Method for ultrasonic extrusion of a flowable food substrate

Abstract

This invention relates generally to ultrasonic extrusion apparatus, methods and products. A flowable substrate may be supplied by an infeed to an extrusion chamber having an ultrasonic horn. The flowable substrate contacts the ultrasonic resonant horn and receives ultrasonic energy before and/or as passing through an extrusion orifice. Suitable flowable substrates may include meat emulsions, pomace solutions, and dough. The extruded product may have virtually any solid or hollow shape. The flowable substrate may form a shape-retaining product that may be cut without significantly deforming.

I claim: 
     
         1 . A method of extruding a flowable food substrate comprising:
 providing a flowable food substrate to an infeed from a motive force;   flowing the flowable food substrate from the infeed into a chamber with an ultrasonic horn;   contacting the flowable food substrate with the ultrasonic horn;   energizing the ultrasonic horn with ultrasonic energy;   transferring energy from the ultrasonic horn to the flowable food substrate; and   extruding the flowable substrate through an extrusion orifice   
     
     
         2 . The method of extruding a flowable food substrate of  claim 1 , further comprising coextrusion of a filling into the product by application of ultrasonic energy to one or both the extruded materials. 
     
     
         3 . The method of extruding a flowable food substrate of  claim 1 , wherein the flowable food substrate includes at least one of shortbread dough, cracker dough, pretzel dough, cookie dough, pasta dough, bread dough, grissini, meat emulsions, fruit pomace, and vegetable pomace. 
     
     
         4 . The method of extruding a flowable food substrate of  claim 1 , wherein the ultrasonic energy has a frequency of about of about 15 KHz to about 40 KHz. 
     
     
         5 . The method of extruding a flowable food substrate of  claim 1 , wherein the ultrasonic energy performs one of the group consisting of coagulation, neutralization, agglomerating, pasteurization, drying, cooking, setting, conditioning, tempering, hardening, emulsification, gelatinizing, homogenization, dispersion, melting, liquefaction, plasticizing and combinations thereof. 
     
     
         6 . The method of extruding a flowable food substrate of  claim 1 , wherein the ultrasonic energy performs cooking of the flowable substrate. 
     
     
         7 . The method of extruding a flowable food substrate of  claim 1 , wherein the ultrasonic energy performs plasticizing and the flowable substrate. 
     
     
         8 . The method of extruding a flowable food substrate of  claim 1 , further comprising the step of ultrasonically neutralizing enzymes within the flowable substrate. 
     
     
         9 . The method of extruding a flowable food substrate of  claim 1 , wherein extruding forms a shape-retaining product. 
     
     
         10 . The method of extruding a flowable food substrate of  claim 9 , wherein the product has a solid or a hollow cross section. 
     
     
         11 . The method of extruding a flowable food substrate of  claim 9 , wherein a cross section shape of the product includes one of the group consisting of round, oval, elliptical, square, trapezoid, rectangle, ribbon, triangle, hexagon, octagon, decagon, cross, star, heart, spade, club, shamrock, pumpkin, banner, diamond, crescent, kitty, wreath, tree, annulus, pipe, round with square, and triangle with square. 
     
     
         12 . The method of extruding a flowable food substrate of  claim 9 , further comprising the step of ultrasonically gelling pectin from within the flowable substrate. 
     
     
         13 . The method of extruding a flowable food substrate of  claim 9 , further comprising the step of ultrasonically agglomerating particles within the flowable substrate. 
     
     
         14 . The method of extruding a flowable food substrate of  claim 9 , further comprising immediately slicing the product into shape-retaining pieces following extruding. 
     
     
         15 . The method of extruding a flowable food substrate of  claim 9 , further comprising the step of ultrasonically setting protein from within the flowable substrate. 
     
     
         16 . An extruded product comprising:
 a flowable food substrate formed into a shape by ultrasonic extrusion; and   a member of the group consisting of a coloring agent, a moistening agent, a flavoring agent, a sweetening agent, and combinations thereof.   
     
     
         17 . The ultrasonically extruded product of  claim 16 , wherein the flowable food substrate includes ultrasonically settable protein to form a shape-retaining product. 
     
     
         18 . The ultrasonically extruded product of  claim 16 , wherein the flowable food substrate includes ultrasonically gellable pectin to form a shape-retaining product. 
     
     
         19 . The ultrasonically extruded product of  claim 16 , wherein the flowable food substrate includes pomace. 
     
     
         20 . The ultrasonically extruded product of  claim 16 , wherein the flowable substrate includes fruit-based or vegetable-based material.