Abstract: An extruder die assembly and method for using same is disclosed that may be adapted to a wide variety of commercial-grade extrusion devices common in the food industry. The disclosed method comprises extruding a known composition of a farinaceous food product through the extruder die assembly of the present invention to produce a flavored direct-expanded food product exhibiting enhanced flavor characteristics, but requiring no post-extrusion drying or seasoning process. The injection section of the extruder die assembly is used to impart flavoring additives into the extrudate mass shortly before expansion, thereby preserving the flavoring characteristics of the additive by minimizing the heat exposure of the flavoring additive. The extruder die assembly may also include static mixing elements downstream from the injection section to homogenize the flavoring or seasoning media into the flowing mass of extrudate.

Abstract: An automated machine and process to form a food product consisting of a batter shell and a food filling. The process is started with a cooking matrix that includes a plurality of cooking openings to receive the batter. The batter is cooked to form shells. The automated process then inserts the food filling into the shells, and packages the filled shells as end products.

Abstract: An extrusion nozzle including an outlet port having a single opening with a first region, second region, and a pinched region between the two. The pinched region reduces the dimensions of the extrudate in relation to the dimensions associated with the first and second regions. In that way, the extrudate is joined together but may be easily separated into two separate pieces with dimensions related to the dimensions of the first and second region.

Abstract: A method for inserting one foodstuff, such as sandwich fixings, into a second foodstuff, such as a bread bun, which includes forming a cavity in the second foodstuff. The cavity may be formed by drilling with an elongated, cylindrical drill bit. The first foodstuff is inserted into the cavity by placing the first foodstuff into a carrier, and inserting the carrier into the cavity of the second foodstuff. The carrier is withdrawn while preventing the first foodstuff from exiting the cavity. The carrier can be a flexible sheet of material, onto which the first foodstuff is placed, rolled into a sleeve, and inserted into the cavity. The resulting foodstuff, such as a sandwich, has a substantially continuous wall of bread maintaining the first foodstuff within the second foodstuff.

Abstract: A nutritionally complete, shelf stable pet food product and process of manufacture includes two different textures which has a meaty outer component and a inner bone-like component.

Abstract: Two or more different materials such as food material are co-extruded through adjacent orifices of an extruder. The flows of the two materials are cut in a direction transverse to the flow to form segments of flow. These segments are interspersed so as to join upstream and downstream of each segment of first material to a segment of a second material. Generally two rows of joined segmented flows are extruded side by side. Preferably between the tow rows is formed a boundary cell wall which usually is transformed to a harder material after extrusion. Cell walls of the harder material may surround, in two or three dimensions, cells of softer of foamed material. The apparatus and method to provide the food product having the cell like structure is particularly useful for producing confectionery products formed of chocolate, marzipan or dough materials.

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 and apparatus for producing co-extruded pasta such as stuffed rigatoni and for providing the ability to make a plurality of end crimps with a single die. The method involves distributing pasta dough from an extruder to multiple co-extrusion die inserts that are arranged in a straight line. The straight-line design allows the co-extruded dough strands to drop directly into a single crimp/cut die that has a selected straight, angular or other cut. The invention may be adapted and utilized on any new or pre-existing pasta dough extruders.

Abstract: A dual texture pet or animal food product having inner and outer components. The soft inner component contains a mixture of lipid and solid ingredients and has a water activity, aw, less than about 0.65 and a total moisture content less than about 15 wt %. The outer component is a cereal based shell containing at least one ingredient comprising a carbohydrate, fat, protein or combination thereof, the shell component having a total moisture content less than about 20 wt %. The shell component completely surrounds the soft inner component and is formed by the co-extrusion of the soft inner component within the shell component to form one dual component pet or animal food product.

Abstract: A dough and a filling for making a toaster pastry and a method for making same. A method of forming the dough for the toaster pastry, comprises forming a blend of ingredients comprising wheat flour of from about 25 to about 44% by weight of ingredients for the dough, wheat farina of from about 13 to about 35% by weight of ingredients for the dough, shortening of from about 1.5 to about 2.5% by weight of ingredients for the dough, and water of from about 25 to about 35% by weight of ingredients for the dough; adding puff pastry shortening in the form of cubes such that the amount of puff pastry shortening is in the range of from about 5 to about 15% by weight of the ingredients for the pastry; and blending the ingredients such that a heterogeneous mixture of the cubes of shortening in the remainder of the ingredients is obtained.

Abstract: There is provided a method of and apparatus for forming a food by wrapping an inner material with an outer skin material, and the method of and apparatus for sealing the outer skin material more surely in a state where the inner material is disposed on the outer skin material. The food forming apparatus comprises a first shutter (1), a second shutter (2) disposed under the first shutter (1), and support means (6) disposed under the second shutter (2) wherein an operation start timing of the second shutter (2) subsequent to starting of the operation of the first shutter (1) is adjusted appropriately, and a position of the support member (60) is adjusted appropriately, thereby adjusting the amount of collection of the peripheral portion of the curst material (F), thereby wrapping an inner material (G) with the outer skin material (F) in response to the different sizes of the curst material (F) and the inner material (G), thereby surely forming the food.

Abstract: A ready to bake dough product with a shaped filling is disclosed. The filling is sized and configured so as to minimize or avoid exposure or spilling during processing, handling, or baking. The shape of the filling is configured such that it has a shorter distance vertically than horizontally. The shape of the filling may be substantially in the form of a rectangle, triangle, pentagon, hexagon, half circle, diamond, trapezoid, oval, or similar shapes.

Abstract: A grooved, pre-proofed, freezer-to-oven pizza crust dough. The dough includes a top surface for a pizza filling, and a bottom surface opposing the top surface and contacting a pizza pan. The bottom surface of the dough defines a plurality of grooves which provide the dough with a uniformly cooked surface upon baking the dough.

Abstract: A method of preparing a pizza is disclosed comprising the steps of forming a pizza shell, applying a predetermined quantity of pizza or tomato sauce to an upper surface of the pizza shell to form a pizza base, cooking the pizza base for a first predetermined time period at a first predetermined temperature and subsequently cooling the pizza base having a still moist sauce thereon to at or near room temperature. Once cooled, a predetermined quantity of pizza toppings are placed on the moist sauce including at least one of additional pizza sauce, cheese, meats, vegetables and spices is applied to the pizza base with the pizza now being fully prepared and either placed in a refrigerator for future use or further heated for a second predetermined time period at a second predetermined temperature and subsequently served to the consumer. By preparing the pizza in accordance with this method, the cheese and pizza sauce are prevented from blending with one another prior to consumption of the pizza by the consumer.

Abstract: A process for making bread snacks with fillings of high water content is disclosed and the snacks have shelf lives at chilled or ambient temperatures of more than six weeks. Baked bread is used as raw material.

Abstract: A frozen confection dispensing machine for dispensing a predetermined volume of a frozen confection. In one embodiment, the machine includes a user interface and programmable control circuit to allow an operator to select the volume of extruded frozen confection for a particular product. In another embodiment, the machine includes a readily accessible hollow member to supply the machine with additional mix without interrupting extrusion of the frozen confection. In another embodiment, a plurality of frozen confection dispensing machines are located adjacent a conveyor belt for filling a pastry product with a selected volume of frozen confection.

Abstract: Potato-based food products tolerable by gluten-intolerant individuals and methods of making and using the same. In one aspect, potato-based food products are formed by methods that include the steps of: (a) heating a potato-based ingredient substantially free of gluten to a temperature of from about 130° F. to about 260° F. for sufficient time to allow said potato-based ingredient to be mashed; (b) mashing the potato-based ingredient for a sufficient amount of time for the ingredient to form a dough-like consistency; (c) shaping the potato-based ingredient into shaped pieces; and (d) heating the shaped pieces in an environment at a temperature of about 300° F. to about 500° F. for sufficient time to attain a potato-based food product having a hardened crust. The invention further encompasses filled food articles and packaged foods comprising potato-based food products according to the invention.

Abstract: A method for preparing an edible, crunchy material comprising a batter containing a small amount of protein, 8-45% moisture, 35-60% sugar and 12-63% of a nut material and wherein the batter is heated at a temperature of 100-180° C. for period of 30-42 seconds which serves as an envelope for another food material.

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 method for inserting one foodstuff, such as sandwich fixings, into a second foodstuff, such as a bread bun, which includes forming a cavity in the second foodstuff. The cavity may be formed by drilling with an elongated, cylindrical drill bit. The first foodstuff is inserted into the cavity by placing the first foodstuff into a carrier, and inserting the carrier into the cavity of the second foodstuff. The carrier is withdrawn while preventing the first foodstuff from exiting the cavity. The carrier can be a flexible sheet of material, onto which the first foodstuff is placed, rolled into a sleeve, and inserted into the cavity. The resulting foodstuff, such as a sandwich, has a substantially continuous wall of bread maintaining the first foodstuff within the second foodstuff.

Abstract: The invention provides sponges (foams) produced from hydrocolloids by the expansion of gels of these. The foams have properties which can be varied, such as water absorption, biodegradibility, pore size and structure. Edible products can be produced which may contain an edible plasticizer, a sugar or sugar substitute and possibly also a flavoring agent or taste enhancer. The novel sponges are produced by preparing a gel of a hydrocolloid, and either sealing it in a closed vessel with a liquid of similar composition, pressurizing the vessel and abruptly releasing the pressure, followed by freeze drying, or by incorporating in such a gel a suitable microorganism, such as a yeast and inducing fermentation in the presence of a suitable nutrient medium, so that the carbon dioxide formed results in the expansion and foam formation, which is processed to the final product. The sponges-foams of the invention are such, that the initial network of the gel is maintained.

Abstract: A device is particularly well suited for introducing a continuous length of food stuffing into an elongated food product. The device uses a tube having opposite, open ends and an inner wall defining a longitudinal passage extending between such opposite ends. The length of foodstuffing is received in this longitudinal passage. The tube is inserted into the food product being stuffed, and a pointed cap on the end of the tube guides it through the food product. A ram is used in conjunction with the tube to keep the foodstuffing material in substantial registration with the ends of the food product and to assist in withdrawing the tube after the foodstuffing has been deposited in the food product. An optional parallel knife assembly is used to create an incision extending through the food product to ease the subsequent insertion of the foodstuffing therein.

Abstract: A method of baking bread from dough including the steps of preparing the dough, rolling out the dough into a flat strip in the range of approximately 1-30 mm, cutting the strip of dough into pieces, baking the flat pieces of dough in an oven for a short time (in the range of approximately 2-8 minutes) at a temperature in the range of approximately 250-270° C. and cooling and, if desired, packaging the flat pieces of baked bread. The method of the present invention saves a great deal of time, energy and labor, and results in an attractive product. The invention also includes the resultant bread and a cutting means for use with the method.

Abstract: A method is disclosed for preparing bakery goods having a plurality of edible particles on a top surface having substantially one hundred percent show and a home-made appearance. Also disclosed are novel baked goods prepared by the method and a novel cookie dough that has a transverse dimensional spread of at least 1.75 times after baking.

Abstract: The present invention provides a ganache-type chocolate composition outstanding in inclusion (mechanical) fitness when contained in confectionery dough, and moreover having good baking tolerance. The chocolate composition includes 1 to 30 wt. % non-fat cacao part, 10 to 50 wt. % fats/oils, 4 to 40 wt. % moisture and by anhydride conversion, 0.2 to 10 wt. % heat-coagulating proteins, and is in non-liquid at 5° C. Chocolate confectionery may be easily manufactured by including or coating this chocolate composition in/on other confectionery dough. Moreover, separately baking the chocolate composition itself can provide chocolate confectionery having new tastes/textures.

Abstract: A co-extruded dual component animal food product has an outer component containing at least 60% cereal and an inner cream textured component which has water soluble components in an aqueous phase that forms a stable emulsion with a lipid free hydrocarbon phase. The hydrocarbon phase contains soluble additives. Careful stepwise addition of additives to the appropriate phases and then of the phase together ensures a stable inner component which does not leach through the outer component.

Abstract: According to one aspect of the invention, a pasta product having a pocket is provided with a filling which has a sauce-like consistency when in a hydrated state. According to another aspect of the invention, both the pasta body and the filling have a composition which permits them to be dehydrated to a moisture level sufficient to be packaged, shipped, and stored, as a dry good without the need for pasteurization, while permitting rehydration upon cooking to an extent that the pasta body achieves a desired supple texture and the filling achieves a sauce-like texture. The filling of the present invention is capable of dehydration to shelf-stable moisture levels while maintaining rehydratability to a sauce-like consistency and texture.

Abstract: Disclosed is a perogie maker for producing individual perogies from a single layer of dough. The perogie maker consists of round, hollow cylinders attached to one another at the ends of the cylinders by rotatable hinges. The cylinders have alternating raised and lowered notches, and a ridge surrounding the outside of at least part of the cylinder which is capable of cutting through dough. When handles attached to the cylinders are brought together the raised notches close on lowered notches and a layer of dough is folded as such to produce sealed perogies, with excess dough being trimmed by the ridge.

Abstract: A filled pastry that can be baked in a microwave to achieve a baked pastry-like taste and a crisp final texture is described. The pastry mixture includes flour, a first fat, water, yeast, emulsifier, pentosanase, and amino acids. A liquid filling with a high water content is trapped in the pastry by a moisture barrier placed in contact therewith. The moisture barrier contains from about 80 to about 98 percent fat, from about 7 percent to about 13 percent of a film-forming protein, and from about 0.7 to about 1.3 percent of a hydrocolloid. The fat may includes medium-chain triglycerides whose melting point is between 20° C. and 35° C. The film-forming protein may be calcium or sodium caseinate. The hydrocolloid may be an iota-type carrageenan. This moisture barrier mixture is disposed between the filling and the pastry in an amount of about 1 to about 15 g/100 cm2.

Abstract: A frozen confection dispensing machine for dispensing a predetermined volume of a frozen confection. In one embodiment, the machine includes a user interface and programmable control circuit to allow an operator to select the volume of extruded frozen confection for a particular product. In another embodiment, the machine includes a readily accessible hollow member to supply the machine with additional mix without interrupting extrusion of the frozen confection. In another embodiment, a plurality of frozen confection dispensing machines are located adjacent a conveyor belt for filling a pastry product with a selected volume of frozen confection.

Abstract: A system and method are provided for forming IQF shreds of mozzarella cheese into a bead form and depositing the bead on the periphery of a pizza crust for forming a pizza with a cheese stuffed rim. The IQF shreds are heated and then extruded to form the bead placed on the crust periphery via a high speed extrusion head. Heating and extrusion techniques are disclosed that work the IQF shreds into an extrudable mass or paste that, although lacking the desired stringiness quality, reconstitutes upon baking such that stringiness comparable to more expensive string mozzarella cheese is achieved.

Abstract: A savory snack product with two layers of a whipped and baked savory sponge and a filling in-between, with the sponge having an aw value of between about 0.6 and 0.85, a pH value of between about 3.5 and 5.5 and an overrun of between about 30 and 170%, and the filling being a water-in-oil emulsion that has an aw value of between about 0.6 and 0.85, a pH of between about 3.5 and 5.5 and an overrun of below about 150%.

Abstract: The present invention includes an ergonomic snack piece having improved hand held characteristics and dip containment and a method to make such a snack piece. More particularly, the present invention relates to a ergonomic snack piece that optimizes an engagement angle and hold angle of the snack piece. Even more particularly, the present invention relates to a snack piece having a dip containment well and a grip region that provides improved dip-condiment retention while simultaneously providing the user areas to hold the chip and thus avoiding messy finger contact with the dip.

Abstract: A food product comprising one or more plastic food substrates is formed into a helical configuration and coated with a fluid barrier agent to prevent reannealing of adjacent turns of the product. The fluid barrier agent may be an edible vegetable oil such, for example, as hydrogenated vegetable oil, Soya oil, rape oil, sunflower oil, safflower oil, peanut oil or a mixture of such oils. The product may define a single helix or a multiple helix, e.g. a double or triple helix.

Abstract: A shelf-stable filled pasta and a method of making same, the method comprising providing an acid-treated or acid-containing fillable pasta piece having a pH of about 4.6 or less; inserting filling into the fillable pasta piece; exposing the filling in the filled pasta piece to microwave or radio frequency radiation to reduce the water activity in the filling to about 0.85 or less; sealing the filled pasta piece in a package; and pasteurizing the filled pasta piece at any point in the process after the filling has been inserted into the fillable pasta piece. The shelf-stable filled pasta is a pasta made by the foregoing method.

Abstract: Creamy, reduced fat, low-moisture lipid-based fillings. The fillings comprise: (a) at least about 20% non-digestible lipid; and (b) from about 0.5% to about 35% crystallizing lipid. The fillings can additionally comprise other suitable optional ingredients. The filling has a water activity of less than about 0.6 and has at least about 20% less digestible fat than a comparable full-fat lipid-based filling. In one embodiment, a cheese filling comprises: (a) from about 20% to about 60% non-digestible lipid; (b) from about 0.5% to about 35% crystallizing lipid; (c) from about 20% to about 75% dehydrated cheese powder; and (d) from about 0% to about 55% bulking agent. The fillings can be used with any suitable substrate, but are especially suitable for use in random packed food products, especially sandwich biscuits. Sandwich biscuits made with the fillings adhere well to the biscuits so that the sandwich biscuits are not misaligned, smeared, or subject to splitting or decapping in production or after storage.

Abstract: Method of filling a bagel or a bread product having a hardened outer surface and softer interior. The outer surface is broken by the sharpened end of a filling spout. The bagel or bread product is moved relative to the spout to shroud the spout and push aside the softer interior. The spout eventually extends most of the length of the bagel or bread product, but its sharpened end is not positioned to break through. The bagel or bread product is moved relative to the spout in the opposite direction to a partially withdrawn position. Foodstuff is injected through the spout and into the channel formed at the partially withdrawn position. The bagel or bread product is further withdrawn and foodstuff is injected again. Finally, the bagel or bread product is withdrawn sufficiently to separate from the spout.

Abstract: A process for making a tubular shaped hand held convenience snack food type product comprising the steps of formulating dough comprising potato shreds, cellulose gum and starch, extruding the dough through a multiple extrusion nozzle to form continuous ropes having two or more axial cavities which can be filled with savory fillings, optionally compressing the ropes, cutting and crimping ropes to form uncooked cut casings and then cooking and freezing. The dough has a moisture content of about 55% to about 75%, preferably about 60% to about 72%, to facilitate extrusion without impairing the potato shred material.

Abstract: A baked toastable freezer stable filled waffle is disclosed. The filled waffle has a batter-based outer casing material that surrounds an inner filling material. Utilization of a filling material having a water content and water activity level below that of the outer casing material enables the formation of a toastable freezer stable filled waffle. The filled waffle can be stored frozen and reheated rapidly in a conventional toaster without burning or charring of the outer casing material and complete heating of the inner filling material.

Abstract: A method of preparing parbaked food products, such as pizza crust shells, apparatus and dough formulation used therein, and the product produced by the process. The process comprises the steps of providing a dough including flour, sugar and water, and preferably also a leavening agent such as instant yeast. The dough is rounded, first proofed, panned, pressed and second proofed. The prepared dough piece is then steam hydrated under conditions sufficient to cause moisture absorption and a resultant increase in moisture content throughout the dough. Then the hydrated dough piece is immediately sequentially parbaked until gelatinization of the starch is complete. At least one parbaking condition is adjusted selected from the group consisting of initial dough temperature, oven temperature, parbaking time, dough absorption and dough thickness and coordinated with the moisture content condition of the dough upon completion of the steam hydration for thereby delaying external browning of the dough.

Abstract: A multiple extrusion nozzle having an outer extrusion segment and an inner extrusion segment for extrusion of casing, particularly potato dough casing material, having two or more axial cavities.

Abstract: A dual texture pet or animal food product having inner and outer components. The soft inner component contains a mixture of lipid and solid ingredients and has a water activity, aw, less than about 0.65 and a total moisture content less than about 15 wt %. The outer component is a cereal based shell containing at least one ingredient comprising a carbohydrate, fat, protein or combination thereof, the shell component having a total moisture content less than about 20 wt %. The shell component completely surrounds the soft inner component and is formed by the co-extrusion of the soft inner component within the shell component to form one dual component pet or animal food product.

Abstract: A baked, shelf-stable, hand-held snack bar comprised of a crust and a smooth, creamy cheesecake-like filling. The crust surrounds the bottom and longitudinal sides of the bar. The filing is exposed on its top surface. The filing and crust are each formulated to water activity of 0.60-0.90 and the filling has a milk fat content of less than 10%.

Abstract: A microwavabel pasta pie (10) and pan (32) assembly, includes a shell (12) formed by grid-shaped walls (16) integrally formed within an outer wall (18) to thereby define a plurality of vertical, open through passages (14). The shell (12) is supported upon a pie plate (32) having a planar bottom (34) which closes the bottom face (20) of the shell (12) and of the passages (14). A filling (38) is located within and retained by the passages (14) and the pie plate (32), and a topping (40) such as powdered cheese is provided on the filling (38). The pasta pie (10) is frozen inside of a plastic bag (42). In the most preferred form, the pasta pie (10) is cooked in a microwave oven, with the pie plate (32) being disposable and utilized during microwave cooking as well as during serving and consumption.

Abstract: A delivery system for process unstable or sensitive ingredients that consists of a dual texture food product having a first and second component. The first component contains a mixture of lipid and solid ingredients forming a cream-textured matrix that is formed without an aqueous phase and a total moisture content less than about 15 wt %. The first component includes a process unstable or sensitive ingredient. The second component contains at least one ingredient comprising a carbohydrate, fat, protein or combination thereof. The second component has a total moisture content less than about 20 wt %. The second component completely surrounds the cream-textured matrix of the first component thereby maintaining the viability of the process unstable or sensitive ingredient. The food product delivery system is formed by the co-extrusion of the first component within the second component to form one dual component extrudate.

Abstract: A pourable dessert liquid product comprising a protein source; fat; sweetener; stabilizer; flavoring agent; and emulsifier.

Abstract: A method of shaping a spherical body composed of an outer covering layer and an inner filling, comprising a holder frame, a rotary wheel rotated forwards and backwards alternatively in the holder frame, and triangular cutter members coupled to the rotary wheel and arranged in sliding contact with each other and moved with the rotary wheel between a first position to form a center opening for the passing of a continuously fed cylindrical body consisting of dough crust and a filling, and a second position to shape a spherical body consisting of dough crust and a filling from the continuously fed cylindrical body.

Abstract: A cereal flour dough sheet-derived food, which contains a cereal material-derived water-soluble fraction in a portion of food where deterioration of palatability in texture occurs, said fraction having an equilibrium moisture content of from 10% by weight to 80% by weight at 25° C. and a glass transition moisture of from 1% by weight to 30% by weight at 25° C., and said fraction being contained in an amount of from 0.2% by weight to 50% by weight calculated as the solid content based on the total solid content of said portion. It is possible to provide edible substances capable of effectively inhibiting deterioration of palatability of food which occurs due, for example, to the reduction of moisture during preservation and/or cooking of processed food products and food materials containing various cereal flours, particularly cereal flour dough sheet-derived food products.

Abstract: An apparatus and method are provided for cutting and shaping food products consisting of a filling and a crust from bar-shaped food material. This apparatus comprises shutter members, each having a cutting surface and a sliding surface, a holding member that bridges and holds two adjacent shutter members, shafts equidistantly disposed on an imaginary circle, and driving means for synchronously rotating shutter members in the horizontal direction by the rotation of shafts.

Abstract: A method of making a composite ice-cream cone having a preformed, closed-bottomed wafer shell. The shell has an inner surface, a length, an outer surface, and an upper edge. A separate, preformed, closed-bottomed chocolate shell has a lower portion and an upper portion, and a filling of a frozen product contained in both said lower and upper portions.