Abstract: The method for producing extruded, farinaceous pellets includes extruding a mixture so that it expands upon exiting an extruder. This prepuffed ribbon is then subjected to stretching and cutting steps to produce pellets. The prepuffing reduces the moisture content of the ribbon so that cut pellets made from the ribbon can be immediately processed without the need for a moisture conditioning and/or dehydration step. In stretching, the extrudate ribbon is passed through a set of rollers to increase the extrudate ribbon's velocity thereby causing the ribbon to stretch. Stretching the extrudate ribbon causes a reduction in thickness along with an increase in density. After cutting, the pellets can then be expanded in a puffing stage to produce a product that has a desirable light and crunchy texture.

Abstract: A method of adding oil and fat to porous feed is disclosed wherein porous feed together with oil and fat are continuously inserted into a partially evacuated chamber of an oil and fat adding apparatus while, simultaneously, porous feed that has remained therein for a specified time is continuously being removed from the chamber. The continuous nature of this method allows porous feed having high fat and oil content to be produced more rapidly than previously possible.

Abstract: For producing coiled bakery products, a nozzle arrangement (10) comprises an inner nozzle (14), which is disposed coaxially with an axis of rotation (26), and an outer nozzle (18, 19), which is disposed axially offset relative to said inner nozzle (14), wherein the outer nozzle (14) is rotatable about the axis of rotation (26).

Abstract: A frozen, filled, yeast-bread product and a method for producing the same, the method including coextruding an unrisen yeast-bread dough and a filling through an extruder that is capable of at least encasing the filling with the unrisen yeast-bread dough to form a filled, unrisen yeast-bread dough; shaping the filled, unrisen yeast-bread dough into a consistent elongated shape; proofing, baking, enrobing, and freezing the filled, unrisen yeast-bread dough to form a frozen, filled, yeast-leavened bread product that experiences substantially no leaking of filling from out of the bread product.

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: A method and apparatus for reforming small pieces of natural cheese or other dairy products, such as shreds, trim, or offcuts, wherein the small pieces are fed through a mechanical pump and a die that form the product into a cohesive larger chunk. The mechanical pump and the die operate such that natural cheese pieces may be formed into a larger chunk of natural cheese having a very similar texture and appearance to that of the original product.

Abstract: An improved low shear extrusion and dehydrating apparatus (10) and method is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is at least about 2, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: A process of manufacturing a cooked-extruded-expanded dietetically valuable snack product mainly comprising an amylaceous material and milk solids, and which has a fine, porous, crunchy, smooth and melt-in-the-mouth texture while being rich in protein and calcium

Abstract: An improved low shear extrusion and dehydrating apparatus (10) and method is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is at least about 2, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: Multi-colored products, particularly food products, are obtained by preparing a base mixture suitable for preparing an emulsion, pumping the base material mixture to an emulsifier device and supplying a coloring solution to the emulsifier device and emulsifying the base material mixture and coloring solution to obtain a colored material mixture emulsion, passing the colored emulsion to a distribution valve which is connected to a plurality of parallel piping lines connected in series to extruders to pass differing colored emulsions to the extruders for extrusion.

Abstract: A process for preparing a coated low-fat and fat-free pretzels having a surface area to inner volume ratio of from about 22 inches−1 (8.66 cm−1) to about 40 inches−1 (15.75 cm−1), a pH of about 8 or less, a digestible fat content of less than 3 g per 28 g serving, and a moisture content of from about 1% to about 4%. The large surface area to inner volume ratio permits the use of reduced concentrations of caustic solution and facilitates drying. Coated pretzels are prepared by: (1) applying a warm coating comprising a carbohydrate selected from modified starch, corn syrup solids, maltodextrins, dextrins, and mixtures thereof; water; and preferably flavoring to ready-to-eat pretzels while tumbling; (2) adding sugar and optionally salt to the tumbling pretzels; (3) removing the pretzels from the tumbling device; and (4) drying the pretzels with the products stationary. The pretzels have substantially improved texture, taste and flavor display.

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 food product comprising continuous aligned bundles of formed fibers extending between faces of the food product is provided. The fibers in this food product are newly formed and fixed during its preparation. This novel food product may be prepared by forcing dough to move along an axis extending through a passageway toward an axial opening at a far end of the passageway, while transferring heat to at least that portion of the moving dough proximal said second end and controlling the heat transfer and speed of movement of the dough such that fibrous food product with essentially aligned axial fibers egresses through said opening.

Abstract: Disclosed is an expandable half-product comprising a starchy farinaceous material, wherein the starch molecules of the farinaceous material are unidirectionally aligned and form a matrix of randomly aligned starch molecules upon exposure to microwave radiation to form a puffed half-product having at least twice the dimensions of the unmicrowaved half-product. Methods of preparing the products are also disclosed.

Abstract: An apparatus and method for food extrusion is provided. The apparatus includes a substantially circular plate having a plurality of holes in an offsetting arrangement thereon. The arrangement of the holes provide food extruded through the apparatus with a shape which approximates the arrangement.

Abstract: A process for manufacturing a composite consumable product by double extrusion, wherein a liquid or pasty consumable substance is prepared in a first section of a twin-screw extruder, a plasticizable consumable substance is cooked-extruded in a second section of the twin-screw extruder, wherein the first and second sections are separated dynamically, to provide at least one strand of a cooked-extruded mass that is cut into pieces. The liquid or pasty consumable substance is added to the cooked-extruded mass to provide pieces of a composite consumable product.

Abstract: In the process of producing corn-based pellets, preconditioner steam and water addition, as well as extruder water or screw configuration and RPM, can be manipulated to precisely control the cook level, gelatinization, and moisture level of the meal during processing, and level of defects despite minor variation in the characteristics of the corn flour. Specifically, the preconditioner added steam-to-water ratio can be manipulated to effect cook, hydration, and partial gelatinization of the meal. In the extruder, lower extruder rotational speeds increase the residence time and increases cook. With the increase in residence time the volume of bed pack in the extruder increases. This can be reversed by adding water directly into the extruder, thereby decreasing the viscosity of the meal in the extruder. Product bulk density is changed by increasing and decreasing cook of the meal.

Abstract: The present invention includes an expanded cereal-type product and a method for making such a product wherein the cereal-type product has a high protein content. A starch derived from a tuber is used to aid in expanding the extrudate to form cereal-type pieces. The amount of denatured protein relative to functional protein is adjusted to obtain selected textured characteristics.

Abstract: In the process of producing masa based expandable pellets, preconditioner steam and water addition, as well as extruder water and RPM, can be manipulated to precisely control the cook level, gelatinization, and moisture level of the meal during processing, and level of defects despite minor variation in the characteristics of the masa flour. Specifically, the preconditioner added steam-to-water ratio can be manipulated to effect cook, hydration, and partial gelatinization of the meal. In the extruder, lower extruder rotational speeds increase the residence time and increases cook. With the increase in residence time the volume of bed pack in the extruder increases. This can be reversed by adding water directly into the extruder, thereby decreasing the viscosity of the meal in the extruder. Product bulk density is changed by increasing and decreasing cook of the meal.

Abstract: Disclosed are low-fat and fat-free snacks having a glossy coating and a process for making the same. Disclosed in a preferred embodiment are coated low-fat and fat-free pretzels having a surface area to inner volume ratio of from about 22 inches−1 (8.66 cm−1) to about 40 inches−1 (15.75 cm−1), a pH of about 8 or less, a digestible fat content of less than 3 g per 28 g serving, and a moisture content of from about 1% to about 4%. The large surface area to inner volume ratio permits the use of reduced concentrations of caustic solution and facilitates drying. Coated pretzels are prepared by: (1) applying a warm coating comprising a carbohydrate selected from modified starch, corn syrup solids, maltodextrins, dextrins, and mixtures thereof; water; and preferably flavoring to ready-to-eat pretzels while tumbling; (2) adding sugar and optionally salt to the tumbling pretzels; (3) removing the pretzels from the tumbling device; and (4) drying the pretzels with the products stationary.

Abstract: A coated confectionery having a crispy starch based center with a thin continuous rigid outer, coating is disclosed. The integrity of the thin continuous rigid outer coating is maintained even after prolonged storage. Also disclosed is a method for preparing such coated confectionery.

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: A method for providing an expandable half-product is described comprising a starchy farinaceous material, wherein the starch molecules of the farinaceous material are unidirectionally aligned and form a matrix of randomly aligned starch molecules upon exposure to microwave radiation to form a puffed half-product having at least twice the dimensions of the unmicrowaved half-product.

Abstract: A method for preparing a snack food comprises the steps of subjecting dough for snack foods to a puffing treatment through hot-air drying and then incorporating, into the puffed snack dough, oils and fats having a saturated fatty acid content of not more than 40% and an unsaturated fatty acid content of not less than 50%, as an oil and fat component. The method permits the preparation of a snack food that makes it possible to provide the smooth and easy melting ability of the oil and fat component in the mouth, which has light taste and texture and leaves a pleasant aftertaste.

Abstract: Disclosed are apparatus (10) for making a complexly patterned extrudate. The apparatus (10) includes a food cooker extruder (12) for providing at least one extrudable food product, at least one food color supply (18), a pattern forming die (20) for mixing the food color and extrudate food product to form a complexly patterned food product, a reducing passageway for reducing the cross sectional area of the patterned dough from an inlet end (34) to outlet end (36) of at least 50:1 at an average convergence angle of .ltoreq.45.degree. and an extruder exit port at the discharge end of the reducing passageway. The methods comprise the steps of: providing a plastic extrudable food mass; providing at least one color; mixing the food mass and color to form an organized complexly patterned food dough having an initial cross sectional area; reducing the initial cross sectional area by a factor of at least 50:1 with an average convergence angle of .ltoreq.45.degree.

Abstract: Using a metal mold (8) having an insulating section provided with vapor release sections, pressure outside the metal mold (8) is reduced, and heating is performed while releasing vapor produced thereby through the vapor release sections. This can prevent insulation breakdown caused by condensation of large amounts of vapor produced by ingredients during molding and heating of molded baked snacks by means of resistance heating, dielectric heating, etc.

Abstract: An adjustable variable flow restriction element and an extruder containing the same are provided for mechanically controlling the bulk density of an extruded material. The adjustable flow restriction element is located in an extruder proximate to the die of the extruder in position to partially block the downstream flow of material through the extruder. The adjustable flow restriction element is structured to be capable of assuming one of a plurality of uniquely flow restrictive positions, where the degree of restriction of flow controls the bulk density of an extruded material. A method of mechanically controlling the bulk density of an extruded material by restricting the flow of the material through an extruder is also provided.

Abstract: A process for the manufacture of cooked cereals or dry pet food which comprises preparing a mixture of water and a dry premix mainly comprising cereal flour or semolina, cooking the mixture and extruding it by pressing it through an extrusion die with the aid of a gear pump.

Abstract: For preparing an extrusion-cooked food product, a food component emulsifier is combined with water to obtain an aqueous dispersion of the emulsifier, and the dispersion is fed into an extruder for being mixed with food components being mixed and heated in the extruder to prepare the extrusion-cooked product.

Abstract: Process for the preparation of a foodstuff by extrusion, in which a food substance is introduced into, mixed and cooked in a first section of a twin-screw extruder, the cooking of the mass obtained in a cooker connected up in parallel with the first section and a second section of the extruder dynamically separated from the first is prolonged, and the cooked mass is reintroduced into the second section, the mass is extruded by passing it through a die and the extruded product is cut.

Abstract: Process for preparing a foodstuff by extrusion, in which a first food substance to be processed is introduced into a first section of a twin-screw extruder, a second food substance to be processed is introduced into a second section of the twin-screw extruder, this section being separated dynamically from the first, these substances are each processed independently in their own section of the extruder, the two masses obtained are extruded, passing them through at least one die, and the extruded product or products is or are cut.

Abstract: A method of forming a weather resistant sweet corn based animal feed product includes mixing sweet corn and water to form a sticky mixture which is then extruded through an open tapering die where the mixture is greatly pressurized and ejected as a continuous log of a size and shape dictated by the die. The log is then cut to length to produce weather resistant sweet corn based animal feed products.

Abstract: Apparatus and methods are disclosed where plastic extrudable food product is provided such as by a food cooker extruder and is mixed with an additive to form a patterned food product, such as by a pattern forming die. The cross-sectional area of the patterned food product is reduced from an inlet end to an outlet end by a factor of at least 50:1 at an average convergence angle of <45.degree. while maintaining the cross-sectional pattern to form a reduced cross-sectional patterned dough, and then is extruded through a die port having an opening equal to the reduced cross-sectional area to form a complexly patterned extrudate.

Abstract: Apparatus for positive displacement metering of viscous material. Positive displacement and non-positive pumping of material to be metered is provided. The positive displacement pumping includes pressure release apparatus to avoid excessive pressure build-up. One pressure release apparatus includes an expansion chamber to moderate pressure changes.

Abstract: Disclosed is a food product having at least one distinct phase and a process and apparatus for producing such a product wherein a blend of ingredients, having a moisture content, is extruded in separate streams, and a coloring, flavoring or texturizing agent is added to the extruded streams at a pre-determined point. The streams are re-combined and then passed through a static mixer which produces minimal mixing while allowing a smooth separation and a proper flow into a die insert such as a shaping die.

Abstract: A sweetened extruded food product based on a vegetable material containing a sweetener incorporated before extrusion is formulated so that the sweetener contains a significant proportion of sucralose. In particular, the sucralose provides at least 50%, preferably at least about 75%, of the sweetness.

Abstract: A method and pellet mill apparatus for the continuous preparation of improved animal feed pellets cooks a grain mash with steam under superatmospheric pressure which extends through a conditioning chamber within the mill and to an extrusion die to increase conditioning and gelatinization of the mash.

Abstract: An improved extrusion process for making a reconstitutable instant refried bean product, the process including:introducing a bean grind into a co-rotating twin screw extruder;adding sufficient water to the extruder to elevate the moisture content of the bean grind to be in the range of 25-40% by weight;heating the bean grind to a temperature in the range of 100.degree. C. to 180.degree. C.;extruding the cooked bean grind;the improvement including:advancing and massaging the bean grind towards an extrusion die to gelatinize the bean starch and still maintain starch granule integrity in forming a bean dough;selecting a die restriction such that pressure necessary to force such bean dough through the die is approximately equal to the vapor pressure of steam built up due to the product temperatures generated inside the extruder, and by virtue of die selection minimizing expansion and retrogradation of such bean dough;exploding such bean dough from the die as the steam and product escape.

Abstract: A dried food composition is prepared by extrusion-cooking and drying so that the composition has a specific gravity of from 150 g/l to 500 g/l, and when rehydrated during preparation of such as a soup, the composition floats during rehydration. To prepare the composition, cereal flour and/or semolina, a fat, water and a protein and/or glucide filler substance ingredients are introduced into a twin-screw extruder and extrusion-cooked, the extruded, cooked product is cut into pieces and then, the product pieces are dried, and the ingredients are in amounts and are extrusion-cooked under a temperature of from 80.degree. C. to 160.degree. C. under a pressure of from 60 bar to 150 bar so that upon extrusion-cooking, the extruded, cooked product has, by weight, a fat content of from 6% to 14% and a moisture content of from about 10% to 16% and so that upon the extrusion cooking and drying, the dried product has a specific gravity of from 15 g/l to 500 g/l.

Abstract: An extrusion die apparatus adapted for coupling to the outlet end of an extruder barrel and corresponding methods of use are described. The die apparatus, when so coupled to the extruder barrel, has 1) an inlet-end chamber downstream of and in communication with the interior of the extruder barrel, 2) a secondary chamber downstream of and in communication with the inlet-end chamber, and 3) a plurality of individual, spaced die-outlet orifices downstream of and in communication with the secondary chamber. The die apparatus includes manually or automatically controllable inserts for controlling the operating pressures within the chambers and outlet orifices. These operating pressures are adjusted so that the pressure within the inlet-end chamber, which controls cooking, is greater than the pressure within the secondary chamber, and the pressure within the secondary chamber is greater than the pressure within each outlet orifice. In operation, the die apparatus receives product from the extruder barrel.

Abstract: A product densification method for producing sinking aquatic feed, densified cattle "range cubes" or the like includes a conventional cooking extruder into which feed ingredients, including cereal grains and additives, are introduced. The feed ingredients are cooked, gelatinized and expanded in the cooking extruder to form an intermediate feed product. The intermediate feed product is then loaded onto a cooling conveyor where it is transported to a product densification unit or PDU. The PDU is a specially designed high speed, low shear extruder which is adapted to densify and shape the intermediate feed product into a final feed product which is dense enough to sink in water and stable enough to stay together for a considerable period of time while submerged or exposed to weather. The density of the sinking feed, and therefore, the sink rate thereof, can be controlled by controlling the shaft speed of the high speed screw in the PDU.

Abstract: A process for enrichment of animal food with fat is described wherein air cell bubbles are introduced to a highly dense product in the extrusion system by the utilization of carbonation technology into the oils and fats with various functional and textural properties. It includes the use of low to highly charged oils and fats with various gases under pressure injected into the extrusion stream within the extruder under lower pressure to assist in the expansion of the extrudate once it leaves the die nozzle.

Abstract: A cooking-extruding apparatus and method for the cooking-extrusion of biopolymers for the production of thermally treated food granulates, snack products, cereals or similar products. The cooker-extruder having a feeding hopper, a conveying screw, an exit nozzle, and at least one spatula-pump disposed between the conveying screw and the exit nozzle. Each spatula-pump includes a spatula element and plate having a matrix of holes. In operation, the spatula element assists the material being processed through the plate having a matrix of holes. An embodiment of the apparatus of the present invention includes the use of two conveying screws. The spatula-pumps are arranged serially such that the material being processed passes through one spatula-pump to the next until it is passed through the exit nozzle of the apparatus.

Abstract: A method and machine for making churros. The machine extrudes churros through a die. The die has a central mandrel so that hollow churros are made which can be filled. The churros are extruded from the machine when an operator rams a crank on the machine. Consistent, high quality churros can be made at high production rates suitable for use in a restaurant.

Abstract: This apparatus provides positive displacement synchronized metering of pressurized food material to a plurality of dies using several positive displacement metering apparatus. The metering is provided by the energy of pressurized material itself, or, for more viscous material, it can be supplemented by a motor. Supplemental material can also be introduced along with the food material to modify the characteristics of the food material.

Abstract: Instant fresh corn dough or masa may be prepared in short processing times, with low energy consumption and without liquid wastes by extruding a mixture of corn flour, lime and water in an extrusion or kneading chamber until a homogeneous dough is obtained, heating the homogeneous dough to cooking temperature while kneading is continued, expelling the cooked dough through a die from the extrusion chamber to a holding chamber, cooling the dough in said holding chamber and discharging the cooked and cooled dough through a discharge orifice, whereby the total processing time may be reduced to between 1.5 to a maximum of 7 minutes for the preparation of a fully nixtamalized corn dough or masa.

Abstract: A process for adding fat to an extruded pet food composition using an under oil cutting process wherein the extrudate is simultaneously cut, infused with oil and dried to form food pellets.

Abstract: An assembly (10) is disclosed including a rotor (38) extending into a rotor bore (24) and into a dough chamber (26) of a die housing (16), with the rotor (38) rotating at relatively high speeds in the order of 4,000 RPM. A bushing (62) is provided in the rotor bore (24) to provide a seal with the rotor (38). The bushing (62) has a small clearance with the rotor (38) sufficient to reduce frictional forces to minimize wear while effectively preventing passage of the extrudable dough under pressure in the order of 2,800 psi (200 kg per square centimeter) through the rotor bore (24) and around the rotor (38). The dough which does pass through the small clearance is allowed to fall away from the rotor (38) outside of the rotor bore (24).

Abstract: A dog treat food product is disclosed which is extruded from a nutritionally balanced mixture of carbohydrate, protein, fat, vitamins and minerals. The dog treat food product exhibits improved resistance to breakage on impact by drying pieces of the extrudate under controlled conditions of humidity to a moisture level of between 6-10% by weight at a relative humidity of about 5 to about 25%, a dry bulb temperature of about 150.degree. to about 250.degree. F., a wet bulb temperature of about 105.degree. to about 150.degree. F. and for at least 15 minutes.

Abstract: A method and apparatus for the manufacture of a pet food having a transverse, fibrous striated matrix which imparts a superior mechanical cleaning action to the teeth of a pet when chewed. The apparatus includes an extruder through which a fiber bearing food mixture is advanced, the discharge outlet end of which is equipped with a die assembly which induces a state of laminar flow in the food material stream. The die assembly is constructed of a first spacer plate having an annular opening positioned to receive and stabilize the food stream advanced through the die assembly. A breaker plate adjacent to the first spacer plate, receives the flow stabilized food stream and effects a first, discontinuous, alignment of the fibers in the stream. A second spacer plate receives the food stream discharged form the breaker plate. The second spacer plate has a length at least twice that of the first spacer plate, whereby the fibers in the food stream are aligned into a continuous transversely aligned state.