CA2532968A1 - Apparatus and method for improving dimensional quality of direct-expanded food products having complex shapes - Google Patents

Apparatus and method for improving dimensional quality of direct-expanded food products having complex shapes Download PDF

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Publication number
CA2532968A1
CA2532968A1 CA002532968A CA2532968A CA2532968A1 CA 2532968 A1 CA2532968 A1 CA 2532968A1 CA 002532968 A CA002532968 A CA 002532968A CA 2532968 A CA2532968 A CA 2532968A CA 2532968 A1 CA2532968 A1 CA 2532968A1
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CA
Canada
Prior art keywords
nozzle
passageway
section
inlet
insert
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002532968A
Other languages
French (fr)
Other versions
CA2532968C (en
Inventor
Jorge C. Morales-Alvarez
Eugenio Bortone
Lewis Conrad Keller
Edward Leon Ouellette
Scott Alan Richey
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Frito Lay North America Inc
Original Assignee
Frito-Lay North America, Inc.
Jorge C. Morales-Alvarez
Eugenio Bortone
Lewis Conrad Keller
Edward Leon Ouellette
Scott Alan Richey
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US10/622,400 external-priority patent/US7252847B2/en
Priority claimed from US10/623,048 external-priority patent/US6854970B2/en
Application filed by Frito-Lay North America, Inc., Jorge C. Morales-Alvarez, Eugenio Bortone, Lewis Conrad Keller, Edward Leon Ouellette, Scott Alan Richey filed Critical Frito-Lay North America, Inc.
Publication of CA2532968A1 publication Critical patent/CA2532968A1/en
Application granted granted Critical
Publication of CA2532968C publication Critical patent/CA2532968C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
    • A23G1/00—Cocoa; Cocoa products, e.g. chocolate; Substitutes therefor
    • A23G1/04—Apparatus specially adapted for manufacture or treatment of cocoa or cocoa products
    • A23G1/20—Apparatus for moulding, cutting, or dispensing chocolate
    • A23G1/201—Apparatus not covered by groups A23G1/21 - A23G1/28
    • A23G1/202—Apparatus in which the material is shaped at least partially by a die; Extrusion of cross-sections or plates, optionally with the associated cutting device
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
    • A23G3/00—Sweetmeats; Confectionery; Marzipan; Coated or filled products
    • A23G3/0002—Processes of manufacture not relating to composition and compounding ingredients
    • A23G3/0004—Processes specially adapted for manufacture or treatment of sweetmeats or confectionery
    • A23G3/0019—Shaping of liquid, paste, powder; Manufacture of moulded articles, e.g. modelling, moulding, calendering
    • A23G3/0021—Processes in which the material is shaped at least partially by a die; Extrusion of cross-sections or plates, optionally the associated cutting
    • A23G3/0023—Processes for cutting, modelling of sections or plates; Embossing, punching
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
    • A23G3/00—Sweetmeats; Confectionery; Marzipan; Coated or filled products
    • A23G3/0002—Processes of manufacture not relating to composition and compounding ingredients
    • A23G3/0004—Processes specially adapted for manufacture or treatment of sweetmeats or confectionery
    • A23G3/0019—Shaping of liquid, paste, powder; Manufacture of moulded articles, e.g. modelling, moulding, calendering
    • A23G3/0042—Moulding or shaping of cellular or expanded articles
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
    • A23G3/00—Sweetmeats; Confectionery; Marzipan; Coated or filled products
    • A23G3/02—Apparatus specially adapted for manufacture or treatment of sweetmeats or confectionery; Accessories therefor
    • A23G3/0236—Shaping of liquid, paste, powder; Manufacture of moulded articles, e.g. modelling, moulding, calendering
    • A23G3/0242—Apparatus in which the material is shaped at least partially by a die; Extrusion of cross-sections or plates, optionally the associated cutting device
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/161—Puffed cereals, e.g. popcorn or puffed rice
    • A23L7/165—Preparation of puffed cereals involving preparation of meal or dough as an intermediate step
    • A23L7/17—Preparation of puffed cereals involving preparation of meal or dough as an intermediate step by extrusion
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/20—Extruding
    • A23P30/25—Co-extrusion of different foodstuffs
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/30—Puffing or expanding
    • A23P30/32—Puffing or expanding by pressure release, e.g. explosion puffing; by vacuum treatment
    • A23P30/34—Puffing or expanding by pressure release, e.g. explosion puffing; by vacuum treatment by extrusion-expansion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/06—Rod-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/11—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/19—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their edges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/285—Feeding the extrusion material to the extruder
    • B29C48/29—Feeding the extrusion material to the extruder in liquid form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/304—Extrusion nozzles or dies specially adapted for bringing together components, e.g. melts within the die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/60—Multitubular or multicompartmented articles, e.g. honeycomb

Abstract

The present invention comprises an improved extruder die assembly and method for using same to impart a distinct colored and/or flavored pattern into an extrudable food mass during the extrusion process. The extruder die assembly includes a forming section (1200) and an injection section (1300) for imparting the distinct colored and/or flavored pattern into an extrudable food mass. The resulting food mass is compressed through a converging nozzle bore in the nozzle section (1400) to produce an extruded food product. The converging nozzle section may also include axially aligned ridgelines (1420a, 1420b) which gradually project into the bore of the nozzle as the nozzle converges to gradually disrupt the axial flow of an extrudate at specific peripheral points thereby altering the extrudate's velocity profile, which improves the quality of dimensional design aspects of the resulting extruded, complexly shaped, direct expanded food products.

Claims (84)

1. An extruder die assembly for improving the dimensional quality of complexly shaped, direct expanded food products, comprising in combination:
(a) an imprinting insert element having a first aperture defined therethrough and at least one prong extending into the first aperture;
(b) 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;
wherein each of the at least one projection aligns with a prong when said first and second apertures are coaxially aligned.
2. The extruder die assembly of Claim 1 further comprising in combination a plurality of spacer insert elements having a third aperture defined therethrough, wherein said apertures are all coaxially aligned.
3. The extruder die assembly of Claim 2 wherein the plurality of spacer insert elements are positioned upstream of the imprinting insert element.
4. The extruder die assembly of Claim 2 wherein at least one of the plurality of spacer insert elements are positioned between the imprinting insert element and the forming insert element.
5. The extruder die assembly of Claim 2 further comprising in combination a transition insert section having a passageway with an inlet and an outlet defined therethrough and positioned upstream of the said elements, wherein the passageway and said apertures are all coaxially aligned.
6. The extruder die assembly of Claim 5 wherein the outlet has a circumference matching the third aperture.
7. The extruder die assembly of Claim 1 wherein the forming insert element is positioned at least 5 mm downstream from the imprinting insert element.
8. The extruder die assembly of Claim 1 wherein the forming insert element is positioned less than 55 mm downstream from the imprinting insert element.
9. The extruder die assembly of Claim 1 wherein the forming insert element is positioned approximately 10 mm downstream from the imprinting insert element.
10. An apparatus for improving the dimensional quality of complexly shaped, direct expanded food products, comprising in combination:
(a) ~means for supplying an extrudate flow wherein said means for supplying comprises means for receiving and directing the extrudate flow down a first passageway;
(b) ~an imprinting insert die positioned downstream from the supplying means and having a first aperture defined therethrough which is coaxially aligned with the first passageway, and having at least one prong extending into the first aperture;
(c) ~a forming insert die positioned downstream from the imprinting insert and having a second aperture defined therethrough which is coaxially aligned with the first passageway and the first aperture, and wherein the shape of the second aperture is defined by at least one projection extending into the second aperture;
wherein each of the at least one projection aligns with a prong when said first and second apertures are coaxially aligned.
11. The apparatus of Claim 10 further comprising in combination a plurality of spacer insert dies positioned downstream from the supplying means and having a third aperture defined therethrough which is coaxially aligned with the first passageway and the first and second apertures.
12. The apparatus of Claim 11 wherein the plurality of spacer insert dies are positioned upstream of the imprinting insert die.
13. The apparatus of Claim 11 wherein one or more of the plurality of spacer insert dies are positioned between the imprinting insert die and the forming insert die.
14. The apparatus of Claim 11 further comprising in combination a transition insert section positioned downstream from the supplying means but upstream from said dies and having with an second passageway with an inlet and an outlet defined therethrough, wherein said second passageway is coaxially aligned with the first passageway.
15. The apparatus of Claim 14 wherein the inlet of the second passageway matches the circumference of the first passageway and the outlet has a circumference matching the third aperture.
16. The apparatus of Claim 10 wherein the forming insert die is positioned at least than 5 mm downstream from the imprinting insert die.
17. The apparatus of Claim 10 wherein the forming insert die is positioned less than 55 mm downstream from the imprinting insert die.
18. The apparatus of Claim 10 wherein the forming insert die is positioned approximately mm downstream from the imprinting insert die.

36~
19. An method for improving the dimensional quality of complexly shaped, direct expanded food products, comprising in combination:
(a) ~supplying an extrudate flow comprising receiving and directing the extrudate flow down a first passageway;
(b) ~directing the extrudate flow through an imprinting insert die positioned downstream from the first passageway, wherein said imprinting insert die has a first aperture defined therethrough which is coaxially aligned with the first passageway, and has at least one prong extending into the first aperture;
(c) ~directing the extrudate flow through a forming insert die positioned downstream from the imprinting insert, wherein said forming insert die has a second aperture defined therethrough which is coaxially aligned with the first passageway and the first aperture, and the shape of the second aperture is defined by one or more projections extending into the second aperture;
wherein each of the at least one projection aligns with a prong when said first and second apertures are coaxially aligned.
20. The method of Claim 19 further comprising in combination, positioning a plurality of spacer insert dies upstream from the forming insert die, wherein said spacer insert dies each have a third aperture defined therethrough which is coaxially aligned with the first passageway and the first and second apertures.
21. The method of Claim 20 wherein the plurality of spacer insert dies are positioned upstream of the imprinting insert die.
22. The method of Claim 20 wherein one or more of the plurality of spacer insert dies are positioned between the imprinting insert die and the forming insert die.
23. The method of Claim 19 wherein the forming insert die is positioned at least 5 mm downstream from the imprinting insert die.
24. The method of Claim 19 wherein the forming insert die is positioned less than 55 mm downstream from the imprinting insert die.
25. The method of Claim 19 wherein the forming insert die is positioned approximately 10 nm downstream from the imprinting insert die.
26. ~A nozzle for supplying a pressurized fluid to an injection section that is integral to an extruder die assembly, said assembly enclosed within a housing, comprising:
a generally tubular body having a passageway defined therethrough and comprising, an inlet section having a coupling mechanism for selectively connecting said passageway in fluid communication with a pressurized fluid source;
an outlet section having a discharge port in fluid communication with said passageway;
a first sealing mechanism for forming a seal between said body and an aperture formed in said housing; and a second sealing mechanism for forming a seal between said outlet section and an inlet formed in said extruder die assembly, wherein said inlet connects said discharge port in fluid communication with said injection section.
27. ~The nozzle of Claim 26, wherein said coupling mechanism comprises a threaded fitting.
28. ~The nozzle of Claim 26, wherein said coupling mechanism comprises a threaded female fitting adapted to mate with threads located on a threaded male fitting attached to said pressurized fluid source upon rotation of said nozzle.
29. ~The nozzle of Claim 28, wherein said threaded fitting comprises a hexagonal NPT
threaded fitting.
30. ~The nozzle of Claim 26, wherein said first sealing mechanism comprises a sealing screw thread mechanism formed on a portion of said body, said screw thread mechanism adapted to mate with threads located in said aperture upon rotation of said nozzle.
31. ~The nozzle of Claim 26, wherein said second sealing mechanism comprises a portion of said outlet section having a shape that is complementary to said inlet.
32. ~The nozzle of Claim 31, wherein said outlet section is generally paraboloididal shaped, and said portion of said outlet section is spherically shaped.
33.~A nozzle for supplying a pressurized fluid to an extruder die assembly enclosed within an extruder die plate, comprising:
a generally tubular body having an inlet section, an outlet section, and a passageway defined therebetween;
a first sealing mechanism for forming a seal between said body and an aperture formed in said extruder die plate;
a second sealing mechanism for forming a seal between said outlet section and a supply port inlet formed in said extruder die assembly.
34. ~The nozzle of Claim 33, wherein said inlet section has a coupling mechanism for selectively connecting said passageway in fluid communication with a pressurized fluid source.
35. ~The nozzle of Claim 34, wherein said coupling mechanism comprises a threaded female fitting adapted to mate with threads located on a threaded male fitting attached to said pressurized fluid source upon rotation of said nozzle.
36. ~The nozzle of Claim 33, wherein said inlet section comprises a hexagonal NPT female threaded fitting.
37. ~The nozzle of Claim 33, wherein said first sealing mechanism comprises a sealing screw thread mechanism formed on a portion of said body, said screw thread mechanism adapted to mate with threads located in said aperture upon rotation of said nozzle.
38. ~The nozzle of Claim 33, wherein said second sealing mechanism comprises a portion of said outlet section having a shape that is complementary to said supply port inlet.
39. ~The nozzle of Claim 38, wherein said outlet section is generally paraboloididal shaped, and said portion of said outlet section is spherically shaped.
40. ~The nozzle of Claim 39, wherein said supply port inlet is a concavity defined by half of a sphere of a fixed radius formed in said extruder die assembly that is complementary to the spherically shaped portion of said outlet section.
41. The nozzle of Claim 40, wherein a portion of said supply port inlet is in fluid communication with an injection mechanism that is integral to said extruder die assembly.
42. The nozzle of Claim 41, wherein said passageway defines an outlet port in said portion of said outlet section, said outlet port having a lateral cross sectional area that is smaller than said portion of the supply port inlet.
43. The nozzle of Claim 38, wherein said outlet section is smooth.
44. A nozzle assembly for supplying a pressurized fluid to an extruder die assembly enclosed within a housing, comprising:
a generally tubular body having passageway therethrough defining an inlet and a~
discharge, and comprising, an inlet section having a coupling mechanism for selectively connecting said inlet in fluid communication with a pressurized fluid source;
a middle section having a first sealing mechanism formed thereon for forming a seal between said body and an aperture formed in said housing;
an outlet section having a portion containing said discharge and having a second sealing mechanism for forming a seal between said portion of the~
outlet section and a supply port inlet formed in said extruder die assembly.
45. The nozzle assembly of Claim 44, wherein said inlet section is selectably attached to said a first end of said middle section and said outlet section is selectably attached to a second end of said middle section.
46. The nozzle assembly of Claim 44, wherein said coupling mechanism comprises a threaded female fitting adapted to mate with threads located on a threaded male fitting attached to said pressurized fluid source upon rotation of said nozzle.
47. The nozzle assembly of Claim 44, wherein said inlet section comprises a hexagonal NPT female threaded fitting.
48. The nozzle assembly of Claim 44, wherein said first sealing mechanism comprises a sealing screw thread mechanism formed on a portion of said middle section;
said screw thread mechanism adapted to mate with threads located in said aperture upon rotation of said nozzle.
49. The nozzle assembly of Claim 44, wherein said second sealing mechanism comprises a portion of said outlet section having a shape that is complementary to said supply port inlet.
50. The nozzle assembly of Claim 49, wherein said outlet section is generally paraboloididal shaped, and said portion of said outlet section is spherically shaped.
51. The nozzle assembly of Claim 50, wherein said supply port inlet is a concavity defined by half of a sphere of a fixed radius formed in said extruder die assembly that is complementary to the spherically shaped portion of said outlet section.
52. The nozzle assembly of Claim 51, wherein a portion of said supply port inlet is in fluid communication with an injection mechanism that is integral to said extruder die assembly.
53. The nozzle assembly of Claim 52, wherein said discharge has a lateral cross sectional area smaller than said portion of the supply port inlet.
54. A method for producing an expanded, farinaceous food product having enhanced flavor characteristics without the use of a drying oven, said method comprising, in combination, the following steps:
(a) plasticizing a farinaceous food mixture into a first extrudate flow containing from about 5 weight percent to about 17 weight percent of at least one plasticizer selected from monosaccharides, polysaccharides, and edible alcohols and having a moisture content from about 9 weight percent to about 17 weight percent in an extruder barrel having a barrel pressure equal to or in excess of the vapor pressure of the water in the mixture;
(b) directing the first extrudate flow from said extruder barrel to a central passageway;
(c) imparting at least one cleft in the first extrudate flow thereby dividing the first extrudate flow into a plurality of adjacent flowing extrudate flows;
(d) injecting a flavored fluid additive into the at least one cleft between the plurality of adjacent flowing extrudate flows;
(i) wherein the injecting step utilizes a co-injection die insert having at least one capillary channel in fluid communication with a peripheral reservoir manifold circumscribing the injection assembly, (ii) wherein the injection step further utilizes a supply port fluidly connecting the peripheral reservoir manifold to a fluid additive source;
(e) coalescing the plurality of adjacent flowing extrudate flows into a second extrudate flow while generally maintaining the fluid additive's relative position between the plurality of adjacent flowing extrudate flows; and (f) extruding the second extrudate flow through a nozzle section into a zone of ambient pressure below the vapor pressure of the water in the mixture;
thereby producing a crisp flavored product having a moisture content from about 4 weight percent to about 8 weight percent and a water activity from about 0.30 to about 0.45.
55. The method of Claim 54, wherein the plasticizer is selected from the group consisting of maltodextrin, polydextrose, sucrose, corn syrup solids, and glycerol.
56. The method of Claim 54, wherein the plasticizer is a mixture containing from about 4%
to about 6% corn syrup solids, from about 3% to about 6% polydextrose, from about 0.5% to about 2% sucrose, and from about 0.5% to about 2.5% glycerol, based on the total weight of the farinaceous food mixture.
57. The method of Claim 54, comprising adding as the plasticizer from about 6 weight percent to about 15 weight percent, based on the total weight of the farinaceous food mixture, one or more of the group consisting of sucrose, maltose, fructose, dextrose, polysaccharides, and edible alcohols.
58. The method of Claim 54, wherein the farinaceous food mixture is plasticized by contacting it with co-rotating twin extruder screws in the extruder barrel.
59. The method of Claim 54, wherein the farinaceous food mixture contains at least one material selected from the group consisting of meals, flours, and starches derived from corn, wheat, rice, oats, barley, potatoes, rye, tapioca and other cereal crops, legumes, and tubers.
60. The method of Claim 54, wherein the farinaceous food mixture contains corn meal.
61. The method of Claim 54, wherein said nozzle section reduces the cross sectional area of the second extrudate flow by a factor less than 20:1.
62. The method of Claim 61, wherein said nozzle section reduces the cross sectional area of the second extrudate flow by a factor greater than 4:1.
63. The method of Claim 54, wherein the fluid additive is colored.
64. The method of Claim 54, wherein the fluid additive comprises a first color and the farinaceous food mixture comprises a second color.
65. The method of Claim 54, further comprising between steps (e) and (f), the step of mixing said flavored fluid additive and said second extrudate into a more homogeneous mixture with a static mixing mechanism positioned in said passageway.
66. A crisp, expanded, farinaceous food product exhibiting enhanced flavor characteristics, and having a moisture content from about 4 weight percent to about 8 weight percent and a water activity of from about 0.30 to about 0.45, which is produced by the process of claim 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, or 65.
67. An apparatus for improving the dimensional quality of complexly-shaped, direct expanded food products having a distinct pattern imparted therein, comprising:
(a) means for supplying an extrudate flow having said distinct pattern imparted into a portion of its lateral cross-section, wherein said supplying means comprises a first passageway;
(b) an extrusion section having a nozzle bore formed therethrough and fluidly connected to said first passageway, said nozzle bore having a complexly-shaped cross-sectional area that converges over its axial length from an inlet to an outlet, and includes at least one axially aligned ridgeline that gradually projects into the nozzle bore as said nozzle converges;
wherein said inlet has a periphery which circumscribes the first passageway.
68. The apparatus of Claim 67, wherein said axially aligned ridgeline disrupts the extrudate flow in close proximity to said ridgeline.
69. The apparatus of Claim 68, wherein said axially aligned ridgeline does not disrupt said portion of the extrudate flow having the distinct pattern imparted into its lateral cross-section.
70. The apparatus of Claim 69, wherein the complexly-shaped cross-sectional area resembles a baseball glove.
71. The apparatus of Claim 70, wherein the distinct pattern imparted resembles a baseball.
72. The apparatus of Claim 71, wherein the cross-sectional area of the converging passageway is reduced by a factor less than 20:1 between the inlet and the outlet of the extrusion nozzle.
73. The apparatus of Claim 71, wherein the cross-sectional area of the converging passageway is reduced by a factor greater than 4:1 between the inlet and the outlet of the extrusion nozzle.
74. An apparatus for improving the dimensional quality of complexly-shaped, direct expanded food products having a distinct pattern imparted therein, comprising an extrusion nozzle having a passageway formed therethrough; said passageway having a complexly-shaped cross-sectional area that converges over its axial length from an inlet to an outlet, and includes at least one axially aligned ridgeline that gradually projects into the passageway as said passageway converges.
75. The apparatus of Claim 74, wherein the complex-shaped cross-section is resembles a baseball glove.
76. The apparatus of Claim 74, wherein the cross-sectional area of the converging passageway is reduced by a factor less than 20:1 between the inlet and the outlet of the extrusion nozzle.
77. The apparatus of Claim 74, wherein the cross-sectional area of the converging passageway is reduced by a factor greater than 4:1 between the inlet and the outlet of the extrusion nozzle.
78. A method for improving the dimensional quality of complexly-shaped, direct expanded food products having a distinct pattern imparted therein, comprising the following steps:
(a) supplying an extrudate flow having said distinct pattern imparted into a portion of its lateral cross-section to a first passageway;
(b) directing the extrudate flow through an extrusion nozzle comprising a nozzle bore having a complexly-shaped cross-sectional area that converges over its axial length from an inlet to an outlet, and includes at least one axially aligned ridgeline that gradually projects into the nozzle bore as said nozzle converges;
wherein said axially aligned ridgeline disrupts the extrudate flow in close proximity to said ridgeline but not the portion of the extrudate flow having the distinct pattern imparted into its lateral cross-section.
79. The apparatus of Claim 78, wherein said distinct pattern generally maintains a constant aspect ratio while being directed through said converging nozzle bore.
80. An extruder die assembly for improving the dimensional quality of a complexly shaped, direct expanded food product while imparting a distinct pattern therein, comprising (a) a forming section comprising, (i) an entrance face having an inlet, (ii) a central passageway having extending from the inlet to an outlet, (iii) a forming die element traversing the central passageway, and (iv) an exit face having a first peripheral groove which circumscribes the outlet;
(b) an injection section comprising, (i) an entrance face having a second peripheral groove circumscribing a co-injection die insert; said co-injection die insert having at least one capillary channel in fluid communication with the second peripheral groove, wherein said capillary channel includes an upstream discharge and a downstream discharge, (ii) a supply port fluidly connecting the second peripheral groove to a fluid additive source; and (c) means for coupling and sealing the exit face of the forming section to the entrance face of the injection section thereby positioning and aligning:
(i) the first and second peripheral grooves so as to form and isolate a peripheral reservoir manifold therebetween, (ii) the forming die element and the co-injection die insert so as to seal the upstream discharge of the capillary channel.

(d) a nozzle section comprising (i) an entrance face having a complexly-shaped inlet, said inlet having a periphery which circumscribes said central passageway;
(ii) a converging nozzle bore having at least one axially aligned ridgeline, wherein said ridgeline gradually projects into the nozzle bore as said nozzle bore converges; and (iii) an outlet.
81. The apparatus of Claim 80, wherein the complexly-shaped cross-sectional area resembles a baseball glove.
82. The apparatus of Claim 81, wherein the distinct pattern imparted resembles a baseball.
83. The apparatus of Claim 80, wherein the cross-sectional area of the converging nozzle bore is reduced by a factor less than 20:1 between the inlet and the outlet of the extrusion nozzle.
84. The apparatus of Claim 80, wherein the cross-sectional area of the converging nozzle bore is reduced by a factor greater than 4:1 between the inlet and the outlet of the extrusion nozzle.
CA2532968A 2003-07-18 2004-07-15 Apparatus and method for improving dimensional quality of direct-expanded food products having complex shapes Expired - Fee Related CA2532968C (en)

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
US10/622,400 US7252847B2 (en) 2001-10-29 2003-07-18 Flavored extruded food product
US10/622,400 2003-07-18
US10/623,048 2003-07-18
US10/623,048 US6854970B2 (en) 2001-10-29 2003-07-18 Extruder die injection nozzle
US10/891,381 US7648352B2 (en) 2001-10-29 2004-07-14 Apparatus for imprinting lines on direct-expanded food products having complex shapes with improved dimensional quality
US10/891,381 2004-07-14
PCT/US2004/022685 WO2005009149A1 (en) 2003-07-18 2004-07-15 Apparatus and method for imprinting lines on direct-expanded food products having complex shapes with improved dimensional quality

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US20100074981A1 (en) 2010-03-25
CA2532968C (en) 2011-02-22
EP1659889A1 (en) 2006-05-31
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