Food or edible material: processes – compositions – and products – Filling cavity in edible solid preform with edible material – Dough type preform
Reexamination Certificate
2000-04-28
2002-04-23
Corbin, Arthur L. (Department: 1761)
Food or edible material: processes, compositions, and products
Filling cavity in edible solid preform with edible material
Dough type preform
C426S284000, C426S514000, C426S516000, C426S550000, C426S637000
Reexamination Certificate
active
06375997
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns a process for making hand held and convenience snack food products comprising potato shreds. The process comprises formulating dough having a moisture content of about 55% to about 75%, preferably about 60% to about 72%, comprising potato shreds, cellulose gum, starch and other ingredients. The dough is extruded through a multiple extrusion nozzle, which in preferred embodiments comprises an outer extrusion segment and an inner extrusion segment which can be inserted into the outer extrusion segment to provide for extrusion of continuous ropes or casings having two or more axial cavities which are filled with savory fillings. If the continuous ropes are not of desired size and/or shape following extrusion, the continuous ropes may optionally be subjected to a roll over operation. The continuous ropes are cut and crimped to form uncooked cut casings. The uncooked cut casings are then cooked by baking, frying, par-baking or par-frying, combinations thereof or otherwise, and frozen to obtain the handheld convenience snack food product.
2. The Related Art
Hand held convenience snack foods having a filling surrounded by a casing typically have casings made from bakery formulas involving pastry dough. Bakery formulas generally involve grains and flours and the pastry dough tends to be homogenous which is both easy to form by extrusion or other means, or otherwise easy to fill. An example is cereal bar mixes made with pastry dough comprising multi-grains, and although these materials tend to have coarser grains compared to other pastry dough ingredients, the particles have substantial uniformity thus facilitating extrusion and filling.
Potato shreds are nonuniform and have bigger and longer particle size compared to grains and flours. As a result, dough comprising potato shreds lacks uniformity and is more difficult to handle and extrude. Dough comprising potato shreds will have the tendency to form open surfaces after extrusion or during the forming or filling process.
U.S. Pat. No. 4,888,192 concerns a method of extruding baked goods in the form of an extruded rope comprised of three materials. An outer expanded crispy layer and two non-dough filler materials are described as components. The dough is extruded under pressure and expands upon release from the nozzle surrounding a pair of tubes which place the filling into the center of the tubes. The filling material is supplied to the extruder through separate tubes and there is no discussion in the patent that the nozzle and/or extruder can be used to extrude dough comprising potato shreds.
U.S. Pat. No. 4,259,051 addresses extrusion apparatus for forming a hollow foodstuff of extruded plastic material which can be simultaneously filled. There is no discussion in the patent that the apparatus can be used for potato shred dough, and the apparatus cannot likely be used for extruding a plurality of axial cavities.
U.S. Pat. No. 5,527,179 describes an apparatus for extruding dough in hollow form through the use of a solid pin within the extrusion nozzle. U.S. Pat. No. 4,900,572 describes an apparatus for making dog food where an outer layer is extruded into a chamber having sleeves. An inner layer is extruded through the sleeves and, thus, the inner layer becomes covered by the outer layer. U.S. Pat. No. 5,645,872 describes extrusion of hollow shapes of material subject to coagulation by allowing gas or liquid to flow into the center cavity after extrusion to foster coagulation and avoid collapse of the hollow extruded shape.
U.S. Pat. No. 4,828,856 describes hash brown type potato products made from de-hydrated formed or fabricated potato shreds which can be re-hydrated and formed into patties said to simulate fresh cut potato products. The re-hydrated mass has a moisture content of 40% to 55% so that the product can be sheeted with a 1 to 2 millimeter opening between sheeting rolls. The potato dough made from the shreds described in this patent cannot be extruded because of needed high extrusion pressures which are said to rupture a significant portion of the potato cells. Non-critical ingredients for these products are carboxymethylcellulose, which is said to be a processing aid for the sheeting operation, and certain food gums to reduce fat or oil pickup (uptake) during frying. U.S. Pat. No. 5,492,704 describes a process for making potato strands comprising shreds for use in hash brown potatoes, and re-hydration of the shreds in the form of sheets to make a hash brown potato product is exemplified in the patent.
U.S. Pat. No. 5,891,596 describes potato mixtures shaped by extrusion or otherwise that are processed as a reduced fat flash frozen potato product. The formed potato shapes are made from blended potato pieces, and the blended product contains small pieces and, thus, not potato shreds. U.S. Pat. No. 3,399,062 describes dehydrated granular products, such as crushed dehydrated potatoes, containing some aggregates of individual cells, re-hydrated at low temperature in the presence of cellulose ether thermal gelling agent and extruded to obtain a french fried potato product.
U.S. Pat. No. 3,975,549 describes agglomerated dehydrated potato products made from dehydrated potato particles that, after re-hydration with a binder, are extruded to form french fries. The binder may be either a gum, such as guar gum, or free starch from modifying the potato solids. U.S. Pat. No. 3,987,210 describes an extruded french fried potato product comprising dehydrated potatoes in the form of flakes, granules, flour, diced pieces or mixtures thereof with a binder comprising more than about 25% amylose starch. The starch is said to retrograde when heated with water to form a film around the product and provide an oil barrier.
U.S. Pat. No. 3,486,673 describes extruded french fried potato products comprising dehydrated mashed potatoes, methyl cellulose and polygalacomannan gum, which are said to be essential ingredients. The combination of ingredients reportedly provide the product with an irregular external crust which permits the product to pick up a modest amount oil during frying. U.S. Pat. No. 5,242,699 addresses an application of a hydrocolloid coating to potato strips to provide an exterior crust when the strips are blanched or par-fried which may also retard oil adsorption into the potato strip. U.S. Pat. No. 5,620,727 concerns use of low molecular weight ionic hydrocolloid compositions to make film to reduce oil uptake. U.S. Pat. No. 3,687,688 concerns immersion of potato into a batter comprising sodium alginate for moisture control, and U.S. Pat. No. 4,900,573 concerns batter comprising hydroxypropyl methylcellulose which is said to function as an oil barrier.
Fat absorption/uptake of fried foods is one of the major concerns of consumers, particularly with respect to dietary concerns as fat provides approximately 9 calories. per gram to the food. Also, fat leaching from a prepared product during re-heating or reconstituting causes a greasy feel to food, and imparts undesirable organoleptic qualities to the food.
An object of the invention is a process that allows for the extrusion and processing of dough material comprising potato shreds to obtain an organoleptically acceptable and pleasing hand held convenience snack food, which can be easily reconstituted by the consumer, having a casing with axial cavities and savory fillings. These objects are achieved by the process and equipment described herein, particularly with regard to the moisture content of the dough material which enables extrusion without impairing the characteristics of the potato shred dough, the multiple extrusion nozzle and the cutting and crimping step of the process which isolates the savory filling material within the casing.
It is a further object of the invention to enable extrusion of a product having an outer casing with one or more axial indented ridge type connectors that allows sections of the casing to be broken apart so that the product can be consumed individually. A further object
Baggen Marc
Panarisi Joseph
Sheen Shiowshuh
Slesinski Alan J.
Bestfoods
Corbin Arthur L.
Plotkin Ellen
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