Abstract: A large-scale additive manufacturing system for printing a structure includes an extrusion system and a knitting system. The extrusion system includes a nozzle configured to receive a supply of structural material and to selectively dispense the structural material in flowable form, and a first gantry configured to move the nozzle along toolpaths defined according to a structure to be printed such that structural material may be dispensed along the toolpaths to print a series of structural layers, wherein the series of structural layers bond together to form all or a portion of the structure.

Abstract: A large-scale additive manufacturing system for printing a structure includes an extrusion system and a knitting system. The extrusion system includes a nozzle configured to receive a supply of structural material and to selectively dispense the structural material in flowable form, and a first gantry configured to move the nozzle along toolpaths defined according to a structure to be printed such that structural material may be dispensed along the toolpaths to print a series of structural layers, wherein the series of structural layers bond together to form all or a portion of the structure.

Abstract: A cookie intermediate and a process for forming a cookie intermediate having a visual feature depicted on both a top surface and a bottom surface of the cookie intermediate. A cookie dough and an edible filling are substantially simultaneously extruded such that the edible filling is encased within the cookie dough to form a cookie rope. The cookie rope is sliced such that the edible filling is exposed on both a top and bottom surface of the individually sliced cookie intermediates. The extruder includes a die assembly that extrudes the edible filling in a desired shape or configuration such that after slicing, the edible filling displays a visual feature on the top and bottom surfaces of the cookie intermediate.

Abstract: A cutting mechanism (40) in a preferred form of an ultrasonically vibrating titanium knife (42) is moved in a cutting path parallel to but without physical contact with the die face (18) of an extrusion die (16) with its faces (46, 48) at a minor acute angle relative to the die face (18). The die face (18) is at an acute angle to the conveyance direction of a conveyance mechanism (12) defining a preferred form of a takeaway device. The cutting mechanism (40) is moved in a return path from the completion of the cutting path in the extrudate direction away from the die face (18), away from the conveyance mechanism (12), and then towards the die face (18) to the initiation of the cutting path. The cutting mechanism (40) is spaced from and does not physically contact the conveyance mechanism (12) at all times in the cutting path so that the individual piece is cut from the extrudate in mid-air.

Abstract: Methods for making an uncooked extruded dough product are provided, comprising extruding a dough composition of pre-gelatinized starch comprising at least about 75 percent of amylopectin, flour, leavening agent and water through a die under conditions so that the dough composition does not exceed 140° F. throughout the extrusion process. The resulting dough product when cooked has a baked specific volume of greater than about 3.0 cc/g. Products of this process, including filled products, are also provided.

Abstract: A method of preparing a partially thermal treated dough intermediate which has reduced tendency to adhere to the processing apparatus is disclosed. The dough intermediate is thermal treated to create a temporary impermeable barrier on each of the layers of the intermediate.

Abstract: The present invention relates to shaped cookie dough intermediates provided in an easy to use and convenient format, having an integral design element which can be provided on a commercially produced scale. The shaped cookie dough intermediate can be produced in various configurations and have any sort of internally, preformed design element. More specifically, the present invention is directed to the creation of individual cookie dough intermediates that have predetermined shapes other than generally circular and which include an interior arrangement of other dough shapes, designs or elements in order to create a composite cookie dough intermediate that is illustrative of a particular theme or event, such as holiday, special occasion, sporting event and the like.

Abstract: The present invention relates to packaged, convenient to use cookie intermediates having an integral design element which can be provided on a commercially produced scale. The individual cookie dough intermediates can be produced having any sort of internally, predetermined design element and is provided in a convenient packaging arrangement. More specifically, the present invention is directed to the creation of individual predetermined dough intermediates that include an interior and integral arrangement of dough shapes, designs or elements in order to create a composite cookie dough intermediate that is illustrative of a particular theme or event, such as holidays, special occasions, sporting events and the like, that are provided in a ready to use, convenient format without requiring any additional slicing, breaking or similar action prior to baking or cooking.

Abstract: Potato products that retain shred integrity and that are sufficiently thin to fit into a standard toaster have been produced. In some embodiments, the potato products contain a filling. The potato products contain a network of shredded potatoes that enables the potato products to retain structural integrity during production and further manipulation of the product. Extrusion and sheeting methods are used to obtain potato products that retain the desirable shred integrity. A method and apparatus is provided for simultaneously cutting and crimping individual food items from a filled extruded or sheeted product.

Abstract: A process comprises the steps, in order, of preparing a unbaked dough having a surface consistency such that the unbaked dough is processable in automated dough processing equipment; forming a dough product from the unbaked dough; baking the formed dough product; treating the baked dough product by applying a fat composition thereto under conditions to allow absorption of a sufficient amount of the fat into the dough to noticeably improve textural properties of the baked dough product after microwave reheating as compared to a like product without fat absorbed therein; and storing the treated baked dough product in a frozen state. Products and methods of preparing said products for consumption are also provided.

Abstract: The present invention relates to a partially thermal treated dough intermediate which has reduced tendency to adhere to the processing apparatus. The dough intermediate of the present invention is thermal treated to create a temporary impermeable barrier on each of the layers of the intermediate.

Abstract: A extrusion method is used to obtained leavened dough products with desirable characteristics. A chemical leavener is used to release carbon dioxide within the extruder and/or a premixer to yield an expanded dough following the extrusion process. In some embodiments, improved dough products are produced. The improved dough products following frying have improved freeze/thaw cycling performance and can be microwave cooked to yield a tender dough with desirable characteristics. The improved dough can be described by the degree of expansion and its cooking properties.

Abstract: Methods for making an uncooked extruded dough product are provided, comprising extruding a dough composition of pre-gelatinized starch comprising at least about 75 percent of amylopectin, flour, leavening agent and water through a die under conditions so that the dough composition does not exceed 140° F. throughout the extrusion process. The resulting dough product when cooked has a baked specific volume of greater than about 3.0 cc/g. Products of this process, including filled products, are also provided.

Abstract: Batter-derived food products were made that have a continuous spongy structure with a filling encased within the spongy structure. In some embodiments, filled pancakes with encased filling were made. The filled food products were made by depositing the filling on partially cooked components. After the filling was deposited, the partially cooked components were heated further to generate a fully cooked food product with filling encased within the cooked food product. In some embodiments, a pancake component with the filling deposited was combined with another pancake component and further heated to seal the edges and produce a filled pancake with the filling sealed within the pancake.

Abstract: A extrusion method is used to obtained leavened dough products with desirable characteristics. A chemical leavener is used to release carbon dioxide within the extruder and/or a premixer to yield an expanded dough following the extrusion process. In some embodiments, improved dough products are produced. The improved dough products following frying have improved freeze/thaw cycling performance and can be microwave cooked to yield a tender dough with desirable characteristics. The improved dough can be described by the degree of expansion and its cooking properties.

Abstract: A extrusion method is used to obtained leavened dough products with desirable characteristics. A chemical leavener is used to release carbon dioxide within the extruder and/or a premixer to yield an expanded dough following the extrusion process. The improved dough can be described by the degree of expansion and its cooking properties.

Abstract: Method and apparatus applies a strip or stream of fluid to a moving dough sheet. The apparatus has a fluid flow regulator coupled to a fluid source providing positive pressure, and a nozzle coupled to the fluid flow regulator and disposed proximate the dough sheet such that drops of fluid emerging from the nozzle contact the dough sheet before falling from the nozzle.

Abstract: A method is described for forming dough product containing a filling. The method includes making projections on the surface of the dough product. The projections serve to isolate a volume of dough away from the main body of the dough product, so the moisture from the filling inside the main body of the dough product cannot readily migrate into the projections. The dough product with its projections attains a significant level of crispness upon frying, and retains the crispness upon reheating, even after a freeze/thaw cycle.