U.S. patent application number 14/924009 was filed with the patent office on 2016-02-18 for method for ultrasonic extrusion of a flowable food substrate.
This patent application is currently assigned to Creative Resonance, Inc.. The applicant listed for this patent is Roberto Capodieci. Invention is credited to Roberto Capodieci.
Application Number | 20160044939 14/924009 |
Document ID | / |
Family ID | 38285838 |
Filed Date | 2016-02-18 |
United States Patent
Application |
20160044939 |
Kind Code |
A1 |
Capodieci; Roberto |
February 18, 2016 |
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.
Inventors: |
Capodieci; Roberto;
(Scottsdale, AZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Capodieci; Roberto |
Scottsdale |
AZ |
US |
|
|
Assignee: |
Creative Resonance, Inc.
Glen Ellyn
IL
|
Family ID: |
38285838 |
Appl. No.: |
14/924009 |
Filed: |
October 27, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11786676 |
Apr 12, 2007 |
9167845 |
|
|
14924009 |
|
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|
60843141 |
Sep 8, 2006 |
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Current U.S.
Class: |
426/238 ;
426/531; 426/577; 426/615; 426/656 |
Current CPC
Class: |
A23L 3/30 20130101; A23L
29/231 20160801; A23L 3/005 20130101; A21C 11/16 20130101; A23V
2002/00 20130101; A47J 37/0694 20130101; A23L 19/00 20160801; A23L
5/32 20160801; A21D 13/37 20170101; A23L 13/60 20160801; A21D 6/00
20130101; A23P 30/20 20160801 |
International
Class: |
A23L 1/025 20060101
A23L001/025; A23L 1/317 20060101 A23L001/317; A23L 1/00 20060101
A23L001/00; A21D 6/00 20060101 A21D006/00; A23L 1/0524 20060101
A23L001/0524; A23L 1/212 20060101 A23L001/212 |
Claims
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.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/786,676, filed 12 Apr. 2007 which claims
the benefit of U.S. Provisional Application No. 60/843,141 filed on
8 Sep. 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to ultrasonic extrusion
apparatus, methods, and products. Specifically, this invention
relates to a flowable substrate that is formed into a product with
the addition of ultrasonic energy.
[0004] 2. Discussion of Related Art
[0005] Many edible products are produced by conventional extrusion
devices, such as, augers and screws to form solid or hollow
products. However, these conventional devices may have slower line
speeds than desired and may necessitate additional duplicate units
to achieve needed throughput rates. The additional units increase
capital expenditures for equipment and factory floor space. The
additional units increase cleaning and sterilization requirements
between product batches.
[0006] Often conventional extruded product does not hold its shape
as well as may be desired, especially during subsequent processing,
such as, slicing and baking. Often long ovens are employed to dry a
product rope to a sufficient level before a slicing machine.
Similarly, conventional extruded products may not be as dense
and/or as uniform as desired.
SUMMARY OF THE INVENTION
[0007] There exists a need for an improved apparatus for extrusion
of a flowable substrate which results in an improved extruded
product. This need may be met at least in part by an ultrasonic
extrusion apparatus having increased throughput to produce a
uniform and dense ultrasonically extruded product.
[0008] An apparatus for extruding a flowable substrate may include
an infeed to supply the flowable substrate and a chamber having an
extrusion orifice in communication with the infeed. An ultrasonic
horn may extend into the chamber and across the extrusion orifice
so that an extrusion path of the flowable substrate extends across
the ultrasonic horn.
[0009] The apparatus for ultrasonic extrusion may further include a
booster coupled to the ultrasonic horn, a converter coupled to the
booster and a power supply connected to the converter. Preferably,
the apparatus for ultrasonic extrusion Inay also include an
adjustment mechanism for varying a position of the ultrasonic horn
with respect to the chamber. The adjustment mechanism may mount to
a nodal ring on the ultrasonic horn.
[0010] The extrusion chamber may generally be formed by a base and
a top cover which may be removable. Preferably, the extrusion
chamber may substantially conform to a shape of the extrusion
orifice. The chamber and the ultrasonic horn may have substantially
rounded surfaces to maximize flow of flowable substrate and
minimize catch points which may be detrimental to certain
ingredients, such as puffed cereal. The ultrasonic horn may be
substantially congruent with the extrusion orifice and may extend
into and/or through the extrusion orifice. The extrusion orifice
may include a plurality of small apertures, such as, for example,
to make a spaghetti-like product.
[0011] The extrusion orifice may include a tapered profile from the
chamber toward the extrusion orifice. The extrusion orifice may
include virtually any shape and/or size. The chamber may be
substantially contoured to the ultrasonic resonant horn.
[0012] An additional configuration of the apparatus for
ultrasonically extruding a flowable substrate may include a chamber
with an infeed for supplying a flowable substrate to the chamber
and having a plurality of extrusion orifices. A plurality of
ultrasonic resonant drivers may correspond to the plurality of
extrusion orifices. The ultrasonic resonant drivers may be
energized by a mother horn coupled to the plurality of resonant
drivers. The chamber may include more than one infeed and the
chamber may be divided into separate chambers which may have
individual or shared infeeds.
[0013] This invention further includes a method of extruding a
flowable substrate which may include providing a flowable substrate
to an infeed from a motive force and flowing the flowable substrate
from the infeed into a chamber, where the chamber contains an
ultrasonic horn. Then the method may include contacting the
flowable substrate with the ultrasonic horn and energizing the
ultrasonic horn with ultrasonic energy. Other steps of the method
may include transferring energy from the ultrasonic horn to the
flowable substrate and extruding the flowable substrate through an
extrusion orifice to form a product.
[0014] Preferably, the method may include at least one of the steps
of gelling pectin, agglomerating particles, setting proteins or
other suitable steps to form a shape-retaining product. The
ultrasonic energy may have a frequency of about of about 20 khz to
about 40 khz. The method may further include immediately slicing
the product into shape-retaining pieces following the extruding
step.
[0015] The extruded flowable substrate may produce a product having
a solid cross section or a hollow cross section in virtually any
shape, such as, for example, round, oval, square, rectangle,
triangle, star, crescent, and irregular shapes.
[0016] An extruded product of this invention, may include a
flowable 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. The ultrasonically extruded product may contain a flowable
substrate which includes an ultrasonically settable protein,
ultrasonically gellable pectin, or pomace which may include at
least one of fruit material and/or vegetable material to form a
shape-retaining product. Desirably, the flowable substrate may
include apple-based material.
[0017] Other objects and advantages will be apparent to those
skilled in the art from the following detailed description taken in
conjunction with the appended claims and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above and other objects of this invention can be better
understood when the specification is read in view of the drawings,
wherein:
[0019] FIG. 1 is a sectional view of an apparatus for ultrasonic
extrusion, according to one preferred embodiment of this
invention;
[0020] FIG. 2 is a sectional view of an apparatus for ultrasonic
extrusion, according to one preferred embodiment of this
invention;
[0021] FIG. 3 is a sectional view of an apparatus for ultrasonic
extrusion, according to one preferred embodiment of this
invention;
[0022] FIG. 4A is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0023] FIG. 4B is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0024] FIG. 4C is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0025] FIG. 4D is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0026] FIG. 4EA is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0027] FIG. 4F is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0028] FIG. 4G is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0029] FIG. 4H is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0030] FIG. 4I is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0031] FIG. 4J is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0032] FIG. 4K is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0033] FIG. 4L is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0034] FIG. 4M is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0035] FIG. 4N is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0036] FIG. 4O is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0037] FIG. 4P is a sectional view of an orifice shape, according
to one preferred embodiment of this invention;
[0038] FIG. 5 is a sectional view of an apparatus for ultrasonic
extrusion, according to one preferred embodiment of this
invention;
[0039] FIG. 6A is a sectional view of an ultrasonically extruded
product, according to one preferred embodiment of this
invention;
[0040] FIG. 6B is a sectional view of an ultrasonically extruded
product, according to one preferred embodiment of this invention;
and
[0041] FIG. 7 is a sectional view of an apparatus for ultrasonic
extrusion, according to one preferred embodiment of this
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Ultrasonic extrusion may provide an effective manner to
supply or inject energy into flowable substrate 78 or material.
Ultrasonic energy may impart a significant amount of energy or
power rapidly to flowable substrate 78 in a targeted, a measured
and a precise manner or method to generate or create significant
changes in flowable substrate 78 and the extrusion process.
Typically, three variables may readily affect the ultrasonic
extrusion process. The first is the e or contact of flowable
substrate 78 with an ultrasonic energy source. The second is the
amplitude of the ultrasonic energy and the third are the contact
forces between flowable substrate 78 and the ultrasonic energy
source. Other variables, such as, for example, rheological
properties of flowable substrate 78, shape of the ultrasonic energy
source and volume of extrusion cavity 50, may also affect the
resulting extruded material.
[0043] Typical benefits of ultrasonic extrusion may include
densified product 76, uniform product 76, firmer-held-together
product 76, and/or puffed or fluffy product 76 when using certain
flowable substrates 78 at proper processing conditions.
[0044] Ultrasonic extrusion may produce unexpected results which
may include shape-retaining product 76, that is product 76 that
retains a desired shape following extrusion, and significant
extruder throughput increases. Surprisingly, increases of 3, 5, 7
and 10 times nonultrasonically energized extruder throughput may be
realized by the addition of ultrasonic energy. Without being bound
by theory, ultrasonic energy may push flowable substrate 78 through
extrusion orifice 58 and thus reduce a back pressure on the
extruder screw which allows additional flow or volume of flowable
substrate 78.
Apparatus
[0045] FIG.1 shows a sectional view of apparatus 20 for ultrasonic
extrusion of flowable substrate 78 to produce product 76.
Desirably, apparatus 20 mounts on or joins to an infeed device, not
shown. Suitable infeed devices may include, without limitation,
extruders, augers, conveyors, progressive cavity pumps, positive
displacement pumps and any other suitable delivery vehicle for
supply or dispensing of flowable substrate 78 with a motive force.
Desirably, infeed, not shown, provides flowable substrate 78 in at
least a substantially continuous manner. According to a preferred
embodiment of this invention, the infeed device is a varying pitch
single screw extruder.
[0046] Flowable substrate 78 may broadly include, without
limitation, dough, batters, chocolate refinings, meat emulsions,
creams, and any other suitable extrudable material. Desirably,
flowable substrate 78 becomes at least a part of a food product.
Flowable substrate 78 may include a substantially homogeneous
material, such as, for example, short bread cookie dough or pretzel
dough. Inclusions 80 or mix-ins such as nuts, candies, jellied
fruits, dehydrated vegetables, protein cubes and any other suitable
nonhomogeneous item may be included in flowable substrate 78.
Plowable substrate 78 may further include cosmetics and other
personal hygiene products generally having a substantially solid
end-use form, such as, for example, lipsticks and soaps. According
to a preferred embodiment of this invention, flowable substrate 78
is a meat emulsion used to produce pet food.
[0047] Typically, apparatus 20 may include an ultrasonic transducer
system. An ultrasonic transducer system may include components such
as, for example: a power supply, not shown; radio frequency cable,
not shown; amphenol connector, not shown; converter 22; converter
coupling 24; booster 28; booster coupling 30; and ultrasonic horn
34.
[0048] Typically, converter 22 receives an electrical input signal
from the power supply or source to produce, transform, or make
ultrasonic mechanical vibrations or energy. Converter 22 may be any
size needed to supply adequate ultrasonic energy to flowable
substrate 78. Adequate ultrasonic energy may depend upon many
variables, such as, for example, the volumetric flowrate of
flowable substrate 78, the rheological properties of flowable
substrate 78, a thickness and/or viscosity of flowable substrate
78, and a dimension and/or shape of an extruded item. According to
a preferred embodiment of this invention, converter 22 has a
frequency of about 20 khz to about 40 khz.
[0049] An ultrasonic transducer system may optionally include one
or more boosters 28. Booster 28 generally serves to increase or
decrease amplitude or wave height of the ultrasonic energy. Booster
28 may include a booster nodal ring, not shown, which does not
vibrate with the frequency of converter 22. Booster nodal rings or
inert rings and points may be used for mounting, supporting or
fixing a location of booster 28. Boosters 28 generally may change
amplitude by a factor of about 0.5 to about 3 times the amplitude
produced by converter 22.
[0050] Desirably, converter coupling 24 ultrasonically connects to
or provides ultrasonic communication between converter 22 and
booster 28. Converter coupling 24 may include, without limitation,
relatively permanent unions, such as, for example, brazing or
electron beam welding, and interchangeable or replaceable unions,
such as, for example, mechanical flanges, clamps, and threaded
connectors. According to a preferred embodiment of this invention,
converter coupling includes a properly torqued threaded stud
inserted into corresponding threaded bores on converter 22 and
booster 28.
[0051] Converter anti-fretting device 26 may be included between
mating surfaces of converter 22 and booster 28. Fretting may occur
as the ultrasonic energy causes friction between mating surfaces.
This friction may rapidly generate significant heat and detune the
harmonics of the transducer system resulting in transducer system
reliability and/or power supply overload and/or failure. This
action may create bumps or ripples on the mating surfaces which may
produce galling or welding of the mating surfaces. Anti-fretting
device 26 may include silicone grease, polymer washers, and any
other suitable material to transmit ultrasonic energy and prevent
fretting. According to a preferred embodiment of this invention, a
Mylar.RTM. washer is placed or sandwiched between converter 22 and
booster 28.
[0052] Ultrasonic transducer system may further include ultrasonic
horn 34 or sonotrode. Ultrasonic horn 34 may be the primary device
for delivery of ultrasonic energy into flowable substrate 78.
Desirably, ultrasonic horn 34 may be compatible with flowable
substrate 78, such as chemically resistant or inert and desirably
not changing a taste and/or a color of flowable substrate 78.
Materials of construction for ultrasonic horn 34 may include
aluminum, titanium, steel and any other suitable ultrasonic
transmitting material. Ultrasonic horn 34 may have treated exterior
surfaces, such as, for example, anodized aluminum for hardness,
carbided steel for abrasion resistance and any other suitable
treatment to produce desired results.
[0053] Ultrasonic horn 34 may be sanitized and/or sterilized for
use with edible items. According to a preferred embodiment of this
invention, apparatus 20 and ultrasonic horn 34 has an inherent
clean in place capability such that between product batches a
cleaning solution, such as, for example, water and iodine, can be
introduced desirably with the ultrasonic energy source active to
allow cavitation to assist in cleaning.
[0054] Ultrasonic horn 34 may include horn nodal ring 36 which may
have the characteristics and qualities described above for a
booster nodal ring, not shown. Ultrasonic horn 34 may generally be
of any suitable size and shape for imparting ultrasonic energy into
flowable substrate 78. According to a preferred embodiment of this
invention, ultrasonic horn 34 has substantially rounded
surfaces.
[0055] Ultrasonic transducer system may further include booster
coupling 30 and booster anti-fretting device 32 which may have
characteristics and qualities described above with respect to
converter coupling 24 and converter anti-fretting device 26,
respectively.
[0056] Desirably, the ultrasonic transducer system includes an
adjustment mechanism for varying at least one of: an insertion of
the ultrasonic horn 34 into extrusion chamber 50, a volume of
extrusion chamber 50, a residence time of flowable substrate 78
within in ultrasonic chamber 50, a back pressure on extrusion
orifice 58, inclusion 80 passageway or clearance, a contact force
between flowable substrate 78 and ultrasonic horn 34, and
combinations thereof.
[0057] As shown in FIG. 1 and according a preferred embodiment of
this invention, the adjustment mechanism may include horn adjusting
ring 38, at least one positioning screw 44 and at least one
positioning nut 46. Desirably, horn adjusting ring 38 mounts to
horn nodal ring 36. Horn adjusting ring 38 may include any
supporting and calibrating mechanism to clamp or hold horn nodal
ring 36. According to a preferred embodiment of this invention,
horn adjusting ring 38 includes a split design to allow or
facilitate installation and/or removal.
[0058] Horn adjusting ring 38 may further include at least one
o-ring 40 to aid in clamping horn nodal ring 36. Suitable materials
for o-ring 40 may include, for example, natural or synthetic
rubbers and elastomers. According to a preferred embodiment of this
invention, o-ring 40 is Buna rubber.
[0059] The adjustment mechanism with adjusting screws 44 may insert
or remove ultrasonic horn 34 from extrusion chamber 50. Typically,
positioning screws 44 include a threaded rod or stud of sufficient
length to facilitate operation and/or maintenance of apparatus 20.
According to a preferred embodiment of this invention, three
positioning screws 44 substantially support horn adjusting ring 38
at substantially equally spaced locations.
[0060] Positioning screws 44 may include positioning nuts 46 to
locate or dial-in a location or position of ultrasonic transducer
system with respect to a position within extrusion chamber 50.
Typically, positioning nuts 46 may include helically threaded nuts
or collars with a diameter corresponding to positioning screws 44.
Positioning nuts 46 may include items being manually or tool
adjusted and may include locking or vibration-resistant
mechanisms.
[0061] Those skilled in the art and guided by the teachings herein
will readily appreciate that the adjustment mechanism may include
any suitable design to engage and adjust ultrasonic horn 34 in
extrusion chamber 50 and is not limited to configurations shown in
the figures and described explicitly herein.
[0062] Extrusion chamber 50 may include a space or void generally
formed by top plate 48 and base 52. Desirably, top plate 48 or
removable cover may be removable to allow access to extrusion
chamber 50 for fabrication and/or cleaning. Top plate 48 and
ultrasonic horn 34 may include seal 54 in between. Seal 54 may be
compatible with flowable substrate 78 and may prevent flowable
substrate 78 from escaping or exiting from extrusion chamber 50
around or between ultrasonic horn 34 and a hole or opening in top
plate 48. Desirably, seal 54 may apply minimal force perpendicular
to a side of ultrasonic horn 34. Too much force may impede or
dampen ultrasonic horn 34 and/or cause seal 54 failure due to heat
build up, while too little may allow leakage. According to a
preferred embodiment of this invention, seal 54 may include an
anti-reflux o-ring made of Teflon.RTM. elastomers. Ultrasonic horn
34 desirably may include a substantially parallel surface and/or a
substantially equal diameter to facilitate adjustment mechanism and
seal 54 cooperation.
[0063] Base 52 may further include infeed coupling 56 for attaching
or mating with infeed device, not shown. Base 52 may include
additional heating or cooling systems depending on the thermal
processing requirements for flowable substrate 78. Typically,
infeed coupling 56 may include mechanical couplings and/or joints.
According to a preferred embodiment of this invention, infeed
coupling 56 includes a flange.
[0064] Infeed coupling 56 may form part of infeed channel 64 or
path for flowable substrate 78. Desirably, infeed channel 64
maintains a substantially similar diameter to infeed device.
[0065] Infeed channel 64 may connect with or extend into extrusion
chamber 50. Extrusion chamber 50 may have chamber surface 66.
Generally, chamber surface 66 may be contoured, rounded, and/or
smoothed to avoid or minimize sharp edges or transitions where
flowable substrate 78 may accumulate or collect. Generally,
extrusion chamber 50 may substantially conform to a shape of
extrusion orifice 58. Conform may generally include being similar
and/or identical with substantial shape compliance. It may be
desirable that flowable substrate 78 properly follows the lateral
surface of ultrasonic horn 34 as it proceeds to and through
extrusion orifice 58. It may be further desirable that extrusion
chamber 50 provides minimal resistance to the flowable substrate 78
flow thereby permitting a free flowing supply of flowable substrate
78 through extrusion chamber 50 and out of extrusion orifice
58.
[0066] Chamber surface 66 may include layers or treatments to
improve surface characteristics, such as, for example, increased
abrasion resistance by weld overlay and/or reduced sticking by
application of a fluoropolymer.
[0067] According to a preferred embodiment of this invention,
apparatus 20 for extruding flowable substrate 78 may include an
infeed, not shown, an extrusion chamber 50 having extrusion orifice
58; and ultrasonic horn 34 extending into extrusion chamber 50 and
across extrusion orifice 58 so that an extrusion path of flowable
substrate 78 extends across ultrasonic horn 34. Across generally
may include at least substantially aligned with or along.
Typically, the extrusion path creates sufficient contact between
flowable substrate 78 and ultrasonic horn 34 to impart or transfer
a desired level of ultrasonic energy. Ultrasonic horn 34 may pass
or extend therethrough extrusion chamber 50.
[0068] Extrusion chamber 50 may be profiled to increase a pressure
on flowable substrate 78 approaching ultrasonic horn 34. According
to a preferred embodiment of this invention, apparatus 20 for
extruding flowable substrate78 may include an interior profile of
extrusion chamber 50 that is substantially contoured to and/or
around ultrasonic horn 34.
[0069] Extrusion chamber 50 may include at least one extrusion
channel 62. Extrusion channel 62 may be tapered or flared to focus
flowable substrate 78 and/or ultrasonic energy during extrusion.
Generally, extrusion orifice 58, hole or bore may, but not
necessarily, be located at an end of extrusion channel 62.
Extrusion channel 62 may connect extrusion orifice 58 by a profile
from extrusion chamber 50.
[0070] Extrusion chamber 50 may be formed generally in-line with
the infeed, not shown, and include extrusion orifice 58 formed
generally at an angle relative to the infeed, not shown. Other
suitable configurations of extrusion chamber 50 may be possible as
desired that similarly permit passage of flowable substrate 78 from
the infeed, not shown, and through extrusion orifice 58, such as,
for example, in-line or obtuse angles. Generally, a centerline of
ultrasonic horn 34 at least substantially may align with a center
line of extrusion orifice 58.
[0071] As discussed in detail, below extrusion orifice 58 may have
virtually any shape and/or size to accommodate desired end products
76. Generally, extrusion chamber 50 may contour or substantially
conform to a shape of extrusion orifice 58. Desirably, the contour
of extrusion chamber 50 provides a substantially equal residence or
dwell time for flowable substrate 78 to impart or deliver a
consistent amount or quantity of ultrasonic energy into flowable
substrate 78 and produce a uniform and consistent product 76.
Contour of extrusion chamber 50 may also be designed to include an
inclusion 80 passageway. Generally, for product 76 having
inclusions 80, inclusion 80 passageway, space or distance between
two surfaces such as, for example, chamber surface 66 and
ultrasonic horn 34 may be at least equal to an average particle
diameter or size of inclusion 80.
[0072] Ultrasonic horn 34 may have horn face 60, end or tip located
at a distal end of ultrasonic horn 34. Desirably, horn face 60 may
be at least substantially congruent with extrusion orifice 58.
Congruent may include items that are generally superposable so as
to be coincident throughout, such as, for example, a star with a
distance of 2 inches from tip to tip or point to point may be
congruent with a circle having a diameter of 2 inches. Generally,
horn face 60 may be any size, shape, and/or diameter depending on
such variables as the size of product 76, opening of extrusion
orifice 58, and properties of flowable substrate 78. Horn face 60
and ultrasonic horn 34 generally may be engineered using harmonic
principles, theories, rules and formulas to provide efficient and
reliable designs in the needed and desired shapes, profiles, sizes,
lengths and/or diameters. Typical horn face 60 shapes may include
rounded, curved, domed, flattened and flat. FIG. 1 shows a
substantially domed horn face 60, while FIG. 2 shows a
substantially flat horn face 60.
[0073] Generally, product 76 shape may be formed or determined by a
shape of extrusion orifice 58 or extrusion opening. Extrusion
orifice 58 may have virtually any simple or complex shape. Some
typical shapes are shown in FIGS. 4A-4P and may include broadly,
without limitation: 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,
triangle with square, and any other suitable combination of linear
and/or arcuate shapes having regular or irregular outlines.
Fanciful shapes may be used to produce novelty or seasonal products
76.
[0074] Particularly, as shown in FIGS. 4A-4M, extrusion orifice 58
may produce a solid or non-hollow product 76 when viewed in a cross
section or generally transverse to extrusion orifice 58. Ultrasonic
extrusion may form product 76 or a rope that is somewhat
substantially rigid, which is capable of being further processed
without significantly losing the extruded shape. Further processing
may include, broadly, cutting, portioning, slicing, baking,
cooking, dehydrating, steaming, frying, packaging and any other
suitable step or action to prepare or produce a finished product
76.
[0075] Typically, solid product 76 may be formed when ultrasonic
horn 34 ends close to or directly adjacent to extrusion orifice 58.
Horn face 60 may extend toward extrusion orifice 58 according to
one preferred embodiment of this invention so as to permit a solid
rope of end product 76. In this embodiment, horn face 60 may be
generally rounded so as to permit a smooth and unimpeded flow of
flowable substrate 78 out of extrusion orifice 58 while maintaining
close proximity of flowable substrate 78 with the sonically
activated portions ultrasonic horn 34.
[0076] Particularly, as shown in FIGS. 4N-4P, extrusion orifice 58
may produce a hollow rope or open product 76. Extrusion orifice 58
may have an inset form or mold to create a hollow product 76, such
as, for example, as may be used to form rigatoni or other hollow
pastas. Suitable inset forms may include a pin or a piercing
mandrel. Positive pressure may be applied through the pin.
According to a preferred embodiment of this invention and as shown
in FIG. 2, hollow product 76 may be formed or shaped by ultrasonic
horn 34 inserting or protruding at least part way into and/or
through extrusion channel 62 and/or extrusion orifice 58 to form
annulus 68 or a substantially concentric shape. Hollow product 76
may be filled or injected with an additional material or filling,
such as, for example, creams, fruits, cheeses, meats and any other
suitable flavor and/or texture item.
[0077] Horn face 60 may extend into extrusion orifice 58 preferably
so as to form an inner diameter of end product 76. The walls of
extrusion orifice 58 preferably may form the outer diameter of end
product 76 which may be a generally tubular, hollow and generally
continuous rope of product 76.
[0078] Coextrusion of a filling into product 76 may be done by
application of ultrasonic energy to one or both the extruded
materials, such as for example performing ultrasonic extrusion on
both an external dough and an internal meat emulsion to result in a
product having some rigidity or stiffness to both the shell and
filling for downstream processing, such as, for example to make a
pizza roll.
[0079] As shown in FIG. 7 and according to a preferred embodiment
of this invention, apparatus 20 may include ultrasonic horn 34
which has at least one coextrusion port 82 leading or connected to
coextrusion passage 84. Desirably, coextrusion port 82 is located
on a nodal ring 36 to facilitate reliable connection. Desirably,
coextrusion passageway 84 provides ultrasonic energy to the
internal material. Generally, coextruded product 78 may have
generally two different materials but may include only one to allow
ultrasonic energy injection to the core of product 78. Coextruded
product 78 may generally have any substantially congruent shapes
for the inside and outside materials when using two materials.
Generally, coextrusion passage 84 may end at horn face 60 and
optionally may include a separate orifice or restriction structure
integral to ultrasonic horn 34.
[0080] According to a preferred embodiment of this invention and as
shown in FIG. 3, apparatus 20 may include a die or die plate 70
having a plurality of (more than one of) or multiple apertures or
relatively small bores and/or shapes. This configuration may be
useful for producing product 76 having a finer or smaller diameter,
such as, for example, angel hair pasta. Horn face 60 may extend
generally across extrusion orifice 58 which includes an extrusion
die. According to this preferred embodiment of this invention, horn
face 60 may be generally planar so as to permit a smooth and
unimpeded flow of flowable substrate 78 through die plate 70 while
maintaining close proximity of flowable substrate 78 with sonically
activated portions of ultrasonic horn 34.
[0081] As shown in FIG. 5 and according to a preferred embodiment
of this invention, apparatus 20 for extruding flowable substrate 78
may include: a plurality of or several ultrasonic resonant drivers
74 corresponding to or associated with a plurality of or several
extrusion orifices 58 in extrusion chamber 50; back driver or
mother horn 72 coupled or in ultrasonic communication with the
plurality of resonant drivers 74; and an infeed, not shown, for
supplying flowable substrate 78 to the extrusion chamber 50. A
composite horn typically may consist of a mother horn 72 and a
plurality of resonant drivers 72. Desirably, resonant drivers 74
may be in a front position relative to the back driver and may
vibrate substantially independent of each other and/or the back
driver.
[0082] Generally, mother horn 72 and resonant drivers 72 may have a
length equal to a one or more 1/2 wavelengths of the frequency of
the ultrasonic energy, such as, for example, the backdriver may and
the resonant driver 72 may have a total length of one
wavelength.
[0083] Desirably, infeed channel 64 may provide feed of flowable
substrate 78 in a substantially uniform manner to ensure
substantially equal ultrasonic energy injecting or contacting with
all product 76 from all extrusion orifices 58. According to a
preferred embodiment of this invention, infeed channel 64 may be
located in a rear position. One infeed channel 64 may supply more
than one extrusion orifice 58 and typically a substantially equal
contact time will occur for each resonant driver 74.
[0084] Virtually any number of resonant drivers 74 may be included
in apparatus 20 as limited by designs and configurations of mother
horn 72. Generally, mother horn 72 may include rectangular or
circular arrangements. Placing multiple ultrasonically extruded
lines in relatively close proximity and sharing a common ultrasonic
transducer system may significantly reduce installed capital costs,
save on shop floor space, and/or provide significant throughput or
volume increases while producing the same or different shapes on
each line.
[0085] According to a preferred embodiment of this invention,
combinations of apparatus 20 may be used to produce items having
several different shapes or profiles, such as, for example,
alphabet-shaped noodles for soup. Coproducing multiple shapes may
significantly reduce inventorying or storage requirements and costs
for intermediate materials which may also increase or improve
product 76 freshness and/or consistency.
[0086] Apparatus 20 may include more than one infeed channel 64.
Multiple infeed channels 64 may improve flowable substrate 78
distribution to extrusion orifice 58, as shown in FIG. 6. According
to a preferred embodiment of this invention, apparatus 20 for
extruding flowable substrate 78 may include each ultrasonic
resonant driver 74 located in a separate or divided extrusion
chamber 50 having a corresponding or an associated infeed, not
shown. This configuration may allow coproduction of multiple
different materials and/or shapes from the same apparatus 20, such
as, for example, feeding red, white, and green pasta dough to each
a separate infeed, not shown, to simultaneously produce tricolored
pasta as may commonly be used in pasta salads.
[0087] According to a preferred embodiment of this invention,
ultrasonic horn 34 may comprise a single horn inserted into
extrusion chamber 50 however mother horn 72 may alternatively be
desirable. Mother horn 72 or back driver generally may include a
mother horn carrying a plurality of resonant drivers 74. Mother
horn 72 may be utilized in extrusion chamber 50 using resonant
drivers 74 of suitable sizes and shapes. Mother horn 72 may be
rectangular or circular shape and include resonant drivers 74 of
suitable shape to be compatible with that of extrusion orifice 58.
Resonant drivers 54 may generally have characteristics discussed
above with respect to ultrasonic horn 34. Preferably, one or more
adjustment mechanisms may be included to position one or more
resonant drivers 74 within extrusion chamber 50.
Method
[0088] This invention further may include a method for
ultrasonically extruding flowable substrate 78. According to a
preferred embodiment of this invention, the method of extruding
flowable substrate 78 may include: providing flowable substrate 78
to an infeed, not shown, from a motive force; flowing flowable
substrate 78 from the infeed, not shown, into extrusion chamber 50
with ultrasonic horn 34; contacting flowable substrate 78 with
ultrasonic horn 34; energizing ultrasonic horn 34 with ultrasonic
energy; transferring energy from ultrasonic horn 34 to flowable
substrate 78; and extruding flowable substrate 78 through extrusion
orifice 58 to form product 76. Generally, steps listed in these
methods do not explicitly or implicitly connote or denote a
preferred order or an amount. Contacting may generally involve
physically touching two items together and preferably includes
manners that provide sufficient transmission of ultrasonic energy
between the items.
[0089] According to a preferred embodiment of this invention, the
method of extruding flowable substrate 78 may further include
ultrasonically gelling pectin from within flowable substrate 78.
According to another preferred embodiment of this invention, the
method of extruding flowable substrate 78 may further include
ultrasonically agglomerating particles within flowable substrate
78. According to another preferred embodiment of this invention,
the method of extruding flowable substrate 78 may further include
ultrasonically setting protein within flowable substrate 78.
According to another preferred embodiment of this invention, the
method of extruding flowable substrate 78 may further include
ultrasonically neutralizing enzymes within flowable substrate 78,
such as, for example, in wheat germ particles. Neutralized wheat
germ particles may be particularly useful for baking
applications.
[0090] Desirably, but not necessarily, flowable substrate 78 forms
a solid formed product 76 but may depending on flowable substrate
78 and desired uses may also form a loosely formed or agglomerated
material that can readily be broken apart, such as, for example, by
moving on a vibratory conveyor. Alternately, flowable substrate 78
may remain as substantially discrete or individual particles
following ultrasonic extrusion.
[0091] Desirably, but not necessarily, ultrasonic energy used in
the methods of this invention may have a frequency of about of
about 20 khz to about 40 khz.
[0092] According to a preferred embodiment of this invention, the
method of extruding flowable substrate 78 may further include
immediately slicing product 76 into shape-retaining pieces
following extruding. Immediately may generally be within a few
seconds to brief moments after product 76 exits extrusion orifice
58.
[0093] In operation, flowable substrate 78 may be provided into
extrusion chamber 50 and across and/or around ultrasonic horn 34.
Energy may be applied to ultrasonic horn 34, either continuously or
intermittently and at constant or modulated amplitude, and flowable
substrate 78 may then be extruded through extrusion orifice 58. As
a result, flowable substrate 78 may be conditioned in a desired
manner and may be shaped or formed into a desirable configuration
or shape. Variations in the processing conditions may create
additional textural complexities or characteristics for product
76.
Product
[0094] According to a preferred embodiment of this invention and
shown in FIG. 6A, product 76 may include flowable substrate 78 to
form a substantially continuous rope having a bar or bar-like
shape. According to a preferred embodiment of this invention and as
shown in FIG. 6B, product 76 may include flowable substrate 78 and
inclusion 80 of at least one different material from flowable
substrate 78.
[0095] According to a preferred embodiment of this invention,
extruded product 76 may include: flowable substrate 78 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.
[0096] Coloring agents typically may include food colorings in
liquid or solution form, solid pigments, such as titanium dioxide
and any other suitable color imparting or enhancing material.
Moistening agents may include water, milk, alcohol, honey,
emulsions and any other suitable wetting or dampening material.
Flavoring agents may include broadly spices, salts, peppers,
aromatics, synthetic flavors, natural extracts and any other
suitable taste imparting compound. Sweetening agents may include
simple and complex sugars, corn syrup, refined and unrefined cane
or beet products, artificial sweeteners and any other suitable
material to modify or stimulate receptors on a sweet sensing area
of the tongue.
[0097] According to a preferred embodiment of this invention,
ultrasonically extruded product 76 may include flowable substrate
78 which has ultrasonically settable or fixable proteins to form a
shape-retaining product 76. According to a preferred embodiment of
this invention, ultrasonically extruded product 76 may include
flowable substrate 78 which includes ultrasonically gellable or
gelatinizable pectin to form a shape-retaining product 76.
[0098] Desirable flowable substrates 78 may include pomace derived
or made from fruit and/or vegetable material. According to a
preferred embodiment of this invention, ultrasonically extruded
product 76 may include flowable substrate 78 which includes
apple-based material. Possible sources of pomace may include
apples, pears, peaches, grapes, grape seeds, olives, carrots,
tomatoes, beans, soy beans, potatoes, corn, wheat, peppers, and any
other suitable material formable by ultrasonic energy.
[0099] Without being bound by theory, ultrasonic extrusion
generally may form shape-retaining product 76 from flowable
substrate 78. Shape-retaining, generally may include that product
76 holds or maintains a shape or form upon exit from extrusion
orifice 58. Desirably, shape-retaining may include retaining shape
during additional processing steps, such as, for example cutting or
portioning. Nonshape-retaining may include items that permanently
do not recover at least 50% of their height when sliced. Typically,
high water content dough may exhibit nonshape-retaining
characteristics when processed using conventional extrusion
processes.
[0100] Without being bound by theory, for some flowable substrates
78, ultrasonic energy may set or lock a shape of product 76 by
altering a protein structure, such as, for example, coiling or
folding at a molecular level of a meat emulsion.
[0101] Other flowable substrates 78 may have complex carbohydrates,
starches, sugars and/or other polysaccharides that may be altered
by ultrasonic energy. Some flowable substrates 78 may desirably
include pectin which upon application of ultrasonic energy may be
released from breaking down or collapsing cellular walls or
structures. The pectin may then gel or coalesce to impart
shape-retaining characteristics which may include a jellied like
effect.
[0102] Ultrasonic energy may bind particles together to form or
fuse an aggregate, such as, for example using puffed cereals.
Application of a minor or modest amount of moisture may further
assist or facilitate agglomeration ultrasonic processes. Desirably,
additional liquids such as syrups including, for example, fruit
syrups or corn syrups may provide flavor and/or sweetness to
product 76 while aiding the shape-retaining ultrasonic extrusion
process by imparting moisture.
[0103] According to a preferred embodiment of this invention,
flowable substrate 78 may include fruit and/or vegetable pomace.
Pomace typically may include a byproduct or residue of another
processing step, such as, for example squeezing juice from grapes,
carrots or apples. Pomace-based product 76 and materials may
provide heathy alternatives to conventional candy bars and other
junk food products as typically dispensed or sold from vending
machines.
[0104] Flowable substrate 78 according to a preferred embodiment of
this invention may comprise an edible substrate, such as, for
example, shortbread dough, cracker dough, pretzel dough, cookie
dough, bread dough, grissini or bread sticks, and the like. The
edible substrate may additionally or alternatively comprise
chocolate refinings, spreads, creams, amids, starches,
carbohydrates, sugars, meat emulsions, sauces such as ketchup, BBQ
sauces and the like.
[0105] Desirably ultrasonic extrusion may include an accompanying
processing action. Such processing actions may include coagulation
of proteins such as during the extrusion of meat emulsions.
Pasteurization may comprise an additional or alternative processing
action, such as during the extrusion of dairy products. Other
processing actions may include drying, setting, conditioning,
tempering, hardening, emulsification, homogenization, dispersion,
melting, liquefaction, plasticizing and other suitable processing
actions that may be accomplished using a suitable ultrasonic
set-up.
[0106] For example, without limitation, pretzel dough may be
provided into a configuration as shown in FIG. 2. Horn face 60 may
be configured in a generally circular geometry and the sidewall of
extrusion orifice 58 may be formed around ultrasonic horn 34. As a
result a desired geometry may include about 12 mm OD and an about 8
mm ID forming a tubular pretzel shape about 22 mm long. Before the
pretzel dough is passed through extrusion chamber 50, it may
include a moisture content of 45% and after passage through
extrusion chamber 50 a controlled amount of moisture may be removed
from the pretzel dough but leaving enough moisture for adequate
puffing or raising during subsequent baking or other processes. Too
little moisture in a dough may lead to a finished material with
less than desired texture or other characteristics. The ultrasonic
extrusion may interact with proteins and/or other molecules to
properly maintain a set, tubular shape which may be cut as early as
at the extruder face without distortion and maintain its shape
without collapsing. Such a manufacturing method may subsequently,
after baking, permit the pretzel products to be filled with a
desirable filling, such as, for example, cheese, sauce, jelly,
chocolate, peanut butter and any other suitable flavored material.
Ultrasonic extrusion may reduce the need for long conventional
radio frequency or dielectric ovens in subsequent processing
steps.
[0107] According to another desired application of this invention,
flowable substrate 78 may include chocolate refinings. As the
chocolate refinings may pass through extrusion chamber 50 and
across ultrasonic horn 34, the dry chocolate flakes may be rapidly
plasticized and emerge as a generally continuous plastic rope of
chocolate that may then be utilized in post-processing, such as,
for example, melting, molding, portioning, conching and novel
conching.
[0108] Chocolate and other temperature sensitive materials may be
particularly suited to ultrasonic extrusion since it imparts a
significant amount of energy into product in a quick or short time.
This rapid energy application may minimize product burning and
other degradation.
[0109] According to another desired application of this invention,
flowable substrate 78 may comprise meat emulsions which are passed
through the extruder auger and into extrusion chamber 50. As energy
is applied to ultrasonic horn 34 in extrusion chamber 50, the meat
emulsions may pass out of extrusion orifice 58 in a coagulated form
and a generally unitized flexible rope of meat product, such as
sausage or sausage-like. Suitable meat items may broadly include
beef, chicken, turkey, pork, buffalo, fish, any other suitable
relatively high protein-containing material and combinations
thereof.
[0110] According to another desired application of this invention,
flowable substrate 78 may be wheat germ which is passed through the
extruder auger and in extrusion chamber 50. As energy is applied to
ultrasonic horn 34 in extrusion chamber 50, the enzymes in the
wheat germ particulate are preferably rapidly neutralized.
[0111] According to yet another desired application of this
invention, wet pasta dough may be passed through the desired
configuration of extrusion chamber 50 and as the pasta passes
across ultrasonic horn 34 and through extruder die plate 70, the
pasta is set and/or pasteurized resulting in a processed pasta
product. Both dry pasta or low moisture and fresh or higher
moisture pasta may benefit from ultrasonic extrusion. Dry pasta may
have a reduced oven drying time and reduced product loss from
cracking as occurs when drying a wet dough. Fresh pasta with
typically about 33% to about 35% moisture desirably is pasturized
to improve shelf life and prevent spoilage from mold and reduce or
eliminate a drying step.
[0112] The processing and extrusion according to a preferred
embodiment of this invention may be modified by controlling the
feed pressure of flowable substrate 78, the feed speed or velocity
of the `flowable substrate 78, the amplitude of the ultrasonic
vibrations, flowable substrate 78 temperature, size of extrusion
orifice 58 and other factors.
[0113] This invention encompasses ultrasonic extrusion apparatus,
methods, and products. Headers provided in this Detailed
Description of the Invention are not intended to be limiting, such
as, for example, product shapes described under the Apparatus
heading should broadly be applied to the Method and the Product
sections as well.
[0114] While in the foregoing specification this invention has been
described in relation to certain embodiments thereof, and many
details have been set forth for purpose of illustration, it will be
apparent to those skilled in the art that the invention is
susceptible to additional embodiments and that certain of the
details described herein can be varied considerably without
departing from the basic principles of the invention.
* * * * *