U.S. patent application number 09/847903 was filed with the patent office on 2001-10-11 for extrusion die.
This patent application is currently assigned to Nestec S.A., Swiss corporate. Invention is credited to Deutsch, Roman, Heck, Ernst, Martin, Jean-Pierre.
Application Number | 20010028900 09/847903 |
Document ID | / |
Family ID | 8240170 |
Filed Date | 2001-10-11 |
United States Patent
Application |
20010028900 |
Kind Code |
A1 |
Deutsch, Roman ; et
al. |
October 11, 2001 |
Extrusion die
Abstract
A process for manufacturing an expanded cereal with the overall
shape of an array of touching balls and an extrusion die and an
extruder for use with the process. The die includes a feed ring for
receiving material from an extruder, a cylindrical distribution
chamber having a front wall and rear wall which includes the feed
ring, and an array of parallel extrusion tubes provided in the
front wall of the distribution chamber. The feed ring is in
communication with the array of parallel extrusion tubes through
the distribution chamber. The distribution chamber also includes a
cylindrical distribution insert that extends axially from the
center of the feed ring towards the front wall but spaced from the
array of extrusion tubes. The process involves cooking and
extruding a mixture of starchy material, sugar, oil, and water in a
cooker-extruder and forcing the cooked material through the
extrusion die.
Inventors: |
Deutsch, Roman; (Lutry,
CH) ; Heck, Ernst; (Vufflens-La-Ville, CH) ;
Martin, Jean-Pierre; (Villars-Burquin, CH) |
Correspondence
Address: |
WINSTON & STRAWN
200 PARK AVENUE
NEW YORK
NY
10166-4193
US
|
Assignee: |
Nestec S.A., Swiss
corporate
Vevey
CH
|
Family ID: |
8240170 |
Appl. No.: |
09/847903 |
Filed: |
May 3, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09847903 |
May 3, 2001 |
|
|
|
09559544 |
Apr 28, 2000 |
|
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|
6258396 |
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Current U.S.
Class: |
425/307 ;
425/464 |
Current CPC
Class: |
A23L 7/17 20160801; A23P
30/34 20160801; A21C 11/16 20130101 |
Class at
Publication: |
425/307 ;
425/464 |
International
Class: |
B29C 059/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 30, 1999 |
EP |
99201367.2 |
Claims
What is claimed is:
1. An extrusion die comprising a feed ring for receiving material
from an extruder; a cylindrical distribution chamber having a front
wall and a rear wall that includes the feed ring; an array of
parallel extrusion tubes provided in a front wall of the
distribution chamber, wherein the array of parallel extrusion tubes
is in communication with the feed ring through the distribution
chamber; and a cylindrical distribution insert that extends axially
from the center of the feed ring towards the front wall but is
spaced from the array of tubes.
2. The extrusion die of claim 1, wherein the array of parallel
extrusion tubes comprises between about 12 to 30 tubes.
3. The extrusion die of claim 1, wherein the tubes of the array
have a cross sectional shapes comprising one or more of a circle,
oval, polygon, triangle, square, rectangle, or trapezoid.
4. The extrusion die of claim 1, wherein the tubes are aligned
along one or more axes or curves when viewed in cross section.
5. The extrusion die of claim 1, wherein the dimensions of the
cross section of each tube is between about 1 and 4 mm.
6. The extrusion die of claim 1, wherein the area of the cross
section of each tube is between about 1 and 16 mm.sup.2.
7. The extrusion die of claim 1, wherein the distance between two
adjacent tubes in the array is between about 0.2 and 0.6 mm.
8. The extrusion die of claim 1, wherein the array of parallel
extrusion tubes is in two groups with parallel intersecting
axes.
9. An extruder comprising an elongated barrel, one or two
processing screws within the elongated barrel, at least one
extrusion die according to claim 1, and a cutting means.
10. The extruder of claim 9, comprising more than one die; wherein
the barrel has an upstream end and a downstream end, wherein the
downstream end of the barrel is secured to a front plate provided
with an orifice that is in communication with the barrel, the front
plate is attached to a second plate having an opening that is in
communication with the orifice of the front plate, and a
bell-shaped pre-distribution chamber, wherein the bell-shaped
pre-distribution chamber is attached to the second plate and is in
communication with the opening of the second plate and is in
communication with the feed rings of the extrusion die; and wherein
the cutting means is a rotary cutter that rotates against the
outlet orifices of the extrusion tubes.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a division of U.S. application Ser. No.
09/559,544, filed Apr. 28, 2000, the content of which is expressly
incorporated herein by reference thereto.
FIELD OF THE INVENTION
[0002] The present invention is directed to an extrusion die, an
extruder comprising the extrusion die, a method for manufacturing
an expanded cereal using the extrusion die, and an expanded cereal
that is obtained by extrusion through the die.
BACKGROUND
[0003] EP 0,898,890 describes an extrusion die for producing a
product that has the overall shape of a nucleus surrounded by a
ring. The product is obtained by extruding a single substance
through a die having a feed orifice plate that opens into an
extrusion chamber that is divided into two concentric chambers by a
separating cone. The position of the cone can be adjusted relative
to the outer casing of the die. This adjusts the relative size of
the extrusion openings and hence the size of the nucleus and outer
ring.
[0004] U.S. Pat. No. 2,858,218 describes a cereal in the form of
flakes which has a relief comparable to the surface of a raspberry,
and a method for obtaining such a cereal. The method involves
cooking a mixture of cereal and water at atmospheric pressure,
extruding the resulting cooked paste, using a piston to drive the
cooked paste through a die having a number of holes to form
parallel filaments of the cooked paste, combining the filaments,
laterally compressing the bundle in a tubular extension of the die
so that filaments stick together and form a cylinder, drying the
cylinder, cutting the cylinder transversely into thin slices, and
causing the slices to swell under the action of heat.
[0005] U.S. Pat. No. 3,482,992 describes a cereal in the form of
flakes made up of touching pieces, the intersection where the
pieces meet being colored, and a method for obtaining such a
cereal. The method involves cooking a mixture of cereal and water
in a cooking device to provide a cooked paste; extruding the cooked
paste through a die which has a number of circular outlet orifices,
in particular six holes arranged in a circle around a central hole;
and injecting a colorant through small intermediate holes to form
parallel strands of cooked paste which are colored at their
interface. The strands are combined into a bundle and compressed
laterally in a tubular extension of the die so that they stick
together and form a composite strand. The diameter of the strand is
then reduced by drawing it longitudinally and the strand is cut
transversely into thin slices. The slices are dried and made to
swell under the action of heat.
[0006] The object of the present invention is to provide an
extrusion die that makes it possible to produce an expanded cereal
with a particularly attractive three-dimensional shape, the
three-dimensional shape being an array of touching balls.
SUMMARY OF THE INVENTION
[0007] The present invention relates to an extrusion die to prepare
an expanded cereal. The extrusion die includes a feed ring for
receiving material from an extuder; a cylindrical distribution
chamber having a front wall and a rear wall that includes the feed
ring; an array of parallel extrusion tubes provided in a front wall
of the distribution chamber, wherein the array of parallel
extrusion tubes is in communication with the feed ring through the
distribution chamber; and a cylindrical distribution insert that
extends axially from the center of the feed ring towards the front
wall but is spaced from the array of tubes.
[0008] The array of parallel extrusion tubes may include between
about 12 to 30 tubes. The tubes of the array may have a cross
sectional shape that is one or more of a circle, oval, polygon,
triangle, square, rectangle, or trapezoid. The tubes may be aligned
along one or more axes or curves when viewed in cross section. The
dimensions of the cross section of each tube may be between about 1
and 4 mm and the area of the cross section of each tube may be
between about 1 and 16 mm.sup.2. The distance between two adjacent
tubes in the array may be between about 0.2 and 0.6 mm. The array
of parallel extrusion tubes may be in two groups with parallel
intersecting axes.
[0009] The invention also relates to an extruder that includes an
elongated barrel, one or two processing screws within the elongated
barrel, at least one extrusion die as described above, and a
cutting means.
[0010] In one embodiment the extruder has more than one die. In
this embodiment the barrel has an upstream end and a downstream
end, wherein the downstream end of the barrel is secured to a front
plate provided with an orifice that is in communication with the
barrel, the front plate is attached to a second plate having an
opening that is in communication with the orifice of the front
plate, and a bell-shaped pre-distribution chamber, wherein the bell
shaped distribution chamber is attached to the second plate and is
in communication with the opening of the second plate and is in
communication with the feed rings of the extrusion die; and the
cutting means is a rotary cutter that rotates against the outlet
orifices of the extrusion tubes.
[0011] The invention also relates to a method of manufacturing an
expanded cereal with the overall shape of an array of touching
balls. The method involves the steps of providing a cooker-extruder
having an elongated barrel with one or two processing screws within
the elongated barrel with a mixture of between about 60 and 90
parts by weight of a starchy material, up to 15 parts by weight of
sugar, up to 10 parts by weight of oil, and a sufficient amount of
water so that the mixture has a water content of between about 15
and 25 percent by weight; cooking the mixture under positive
pressure in the cooker-extruder to provide a thermoplastic
substance; extruding the thermoplastic substance through at least
one die having an array of parallel extrusion tubes each having an
outlet orifice so that the thermoplastic substance expands when it
exits the outlet orifices of the extrusion tubes to provide a
bundle of strands of expanded thermoplastic substance that stick
together; and cutting the bundle into slices as they exit from the
outlet orifices of the extrusion tubes to provide an expanded
cereal.
[0012] The cooking may be conducted at a temperature of between
about 105.degree. C. and 180.degree. C., a pressure of between
about 40 and 180 bar, a rotation speed for the one or more screws
of between about 240 and 370 rpm, and wherein the ratio of the
length of the screw to the diameter of the screw is between about 9
and 24. The coefficient of expansion for the extruded strands may
be between about 2 and 4. The extruded strands may have a porous
texture. The extruded strands may have a residual water content of
between about 5 and 12 percent and may be further dried to a water
content of between about 1 and 3 percent.
[0013] The starchy material may be one or more of a flour selected
from the group consisting of wheat, barley, rice, and corn flour or
a starch selected from the group consisting of wheat, barley, rice,
tapioca, potato, and corn starch. The sugar may be one or more of
sucrose, glucose, or fructose. The oil may be present in an amount
of between about 4 and 10 percent by weight and may be a butter oil
or a vegetable oil. The mixture further include up to 1.5 parts of
calcium that may be provided by calcium carbonate or calcium
triphosphate or one or more vitamins, trace elements, sodium
chloride colorings, or flavorings.
[0014] The invention further relates to an expanded cereal prepared
by the method of the invention. The expanded cereal product may be
coated with one or more of a chocolate coating, a sugar syrup, a
fruit syrup, a honey syrup, or a coating that contains one or more
vitamins or flavorings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an axial view of one embodiment of the die of the
invention;
[0016] FIG. 2 is a cross section view of the die depicted in FIG.
1,
[0017] FIG. 3 is a partial cross section view of one embodiment of
an extruder comprising a number of dies;
[0018] FIG. 4 is a face view of the extruder depicted in FIG. 3;
and
[0019] FIG. 5 is a photograph showing one embodiment of the cereal
from three different angles.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The extrusion die of the invention is depicted in FIG. 1.
The extrusion die comprises a feed ring 1 that forms the rear wall
of a cylindrical distribution chamber 2 and opens into the
cylindrical distribution chamber 2. The cylindrical distribution
chamber 2 communicates with an array of parallel extrusion tubes 3
provided in a front wall 4 of the cylindrical distribution chamber
2. A cylindrical distribution insert 5 extends axially from the
center of the feed ring 1 towards the front wall but is spaced from
the front wall. Preferably, the space between the cylindrical
distribution insert 5 and the front wall is between about 1 and 5
mm.
[0021] The feed ring 1 may be, for example in the form of two
concentric annuli 11 and 12 connected by juxtaposed tubular hoops
13. The number of tubular hoops may vary from between about 4 and
20, preferably between about 5 and 12.
[0022] The cylindrical distribution insert 5 has a first
cylindrical upstream part 16 and a second frustoconical downstream
part 17. The cylindrical distribution insert 5 evens out the rate
of displacement across the width of the extrusion front when a
thermoplastic material is extruded through the cylindrical
distribution chamber. The cylindrical distribution insert 5 assures
that the flow of material through the array of tubes is distributed
homogeneously in front of the array. By homogeneously is meant
there are no preferential paths for the material being extruded to
follow and that the flow of material has substantially the same
speed in front of each individual tube of the array. The width of
the extrusion front corresponds to the width or diameter of the
array of parallel extrusion tubes.
[0023] The array of extrusion tubes 3 is an array of several
individual cylindrical parallel tubes. The array may comprise from
about 2 to 40 tubes, preferably from about 12 to 30 tubes. The
individual tubes of the array may have cross sections in a variety
of shapes including, but not limited to a, circle, oval, polygon,
triangle, square, rectangle, and trapezoid. The shape and size of
the cross section of the individual tubes in any given array may be
the same or different. Preferably, the tubes are arranged so that
they are aligned along a number of axes or curves when viewed in
cross section. The tubes, however, may also be arranged randomly
and in no particular order. The cross section of the tubes may have
dimensions, i.e., diameters, lengths, or widths of between about 1
and 4 mm. Preferably, the cross section of the tubes has a surface
area or aperture of between about 1 and 16 mm.sup.2. Preferably,
the tubes are relatively close together. The distance between two
tubes of the array may be from about 0.2 to 0.6 mm. In a preferred
embodiment 24 cylindrical tubes each having the same circular cross
section are arranged in two groups with parallel axes intersecting
at angles as depicted in FIG. 4.
[0024] The extruder of the invention comprises an elongated barrel
containing one or two processing screws, at least one extrusion die
of the invention, and a cutting means.
[0025] The phrase "processing screw" means an extrusion screw
rotating inside the bore of a barrel or two extrusion screws
rotating inside of two secant bores of a barrel. The screws have
processing members such as flights helically wound about their
axis. The configuration, pitch, depth, and hand of the flights may
be configured in various ways along the axis of the screw so as to
define zones for various processing operations such as conveying,
wetting, mixing, shearing, compressing, and/or cooking. The
processing screws may be made as a single piece or by assembling
various processing members by successively slipping the processing
members onto a spindle.
[0026] The cutting means cuts the extrudate as it emerges from the
outlet orifices of the extrusion tubes. Preferably, the cutting
means is a rotary cutter 14 that rotates against the outlet
orifices of the extrusion tubes 3 of the array, i.e., against the
front wall of the die. The rotating cutter may have one blade or a
number of blades, preferably the rotating cutter has between about
2 and 4 blades.
[0027] The extruder may include several extrusion dies such as
those depicted in FIGS. 1 and 2. FIGS. 3 and 4, depict an
embodiment of the invention wherein the extruder comprises a number
of extrusion dies. In FIG. 3 the downstream end of the elongated
extrusion barrel ends at a front plate 7 that is provided with an
orifice 8 that is in communication with the barrel. The front plate
7 is attached to a second plate 15 having an opening 10 that is in
communication with the opening 8 in the front plate 7 and is in
communication with a bell shaped pre-distribution chamber 9. The
pre-distribution chamber 9 communicates with the distribution
chambers 2 of the dies via the feed rings 1. Preferably, the
extruder has between about 2 and 30 dies.
[0028] By downstream end of the extruder is meant the end of the
extruder closest to the extrusion die. By upstream end of the
extruder is meant the end of the extruder most distant from to the
extrusion die. The overall flow of material in the extruder is from
the upstream end towards the downstream end.
[0029] When the extruder has several dies, the number of dies that
can be used can be adjusted according to the output of the
extruder. For example, one die in two or one die in three can be
closed by blocking the dies feed ring 1 with a cover. The cover is
fixed to the dies center and replaces the distribution insert 5.
FIG. 3 depicts an extruder wherein the lower die is blocked by
replacing the distribution insert 5 with a cover 15 to block the
feed ring 1 of the die.
[0030] The extruder of the invention can be used to prepare a
cereal that has the overall shape of an array of touching balls.
The touching balls of the array may be of similar or different
shapes, preferably they are round and/or elongated. The touching
balls may be aligned or may not be aligned along an axes or a
curve. The array may have an overall thickness of between about 4
and 16 mm. The overall shape of the array may be flat or it may be
somewhat curved. A variety of shapes are possible for the overall
periphery of the array. Preferably the shape of the periphery of
the array is square, rectangular, circular, or oval, modulated by
the bumps formed by the balls located at the edges.
[0031] The cereal of the invention may be used to manufacture a
variety of products such as, for example, breakfast cereals,
crunchy pet food, and the like.
[0032] When the cereal of the invention is a breakfast cereal it
can be eaten as it is or it may be coated. Suitable coatings for
use with the cereal of the invention include, but are not limited
to, a chocolate coating, a sugar syrup, a fruit syrup, a honey
syrup, and a coating containing vitamins and flavorings.
[0033] FIG. 5 depicts one embodiment of the cereal that can be
obtained by extrusion through a die similar to those depicted in
FIGS. 1 and 4.
[0034] In this embodiment, the cereal has the overall shape of an
array of touching balls of the same round shape and of the same
dimensions aligned in two groups with parallel axes intersecting at
angles. The array of balls has a periphery of overall rectangular
shape but is slightly curved on one side (the side where the cutter
detached the cereal from the composite strand leaving the die).
[0035] The cereal, having the overall shape of an array of touching
balls, is prepared by forming a mixture comprising between about 60
and 90 parts by weight of a starchy material, up to about 15 parts
by weight of sugar, and up to about 10 parts by weight of oil, and
adding sufficient water to provide a water content of between about
15 to 25 percent by weight. The resulting mixture is then cooked,
extruded, and expanded at a pressure of between about 40 to 180 bar
and a temperature between about 105.degree. C. and 180.degree. C.
The mixture is extruded through at least one die comprising an
array of parallel extrusion tubes so as to obtain a bundle of
strands of expanded thermoplastic substance that stick together.
The bundle is then cut into slices at the outlet orifices of the
extrusion tubes.
[0036] The starchy material may be a cereal flour including, but
not limited to, one or more of wheat, barley, rice, or corn flour.
The starch material may also be a starch including, but not limited
to, one or more of wheat, barley, rice, tapioca, potato, or corn
starch.
[0037] Any sugar suitable for manufacturing cereal may be used
according to the method of the invention. For example, the sugar
may be sucrose, glucose or fructose.
[0038] The oil is preferably added in the proportion of between
about 4 and 10 parts by weight. Oils that may be used in the method
of the invention include, but are not limited to, butter oil and
vegetable oils such as palm nut oil.
[0039] The mixture may further contain up to 1.5 parts of calcium,
for example, in the form of calcium carbonate or calcium
triphosphate.
[0040] The mixture may further include other additives including,
but not limited to, vitamins, trace elements, sodium chloride,
colorings, and artificial or natural flavorings such as cocoa. For
example, up to 6 parts of cocoa may be added.
[0041] The cooking and extrusion may be performed in a
cooker-extruder having a screw with a length to diameter ratio of
between about 9 and 24, with the screws rotating at between about
240 and 370 rpm, at a pressure in the range of about 40 and 180
bar, and at a temperature in the range of about 105.degree. C. to
180.degree. C. The cooked and extruded mixture expands as it exits
the cooker-extruder due to the decrease in pressure. Preferably the
extruded strands exhibit an expansion coefficient for the extruded
strands of between about 2 and 4. By "expansion coefficient" is
meant the increase in volume of the mixture after it exits the die
relative to the volume of the mixture before it goes through the
die.
[0042] Water escapes from the thermoplastic mass in the form of
steam during expansion so that the extruded strands have a porous
texture. The residual water content of the extruded strands is
preferably between about 5 and 12 percent.
[0043] The resulting expanded cereal may be further dried.
Preferably, the cereal is dried by passing it continuously through
a hot air oven until the residual water content is reduced to
between about 1 to 3 percent.
EXAMPLES
[0044] The invention is further defined by reference to the
following examples describing in detail the production of a
preferred form of the cereal of the invention, an expanded
breakfast cereal. The example is representative, and should not be
construed to limit the scope of the invention in any way.
[0045] The cereal is prepared by cooking and extruding a mixture
based on flour and water in a cooker-extruder comprising several
dies according to the invention. In the following example, as in
the entirety of this description, parts and percentages are given
by weight.
[0046] A twin-screw cooker-extruder comprising several dies similar
to the one illustrated in FIGS. 3 and 4 was used to produce
expanded cereals with the shape of an array of touching round balls
as illustrated in FIG. 5.
[0047] A mixture with the following composition was prepared (in
parts, except for the added water):
1 Rice flour 40 Cornflour 12 Wheat flour 22 Sucrose 10 Palm nut oil
5 Salt/spices 3
[0048] Water (added to a water content of 18 percent)
[0049] The dry powders were first mixed and the resulting dry
mixture, the oil, and the water added to a CLEXTRAL type BC-72
twin-screw extruder equipped with a screw having a diameter of 88
mm and a length of 900 mm. The resulting mixture was mixed in the
extruder.
[0050] The mixture was then cooked and extruded at a temperature of
about 170.degree. C. and a pressure of between about 100 and 120
bar, with the extruder screws rotating at 310 rpm.
[0051] The resulting thermoplastic mass was extruded through 6
arrays of 24 extrusion tubes, the extrusion tubes having a diameter
of 1.3 mm and the distance between two tubes being 0.3 mm.
[0052] The thermoplastic mass was extruded into the ambient space
and immediately cut into slices using a four-bladed cutter rotating
against the front wall of the dies at a speed of 800 rpm.
[0053] The resulting cereal had the overall shape of an array of 24
touching balls with the same round shape and the same dimensions
and aligned in two groups having parallel axes that intersect at
angles. The array of balls had a periphery with an overall
rectangular shape that was slightly curved on the side where the
cutter detached the cereal from the composite strand leaving the
die.
[0054] The cereal had a thickness of about 6 mm, a width of about
15 mm, and a length of about 20 mm.
* * * * *