Apparatus and Method for Imprinting Lines on Direct-Expanded Food Products Having Complex Shapes With Improved Dimensional Quality

Abstract

The improved apparatus includes an improved extruder die assembly comprising a forming section, an injection section, and a converging nozzle section having axially aligned ridgelines 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. By gradually disrupting the axial flow in close proximity to the projecting ridgelines prior to its extrusion, the dimensional quality of the resulting direct expanded food piece is greatly improved. Moreover, by carefully positioning the capillary channels of the injection section into that portion of the flowing extrudate not affected by the axially aligned ridgelines, a distinct colored and/or flavored pattern is imparted into the extrudable food mass during the extrusion process while improving the quality of dimensional design aspects of the resulting extruded, complexly shaped, direct expanded food products.

1 . An apparatus for improving the dimensional quality of complexly-shaped, direct expanded food products having a distinct pattern imparted therein, comprising:
 (a) an internal peripheral reservoir manifold fluidly connected to at least one capillary channel for supplying at least one continuous, curvilinear band of fluid additive, said reservoir manifold formed by two interlocking sections;   (b) means for supplying an extrudate flow having said distinct pattern imparted into a portion of its lateral cross-section by said fluid additive, wherein said supplying means comprises a first passageway;   (c) an extrusion nozzle section having a nozzle bore formed therethrough and fluidly connected to said first passageway, said nozzle section having a complexly-shaped inlet and said nozzle bore having a complexly-shaped cross-sectional area that converges over its axial length from said inlet to a complexly-shaped outlet, and includes at least one axially aligned ridgeline that gradually projects along the entire length of the nozzle bore as said nozzle bore converges;   wherein said inlet has a periphery which circumscribes the first passageway.   
   
   
       2 . The apparatus of  claim 1 , wherein said axially aligned ridgeline disrupts the extrudate flow in close proximity to said ridgeline. 
   
   
       3 . The apparatus of  claim 2 , wherein said axially aligned ridgeline does not disrupt said portion of the extrudate flow having the distinct pattern imparted into its lateral cross-section. 
   
   
       4 . The apparatus of  claim 3 , wherein the complexly-shaped cross-sectional area resembles a baseball glove. 
   
   
       5 . The apparatus of  claim 4 , wherein the distinct pattern imparted resembles a baseball. 
   
   
       6 . The apparatus of  claim 5 , 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 bore. 
   
   
       7 . The apparatus of  claim 5 , 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 bore. 
   
   
       8 . 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 and an annular internal peripheral reservoir manifold formed by two interlocking sections and fluidly connected to at least one capillary channel through which at least one continuous, curvilinear band of fluid additive may be supplied; said passageway having a complexly-shaped cross-sectional area that converges over its axial length from complexly-shaped inlet to an outlet, and includes at least one axially aligned ridgeline that gradually projects into the passageway as said passageway converges. 
   
   
       9 . The apparatus of  claim 8 , wherein the complex-shaped cross-section resembles a baseball glove. 
   
   
       10 . The apparatus of  claim 8 , 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. 
   
   
       11 . The apparatus of  claim 8 , 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. 
   
   
       12 . The apparatus of  claim 1 , wherein said continuous, curvilinear band of fluid additive is supplied through the entire exit face of said capillary channel. 
   
   
       13 . The apparatus of  claim 8 , wherein said continuous, curvilinear band of fluid additive is supplied through the entire exit face of said capillary channel. 
   
   
       14 . The apparatus of  claim 1 , wherein said interlocking sections seal said reservoir manifold.