Abstract: This invention relates generally to ultrasonic extrusion apparatus, methods and products. A flowable substrate may be supplied by an infeed to an extrusion chamber having an ultrasonic horn. The flowable substrate contacts the ultrasonic resonant horn and receives ultrasonic energy before and/or as passing through an extrusion orifice. Suitable flowable substrates may include meat emulsions, pomace solutions, and dough. The extruded product may have virtually any solid or hollow shape. The flowable substrate may form a shape-retaining product that may be cut without significantly deforming.

Abstract: This invention relates generally to ultrasonic extrusion apparatus, methods and products. A flowable substrate may be supplied by an infeed to an extrusion chamber having an ultrasonic horn. The flowable substrate contacts the ultrasonic resonant horn and receives ultrasonic energy before and/or as passing through an extrusion orifice. Suitable flowable substrates may include meat emulsions, pomace solutions, and dough. The extruded product may have virtually any solid or hollow shape. The flowable substrate may form a shape-retaining product that may be cut without significantly deforming.

Abstract: A method for manufacturing a snack food with from a non-cohesive homogeneous blend of ingredients using an ultrasonic horn and an anvil to form an agglomerated, cohesive and portable snack without the use of additives, including but not limited to preservatives, plasticizers, binders and fluidizers.

Abstract: A method for manufacturing pet food with an ultrasonic horn and an anvil, using human grade ingredients without the use of additives, including but not limited to preservatives, plasticizers, binders and fluidizers.

Abstract: An apparatus and method for manufacturing a novelty sealed food product having a complex shape. The apparatus including an anvil plate and an ultrasonic horn that seals a filling within a pair of food substrates with an ultrasonic vibration and without a sealing additive, such as a carbohydrate or a hydrocolloid.

Abstract: A method and system for ultrasonic sealing of food product packaging is provided. The ultrasonic sealing system preferably includes a food product packaging-positioning system that delivers food product packaging and food product into direct on-item-packaging forming box. The direct on-item-packaging forming box then receives the food product packaging and forms it directly around the supplied food product forming a partially packaged food product. The partially packaged food product is then ultrasonically edge sealed around the food product by an ultrasonic food product packaging fin-sealing unit forming a partially sealed food product packaging. The partially sealed food product packaging then enters a food product packaging end-sealing unit which ultrasonically seals and crimps the ends of the food product packaging resulting in a fully packaged and ultrasonically sealed food product.

Abstract: A method for manufacturing pet food with an ultrasonic horn and an anvil, using human grade ingredients without the use of additives, including but not limited to preservatives, plasticizers, binders and fluidizers.

Abstract: An apparatus for cutting food product includes an ultrasonic resonant horn. A reciprocating cutting tool is mounted with respect to the ultrasonic resonant horn, and includes a plurality of longitudinally oriented first cutting blades and a plurality of transversely oriented second cutting blades. Each second cutting blade is positioned between and connected with adjacent first cutting blades. Also disclosed is a method for forming a plurality of food product cubes from a food product base.

Abstract: A method and system for ultrasonic sealing of food product packaging is provided. The ultrasonic sealing system preferably includes a food product packaging-positioning system that delivers food product packaging and food product into direct on-item-packaging forming box. The direct on-item-packaging forming box then receives the food product packaging and forms it directly around the supplied food product forming a partially packaged food product. The partially packaged food product is then ultrasonically edge sealed around the food product by an ultrasonic food product packaging fin-sealing unit forming a partially sealed food product packaging. The partially sealed food product packaging then enters a food product packaging end-sealing unit which ultrasonically seals and crimps the ends of the food product packaging resulting in a fully packaged and ultrasonically sealed food product.

Abstract: This invention relates generally to cutting product by ultrasonic tools and methods. Specifically, the invention relates to an elongated cutting element removably coupled to an ultrasonic resonant horn to form a cutting zone and a method of use. The elongated cutting element can include simple, less costly, easily replaceable elements that resonate at ultrasonic frequencies but don't follow complex and restrictive acoustic rules.

Abstract: This invention relates generally to ultrasonic extrusion apparatus, methods and products. A flowable substrate may be supplied by an infeed to an extrusion chamber having an ultrasonic horn. The flowable substrate contacts the ultrasonic resonant horn and receives ultrasonic energy before and/or as passing through an extrusion orifice. Suitable flowable substrates may include meat emulsions, pomace solutions, and dough. The extruded product may have virtually any solid or hollow shape. The flowable substrate may form a shape-retaining product that may be cut without significantly deforming.

Abstract: An apparatus (30) and method for ultrasonically energized slitting of a slab of confectionary material wherein a slitting tool (33a) incorporates a plurality of slitting knives (37a) spaced apart in accordance with the desired width of the product, which strips are further processed by transverse cutting and/or molding or other processing steps such as chocolate enrobing to provide improved confectionary products.

Abstract: A method for portioning a food product at a single location with a single cutting system includes transporting a food product to a cutting station, activating a multi-axis robotic arm to position at least one ultrasonic cutting blade in proximity to the food product, cutting the food product along a first axis, activating the robotic arm to reposition the at least one ultrasonic cutting blade, and cutting the food product along a second axis. The robotic arm may be programmed to perform a variety of cutting motions and/or cutting patterns. Additionally, the method may include the step of cutting the food product along a third axis.

Abstract: A method and system for ultrasonic sealing of food product packaging is provided. The ultrasonic sealing system preferably includes a food product packaging-positioning system that delivers food product packaging and food product into direct on-item-packaging forming box. The direct on-item-packaging forming box then receives the food product packaging and forms it directly around the supplied food product forming a partially packaged food product. The partially packaged food product is then ultrasonically edge sealed around the food product by an ultrasonic food product packaging fin-sealing unit forming a partially sealed food product packaging. The partially sealed food product packaging then enters a food product packaging end-sealing unit which ultrasonically seals and crimps the ends of the food product packaging resulting in a fully packaged and ultrasonically sealed food product.

Abstract: A system and method of ultrasonic rotary forming food products is provided. The system (400) includes a first ultrasonically activated rotary wheel (412) including a first cavity (414) for receiving a food product and a secondary rotary wheel (418). The first ultrasonically activated rotary wheel and said second rotary wheel rotate such that food product within the first cavity contacts the second rotary wheel to form an individually formed food product. The product passes from the first cavity to form a single formed food product. The system also includes a food product delivery system for delivering food product to the first ultrasonically activated rotary wheel and the second rotary wheel. The second rotary wheel may also be an ultrasonically activated rotary wheel having cavities (420) formed on the outer circumferential edge (415) of the wheel.

Abstract: A system and method for forming a cooked, shaped product (e.g., an animal food) is provided. A flowable substrate is introduced into one or more shaping chambers in a fixture configured to both shape and cook the substrate. An ultrasonic energy source in communication with the fixture vibrates the walls of the one of more shaping chambers to cook the substrate in a desired manner. The fixture also may be configured to produce a shaped, hollow product and a multi-layer product.

Abstract: An apparatus for cutting food product includes an ultrasonic resonant horn. A reciprocating cutting tool is mounted with respect to the ultrasonic resonant horn, and includes a plurality of longitudinally oriented first cutting blades and a plurality of transversely oriented second cutting blades. Each second cutting blade is positioned between and connected with adjacent first cutting blades. Also disclosed is a method for forming a plurality of food product cubes from a food product base.

Abstract: A system and method for moving a flowable substrate through a chamber is provided. The chamber extends between first and second open ends and is both shaped and heated such that the flowable substrate can be shaped and cooked therein. A pushing force is applied to the cooked substrate to expel the cooked substrate through the second open end. In one embodiment, the pushing force is provided by a pushing device that extends into the chamber at the first open end to loosen the cooked substrate from the chamber walls and to cause the cooked substrate to exit the chamber through the second open end. In another embodiment, the pushing force is provided by a fill device that continuously introduces the flowable substrate into the chamber. In certain embodiments, an ultrasonic energy source may be provided to prevent adherence of the food product to the chamber walls and/or to assist in loosening any adhered food product from the chamber walls.

Abstract: A method and system for ultrasonic sealing of food product packaging is provided. The ultrasonic sealing system preferably includes a food product packaging-positioning system that delivers food product packaging and food product into direct on-item-packaging forming box. The direct on-item-packaging forming box then receives the food product packaging and forms it directly around the supplied food product forming a partially packaged food product. The partially packaged food product is then ultrasonically edge sealed around the food product by an ultrasonic food product packaging fin-sealing unit forming a partially sealed food product packaging. The partially sealed food product packaging then enters a food product packaging end-sealing unit which ultrasonically seals and crimps the ends of the food product packaging resulting in a fully packaged and ultrasonically sealed food product.

Abstract: A method and system for ultrasonic sealing of food product packaging is provided. The ultrasonic sealing system preferably includes a food product packaging-positioning system that delivers food product packaging and food product into direct on-item-packaging forming box. The direct on-item-packaging forming box then receives the food product packaging and forms it directly around the supplied food product forming a partially packaged food product. The partially packaged food product is then ultrasonically edge sealed around the food product by an ultrasonic food product packaging fin-sealing unit forming a partially sealed food product packaging. The partially sealed food product packaging then enters a food product packaging end-sealing unit which ultrasonically seals and crimps the ends of the food product packaging resulting in a fully packaged and ultrasonically sealed food product.