IMPROVED DOUGH DELIVERY SYSTEM & METHOD

This is an international patent application filed under 35

U. S. C. §363 claiming priority under 35 U. S. C. §119 (e) (1), of United

States provisional patent application Ser. No. 60/977,252, filed October 3, 2007, and incorporated herein by reference in its entirety .

TECHNICAL FIELD

The present invention relates generally to the processing of viscous and/or extrudable material such as foodstuffs, e.g., dough or dough-like material, and, more particularly, to a improved dough delivery system which enables production of a plurality of extruded and/or co-extruded dough products from characteristic doughs discharged from the delivery system.

BACKGROUND OF THE INVENTION

Extruded foodstuffs, in the form of confections, cereals, pet food, etc. are well known, as are the operations and equipment associated with the manufacture or production of same. Numerous production related challenges have been identified, primarily owing to marketplace demands for greater efficiency, whether predicated upon notions of throughput, output, or production versatility. Moreover, efforts to distinguish goods in the marketplace have necessitated a departure in the nature of produced products (i.e.,

efforts to combat refrains of "seen it; done it" via the production of novel foodstuffs and the like) , as well as the manner in which heretofore known and developing products are packaged and presented to consumers (e.g., the delivery of at least two or more "different" products via a "multi-pack") . Therefore, in as much as issues pertaining to extrusion per se and the attendant operations of distribution and/or of metering viscous food and non-food material no doubt remain, there is a need to address issues relating to and/or to improve upon the provision of a single extruder or similar device capable of simultaneously processing different characterized intermediaries, and most advantageously to do so in furtherance of simultaneously and selectively producing a variety of differently characterized products.

Christensen et al . (U.S. Pat. No. 5,776,534) and Cremers et al. (U.S. Pat. No. 5,919,509), each of which describe with some particularity the challenges and/or shortcomings of "current" practices, sought to provide apparatus and methods for providing a plurality or multiplicity of dough streams from a single extruder wherein each of the streams has a distinct color and/or flavor, with the latter providing specificity with regard to a die head and registration section thereof for use with the underlaying apparatus. In each teaching, which appears generally representative of the art, there exists a direct correspondence or correlation between the formed distinct dough streams and the die ports of the

multi-port extrusion die head.

Tedman et al . (U.S. Pat. No. 6,719,448 B2) likewise purports to have addressed the shortcomings of the prior art, and generally provides for the simultaneous production of differently characterized final products using a single, initially processed dough stream. Again, product formation is predicated upon the passage of each of the intermediately processed dough streams to and through a corresponding dedicated die port of die ports of the multi-port extrusion die head assembly. Smith et al . (U.S. Pat. Appl . Pub. No. US 2007/0172566 Al) provide a cavity transfer mixing operation down stream of a single, double or triple dough source supply. Each cavity transfer mixer of the cavity transfer mixing operation is configured or operated to produce a distinct single dough output in lieu of passage through a die head.

Hannaford (U.S. Pat. Appl. Pub. No. US 2005/0260320 Al), the entirety of which is incorporated herein by reference, provide systems and/or processes, characterized by flow metering means, for producing plural, uniquely characterized metered dough products from a single dough source. Optional subsequent processing via an extrusion or co-extrusion die is likewise contemplated.

In as much as efforts have be made to more efficiently or expeditiously produce a multiplicity or plurality of unique dough products from an initial dough source, heretofore known systems

and/or approaches do so as a result of equating unique substreams processed and/or produced from the initial dough source with a

"finished" dough product. More particularly, one or more initially processed (i.e., altered) doughs from a dough source are correspondingly directed to a dedicated subsequent processing step

(e.g., die ports of a multi-port extrusion die head, cavity transfer mixers of a cavity transfer mixing operation, flow metering cells of a flow metering means, etc.) .

In light of the foregoing, and as a practical matter, the production of several uniquely characterized varieties of finished dough products from a single line are greatly limited/hindered. For example, and without limitation, serial operation of the line is generally required when multiple products are to be commonly packaged (i.e., production of product "A" or product A family members, then line shut down/clean-up followed by product "B" production with storage of product "A, " then line shut down/cleanup followed by product "C" production with the storage of product "B" and the continued storage of product "A, " then further and aggregate processing in furtherance of collating, packaging, etc.) . Alternately, if extrusion of a series of different extruded products on the same line are sought, then line shut down/clean-up followed by die change out or the like, and a line restart is necessary .

Thus, it remains advantageous to improve known devices,

systems, and processes relating to the extrusion, dispensing, and/or processing of viscous materials such as dough or dough-like foodstuffs in furtherance of producing multi-component products. More particularly, it is desirable to eliminate elements while retaining functionality in such processes or systems, and further, to reassess unit operation functionality in furtherance of providing advantageous processing flexibility and versatility. More particularly, it is believed advantageous to provide, collectively or in the alternative, a system, apparatus, process and/or method to produce or greatly aid in the production of a multi-configured dough product, and/or a multiple-colored (or, textured, or flavored, or scented, etc.) dough product from a single source of dough, especially in the context of feeding extrusion or co- extrusion dies and the like, wherein the dough supply is adapted to selectively direct, pass or form substreams of streams of dough of at least a single characteristic dough in furtherance of producing a plurality of varied dough products.

BRIEF SUMMARY OF THE INVENTION A dough delivery system for delivery of a multiplicity of characteristic dough intermediaries having origins in at least one, and preferably, at least two characteristic doughs to a die characterized by a plurality of die orifices is provided. The dough delivery system comprises a dough supply adapted to selectively

form and/or pass a subset of characteristic dough intermediaries of the multiplicity of characteristic dough intermediaries in furtherance of producing a plurality of multi-component dough products wherein each multi-component dough product of the plurality of multi-component dough products comprise a further subset of the subset of characteristic dough intermediaries of the multiplicity of characteristic dough intermediaries.

Advantageously, the subset of characteristic dough intermediaries of the multiplicity of characteristic dough intermediaries formed, passed, produced, etc. may be subsequently processed via passage to select orifices of a plurality of die orifices of a die. Similarly, the subset of characteristic dough intermediaries of the multiplicity of characteristic dough intermediaries formed, passed, produced, etc. may be subsequently processed via passage to flow metering means in advance of or in lieu of die delivery. It is contemplated that dough from a single source may be selectively processed to form a select variety of multi-configured dough products, and/or that dough from greater than a single source may be likewise selectively processed to form a select variety of multi-configured dough products characterized by at least two unique dough sources or intermediaries.

Moreover, the system dough supply may advantageously comprise at least two dough manifolds, a characteristic dough of the at least two characteristic doughs passing through each dough manifold

of the at least two dough manifolds. In as much as plural discrete manifolds may be provided, multi-chambered manifolds are especially well suited for the practice described herein. For example, a characteristic dough of the at least two characteristic doughs may passing through each compartment of compartments of the multi ^¬ compartment manifold.

Further still, wherein the multi-compartment manifold includes a multiplicity of manifold discharge orifices, it is contemplated that the selective formation and/or passage of a subset of characteristic dough intermediaries of the multiplicity of characteristic dough intermediaries is accomplished by select receipt of orifice plugs within select manifold discharge orifices of the multiplicity of manifold discharge orifices. Moreover, a valve array operatively linked to the multiplicity of manifold discharge orifices, or provision of an apertured mask plate for receipt over at least a portion of the multiplicity of manifold discharge orifices is likewise contemplated.

More specific features and advantages obtained in view of the summary features will become apparent with reference to the drawing f igures and DETAI LED DESCRIPT ION OF THE INVENT ION .

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings wherein like numerals are used to designate like parts of the invention throughout the figures:

FIG. 1 represents an exemplary, non-limiting dough processing system plan for the production of "filled" rope twists, more particularly, paste and licorice extruders are shown supplying a work station characterized by a flow metered dough manifold in combination with a co-extrusion die;

FIG. 2 represents a section about line 2-2 of FIG. 1, chambers of a multi-chambered extruder manifold shown in relation, to among other things, flow metering means;

FIGS. 3 & 3A represent a cross-section of a six (6) chambered extruder manifold, and an associated egress orifice configuration thereof, respectively;

FIGS. 4 & 4A represent a cross-section of a three (3) chambered extruder manifold, and an associated egress orifice configuration thereof, respectively; FIG. 5 & 5A represent a non-limiting adaptation of the chambered manifold of FIG. 4, namely, the select addition of orifice plugs to thereby permit select egress of a subset of characteristic dough intermediaries from the extruder manifold for subsequent select processing; FIG. 6 & 6A represent a further non-limiting adaptation of the chambered manifold of FIG. 7, namely, the select addition of a mask plate to thereby permit select egress of a subset of characteristic dough intermediaries from the extruder manifold for subsequent select processing;

FIG. 7 represents the adapted chambered manifold of FIG. 6 in operative combination with flow metering means;

FIG. 8 represents an adapted variant of the structures and relations of FIG. 2; FIG. 9 represents the multi-chambered extruder manifold of FIG. 8 shown partially disintegrated from the flow metering means thereof;

FIG. 10 represents a perspective view of the partially disintegrated structures of FIG. 9, including a view of a manifold plate of the multi-chambered extruder and metering cells of the flow metering means.

DETAILED DESCRIPTION OF THE INVENTION

In advance of the subject detailed description, several threshold observations are in order. It is to be understood that there is to follow representative or exemplary environments, contexts, or processes within which the subject invention is indicated as operative. Suffice it to say that the particulars of such environments, contexts, or processes are intended generally as just that, and are thereby not to be interpreted as limiting the scope of the subject invention/inventions, which are delimited by the appended claims. Moreover, in as much as the following discussion is directed to one or more advancements not inconsistent with Applicant's general field of endeavor and heretofore known

efforts, e.g., U.S. Pat. No. 5,536,517 entitled "Multidie Positive Displacement Metering Apparatus and Process, " incorporated herein by reference in its entirety, along with the previously cited '320 publication entitled "Multicolored Flow Divider, " for the sake of clarity, this discussion proceeds in light of the scope and parameters of those teachings.

With regard to the figures, FIGS. 1 & 2 are generally directed to an exemplary, non-limiting dough processing system which will serve as a basis of further discussion, namely, a system characterized by initial dough extrusion with discharge to a multi- chambered extruder manifold; passage of unique dough streams/substreams from the manifold to flow metering means; and, subsequent co-extrusion of the metered unique dough streams/substreams. Manifold or barrel egress is depicted in FIGS. 3/3A on the one hand, and FIGS. 4/4A on the other hand wherein fixed unique dough from multi-compartment manifolds is discharged for subsequent processing, e.g., flow metering or extrusion via ports of a multi-port die head or the like. Non-limiting inventive adaptations of a chambered manifold or barrel are generally depicted in FIGS. 5/5A & 6/6A, with a chambered manifold so adapted in operative combination with flow metering means depicted in FIG. 7. An adapted variant of the manifold, metering and coextrusion die subassembly of FIG. 1 is depicted in FIG. 8, a hinged linkage or interface for and between the manifold and metering means thereof

depicted in FIGS. 9 & 10.

With reference now to FIGS. 1 & 2, there is depicted a system 20 for the production of "filled" rope twists. Dough extruders feed a work station characterized by flow metered manifolds and a coextrusion die, more particularly, a "paste" extruder 22 feeds a multi-chambered paste manifold or barrel 24, and a "licorice" extruder 26 feeds a multi-chambered licorice manifold or barrel 28. Multiple characteristic paste intermediaries pass from the paste manifold 24 into flow metering means, e.g., positive displacement metering means 30, more particularly, and as shown, a series of flow divider cells 32 characterized by driven gear pairs. The multiple characteristic licorice intermediaries are similarly processed. Thereafter, as shown, metered streams of characteristic paste and licorice intermediaries are fed to, in the instant process, a rotating co-extrusion die 34 to produce filled rope twists .

As should be readily appreciated, each chamber, compartment, etc. of the manifold is intended to delivery a unique or specifically characterized dough or dough intermediary. Add mix means for selectively modifying an initial dough material so as to form unique or specifically characterized dough or dough intermediaries are well known in the art, see e.g., the teachings cited earlier and incorporated herein by reference, especially Applicant's prior teachings, and as such will not be further

detailed here.

With reference now generally to manifold or barrel 40 of FIGS.

3/3A & 4/4A, each specifically characterized dough or dough intermediary passes from its manifold or barrel chamber, compartment, etc. 42, via regulated channels, passageways, etc.

(not shown) , to manifold egress means, more particularly, a multiplicity of manifold discharge orifices 44 (see e.g., FIGS. 3A or 4A) . For example, in connection to the six (6) compartment manifold of FIG. 3, dough intermediaries A-F are indicated as occupying same. Adaptation of the manifold or barrel, as by drilling/boring and providing flow regulating means such as plugs, valves, etc. results in the formation of substreams of each of characteristic dough intermediaries A-F as indicated by the "fixed" adaptation of the barrel; with reference to FIG. 3A, a first row 46 of barrel egress apertures or orifices 44 permit discharge of intermediaries A-C in an alternating arrangement as indicated, with an off-set second row 48, relative to first row 46, of barrel egress apertures or orifices 44 permitting discharge of intermediaries D-F in an alternating arrangement as indicated. As a practical matter, the manifold or barrel 40 is advantageously equipped with a manifold or discharge plate 50 (see e.g., FIG. 9 or 10) which is adapted to permit operative union of the manifold to the flow metering means.

Referring now generally to FIGS. 5-7, there is depicted first

(FIG. 5/5A) and second (FIG. 6/6A) representative inventive adaptations to/for a manifold or barrel, with the adapted manifold of FIG. 6 shown in operative combination with flow metering means

(FIG. 7) . Each approach, including alternate functional/structural equivalents, permits conversion of what is essentially a fixedly plumbed or "hard-wired" extruder manifold into a user select processing device or apparatus. Within a given parameterization of a extruder manifold, see e.g., manifold 40 of FIG. 4, wherein dough intermediaries X-Z are directed for egress in sequential rows so as to form and pass streams of characteristic dough intermediaries X-Z as indicated, subsets or substreams of streams of the characteristic dough intermediaries being selectively passed on for further select processing.

In connection to FIGS. 5/5A, the select addition of orifice plugs 52 (i.e., the selective receipt of orifice plugs within orifices delimiting manifold egress) to thereby permit select egress of chambered doughs from the extruder manifold or barrel for subsequent select processing is depicted. In keeping with the X-Z dough intermediaries of FIG. 4, via the select addition of orifice plugs 52, select substreams of streams of characteristic dough intermediaries X-Z (i.e., Xl, X4, Xl, XlO; Y2, Y5, Y8, YIl; Z3, Z6, Z9, Z12 as indicated) are sent or delivered to select cells of the flow metering means, or into select dies associated with formation of a "finished" product. With a configuration as

indicated in FIG. 5A, for any three by three array of manifold orifices, one substream of each stream of dough intermediary X-Z is discharged so as to be vertically off-set from the others. It should be readily appreciated that numerous manifold discharge orifice subsets are available, more particularly, those that may be quickly set, reset etc., at the will of the operator as by select integration of plugs or the like to/with an extruder manifold.

In connection to FIG. 6/6A, the select addition an apertured "mask" plate 54 (i.e., the selective receipt of a uniquely patterned plate intended to operatively overlay the manifold discharge orifices as by known mechanical fasteners or the like) to thereby permit select egress of chambered doughs from the extruder manifold or barrel for subsequent select processing is depicted. As shown, the mask plate 54 is patterned so as to acheive the manifold discharge output of the adapted manifold of FIGS. 5/5A. Again, it should be readily appreciated that numerous manifold discharge orifice subsets are available, more particularly, those that may be quickly set, reset etc., at the will of the operator as by select integration of a select mask plate to/with an extruder manifold. In connection to FIG. 7, the adapted extruder manifold of FIG. 6 is depicted in operative combination with flow metering means, advantageously, but not necessarily, flow metering means comprising a multi-cell positive displacement apparatus 30 as depicted in herein, see e.g., FIG. 10. In addition to the inherent value of

flow metering in advance of further or final dough stream or substream processing, considerable process versatility is provided via the ability to selective and easily direct at least a portion of the metered streams for subsequent processing (see e.g., Applicant's '320 publication) . Thus, the synergistic effects of an adapted extruder manifold, as described and contemplated, with a multi-cell flow divider offers the potential for great operational advantage .

Finally, reference is now made to FIGS. 8-10 wherein a further advancement is depicted in relation to a flow metered dough intermediary operation, and more particularly, and alternately, in connection to practical considerations for the disclosed and otherwise contemplated/ascertainable functional/structural equivalents of the extrusion manifold adaptations of FIGS. 5 & 6. As is readily appreciated via comparison of FIGS. 9 & 10 with FIG. 8, a hinged interface 60 for and between an extruder manifold 40 and flow dividing means, e.g., positive displacement metering means 30, is provided. In as much as the barrel 40, as shown, is pivotably or hingedly disengagable from the remainder of the subassembly 62 (i.e., the subcombination of the flow dividing means and the co-extrusion die), processing applications etc. may dictate that the flow dividing means or a subcombination including same be the "traveling" element as opposed to a static or fixed element.

As shown, a linkage 64 unites the extruder barrel 40 to/with

the flow metering apparatus 30. A link 66, extending from the barrel 40 and characterized by an elongate slot 68, is operatively received upon a fastener 70 or the like that is anchored to or otherwise integrated with the flow metering apparatus 30. As indicated with reference to FIG. 9, the link slot 68 permits translation of the barrel 40 relative to the fastener 70 (i.e., flow metering apparatus 30) as well as pivot motion of a free end thereof for operative attachment of the barrel to the flow metering apparatus. With such arrangement and/or configuration, in addition to greatly facilitating maintenance and cleaning operations for all elements of the subassembly (i.e., the barrel, the flow metering apparatus and the die) , such easy access to the manifold or barrel plate (FIG. 10) permits quick and easy adaptation thereof in furtherance of selectively altering the discharge of dough intermediaries.

It is to be understood that this disclosure, in many respects, is only illustrative. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention and scope of the appended claims. Changes may be made in a variety of details, particularly in matters of shape, size, material, and arrangement of parts, as the case may be, without exceeding the scope of the invention. Moreover, the terms and expressions that have been employed in the foregoing

specification are used as terms of description and not of limitation, and are not intended to exclude equivalents of the features shown and described or portions of them. Accordingly, those of ordinary skilled in the art will realize that the invention is intended to encompass all modifications and alternative arrangements included within the spirit and scope of the invention, as set forth, defined and limited only by the appended claims.