BACKGROUND OF THE INVENTION

1 . Field of the invention

[ 0001 J The invention relates to extruded products and more particularly to processing a stream of product from an extruder to achieve a desired shape.

2. Description of the Related Art

[0002] Extruders are used in the preparation of various products, including food products such as ready-to-eat ("R-T-E") cereals. Extruders such as cooker extruders can be desirable because a single machine can produce large quantities of a cooked dough in a short period of time. Such cooker extruders can be used to prepare cooked dough extrudates which can thereafter be formed into individual cereal or snack pieces. The formation of such pieces may involve puffing the pieces to form finished puffed R-T-E cereals. In another variation, the capabilities of the extruder and the characteristics of the cooked cereal dough are such that the dough puffs immediately upon being extruded and is cut into individual puffed pieces at the die head.

SUMMARY OF THE INVENTION

[0003] In summary, the invention is an apparatus and method for producing a substantially spiral shaped food product. The apparatus includes a die defining a plurality of apertures disposed in a circle about a center. The apparatus also includes at least one" cutting blade disposed for rotation about the center and operable to intermittently pass fully across each of the apertures during rotation. The apparatus also includes a plurality of sl icing blades arranged for individual rotation about one of the plurality of apertures. The plurality of slicing blades are also arranged for continuous extension less than fully across the one aperture. The apparatus also includes a planetary coupling arrangement operably disposed to facilitate reciprocating rotation between the at least one cutting blade and the plurality of slicing blades.

[0004] The subject invention further provides for a shaping assembly that produces a discrete spiral shaped food product. The shaping assembly includes a die that defines at least one aperture that is centered on an aperture axis. The at least one aperture extends to an aperture exit and allows for the movement of a stream of food mass through the aperture and out the aperture exit. A shaping tool includes at least one slicing blade that is disposed over at least a portion of the aperture exit to slice the stream of food mass into a pl ural ity of food mass portions. A coupl i ng arrangement engages the shaping tool to faci litate rotation of the slicing blade to spin the plurality of food mass portions into a spiral shaped stream of food mass. The slicing blade simultaneously slices and spins the stream of food mass to create the spiral shaped stream of food mass. A crimping apparatus is used to cut the spiral shaped stream of food mass into the discrete spiral shaped food products.

BRIEF DESCRIPTION OF THE DRAWINGS

(00051 Applications of the present invention wi l l become apparent to those ski lled in the art when the fol lowing description of an exemplary embodiment for practicing the invention is read in conj unction with the accompanying drawings:

[0006] Figure 1 is a schematic view of an exemplary operating embodiment of the invention;

(0007] Figure 2 is a cross-sectional view of a shaping assembly having a shaping tool according to the exemplary embodiment of the invention;

(0008] Figure 3 is left-hand view of a blade of the shaping tool according the exemplary embodiment of the invention;

[0009] Figure 4 is a front view of the blade shown in Figure 3;

(001 0] Figure 5 is a first perspective view of the exemplary shaping assembly wherein a shaping tool supporting plate has been removed;

(001 1 ] Figure 6 is a second perspective view of the exemplary shaping assembly with the shaping tool supporting plate;

[0012] Figure 7 is a cross-sectional view of a shaping assembly having a shaping tool according to a second exemplary embodiment of the subject invention;

[0013 ] Figure 8 is a perspective view of a slicing blade according the second exemplary embodiment of the subject invention;

|0014] Figure 9 is a perspective view of a slicing blade according the second exemplary embodiment of the subject invention;

[0015] Figure 1 0 is a first perspective view of a second exemplary shaping assembly wherein a shaping tool supporting plate has been removed;

(0016] Figure 1 1 is a second perspective view of the second exemplary shaping assembly with the shaping tool supporting plate; | 001 7| Figure 1 2 is a schematic view of a secondary exemplary operating embodi ment of the present inv ention; and

[0018] Figure 13 is a partial perspective view of the second exemplary shaping assembly showing a spiral shaped stream of food mass being feed to a crimper.

DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT

( 001 ) Referring now to Figure 1 , in an exemplary embodiment of the invention, a food mass 1 0 is moved through an extruder 12 to a shaping assembly 14 and turned into a helically-shaped food product 15. The food mass 10 is worked by one or more screws in the extruder 12. The food mass 10 is subject to relatively high pressure such that water within the food mass 10 is superheated. The food mass 10 can be formulated such that the resulti ng discrete food product 1 5 is a snack piece or a cereal piece or any other kind of edible item.

[0020| Referring now to Figure 2, in the exemplary embodiment of a shaping tool, the shaping assembly 1 4 includes a channeling die plate 16 cooperating with the extruder 1 2 and forming one or more exit ports 18. An outlet 20 of the extruder 12 opens to a surface 22 of the channeling die plate 16. The food mass 10, still at high pressure, flows along the surface 22 to the one or more exit ports 1 8. The food mass 1 0 moves through a channel 24 between the outlet 20 of the extruder 1 2 and the exit port 1 8. The channel 24 can be defined by the flat surface 22 and a groove formed in the extruder 12, or by a flat surface of the extruder 12 and a groove in the surface 22, or by an additional plate disposed between the extruder 12 and the channeling die plate 1 6.

[0021 J The shaping assembly 14 includes a die that defines at least one aperture 28 that is centered on an aperture axis 40. The at least one aperture 28 extends to an aperture exit 32 and allows for the movement of a stream of food mass 1 0 through the aperture 28 and out the aperture exit 32. Whi le the die may only define a single aperture 28, the die may define a plurality of apertures 28 that are arrayed about a spindle axis 60, with each of the plurality of apertures 28 being centered on a corresponding aperture axis 40.

[0022) In the exemplary embodiment of the invention, the shaping assembly 14 includes a shaping tool supporting plate 26 adjacent to the channeling die plate 16. The plates 1 6, 26 define apertures 28, 30 al igned and in communication with one another to define the exit port 1 8. The aperture 30 of the plate 26 narrows with the respect to the aperture 28 prior to an exit 32 of the exit port 18 to increase the pressure of the food mass 1 0.

10023 j In an alternative embodiment of the invention, one or more coloring materials can be added to the food mass 10 prior to the exit 32 to modify the visual appearance of the finished food product 1 5. Also, one or more substreams of the food mass 1 0 can be combined to modi fy the taste, appearance and/or texture of the finished food product 1 5. In the exemplary embodiment of the invention, an insert 34 is disposed in the exit port 1 8 to accommodate the addition of two different colors, a first color on the outside of the food product immediately emerging from the exit 32 and a second color on the i nside of the food product immediately emerging from the exit 32. The insert 34 includes a shaft portion 35 that is centered and extends along the aperture axis 40 or axis 40 of the exit port 18.

[0024| With use of the insert 34, the resultant stream of food mass 10 includes a first food mass that is surrounded by a second food mass as the stream of food mass 10 exits the aperture exit 32. The first and second food masses differ from each other by at least one of color, taste and texture. When two food masses are used, a second extruder 12a may be used to feed the second food mass to the insert 34. The second extruder 12a may include an outlet 20a that feeds the second food mass to the insert 34. The second food mass moves through a channel 24a between the outlet 20a of the extruder 12a and the insert 34.

(0025] The food mass 10 exits high pressure conditions at the exit 32. The shaping assembly 14 is disposed adjacent the exit 32 and includes a shaping tool 36 at the exit 32 to induce a spiral or helix shape in the food mass 10 exiting the exit 32. The shaping tool 36 of the exemplary embodiment of the invention i nc ludes a blade 38 extending at least partially across the exit 32. The shaping tool 36 rotates about the aperture axis 40 or center axis 40 of the exit 32 as the food mass 10 passes out of the exit 32.

[0026] In the exemplary embodiment of the invention, the blade 38 extends halfway across the exit 32. A free end or cantilevered end 42 of the blade 38 (shown in Figures 3 and 4) is disposed in a groove 44 of the shaft portion 35 to reduce the likelihood of deflection o f the blade 38. The groove 44 is annular and extends around the axis 40. The exemplary blade 38 includes a notch 46 shaped to correspond to the shape of the bottom of the groove 44. In one possible alternative embodiment of the invention, a blade could extend fully across the exit 32 in place of the blade 38 that extends partially across the ex it 32.

[ 0027] In an alternative embodiment, the shaping tool 36 includes at least one sl icing blade 38 that is disposed over at least a portion of the aperture exit 32 to slice the stream o f food mass 1 0 into a plurality of food mass portions. The slicing blade 38 si multaneously slices and spins the stream of food mass 10 to create the spiral shaped stream of food mass 1 1 exiting the aperture exit 32. A slicing blade 38 has a blade th ickness t _b that extends axially along the aperture axis 40 to slice the stream of food mass 1 0 into the plurality of food mass portions as the stream of food mass 10 exits the aperture ex it 32. The thickness of the slicing blade 38 allows for the slicing blade 38 to si multaneously slice and spin the stream of food mass 1 0 into the spiral shaped stream of food mass 1 1 that exits the aperture exit 32. In the preferred embodiment, the slicing blade 38 slices the stream of food mass 1 0 into a plurality of equally sized food mass portions. Whi le a single slicing blade 38 may be used, as seen in Figure 8, a plurality of sl icing blades 38, as seen in Figure 9, may be used.

[0028] As seen in Figure 8 and 9, the shaping tool 36 may include a plate portion

62 that is O-shaped and has an outer plate periphery 66 and an inner plate periphery 68. Whi le the exemplary embodiment the plate portion 66 is O-shaped, the plate portion 66 may be any shape known in the art. The inner plate periphery 68 defines a plate opening 70 that overl ies the aperture exit 32. The stream of food mass 10 is fed from the aperture exit 32 and through the plate opening 70. The plate portion 62 may include at least one support portion 64 that extends outwardly from the outer plate periphery 66. The support portion 64 defines a support opening 72 that is capable of receiving a securing mechanism, such as a pin or screw, to secure the plate portion 62 to the shaping assembly 14. In the preferred embodiment, the plate portion 62 is secured to a satellite gear 48 such that the plate portion 62 rotates with the satellite gear 48 in operation.

[0029| As seen in Figure 8, the slicing blade 38 extends across the plate opening

70 with the blade thickness ¾ extending axially along the aperture axis 40 to slice the ax ial ly fed stream of food mass 1 0 into a plural ity of food mass portions. It should be appreciated that the plurality of food mass portions results from a single rope of stream of food mass 10 being sliced by the slicing blade 38 as the stream of food mass 10 is fed through the slicing blade 38. In the preferred embodiment, the plural ity of food mass port ions are equal ly sized.

[0030] As the plate portion 62 and the slicing blade 38 disposed within the plate opening 70 are rotated, the plurality of food mass portions are spun into the spiral shaped stream of food mass 1 1 . When a plurality of slicing blades 38 are used, as seen in Figure 9, the slicing blades 38 may be spaced equally about the inner plate periphery 68 of the plate portion 62 to sl ice the stream of food mass 1 0 into a plurali ty of equal ly sized food mass portions. In this alternative embodiment, the plurality of sl icing blades 38 intersect or engage each other at the center of the plate opening 70.

[0031 j The shaping tool 36 is fixed to a satellite gear 48. The shaping tool 36 is releasibly fixed to the gear 48 such that the shaping tool 36 can be replaced as required. The exemplary shaping tool 36 is rotated about the axis 40 by the cooperation between the satel l ite gear 48. a primary or sun gear 50, a spindle 52, and a motor 54 (shown in Figure 5 ). The motor 54 rotates the spindle 52. The spindle 52 and the primary gear 50 are fixed together for concuiTent rotation with one another about an axis 60 or spindle axis 60. The primary gear 50 and the satellite gear 48 are engaged for reciprocating rotation with respect to one another. In addition, the primary gear 50 and the satellite gear 48 may be engaged for any rotation with respect to one another.

[0032] The plates 16 and 26 include a plurality of exit ports similar to exit port 1 8; the exit ports being arrayed around the axis 60.

10033 ] The arrangement and operation of the shaping tool 36 results in the food mass 1 0 being curled, spiraled, and/or helical shaped downstream of the shaping tool 36. The speed of rotation of the shaping tool 36 about the axis 40 can be varied to vary the extent or degree of curling. In another words, the relative tightness of the helix can be varied by varying the speed of rotation of the shaping tool 36. Also, the speed at which the food mass 1 0 ex its the exit 32 can be varied in combination with varying the speed of rotation of the shaping tool 36 to vary the degree of curling.

[0034] The shaping assembly 1 4 of the exemplary embodiment of the invention inc ludes a cutter 56 to separate the stream of the food mass 10 into discrete food pieces 1 5. The cutter 56 can include one or more blades 58 rotating about the axis 60. The axis 60 the exemplary embodiment of the invention is the center axis of the extruder 12 and is spaced from and parallel to the axis 40. The cutter 56 is fixed with respect to the gear 50 and the spindle 52 for concurrent rotation. The speed of rotation of the cutter 56 about the ax is 60 can be varied relative to the speed of rotation of the shaping tool 36 by modifying the gear teeth, or gear ratio, of the gears 48 and 50.

10035] in addition to the cutter 56, a crimping apparatus 74 may be used to sever the discrete spiral shaped food products 1 5 from the stream of food mass 1 0. The cri mping apparatus 74 may be used to separate the spiral shaped stream of food mass 1 1 into the discrete spiral shaped food products 1 5. That is, the crimping apparatus 74 pinches and cuts the spiral shaped stream of food mass 1 1 into the discrete spiral shaped food product 1 5. In the exemplary embodiment, the crimping apparatus 74 is spaced from the shaping tool. The crimping apparatus is separate and distinct from the shaping assembly 14.

[0036] In the exemplary embodiment, the crimping apparatus 74 includes at least one receiving port 76 that is in communication with the aperture exit 32 of the aperture 28. The receiving port 76 receives the spiral shaped stream of food mass 1 1 from the shaping tool 36 to separate, pinch or cut the spiral shaped stream of food mass 1 1 into the discrete spiral shaped food product 1 5.

[0037] While the crimping apparatus 74 may include a single receiving port 76 that corresponds to a single aperture exit 32 in the shaping tool 36, the crimping apparatus 74 in the preferred embodiment includes a plurality of receiving ports 76. If a plurality of receiving ports 76 are utilized, each one of the plurality of receiving ports 76 is in communication with one of the aperture exits 32 of the plurality of apertures 28. That is, each of the receiving ports 76 corresponds to an aperture exit 32 to receive the spiral shaped stream of food mass 1 1 from the corresponding aperture 28 and separate this spiral shaped stream of food mass 1 1 into the discrete spiral shaped food products 1 5.

[0038] In the exemplary embodiment, the crimping apparatus 74 may be any cri mper or cutter known in the art, including, but not limited to a cereal crimper.

[0039] Thus, a planetary coupling arrangement is defined between the gears 48, 50 to faci l itate rotation between the cutting blade 58 and the shaping blade 38. Embodiments o f the invention can include a pl urality of shaping blades 38 and a plurality of cutting blades 58. The planetary coupling arrangement allows for a compact arrangement for a plurality of food streams exiting a plurality of exit ports. [0040] The coupling arrangement engages the shaping tool 36 to facilitate rotation of the slicing blade 38 to spin the plural ity of food mass portions into a spiral shaped stream of food mass 1 1 . The coupling arrangement includes a spindle 52 that is centered on a spindle axis 60. The coupling arrangement engages both the shaping tool and the spi ndle 52 to faci litate rotation between the shaping tool and the spindle 52 as the spindle 52 is rotated. The spindle 52 may be rotated by a motor. The primary gear 50 is centered on the spindle axis 60 and may be fixed to the spindle 52 to rotate with the spindle 52 about the spindle axis 60. The satellite gear 48 is centered on the aperture axis 40 and engages the primary gear 50 to rotate with the primary gear 50 and about the aperture axis 40. When a plurality of apertures 28 are disposed in the die, a plurality of satellite gears 48 are used. Each of the aperture exits 32 has a satellite gear 48 that is disposed about the aperture 28 to rotate a slicing blade 38 secured thereto over the aperture exit 32 to slice the stream of food mass 1 0 into a plurality of food mass portions and simultaneously rotate the plurality of food mass portions to form the spiral shaped food mass 10.

[0041 ] The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modi fications to the disclosed embodiment may become apparent to those skilled in the art and do come w ithin the scope of the invention. Accordingly, the scope of legal protection afforded this invention can only be determined by studying the following claims.