) includes an elongated barrel (26) with at least one elongated, axially flighted, rotatable screw assembly (58) therein. The barrel (26) includes a mid-barrel variable restriction valve assembly (32), and the screw assembly (58) has a disrupting/homogenizing screw section (66) therein upstream of the valve assembly (32). The screw section (66) includes a plurality of alternating pitch screw parts (82-92). Preferably, the barrel (26) also has an atmospheric vent (36) downstream of the valve assembly (32).

Abstract: An improved phase transition analyzer (22) is provided which greatly facilitates analysis of composite mixtures such as protein and starch-containing extrudate mixtures to give valuable information about the mixture, e.g., glass transition and melt transition temperatures, Tg and Tm. The analyzer (22) includes a body (74) having a chamber (192) adapted to receive a sample (196) of a material to be analyzed, together with a force-applying assembly (34-40, 68) operable to apply a compressive force to the sample 196 and a heating assembly (96, 138). In order to determine Tg, the sample (196) is progressively heated under sustained exertion of compaction force with chamber (192) closed. The sample (196) is compacted and the volume of chamber (192) correspondingly decreases, this being sensed by movement of a portion (34, 36) of the force-applying assembly (34-40, 68) by a displacement transducer (44).

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: 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: 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.