Abstract: A continuous tortilla chip cutting system where tortilla carried on a conveyor are continuously divided by a cutting mechanism into pre-cuts for frying into chips. A programmable controller drives a servo motor that moves an upper surface of the conveyor at a known velocity V, and a detector located above the conveyor at a known distance D from the cutting mechanism alerts the controller to the imminent arrival of the tortilla. The controller also controls a servo motor that actuates the cutting mechanism in a stop/start fashion. Based on the detection of the tortilla, the controller drives the servo motor associated with the cutting mechanism at just the right time and at just the right speed so that the cutter mechanism cuts each arriving tortilla into predictable sub-units called “pre-cuts” based on the velocity V of the conveyor belt, the detection of the flat bread unit carried by the conveyor, and the known distance between the moving flat bread unit and the cutter assembly.

Abstract: A high pressure process and system for the production of fresh whole corn masa, nixtamalized whole corn flour, and derivates wherein dry corn grains are transported by means of an elevator to a series of cleaning screens to separate impurities and foreign material before they are subjected to a cooking step. The corn grains as well as lime and water are fed continuously to a cooking device, which is subjected under a combination of pressure and temperature, to reduce the time of cooking of the whole corn grains. So, nixtamalized corn grains are obtained for the preparation of fresh whole corn masa and nixtamalized whole corn flour for tortillas, tortilla chips or the like.

Abstract: A process for the production of fresh masa, nixtamalized flour and derived produts is disclosed. Water-lime cooking of pericarp fractions of the corn, and appropriate hydration of the germ and endosperm fractions of the corn is achieved to prepare fresh masa, nixtamalized corn flour and derived products. The pericarp fractions are cooked with lime and water at a temperature between about 50° C. to about 300° C. The germ and endosperm fractions are hydrated with water. The pericarp fractions and the germ-endosperm fractions are milled separately, and the milled pericarp, germ and endosperm fractions are then mixed for producing fresh corn masa. The fresh corn masa can be dehydrated and milled for producing nixtamalizaed corn flour. Also, the pericarp, germ and endosperm fractions can be dried in order to produce nixtamalized corn flour.