Abstract: A co-rotating twin screw processor for preparing dry granules including an input zone having one or more powder feeders for feeding an input material into the processor, a steam feeder configured to introduce steam as a granulation activating agent in to the processor, a granulation zone for granulating the input material in the presence of steam to form granules, a controller configured to control operation and feed rate of at least one of the powder feeder or the steam feeder such that 2.5 to 5 percent w/w of the steam with respect to the input material is available for granulation, and a discharge zone haring a non-extruding opening for collecting dry granules.

Abstract: Methods of preparation and improved oat based puffed R-T-E or breakfast cereal products resulting there from with reduced sodium levels that provide good cooked grain flavor relative to other low or no sodium cooked cereal products and that approach the quality of higher sodium level products are provided. The methods include formulating cooked cereal doughs with minimal levels of sodium chloride and including a blend of potassium chloride and choline chloride. The cooked cereal dough is formed into pellets and gun puffed to form puff products having a total pyrazine content of at least 200 ppm. The puffed products are topically coated with saline solution and dried to provide the present improved low sodium high flavor finished breakfast cereal products.

Abstract: A method for making an expanded snack piece using supercritical fluid extrusion is disclosed. A mixture of shear thinning starch and heat-sensitive ingredients are input into an extruder, hydrated, and mixed with supercritical fluid. The extrudate can be subjected to further processing to set or alter its structure.

Abstract: A method to produce a food product comprises the steps of providing a plurality of flint corn kernels; drying the flint corn kernels; popping the flint corn kernels; cooling the porous, airy, elastic foam particles produced during popping; cutting with a moving blade said porous, airy foam particles into pieces having a width greater than 0.005 inches to produce an elastic, air entrained popcorn flour occupying a volume; and, vacuum packaging the elastic popcorn flour to reduce the volume occupied by the popcorn flour.

Abstract: The present invention relates to a method for preparing instant dried scorched rice with excellent resilience, comprising washing a mixture of nonglutinous rice and glutinous rice, followed by soaking, adding polygonatum concentrate and rice starch, as a separate process, to the washed rice to prepare rice cooking water, followed by performing rice cooking to prepare cooked rice, mixing the cooked rice with purified water in a scorched rice forming apparatus to prepare scorched rice and grinding to prepare instant dried scorched rice.

Abstract: Extruded, directly expanded, high fiber reduced calorie food products, such as a ready-to-eat (RTE) cereal or sweet or savory snack, are produced at high production rates without substantial loss of extrusion functionality and extrudability by replacing a substantial portion of at least one flour with a gelatinized, enzyme-resistant starch type III ingredient or bulking agent as a reduced-calorie, high fiber flour replacer. The resistant starch type III ingredient or bulking agent contains an enzyme-resistant starch type III having a melting point with an endothermic peak temperature of at least about 140° C., and may have a water-holding capacity of less than 3 grams water per gram of the starch-based bulking agent. The total dietary fiber retention of the gelatinized, starch-based bulking agent may be at least about 90% by weight after extrusion using a die temperature of least about 100° C., and a die pressure of at least about 150 psig.

Abstract: A method of manufacture of a crumb coated food product comprising the steps of forming an aqueous mixture comprising: a flour mixture comprising one or more flours, sodium bicarbonate, optional additives selected from processing aids, salts, colorants and, water; adding the mixture into an extruder; adding an aqueous gelling agent to the extruder; extruding the resultant mixture at a temperature greater than 100° C. to form an extrudate; allowing the extrudate to expand to form a porous product; drying the product, and milling the dried product to form a crumb.

Abstract: A cereal composition comprising a waxy starch in an amount from about 5 to about 15% by weight of the total composition and a cereal mixture comprising a fiber source in an amount from about 1 to about 15% by weight of the total composition. The cereal composition is mixed with water and expanded by extrusion to form a high-fiber cereal product. Also, a method of producing a high fiber expanded cereal product comprising the step of combining a waxy starch in an amount from about 5 to about 15% by weight of the total composition and a cereal mixture comprising a fiber source in an amount from about 1 to about 15% by weight of the total composition to form a total cereal composition. The total cereal composition is mixed with water and extruded to form an expanded cereal product.

Abstract: A method for producing wafers by extrusion comprising the steps of a. Preparing an ingredient mix b. Feeding the mix in an extruder and cooking the mix c. Extruding the cooked mix such that an extruded and expanded non-planar structure is formed d. Unfolding the structure to give a large extruded sheet e. Subjecting the extruded sheet to stretching/pulling f. Adjusting the sheet in order to obtain a desired thickness g. Drying the sheet h. Separating the sheet into wafers of desired dimensions The invention also relates to the wafers thus produced and to a wafer production line.

Abstract: Improved extruded starch-bearing products (e.g., starches, starch-bearing legumes, starch-bearing grains and formulations containing any of the foregoing) are provided having relatively high cook values and low cold water viscosities. The products are prepared by initial preconditioning to partially cook the starting material(s), followed by low shear extrusion cooking, with a total STE/SME ratio of at least about 4.

Abstract: A method for making a quick-cook grain or pulse via flat plate compression or gun puffing by controlling the porosity of the grain or pulse. Further, the grain or pulse made in accordance with this invention retains the texture, flavor and appearance of the original grain or pulse.

Abstract: An extruded, directly expanded, high fiber reduced calorie food product, such as a ready-to-eat (RTE) cereal or sweet or savory snack, is produced at high production rates without substantial loss of extrusion functionality and extrudability by replacing a substantial portion of at least one flour with a gelatinized, enzyme-resistant starch type III ingredient or bulking agent as a reduced-calorie, high fiber flour replacer. The resistant starch type III ingredient or bulking agent contains an enzyme-resistant starch type III having a melting point with an endothermic peak temperature of at least about 140° C., and may have a water-holding capacity of less than 3 grams water per gram of the starch-based bulking agent. The total dietary fiber retention of the gelatinized, starch-based bulking agent may be at least about 90% by weight after the extrusion using a die temperature of least about 100° C., and a die pressure of at least about 150 psig.

Abstract: The invention relates to a method for the continuous production of an expanded edible food product obtained by cooking-extrusion and containing solid inclusions having a size larger than 0.5 mm.

Abstract: A process for the production of fresh masa, nixtamalized flour and derived products. The invention is a new process for production of corn masa (dough) to be used in the production of tortillas, fried or baked tortilla chips, tostadas, or corn chips. The new process produces masa directly from raw materials without the traditional cooking and steeping steps. It utilizes a series of processing steps including dry blending, hydrating, and working dough in an extruder having a unique screw configuration. The new process uses very little water and emits no waste water.

Abstract: A popcorn popper having a heat source transferring heat to a heating surface and also having a reflective surface for focusing the heat radiated by the heat source toward the heating surface. The popcorn popper can include a mechanical stirrer on the heating surface for shifting the kernels during heating and evenly distributing the kernels across the heating surface. The popcorn popper can have a cover with an integrated reservoir for holding toppings for the popcorn, wherein the reservoir is adapted to drain the topping through the cover without fouling the cover air vents and evenly distribute the topping onto the kernels.

Abstract: An apparatus and method for producing a substantially spiral shaped food product is disclosed herein. The apparatus includes a die defining a plurality of apertures disposed in a circle about a center. The apparatus also includes at least one cutting blade disposed for rotation about the center and operable to intermittently pass fully across each of the apertures during rotation. The apparatus also includes a plurality of slicing blades arranged for individual rotation about one of the plurality of apertures. The plurality of slicing blades are also arranged for continuous extension less than fully across the one aperture. The apparatus also includes a planetary coupling arrangement operably disposed to facilitate reciprocating rotation between the at least one cutting blade and the plurality of slicing blades.

Abstract: Improved extruded starch-bearing grain products (e.g., corn and wheat) are provided having relatively high cook values and low cold water viscosities. The products are prepared by initial preconditioning to partially cook the starting material(s), followed by low shear extrusion cooking, with a total STE/SME ratio of at least about 4.

Abstract: A hand-held oatmeal product is provided that is ready to eat. The oatmeal product may be packaged in a retortable pouch. Methods of making the oatmeal product are provided.

Abstract: An extruded, directly expanded, high fiber reduced calorie food product, such as a ready-to-eat (RTE) cereal or sweet or savory snack, is produced at high production rates without substantial loss of extrusion functionality and extrudability by replacing a substantial portion of at least one flour with a gelatinized, enzyme-resistant starch type III ingredient or bulking agent as a reduced-calorie, high fiber flour replacer. The resistant starch type III ingredient or bulking agent contains an enzyme-resistant starch type III having a melting point with an endothermic peak temperature of at least about 140° C., and may have a water-holding capacity of less than 3 grams water per gram of the starch-based bulking agent. The total dietary fiber retention of the gelatinized, starch-based bulking agent may be at least about 90% by weight after the extrusion using a die temperature of least about 100° C., and a die pressure of at least about 150 psig.

Abstract: High-capacity extrusion die assemblies (20, 90, 130, 140, 180, 252) each having a tubular sections (44, 146, 162, 268) and an elongated, axially rotatable, helically flighted screw section (56, 56a, 152, 168, 276, 278) which cooperatively define frustoconical, outwardly diverging material flow paths (75, 160, 291) at constant or differing divergence angles of from about 1-11°. The use of diverging tubular sections (44, 146, 162, 268) and screw sections (56, 56a, 152, 168, 276, 278) permits the use of larger die plates (76, 118, 292) with an increased number of die openings (80, 124, 296). This allows significant increases in extrusion production rates. The die assemblies (20, 90, 130, 140, 180, 252) can be used in the production of a wide number of human foods or animal feeds, and particularly aquatic feeds of the floating or sinking variety.

Abstract: The present invention comprises an improved extruder die assembly and method for using same to improve the quality of dimensional design aspects of extruded, complexly shaped, direct expanded food products. The improved system includes an improved die assembly comprising a first die and a second die having at least one orifice. A majority of the total pressure drop occurs in the first die to pre-expand the dough prior to the dough entering the second die. The orifices in the first die can be individually configured to obtain differing dough flow speeds resulting in a desired flow pattern. A plurality of extruded dough ropes formed at each orifice exit of the first die can meld together in the bore and exit the second die. Color or flavor can be added at the first die to enhance the food product.

Abstract: A method for making partially popped popcorn from hulled corn kernel is provided. A hulled corn comprising a pericarp structure and interior endosperm having an internal moisture content is modified, such as by boiling, soaking or steaming, to achieve a predetermined moisture content sufficient to inhibit but not prevent popping of the kernel. The modified kernel is exposed to a heated environment, such as a hot air popper, until the modified endosperm expands and ruptures the endosperm, resulting in a partially popped kernel.

Abstract: A method of manufacturing starch-free flour includes the steps of grinding a starch-free rice bran to form a bran powder; finely grinding the bran powder under a predetermined circumstance to form nano bran fine particles carrying positive charges and having water and oil absorbing ability; and mixing the nano bran fine particles with protein powders and gluten powders to form the starch-free flour.

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: Disclosed are ready-to-eat puffed dried food products that are high both in protein and in fiber. The cereals contain sufficient amounts of at least one protein ingredient to provide a total protein content about 50% to 75% (dry weight) of the cooked food product; sufficient amounts of at least one dietary fiber ingredient to provide a total fiber content of about 1-45% (dry weight); and sufficient amounts of a starch containing ingredient to provide a starch content of about 5-45%. The food products have a crush strength raging from about 0.25 to 3.5 kg/cm3.

Abstract: The present invention comprises an improved extruder die assembly and method for using same to improve the quality of dimensional design aspects of extruded, complexly shaped, direct expanded food products. The improved system includes an improved extruder die assembly comprising an imprinting insert element having a first aperture defined therethrough and at least one prong extending into the first aperture, and a forming insert element having a second aperture defined therethrough and positioned downstream from the imprinting insert element, wherein the shape of the second aperture is defined by at least one projection extending into the second aperture, and wherein each of the at least one projection aligns with a prong when the first and second apertures are coaxially aligned. The improved extruder die assembly of the present invention is designed for adaptation to a wide variety of commercial-grade extrusion devices common in the food industry.

Abstract: A starch hydrolysis food making process comprises mixing rice flour and rice syrup or honey in equal parts, adding amylase enzymes to the mixture, and extruding for a few seconds at an elevated temperature. Water may be added to the rice flour mixture to adjust the final product texture. A second extrusion can be used to adjust the pH. In a second starch hydrolysis method embodiment of the present invention, one part of water is mixed with five parts of rice flour. Then amylase enzymes are added to the mixture and extruded for a few seconds at an elevated temperature. The extrusion products are then packaged as food ingredients.

Abstract: The present invention includes a method of making a puffed food starch material snack, in particular starch material from grains, having an improved crispy texture and a more aesthetic appearance. The products may be snack chips, cakes, crackers or the like, made from food starch material. Preferably, the starch material is provided primarily in the form of individual kernels or pellets of a cereal grain, such as rice, corn, wheat, rye, oats, millet, sorghum, barley, buckwheat, or mixtures thereof. According to one method, a puffing chamber is provided having inner surfaces and a chamber volume. An amount of the food starch material is placed into the puffing chamber. The amount of food starch material is caused to volumetrically expand. The expanding food starch material is constrained in its expansion in at least a first dimension, while permitting unconstrained expansion of the amount in at least a second dimension.

Abstract: The invention described in this application relates to food compositions such as breakfast cereals, bread and the like which have an enhanced dietary fiber content. In each case the source of dietary fiber is a starch, preferably a maize starch, having an amylose content of 50% or more, the starch being incorporated into a food composition as appropriate. Alternatively, grains or legumes or parts thereof which include starch of this amylose content may be used.

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: A method is described in which expanded snack and breakfast cereal products are produced with durum wheat flour, durum semolina, durum granular or other products of Triticum Durum and which can be produced in a simple and quick process which, surprisingly, eliminates the disadvantages of prior art. Furthermore, the invention related to a product produced according to the new method.

Abstract: Hard candy exhibiting a plurality of segments having differing colors and varying widths is produced by depositing a plurality of supersaturated solutions of ingredients of differing colors into a mold through a nozzle which has openings around its periphery wherein the openings have different widths.

Abstract: The present invention includes puffed-food starch material snack, in particular starch material from grains, having an improved crispy texture and a more aesthetic appearance and methods for preparing them. In general terms, the products are snack chips, cakes, crackers or the like, made from food starch material. Preferably, the starch material is provided primarily in the form of individual kernels or pellets of a cereal grain, such as rice, corn, wheat, rye, oats, millet, sorghum, barley, buckwheat, or mixtures thereof. Quantities of other food starch material es may also be employed as a co-mixed constituent, or the primary source of bulk starch material, for example potato starch material. A quantity of the grain is puffed (expanded) in a manner which forms a snack product of considerable crispiness, lightness, and unique texture to both the mouth and eye.

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: An extrudable food product is provided by a food cooker extruder (12) and is mixed with an additive to form a patterned food product, using a pattern forming die (20, 220). The cross-sectional area of the patterned food product is reduced from an inlet end (34) to an outlet end (36) by a factor of at least 50:1 at an average convergence angle of ≦45° while maintaining the cross-sectional pattern to form a reduced cross-sectional patterned dough, and then is extruded through a die port (13) having an opening equal to the reduced cross-sectional area to form a complexly patterned extrudate. The food product comprising, multiple extrudates are simultaneously formed with the flow rates for each extrudate being adjustable by an adjuster plug (16) including a smooth cylindrical portion (86) extendable into a passageway (14) having a circular cross section of a larger diameter than the cylindrical portion (86).

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 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: The invention described in this application relates to food compositions such as breakfast cereals, bread and the like which have an enhanced dietary fibre content. In each case the source of dietary fibre is a starch, preferably a maize starch, having an amylose content of 50% or more, the starch being incorporated into a food composition as appropriate. Alternatively, grains or legumes or parts thereof which include starch of this amylose content may be used.

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 process for manufacturing an expanded cereal with the overall shape of an array of touching balls and an extrusion die and an extruder for use with the process. The die includes a feed ring for receiving material from an extruder, a cylindrical distribution chamber having a front wall and rear wall which includes the feed ring, and an array of parallel extrusion tubes provided in the front wall of the distribution chamber. The feed ring is in communication with the array of parallel extrusion tubes through the distribution chamber. The distribution chamber also includes a cylindrical distribution insert that extends axially from the center of the feed ring towards the front wall but spaced from the array of extrusion tubes. The process involves cooking and extruding a mixture of starchy material, sugar, oil, and water in a cooker-extruder and forcing the cooked material through the extrusion die.

Abstract: The present invention relates to a method for preparing an instant soakable rice product which comprises dehydrated rice. The instant soakable rice product is rehydrated in use by the addition of hot water over a period of 3-5 minutes. The method of the invention involves a sequence of steps including a first soaking step at ambient temperature, a first steaming step, a second soaking step at an elevated temperature compared to the first soaking step and a second steaming step. The rice is then dried and puffed to form the instant soakable rice product of the invention.

Abstract: A process and apparatus for recovering organic and inorganic matter from waste material wherein the waste material is sterilized and solid organic matter becomes soft when subjected to heat and pressure. The process may be carried out by first, feeding the waste material into a perforated container (10) mounted within a closed chamber (14). Next, the waste material is agitated and subjected to heat and pressure which sterilizes it and softens the organic matter contained therein. After heating under pressure, the pressure may be suddenly released from the chamber (10) which forces the softened organic matter outwardly through the perforations (12) of the container, thus separating the organic matter from the solid inorganic matter.

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: 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 gelatinized cereal product which contains a plant material which is a source of inulin; for example chicory. Sufficient of the plant material is included to provide at least about 0.25% by weight of inulin on a dry basis. The cereal product may be used as a pet food or breakfast cereal.

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: 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: A transportable and size-adjustable ripening apparatus for controlled ripening of produce includes a chamber defined by a ceiling, a floor, and walls connecting the ceiling and the floor. The chamber is configured to receive a row of boxed produce that defines an interstitial volume with one of the walls to create a low-pressure plenum. The ripening apparatus also includes an air flow control system for transferring air between a high pressure plenum and the low pressure plenum, and which controls the temperature of the transferred air. The plena are generally enclosed to inhibit airflow therebetween except for airflow through the air control system and through openings in the produce boxes. The air control system includes one system for controlling the flow of air through a refrigeration unit, and another system for circulating air without refrigeration. The invention is preferably constructed from an existing ISO (International Standards Organization) container.

Abstract: The method of adjusting the saturation concentration of a drug in a transdermal composition for application to the dermis, which comprises mixing polymers having differing solubility parameters, so as to modulate the delivery of the drug. This results in the ability to achieve a predetermined permeation rate of the drug into and through the dermis. In one embodiment, a dermal composition of the present invention comprises a drug, an acrylate polymer, and a polysiloxane. The dermal compositions can be produced by a variety of methods known in the preparation of drug-containing adhesive preparations, including the mixing of the polymers, drug, and additional ingredients in solution, followed by removal of the processing solvents. The method and composition of this invention permit selectable loading of the drug into the dermal formulation and adjustment of the delivery rate of the drug from the composition through the dermis, while maintaining acceptable shear, tack, and peel adhesive properties.