Patent Publication Number: US-2005123663-A1

Title: Shredded food products and methods of producing and applying shredded food products

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      This application claims priority to U.S. application Ser. No. 60/513,145, filed on Oct. 21, 2003. 
    
    
     BACKGROUND  
      1. Field of the Invention  
      The invention relates generally to shredded formable food products and methods of producing and applying to another food product. More specifically, the invention relates to shredded cheeses and method of producing shredded cheeses for application to a food product.  
      2. General Background of the Invention  
      A common method of making a food product involves applying fragments of topping to the surface of the food product. For example, cheese shreds may be deposited on the surface of a pizza or icing fragments may be deposited on the surface of a pastry. Toppings provide additional flavor and also add dimensionality to the appearance of the food product.  
      It is known in the food industry to deposit pre-made or on-line shredded cheese as a topping on a variety of products, such as pizza, hand-held sandwiches, snack items and the like. Many processes involve simply applying a traditional cheese that has been shredded. Such cheeses, however, suffer from many deficiencies. The cheese by its very nature may be inconsistent in its viscosity, dispersement of fats or other ingredients, or size. Thus, a cheese that is more homogeneous in the dispersal of its ingredients and in size is needed.  
      Depositing of cheese is generally done with a raking carousel or a vibratory belt or other conveyer. These methods are limited in that the variability of depositing the shredded cheese is high, from around 5% to as much as 25%. Additionally, these methods create large amounts of wasted cheese that is either discarded or additional resources must be used to recycle the cheese. What is needed is a method for depositing cheese on a food product that is continuously and evenly distributed and reduces waste.  
     BRIEF SUMMARY  
      Certain embodiments of the invention provide a method for producing fragments of a food product. The method includes providing an amount of a formable food product, dividing a single input flow of the formable food product into multiple output streams, extruding the formable food product through an orifice to form strands and cutting the strands of formable food product into pieces.  
      Other embodiments of the invention provide a method for producing producing a shredded cheese product. The method includes providing an amount of a cheese product, dividing a single input flow of the cheese product into multiple output streams, extruding the cheese product through orifices to form strands and cutting the strands of cheese product into pieces.  
      Certain embodiments of the invention provide a method of applying a shredded cheese product on a dough product. The method includes providing an amount of a cheese product, working the cheese product to render it flowable, dividing a single input flow of the cheese product into multiple output streams, extruding the cheese product through orifices into strands, cutting the strands into pieces, depositing the pieces of cheese product onto a dough product and compressing the pieces of cheese product into the dough product.  
      Other embodiments of the invention provide a shredded cheese product produced by a method including providing an amount of a cheese product, dividing a single input flow of the cheese product into multiple output streams, extruding the cheese product through orifices to form strands and cutting the strands of cheese product into pieces. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a diagram of a process for forming shredded cheese according to certain embodiments of the invention.  
       FIG. 2  is a diagram of a process for impregnating a shredded cheese according to certain embodiments of the invention into a dough product.  
       FIG. 3A  is an end view of a manifold of a pipe nozzle according to certain embodiments of the invention.  
       FIG. 3B  is an end view of cross-section of a die plate of a pipe nozzle according to certain embodiments of the invention.  
       FIG. 3C  is an end view sectional view of flow adjustment bar of a pipe nozzle according to certain embodiments of the invention.  
       FIG. 3D  is an end view of a screw-in plug of a pipe nozzle according to certain embodiments of the invention.  
       FIG. 4  is a side sectional view of a cutting mechanism and pipe nozzle according to certain embodiments of the invention.  
       FIG. 5A  is a bottom plan view of a manifold of a pipe nozzle according to certain embodiments of the invention.  
       FIG. 5B  is a bottom plan view of a die plate of a pipe nozzle according to certain embodiments of the invention.  
       FIG. 5C  is a bottom plan view of a flow adjustment bar of a pipe nozzle according to certain embodiments of the invention.  
       FIG. 5D  is a bottom plan view of screw-in plugs of a pipe nozzle according to certain embodiments of the invention. 
    
    
     DETAILED DESCRIPTION  
      Embodiments of the invention will now be described more fully with reference to the drawings.  
      Certain embodiments of the invention are directed to a method for producing a shredded food product. A continuous process forms a formable food product into a shredded food product. As used herein, formable food product refers to any food product that is capable of being extruded or otherwise formed into a particular shape. Examples of a formable product include, but are not limited to, cheese, butter, margarine, peanut butter, chocolate, meat, dough and pretzels.  
      Other embodiments of the invention produce a shredded cheese product. The starting cheese product may be in any starting form, such as block form, cubed, chunked, shredded, torn or chopped. The starting cheese product may be any type of cheese. Mozzarella or provarella (a mozzarella and provolone blend) have been found to be good starting cheese products. Additional cheeses, such as ramona, parmesan, etc. may be added for flavor.  
      A continuous process for producing a shredded food product is shown in  FIG. 1 . If a solid formable food product is used as the starting product, the formable food product is comminuted to a size sufficient to fit in a hopper  10  attached to a pump  12 . The formable food product may be compressed and otherwise worked through a pump  12  until it is “flowable.” As used herein, flowable generally refers to a semi-solid or liquid state in which the product moves or runs smoothly with substantially unbroken continuity, as in the manner characteristic of a fluid. The pump  12  converts blocked, cubed, diced or shredded forms of a solid starting food product into a flowable form, which can be pumped under pressure. The pump  12  may be any pump  12  that can accurately dose and apply a formable food product in conjunction with a die plate. For example, the pump  12  may be any one of the following types: a conventional positive displacement pump, a progressively reducing cavity type, such as from vendor Moyno, other single or twin screw extruder, such as from vendors Clextral Group, Reiser or Vemag Maschinenbau, or a vane pump, such as from vendors Risco or Reiser. A positive displacement double screw vacuum pump with a tote dumper and an auger in the hopper has been found to be particularly useful for practicing the invention.  
      In some embodiments, the formable food product is pumped through pipe  14  to a dividing manifold  16 , which is preferably in communication with a series of dies or a die plate  20 . The dividing manifold  16  provides a mechanism to precisely divide a single input flow of the pipe  14  from the pump exit into multiple output streams of equal flow for further processing. The division of a single input flow into multiple output streams is herein referred to as “flow-dividing.” In some embodiments, the flow of the formable food product may expand from the pipe  14  exiting the pump  12 , which may be approximately three to four inches, to the multiple output streams of the dividing manifold  16 , which may be approximately four to fifty inches.  
      The formable food product flows from the dividing manifold  16  to a water wheel  18 , such as that manufactured by Reiser. The water wheel  18  operates using a series of vertical vane pumps in a cylindrical housing. The vane pumps are directly connected by metal shafts which ensure that each vane pump rotates at the same rate and delivers the same amount of material. Any one of the above-mentioned pumps  12  may be used to fill the cavities of each vane pump full and distribute the formable food product across the length of a die plate  20 .  
      In other embodiments, flow dividing takes place with a unique pipe nozzle  50 , as shown in  FIGS. 3, 4  and  5 A-D. The pipe nozzle  50  may include a generally tubular stainless steel manifold  52  with sanitary fittings  60  on each end. In preferred embodiments, the manifold  52  is square, but has a generally cylindrical input opening  64 . The input opening  64  is in communication with an output opening  66 . A number of holes  62  may be located along the length of manifold  52  to attach a die plate  54 .  
      The pipe nozzle  50  preferably includes a separate die plate  54  to allow the diameter and number of extrusion holes to be easily changed. The output opening  66  of the manifold  52  is in communication with an input opening  68  in the die plate  54 . The die plate  54  may be attached to the manifold  52  by any conventional method, such as rivets, screws, bolts, etc. In some embodiments, the die plate  54  includes holes  74  which receive screws (not shown) that attach the die plate  54  to holes  62  along the length of manifold  52 . The input opening  68  in the die plate  54  may include an area  70  for receiving a flow adjustment bar, discussed further below. The die plate includes holes or dies  72  through which the formable food product is extruded.  
      A flow adjustment bar  56  may be used to control the flow characteristics across the length of the die plate  54 . The flow adjustment bar  56  may fit within an area  70  within the input opening  68  in the die plate  54 . The flow adjustment bar  56  is attached to the die plate  54  by screw-in plugs  58 . The screw-in plugs  58  provides a mechanism for moving the flow adjustment bar  56  so that it controls the stream of formable food product leaving the output opening  66  in the manifold  52 . Because the input opening  68  is in communication with the extrusion dies  72 , the placement of the adjustment bar  56  affects the flow rate of the stream as it moves through the extrusion dies  72 .  
      The pumped formable food product flows through the series of dies on die plate  20  or die plate  54  as continuous and even strands or strings. The dies may be altered to achieve any desired shape, such as oval, elliptical, L-shaped, triangular, etc. In certain embodiments, the dies through which the formable food product is extruded are designed to replicate a cheese shred  22 .  
      In some embodiments, for example, when drier starting food products are used, the strands or strings spontaneously break into smaller pieces. In other embodiments, the strands or strings are cut with a knife or other cutting device, such as an air blow off, a wire knife, a metal guillotine, rotary cutter, knock-off or a flicker wheel. In some embodiments, the cutting device features a reciprocating or circular motion. The motion of the cutting device and exit speed of the formable food product are two factors that regulate the length of the final food product. The cutting device includes a mechanism for cutting the continuously extruded strands to lengths as short as  1  mm but more preferably 3-10 mm. The cutting mechanism may be an air nozzle that provides a non-contact means of cutting the strands. In other embodiments, the cutting mechanism is a blade and holder attached to the pipe nozzle body. The blade can be moved back and forth by an air cylinder.  
      In still other embodiments, shown in  FIG. 4 , the cutting mechanism uses a rotating blade  30 , which shears the strands. The length of the cut strands can be determined by the rotational speed of the precisely controlled driven motor  32  by rotating blade  30 . In preferred embodiments, the cutting blade  30  is relocated to more clearance between it and the die plate  54 . This aids in keeping the cutting blade  30  from accumulating cheese. Additionally, other methods, such as ultrasonic wave technology may be used to keep the cutting blade clean. The shred size, thickness, and texture characteristics may be adjusted by the die plate, cut-off rate, pump speed and type of cheese.  
      As shown in  FIG. 2 , the shredded food product  22  may be applied to the surface of a base food product  24  by falling from the die plate  20  by gravity to the top surface of base food product  24 , such as a sandwich, pizza or other food item. As used herein, base food product refers to any food product on which the formable food product may be applied to, mixed with, pressed into or otherwise combined with the formable food product.  
      The distance the shredded food product  22  falls from the die plate  20  to the base food product  24  is preferably from about 2 inches to about 24 inches. The die plate  20  is preferably stationary above the base food product  24  and the base food product  24  travels beneath the die plate  20  at a specified speed. Conversely, the die plate  20  can also move as the base food product  24  moves, or the base food product  24  can remain stationary as the die plate or plates  20  move relative to the base food product  24 . Alternatively, multiple die plates  20  may apply the shredded food product  22  with or without motion relative to the base food product  24 .  
      Any or all of the pump  12 , manifold  16  and/or die plate  20 , among other components, may or may not be jacketed or electrically heat traced for temperature control as an aid to flow and even distribution. Additionally, the components may be cooled as needed to aid in the solidification of a formable food product.  
      Applying the shredded food product  22  to base food products  24  such as sandwiches and pizzas involves little or no recycling of cheese since generally all of it is used on the top surface of the base food product. However, the shredded food product  22  is also appropriate for applications in which overflow of the shredded food product  22  is expected and is designed to be recycled. Applying the shredded food product  22  in this manner to the top surface of a base food product  24  can be used in pizza processes or any other food product requiring accurate and consistent application of shredded food product  22 .  
      As shown in  FIG. 2 , in some embodiments, the shredded food product  22  may be impregnated into a base food product  24 . After the shredded food product  22  is deposited onto a base food product  24 , the shredded cheese product  22  may be compressed into the base food product  24 . In some embodiments, the base food product  24  with the shredded food product  22  deposited thereon passes through a two-roll sheeter or reduction roller  28 . The pressure from the reduction roller  28  causes the shredded food product  22  to stick to the surface of the base food product  24  and offers a method to adjust the three-dimensional appearance of the shredded food product  22 .  
      The following examples will serve to further illustrate the present invention without, at the same time, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that that resort may be had to various other embodiments, modifications and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit and scope of the invention.  
     EXAMPLE 1  
      Production of a Cheese Shred Using a Pipe Nozzle.  
      The starting material is a 17 lb block of Dairy Source™ cheese. The blocks of cheese are cut into thirds by hand cheese wire. The cheese temperature was 42° F.-47° F. at the time of use and reached a temperature of 59° F. after extrusion.  
      The pressure in the system is between 350 and 500 psi. The chunked cheese is placed in a Vemag 15C stuffer pump. The Vemag speed is 22.8. to provide approximately 3 grams of cheese on fifteen 2.25 inches by 6.0 inches cheese collection plates on a conveyer. The conveyor speed is 33 feet per minute.  
      When the cheese exits the pump, it is dispersed to a 34-inch pipe nozzle. The cheese is extruded through a series of holes approximately 1.0 mm in diameter. The holes are specifically designed so that a cross section of the extruded cheese resembles a cheese shred. The cheese is extruded in continuous strands.  
      A rotating blade is used to cut the cheese from the die plate. The blade rotates at 812 rpm. The length of the cheese shreds is adjusted by changing the rotation rate of the blade. The shredded cheese product is cylindrical and is 1.5-3.0 mm in diameter. The shredded cheese product is 0.5-1.5 inches in length.  
     EXAMPLE 2  
      Production of a Cheese Shred Using Water Wheel.  
      The starting material is a 17 lb block of Dairy Source™ cheese. The blocks of cheese are cut into thirds by hand cheese wire. The cheese temperature was 42° F.-47° F. at the time of use and reached a temperature of 59° F. after extrusion.  
      The pressure in the system is between about 350 and 500 psi. The chunked cheese is placed in a Vemag 15C stuffer pump. The Vemag speed is 18 to provide approximately 3 grams of cheese on fifteen 2.25 inches by 6.0 inches cheese collection plates on a conveyer. The conveyor speed is 33 feet per minute.  
      When the cheese exits the pump, it is initially dispersed to a Reiser 34-inch water wheel via a manifold. The cheese is extruded through a 69-hole die plate or a 102-hole die plate, with holes approximately 1.0 mm in diameter. The holes are specifically designed so that a cross section of the extruded cheese resembles a cheese shred. The cheese is extruded in continuous strands.  
      A rotating blade is used to cut the cheese from the die plate. The length of the cheese shreds is adjusted by changing the rotation rate of the blade. The shredded cheese product is cylindrical and is 1.5-3.0 mm in diameter. The shredded cheese product is 0.5-1.5 inches in length.  
     EXAMPLE 3  
      Application of a Cheese Shred to a Dough Product.  
      The cheese shreds from Example 2 are applied to a dough product using reduction rollers. The reduction rollers are dusted with common bread flour to insure that the cheese shreds do not adhere to the surface of the top reduction roller. The cheese shreds first drop onto a sheet of dough. The dough with the cheese shreds on its top surface then is pulled through the reduction rollers. The reduction rollers compress the cheese into the dough. When the resulting dough product is cooked, the cheese shreds provide a pleasing contrast with the dough and add to the three-dimensional appearance of the surface of the dough.  
      The foregoing description is provided for describing various embodiments and structures relating to the invention. Various modifications, additions and deletions may be made to these embodiments and/or structures without departing from the scope and spirit of the invention.