Apparatus and Method for Improving the Dimensional Quality of Extruded Food Products Having Complex Shapes

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.

1 - 26 . (canceled) 
   
   
       27 . An asymmetrical three-dimensional extruded food product made from the following method:
 a) supplying a first die comprising a plurality of first die orifices wherein said first die orifices are configured to obtain said desired target shape;   b) supplying a second die having one and only one second die orifice wherein said second die orifice is configured to obtain said desired target shape, wherein said second die is connected to said first die;   c) extruding a dough through said first die having a first pressure drop into a bore disposed between the first die and second die thereby:
 forming a pre-expanded dough rope at each said first die orifice from said dough; 
 flashing vapor from each said pre-expanded dough rope; 
 restraining expansion in a radial direction with said bore disposed between the first die and second die; and 
   d) extruding said pre-expanded dough ropes through said second die having a second pressure drop thereby forming an extruded food product having said desired target shape.   
   
   
       28 . The food product of  claim 27  wherein at least one of said plurality of said first die orifices at step a) comprises a different cross sectional area than at least one remaining first die orifice. 
   
   
       29 . The food product of  claim 27  wherein said at least one of said plurality of said first die orifices at step a) comprises a different channel length than at least one remaining first die orifice. 
   
   
       30 . The food product of  claim 27  wherein at least one of said plurality of said first die orifices at step a) comprises a varying intra-channel length. 
   
   
       31 . The food product of  claim 27  wherein substantially no radial expansion occurs during extruding step d) to produce said food product as a high-definition food product having substantially square edges. 
   
   
       32 . The food product of  claim 27  further comprising a porous food product with a visible open cellular structure. 
   
   
       33 . A symmetrical food product made from the following method:
 a) supplying a first die comprising a plurality of first die orifices wherein said first die orifices are configured to obtain said desired target shape;   b) supplying a second die having one and only one second die orifice wherein said second die orifice is configured to obtain said desired target shape, wherein said second die is connected to said first die;   c) extruding a dough through said first die having a first pressure drop into a bore disposed between the first die and second die thereby:
 forming a pre-expanded dough rope at each said first die orifice from said dough; 
 flashing vapor from each said pre-expanded dough rope; 
 restraining expansion in a radial direction with said bore disposed between the first die and second die; and 
   d) extruding said pre-expanded dough ropes through said second die having a second pressure drop thereby forming an extruded food product having said desired target shape.   
   
   
       34 . The food product of  claim 33  wherein substantially no radial expansion occurs during extruding step d) to produce said food product as a high-definition food product having substantially square edges. 
   
   
       35 . The food product of  claim 33  further comprising a porous food product with a visible open cellular structure.