Casting food products to controlled dimensions

Abstract

A device and process for adjustably controlling the dimensions of an extruded food product cast into a sheet using, for example, a pressure manifold mounted on a casting belt, or a chill roll/gauge roller combination.

1 .- 15 . (canceled)  
   
   
       16 . A casting apparatus comprising: 
 a moving support surface;    a delivery device configured to deposit the food product over the moving support surface to a predetermined width; and    opposing side rails rotationally adjustable about a longitudinal axis thereof and adjacent at least a portion of a longitudinal periphery of the moving support surface.    
   
   
       17 . The casting apparatus of  claim 16 , wherein the opposing side rails extend on the longitudinal periphery of the support surface a distance sufficient to allow the food product to retain the predetermined width in the absence of a lateral support.  
   
   
       18 . The casting apparatus of  claim 16 , wherein the opposing side rails comprise plastic rails.  
   
   
       19 . The casting apparatus of  claim 16 , wherein the opposing side rails are attached to adjustable metal brackets, and wherein the adjustable metal brackets are configured to permit at least one of the opposing side rails to be positioned at a fixed angle relative to the moving support surface.  
   
   
       20 . The casting apparatus of  claim 16  further comprising: 
 adjustable brackets attached to the opposing side rails, wherein the adjustable brackets include a slot therein and a transverse opening therethrough; and    a support arm engaging the slot, the support arm including a rod extending from the support arm at substantially a right angle and engaging the transverse opening.    
   
   
       21 . The casting apparatus of  claim 16 , wherein the angle between one or both of the side rails and the plane of the support surface is adjustable.  
   
   
       22 . The casting apparatus of  claim 16 , wherein the casting apparatus is configured for casting a food product that comprises processed cheese.  
   
   
       23 . The casting apparatus of  claim 16 , wherein the casting apparatus is configured for casting a gelatin-based food product.  
   
   
       24 . A process for casting a food product, the process comprising: 
 providing a moving support surface;    depositing the food product on the moving support surface to a predetermined width; and    controlling the width of the sheet of the food product on the moving support using opposing side rails that are rotationally adjustable about a longitudinal axis thereof,    wherein the adjustable side rails are adjacent at least a portion of a longitudinal periphery of the support surface.    
   
   
       25 . The process of  claim 24 , wherein the adjustable side rails extend on the longitudinal periphery of the support surface a distance sufficient to allow the food product to retain the predetermined width in the absence of a lateral support.  
   
   
       26 . The process of  claim 24  further comprising chilling an underside of the moving support surface, such that the food product is cooled as it travels on the moving support surface, wherein the opposing side rails cooperate with the moving support surface to retain the predetermined width of the food product.  
   
   
       27 . The process of  claim 24 , wherein controlling the width of the sheet of the food product on the moving support comprises rotating the opposing side rails to a fixed angular orientation with respect to the plane of the moving support surface.  
   
   
       28 . The casting process of  claim 24 , wherein controlling the width of the sheet of the food product on the moving support comprises adjusting the distance between the opposing side rails.  
   
   
       29 . The casting process of  claim 24 , wherein controlling the width of the sheet of the food product using opposing adjustable side rails comprises providing opposing adjustable side rails extending on longitudinal periphery of the moving support surface a distance of at least about 4 feet from a point of deposition on the moving support surface.  
   
   
       30 . A casting apparatus for extruding and casting a food product into a sheet having predetermined dimensions, the apparatus comprising: 
 a chilled casting belt;    a manifold configured to distribute a low viscosity food product in a molten form to a predetermined width onto the chilled casting belt; and    opposing adjustable side rails adjacent each side of the chilled casting belt,    wherein the opposing adjustable side rails are configured to rotate about a longitudinal axis thereof.    
   
   
       31 . The casting apparatus of  claim 30 , wherein the opposing adjustable side rails extend along the chilled casting belt a distance sufficient to allow the food product to retain the predetermined width in the absence of a lateral support.  
   
   
       32 . The casting apparatus of  claim 30 , wherein the opposing adjustable side rails extend along the chilled casting belt a distance of at least about 4 feet from the manifold.  
   
   
       33 . The casting apparatus of  claim 30 , wherein the opposing adjustable side rails further comprise adjustable brackets attached to the side rails, wherein the bracket are slidably engaged to rigid support members, such that the side rails can be rotated and set at a fixed angular orientation with respect to the plane of the chilled casting belt.  
   
   
       34 . The casting apparatus of  claim 30 , wherein the chilled casting belt comprises an underside cooling surface that is contacted by a cooling fluid, such that the food product is cooled as it travels on the casting belt, and wherein the opposing adjustable side rails cooperate with the casting belt to retain the predetermined width of the food product.  
   
   
       35 . The casting apparatus of  claim 30 , wherein the opposing adjustable side rails comprise plastic rails.