CA1242610A - Method and apparatus for co-extrusion of a dough mass with particulate matter in the outer dough - Google Patents
Method and apparatus for co-extrusion of a dough mass with particulate matter in the outer doughInfo
- Publication number
- CA1242610A CA1242610A CA000486643A CA486643A CA1242610A CA 1242610 A CA1242610 A CA 1242610A CA 000486643 A CA000486643 A CA 000486643A CA 486643 A CA486643 A CA 486643A CA 1242610 A CA1242610 A CA 1242610A
- Authority
- CA
- Canada
- Prior art keywords
- dough
- extrusion port
- recited
- particulate material
- outer portion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21C—MACHINES OR EQUIPMENT FOR MAKING OR PROCESSING DOUGHS; HANDLING BAKED ARTICLES MADE FROM DOUGH
- A21C9/00—Other apparatus for handling dough or dough pieces
- A21C9/06—Apparatus for filling pieces of dough such as doughnuts
-
- A—HUMAN NECESSITIES
- A21—BAKING; EDIBLE DOUGHS
- A21C—MACHINES OR EQUIPMENT FOR MAKING OR PROCESSING DOUGHS; HANDLING BAKED ARTICLES MADE FROM DOUGH
- A21C11/00—Other machines for forming the dough into its final shape before cooking or baking
- A21C11/16—Extruding machines
- A21C11/163—Applying co-extrusion, i.e. extruding two or more plastic substances simultaneously, e.g. for making filled dough products; Making products from two or more different substances supplied to the extruder
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
- A23G3/00—Sweetmeats; Confectionery; Marzipan; Coated or filled products
- A23G3/02—Apparatus specially adapted for manufacture or treatment of sweetmeats or confectionery; Accessories therefor
- A23G3/20—Apparatus for coating or filling sweetmeats or confectionery
- A23G3/2007—Manufacture of filled articles, composite articles, multi-layered articles
- A23G3/2015—Manufacture of filled articles, composite articles, multi-layered articles the material being shaped at least partially by a die; Extrusion of filled or multi-layered cross-sections or plates, optionally with the associated cutting device
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
- A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
- A23P30/20—Extruding
- A23P30/25—Co-extrusion of different foodstuffs
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S425/00—Plastic article or earthenware shaping or treating: apparatus
- Y10S425/243—Extrusion or injection molding
Abstract
ABSTRACT OF THE DISCLOSURE
A continuous co-extruded food product is formed having dissimilar inner and outer portions wherein the inner portion is enveloped by the outer portion and the outer portion is a dough containing particulate material such as chocolate chips. The product is formed by an inner extrusion port being recessed a distance d from an outer extrusion port with the distance d being sufficient for permitting particulate material in the outer dough portion to pass through an exit passage between the inner and outer extrusion ports without clogging or agglomeration. Turbulence is induced in the outer dough portion which envelops the inner portion thereby causing the particulate material to tumble whereby at least a portion of the particulate material partially penetrates the exterior surface of the outer dough portion enveloping the inner portion. Dough is removed from the surface of the part of the particulate material penetrating the exterior surface of the outer dough portion.
In a preferred embodiment, the outer extrusion port includes a land surface generally parallel to the axis of the outer extrusion port and a bevel surface at the interior surface of the outer extrusion port. The land surface intersects the beveled surface at a generally sharp line of interjection.
The generally sharp line of intersection and the bevel surface cause the tumbling of the particulate material. The land surface removes dough from the surface of the particulate material which penetrates the exterior surface of the outer dough portion.
A continuous co-extruded food product is formed having dissimilar inner and outer portions wherein the inner portion is enveloped by the outer portion and the outer portion is a dough containing particulate material such as chocolate chips. The product is formed by an inner extrusion port being recessed a distance d from an outer extrusion port with the distance d being sufficient for permitting particulate material in the outer dough portion to pass through an exit passage between the inner and outer extrusion ports without clogging or agglomeration. Turbulence is induced in the outer dough portion which envelops the inner portion thereby causing the particulate material to tumble whereby at least a portion of the particulate material partially penetrates the exterior surface of the outer dough portion enveloping the inner portion. Dough is removed from the surface of the part of the particulate material penetrating the exterior surface of the outer dough portion.
In a preferred embodiment, the outer extrusion port includes a land surface generally parallel to the axis of the outer extrusion port and a bevel surface at the interior surface of the outer extrusion port. The land surface intersects the beveled surface at a generally sharp line of interjection.
The generally sharp line of intersection and the bevel surface cause the tumbling of the particulate material. The land surface removes dough from the surface of the particulate material which penetrates the exterior surface of the outer dough portion.
Description
~2~
METHOD AND APPARATUS FOR CO-EXTRUSION OF
~ A DOUGH MASS WITH PARTICULATE MATTER IN
! ~ THE OUTER DOUGH
METHOD AND APPARATUS FOR CO-EXTRUSION OF
~ A DOUGH MASS WITH PARTICULATE MATTER IN
! ~ THE OUTER DOUGH
2 The present invention relates to the manufacture of
3 edible products having dissimilar inner and outer portions.
4 I More particularly, the present invention ls directed to the manufacture of food products wherein an inner dough portion ls 6 enveloped by an outer dough portion and the outer dough 7 portion contains particulate matter.
8 ~ACKGROUND OF THE INVENTION
9 The types of product~ to which the present invention relates include baked goods that are baked from dough pieces 11 having an outer layer of farinaceous dough and a core which 12 may be a dissimilar dough or another material ~uch as a ~am, 13 cream, puree, paste, or other extrudable form of fruit, 1~ cheese, meat, vegetable, confection or other edible substance. I
In those product~ where the core is also a doueh, the inner 16 and outer doughs would be advantageously dissimilar in 17 composition ~o as to produce difrerent tastes, colors, 18 appearances, textures, consistencies, or the like in the inner 19 and outer portions of the baked product. Re~ardless of the composition of the lnner and outer portions, the present 21 invention i9 directed to products having particulate matter, 22 ~ such as chocolate chips, candied Pruit, nuts, raisins, and the 23 llke, in the outer portion.
24 li In the past, products having dlfferent inner and 25 1l outer portions have been formed by concentrically extruding an 26 1 extrudate rope as shown in U.S. Patent No. 3,572,259 to 27 Hayashi.
28 1 An automatic machine for maklng filled baked goods 29 1 l~ described in U.S. Patent No. 3,196,810 to Roth. In this 3 ~I patent, a plurality of die~ dispo3e flavoring material within `" 11 l~Z~O
:! 'I
l l 1 a dough. U.S. Patent No. 3,778,209 to Wallace et al. discloses 2 an apparatus for forming a ~ood extrusion in ~hich an inner 3 1l meat food is totally enrobed by an outer moldable food by 4 1l usin~ a co-extruqion nozzle and a pair of augers to force ~ood products through the co-extrusion nozzle from a respective 6 I palr of ~ood hoppers. Augers are particularly u3*ful for the 7 extrusion Or foods, such as dough, in order to achieve a 8 ~ consistent quality, reliabllity and high efficiency in the g high speed manufacture Or snacks ~uch as cookies, chocolate 10 1 layered foods and the like.
11 In the manufacture of co-extruded food substances, 12 it is common to require that the outer food substance 13 ,encapsulates or enrobes an inner food substance. In U.S.
Patent Nos. 3,77B,209 to ~allace et al. and 3,249,068 to Gembicki, the enrobing action i~ obtained by controlling the 16 motion of a plunger or piston u~ed in oonnection with the 17 feedin~ of the food material to be encapsulated. In U.S.
lB Patent No. 4,251,201 to Krysiak, an enrobed food piece is 19 produced with an apparatus that includes specially sequenced feed mechanisms u~ed to co-extrude an lnner and outer ~ood 21 1' product from coaxlal dles ln comblnation wlth a sequence 22 ~ coordlnated irls shaped cut-off valve that is closely mounted 23 ' to the di~charge ports of the extrusion dies. The iris valve 24 ~I cut~ the co-extrusion ~ust at a tlme when the feed Or both the 25 1 inner filler and outer enrobing foods is interrupted and the 26 space in which the valve acts ls essentially ~illed with the 27 outer enrobing food. This technique appears to depend upon a 28 ~ relatively easy flowability of the outer food substance so as 29 1, to coat the rear of the inner ~ood while the iris valve is about to close and appears limited in operating speed because ` 1293-111 the feed of both inner and outer foods must be interrupted for each Eood piece manufactured.
More recently, relatively high speed methods and apparatuses have been developed whereby an inner dough co-extruded with an outer dough is enrobed by severing the outer dough with a blunt severing edge or a severing element which simultaneously draws the outer dough over the inner dough on both sides of a severed element to form a fully enrobed food piece.
In all the known methods discussed above, there is no disclosure of including particulate matter in the outer dough portion. Consequently, none of the references disclose any method or apparatus which facilitates inclusion of particulate matter in the outer portion of a co-extruded dough rope.
Experience in the art of co-extrusion has taught that certain difficulties are encountered in extruding an outer tube of doughy mass containing particulate matter. For example, the normal configuration of the die head is such that the annular space between the outside circumference of the inner extrusion port and the inside of the outer extrusion port prevents smooth passage of the particulate matter. In some cases, the space when adjusted to provide the proper flow rate and tube thickness is simply too small to allow passage of the particles. Another problem encountered is the agglomeration of particles as they enter the exit passage which blocks the flow of extrusion or causes an uneven outer tube of dough.
~hen it is desired to éxtrude a particle-containing _ ~ !
1 outer tube of dough mass to produce an attractive relatively 2 smooth-skinned confectionery or cookie having the particulate 3 1I matter appear as if placed thereon externally or prepared by 4 hand, the problems are lntensiried. The particles are desirably free from a partial coverin~ by the doughy mass.
6 This enhances the appearance of the finished product which i~
7 ; an important commercial consideration. In order to enhance 8 the product'~ appearance, the particles should penetrate the g exterior surface o~ the outer dough and should be free of a 'Ipartial covering by the doughy mass.
11 A further consideration relative to extruding the 12 i outer tube of doughy mass with particles ls that the integrity 13 f the outer dough portion should be maintained, especially in 14 , the case of co-extruded cookie dough, so that the final ~ product appear~ wholly handmade. Any discontinuities through 16 which the inner portlon can be seen slgniricantly erodes the 17 appearance of a handmade quality for the product.
18 Moreover, it would be desirable that each of the 19 j, above considerations be resolved while maintaining high speed production.
?l OBJECTS OF THE INVENTION
22 '; It ls therefore an obJect of the present invention 23 to overcome the problems hereinberore discussed with respect 24 to co-extrudlng a two-component doughy mas~ having an inner 1 and outer portion in which the outer portion contains 26 ' particulate material.
27 It ls a ~urther ob~ect of the present invention to 28 provide a method and apparatus for co-extruding an inner 29 !; doughy mass and an outer doughy mass containing particulate 30 ` material wherein at least a portlon Or the particles in the . ' outer doughymass penetrate the exterior surface of the outer doughy mass and any partial dough covering of the particulate material penetrating the exterior surface of the outer doughy mass is substantially removed.
It is yet another object of the present invention to provide a method and apparatus for the manufacture of chocolate chip cookie products comprising a dissimilar inner dough and an outer dough by means of co-extrusion of the inner dough and a chocolate chip containing outer dough wherein the chocolate chips penetrate the outer dough exterior surface and the resultant chocolate chip cookie product has a commercially desirable handmade appearance.
These and other objects of the present invention will become apparent from the following description and claims in conjunction with the drawings.
SUMM~RY OF THE INVENTION
-The present invention provides a co-extrusion apparatus for forming a continuous food product having dissimilar inner and outer portions wherein said inner portion is enveloped by said outer portion and said outer portion is a dough containing particulate material composed of particles, said apparatus compri~ing: an inner extrusion port having an exit orifice with a first cross-sectional area through which said inner portion is extruded; an outer extrusion port having an exit orifice with a second cross-sectional area greater in area than said first cross-sectional area wherein said inner lZ426~0 61293-lll extrusion port is recessed a distance d from said outer extrusion port with said recessed distance defining an exit passage between said inner extrusion port and said outer extrusion port and wherein said distance d is sufficient to permit said particles of said particulate material contained in said dough of said outer portion to pass through said exit passage; first conduit means communicating with said inner extrusion port for providing said inner portion thereto; second conduit means communicating with said exit passage for providing said outer dough portion containing particulate material thereto, whereby said outer dough portion containing particulate material passes through said exit passage and envelops said inner portion extruded through said inner extrusion port and wherein said inner portion enveloped by ~aid outer portion passes through said outer extrusion port thereby forming a composite food product having dissimilar inner and outer portions; means for inducing turbulence in said outer dough portion enveloping said inner portion whereby said particulate material in said outer dough portion tumble and at least a portion of the particles of said particulate material have a part thereof penetrate the exterior surface of said outer dough portion; and means for substantially removing dough from the parts said particles which penetrate said exterior surface of said outer dough portion.
The present invention provides a co-extrusion method for forming a continuous food product having dissimilar inner -- 5a -, ,; ., , .. ., ~
26~(~
and outer portions wherein said inner portion is enveloped in intimate contact by said outer portion and said outer portion is a dough material, said method comprising: providing edible particulate material in said outer portion dough material;
extruding said inner portion through an inner extrusion port;
passing said outer portion dough material containing particulate material through an exit passage formed by recessing said inner extrusion port a distance D from an outer extrusion port wherein said distance D is sufficient to permit said particulate material contained in said outer portion dough material to pass through said exit passage whereby said outer portion dough material envelops said inner portion passing said inner portion enveloped by said outer portion dough material through said outer extxusion port thereby forming a composite rope-like food product having said outer portion dough material in intimate contact with said inner portion; creating turbulence in said outer portion dough material enveloping said inner portion at the intersection where the outer dough surrounds said inner dough thereby causing at least a portion of particles of said particulate material to tumble and to partially penetrate the exterior surface of said outer portion dough material prior to said composite rope-like food product exiting said outer extrusion port; bringing said outer portion dough material into contact with a land surface provided in said outer extrusion port after said turbulence-causing step, thereby -- ~LZ42610 removing dough from the part of said particles penetrating the exterior surface of said outer portion dough material prior to said composite rope-like food product exiting said outer extrusion port.
It is preferrable that the inner extrusion port be recessed from the outer extrusion port by a distance (d) sufficient to allow passage of the outer dough containing particulate material therebetween without agglomeration of the particles. This distance is suitably at least about 1.25 times the maximum dimension of the particulate material in the outer doughy mass.
In one embodiment, the turbulence-inducing means includes a generally annular beveled edge on the interior side of the orifice af the outer extrusion port contiguous with a generally annular land surface generally parallel with respect to the axis of outer extrusion port. The annular beveled edge meets the annular land surface at a substantially sharp intersection. The generally annular land sur-face has a length sufficient to remove dough coverings from the parts of the particles penetrating the exterior surface of the outer dough portion. Preferably, the angle of the beveled edge is between about 15 and about 60, while the annular land surface is from about 1/16 inch to about 5/16 inch in length and is preferably about 3/16 inch in length.
In one preferred embodiment of the present invention, the outer dough portion is a chocolate chip cookie dough - 6a -6~0 61293-lll - containing chocolate chips as the pariculate material. The inner doughy mass is a dissimilar chocolate chip cookie dough which may include a humectant so that the dough remains moist and chewy, even after baking. If desired, the inner doughy mass may also contain chocolate chips to enhance the flavor and sweetness of the inner dough.
The present invention provides a continuous dough extrudate having dissimilar inner and outer dough portions. The outer portion envelopes the inner portion and contains particulate matter. During the co-extrusion, the particles are tumbled to a degree sufficient to penetrate the exterior surface of the outer portion of the extrudate. Moreover, the co-extruded dough rope has a smooth overall appearance without any discontinuities or voids in the outer portion through which the inner doughy mass can be seen, and there is no partial covering or "skin" of the doughy mass over the particles which have penetrated the exterior surface of the outer dough portion.
The present invention can easily be adapted for use in a high speed pxocess without extensive modifications to existing equipment.
;
~;~9~Z6~0 . I 1 2 ,; In the drawings forming part hereof:
3 Fig, 1 is a schematic side view, partially ln 4 1l cross-section, Or one embodiment of a co-extrusion apparatus ; in accordance with the present invention;
6 ' FiB. 2 is a ~impliried schematic cro~-3ectional 7 , view of an embodiment similar to that illustrated in Fig. 1 of 8 i a co-extrusion apparatus in accordance with the present g invention;
Fig. 3 is a simpliried ~chematic cross-sectional 11 view similar to that Or Fig. 2 which further illuAtrate~ an 12 inner doughy mass and outer doughy mass containing particulate ! material;
Fig. 4 is a simplified schematic lllustration Or an alternate embodiment of an outer extrusion port which may be 16 used with the apparatus of Fig. l; and 17 Fig. 5 i9 a schematic side view, partially in 18 cross-section, similar to that of Fig. 1 which further shows 19 1 an inner doughy masq and an outer doughy mass containing particulate material ~nd lllustrateq operation in accordance 2~ ¦ with one embodiment of the present invention.
22 , DESCRIPTION OF THE PREFERRED EMBODIMENTS
, In order to provide a more complete understanding of 24 'I the present invention and an appreciation Or its advantages a 25 1I detailed description of preferred embodiments is presented 26 j' below, 27 Figure 1 is a qchematic representation of a co-2~ l extru3ion apparatus 5 in accordance ~ith the present 29 jl invention, The co-extrusion apparatus 5 comprises a die casing 7 and an inner filler tube or inner extrusion conduit , -8-.
\
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1 10. The end of lnner extruslon conduit 10 terminates with 2 inner extrusion port 11. Surrounding filler tube or inner 3 extrusion conduit 10 is outer extrusion conduit 23 ~hich is 4 I defined by the outer wall of lnner extrusion conduit 10 and the wall 29 of die casing 7. ~ounted on the bottom of die 6 casin~ 7 and po9itioned below inner extru~ion port 11 is 7 - extrusion die plate 20 ln which is provlded outer extrusion 8 ! port 21. Positioned below outer extrusion port 21 is conveyor 9 ~eans 30 for receiving and transporting the co-extruded doughy rope to, e.g., an oven.
11 Apparatus for the manufacture of food products 12 having dissimilar inner and outer portions by co-extrusion 13 through concentric inner and outer extrusion nozzles or 4 ~ conduits are themYelves well known and do not require detailed discussion. Examples Or prior art apparatus are ~hown in the 16 prior art patents discuYsed in the foregoing.
17 In accordance with conventional constructions, an 18 inner doughy mass would be fed ~ia conduit means from a first 19 I hopper to inner extru~ion conduit or flller tube 10 by l; conventional means ~not illustrated). Likewise, an outer 27 I doughy mas~ would be fed via conduit means from a second 22 hopper to the outer extrusion conduit means 23 by conventional 23 means (not illustrated). Means for feeding the inner doughy 24 mass to filler tube 10 and the outer doughy mass to the outer ' extrusion conduit 23 may be, e.g., well known auger devices.
26 Feeding of the doughy masses through the extrusion conduits 27 may also be accomplished by appropriate gas pressure. The 28 manner and means of reeding doughy mas~es to inner and outer 29 co-extrusion condults are ~ell known in the srt and ~orm no ; part o~ the present invention. Therefore, they are not _ g _ Il lZ~2610 , I I
1 di~u~ed in detail hereln.
Conduit means 31 and conduit mean~ 37 are 3 l lllu~trated ln phantom in Fig. 1 and repre~ent mean~ for ~ li feeding the inner doughy mass to riller tube 10 and the outer ~ doughy mass to outer extrusion conduit 23 respectively. As 6 11 illustrated in Flg. 1, the outer extruslon conduit 23 is 7 ! greater ln area on the riBht hand ~ide of the figure ~here the 8 outer doughy mass 1~ fed lnto the outer extruslon conduit.
9 ' The outer doughy mass surround the inner filler tube 10 and lo l;is forced through exit pas~age 28 between inner extruQlon port 11 11 and bottom die plate 20 whereby the outer doughy mass 12 surrounds and envelopes the inner doughy mass extruded through 13 the lnner extrusion port 11. The composite outer doughy mas~
14 ~ enveloping the inner dou~hy maQ~ i~ forced or co-extruded through the outer extrusion port 21 of extruRion die 20. The 16 general arrangement of such co-extrusion devices are themselves well known in the art.
18 Inner filler tube 10 and the inner extrusion port 11 19 I may assume a variety of geometrical cro~s-3ectioni. Suitably, the geometrical cro~s-section Or filler tube 10 and inner 21 1l extrusion porS 11 i8 circular. Slmilarly, annular-like outer 22 ; extru~lon conduit 23 and outer extrusion port 21 may assume a 23 ' variety of geometrical cross-sections. Suitably, outer 24 1 extru~ion port 21 has a circular cross-~ection. The cross-! sectional area of outer extrusion port 21 is Breater than the 26 ~' cro~s-~ectlonal area Or the inner extrusion port 11 in order 27 ! that the outer doughy mass may envelop the inner doughy mass 28 l, to provlde the co-extruded rope-like product havlng dissimilar 29 ~l outer and lnner portion~ in accordance wlth the ~ell-known 1, practice of the art.
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1 ~s lllustrated in Flg. 1, the left periphery of 2 . inner extrusion port 11 i~ positloned in approximate alignment 3 ,,~ith the left land surface 24 of the outer extrusion port 21 4 . of bottom die plate 20. Such an alignment is found ~ advantageous for producing a satisfactory product ~hen the 6 co-extruded rope-like product having dissimilar outer and 7 inner portions is received and tranQported away by conveyor 8 means 30 moving to the right as indicated by the arrow A in g Fig. 1. That is, when the conveyor means 3~ is moving as , indicated by the arrow A, best results in the quallty of the 11 co-extruded product are not generally obtained by 12 concentrically positioning the inner extru~ion port 11 with 13 respect to the outer extrusion port 21. The exact lateral 14 I positioning of the inner extrusion port 11 with respect to the outer extrusion port 21 for producing an optimum quality 16 product may vary slightly depending on the composition Or the 17 inner and outer doughy masses and the linear Qpeed of conveyor lB means 30 but can be routinely determined in view of the 19 !, foregoing general guidance. Means (not illustrated) ~ould be provided to laterally move die casing 7 and thereby outer 21 extrusion port 21 with respect to inner extrusion port 11.
22 ~ In accordance with the present invention, 23 1' particulate material, Quch aQ chocolate chips, are disposed in 24 li the outer doughy mass which is forced through the outer 1~, extrusion conduit 23. In accordance with the present 26 1 inventlon, means are provided to tumble the particulate 27 material Or the outer doughy mass enveloping the inner doughy 28 mass QO that at least a portion Or the particulate material 29 ;j penetrateY the exterior surrace of outer doughy mass portion 1 Or the co-extruded rope-like product formed from dissimilar :~2426~
1 ~nner and ouker portion Further, ln accordance with the 2 I present invention, mean~ are provided whereby partial oovering 3 ¦~ Or the partlcles penetrating the exterior surrace Or the outer ~ portlon Or the co-extruded product are removed.
The method and apparatus ln accordance with the 6 I pre3ent invention will now be explained in greater detail with 7 j reference to Fig. 1 and Fig. 2 ~herein Fig. 2 is a ~chematic 8 detail illustration Or filler tube 10 and the botto~ die plate g ~ 20. Reference i8 also made to Fig. 3, which i~ ilar to ,~ Fig. 2, and which ~chematically lllustrates the co-extruAion 11 o~ lnner doughy ma~ 34 and outer doughy ma~ 32 containing 12 particulate material 26 whereby co-extruded rope-liks product 13 35 is formed from dissimilar inner dough 34 and outer dough 32 14 and a portion Or the partlculate material 26 penetrates the exterior sur~ace 33 of the outer dough 32 of the rope-like 16 product 35. In Fig~. 2 and 3, inner extrusion port 11 is 17 illustrated positioned generally concentric with outer 18 extrusion port 21 for clari~y of illustration. Ho~ever, as 19 ll hereinbefore discu sed, such posltioning o~ the inner , extru~ion port 11 wlth respect to the outer extrusion port 21 21 ' i~ not always optlmum ror all operating conditions.
22 Outer extrusion port 21 havln~ an orifice 25 i~ !
23 l' for~ed in bottom die plate 20 and lncludes an annular land ~4 , ~urrace 24 and an annular bevel Aurface 22 on the lnterior 1 side of outer extru~lon port 21. Annular land ~urface 24 26 1 intersects annular bevel surface or edge 22 at point 27 27 i thereby ~ormlng an annular line Or intersection. Annular land 28 ! surrace 24 i~ a peripheral surrace Or outer extrusion port 21 29 ~ and i3 parallel to the axl~ o~ outer extru~ion port 21. Bevel 3o , surrace 22 i~ located on the inner or lnterior ~ide of the .
_12-~2~Z6 .
1 outer extrusion port 21 (l.e., the ~ide of outer extrusion 2 port 21 facing the inner extension port 11). Bevel surrace 22 3 ,lextends around the perimeter of the outer extru~ion port 21.
4 " Bevel edge or qurface 22 is formed at an angle c with a line ,perpendicular to the axis of outer extrusion port 21 or 6 I therefore with the surface of land surrace 24.
7 The turbulence inducing means, in accordance with 8 the present invention, compriqes bevel edge or qurface 22 and g the line Or intersection 27 between bevel edge 22 and land , surface 24. It is important tbat the line Or intersection 27 11 between bevel surface 22 and land surface 24 be ~ubstantially 12 sharp. This qubstantially sharp intersection 27 is very 13 e~fective for inducing turbulence in particulate matter 26 of 14 the outer dough 32.
By Yubstantially sharp is meant that it is 16 permissible for the line of intersection 27 to have a very 17 small radius. A very small radius may be desirable from a 18 ;I practical viewpoint to prevent an operator, e.g., from 19 ,l inadvertently outting himself when handling the apparatus. A
sharp line Or inter~ection ~i.e., not even having a small 21 ; radius) would otherwise give totally ~ati~factory performance.
22 ' It is important, however, that there not be a large radius at 23 the lntersectlon between bevel edge 27 and the annular land ~4 surface 24. A large radius would not result in the desired ~I creation of turbulence in the outer dough 32 and ~he tumbling 26 ,1 of the particulate material 26 and therefore the ~ubsequent Il 27 satisfactory penetration of the exterior surface 33 of the 28 l compoqite rope-like product 35 will not be achieved.
29 ' The land surrace 24 having a length parallel to the , axis of outer extru~ion port 21 serve~ to remove partial dough ~2426~
1 covering or dough ~kin rrom the partlculate ~aterial 26 which 2 , penetrates the outer dough surrace 33 of the outer dough due 3 to the tumbllng of particulate materlal 26 caused by the line ~ 1 of intersection 27. The length of the land ~urraoe 24 must be surricient to sub~tantially remove any partial dough coverlng 6 1 or skin from the partlculate material 26 ~hich penetrates the 7 outer exterior surrace 33 of the outer dough. However, if the 8 length Or land ~urrace 24 is too long, lt may ~unction to push g the partlculate material 26 whlch has penetrated the outer I dough surface 33 back into the dough.
11 In accordance with the present invention, the inner 12 ; extrusion port 11 Or filler tube 10 is reces~ed rrom the outer 13 extrusion port 21 a distance d. Recessing the inner extrusion 14 port 11 a distance d from the outer extrusion port 21 defines an exit passage 28 through which the outer doughy mass 16 containin~ partlculate materlal 26 passes as lt begins to 17 envelop the inner doughy mass 34 exiting the inner extrusion 18 j port 11. The distance d ls selected to be surficient to 19 permlt passage o~ the particles of the partlculate material 26 contalned ln the outer dough 32 through the exit passage 28 21 ~ without clogging or agglomeration.
22 ' Advantageously the distance d ls selected to be at 23 least about 1.25 times the maximum dimenslon of the large~t 24 j particles 26 diRposed in the outer doughy mass 32 in order to ' prevent agglomeration or clogging of the particulate material 26 26 in the annular exit passage 2~. In most appllcations, d 27 ' ~ould not equal more than approxlmately 2 because as d gets 28 ,l larger in most instances the cro~s-~ectional area of orifice 29 1 25 Or the outer extruqion or~rice 21 would tend to grow j rapidly larger and the thlckne~s Or the outer doughy mass 32 _14-Il lZ~Z~
1 would tend to become large with respect to the thickness of 2 I the inner doughy mass 34 of the rope-llke co-extruded product 3 35 and thereby not result in ~hat is usually considered a ~ ,Idesirable commercial product. It will be understood that the diqtance d is not defined by random very large particles which 6 ~do not conform to the intended commerclal particle 3ize or 7 grade. In general, the closest distance d from the inner 8 extrusion port 11 to the outer extrusion port 21 i~ about 5/16 g , inch to about 7/16 lnch with 5/16 inch bein8 Yatisfactory in 1~ 1 many appllcatlons.
11 The land ~urface 24 may be circular having a 12 constant dia~eter and a smooth surface. If land ~urface 24 i~
13 circular, ~uitable diameters ror the outer extrusion port 14 oririce 25 are from about 11/16 inch to about 1-1/B inch. The orifice of the inner extrusion port iq ~uitably circular in 16 cross-section having a diameter of from about 9/16 inch to 17 about 1 inch. The cross-sectional area o~ the orifice Or the 18 outer extrusion port 21 would be greater than the cross-19 1, qectional area o~ the orifice of the lnner extrusion port 11.
Good results have been achleved when the outer extrusion port 21 ` orifice has a dlameter Or 27/32 inch and the inner extrusion 22 l port orlfice ha~ a diameter of 5/8 lnch. As hereinbefore 23 ' di3cus3ed, the inner extrusion port 11 and the outer extrusion 24 ~ port 21 do not have to have a circular or annular cross-1 section. Other cros~-~ectional geometrie3 rorming a closed 26 , perimeter can give sati~ractory results and this is re~erred 27 i to herein as generally annular.
28 The angle c of the beveled edge 22 i9 generally 29 " greater than about 15. Very qati~factory re~ults have been 30 1l achieved when the angle c iq 60-. Sultable lengths for the 1~42~
1 lan~. sur~ace 24 parallel to the axis of the outer extru~ion 2 port 21 (dimension e of Fig. 2) are from about 1/16 inch to 3 ¦ about 5/16 lnch with a length o~ about 1/8 inch having been 4 1 ~ound sati~ractory.
The bottom die plate 20 having the outer extrusion 6 ~ port 21 formed thereln may be rabricated from a 3ingle molded 7 or machined material as illustrated in Fig. 2 or it may be 8 rabricated from an inside plate having the beveled surrace or 9 edge 22 bonded in combinatlon with an out~ide plate o~ the ,~ same or different material which provides the annular land 11 surrace 24 aq illustrated in Fig. 3. In either case, the 12 sharp or generally sharp line o~ lntersection 27 will be 13 provlded between the beveled edge 22 and the land surface 24.
As illu~trated ln Flg. 4, the land surrace 24 of the outer extrusion port 21 may be provlded with longltudinal 16 scallops 37, l.e., 3callops extending in the directlon Or the 17 axls Or the outer extru~lon port 21. If used, the scallops 18 deslrably would be of a size ~o aq to prevent complete entry 19 Or particles of the particulate matter 26 disposed in the outer doughy mass 32.
21 , Operation of the present invention may be described 22 . in con~unction with FiB. 3 and Fig. 5. An lnner dough 34 is 23 ~ed under pre~sure through filler tube or lnner extrusion 24 conduit 10 by means such as an auger or gas pre~sure as 1I hereinbe~ore di~cus~ed. An outer dough 32 which iY dissimllar 26 , to the innèr dough 34 i~ red under pressure through outer 27 ~ extrusion conduit 23, In accordance with the pre~ent 28 1 lnvention, the outer dough 32 contains partlculate material 29 , 26. The lnner dough 34 exits inner extrusion port 11 and is enveloped by the outer dough 32 which exit~ the annular exit , .
261~
1 passage 28. The lnner dough 34 enveloped by the outer dsugh 2 32 pa~ses through the outer extrusion port 21. The 3 particulate material 26 in the outer dough 32 ls caused to 4 I tumble as the outer doueh passes over bevel edge 22 and the substantially ~harp line of intersection 27. The 6 substantially qharp line o~ intersectlon 27 i5 of particular 7 importance in the embodiment described ror causing tumbling of 8 the particulate material 26 or stated otherwi~e, inducing g turbulence ln the outer doughy mass 32 whereby tumbling o~ the 'particulate material 26 takes place.
11 At least a portion Or the particles o~ the 12 particulate ~aterial 26 which has been caused to tumble by the 13 turbulence inducing means wlll partially break through the 14 exterlor surface 33 of the outer doughy mass 32 as the inner doughy mass 34 and the outer doughy maQS 32 co-extruded 16 product passes through the land surface 24. The land surface 17 24 substantially remove~ partial dough coverlngs or skin rrom 18 the particulate matter 26 that has penetrated the exterior 19 I surrace 33 of the outer doughy mass 32. It will be appreciated that a portion of the particulate material 26 will 21 remain embedded within the outer doughy mass 32. However, a 2~ sufficlent amount Or particles Or the particulate material 26 23 will be tumbled at or near the sur~ace of the outer doughy 24 ' masY to render the desired appearance to the extruded dough l rope-like product 35.
26 l! The composite doughy rope-like product 35 exits the ~7 1 outer extruqlon port 21 and ls received and tran~ported away 28 ,, by horizontally disposed conveyor means 30. Typically, the 29 I composite doughy rope-like product 35 on conveyer means 30 I would be cut lnto lndlvidual portions by any convenlent 1' , li ~
1 lZ4Z6~0 , 1 ' cutting means which are well known in the art. The cut 2 portlons of the rope-llke product would be further transported 3 '~to an oven for baking.
~ 1l The operation of the apparatus and method of the present invention would mo~t advantageou~ly be carried out 6 , continuously ln an automated process. The composite doughy 7 , rope-like product 35 may be extruded at a rate a~ low as about 8 ! 2 reet/mlnute and the deslred tumbllng efrect wlll be 9 achleved. The maximum speed Or extruslon o~ the rope-like I product 35 may be typlcally 35 ~eet/mlnute. The maxlmum speed 11 of extrusion Or the rope-llke product 35 is determined by 1~ practical considerations such as the slze of the oven and the avoidance Or tears ln the outer dough 32 of the composite 14 rope-like product 35. In general, the conveyer means 30 picks up and carries away the co-extruded compo~lte dough rope-like 16 product 35 at a speed equal to or ~ust slightly 8reater than 17 the speed of extrusion 90 that the rope-like product 35 is 18 oriented ln the direction of travel of the conveyor means ~0 19 ~ but is not overly extended so a to cause unsightly discontinuitles in the outer dough portion.
21 The method and apparatus of the present lnvention 22 may be readily adapted for u~e on many co-extrusion 23 i apparatuses for manufacturing food products havlng dissimilar 24 i! lnner and outer portlons.
1, The apparatus and method of the present inventlon is 26 , hlghly advantageous for the automated manu~acture Or chocolate 27 l chlp cookies having a dissimilar lnner dough and outer dough 28 and wherein the finished product has a commercially desirable 29 !I handmade appearance. In accordance with a preferred 3o 1 embodlment of the pre~ent lnventlon, the inner dough 34 would ~L24Z~;~LO
1 be a chocolate chip cookie dough with or without chooolate 2 chips. The outer dough 32 would also be a chocolate chip 3 ~ cookie dough, suitably dissimilar to the inner dough, and, in 4 j, accordance with the pre~ent lnvention, would contain chocolate , chip3. The chocolate chip cookies would be manufactured by 6 I the apparatus and msthod in accordance with the present 7 invention as hereinbefore described. Suitably, the inner ~ dough would contain a humectant in order to render the 9 finished product with a moist and chewy inner texture after 'baking. The outer dough can be a normal chocolate chip cookie 11 , dough which takes on a crispy brown appearance and texture 12 after baking.
13 The size of the chocolate chips, i.e. the 14 particulate matter 26, in the outer dough ma~ 32 oan be of the size which provides from about 1,5~0 chips per pound to 16 about 10,000 chlps per pound. An advantageous chlp size is 17 about 4,600 chips per pound to about 5,000 chlps per pound 18 with about 4,800 chips per pound being a particularly 19 j desirable chip slze. The concentration Or chocolate chips ln the outer dough 32 at the exit pas~age 28 may be from about 3 21 , to about 40~ by weight based on the dough and is suitably 22 ' about 7% to about 20% by weight. A concentration Or chocolate 23 '~ chips Or about 15~ by weight based on the dough has been found 24 useful. The speciric embodiment3 hereln be~ore described are partlcularly u~erul ~or the manuracture of chocolate ch~p 26 1I cookles. The lnner dough may or may not contain manuracture 27 Or chocolate chlp cookies. Satisractory cookles can be made 28 wlthout chocolate chip3 ln the inner dough.
29 Chocolate chlp cookle product prepared in accordance with the method and apparatus Or the present invention has 1.
I _19_ ~Z4~
1 ` chocolate chips di per3ed over and penetrating the entire 2 exterior surface o~ the cookie without the preqence of an 3 ,' unappealing or unsightly thin layer Or baked dough crusit covering the chocolate chipQ. The chocolate chip cookie ll product which is prepared by the method and apparatuq in 6 ~ accordance with the present invention has a commercially 7 l~ desirable handmade appearance even though it is prepared by an 8 automated, continuou~ method of manufacture.
g ~ In comparison, chocolate chip cookies prepared by l' contentional co-extrusion methods and apparatus for food 11 products having dissimilar outer and inner portions wlll not 12 have chocolate chips protruding through the exterior surface 13 ' f the outer dough and uncovered by a baked doughy layer.
Although prererred embodiments of the method and apparatus of the present invention have been deQcribed in 16 I detail, it is contemplated that changes and modifications may be made thereto by one skilled in the art all within the 18 spirit and iscope of the present invention as described herein 19 il and as defined in the appended claims.
24 I:
29 1, l -20-
8 ~ACKGROUND OF THE INVENTION
9 The types of product~ to which the present invention relates include baked goods that are baked from dough pieces 11 having an outer layer of farinaceous dough and a core which 12 may be a dissimilar dough or another material ~uch as a ~am, 13 cream, puree, paste, or other extrudable form of fruit, 1~ cheese, meat, vegetable, confection or other edible substance. I
In those product~ where the core is also a doueh, the inner 16 and outer doughs would be advantageously dissimilar in 17 composition ~o as to produce difrerent tastes, colors, 18 appearances, textures, consistencies, or the like in the inner 19 and outer portions of the baked product. Re~ardless of the composition of the lnner and outer portions, the present 21 invention i9 directed to products having particulate matter, 22 ~ such as chocolate chips, candied Pruit, nuts, raisins, and the 23 llke, in the outer portion.
24 li In the past, products having dlfferent inner and 25 1l outer portions have been formed by concentrically extruding an 26 1 extrudate rope as shown in U.S. Patent No. 3,572,259 to 27 Hayashi.
28 1 An automatic machine for maklng filled baked goods 29 1 l~ described in U.S. Patent No. 3,196,810 to Roth. In this 3 ~I patent, a plurality of die~ dispo3e flavoring material within `" 11 l~Z~O
:! 'I
l l 1 a dough. U.S. Patent No. 3,778,209 to Wallace et al. discloses 2 an apparatus for forming a ~ood extrusion in ~hich an inner 3 1l meat food is totally enrobed by an outer moldable food by 4 1l usin~ a co-extruqion nozzle and a pair of augers to force ~ood products through the co-extrusion nozzle from a respective 6 I palr of ~ood hoppers. Augers are particularly u3*ful for the 7 extrusion Or foods, such as dough, in order to achieve a 8 ~ consistent quality, reliabllity and high efficiency in the g high speed manufacture Or snacks ~uch as cookies, chocolate 10 1 layered foods and the like.
11 In the manufacture of co-extruded food substances, 12 it is common to require that the outer food substance 13 ,encapsulates or enrobes an inner food substance. In U.S.
Patent Nos. 3,77B,209 to ~allace et al. and 3,249,068 to Gembicki, the enrobing action i~ obtained by controlling the 16 motion of a plunger or piston u~ed in oonnection with the 17 feedin~ of the food material to be encapsulated. In U.S.
lB Patent No. 4,251,201 to Krysiak, an enrobed food piece is 19 produced with an apparatus that includes specially sequenced feed mechanisms u~ed to co-extrude an lnner and outer ~ood 21 1' product from coaxlal dles ln comblnation wlth a sequence 22 ~ coordlnated irls shaped cut-off valve that is closely mounted 23 ' to the di~charge ports of the extrusion dies. The iris valve 24 ~I cut~ the co-extrusion ~ust at a tlme when the feed Or both the 25 1 inner filler and outer enrobing foods is interrupted and the 26 space in which the valve acts ls essentially ~illed with the 27 outer enrobing food. This technique appears to depend upon a 28 ~ relatively easy flowability of the outer food substance so as 29 1, to coat the rear of the inner ~ood while the iris valve is about to close and appears limited in operating speed because ` 1293-111 the feed of both inner and outer foods must be interrupted for each Eood piece manufactured.
More recently, relatively high speed methods and apparatuses have been developed whereby an inner dough co-extruded with an outer dough is enrobed by severing the outer dough with a blunt severing edge or a severing element which simultaneously draws the outer dough over the inner dough on both sides of a severed element to form a fully enrobed food piece.
In all the known methods discussed above, there is no disclosure of including particulate matter in the outer dough portion. Consequently, none of the references disclose any method or apparatus which facilitates inclusion of particulate matter in the outer portion of a co-extruded dough rope.
Experience in the art of co-extrusion has taught that certain difficulties are encountered in extruding an outer tube of doughy mass containing particulate matter. For example, the normal configuration of the die head is such that the annular space between the outside circumference of the inner extrusion port and the inside of the outer extrusion port prevents smooth passage of the particulate matter. In some cases, the space when adjusted to provide the proper flow rate and tube thickness is simply too small to allow passage of the particles. Another problem encountered is the agglomeration of particles as they enter the exit passage which blocks the flow of extrusion or causes an uneven outer tube of dough.
~hen it is desired to éxtrude a particle-containing _ ~ !
1 outer tube of dough mass to produce an attractive relatively 2 smooth-skinned confectionery or cookie having the particulate 3 1I matter appear as if placed thereon externally or prepared by 4 hand, the problems are lntensiried. The particles are desirably free from a partial coverin~ by the doughy mass.
6 This enhances the appearance of the finished product which i~
7 ; an important commercial consideration. In order to enhance 8 the product'~ appearance, the particles should penetrate the g exterior surface o~ the outer dough and should be free of a 'Ipartial covering by the doughy mass.
11 A further consideration relative to extruding the 12 i outer tube of doughy mass with particles ls that the integrity 13 f the outer dough portion should be maintained, especially in 14 , the case of co-extruded cookie dough, so that the final ~ product appear~ wholly handmade. Any discontinuities through 16 which the inner portlon can be seen slgniricantly erodes the 17 appearance of a handmade quality for the product.
18 Moreover, it would be desirable that each of the 19 j, above considerations be resolved while maintaining high speed production.
?l OBJECTS OF THE INVENTION
22 '; It ls therefore an obJect of the present invention 23 to overcome the problems hereinberore discussed with respect 24 to co-extrudlng a two-component doughy mas~ having an inner 1 and outer portion in which the outer portion contains 26 ' particulate material.
27 It ls a ~urther ob~ect of the present invention to 28 provide a method and apparatus for co-extruding an inner 29 !; doughy mass and an outer doughy mass containing particulate 30 ` material wherein at least a portlon Or the particles in the . ' outer doughymass penetrate the exterior surface of the outer doughy mass and any partial dough covering of the particulate material penetrating the exterior surface of the outer doughy mass is substantially removed.
It is yet another object of the present invention to provide a method and apparatus for the manufacture of chocolate chip cookie products comprising a dissimilar inner dough and an outer dough by means of co-extrusion of the inner dough and a chocolate chip containing outer dough wherein the chocolate chips penetrate the outer dough exterior surface and the resultant chocolate chip cookie product has a commercially desirable handmade appearance.
These and other objects of the present invention will become apparent from the following description and claims in conjunction with the drawings.
SUMM~RY OF THE INVENTION
-The present invention provides a co-extrusion apparatus for forming a continuous food product having dissimilar inner and outer portions wherein said inner portion is enveloped by said outer portion and said outer portion is a dough containing particulate material composed of particles, said apparatus compri~ing: an inner extrusion port having an exit orifice with a first cross-sectional area through which said inner portion is extruded; an outer extrusion port having an exit orifice with a second cross-sectional area greater in area than said first cross-sectional area wherein said inner lZ426~0 61293-lll extrusion port is recessed a distance d from said outer extrusion port with said recessed distance defining an exit passage between said inner extrusion port and said outer extrusion port and wherein said distance d is sufficient to permit said particles of said particulate material contained in said dough of said outer portion to pass through said exit passage; first conduit means communicating with said inner extrusion port for providing said inner portion thereto; second conduit means communicating with said exit passage for providing said outer dough portion containing particulate material thereto, whereby said outer dough portion containing particulate material passes through said exit passage and envelops said inner portion extruded through said inner extrusion port and wherein said inner portion enveloped by ~aid outer portion passes through said outer extrusion port thereby forming a composite food product having dissimilar inner and outer portions; means for inducing turbulence in said outer dough portion enveloping said inner portion whereby said particulate material in said outer dough portion tumble and at least a portion of the particles of said particulate material have a part thereof penetrate the exterior surface of said outer dough portion; and means for substantially removing dough from the parts said particles which penetrate said exterior surface of said outer dough portion.
The present invention provides a co-extrusion method for forming a continuous food product having dissimilar inner -- 5a -, ,; ., , .. ., ~
26~(~
and outer portions wherein said inner portion is enveloped in intimate contact by said outer portion and said outer portion is a dough material, said method comprising: providing edible particulate material in said outer portion dough material;
extruding said inner portion through an inner extrusion port;
passing said outer portion dough material containing particulate material through an exit passage formed by recessing said inner extrusion port a distance D from an outer extrusion port wherein said distance D is sufficient to permit said particulate material contained in said outer portion dough material to pass through said exit passage whereby said outer portion dough material envelops said inner portion passing said inner portion enveloped by said outer portion dough material through said outer extxusion port thereby forming a composite rope-like food product having said outer portion dough material in intimate contact with said inner portion; creating turbulence in said outer portion dough material enveloping said inner portion at the intersection where the outer dough surrounds said inner dough thereby causing at least a portion of particles of said particulate material to tumble and to partially penetrate the exterior surface of said outer portion dough material prior to said composite rope-like food product exiting said outer extrusion port; bringing said outer portion dough material into contact with a land surface provided in said outer extrusion port after said turbulence-causing step, thereby -- ~LZ42610 removing dough from the part of said particles penetrating the exterior surface of said outer portion dough material prior to said composite rope-like food product exiting said outer extrusion port.
It is preferrable that the inner extrusion port be recessed from the outer extrusion port by a distance (d) sufficient to allow passage of the outer dough containing particulate material therebetween without agglomeration of the particles. This distance is suitably at least about 1.25 times the maximum dimension of the particulate material in the outer doughy mass.
In one embodiment, the turbulence-inducing means includes a generally annular beveled edge on the interior side of the orifice af the outer extrusion port contiguous with a generally annular land surface generally parallel with respect to the axis of outer extrusion port. The annular beveled edge meets the annular land surface at a substantially sharp intersection. The generally annular land sur-face has a length sufficient to remove dough coverings from the parts of the particles penetrating the exterior surface of the outer dough portion. Preferably, the angle of the beveled edge is between about 15 and about 60, while the annular land surface is from about 1/16 inch to about 5/16 inch in length and is preferably about 3/16 inch in length.
In one preferred embodiment of the present invention, the outer dough portion is a chocolate chip cookie dough - 6a -6~0 61293-lll - containing chocolate chips as the pariculate material. The inner doughy mass is a dissimilar chocolate chip cookie dough which may include a humectant so that the dough remains moist and chewy, even after baking. If desired, the inner doughy mass may also contain chocolate chips to enhance the flavor and sweetness of the inner dough.
The present invention provides a continuous dough extrudate having dissimilar inner and outer dough portions. The outer portion envelopes the inner portion and contains particulate matter. During the co-extrusion, the particles are tumbled to a degree sufficient to penetrate the exterior surface of the outer portion of the extrudate. Moreover, the co-extruded dough rope has a smooth overall appearance without any discontinuities or voids in the outer portion through which the inner doughy mass can be seen, and there is no partial covering or "skin" of the doughy mass over the particles which have penetrated the exterior surface of the outer dough portion.
The present invention can easily be adapted for use in a high speed pxocess without extensive modifications to existing equipment.
;
~;~9~Z6~0 . I 1 2 ,; In the drawings forming part hereof:
3 Fig, 1 is a schematic side view, partially ln 4 1l cross-section, Or one embodiment of a co-extrusion apparatus ; in accordance with the present invention;
6 ' FiB. 2 is a ~impliried schematic cro~-3ectional 7 , view of an embodiment similar to that illustrated in Fig. 1 of 8 i a co-extrusion apparatus in accordance with the present g invention;
Fig. 3 is a simpliried ~chematic cross-sectional 11 view similar to that Or Fig. 2 which further illuAtrate~ an 12 inner doughy mass and outer doughy mass containing particulate ! material;
Fig. 4 is a simplified schematic lllustration Or an alternate embodiment of an outer extrusion port which may be 16 used with the apparatus of Fig. l; and 17 Fig. 5 i9 a schematic side view, partially in 18 cross-section, similar to that of Fig. 1 which further shows 19 1 an inner doughy masq and an outer doughy mass containing particulate material ~nd lllustrateq operation in accordance 2~ ¦ with one embodiment of the present invention.
22 , DESCRIPTION OF THE PREFERRED EMBODIMENTS
, In order to provide a more complete understanding of 24 'I the present invention and an appreciation Or its advantages a 25 1I detailed description of preferred embodiments is presented 26 j' below, 27 Figure 1 is a qchematic representation of a co-2~ l extru3ion apparatus 5 in accordance ~ith the present 29 jl invention, The co-extrusion apparatus 5 comprises a die casing 7 and an inner filler tube or inner extrusion conduit , -8-.
\
~Z9~Z6~ !
1 10. The end of lnner extruslon conduit 10 terminates with 2 inner extrusion port 11. Surrounding filler tube or inner 3 extrusion conduit 10 is outer extrusion conduit 23 ~hich is 4 I defined by the outer wall of lnner extrusion conduit 10 and the wall 29 of die casing 7. ~ounted on the bottom of die 6 casin~ 7 and po9itioned below inner extru~ion port 11 is 7 - extrusion die plate 20 ln which is provlded outer extrusion 8 ! port 21. Positioned below outer extrusion port 21 is conveyor 9 ~eans 30 for receiving and transporting the co-extruded doughy rope to, e.g., an oven.
11 Apparatus for the manufacture of food products 12 having dissimilar inner and outer portions by co-extrusion 13 through concentric inner and outer extrusion nozzles or 4 ~ conduits are themYelves well known and do not require detailed discussion. Examples Or prior art apparatus are ~hown in the 16 prior art patents discuYsed in the foregoing.
17 In accordance with conventional constructions, an 18 inner doughy mass would be fed ~ia conduit means from a first 19 I hopper to inner extru~ion conduit or flller tube 10 by l; conventional means ~not illustrated). Likewise, an outer 27 I doughy mas~ would be fed via conduit means from a second 22 hopper to the outer extrusion conduit means 23 by conventional 23 means (not illustrated). Means for feeding the inner doughy 24 mass to filler tube 10 and the outer doughy mass to the outer ' extrusion conduit 23 may be, e.g., well known auger devices.
26 Feeding of the doughy masses through the extrusion conduits 27 may also be accomplished by appropriate gas pressure. The 28 manner and means of reeding doughy mas~es to inner and outer 29 co-extrusion condults are ~ell known in the srt and ~orm no ; part o~ the present invention. Therefore, they are not _ g _ Il lZ~2610 , I I
1 di~u~ed in detail hereln.
Conduit means 31 and conduit mean~ 37 are 3 l lllu~trated ln phantom in Fig. 1 and repre~ent mean~ for ~ li feeding the inner doughy mass to riller tube 10 and the outer ~ doughy mass to outer extrusion conduit 23 respectively. As 6 11 illustrated in Flg. 1, the outer extruslon conduit 23 is 7 ! greater ln area on the riBht hand ~ide of the figure ~here the 8 outer doughy mass 1~ fed lnto the outer extruslon conduit.
9 ' The outer doughy mass surround the inner filler tube 10 and lo l;is forced through exit pas~age 28 between inner extruQlon port 11 11 and bottom die plate 20 whereby the outer doughy mass 12 surrounds and envelopes the inner doughy mass extruded through 13 the lnner extrusion port 11. The composite outer doughy mas~
14 ~ enveloping the inner dou~hy maQ~ i~ forced or co-extruded through the outer extrusion port 21 of extruRion die 20. The 16 general arrangement of such co-extrusion devices are themselves well known in the art.
18 Inner filler tube 10 and the inner extrusion port 11 19 I may assume a variety of geometrical cro~s-3ectioni. Suitably, the geometrical cro~s-section Or filler tube 10 and inner 21 1l extrusion porS 11 i8 circular. Slmilarly, annular-like outer 22 ; extru~lon conduit 23 and outer extrusion port 21 may assume a 23 ' variety of geometrical cross-sections. Suitably, outer 24 1 extru~ion port 21 has a circular cross-~ection. The cross-! sectional area of outer extrusion port 21 is Breater than the 26 ~' cro~s-~ectlonal area Or the inner extrusion port 11 in order 27 ! that the outer doughy mass may envelop the inner doughy mass 28 l, to provlde the co-extruded rope-like product havlng dissimilar 29 ~l outer and lnner portion~ in accordance wlth the ~ell-known 1, practice of the art.
,1 ~z4z~
Il .
1 ~s lllustrated in Flg. 1, the left periphery of 2 . inner extrusion port 11 i~ positloned in approximate alignment 3 ,,~ith the left land surface 24 of the outer extrusion port 21 4 . of bottom die plate 20. Such an alignment is found ~ advantageous for producing a satisfactory product ~hen the 6 co-extruded rope-like product having dissimilar outer and 7 inner portions is received and tranQported away by conveyor 8 means 30 moving to the right as indicated by the arrow A in g Fig. 1. That is, when the conveyor means 3~ is moving as , indicated by the arrow A, best results in the quallty of the 11 co-extruded product are not generally obtained by 12 concentrically positioning the inner extru~ion port 11 with 13 respect to the outer extrusion port 21. The exact lateral 14 I positioning of the inner extrusion port 11 with respect to the outer extrusion port 21 for producing an optimum quality 16 product may vary slightly depending on the composition Or the 17 inner and outer doughy masses and the linear Qpeed of conveyor lB means 30 but can be routinely determined in view of the 19 !, foregoing general guidance. Means (not illustrated) ~ould be provided to laterally move die casing 7 and thereby outer 21 extrusion port 21 with respect to inner extrusion port 11.
22 ~ In accordance with the present invention, 23 1' particulate material, Quch aQ chocolate chips, are disposed in 24 li the outer doughy mass which is forced through the outer 1~, extrusion conduit 23. In accordance with the present 26 1 inventlon, means are provided to tumble the particulate 27 material Or the outer doughy mass enveloping the inner doughy 28 mass QO that at least a portion Or the particulate material 29 ;j penetrateY the exterior surrace of outer doughy mass portion 1 Or the co-extruded rope-like product formed from dissimilar :~2426~
1 ~nner and ouker portion Further, ln accordance with the 2 I present invention, mean~ are provided whereby partial oovering 3 ¦~ Or the partlcles penetrating the exterior surrace Or the outer ~ portlon Or the co-extruded product are removed.
The method and apparatus ln accordance with the 6 I pre3ent invention will now be explained in greater detail with 7 j reference to Fig. 1 and Fig. 2 ~herein Fig. 2 is a ~chematic 8 detail illustration Or filler tube 10 and the botto~ die plate g ~ 20. Reference i8 also made to Fig. 3, which i~ ilar to ,~ Fig. 2, and which ~chematically lllustrates the co-extruAion 11 o~ lnner doughy ma~ 34 and outer doughy ma~ 32 containing 12 particulate material 26 whereby co-extruded rope-liks product 13 35 is formed from dissimilar inner dough 34 and outer dough 32 14 and a portion Or the partlculate material 26 penetrates the exterior sur~ace 33 of the outer dough 32 of the rope-like 16 product 35. In Fig~. 2 and 3, inner extrusion port 11 is 17 illustrated positioned generally concentric with outer 18 extrusion port 21 for clari~y of illustration. Ho~ever, as 19 ll hereinbefore discu sed, such posltioning o~ the inner , extru~ion port 11 wlth respect to the outer extrusion port 21 21 ' i~ not always optlmum ror all operating conditions.
22 Outer extrusion port 21 havln~ an orifice 25 i~ !
23 l' for~ed in bottom die plate 20 and lncludes an annular land ~4 , ~urrace 24 and an annular bevel Aurface 22 on the lnterior 1 side of outer extru~lon port 21. Annular land ~urface 24 26 1 intersects annular bevel surface or edge 22 at point 27 27 i thereby ~ormlng an annular line Or intersection. Annular land 28 ! surrace 24 i~ a peripheral surrace Or outer extrusion port 21 29 ~ and i3 parallel to the axl~ o~ outer extru~ion port 21. Bevel 3o , surrace 22 i~ located on the inner or lnterior ~ide of the .
_12-~2~Z6 .
1 outer extrusion port 21 (l.e., the ~ide of outer extrusion 2 port 21 facing the inner extension port 11). Bevel surrace 22 3 ,lextends around the perimeter of the outer extru~ion port 21.
4 " Bevel edge or qurface 22 is formed at an angle c with a line ,perpendicular to the axis of outer extrusion port 21 or 6 I therefore with the surface of land surrace 24.
7 The turbulence inducing means, in accordance with 8 the present invention, compriqes bevel edge or qurface 22 and g the line Or intersection 27 between bevel edge 22 and land , surface 24. It is important tbat the line Or intersection 27 11 between bevel surface 22 and land surface 24 be ~ubstantially 12 sharp. This qubstantially sharp intersection 27 is very 13 e~fective for inducing turbulence in particulate matter 26 of 14 the outer dough 32.
By Yubstantially sharp is meant that it is 16 permissible for the line of intersection 27 to have a very 17 small radius. A very small radius may be desirable from a 18 ;I practical viewpoint to prevent an operator, e.g., from 19 ,l inadvertently outting himself when handling the apparatus. A
sharp line Or inter~ection ~i.e., not even having a small 21 ; radius) would otherwise give totally ~ati~factory performance.
22 ' It is important, however, that there not be a large radius at 23 the lntersectlon between bevel edge 27 and the annular land ~4 surface 24. A large radius would not result in the desired ~I creation of turbulence in the outer dough 32 and ~he tumbling 26 ,1 of the particulate material 26 and therefore the ~ubsequent Il 27 satisfactory penetration of the exterior surface 33 of the 28 l compoqite rope-like product 35 will not be achieved.
29 ' The land surrace 24 having a length parallel to the , axis of outer extru~ion port 21 serve~ to remove partial dough ~2426~
1 covering or dough ~kin rrom the partlculate ~aterial 26 which 2 , penetrates the outer dough surrace 33 of the outer dough due 3 to the tumbllng of particulate materlal 26 caused by the line ~ 1 of intersection 27. The length of the land ~urraoe 24 must be surricient to sub~tantially remove any partial dough coverlng 6 1 or skin from the partlculate material 26 ~hich penetrates the 7 outer exterior surrace 33 of the outer dough. However, if the 8 length Or land ~urrace 24 is too long, lt may ~unction to push g the partlculate material 26 whlch has penetrated the outer I dough surface 33 back into the dough.
11 In accordance with the present invention, the inner 12 ; extrusion port 11 Or filler tube 10 is reces~ed rrom the outer 13 extrusion port 21 a distance d. Recessing the inner extrusion 14 port 11 a distance d from the outer extrusion port 21 defines an exit passage 28 through which the outer doughy mass 16 containin~ partlculate materlal 26 passes as lt begins to 17 envelop the inner doughy mass 34 exiting the inner extrusion 18 j port 11. The distance d ls selected to be surficient to 19 permlt passage o~ the particles of the partlculate material 26 contalned ln the outer dough 32 through the exit passage 28 21 ~ without clogging or agglomeration.
22 ' Advantageously the distance d ls selected to be at 23 least about 1.25 times the maximum dimenslon of the large~t 24 j particles 26 diRposed in the outer doughy mass 32 in order to ' prevent agglomeration or clogging of the particulate material 26 26 in the annular exit passage 2~. In most appllcations, d 27 ' ~ould not equal more than approxlmately 2 because as d gets 28 ,l larger in most instances the cro~s-~ectional area of orifice 29 1 25 Or the outer extruqion or~rice 21 would tend to grow j rapidly larger and the thlckne~s Or the outer doughy mass 32 _14-Il lZ~Z~
1 would tend to become large with respect to the thickness of 2 I the inner doughy mass 34 of the rope-llke co-extruded product 3 35 and thereby not result in ~hat is usually considered a ~ ,Idesirable commercial product. It will be understood that the diqtance d is not defined by random very large particles which 6 ~do not conform to the intended commerclal particle 3ize or 7 grade. In general, the closest distance d from the inner 8 extrusion port 11 to the outer extrusion port 21 i~ about 5/16 g , inch to about 7/16 lnch with 5/16 inch bein8 Yatisfactory in 1~ 1 many appllcatlons.
11 The land ~urface 24 may be circular having a 12 constant dia~eter and a smooth surface. If land ~urface 24 i~
13 circular, ~uitable diameters ror the outer extrusion port 14 oririce 25 are from about 11/16 inch to about 1-1/B inch. The orifice of the inner extrusion port iq ~uitably circular in 16 cross-section having a diameter of from about 9/16 inch to 17 about 1 inch. The cross-sectional area o~ the orifice Or the 18 outer extrusion port 21 would be greater than the cross-19 1, qectional area o~ the orifice of the lnner extrusion port 11.
Good results have been achleved when the outer extrusion port 21 ` orifice has a dlameter Or 27/32 inch and the inner extrusion 22 l port orlfice ha~ a diameter of 5/8 lnch. As hereinbefore 23 ' di3cus3ed, the inner extrusion port 11 and the outer extrusion 24 ~ port 21 do not have to have a circular or annular cross-1 section. Other cros~-~ectional geometrie3 rorming a closed 26 , perimeter can give sati~ractory results and this is re~erred 27 i to herein as generally annular.
28 The angle c of the beveled edge 22 i9 generally 29 " greater than about 15. Very qati~factory re~ults have been 30 1l achieved when the angle c iq 60-. Sultable lengths for the 1~42~
1 lan~. sur~ace 24 parallel to the axis of the outer extru~ion 2 port 21 (dimension e of Fig. 2) are from about 1/16 inch to 3 ¦ about 5/16 lnch with a length o~ about 1/8 inch having been 4 1 ~ound sati~ractory.
The bottom die plate 20 having the outer extrusion 6 ~ port 21 formed thereln may be rabricated from a 3ingle molded 7 or machined material as illustrated in Fig. 2 or it may be 8 rabricated from an inside plate having the beveled surrace or 9 edge 22 bonded in combinatlon with an out~ide plate o~ the ,~ same or different material which provides the annular land 11 surrace 24 aq illustrated in Fig. 3. In either case, the 12 sharp or generally sharp line o~ lntersection 27 will be 13 provlded between the beveled edge 22 and the land surface 24.
As illu~trated ln Flg. 4, the land surrace 24 of the outer extrusion port 21 may be provlded with longltudinal 16 scallops 37, l.e., 3callops extending in the directlon Or the 17 axls Or the outer extru~lon port 21. If used, the scallops 18 deslrably would be of a size ~o aq to prevent complete entry 19 Or particles of the particulate matter 26 disposed in the outer doughy mass 32.
21 , Operation of the present invention may be described 22 . in con~unction with FiB. 3 and Fig. 5. An lnner dough 34 is 23 ~ed under pre~sure through filler tube or lnner extrusion 24 conduit 10 by means such as an auger or gas pre~sure as 1I hereinbe~ore di~cus~ed. An outer dough 32 which iY dissimllar 26 , to the innèr dough 34 i~ red under pressure through outer 27 ~ extrusion conduit 23, In accordance with the pre~ent 28 1 lnvention, the outer dough 32 contains partlculate material 29 , 26. The lnner dough 34 exits inner extrusion port 11 and is enveloped by the outer dough 32 which exit~ the annular exit , .
261~
1 passage 28. The lnner dough 34 enveloped by the outer dsugh 2 32 pa~ses through the outer extrusion port 21. The 3 particulate material 26 in the outer dough 32 ls caused to 4 I tumble as the outer doueh passes over bevel edge 22 and the substantially ~harp line of intersection 27. The 6 substantially qharp line o~ intersectlon 27 i5 of particular 7 importance in the embodiment described ror causing tumbling of 8 the particulate material 26 or stated otherwi~e, inducing g turbulence ln the outer doughy mass 32 whereby tumbling o~ the 'particulate material 26 takes place.
11 At least a portion Or the particles o~ the 12 particulate ~aterial 26 which has been caused to tumble by the 13 turbulence inducing means wlll partially break through the 14 exterlor surface 33 of the outer doughy mass 32 as the inner doughy mass 34 and the outer doughy maQS 32 co-extruded 16 product passes through the land surface 24. The land surface 17 24 substantially remove~ partial dough coverlngs or skin rrom 18 the particulate matter 26 that has penetrated the exterior 19 I surrace 33 of the outer doughy mass 32. It will be appreciated that a portion of the particulate material 26 will 21 remain embedded within the outer doughy mass 32. However, a 2~ sufficlent amount Or particles Or the particulate material 26 23 will be tumbled at or near the sur~ace of the outer doughy 24 ' masY to render the desired appearance to the extruded dough l rope-like product 35.
26 l! The composite doughy rope-like product 35 exits the ~7 1 outer extruqlon port 21 and ls received and tran~ported away 28 ,, by horizontally disposed conveyor means 30. Typically, the 29 I composite doughy rope-like product 35 on conveyer means 30 I would be cut lnto lndlvidual portions by any convenlent 1' , li ~
1 lZ4Z6~0 , 1 ' cutting means which are well known in the art. The cut 2 portlons of the rope-llke product would be further transported 3 '~to an oven for baking.
~ 1l The operation of the apparatus and method of the present invention would mo~t advantageou~ly be carried out 6 , continuously ln an automated process. The composite doughy 7 , rope-like product 35 may be extruded at a rate a~ low as about 8 ! 2 reet/mlnute and the deslred tumbllng efrect wlll be 9 achleved. The maximum speed Or extruslon o~ the rope-like I product 35 may be typlcally 35 ~eet/mlnute. The maxlmum speed 11 of extrusion Or the rope-llke product 35 is determined by 1~ practical considerations such as the slze of the oven and the avoidance Or tears ln the outer dough 32 of the composite 14 rope-like product 35. In general, the conveyer means 30 picks up and carries away the co-extruded compo~lte dough rope-like 16 product 35 at a speed equal to or ~ust slightly 8reater than 17 the speed of extrusion 90 that the rope-like product 35 is 18 oriented ln the direction of travel of the conveyor means ~0 19 ~ but is not overly extended so a to cause unsightly discontinuitles in the outer dough portion.
21 The method and apparatus of the present lnvention 22 may be readily adapted for u~e on many co-extrusion 23 i apparatuses for manufacturing food products havlng dissimilar 24 i! lnner and outer portlons.
1, The apparatus and method of the present inventlon is 26 , hlghly advantageous for the automated manu~acture Or chocolate 27 l chlp cookies having a dissimilar lnner dough and outer dough 28 and wherein the finished product has a commercially desirable 29 !I handmade appearance. In accordance with a preferred 3o 1 embodlment of the pre~ent lnventlon, the inner dough 34 would ~L24Z~;~LO
1 be a chocolate chip cookie dough with or without chooolate 2 chips. The outer dough 32 would also be a chocolate chip 3 ~ cookie dough, suitably dissimilar to the inner dough, and, in 4 j, accordance with the pre~ent lnvention, would contain chocolate , chip3. The chocolate chip cookies would be manufactured by 6 I the apparatus and msthod in accordance with the present 7 invention as hereinbefore described. Suitably, the inner ~ dough would contain a humectant in order to render the 9 finished product with a moist and chewy inner texture after 'baking. The outer dough can be a normal chocolate chip cookie 11 , dough which takes on a crispy brown appearance and texture 12 after baking.
13 The size of the chocolate chips, i.e. the 14 particulate matter 26, in the outer dough ma~ 32 oan be of the size which provides from about 1,5~0 chips per pound to 16 about 10,000 chlps per pound. An advantageous chlp size is 17 about 4,600 chips per pound to about 5,000 chlps per pound 18 with about 4,800 chips per pound being a particularly 19 j desirable chip slze. The concentration Or chocolate chips ln the outer dough 32 at the exit pas~age 28 may be from about 3 21 , to about 40~ by weight based on the dough and is suitably 22 ' about 7% to about 20% by weight. A concentration Or chocolate 23 '~ chips Or about 15~ by weight based on the dough has been found 24 useful. The speciric embodiment3 hereln be~ore described are partlcularly u~erul ~or the manuracture of chocolate ch~p 26 1I cookles. The lnner dough may or may not contain manuracture 27 Or chocolate chlp cookies. Satisractory cookles can be made 28 wlthout chocolate chip3 ln the inner dough.
29 Chocolate chlp cookle product prepared in accordance with the method and apparatus Or the present invention has 1.
I _19_ ~Z4~
1 ` chocolate chips di per3ed over and penetrating the entire 2 exterior surface o~ the cookie without the preqence of an 3 ,' unappealing or unsightly thin layer Or baked dough crusit covering the chocolate chipQ. The chocolate chip cookie ll product which is prepared by the method and apparatuq in 6 ~ accordance with the present invention has a commercially 7 l~ desirable handmade appearance even though it is prepared by an 8 automated, continuou~ method of manufacture.
g ~ In comparison, chocolate chip cookies prepared by l' contentional co-extrusion methods and apparatus for food 11 products having dissimilar outer and inner portions wlll not 12 have chocolate chips protruding through the exterior surface 13 ' f the outer dough and uncovered by a baked doughy layer.
Although prererred embodiments of the method and apparatus of the present invention have been deQcribed in 16 I detail, it is contemplated that changes and modifications may be made thereto by one skilled in the art all within the 18 spirit and iscope of the present invention as described herein 19 il and as defined in the appended claims.
24 I:
29 1, l -20-
Claims (34)
1. A co-extrusion apparatus for forming a continuous food product having dissimilar inner and outer portions wherein said inner portion is enveloped by said outer portion and said outer portion is a dough containing particulate material composed of particles, said apparatus comprising:
an inner extrusion port having an exit orifice with a first cross-sectional area through which said inner portion is extruded;
an outer extrusion port having an exit orifice with a second cross-sectional area greater in area than said first cross-sectional area wherein said inner extrusion port is recessed a distance d from said outer extrusion port with said recessed distance defining an exit passage between said inner extrusion port and said outer extrusion port and wherein said distance d is sufficient to permit said particles of said particulate material contained in said dough of said outer portion to pass through said exit passage;
first conduit means communicating with said inner extrusion port for providing said inner portion thereto;
second conduit means communicating with said exit passage for providing said outer dough portion containing particulate material thereto, whereby said outer dough portion containing particulate material passes through said exit passage and envelops said inner portion extruded through said inner extrusion port and wherein said inner portion enveloped by said outer portion passes through said outer extrusion port thereby forming a composite food product having dissimilar inner and outer portions;
means for inducing turbulence in said outer dough portion enveloping said inner portion whereby said particulate material in said outer dough portion tumble and at least a portion of the particles of said particulate material have a part thereof penetrate the exterior surface of said outer dough portion; and means for substantially removing dough from the parts said particles which penetrate said exterior surface of said outer dough portion.
an inner extrusion port having an exit orifice with a first cross-sectional area through which said inner portion is extruded;
an outer extrusion port having an exit orifice with a second cross-sectional area greater in area than said first cross-sectional area wherein said inner extrusion port is recessed a distance d from said outer extrusion port with said recessed distance defining an exit passage between said inner extrusion port and said outer extrusion port and wherein said distance d is sufficient to permit said particles of said particulate material contained in said dough of said outer portion to pass through said exit passage;
first conduit means communicating with said inner extrusion port for providing said inner portion thereto;
second conduit means communicating with said exit passage for providing said outer dough portion containing particulate material thereto, whereby said outer dough portion containing particulate material passes through said exit passage and envelops said inner portion extruded through said inner extrusion port and wherein said inner portion enveloped by said outer portion passes through said outer extrusion port thereby forming a composite food product having dissimilar inner and outer portions;
means for inducing turbulence in said outer dough portion enveloping said inner portion whereby said particulate material in said outer dough portion tumble and at least a portion of the particles of said particulate material have a part thereof penetrate the exterior surface of said outer dough portion; and means for substantially removing dough from the parts said particles which penetrate said exterior surface of said outer dough portion.
2. An apparatus as recited in claim 1 wherein said distance d is at least about 1.25 times the largest dimension of the largest particles of said particulate material.
3. An apparatus as recited in claim 1 wherein said distance d is about 1.25 to 2 times the largest dimension of the largest particles of said particulate material.
4. An apparatus as recited in claim 1 wherein said exit orifice of said inner extrusion port and said exit orifice of said outer extrusion port are generally annular and wherein said exit passage between said inner extrusion port and said outer extrusion port is generally annular.
5. An apparatus as recited in claim 1 wherein said turbulence inducing means is located on said outer extrusion port.
6. An apparatus as recited in claim 4 wherein said turbulence inducing means is located on said outer extrusion port.
7. An apparatus as recited in claim 1 wherein said means for removing dough is located on said outer extrusion port.
8. An apparatus as recited in claim 4 wherein said means for removing dough is located on said outer extrusion port.
9. An apparatus as recited in claim 1 wherein said outer extrusion port includes a generally annular land surface oriented generally parallel to the axis of said outer extrusion port with said land surface terminating at the inner side of said outer extrusion port in a generally sharp line of intersection with the interior surface of said outer extrusion port whereby said land surface provides said dough removing means and said generally sharp line of intersection provides said turbulence inducing means.
10. An apparatus as recited in claim 9 wherein said line of intersection is sharp.
11. An apparatus as recited in claim 9 wherein said land surface is smooth and parallel to the axis of said outer extrusion port.
12. An apparatus as recited in claim 9 wherein said land surface includes scallops oriented generally parallel to the axis of said outer extrusion port.
13. An apparatus as recited in claim 9 wherein said and surface has a length parallel to the axis of said outer extrusion port of about 1/16 inch to about 5/16 inch.
14. An apparatus as recited in claim 13 wherein said distance d is at least about 5/16 inch to about 7/16 inch.
15. An apparatus as recited in claim 1 wherein said outer extrusion port includes a generally annular land surface oriented generally parallel to the axis of said outer extrusion port, the inner surface of said outer extrusion port is a generally annular beveled surface intersecting said land surface at the interior side of said land surface thereby forming a generally annular line of intersection wherein said line of intersection is generally sharp whereby said land surface provides said dough removing means and said generally sharp line of intersection provides said turbulence inducing means.
16. An apparatus as recited in claim 15 wherein said line of intersection is sharp.
17. An apparatus as recited in claim 15 wherein said land surface is smooth and parallel to the axis of said outer extrusion port.
18. An apparatus as recited in claim 15 wherein said land surface includes scallops oriented generally parallel to the axis of said outer extrusion port.
19. An apparatus as recited in claim 15 wherein said land surface has a length parallel to the axis of said outer extrusion port of about 1/16 inch to about 5/16 inch.
20. An apparatus as recited in claim 15 wherein said beveled surface forms an angle with a plane perpendicular to the axis of the outer extrusion port.
21. In a co-extrusion method for forming a continuous food product having dissimilar inner and outer portions wherein said inner portion is enveloped in intimate contact by said outer portion and said outer portion is a dough material, said method including the steps of:
extruding the inner portion through an inner extrusion port; and enveloping said inner portion with the outer portion and passing the inner portion and the enveloping outer portion through an outer extrusion port thereby continuously forming a composite rope-like food product having said outer portion in intimate contact with said inner portion; the improvement comprising:
providing edible particulate material in said outer portion dough material prior to said outer portion dough material enveloping said inner portion;
passing said outer portion dough material containing particulate material through an exit passage formed by recessing said inner extrusion port a distance D from an outer extrusion port wherein said distance D is sufficient to permit said particulate material contained in said outer portion dough material to pass through said exit passage whereby said outer portion dough material envelops said inner portion;
causing turbulence in said outer portion dough material when said outer portion is enveloping said inner portion at the intersection where the outer dough surrounds said inner dough whereby particles of said particulate material in said outer portion dough material tumble and therefore at least a portion of said particles partially penetrate the exterior surface of said outer portion dough material; and bringing said outer portion dough material into contact with a land surface provided in said outer extrusion part after said turbulence causing step, thereby removing dough covering the part of said particles which penetrate said exterior surface.
extruding the inner portion through an inner extrusion port; and enveloping said inner portion with the outer portion and passing the inner portion and the enveloping outer portion through an outer extrusion port thereby continuously forming a composite rope-like food product having said outer portion in intimate contact with said inner portion; the improvement comprising:
providing edible particulate material in said outer portion dough material prior to said outer portion dough material enveloping said inner portion;
passing said outer portion dough material containing particulate material through an exit passage formed by recessing said inner extrusion port a distance D from an outer extrusion port wherein said distance D is sufficient to permit said particulate material contained in said outer portion dough material to pass through said exit passage whereby said outer portion dough material envelops said inner portion;
causing turbulence in said outer portion dough material when said outer portion is enveloping said inner portion at the intersection where the outer dough surrounds said inner dough whereby particles of said particulate material in said outer portion dough material tumble and therefore at least a portion of said particles partially penetrate the exterior surface of said outer portion dough material; and bringing said outer portion dough material into contact with a land surface provided in said outer extrusion part after said turbulence causing step, thereby removing dough covering the part of said particles which penetrate said exterior surface.
22. A method as recited in claim 21 wherein said outer portion dough material is a chocolate chip cookie dough, said particulate material is chocolate chips, and said inner portion is a chocolate chip cookie dough.
23. A method as recited in claim 1 or 2 wherein said land surface is provided substantially parallel to the axis of said outer extension port.
24. A co-extrusion method for forming a continuous food product having dissimilar inner and outer portions wherein said inner portion is enveloped in intimate contact by said outer portion and said outer portion is a dough material, said method comprising:
providing edible particulate material in said outer portion dough material;
extruding said inner portion through an inner extrusion port;
passing said outer portion dough material containing particulate material through an exit passage formed by recessing said inner extrusion port a distance D from an outer extrusion port wherein said distance D is sufficient to permit said particulate material contained in said outer portion dough material to pass through said exit passage whereby said outer portion dough material envelops said inner portion;
passing said inner portion enveloped by said outer portion dough material through said outer extrusion port thereby forming a composite rope-like food product having said outer portion dough material in intimate contact with said inner portion;
creating turbulence in said outer portion dough material enveloping said inner portion at the intersection where the outer dough surrounds said inner dough thereby causing at least a portion of particles of said particulate material to tumble and to partially penetrate the exterior surface of said outer portion dough material prior to said composite rope-like food product exiting said outer extrusion port;
bringing said outer portion dough material into contact with a land surface provided in said outer extrusion port after said turbulence-causing step, thereby removing dough from the part of said particles penetrating the exterior surface of said outer portion dough material prior to said composite rope-like food product exiting said outer extrusion port.
providing edible particulate material in said outer portion dough material;
extruding said inner portion through an inner extrusion port;
passing said outer portion dough material containing particulate material through an exit passage formed by recessing said inner extrusion port a distance D from an outer extrusion port wherein said distance D is sufficient to permit said particulate material contained in said outer portion dough material to pass through said exit passage whereby said outer portion dough material envelops said inner portion;
passing said inner portion enveloped by said outer portion dough material through said outer extrusion port thereby forming a composite rope-like food product having said outer portion dough material in intimate contact with said inner portion;
creating turbulence in said outer portion dough material enveloping said inner portion at the intersection where the outer dough surrounds said inner dough thereby causing at least a portion of particles of said particulate material to tumble and to partially penetrate the exterior surface of said outer portion dough material prior to said composite rope-like food product exiting said outer extrusion port;
bringing said outer portion dough material into contact with a land surface provided in said outer extrusion port after said turbulence-causing step, thereby removing dough from the part of said particles penetrating the exterior surface of said outer portion dough material prior to said composite rope-like food product exiting said outer extrusion port.
25. A method as recited in claim 24 wherein said turbulence is created by providing turbulence-inducing means on said outer extrusion port.
26. A method as recited in claim 4 or 5 wherein said land surface is generally parallel to the axis of said outer extrusion port.
27. A method as recited in claim 24 wherein said rope-like food product passed through said outer extrusion port is deposited on a continuously moving horizontally disposed conveyor means travelling at a speed substantially equal to or just slightly faster than the rate of extrusion whereby said composite rope-like food product is oriented in a substantially straight line in the direction of movement of said conveyor means in the absence of discontinuities formed in said outer portion.
28. A method as recited in claim 24 wherein said inner portion is a dough material.
29. A method as recited in claim 24 or 25 wherein said distance d is at least about 1.25 times the maxiumum dimension of the largest particles of said particulate material.
30. A method as recited in claim 24 wherein said outer portion is a chocolate chip cookie dough, said particulate material is chocolate chips, and said inner portion is a chocolate chip cookie dough.
31. A method as recited in claim 30 wherein the size of said chocolate chips ranges from about 1,500 chips/pound to 10,000 chips/pound.
32. A method as recited in claim 31 wherein the concentration of said chocolate chips is about 3 to 40 per cent by weight of the outer portion dough.
33. A method as recited in claim 31 wherein said distance d is at least about 1.25 times the maximum dimension of the largest chocolate chips in said outer portion dough.
34. A method as recited in claim 33 wherein said turbulence is provided by said land surface terminating in a generally sharp line of intersection at the interior side of said outer extrusion port.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US06/630,126 US4579744A (en) | 1984-07-12 | 1984-07-12 | Method for co-extrusing dough mass with particulate matter in the outer dough |
| US630,126 | 1990-12-19 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1242610A true CA1242610A (en) | 1988-10-04 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000486643A Expired CA1242610A (en) | 1984-07-12 | 1985-07-11 | Method and apparatus for co-extrusion of a dough mass with particulate matter in the outer dough |
Country Status (9)
| Country | Link |
|---|---|
| US (2) | US4579744A (en) |
| EP (1) | EP0168255B1 (en) |
| JP (1) | JPS6188835A (en) |
| AT (1) | ATE80771T1 (en) |
| AU (1) | AU566859B2 (en) |
| CA (1) | CA1242610A (en) |
| DE (1) | DE3586669T2 (en) |
| IT (1) | IT1185246B (en) |
| PH (1) | PH21964A (en) |
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| US6964562B2 (en) * | 2002-06-11 | 2005-11-15 | Kerry, Inc. | Extruder die and cutter assembly for extruding filled food pieces |
| US7264836B2 (en) * | 2003-03-21 | 2007-09-04 | Kraft Foods Holdings, Inc. | Production of triple coextruded baked bar goods |
| US20050260329A1 (en) * | 2004-05-18 | 2005-11-24 | Christianita Yusuf | Production of liquid center filled confections |
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| US20060034976A1 (en) * | 2004-08-12 | 2006-02-16 | Cotten Gerald B | Dual textured swirled confections |
| US8361528B2 (en) * | 2007-01-29 | 2013-01-29 | Hearthside Food Solutions Llc | Flake cereal or chip and method for making same |
| US20090016150A1 (en) * | 2007-07-13 | 2009-01-15 | Emile Mimran | Ice cream and topping mixing attachment |
| CA2723491A1 (en) * | 2008-05-06 | 2009-11-12 | Kerry, Inc. | Extrusion die with extrusion port having a shaped extrusion outlet |
| PL2351490T3 (en) * | 2010-01-27 | 2019-04-30 | Kraft Foods R & D Inc | A device and a process for continuously feeding chocolate ingredients as well as a system and a process for producing a chocolate mass |
| US8926308B2 (en) | 2010-04-21 | 2015-01-06 | Intercontinental Great Brands Llc | Dough extruders and methods |
| WO2012076381A1 (en) * | 2010-12-08 | 2012-06-14 | Unilever Plc | Apparatus for the production of frozen confections |
| EP2755494B1 (en) | 2011-09-15 | 2015-06-24 | Unilever PLC | Process for producing frozen confectionery products |
| RU2609247C2 (en) * | 2011-09-20 | 2017-01-31 | Нестек С.А. | Edible toy for animals, intended for chewing and play |
| US9380804B2 (en) * | 2012-07-12 | 2016-07-05 | The Hillshire Brands Company | Systems and methods for food product extrusion |
| PL3426048T3 (en) * | 2016-03-10 | 2020-12-14 | Société des Produits Nestlé S.A. | Use of an extrusion die for extruding a food product and use of a food product manufacturing machine. |
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| TWI814059B (en) * | 2020-08-20 | 2023-09-01 | 日商雷恩自動機股份有限公司 | Forming method of composite food containing granules |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2101075A (en) * | 1935-06-03 | 1937-12-07 | Krag Franz Kielsen | Food dispensing device |
| US2433140A (en) * | 1945-12-08 | 1947-12-23 | Abbotts Dairies Inc | Nut applicator |
| US3249068A (en) * | 1962-06-18 | 1966-05-03 | Marlan Company | Bakery machine |
| US3196810A (en) * | 1963-07-26 | 1965-07-27 | Joe Lowe Corp | Automatic machine for forming, cutting and depositing filled baked goods |
| US3228356A (en) * | 1963-08-21 | 1966-01-11 | Schafer Leonhard | Unique die for extrusion of pastry |
| AT293976B (en) * | 1967-03-30 | 1971-11-10 | Uk Ni I K I Prodovolstvennogo | Formwork for installations for manufacturing products with filling, in particular small cakes |
| US3572259A (en) * | 1969-07-08 | 1971-03-23 | Torahiko Hayashi | Apparatus for molding elastic dough materials from bar shapes into spherical shapes |
| US3778209A (en) * | 1971-12-16 | 1973-12-11 | Dan Morrison Meat Pies Inc | Extruder for food products such as tamales |
| US4266920A (en) * | 1975-03-10 | 1981-05-12 | Rheon Automatic Machinery Co., Ltd. | Apparatus for continuously manufacturing multi-layered dough materials |
| US4251201A (en) * | 1978-09-18 | 1981-02-17 | Krysiak Janusz D | Extrusion apparatus |
| US4303431A (en) * | 1979-07-20 | 1981-12-01 | Torobin Leonard B | Method and apparatus for producing hollow microspheres |
| US4447458A (en) * | 1982-06-01 | 1984-05-08 | Vroman Foods, Inc. | Method of and apparatus for producing and processing frozen confections |
| US4511318A (en) * | 1983-03-16 | 1985-04-16 | The Procter & Gamble Company | Dough rolling apparatus for laminated cookies |
| US4528900A (en) * | 1983-10-11 | 1985-07-16 | Nabisco Brands, Inc. | High production apparatus for forming filled edible products |
-
1984
- 1984-07-12 US US06/630,126 patent/US4579744A/en not_active Expired - Fee Related
-
1985
- 1985-07-10 AU AU44759/85A patent/AU566859B2/en not_active Ceased
- 1985-07-10 PH PH32504A patent/PH21964A/en unknown
- 1985-07-11 EP EP85304966A patent/EP0168255B1/en not_active Expired - Lifetime
- 1985-07-11 CA CA000486643A patent/CA1242610A/en not_active Expired
- 1985-07-11 AT AT85304966T patent/ATE80771T1/en not_active IP Right Cessation
- 1985-07-11 DE DE8585304966T patent/DE3586669T2/en not_active Expired - Fee Related
- 1985-07-12 IT IT21553/85A patent/IT1185246B/en active
- 1985-07-12 JP JP60153905A patent/JPS6188835A/en active Granted
-
1986
- 1986-01-14 US US06/819,153 patent/US4698000A/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| IT1185246B (en) | 1987-11-04 |
| JPS6188835A (en) | 1986-05-07 |
| EP0168255A3 (en) | 1988-01-07 |
| PH21964A (en) | 1988-04-15 |
| AU4475985A (en) | 1986-01-16 |
| JPH0144291B2 (en) | 1989-09-27 |
| US4579744A (en) | 1986-04-01 |
| AU566859B2 (en) | 1987-10-29 |
| IT8521553A0 (en) | 1985-07-12 |
| DE3586669D1 (en) | 1992-10-29 |
| EP0168255A2 (en) | 1986-01-15 |
| US4698000A (en) | 1987-10-06 |
| ATE80771T1 (en) | 1992-10-15 |
| EP0168255B1 (en) | 1992-09-23 |
| DE3586669T2 (en) | 1993-03-04 |
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