Puffing Apparatus For Producing Cereal Crackers And Methods Thereof

Abstract

An apparatus for making puffed food products from starch-containing raw materials. The apparatus has a baking and molding chamber defined by several heatable mold elements. The mold elements are individually actuated by direct hydraulic drive systems. The hydraulic power for these drive systems is selectively derived from a common oil pressure supply system which provides continuously high oil pressure to the direct hydraulic drive system for each mold element. The apparatus also has an improved feed system enabling the supply of raw material into the mold cavity such that no material gets spilled and each mold receives an accurate predetermined quantity of raw material.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]The present application is a continuation of U.S. Ser. No. 12 / 368,458 (to be issued as U.S. Pat. No. 8,227,005 on Jul. 24, 2012).BACKGROUND OF THE INVENTION[0002]The present invention is related generally to the manufacture of puffed food-starch containing products which are obtainable from rice, corn, wheat and other cereal grains but also from other starch source materials like potato, beans etc. including mixtures of different food starches in any suitable form including grains, broke, grit, flour, pellets and the like.[0003]More particularly, this invention relates to an apparatus enabling automatic production of low-fat puffed-food products from any edible starch source in the form of crackers, cakes, wafers or chips of any desired shape, thickness, crispiness and taste, and this with remarkably increased reliability and efficiency over existing methods and machines.[0004]Automatic machines for the making of rice crackers and similar ...

AI Technical Summary

Benefits of technology

[0010]The present invention aims at providing an adequate solution for the production problems and technical shortcomings of prior art technology for puffed cracker production and in particular at removing the above-mentioned technical and economical deficiencies of conventional puffed-food machinery and plants.

[0016]The new direct hydraulic drive means for the mold elements in an apparatus according to the invention surprisingly provides considerable improvements in puffed cracker properties and manufacturing efficiency: a consistently high and constant product quality was achieved, the flexibility to adapt cracker properties w.r.t. composition, texture and shape without risk of burns, seams or desintegration was greatly increased. Moreover machine reliability, incl. trouble-free production runs was remarkably improved. As a result the amount of waste product was tremendously decreased down to below 1.5% on the average.

[0020]2) The hydraulic cylinders are enabled to operate under extremely fast speed because the driving oil pressure is continuously built-up in the pressure line right at the top of the cylinder. This constant high pressure is released instantly at the moment the poppet valve is actuated. This together results in an attainable mold / cracker expansion time of down to ten milliseconds, which is extremely short.

[0022]According to another aspect of the invention a puffing apparatus is provided having an improved feed system enabling the supply of raw material into the mold cavity such that no material gets spilled and each individual mold will receive an accurate predetermined quantity of starch-containing raw material selected from grains, pellets, broke, flour etc. incl. mixtures thereof.

[0023]According to a further aspect of the invention a puffing apparatus is provided having an improved ring mold design allowing pressure-baking and expansion of particularly a plurality of (small) crackers such as mini-snacks, and this without the risk of premature wear or deformation of the ring mold due to heat differential related misalignment between the ring mold cavities and the upper or lower mold punch elements slidable received in said cavities.

Problems solved by technology

These machines produce a lot of noise and are rather energy consuming; furthermore, air cylinders are bulky devices which often are less reliable in terms of baking pressure and cracker thickness requirements.

A drawback of said machine types is the use of a toggle mechanism transmitting hydraulic power to the mold in an indirect way and requiring special care for aligning mold parts and controlling molding pressure.

In addition a movable peripheral mold is more prone to overstraining and risk of mold leakage, giving rise to defective cracker quality and appearance after a period of time.

In addition, the provision of a hydraulic jack together with its oil circuit, oil tank and powering motor on each production machine or unit is rather expensive.

A generally experienced inconvenience in the production of puffed-food snacks by pressure-baking and subsequently expanding a starch-containing cereal or the like mixture in a mold cavity when using currently available technology is the quantity of trash and waste crackers produced by puffing machines, which may amount to 10% or even more of total cracker output.

Further disadvantages of known machines for making puffed crackers include the rather long running-in / starting-up times needed until a stable production regime is reached and the need of frequently cleaning the baking mold elements.

As a result the productivity and economics of a cracker plant, in particular when making small crackers and chips, may be seriously affected.

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