Claims
- 1. Extrusion cooking apparatus comprising:
an elongated extruder including a tubular barrel having an outlet end and at least one elongated, axially rotatable helically flighted screw within the barrel for moving material through the barrel, said extruder having a free volume within said barrel; a drive for axially rotating said screw; and a tubular die assembly operatively coupled to said barrel adjacent said outlet end thereof and including an elongated, tubular body with an apertured die secured to the end of the tubular body remote from said extruder barrel, the volumetric ratio of said die assembly to said extruder free volume being at least about 2.
- 2. The apparatus of claim 1, said volumetric ratio being from about 3-20.
- 3. The apparatus of claim 1, said drive being operable for axially rotating said screw at a rate of at Least about 300 rpm.
- 4. The apparatus of claim 1, including a pair of axially rotatable screws within said barrel.
- 5. The apparatus of claim 1, said extruder having an L/D ratio of from about 5-14.
- 6. The apparatus of claim 1, said die including a substantially centrally located, inwardly extending, flow-directing member.
- 7. The apparatus of claim 1, further including a dehydrating assembly for receiving an extrudate from said die assembly and partially dehydrating said extrudate.
- 8. The apparatus of claim 7, wherein said dehydrating assembly comprises:
a receiver presenting a chamber positioned to receive an extrudate from said die assembly and an agitator within said chamber; apparatus operable to deliver a heated air stream to the chamber of said device in order to partially dehydrate the agitated extrudate therein; and an upright dehydrating tower having a material inlet operatively coupled to said receiver for receiving said partially dehydrated extrudate from said receiver.
- 9. The assembly of claim 8, said dehydrating assembly further including a separator operably coupled to said tower for separating dehydrated extrudate from said air stream as the extrudate rises in said tower.
- 10. The assembly of claim 9, wherein said separator is a cyclone separator.
- 11. The assembly of claim 8, said agitator comprising a plurality of arms mounted radially on a rotating shaft, each of said arms including a pair of blades disposed so that the free edges of said blades form cutting edges directed in the direction of rotation of said shaft.
- 12. The assembly of claim 8, said tower further including a material outlet, the distance between said inlet and outlet being from about 8-25 feet.
- 13. Extrusion cooking apparatus comprising:
an elongated extruder including a tubular barrel having an outlet end and at least one elongated, axially rotatable helically flighted screw within the barrel for moving material through the barrel, said extruder having a free volume within said barrel; a drive for axially rotating said screw; and a tubular die assembly operatively coupled to said barrel adjacent said outlet end thereof and including an elongated, tubular body with an apertured die secured to the end of the tubular body remote from said extruder barrel, said extruder and die assembly cooperatively configured for establishing a retention time ratio of die assembly retention time to extruder retention time of at least about 5.
- 14. The apparatus of claim 13 said retention time ratio being from about 7-15.
- 15. The apparatus of claim 13, said drive operable for rotating said screw at a rate of at least about 300 rpm.
- 16. The apparatus of claim 13, including a pair of axially rotatable screws within said barrel.
- 17. The apparatus of claim 13, said extruder having an L/D ratio of from about 5-14.
- 18. The apparatus of claim 13, said die barrel including a substantially centrally located, inwardly extending, flow-directing member.
- 19. The apparatus of claim 13, said extruder retention time being from about 3-20 seconds.
- 20. The apparatus of claim 13, said die assembly retention time being at least about 15 seconds.
- 21. The apparatus of claim 20, said die assembly retention time being from about 50-600 seconds.
- 22. The apparatus of claim 13, further including a dehydrating assembly for receiving an extrudate from said die assembly and partially dehydrating said extrudate.
- 23. The apparatus of claim 22 wherein said dehydrating assembly comprises:
a receiver presenting a chamber positioned to receive an extrudate from said die assembly and an agitator within said chamber; apparatus operable to deliver a heated air stream to the chamber of said device in order to partially dehydrate the agitated extrudate therein; and an upright dehydrating tower having a material inlet operatively coupled to said receiver for receiving said partially dehydrated extrudate from said receiver.
- 24. The assembly of claim 23, said dehydrating assembly further including a separator operably coupled to said tower for separating dehydrated extrudate from said air stream as the extrudate rises in said tower.
- 25. The assembly of claim 24, wherein said separator is a cyclone separator.
- 26. The assembly of claim 23, said agitator comprising a plurality of arms mounted radially on a rotating shaft, each of said arms including a pair of blades disposed so that the free edges of said blades form cutting edges directed in the direction of rotation of said shaft.
- 27. The assembly of claim 23, said tower further including a material outlet, the distance between said inlet and outlet being from about 8-25 feet.
- 28. A method of processing a product comprising the steps of:
passing said product in serial order through an extruder and a die assembly to yield an extruded product, said extruder comprising an elongated, tubular barrel having an outlet end with at least one elongated, axially rotatable, helically flighted screw within the barrel, said die assembly including an elongated, tubular body operatively coupled to said barrel adjacent the outlet end thereof, and an apertured die coupled to said body adjacent the end thereof remote from said extruder; and during said passing step, rotating said screw at a rate of at least about 300 rpm, and causing said product to experience a retention time ratio of die assembly retention time to extruder retention time of at least about 5.
- 29. The method of claim 28, said retention time ratio being from about 7-15.
- 30. The method of claim 28, the retention time of said product in said extruder being from about 3-20 seconds.
- 31. The method of claim 28, the retention time of said product in said die assembly being at least about 15 seconds.
- 32. The method of claim 31, the retention time of said product in said die assembly being from about 50-600 seconds.
- 33. The method of claim 28, including the step of controlling the temperature of said product within said extruder to a maximum of up to about 150° C.
- 34. The method of claim 28, including the step of controlling the pressure within said extruder to a maximum of from about 50-2000 psi.
- 35. The method of claim 28, said product being a starch-bearing product selected from the group consisting of potato, tapioca, grain, root and tuber starches, rice, wheat, oats, barley, corn rye, and mixtures thereof.
- 36. The method of claim 28, including the step of subjecting said product to a preconditioning step prior to passage thereof through said extruder, said preconditioning step including the steps of adding moisture to the product and heating the product.
- 37. The method of claim 28, including the step of drying said product after passage thereof through said extruder and die assembly.
- 38. The method of claim 28, said product being essentially free of added surfactant.
- 39. The method of claim 36, the retention time of said product in said preconditioner being at least about 15 seconds.
- 40. The method of claim 28, further including the steps of:
agitating said extruded product; and pneumatically passing said agitated product through a dehydrating tower.
- 41. The method of claim 40, wherein said agitating step comprises placing said extruded product into the chamber of a receiver having an agitator within the chamber,
said agitator comprising a plurality of arms mounted radially on a rotating shaft, each of said arms including a pair of blades disposed so that the free edges of said blades form cutting edges directed in the direction of rotation of said shaft, said shaft being rotated during said agitating step so that said blades contact said extruded product.
- 42. The method of claim 40, wherein said agitating step comprises contacting air having an impact temperature of from about 300-550° C. with said extruded product.
- 43. The method of claim 40, wherein said dehydrating tower has a material outlet and said passing step comprises applying negative air pressure to said outlet.
- 44. The method of claim 43, wherein said negative air pressure is applied by a cyclone separator having a material outlet to create an air flow through said separator for further drying the product and for separating said product from said air flow.
- 45. The method of claim 44, further including the step of passing said separated product through said cyclone material outlet, and wherein the amount of time that passes from the beginning of said agitating step to the time when the product passes through said cyclone material outlet is less than about 15 seconds.
- 46. The method of claim 40, wherein the residence time of said agitated product in the tower is from about 1-2 seconds.
- 47. The method of claim 40, wherein the product resulting from said pneumatic passing step has a moisture content of from about 0.5-18% by weight, based upon the total weight of the product taken as 100% by weight.
- 48. The method of claim 40, the retention time of said product in said extruder being from about 3-20 seconds.
- 49. The method of claim 40, the retention time of said product in said die assembly being at least about 15 seconds.
- 50. The method of claim 40, wherein the maximum temperature of the product within said extruder is up to about 150° C.
- 51. The method of claim 40, wherein said starch is selected from the group consisting of grain, root and tuber starches and mixtures thereof, and starch-bearing grain products selected from the group consisting of rice, wheat, oats, barley, corn, rye, and mixtures thereof.
- 52. The method of claim 40, further including the step of subjecting said product to a preconditioning step prior to passage thereof through said extruder, said preconditioning step including the steps of adding moisture to the product and heating the product.
- 53. The method of claim 40, further including the step of introducing an alcohol into said extruder barrel during the passing of said product therethrough.
- 54. A method of processing a product comprising the steps of:
passing said product in serial order through an extruder and a die assembly to yield an extruded product, said extruder comprising an elongated, tubular barrel having an outlet end with at least one elongated, axially rotatable, helically flighted screw within the barrel, said die assembly including an elongated, tubular body operatively coupled to said barrel adjacent the outlet end thereof, and an apertured die coupled to said body adjacent the end thereof remote from said extruder, said extruder having a free volume within said barrel and said die assembly having a free volume within said tubular body, the volumetric ratio of said die assembly to said extruder free volume being at least about 2.
- 55. The method of claim 54, further including the steps of:
agitating said extruded product; and pneumatically passing said agitated product through a dehydrating tower.
- 56. The method of claim 55, wherein said agitating step comprises placing said extruded product into the chamber of a receiver having an agitator within said chamber,
said agitator comprising a plurality of arms mounted radially on a rotating shaft, each of said arms including a pair of blades disposed so that the free edges of said blades form cutting edges directed in the direction of rotation of said shaft, said shaft being rotated during said agitating step so that said blades contact said extruded product.
- 57. The method of claim 55, wherein said agitating step comprises contacting air having an impact temperature of from about 300-550° C. with said extruded product.
- 58. The method of claim 55, wherein said dehydrating tower has a material outlet and said passing step comprises applying negative air pressure to said outlet.
- 59. The method of claim 58, wherein said negative air pressure is applied by a cyclone separator having a material outlet to create an air flow through said separator for further drying the product and for separating said product from said air flow.
- 60. The method of claim 59, further including the step of passing said separated product through said cyclone material outlet, and wherein the amount of time that passes from the beginning of said agitating step to the time when the product passes through said cyclone material outlet is less than about 15 seconds.
- 61. The method of claim 55, wherein the residence time of said agitated product in the tower is from about 1-2 seconds.
- 62. The method of claim 55, wherein the product resulting from said pneumatic passing step has a moisture content of from about 0.5-18% by weight, based upon the total weight of the product taken as 100% by weight.
- 63. The method of claim 55, the retention time of said product in said extruder being from about 3-20 seconds.
- 64. The method of claim 55, the retention time of said product in said die assembly being at least about 15 seconds.
- 65. The method of claim 55, wherein the maximum temperature within said extruder is up to about 150° C.
- 66. The method of claim 55, wherein said product is a starch-bearing product selected from the group consisting of grain, root and tuber starches, rice, wheat, oats, barley, corn, rye, and mixtures thereof.
- 67. The method of claim 55, further including the step of subjecting said product to a preconditioning step prior to passage thereof through said extruder, said preconditioning step including the steps of adding moisture to the product and heating the product.
- 68. The method of claim 55, further including the step of introducing an alcohol into said extruder barrel during the passing of said product therethrough.
- 69. The method of claim 68, wherein said alcohol is ethanol.
- 70. An extruded starch product having a water solubility of at least about 10%.
- 71. The product of claim 70, said starch product being selected from the group consisting of grain, root and tuber starches and mixtures thereof, and starch-bearing grain products selected from the group consisting of rice, wheat, oats, barley, corn, rye, and mixtures thereof.
- 72. The method of claim 28, said product selected from the group consisting of protein-bearing products and nutraceuticals.
- 73. The method of claim 72, said protein bearing products selected from the group consisting of vegetable, dairy and meat protein products.
- 74. The method of claim 54, said product selected from the group consisting of protein-bearing products and nutraceuticals.
- 75. The method of claim 74, said protein bearing products selected from the group consisting of vegetable, dairy and meat protein products.
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Nos. 09/135,203 filed Aug. 17, 1998 and 09/249,648 filed Feb. 12, 1999.
Continuations (1)
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Number |
Date |
Country |
Parent |
09344468 |
Jun 1999 |
US |
Child |
09758555 |
Jan 2001 |
US |
Continuation in Parts (2)
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Number |
Date |
Country |
Parent |
09135203 |
Aug 1998 |
US |
Child |
09344468 |
Jun 1999 |
US |
Parent |
09249648 |
Feb 1999 |
US |
Child |
09344468 |
Jun 1999 |
US |