Note: Descriptions are shown in the official language in which they were submitted.
CA 02475720 2004-07-26
PRODUCTION OF TRIPLE COEXTRUDED BAKED BAR GOODS
Related Applications
[0001] -- ~ ~ _ ,
Field Of The Invention
[0002] This invention relates to the production of bar-shaped baked goods
having
two visually apparent fillings using triple coextrusion.
Background of the Invention
[0003] In the mass production of snack foods or other food products, the
extrusion
process may be employed because it economically provides a high volume of
product
having a uniform configuration and structure. Usually, when designing an
extrusion
process and/or apparatus, the desired properties of the end product must be
considered
along with the processing characteristics of the individual components that
make up the
product. Often, these considerations may require the use of a specific method
and/or
apparatus to achieve a particular result.
[0004] In the design of mass production facilities for the coextnzsion of
snack
products, flow properties such as viscosity, handling properties or other
processing
characteristics of a particular material stream must be factored in. Certain
material
streams may be sensitive to variations in flow rate or direction caused by a
circuitous flow
CA 02475720 2004-07-26
path or obstacles in the flow path. Problems may arise such as high back
pressure,
insufficient mass flow rate and non-uniformity of individual layers in the
product.
[0005] Certain materials may require an extremely smooth and uninterrupted
flow
path in order to remain either in an integral flow stream or a divided flow
stream which is
easily reformed into an integral one. If a change of direction occurs or an
obstacle is
present in the flow path, reformation may be difficult to achieve because the
discrete
streams may not reunite to form a uniform, integral flow. In this instance,
the resultant
product may have unacceptable qualities such as seam lines or striations.
(0006] In other instances, smooth flow paths for the individual streams may be
required to prevent back pressure in pumps and related equipment and low mass
flow
rates, especially for viscous materials.
[0007] Also, coextrusion apparatus often have many potential leak points, due
to
their multiple parts, complex configurations and high operating pressures. As
the number
of concentric layers increase in a coextrudate, for example when three or more
layers are
desired, die complexity increases quite rapidly. Generally, more parts are
needed, flow
paths become disrupted by inlet passages, more potential leak points are
created,
tolerances in the concentric passageways become tighter, flow path directions
change
more frequently or abruptly, and back pressures increase. These problems tend
to become
even more exacerbated as the desired final diameter of the coextrudate rope
and final
product decreases. In producing coextrudate ropes wherein one or more
concentric layers
expand upon exiting the extrusion die, the concentric passageways must be even
smaller
in diameter to achieve a desired final coextrudate rope diameter. For example,
when
coextruding a plurality of fillers with an expandable farinaceous-based cooked
casing,
from a cooker extruder, the casing may expand substantially upon exiting the
triple
2
CA 02475720 2004-07-26
coextrusion die. The outer concentric passage for the casing, and hence the
remaining
inner passageways for the fillings must be sized substantially smaller than
the desired
diameter of the expanded final product.
[0008] After the extrusion step, certain food or snack products are sometimes
shaped in a manner to make them more aesthetically pleasing and/or bite-size.
This
usually requires post-extrusion processing by way of, for example, a candy
making
machine which severs the rope into individual pieces having the shape of the
individual
molds of the candy machine. In the instances where this type of post-extrusion
processing is used, the extrudate rope to be fed into the post-extrusion step
should have a
diameter substantially the same size as the diameter of the final product or
the mold.
Matching of the diameters helps to avoid the production of excessive scrap
during the
continuous molding operation. For example, if a peanut shell-shaped expanded
snack
product is desired, the expanded extrudate rope should be substantially the
same in
diameter as the diameter of the final peanut product. The final product
diameter may be
relatively small if simulation of an actual peanut shell size or bite-size
pieces are desired.
[0009] U.S. Patent Nos. 4,715,803 and 4,748,031 to Koppa disclose an extruder
which provides a triple coextruded product having an inner layer, which is
surrounded, or
enrobed, by an intermediate layer, which is surrounded, or enrobed, by a third
outer-most
layer. The inner layer is a dough having a chewy and moist texture when baked
and the
outer layer is a dough having a crispy texture after baking. These patents
relate
specifically to the introduction of a barrier material between the two dough
layers in order
to achieve the desired product stability and shelf life. The moisture barrier
is injected
through the outer cylindrical layer in a tube upstream of the extruder outlet.
3
CA 02475720 2004-07-26
[0010] A pillow-shaped product, having an outer layer of expanded dough and
two
v
different filler materials is disclosed in U.S. Patent Nos. 4,698,004 and
4,888,192 to
Ramnarine. The penetration of the outer expansible dough by the inner fillers
in the end
product is avoided through the use of a nozzle which can be adjusted to
compensate for
the effects of the fluid flow of the individual streams. The process is
directed to the side-
by-side extrusion of the filler materials.
[0011] U.S. Patent 3,241,503 to Schafer discloses a die for the manufacture of
cookies with concentric rings of different colored dough. The process involves
introducing successive layers of dough through conduits perpendicular to the
die into
annular cavities surrounding a longitudinally extending bore.
[0012] U.S. Patent No. 4,834,999 to Matthews et al discloses triple
coextruding a
meat-based product comprising whole muscle body surrounding a core stuffing,
an outer
casing, and an annular layer of fat between the whole-muscle body and the
outer casing.
[0013) U.S. Patent No. 5,686,128 to Tracey et al discloses the production of a
triple
coextruded snack having a casing material which may be a dough or an
expansible dough
such as a cookie dough, or cracker dough enrobing two fillers. The triple
coextrusion
apparatus includes a unitary die block for all three materials and has smooth
and
uninterrupted flow paths. A small diameter extrudate rope is produced with a
central
filler enrobed by an outer filler, subsequently enrobed by an outer casing
formed from
multiple streams. The outer casing material streams reform into an integral
concentric
layer having no or substantially no seam lines or striations in the outer
casing. The
extrudate ropes may be sufficiently small in diameter, even when the casing is
expanded,
to allow feeding into a candy machine for shaping by molding or crimping to
produce
small diameter snack products without substantial waste or scrap material.
4
CA 02475720 2004-07-26
[0014] Japanese Patent Publication No. 60-070036, published April 20, 1985,
discloses production of three-layered soft food by extruding a core layer,
interlayer, and
outer layer at the same time to mold a three-layered cylindrical material,
rolling the
material while cut into a given size using a cutting and rolling means, and
molding the
material.
[0015] Coextrusion is also used to manufacture mufti-layered plastic articles.
For
example, U.S. Patent Nos. 4,185,954 to Murakami, et al., 5,318,417 to Kopp, et
al., and
5,324,187 to Cook describe apparatus and processes for manufacturing
multilayered
tubular or hollow plastic products where each outer layer is successively
added
downstream to surround the upstream added inner material or materials.
[0016] U.S. Patent Nos. 4,125,585 to Rosenbaum, 4,731,002 to Spence, et al.,
and
4,846,648 to Spence, et al. describe method and apparatus for manufacturing
multilayered
plastic pipe where the inner layer is injected across the central layer and
through a spider.
[0017) U.S. Patent No. 4,364,882 to Doucet describes method and apparatus for
manufacturing multilayered plastic pipe where the central layer is injected
across the
outer layer through a trefoil.
[0018] German patent DT 3044535 (published June 24, 1982) describes method
and apparatus for manufacturing multilayered plastic pipe where one or two
central layers
are injected across the outer layer.
[0019] In producing an extruded baked good having a desired bar shape, such as
a
FIG NEWTON~, configuring die orifices to the same bar shape or cross-section
desired
for the baked good can result in an extruded, unbaked dough with the desired
shape.
However, the dough rope shape or cross-section may change substantially during
baking
due to oven spread resulting in an undesirable baked good shape, such as a
baked product
CA 02475720 2004-07-26
which is too thin. The shape of the die orifices may be changed, for example
to increase
the height of the extruded dough rope so that upon baking the extrudate rope
spreads into
the thinner desired shape. However, it has been found that the use of
concentric, circular
die orifices to produce a cylindrical dough rope results in insufficient oven
spread to
produce a desirable, bar-shaped baked good.
[0020] It has also been found that in producing a baked, bar-shaped product
having
a plurality of concentric fillings, which are visually apparent at each end of
the bar, the
use of a roller to flatten a cylindrical dough rope to achieve a desired bar
shape results in
sticking of the outer dough casing to the roller and tearing of the dough rope
and base
cake. Also, it has been found that in producing a triple coextruded dough rope
having a
cross-section with a substantially smaller height than width, without the use
of a roller,
the middle layer or filling tends to flow towards the ends rather than the top
and bottom.
The resulting baked product tends to have a substantially uneven middle
concentric layer
which is excessively thin or discontinuous at the top and bottom, particularly
as the cross-
sectional height to width ratio of the dough rope decreases.
[0021] Also, as the height or thickness of the dough rope decreases along with
the
thickness of the filler layers, cutting of the baked rope tends to result in
more visual
smearing of one layer of filling into another.
(0022] The present invention provides a method for producing a triple
coextruded
baked good having a bar shape with a substantially smaller height than width,
such as a
FIG NEWTON~ shaped product, without the need for post-extrusion shaping or
mechanical flattening of the dough with a roller, thereby avoiding sticking
and tearing of
the dough by the shaping equipment. Triple coextruded bar shaped products such
as
cookies with dissimilar fillings, such as a fruit filling and a cheese-cake
filling, may be
6
CA 02475720 2004-07-26
continuously produced on a mass production basis. The present invention
provides for
v
the production of baked goods having distinct, at least substantially uniform
concentric
fillings which are visually apparent at opposing cut ends of the baked piece.
Undesirable
excessive flow of a middle filling or layer towards the cross-sectional ends
or sides rather
than the top and bottom of the coextrudate is substantially reduced. Control
of the flow
of the middle filling results in a baked product having a substantially even
middle
concentric layer which is desirably uniformly thick and continuous at least
across the top
and bottom. Cutting of the baked product is accomplished without any
substantial visual
smearing of one layer of filling into another.
Summary of the Invention
[0023] The present invention provides an apparatus and method for the
production
of a baked good or snack in bar form having a cross sectional width that is
substantially
greater than the cross-sectional height using triple coextrusion. In
embodiments of the
invention, the ratio of the maximum cross-sectional width to the maximum cross-
sectional height of the baked good may be at least about 1.75:1, generally at
least about
2.5:1, for example from about 2.7 to 4:1, preferably about 3:1. The snack bar,
such as a
cookie may be baked from a triple coextruded rope having a casing, such as a
cookie
dough enrobing two concentric fillers.
[0024] The triple coextruded rope may be produced by coextruding a dough and
two dissimilar first and second fillings through three concentric die orifices
wherein the
dough is extruded through the outermost die orifice, the first filling or core
is extruded
through the innermost die orifice, and the second or middle filling is
extruded through
the middle die orifice.
7
CA 02475720 2004-07-26
[0025] Undesirable excessive flow of the middle or second filling or layer
towards
the cross-sectional ends rather than the top and bottom of the coextrudate is
substantially
reduced by diverting and constricting or obstructing the flow of the second or
middle
filling through the middle die orifice so that it flows towards the top and
bottom
elongated portions of the middle annulus. The diversion or obstruction results
in an
extrudate rope and a baked product having a substantially even middle
concentric layer
which is desirably uniformly thick and continuous at least across the top and
bottom.
The middle concentric layer may be thicker or substantially the same width-
wise at its
opposing end portions compared to its thickness height-wise at its top and
bottom
portions.
[0026] The diversion or obstruction may be achieved with the use of pins
located in
the middle annulus, extending or protruding from the outer wall of the middle
annulus
towards the inner wall of the middle annulus. The pins help to increase
pressure in the
thicker end regions of the middle annulus and direct flow of the middle layer
or second
filler to the thinner top and bottom regions of the middle annulus thereby
preventing
unevenness and discontinuity in the top and bottom regions.
[0027] Substantial visual smearing of one filler layer, such as a red colored
cherry
filling, into the other, such as a white cheese-cake filling, and vice verse
is avoided or
eliminated by cutting of the baked product preferably with an ultrasonic
cutter.
Brief Description of the Drawings
[0028] FIG. 1 is a perspective view of a triple coextruded baked cookie snack
which may be produced in accordance with the present invention.
[0029] FIG. 2 is a top view of the baked snack of FIG.l .
CA 02475720 2004-07-26
[0030] FIG. 3 is a left side view of the baked snack of FIG.1.
r
[0031] FIG. 4 is a front end view of the baked snack of FIG.1, the rear end
view
(not separately shown) being a minor image thereof.
[0032] FIG. 5 is a right side view of the baked snack of FIG. l .
(0033] FIG. 6 is a bottom view of the baked snack of FIG. l .
[0034) FIG. 7 is an enlarged, schematic, top cross-sectional view of a triple
coextrusion die block which may be used to produce a triple coextrudate rope
which may
be baked and cut to obtain a baked snack as shown in FIG. 1.
[0035] FIG. 8 is an enlarged, schematic, cross-sectional side view of a triple
coextrusion die block which may be used to produce a triple coextrudate rope
which may
be baked and cut to obtain a baked snack as shown in FIG. 1.
[0036] FIG. 9 is an enlarged, schematic, front view showing the three oblong
or
elongated oval die orifices which may be used to produce a triple coextrudate
rope which
may be baked and cut to obtain a baked snack as shown in FIG. 1.
(0037] FIG. 10 is a front perspective view of a middle nozzle of the extrusion
block for extrusion of the middle filler or second layer of the baked good of
FIG. 1.
(0038) FIG. l0A is back perspective view of the middle nozzle of FIG. 10.
[0039] FIG. l OB is a side view of the middle nozzle of FIG. 10.
[0040] FIG. l OC is a cross-sectional view along line l OC-l OC of FIG. l OB.
[0041] FIG. l OD is a top view of the middle nozzle of FIG. 10.
[0042] FIG. l0E is a front view of the downstream end of the middle nozzle of
FIG. 10.
[0043] FIG. l OF is rear view of the upstream end of the middle nozzle of FIG.
10.
9
CA 02475720 2004-07-26
[0044] FIG. 11 is a rear perspective view of a core or central nozzle of the
extrusion block for extrusion of the core or central filler which is the
innermost or first
layer of the baked good of FIG. 1.
[0045] FIG. 11A is a top view of the core or central nozzle of FIG. 11.
[0046] FIG. 11B is a side view of the core or central nozzle of FIG. 11.
[0047] FIG. 11C is a cross-sectional view along line 11C-11C of FIG. 1 lA.
[0048] FIG. 11 D is a cross-sectional view along line 11 D-11 D of FIG. 11 B.
[0049] FIG. 12 is a perspective view of the terminal or end portion of the
core or
central nozzle of FIG. 11.
[0050] FIG. 12A is a top view of the core or central nozzle terminal or end
portion
of FIG. 12.
[0051] FIG. 12B is a side view of the core or central nozzle terminal or end
portion
of FIG. 12.
[0052] FIG. 12C is a cross-sectional view along line 12C-12C of FIG. 12B.
[0053] FIG. 12D is a cross-sectional view along line 12D-12D of FIG. 12C.
[0054] FIG. 12E is a front view of the downstream or exit end of the core or
central
nozzle terminal or end portion of FIG. 12.
[0055] FIG. 12F is rear view of the upstream end of the core or central nozzle
terminal or end portion of FIG. 12.
[0056] FIG. 13 is a rear perspective view of the outer or casing nozzle or die
block
of the extrusion block for extrusion of the casing which is the outermost
layer of the
baked good of FIG. 1.
[0057] FIG. 13A is a front view of the downstream or exit end of he outer or
casing
nozzle or die block of FIG. 13.
CA 02475720 2004-07-26
[0058] FIG. 13B is a cross-sectional view along line 13B-13B of FIG. 13A.
a
[0059] FIG. 13C is a cross-sectional view along line 13C-13C of FIG. 13B.
(0060] FIG. 14 is a perspective view of a preferred, one piece core or central
nozzle of the extrusion block for extrusion of the core or central filler
which is the
innermost or first layer of the baked good of FIG. 1.
[0061] FIG. 14A is a top view of the core or central nozzle of FIG. 14.
[0062] FIG. 14B is a side view of the core or central nozzle of FIG. 14.
[0063) FIG. 14C is a cross-sectional view along line 14C-14C of FIG. 14B.
[0064] FIG. 14D is a detail view of detail 14D in FIG. 14C.
[0065] FIG. 14E is a partial detailed view of the front or exit end of the
core or
central nozzle of FIG. 14.
Detailed Description of the Invention
[0066] The present invention provides a method for producing a triple
extrusion, or
triple coextruded baked good having a bar shape with a substantially smaller
height than
width. For example, the ratio of the maximum cross-sectional width to the
maximum
cross-sectional height of the baked good may be at least about 1.75:1,
generally at least
about 2.5:1, for example from about 2.7 to 4:1, preferably about 3:1. Post-
extrusion
shaping or mechanical flattening of the triple extruded product with a roller
is not needed
prior to or after baking to achieve an oblong or curved rectangle cross-
sectional shape in a
triple coextruded baked snack. Elimination of mechanical shaping and relying
solely
upon oven spread to achieve a desired cross-sectional profile in the baked
good avoids
sticking and tearing of the outer dough or casing by the post extrusion
shaping equipment.
Triple coextruded bar shaped products such as cookies with dissimilar
concentric fillings,
11
CA 02475720 2004-07-26
such as a fruit filling which enrobes or envelops a cheese-cake filling, may
be
r
continuously produced on a mass production basis.
(0067] A triple coextruded baked cookie snack which may be produced by triple
extrusion in accordance with the present invention is shown in FIGS. 1-6. The
baked
product 1 of FIGS. 1-6 has a farinaceous-based casing 3, such as a cookie
dough enrobing
two concentric dissimilar fillers or fillings 5, 7. The innermost, core, or
first filling 5 is
enrobed by a middle or second filler 7 and both fillings 5 and 7 are visually
apparent at
the opposing cut front and rear ends 9 and 1 l, respectively, of the baked
good as shown in
FIGS. 1 and 4. The baked product 1 has a substantially flat top surface 13 and
a
substantially flat bottom surface 15 and rounded or curved sides 17 and
shoulders 19.
The bottom surface may have a slightly indented or recessed central portion 21
with
slightly protruding side edges 23 resulting from cooling or moisture
migration. The ratio
of the maximum cross-sectional width 43 to the maximum cross-sectional height
44 of the
baked good 1 may preferably be about 3:1.
[0068] The core or first filler 5 has a substantially uniform thickness or
height 25
across its width 27 as shown in FIGS. 1 and 4. Likewise, the middle or second
filler 7 has
a substantially uniform thickness or height 29 across its width 30, taking
into account the
height 25 of the first filler 5. The thin top portion 32 of the second fuller
7 above the core
or first filler 5 is at least substantially uniformly thick and continuous
across the width 27
of the core 5. Likewise, the thin bottom portion 34 of the second filler 7
below the core
or first filler 5 is at least substantially uniformly thick and continuous
across the width 27
of the core S. The thin top and bottom portions 32 and 34, respectively may
have at least
substantially the same uniform thickness. The end or side portions 36, 38 of
the middle
or second filler 7 may have at least substantially the same uniform thickness.
The end or
12
CA 02475720 2004-07-26
side portions 36, 38 may have an annular width or thickness 40, 42,
respectively, which is
substantially larger, for example up to about 2 to 4 times larger, or about
the same as the
annular thickness or height of the top and bottom portions 32 and 34.
[0069] The baked snacks such as the cookie snack product 1 of FIGS. 1-6 may be
continuously produced by triple extrusion using one or a plurality of triple
coextrusion die
blocks or nozzles contained in a die head fed by a manifold to produce a
triple
coextrudate rope which may be baked and cut to obtain the baked snack 1. A die
block
50, attached to a die head 52, which may be used to produce the triple
coextrudate rope is
shown schematically in FIGS. 7-9, 10, l0A-IOF, 11, 11A-11D, 12, 12A-12F, 13,
and
13A-13C. The triple coextruded rope may be produced by coextruding a dough or
casing
and two dissimilar first and second fillings through three concentric die
orifices 54, 56, 58
as shown in FIGS 7, 8, and 9. The dough is extruded through the outermost die
orifice
54. The first filling or core is extruded through the innermost die orifice
56. The second
or middle filling is extruded through the middle die orifice 58.
[0070] In a preferred embodiment, to obtain a baked good 1 having a maximum
cross-sectional width 43 to maximum cross-sectional height 44 ratio of about
3:1, the
corresponding ratios for the three concentric die orifices 54, 56, and 58 may
be about
1.8:1 (outermost or casing orifice), 3.8:1 (innermost or core orifice), and
2.4:1 (middle
orifice), respectively. The increased ratio (3:1) for the baked product
compared to the
ratio for the outermost die orifice 54 (1.8:1) is substantially attributed to
oven spread and
lay-time on conveyor belts rather than any mechanical flattening with a roller
or other
flattening means.
[0071] Undesirable excessive flow of the middle or second filling or layer
towards
the cross-sectional ends rather than the top and bottom of the triple
coextrudate is
13
CA 02475720 2004-07-26
substantially reduced by diverting and constricting or obstructing the flow of
the second
or middle f lung through the middle die orifice 58 so that it flows towards
the top and
bottom elongated portions 60, 62, respectively of the middle annulus 64. The
diversion or
obstruction results in an extrudate rope and a baked product having a
substantially even
middle concentric layer which is desirably uniformly thick and continuous at
least across
the top and bottom. The middle concentric layer may be thicker or
substantially the same
width-wise at its opposing end portions compared to its thickness height-wise
at its top
and bottom portions.
[0072] The diversion or obstruction may be achieved with the use of pins 66,
67
located in the middle annulus 64 as shown in FIGS. 7, 9, 10, 10A, and l OC.
FIG. lOC is
a cross-sectional view along line lOC-lOC of FIG. IOB. As depicted in FIGS. 7,
9, and
1 OC, the pins 66, 67 may extend or protrude from the outer wall 69 of the
middle annulus
towards the inner wall 71 of the middle annulus 64. In embodiments of the
invention the
pins may extend from about 20% to about 80%, for example from about 40% to
about
60% across the middle annulus 64. The pins 66, 67 or other obstruction or flow
diverter
may be fixedly secured in or on the wall of the middle nozzle 75 by pressure
fit, screwing,
welding, or other conventional fastening means. The pins 66, 67 are preferably
cylindrical in cross-section, but other flow directing shapes may be employed.
Pin
diameters may range from about 0.5 mm to about 3 mm, for example about 1 mm.
The
pins are located in and help to increase pressure in the thicker end regions
77 of the
middle annulus 64 and direct flow of the middle layer or second filler to the
thinner top
region 79 and thinner bottom region 81 of the middle annulus 64 thereby
preventing
unevenness and discontinuity of the middle or second filler in the top and
bottom regions
79, 81. The obstructions, such as pins 66, 67 may be located sufficiently
upstream of the
14
CA 02475720 2004-07-26
downstream terminus of middle annulus 64, so as to permit the desired
diversion of flow
of the middle layer or second filler in the middle annulus while avoiding any
substantial
flow back from the top and bottom elongated portions 60, 62 to the end
portions 77,
downstream of the pins 66, 67. In embodiments of the invention, the pins 66,
67 may be
located a distance upstream the terminus of middle annulus 64 or upstream
orifice 58,
which is equal to about 1 to 2.5 times the middle annulus width at its
terminus.
[0073] As shown in FIGS. 7-9, the three die orifices 54, 56, 58 may each be
oblong
or elongated oval die orifices with a substantially rectangular, elongated
central portion
and two semi-circular end portions concentrically arranged about a
longitudinal or
horizontal axis 85 and a vertical axis 87.
[0074] As depicted in FIGS. 7-9, 10, l0A-lOF, 11, 11A-11D, 12, 12A-12F, 13,
and 13A-13C the die block 50 includes a middle nozzle 75, a central or core
nozzle 90,
and an outer or casing nozzle 92 which are joined or fitted together to form a
central or
core flow path or bore 94, an annular middle flow path or bore 64, and an
annular outer or
casing flow path or bore 96.
[0075] The middle nozzle 75 of the extrusion block 50 for extrusion of the
middle
filler or second layer of the baked good of FIG. 1 is shown in FIGS. 7-10 and
FIGS.
l0A-lOF. The middle nozzle 75 includes an upstream circular or cylindrical
bore 100
which transitions into a downstream elongated oval bore 102.
[0076] The central or core nozzle 90 of the extrusion block 50 for extrusion
of the
core or first filler of the baked good of FIG. 1 is shown in FIGS. 7-9, 11,
11A-D, 12, and
12A-12F. The central, innermost, or core nozzle 90 includes an upstream
circular bore
104 which transitions into an elongated oval bore 106. The central nozzle 90
is a multi-
piece structure containing an upstream elongated portion 110 joined, by
welding for
CA 02475720 2004-07-26
example at joint 112, to a downstream terminal or end portion 115. FIG. 11C is
a cross-
i
sectional view along line 11C-11C of FIG. 11A and FIG. 11D is a cross-
sectional view
along line 11D-11D of FIG. 11B showing the elongated portion 110 joined to the
oblong
shaped end portion 11 S.
[0077] FIG. 12C is a cross-sectional view along line 12C-12C of FIG. 12B and
FIG. 12D is a cross-sectional view along line 12D-12D of FIG. 12C. The end
portion 115
as shown in FIGS. 12C, 12D and 12F has a slight internal ledge portion 116 in
its
elongated oval bore at its upstream end 118 for receiving the upstream
elongated portion
110. The downstream end 120 contains the elongated oval orifice 56.
[0078] The outer or casing nozzle 92 of the extrusion block 50 for extrusion
of the
dough or casing layer of the baked good of FIG. 1 is shown in FIGS. 7-9, 13,
and 13A-
13C. FIG. 13B is a cross-sectional view along line 13B-13B of FIG. 13A. FIG.
13C is
a cross-sectional view along line 13C-13C of FIG. 13B. The casing nozzle 92
includes
an upstream circular or cylindrical bore 125 which transitions from an
upstream
cylindrical bore 130 into a downstream tapering elongated oval bore 135. The
tapering or
chamfer may be at about 45° and ends at elongated oval orifice 54.
[0079] In a preferred embodiment, the core or central nozzle is fabricated as
a
single or integral piece as shown in FIG. 14 and 14A- 14E. FIG. 14C is a cross-
sectional
view along line 14C-14C of FIG. 14B showing the downstream, elongated oval
orifice
56A of a single piece central or central nozzle 90A. FIG. 14D is a detail view
of the
opposing or upstream end depicted as detail 14D in FIG. 14C. The single piece
core or
central nozzle 90A includes an upstream circular bore 104A which transitions
into an
elongated oval bore 106A and terminates with the elongated oval orifice 56A.
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[0080] The die blocks 50 may be employed with conventional coextruders such as
those manufactured by Meinke, APV, and Rheon Manufacturing Co. A Meinke V45
triple coextruder is preferred. In embodiments of the invention, the triple
coextruder and
up to about 20 die blocks 50 may be employed to produce up to about 20 rows of
triple
coextruded dough ropes having consistent weights from row to row.
[0081] In accordance with preferred embodiments of the present invention, the
triple coextruded dough rope containing the two fillers surrounded by an
unbaked,
unleavened cookie dough may be transported by conveyers to an oven and baked
using
conventional baking temperatures and times to obtain a baked dough rope which
may be
cut into desired bar size lengths, for example from about 1 inch to about 6
inches. In
preferred embodiments, the baked dough ropes are cut into squares, or into
rectangles
which are about 1 5/8 in. long and about 1.5 inches wide.
[0082] Cutting of the dough ropes with a conventional gang traveling cutter
tends
to smear one filler into another. In preferred embodiments, the baked dough
ropes may
be cut using fluid jet cutting, and most preferably with an ultrasonic cutter.
Commercially
available ultrasonic cutters may be employed to avoid or substantially
eliminate
substantial visual smearing of one filler layer, such as a red colored cherry
filling, into the
other, such as a white cheese-cake filling, and vice verse.
(0083] Any conventional filler materials for a snack product may be used as
the
core or first filler and the middle or second filler in the present invention.
The fillers may
be cooked or uncooked and are preferably bakeable without undergoing leakage
or bleed
out from the cut ends of the baked product. The two fillers may preferably
have
substantially the same viscosity but substantially different color, flavor,
texture, or
combinations thereof. In embodiments of the invention the fillers may comprise
jelly,
17
CA 02475720 2004-07-26
peanut butter, jam, chocolate, or a filling made from fruit, vegetable, meat,
candy, cooked
i
dough, pudding, caramel, spices or seasonings such as cinnamon, cheese,
cheesecake or
other edible filler materials, and mixtures thereof. The fillings may
optionally include
particulate material or chunks, for example chocolate chips, butterscotch
chips, or other
flavor chips, chunks of nuts, pieces of fruits such as apple, cherry, peach,
or banana,
raisins, chunks of vegetables, candy or the like. Preferred combinations are:
1) a
cheesecake core filling and a surrounding cherry middle filling, 2) a cream
core filling
and a surrounding strawberry middle filling, and 3) a caramel core filling and
a
surrounding apple middle filling. In other preferred embodiments, one filler
may be a
peanut butter filler and the other may be a jelly or chocolate filler. In
other
embodiments, one filler may be an apple filler with apple particulates and the
other filler
may comprise caramel and cinnamon.
[0084] The casing material may be a conventional leavenable snack dough, such
as
a cookie dough which may undergo insubstantial expansion or leavening upon
extrusion
and substantial or little spread upon baking. The casing material may also
comprise an
expansible dough. The doughs employed are preferably uncooked or substantially
ungelatinized prior to entry into the triple coextrusion die.
18
