US20230036823A1 - Method and Apparatus for Making Co-Extruded Food Product - Google Patents
Method and Apparatus for Making Co-Extruded Food Product Download PDFInfo
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- US20230036823A1 US20230036823A1 US17/963,373 US202217963373A US2023036823A1 US 20230036823 A1 US20230036823 A1 US 20230036823A1 US 202217963373 A US202217963373 A US 202217963373A US 2023036823 A1 US2023036823 A1 US 2023036823A1
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- snack bar
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- snack
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Classifications
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- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21C—MACHINES OR EQUIPMENT FOR MAKING OR PROCESSING DOUGHS; HANDLING BAKED ARTICLES MADE FROM DOUGH
- A21C15/00—Apparatus for handling baked articles
- A21C15/007—Apparatus for filling baked articles
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- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
- A21D13/00—Finished or partly finished bakery products
- A21D13/30—Filled, to be filled or stuffed products
- A21D13/32—Filled, to be filled or stuffed products filled or to be filled after baking, e.g. sandwiches
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- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
- A21D13/00—Finished or partly finished bakery products
- A21D13/30—Filled, to be filled or stuffed products
- A21D13/37—Co-extruded products, i.e. products obtained by simultaneous extrusion of the dough and the filling
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- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21D—TREATMENT, e.g. PRESERVATION, OF FLOUR OR DOUGH, e.g. BY ADDITION OF MATERIALS; BAKING; BAKERY PRODUCTS; PRESERVATION THEREOF
- A21D13/00—Finished or partly finished bakery products
- A21D13/80—Pastry not otherwise provided for elsewhere, e.g. cakes, biscuits or cookies
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- 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
-
- 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
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- 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
- A23G3/0063—Coating or filling sweetmeats or confectionery
- A23G3/0065—Processes for making filled articles, composite articles, multi-layered articles
- A23G3/0068—Processes for making filled articles, composite articles, multi-layered articles the material being shaped at least partially by a die; Extrusion of filled or multi-layered cross-sections or plates, optionally with the associated cutting
-
- 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
- A23G3/20—Apparatus for coating or filling sweetmeats or confectionery
- A23G3/2007—Manufacture of filled articles, composite articles, multi-layered articles
- A23G3/2015—Manufacture of filled articles, composite articles, multi-layered articles the material being shaped at least partially by a die; Extrusion of filled or multi-layered cross-sections or plates, optionally with the associated cutting device
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- 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
- A23L7/117—Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
- A23L7/126—Snacks or the like obtained by binding, shaping or compacting together cereal grains or cereal pieces, e.g. cereal bars
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- 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
- A23P10/00—Shaping or working of foodstuffs characterised by the products
-
- 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
- A23P10/00—Shaping or working of foodstuffs characterised by the products
- A23P10/20—Agglomerating; Granulating; Tabletting
- A23P10/25—Agglomeration or granulation by extrusion or by pressing, e.g. through small holes, through sieves or between surfaces
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- 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
- A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
- A23P20/20—Making of laminated, multi-layered, stuffed or hollow foodstuffs, e.g. by wrapping in preformed edible dough sheets or in edible food containers
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- 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
Definitions
- the invention generally pertains to the art of food and, more particularly, to a method and apparatus for manufacturing a food product including a combination filling material having a main body portion formed from a primary, non-flowable food filling and a secondary food filling, such as a flowable topping, which is embedded in, yet exposed exteriorly of, the primary food filling, wherein both the primary and secondary food fillings are co-extruded, preferably upon a base or crust.
- pastries are common snack products which fulfill some of these needs.
- the filling material is layered directly on a dough or other base.
- a secondary filling can also be employed, such as in the form of a layer of icing or other topping.
- a snack product is produced to include a base or crust, a primary filling material which is non-flowable, and a secondary filling or topping material which is flowable and embedded within, yet externally exposed from, the primary filling material.
- the primary filling material is a cheesecake filling
- the secondary filling material is a fruit filling.
- the primary and secondary fillings are co-extruded, either separate from or with the base.
- the invention is directed to creating a snack product including a base upon which is co-extruded a combined primary and secondary filling. Since the secondary filling is to be embedded within, yet externally exposed from the primary filling, care must be taken to assure that the secondary filling is not enveloped or encompassed by the primary filling.
- This object of the invention is achieved, at least in part, by specific relative positioning of an extrusion nozzle for the secondary filling material relative to an extrusion port for the primary filling material, while also balancing relative flow pressures for the different filling materials.
- This object of the invention is achieved by oscillating or otherwise shifting the extrusion nozzle of the secondary filling relative to the extrusion port for the primary filling. After being constructed, the food product is cut to desired lengths, such as to form snack bars which can be separately packaged for sale.
- FIG. 1 is a perspective view of a combination extrusion and conveying apparatus employed in making a snack bar in accordance with the invention.
- FIG. 2 is an enlarged perspective view of an extrusion unit incorporated in the apparatus of FIG. 1 .
- FIG. 3 is an enlarged, perspective view of a portion of the extrusion unit of FIG. 2 .
- FIG. 4 A is a cross-sectional view taken across a portion of the extrusion unit of FIGS. 2 and 3 .
- FIG. 4 B is a partial cross-sectional view taken across another portion of the extrusion unit.
- FIG. 5 is a perspective view of an extruded food product produced in accordance with the invention.
- FIG. 6 A schematically illustrates an overall extrusion arrangement in accordance with one embodiment of the invention.
- FIG. 6 B schematically illustrates an overall extrusion arrangement in accordance with another embodiment of the invention.
- Extrusion system 2 can be employed to produce a wide range of food products, including rows of elongated, layered snack products such as indicated at 5 - 8 .
- extrusion system 2 is shown to include an outer housing 12 from which extends a control tower 15 , upstanding supports 18 and 19 between which is supported an extruder 22 , and a conveyor 25 upon which the snack products 5 - 8 are formed and transported.
- a particular snack product 5 - 8 made in accordance with the present invention, includes a base 30 , a primary filling 32 and a secondary filling or topping 34 .
- each of the base 30 , primary filling 32 and secondary filling 34 are formed through an extrusion process and, particularly important in connection with the invention, the primary and secondary fillings 32 and 34 are co-extruded, with secondary filling 34 being embedded within primary filling 32 .
- FIG. 2 depicts certain internal structure associated with each of extruder 22 and control tower 15 .
- a base plate 41 and a side plate 43 are provided for an extrusion manifold 47 .
- extrusion manifold 47 is formed with four supply cavities 52 - 55 which are separated by dividers 58 - 60 .
- Extruder 22 also includes an elongated sleeve 65 within which is slidably mounted a cylinder 68 which terminates in an arm 72 .
- a lever 75 includes a first end 77 which is pinned to arm 72 with a pin 79 , and a second end 82 which is drivingly connected to a motor 85 (preferably electric), the operation of which is controlled through one or more switches 87 , 88 provided on control tower 15 .
- motor 85 preferably electric
- activation of motor 85 causes second end 82 of lever 75 to move in a circular path which, in turn, causes cylinder 68 to reciprocate within sleeve 65 .
- cylinder 68 is nearly fully extended such that a terminal end 91 of cylinder 68 is shown projecting from sleeve 65 .
- sleeve 65 is provided with a series of slots 94 - 97 .
- each slot 94 - 97 Arranged at each slot 94 - 97 is a respective manual adjustment knob 100 - 103 .
- the purpose of adjustment knobs 100 - 103 will become more fully apparent below but, at this point, it should just be noted that adjustment knobs 100 - 103 are attached to and reciprocate in unison with cylinder 68 .
- FIG. 3 provides additional details regarding certain structure of extruder 22 discussed above.
- this figure illustrates multiple extrusion ports for extruder 22 . More specifically, note two extrusion ports indicated at 105 and 106 , with extrusion port 105 being in fluid communication with supply cavity 54 and extrusion port 106 being in fluid communication with supply cavity 55 .
- an extrusion nozzle 109 is provided within each extrusion port 105 , 106 and, more specifically, directly adjacent an outlet opening 112 for a respective extrusion port 105 , 106 .
- supply cavities 52 - 55 are employed to supply primary filling 32 for extrusion through the various extrusion ports, including extrusion ports 105 and 106 , while secondary filling 34 is co-extruded through the respective extrusion nozzles 109 .
- a respective flow regulator 114 , 115 is also provided for each extrusion port 105 , 106 .
- the number of extrusion ports 105 , 106 , cavities 52 - 55 and extrusion nozzles 109 can vary in accordance with the invention based on the number of product streams desired. With this in mind, much of the remaining discussion will be directed to providing details of the extrusion structure relied upon to produce a single product stream and it is to be understood that corresponding structure is employed in connection with additional product streams.
- Flow regulator 114 includes a regulator body 127 and a flow adjustment member 129 .
- flow adjustment member 129 is threaded to regulator body 127 and includes a rounded head 132 which projects into the flow path to first extrusion passage 122 .
- first extrusion passage 122 and first extrusion sub-passage 123 Located at the juncture of first extrusion passage 122 and first extrusion sub-passage 123 is cylinder 68 .
- second extrusion passage 136 leading to individual second extrusion sub-passages, such as second extrusion sub-passage 137 associated with a respective extrusion nozzle 109 (shown in FIG. 3 ).
- adjustment knob 102 is connected to a threaded shaft 142 having a head 144 which projects into second extrusion sub-passage 137 .
- adjustment knob 102 can be used to alter a flow rate for secondary filling 34 from extrusion nozzle 109 (shown in FIG. 3 ).
- extrusion nozzle 109 (shown in FIG. 3 ) within extrusion port 105 and relative to outlet opening 112 is important in accordance with the invention. That is, to achieve the desired product configuration, secondary filling 34 must be extruded upstream of but close to outlet opening (die port exit) 112 . More specifically, extrusion nozzle 109 (shown in FIG. 3 ) is positioned directly adjacent outlet opening 112 for desired surface positioning in snack products 5 - 8 . By “directly adjacent” it is meant that a die exit port 147 of extrusion nozzle 109 (shown in FIG.
- a preferred embodiment employs an angle of approximately 50 degrees for a die exit port 147 sized at 3/16 inch (approximately 0.5 cm).
- FIG. 5 illustrates a representative portion of snack product 5 .
- base 30 is formed with upstanding sidewalls 153 and 154 between which is extruded the primary and secondary fillings 32 and 34 .
- primary filling 32 is non-flowable so as to keep its form and remain between sidewalls 153 and 154 .
- secondary filling 34 can be flowable.
- primary filling 32 constitutes a thick cheesecake filling
- secondary filling 34 is a fruit topping.
- other compositions could be employed.
- primary filling 32 could be constituted by peanut butter.
- secondary filling 34 could be a thick fruit or caramel based paste, fruit jelly (with or without small particulates), or the like.
- base 30 can have different compositions, including being graham or chocolate based.
- the co-extrusion arrangement disclosed provides for secondary filling 34 to be embedded in primary filling 32 , yet externally exposed and visible. That is, primary filling 32 has a depth established between a top surface 160 and a bottom surface 162 .
- secondary filling 34 is co-extruded as disclosed, secondary filling 34 is substantially flush with top surface 160 and extends to a point between top surface 160 and bottom surface 162 , such as one-half or more of the depth of primary filling 32 .
- primary filling 32 is non-flowable, i.e., thick, with a modeling clay, marshmallow or Playdough-like consistency so as to have a tendency to keep its shape
- the extrusion of secondary filling 34 causes secondary filling 34 to push into primary filling 32 .
- the extrusion pressures for the primary and secondary fillings 32 and 34 are balanced to achieve this result and the co-extrusion through outlet opening 112 assures the smooth finish as depicted in this figure.
- Exemplary supply pressures in accordance with the invention include 10 psi for a cheesecake-based primary filling 32 , 90 psi for a peanut butter-based primary filling 32 and 30 psi for a fruit or caramel-based secondary filling 34 .
- These pressures, as well as the speed of conveyor 25 also affect the overall filling thicknesses.
- conveyor 25 is operated at between 30-60 ft/min (approximately 9-18 m/min).
- secondary filling 34 extends within primary filling 32 in an oscillating or sinusoidal, non-linear pattern based on the operation of motor 85 and the corresponding reciprocation of cylinder 68 and each extrusion nozzle 109 .
- different patterns can be readily produced, such as by altering a stroke length for cylinder 68 or even deactivating motor 85 to produce a linear pattern.
- Snack product 5 can be cut, such as by laser cutting along cut lines 165 and 166 , to establish individual snack bars, such as indicated at 170 , 171 and 172 , which can be individually wrapped in a package for sale.
- the actual size of each snack bar 170 - 172 can vary in accordance with the invention.
- a preferred embodiment provides for: an overall width in the order of 2-3 inches (approximately 5-7.5 cm); an overall height in the order of 1 ⁇ 2 to 3 ⁇ 4 inches (approximately 1.25-2 cm); and a height or thickness for base 30 in the order of 0.25 inches (approximately .6 cm).
- the length of each snack bar 170 - 172 can vary, but is preferably at least as long as the overall width. In any case, it should be understood that these disclosed embodiments are illustrative and not restrictive.
- base 30 can vary in accordance with the invention.
- the manner in which base 30 is produced/supplied can also vary.
- base 30 can be delivered onto conveyor 25 with a separate extruder 178 arranged upstream of extruder 22 as illustrated in FIG. 6 A , or further co-extruded with primary and secondary fillings 32 and 34 as represented in FIG. 6 B .
- the method and apparatus of the invention can be particularly employed in forming a snack bar with a base establishing a crust and an extruded filling provided on the crust, with the filling including a primary filling constituted by a non-flowable material and a secondary filling, wherein the secondary filling is embedded in, yet externally exposed from, the primary filling.
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Abstract
A snack bar is produced in accordance with a method employing an extrusion apparatus to include a base or crust, a primary filling provided on the base and a second filling or topping embedded in, yet externally exposed from, the primary filling. The primary and secondary fillings are co-extruded, with an extrusion nozzle for the secondary filling being located directly adjacent an extrusion port for the primary filling. The primary filling is non-flowable, while the secondary filling is preferably flowable. The extrusion nozzle can be repositioned either between or during extrusion operations to alter a repeating pattern for the secondary filling.
Description
- This application represents a divisional application of U.S. Pat. Application Serial No. 14/575,686 entitled “Method and Apparatus for Making Co-Extruded Food Product” filed Dec. 18, 2014, pending. The entire content of this application is incorporated herein by reference.
- The invention generally pertains to the art of food and, more particularly, to a method and apparatus for manufacturing a food product including a combination filling material having a main body portion formed from a primary, non-flowable food filling and a secondary food filling, such as a flowable topping, which is embedded in, yet exposed exteriorly of, the primary food filling, wherein both the primary and secondary food fillings are co-extruded, preferably upon a base or crust.
- Lifestyle choices have resulted in many people relying on snack products to satisfy breakfast, between meal and even dessert needs. For instance, pastries are common snack products which fulfill some of these needs. In the case of pastries including a filling material, the filling material is layered directly on a dough or other base. In certain products, a secondary filling can also be employed, such as in the form of a layer of icing or other topping.
- In any event, to satisfy market demand, a wide range of filling-based snack products have been developed and made available for sale. Regardless of the available snack products, it would still be advantageous to be able to produce additional snack products which include multiple filling materials, particularly multiple filling snack products which can be effectively and efficiently produced through a co-extrusion process.
- In accordance with one aspect of the invention, a snack product is produced to include a base or crust, a primary filling material which is non-flowable, and a secondary filling or topping material which is flowable and embedded within, yet externally exposed from, the primary filling material. In one form of the invention, the primary filling material is a cheesecake filling, while the secondary filling material is a fruit filling. In any case, the primary and secondary fillings are co-extruded, either separate from or with the base.
- In particular, the invention is directed to creating a snack product including a base upon which is co-extruded a combined primary and secondary filling. Since the secondary filling is to be embedded within, yet externally exposed from the primary filling, care must be taken to assure that the secondary filling is not enveloped or encompassed by the primary filling. This object of the invention is achieved, at least in part, by specific relative positioning of an extrusion nozzle for the secondary filling material relative to an extrusion port for the primary filling material, while also balancing relative flow pressures for the different filling materials. In addition, in at least one form of the invention, it is desired to provide the secondary filling in a specified, non-linear pattern along a length of the primary filling. This object of the invention is achieved by oscillating or otherwise shifting the extrusion nozzle of the secondary filling relative to the extrusion port for the primary filling. After being constructed, the food product is cut to desired lengths, such as to form snack bars which can be separately packaged for sale.
- Additional objects, features and advantages of the invention will become more readily apparent from the following detailed description when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views.
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FIG. 1 is a perspective view of a combination extrusion and conveying apparatus employed in making a snack bar in accordance with the invention. -
FIG. 2 is an enlarged perspective view of an extrusion unit incorporated in the apparatus ofFIG. 1 . -
FIG. 3 is an enlarged, perspective view of a portion of the extrusion unit ofFIG. 2 . -
FIG. 4A is a cross-sectional view taken across a portion of the extrusion unit ofFIGS. 2 and 3 . -
FIG. 4B is a partial cross-sectional view taken across another portion of the extrusion unit. -
FIG. 5 is a perspective view of an extruded food product produced in accordance with the invention. -
FIG. 6A schematically illustrates an overall extrusion arrangement in accordance with one embodiment of the invention. -
FIG. 6B schematically illustrates an overall extrusion arrangement in accordance with another embodiment of the invention. - With reference to
FIG. 1 , an extrusion system constructed in accordance with the invention is generally indicated at 2.Extrusion system 2 can be employed to produce a wide range of food products, including rows of elongated, layered snack products such as indicated at 5-8. In general,extrusion system 2 is shown to include anouter housing 12 from which extends acontrol tower 15, upstanding supports 18 and 19 between which is supported anextruder 22, and aconveyor 25 upon which the snack products 5-8 are formed and transported. A particular snack product 5-8, made in accordance with the present invention, includes abase 30, aprimary filling 32 and a secondary filling or topping 34. As will be detailed more fully below, each of thebase 30,primary filling 32 andsecondary filling 34 are formed through an extrusion process and, particularly important in connection with the invention, the primary andsecondary fillings secondary filling 34 being embedded withinprimary filling 32. -
FIG. 2 depicts certain internal structure associated with each ofextruder 22 andcontrol tower 15. As shown, for mounting and supporting purposes, abase plate 41 and aside plate 43 are provided for anextrusion manifold 47. In the embodiment depicted wherein four rows of snack products 5-8 are being simultaneously produced,extrusion manifold 47 is formed with four supply cavities 52-55 which are separated by dividers 58-60.Extruder 22 also includes anelongated sleeve 65 within which is slidably mounted acylinder 68 which terminates in anarm 72. Alever 75 includes afirst end 77 which is pinned to arm 72 with apin 79, and asecond end 82 which is drivingly connected to a motor 85 (preferably electric), the operation of which is controlled through one ormore switches control tower 15. With this arrangement, activation ofmotor 85 causessecond end 82 oflever 75 to move in a circular path which, in turn, causescylinder 68 to reciprocate withinsleeve 65. In the position shown,cylinder 68 is nearly fully extended such that aterminal end 91 ofcylinder 68 is shown projecting fromsleeve 65. As also shown,sleeve 65 is provided with a series of slots 94-97. Arranged at each slot 94-97 is a respective manual adjustment knob 100-103. The purpose of adjustment knobs 100-103 will become more fully apparent below but, at this point, it should just be noted that adjustment knobs 100-103 are attached to and reciprocate in unison withcylinder 68. -
FIG. 3 provides additional details regarding certain structure ofextruder 22 discussed above. In addition, this figure illustrates multiple extrusion ports forextruder 22. More specifically, note two extrusion ports indicated at 105 and 106, withextrusion port 105 being in fluid communication withsupply cavity 54 andextrusion port 106 being in fluid communication withsupply cavity 55. In addition, anextrusion nozzle 109 is provided within eachextrusion port respective extrusion port extrusion ports secondary filling 34 is co-extruded through therespective extrusion nozzles 109. Arespective flow regulator extrusion port extrusion ports extrusion nozzles 109 can vary in accordance with the invention based on the number of product streams desired. With this in mind, much of the remaining discussion will be directed to providing details of the extrusion structure relied upon to produce a single product stream and it is to be understood that corresponding structure is employed in connection with additional product streams. - With particular reference to
FIGS. 4A and 4B , the internal configuration of portions ofextruder 22 is illustrated. As shown,supply cavity 54 leads to afirst extrusion passage 122 and then to afirst extrusion sub-passage 123 ofextrusion port 105.Flow regulator 114 includes aregulator body 127 and aflow adjustment member 129. In the embodiment depicted,flow adjustment member 129 is threaded toregulator body 127 and includes arounded head 132 which projects into the flow path tofirst extrusion passage 122. With this arrangement, it should be readily apparent that the rate of supply of primary filling 32 can be readily adjusted by the shifting offlow adjustment member 129 relative toregulator body 127, with this adjustment being shown to be manual in nature but a powered adjustment is also possible. - Basically positioned at the juncture of
first extrusion passage 122 andfirst extrusion sub-passage 123 iscylinder 68. Withincylinder 68 is formed asecond extrusion passage 136 leading to individual second extrusion sub-passages, such assecond extrusion sub-passage 137 associated with a respective extrusion nozzle 109 (shown inFIG. 3 ). As clearly shown in these figures,adjustment knob 102 is connected to a threadedshaft 142 having ahead 144 which projects intosecond extrusion sub-passage 137. In a similar manner to each offlow regulators adjustment knob 102 can be used to alter a flow rate for secondary filling 34 from extrusion nozzle 109 (shown inFIG. 3 ). - At this point, it should be noted that the positioning of extrusion nozzle 109 (shown in
FIG. 3 ) withinextrusion port 105 and relative tooutlet opening 112 is important in accordance with the invention. That is, to achieve the desired product configuration, secondary filling 34 must be extruded upstream of but close to outlet opening (die port exit) 112. More specifically, extrusion nozzle 109 (shown inFIG. 3 ) is positioned directly adjacent outlet opening 112 for desired surface positioning in snack products 5-8. By “directly adjacent” it is meant that adie exit port 147 of extrusion nozzle 109 (shown inFIG. 3 ) must be positioned such that secondary filling 34 is extruded within about ½ inch (approximately 1.25 cm) of outlet opening 112 for the desired co-extrusion profile. That is, it is desired to assure that dieexit port 147 is recessed withinextrusion port 105 by no more than this distance. In addition, the angle ofdie exit port 147 is also important in accordance with the invention. Here, an acute angle to a direction of extrusion for primary filling 32 must be assured to establish a tangential flow, particularly to avoid back pressure on primary filling 32 and to obtain a desired smooth product finish. Although the acute angle could be varied while still achieving the required embedding of the secondary filling 34 and the smooth finish product, a preferred embodiment employs an angle of approximately 50 degrees for adie exit port 147 sized at 3/16 inch (approximately 0.5 cm). -
FIG. 5 illustrates a representative portion ofsnack product 5. Here, it can be seen thatbase 30 is formed withupstanding sidewalls secondary fillings sidewalls base 30 can have different compositions, including being graham or chocolate based. Most important in accordance with the invention is that the co-extrusion arrangement disclosed provides for secondary filling 34 to be embedded in primary filling 32, yet externally exposed and visible. That is, primary filling 32 has a depth established between atop surface 160 and abottom surface 162. When secondary filling 34 is co-extruded as disclosed, secondary filling 34 is substantially flush withtop surface 160 and extends to a point betweentop surface 160 andbottom surface 162, such as one-half or more of the depth of primary filling 32. More particularly, even though primary filling 32 is non-flowable, i.e., thick, with a modeling clay, marshmallow or Playdough-like consistency so as to have a tendency to keep its shape, the extrusion of secondary filling 34 causes secondary filling 34 to push into primary filling 32. The extrusion pressures for the primary andsecondary fillings conveyor 25, also affect the overall filling thicknesses. In preferred embodiments,conveyor 25 is operated at between 30-60 ft/min (approximately 9-18 m/min). - As shown in this figure, secondary filling 34 extends within primary filling 32 in an oscillating or sinusoidal, non-linear pattern based on the operation of
motor 85 and the corresponding reciprocation ofcylinder 68 and eachextrusion nozzle 109. Of course, different patterns can be readily produced, such as by altering a stroke length forcylinder 68 or even deactivatingmotor 85 to produce a linear pattern.Snack product 5 can be cut, such as by laser cutting along cutlines base 30 in the order of 0.25 inches (approximately .6 cm). In addition, the length of each snack bar 170-172 can vary, but is preferably at least as long as the overall width. In any case, it should be understood that these disclosed embodiments are illustrative and not restrictive. - As indicated above, the compositions for
base 30, primary filling 32 and secondary filling 34 can vary in accordance with the invention. In addition, the manner in which base 30 is produced/supplied can also vary. For instance, with reference to the schematics ofFIGS. 6A and 6B ,base 30 can be delivered ontoconveyor 25 with aseparate extruder 178 arranged upstream ofextruder 22 as illustrated inFIG. 6A , or further co-extruded with primary andsecondary fillings FIG. 6B . In any case, although the invention can be employed to make other products, and various changes can be made without departing from the spirit of the invention, as described above, the method and apparatus of the invention can be particularly employed in forming a snack bar with a base establishing a crust and an extruded filling provided on the crust, with the filling including a primary filling constituted by a non-flowable material and a secondary filling, wherein the secondary filling is embedded in, yet externally exposed from, the primary filling.
Claims (21)
1. A snack bar comprising:
a base establishing a crust; and
a filling provided on the crust, said filling including a primary filling constituted by a non-flowable material and a secondary filling, wherein the secondary filling is embedded in, yet externally exposed from, the primary filling.
2. The snack bar of claim 1 , wherein the primary filling has a smooth top surface, said secondary filling being substantially flush with and visible from the top surface.
3. The snack bar of claim 2 , wherein the primary filling has a depth and the secondary filling extends approximately half of the depth.
4. The snack bar of claim 1 , wherein the secondary filling extends within the primary filling in a repeating pattern.
5. The snack bar of claim 4 , wherein the repeating pattern is non-linear.
6. The snack bar of claim 5 , wherein the repeating pattern is sinusoidal.
7. The snack bar of claim 1 , wherein the crust defines a graham cracker or chocolate base for the snack bar.
8. The snack bar of claim 1 , wherein the secondary filling constitutes a flowable material.
9. The snack bar of claim 1 , wherein the primary filling is cheesecake.
10. The snack bar of claim 9 , wherein the secondary filling is a fruit filling.
11. The snack bar of claim 1 , wherein the snack bar has an overall length and an overall width, each being in the order of 2-3 inches (approximately 5-7.5 cm).
12. A snack bar comprising:
a base; and
a filling provided on the base, said filling including a primary filling constituted by a non-flowable material and a secondary filling, wherein the secondary filling is embedded in and deforms, extends approximately half of a depth of, and yet is externally exposed from, the primary filling.
13. The snack bar of claim 12 , wherein the base constitutes a crust of the snack bar.
14. The snack bar of claim 13 , wherein the crust defines a graham cracker or chocolate base for the snack bar.
15. The snack bar of claim 12 , wherein the primary filling has a smooth top surface, and said secondary filling is substantially flush with and visible from the top surface.
15–1. The snack bar of claim 12 , wherein the secondary filling constitutes a flowable material.
16. The snack bar of claim 12 , wherein the primary filling is cheesecake.
17. The snack bar of claim 16 , wherein the secondary filling is a fruit filling.
18. The snack bar of claim 12 , wherein the secondary filling extends within the primary filling in a repeating pattern along a length of the snack bar.
19. The snack bar of claim 18 , wherein the repeating pattern is non-linear.
20. The snack bar of claim 19 , wherein the repeating pattern is sinusoidal.
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US17/963,373 US20230036823A1 (en) | 2014-12-18 | 2022-10-11 | Method and Apparatus for Making Co-Extruded Food Product |
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US14/575,686 US11490625B2 (en) | 2014-12-18 | 2014-12-18 | Method and apparatus for making co-extruded food product |
US17/963,373 US20230036823A1 (en) | 2014-12-18 | 2022-10-11 | Method and Apparatus for Making Co-Extruded Food Product |
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CA2970779A1 (en) | 2016-06-23 |
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EP3232821A1 (en) | 2017-10-25 |
WO2016100092A1 (en) | 2016-06-23 |
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EP3232821A4 (en) | 2018-05-09 |
AU2015362882B2 (en) | 2019-07-25 |
AU2015362882A1 (en) | 2017-07-13 |
US20160174580A1 (en) | 2016-06-23 |
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