Abstract: A method of making a masa-based dough for use in a single mold form fryer. The invention is an improved process of making a buoyant, low density, low moisture content dough that is easily sheetable and results in a fried tortilla chip-like product with a similar texture of traditional tortilla chips. Starch is added to corn masa dough to help control moisture release during frying. The high shear mixing of the dough entrains air through nuclei formation making the dough more buoyant, and results in a smaller particle size of the dough increasing the uniformity of moisture distribution. The uniformity of moisture distribution provides more uniform buoyancy of the masa-based dough as it travels through a single mold form fryer.

Abstract: A pre-packaged microwavable food having a steam emitting source integral to the package permitting preparation of the food product in a broad range of microwave ovens. A food product is placed into a package. A steam emitting source is placed in porous communication with the food product inside the package. When the package is heated, steam blankets the food product. Steam has a positive effect on cooking performance and cooking time. The steam emitting source can be made from an absorbent material or a gel. The food product can be a half-product, pellet, or other microwavable food or snack product.

Abstract: A method for making asymmetrical snack pieces that can be efficiently nested or stacked. A dough preform is mated with a mold as the preform is cooked into a snack piece. The preform takes the shape of the mold. The mold is designed such that the resultant snack piece, when resting upon a flat surface, has an apex and a base of equal height. This is achieved by making the mold such that the centroid of the snack piece lies in a plane that is parallel to a plane formed by the vertices of the snack piece. The snack pieces can then be efficiently nested or stacked.

Abstract: A method of making a masa-based dough for use in a single mold form fryer. The invention is an improved process of making a buoyant, low density, low moisture content dough that is easily sheetable and results in a fried tortilla chip-like product with a similar texture of traditional tortilla chips. Starch is added to corn masa dough to help control moisture release during frying. The high shear mixing of the dough entrains air through nuclei formation making the dough more buoyant, and results in a smaller particle size of the dough increasing the uniformity of moisture distribution. The uniformity of moisture distribution provides more uniform buoyancy of the masa-based dough as it travels through a single mold form fryer.

Abstract: A method and apparatus for making bowl-shaped snack food products, e.g. tortilla chips. The method features placing chip preforms in open bowl-shaped cavities and partially frying the chip preforms by filling them with hot oil from above. Additionally, the preforms are partially fried from below by immersing the lower portions of the preforms in a vat of hot oil and transporting them through the hot oil. After cooking the preforms to a desired moisture content, at which point the preforms retain their bowl shapes outside of or independent of the mold cavities, the preforms are removed from the mold cavities and subsequently cooked to completion in a secondary frying operation. The invention also features an apparatus to carry out the method.

Abstract: A method and apparatus for making bowl-shaped snack food products, e.g. tortilla chips. The method features placing chip preforms in open bowl-shaped cavities and partially frying the chip preforms by filling them with hot oil from above. Additionally, the preforms are partially fried from below by immersing the lower portions of the preforms in a vat of hot oil and transporting them through the hot oil. After cooking the preforms to a desired moisture content, at which point the preforms retain their bowl shapes outside of or independent of the mold cavities, the preforms are removed from the mold cavities and subsequently cooked to completion in a secondary frying operation. The invention also features an apparatus to carry out the method.