Patent Publication Number: US-2017360064-A1

Title: Grain bulk densifying die apparatus and method

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 15/132,991 filed Apr. 19, 2016, which will issue as U.S. Pat. No. 9,750,268 on Sep. 5, 2017. 
    
    
     BACKGROUND OF THE DISCLOSURE 
     Technical Field of the Disclosure 
     The present teachings relate to devices and methods for producing a consistently high density material having a desired length and size. 
     Description of the Related Art 
     In the field of food and feed processing, grain densifying and die systems are used to produce high quality densified grain for industrial purpose and animal consumption. In general, it has been recognized that construction of the die apparatus, also commonly known as a pellet mill or extruder die, is a critical factor in obtaining desirable pellets as well as high production rates. For example, the thickness of the die, the number of holes in the die, and the surface finish of the die have all been found to affect pellet quality. 
     In a typical extrusion die apparatus, it is adapted for coupling to the outlet end of an extruder barrel. In operation, the die apparatus is fed the product from the extruder barrel and shapes the product into a final extrudate, which is cut by a rotating knife to form pellets having predetermined lengths. 
     However, some existing processes fail to remove all the moisture or air or both from the final pellet, which subjects the pellets to increased decomposition and breakdown during normal handling, storage, and transport. This decreases the percentage of useful pellets. 
     In conventional pelleting techniques or extrusion techniques, steam is required to be added to the raw material during product densification. While steam is being added to the raw material, air is also continuously introduced into the raw material causing the material to contain substantially more air and water, which adversely affects the ultimate density. The more air and water contained in the material, the less dense the final product becomes after exiting the die. This is due to the fact that the water is not compressible, whereas air is compressible. Therefore, when the final product is subjected to vibrations and jostling, for example, associated with vehicular transport or transport to an accumulation bin, the product may begin to crumble, split or break apart at sites along weak points where the water and air are mixed within the product. These breaking points in the products create fines, which are the materials that result from products, such as pellets, disintegrating, due to poor quality. Fines can be a function of moisture and high friction or oversized feed ingredient particles. Fines are one of the major factors in determining consumer satisfaction with feed quality. To achieve a sufficiently consistent product with this conventional process, it requires more energy to obtain the desired pellet output. 
     Furthermore, when large diameter or oversized products are produced, they will become even hotter when the raw material mixed with the steam and air is pushed into the final die for forming the shape of the final product. This increased heat causes the water in the product to vaporize into the form of steam which breaks apart the product back to a loose form. One method to mitigate the breaking up of such oversized products is reducing the throughput of raw material through the die, which diminishes the output. 
     Another method to combat this problem of moisture and air entrapped in the raw material is to add binders, or fillers or both that allow the pellet to bind in a dense form in high heat. The problem with this method is that it drastically reduces the nutritional value of the final product by as much as 60%. The pellet quality can be seriously affected with the addition of too much binder. Lowering the nutritional value increases the cost and negatively affects the final product as a nutritional feed product. The farmer has to feed twice as much tonnage to his animals on a daily basis, which is very costly. 
     Therefore, there is a need for a method and apparatus for generating pellets with sufficient density for effective transportation, handling and storage practices, without the need for adding additional binders or fillers or both. There is also a need for a method and apparatus that eliminates fines produced in feed products. There is a further need for a method and apparatus that does not require the reduction in throughput of the process to eliminate fines which is the product breaking up during storage or transport. 
     SUMMARY 
     The present invention may satisfy one or more of the above-mentioned needs. Other features and/or advantages may become apparent from the description which follows. 
     An apparatus for producing a densified grain according to various exemplary embodiments can include a die assembly, a die head, a cooling chamber, and a break-off assembly. In various embodiments, the die assembly can include a first annular end, a second end having a die adapter for receiving a grain material, and a substantially triangular nose cone member at a middle portion thereof. The grain material received by the die adapter is forced through an extrusion passageway that evenly distributes the grain material into each of the orifices thereby producing a high density grain material. 
     In various embodiments, the die head can include at least one plate including a plurality of orifices. Each orifice extends out through the die head such that each orifice defines a plurality of die passageways within the die head for the grain material to pass there through. The die head is mounted to the die body with at least one first fastening mechanisms thereby enclosing the substantially triangular nose cone configured as a flow-direction mechanism to provide an extrusion passageway for the grain material. The grain material received by the die adapter is forced through the extrusion passageway that evenly distributes the grain material into each of the orifices thereby forming the grain material into a shaped grain material having a density before the grain material exits the die head. 
     In various embodiments, each die passageway comprises an inlet surface that tapers downwardly. A plurality of funnel-shaped structures extends from the inlet surface. Each funnel-shaped structure may have a wide inlet and inwardly sloping sides extending downwardly. A constricted passage may extend from the inwardly sloping sides of each funnel-shaped structure. The constructed passage may include a constricted diameter that is smaller than a diameter of a final product of the densified grain, wherein the constricted passage is configured having a linear length sufficient to enable the material to stabilize to the constricted diameter as the material travels therein. 
     In various embodiments, the relief section may be positioned downstream of the constricted passage. The relief section may include an enlarged diameter that defines the diameter of the final product, and the relief section extends to an outlet of the die head. 
     In various embodiments, the cooling assembly, which cools the shaped grain material, may include a cooling chamber having a first end, a second end, a first coolant opening, a second coolant opening, and a coolant passage that extends from the first end to the second end. The first and the second coolant openings are configured to receive at least one coolant to the coolant passage. 
     In some embodiments, the cooling chamber includes a first plate member, a second plate member, and at least one cooling tube. The first plate member can be positioned at the first end and mounted to the die head with the at least one second fastening mechanisms. The second plate member can include a plurality of exit ports positioned at the second end. 
     In various embodiments, the at least one cooling tube includes an inlet end for receiving the shaped grain material and an outlet end. Each cooling tube can be horizontally placed inside the cooling chamber. Each inlet end of the at least one cooling tube can be connected to the at least one die passageway of the die head, and each outlet end of the at least one cooling tube can be connected to the at least one exit port of the second plate member of the cooling chamber. The cooling chamber cools the shaped grain material by passing the shaped grain material through each of the cooling tubes. 
     In various embodiments, the break-off assembly can be configured to break off a preselected length of the shaped grain material. In various embodiments, the break-off assembly comprises at least one stud member and at least cone breaker. At least one stud member can be attached to the second plate member at the second end of the cooling chamber. The at least one cone breaker can be threaded to the at least one stud member. 
     In the following description, certain aspects and embodiments will become evident. It should be understood that the invention, in its broadest sense, could be practiced without having one or more features of these aspects and embodiments. It should be understood that these aspects and embodiments are merely exemplary and explanatory and are not restrictive of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Elements in the figures have not necessarily been drawn to scale in order to enhance their clarity and improve understanding of these various elements and embodiments of the invention. Furthermore, elements that are known to be common and well understood to those in the industry are not depicted in order to provide a clear view of the various embodiments of the invention, thus the drawings are generalized in form in the interest of clarity and conciseness. The skilled artisan will understand that the drawings described below are for illustrative purposes only. The drawings are not intended to limit the scope of the present teachings in any way. 
         FIG. 1  illustrates a schematic representation of an exemplary embodiment of a grain processing apparatus in accordance with the present teachings; 
         FIG. 2A  is an exploded view of a die assembly embodied with the grain processing apparatus shown in  FIG. 1  in accordance with the present teachings; 
         FIG. 2B  illustrates a side view of a die assembly when assembled with a cooling chamber in the grain processing apparatus shown  FIG. 1  in accordance with the present teachings; 
         FIG. 2C  illustrates a perspective view of an exemplary embodiment of a die assembly embodied with the grain processing apparatus shown in  FIG. 1  in accordance with the present teachings; 
         FIG. 3A  illustrates a front view of an exemplary embodiment of a first plate part of a die head embodied with the die assembly shown in accordance with the present teachings; 
         FIG. 3B  illustrates a top view of an exemplary embodiment of inlet surfaces of an orifice in accordance with the present teachings; 
         FIG. 3C  illustrates a side view of an exemplary embodiment of an orifice tapering inwardly down to multiple funnel-shaped members in accordance with the present teachings; 
         FIG. 3D  illustrates a perspective view of an exemplary embodiment of an orifice tapering inwardly down to multiple funnel-shaped members in accordance with the present teachings; 
         FIG. 3E  illustrates a side view of an exemplary embodiment of a passageway extending through a die assembly in accordance with the present teachings; 
         FIG. 3F  illustrates a top view of an exemplary embodiment of four funnel-shaped members formed within a single orifice in accordance with the present teachings; 
         FIG. 3G  illustrates a side view of an exemplary embodiment of a single orifice extending downward to a single funnel-shaped member that connects to a cooling tube in accordance with the present teachings; 
         FIG. 4A  illustrates a side perspective view of an exemplary embodiment of the cooling assembly of  FIG. 1  shown in an opposite direction in accordance with the present teachings; 
         FIG. 4B  illustrates a perspective view of an exemplary embodiment of a second plate part of a die head embodied with a die assembly shown in  FIG. 2C  in accordance with the present teachings; 
         FIG. 5  illustrates a perspective view of an exemplary embodiment of a break-off assembly embodied with the grain processing apparatus shown in  FIG. 1  in accordance with the present teachings; 
         FIG. 6  is a flow chart illustrating an exemplary method for processing densified grain for generating a highly densified grain material having a desired length, shape and size; 
         FIG. 7  illustrates another exemplary embodiment of the break-off assembly shown in  FIG. 5  in accordance with the present teachings; and. 
         FIG. 8  illustrates yet another exemplary embodiment of the break-off assembly shown in  FIG. 5  in accordance with the present teachings; 
         FIG. 9A  illustrates an exemplary embodiment of a die head having a circular cross-section shape including 46 die tubes in accordance with the present teachings; 
         FIG. 9B  illustrates an exemplary embodiment of a die head having a circular cross-section shape including 32 die tubes in accordance with the present teachings; 
         FIG. 9C  illustrates an exemplary embodiment of a die head having a circular cross-section shape including 48 die tubes in accordance with the present teachings; 
         FIG. 9D  illustrates an exemplary embodiment of a die head having an octagon shape including 98 die tubes or channels in accordance with the present teachings; 
         FIG. 10A  illustrates an exemplary embodiment of a conical-shaped funnel that may be employed in the grain processing apparatus in accordance with the present teachings; 
         FIG. 10B  illustrates an exemplary embodiment of a wedge-shaped funnel that may be employed in the grain processing apparatus in accordance with the present teachings; 
         FIG. 10C  illustrates an exemplary embodiment of a transition-shaped funnel that may be employed in the grain processing apparatus in accordance with the present teachings; 
         FIG. 10D  illustrates an exemplary embodiment of a pyramid shaped funnel that may be employed in the grain processing apparatus in accordance with the present teachings; and 
         FIG. 11  illustrates another exemplary embodiment of a die assembly that may be employed in the grain processing apparatus in accordance with the present teachings. 
     
    
    
     DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS 
     Reference will now be made to various embodiments, examples of which are illustrated in the accompanying drawings. However, these various exemplary embodiments are not intended to limit the disclosure. On the contrary, the disclosure is intended to cover alternatives, modifications, and equivalents. 
     Throughout the application, description of various embodiments may use “comprising” language, however, it will be understood by one of skill in the art, that in some specific instances, an embodiment can alternately be described using the language “consisting essentially of” or “consisting of.” 
     For purposes of better understanding the present teachings and in no way limiting the scope of the teachings, it will be clear to one skill in the art that the use of the singular includes the plural unless specifically stated otherwise. Therefore, the terms “a,” “an,” and “at least one” are used interchangeably in this application 
     Unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained. In some instances, “about” can be understood to mean a given value ±15%. Therefore, for example, 100 degrees Fahrenheit (° F.) could mean 95-105° F. At the very least, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. 
     Various embodiments provide a method and apparatus for processing densified grain to generate a consistently high densified grain with a desired length, shape and size. Various embodiments of the die apparatus described herein enhance pellet preparations methods for effective transportation, and handling and storage practices. In various embodiments, the operation of the device may be relatively simple and robust, and may enable pellet preparation without additional equipment, expensive retooling or frequent replacement of various components. 
     Various embodiments relate to a die apparatus and process for making densified grain into a desired shape. Some embodiments may include a die head section, a cooling section, and a break-off section. The die head section may include a die adapter, a die head with nose cone, a plurality of orifices and a plurality of funnel member. In use, the die head section receives the dense hot grain from a bulk densification process under a pressure and splits the dense grain such that it is forced into a plurality of orifices. 
     In various embodiments, the dense grain passes through a passageway defined by an enlarged inlet of the plurality of orifices and travels through the funnel member where the diameter narrows until it reaches a size where the diameter is smaller than a desired product size. The passageway remains at the reduced size for a linear length in order to allow the product to stabilize at that the reduced size. Then, the size of the passageway increases to a larger diameter, which is the diameter of the final desired product. 
     A relief surface is provided in the die at a transition area, where the smallest area of the passageway increases to a larger area that defines the final size of the product. The relief in the die allows for the pressure of the process to be maintained upstream of the die head and does not allow for pressure to continue past the relief of the die head. Thus, the relief in the die enables the use of long cooling tubes to allow the process to produce a high volume output. Without the relief in the die, the pressure applied upstream of the die head would also be applied to the cooling tubes. However, the cooling tubes have been designed to be long in length to assure a long residence time of the dense grain to cool the product while advancing through the cooling tubes. If the upstream pressure is applied to the long cooling tubes, then the process would require substantially more energy and pressure to push the product through the length of the cooling tubes. Without the relief in the die, such a configuration would not be practical in some conventional devices and in some cases would be impossible. 
     In various embodiments, the cooling section comprises a cooling chamber, a cooling passageway, a plurality of cooling tubes, a central chilling system, a temperature gauge, a coolant inlet, a valve bleeder, a valve drain, a coolant outlet and a plurality of pumps. The cooling section receives the hot dense grain from the die head and then cools the product in the plurality of cooling tubes. The cooling passageway is housed such that it surrounds the cooling tubes to create the cooling chamber. The coolant may be re-circulatory pumped through the cooling passageway using a plurality of pumps and managed by a central chilling system. The central chilling system maintains a low coolant temperature such that a substantial amount of heat is removed from the outer surface of the cooling tubes by the cooling medium. 
     Various embodiments of the break-off section may include a break-off cone and a stud plate. The break-off section receives the dense product, which has been cooled down to a temperature from the cooling tubes of the cooling section so that the product is ready to be cut or broken off to a linear length in size. The break-off cone may be, for example, a conical external funnel shaped cone that is threaded onto a stud plate. In various embodiments, the break-off cone can be adjustable by twisting or rotating the cone in a clockwise or counterclockwise direction to move the cone outwards or away from the exit end of the cooling tubes. 
     In an exemplary method for obtaining a consistently high densified product having a linear length from the grain, wherein the grain is densified by the grain bulk densification process, the hot densified grain is compressed by applying pressure, and the process includes one or more of the following steps of: receiving the hot grain at the nose of the die head section from the bulk densification process; allowing the dense grain to pass through the plurality of orifices and along the funnel member of the die head section; receiving the hot, dense grain at the plurality of cooling tubes and cooling the dense grain by maintaining a low coolant temperature; removing the heat from the hot dense grain by re-circulating the coolant inside the cooling chamber; and utilizing the break-off cone of the break-off section to cut the cooled dense grain into a desired shape. 
       FIG. 1  illustrates a schematic view of an exemplary embodiment of a grain processing apparatus  100  for producing a consistently high density grain in accordance with the present teachings. The terms “high density” or “highly densified” are used herein interchangeably to refer to the method and apparatus, according to the present teaching which can bulk densify raw material approximately three times its density in raw loose form. In contrast, conventional methods can bulk densify raw material up to one and a half times its density in raw lose form. Namely, the method and apparatus, according to the present teachings, is capable of obtaining a density greater than conventional systems. One way to overcome the lower mass density and transportation limitations, discussed above, is to densify the material, which converts the raw material into uniform commodity-type products. Densification employs a process such as forcing raw material through a die to form a densified product. Densification increases the bulk density, thereby producing a densified product with improved handling characteristics while reducing storage losses and transportation costs. 
     In  FIG. 1 , various embodiments of the grain processing apparatus  100  may include a die assembly  102 , a cooling assembly  104 , and a break-off assembly  106 . During operation, the die assembly  102  functions to receive the hot grain material under pressure from the bulk densification process (not shown). The die assembly  102  then splits the grain material, feeds it into multiple orifices  122 , and funnels the grain down through the orifices until it forms a final shape and density. After formation of the final shape, the process passes the grain material to the cooling section as a hot, dense, stable product shape in its final form in terms of diameter or area. 
     As illustrated in  FIGS. 1, 2A and 2B , the die assembly  102  can include a die head  108  and a die body  110 . The die assembly  102  may comprise a die head  108  and a die body  110  which connect together by fastening means  148 . In some embodiments, the die head  108  and the die body  110  are removably coupled to each other in the die assembly  102 . In other embodiments, the die head  108  is integral with the die body  110  in the die assembly  102 . 
       FIG. 2A  is an exploded view of the die assembly  102 .  FIG. 2B  illustrates a side view of the die assembly  102  when assembled.  FIG. 2C  depicts an exemplary embodiment of a perspective view of the die assembly  102  when assembled. The die head  108  may include a first plate part  112 , a second plate part  114 , and a third plate part  115 . The first plate part of the die head  112  may include a first section  116  having a plurality of first set of holes  118  and a second section  120  having a plurality of orifices  122 , which are best shown in  FIG. 3A . The second plate part of the die head  114  may include a plurality of second set of holes  130 . When assembled as shown in  FIGS. 1 and 2B , the third plate part  115  at the lower housing body section of the die head  108  section connects to the second plate part  114  by bolts  131  or other fastening means. In lieu of the multiple plates  112 ,  114 ,  115 , in some embodiments, the die head  108  may be formed integrally as a unitary body. The die head  108  can be made of a robust material, for example, such as 4140 alloy steels, D2 steels, and A-2 tool steel that is capable of receiving a large amount of pressure. 
     The die body  110 , as depicted in  FIGS. 1, 2A, and 2B , may include a first annular end  140  having a plurality of third set of holes  142 , a second end  144  having a die adapter  146 , a substantially triangular nose cone member  126  and an extrusion passageway  124 . The die adapter  146  may connect through the use of bolts to an extruder (not shown). The die body  110  can be mounted in a face-to-face engagement with the first plate part of the die head  112  in such a way that the plurality of third set of holes  142 , a plurality of first set of holes  118 , and a plurality of second set of holes  130  in the second plate part  115  are aligned to each other and connected with at least one fastening means  148  thereby enclosing the substantially triangular nose cone member  126  to provide the extrusion passageway  124  for the densified grain. The substantially triangular nose cone member  126  can be located centrally, extending inwardly and can be configured as a flow-directing mechanism for the densified grain. 
     In various embodiments, as best shown in  FIGS. 3A-3E , the plurality of orifices  122  in the die head  108  can be configured to define a conical or funnel-shaped passage having an enlarged inlet and a narrowed outlet end. In some embodiments, funnel-shaped members  123  may be formed inside the orifices  122 . The densified material is forced through the die in the direction of extrusion as shown by the arrow  111  in  FIG. 2B . 
     Each exemplary orifice  122  depicted in  FIGS. 3A and 3B  has an inlet having a substantially rectangular shape. The inlet surfaces of the orifice  122  taper inwardly down to multiple funnel-shaped members  123  ( FIGS. 3C and 3D ). When the material reaches the funnel-shaped members  123 , the material is further divided and forced through the funnel section in the direction of extrusion shown by arrow  111  downward to die tubing  125 . The exemplary embodiments of the funnel-shaped members  123  ( FIGS. 3C and 3D ) have a relatively wide mouth or inlet for receiving the material as it is pushed there through and conical, downwardly sloping side walls. The side walls gradually taper and descend to the die tubing  125 . 
     In the examples shown in  FIGS. 3A, 3B and 3D , six funnel-shaped members  123  are formed inside a single orifice  122 .  FIG. 3F  depicts another exemplary embodiment illustrating four funnel-shaped members  123  formed inside a single orifice  122 . 
       FIG. 3G  illustrates a side view of an exemplary single orifice  122  extending downward to a single funnel-shaped member  123 , which connects to a cooling tube. In  FIG. 3G , the single orifice  122  typically has a cross-sectional area having an inlet width or diameter  129  in a range of about 0.84 inches to 1.36 inches or an area in a range of about 0.55 square inches to 1.45 square inches. Similarly, the inlet width or diameter  139  of the funnel-shaped member  123  is configured as a circular area having a diameter in a range of about 0.58 inches to 1.01 inches or an area in a range of about 0.26 square inches to 0.80 square inches. The width or diameter  149  of the die tubing  125  is configured in a generally circular area having a diameter in a range of about of about 0.28 inches to 0.78 inches or an area in a range of about 0.06 square inches to 0.48 square inches. The height  133  from the inlet of the orifice  122  to the inlet of the funnel-shaped member  123  is approximately 0.75 inches to 0.90 inches. The height  143  from the inlet of the funnel-shaped member  123  to the inlet of the die tubing  125  is approximately 0.90 inches to 1.75 inches. The height  153  from the inlet of the die tubing  125  to the inlet of the cooling tube  156  is approximately 2.00 inches. These dimensions are merely examples. For example, “about” can be understood to mean a given value ±15%. The exact dimensions of the funnel-shaped member are variable depending on the specific treated material and/or the application desired. 
       FIGS. 10A-10D  depict exemplary embodiments of various funnel geometries that can be employed within the die head  108 .  FIG. 10A  illustrates a conical-shaped funnel.  FIG. 10B  depicts a wedge-shaped funnel.  FIG. 10C  illustrates a transition-shaped funnel.  FIG. 10D  depicts a pyramid shaped funnel. In some embodiments, the funnel-shaped members may include at least one channel, groove, or projection to promote mixing to ensure the consistency of the material. 
     As a result of the funnel shape of the orifice, the densified material is compressed laterally and perpendicular due to the forward motion of the material as it advances through the die head  108 . The dense grain passes through an enlarged inlet of the plurality of orifices and travels through the funnel member  123  where the diameter narrows until it reaches die tubing  125  extending from the funnel member  123 . The die tubing  125  is configured having a diameter which is smaller than a desired product size. The diameter of die tubing  125  remains at the reduced size for a linear length in order to allow the product to stabilize at the reduced size as the product travels therein. As depicted in  FIG. 3G , the width or diameter  149  of the die tubing  125  is configured in a generally circular area having a diameter in a range of about of about 0.28 inches to 0.78 inches or an area in a range of about 0.06 square inches to 0.48 square inches. 
     Then, the diameter of the die tubing  125  increases from the reduced size of the die tubing  125  to a larger diameter at a transition area, which is the diameter of the final desired product. As shown, for example, in  FIGS. 3E and 3G , a relief surface  127  is provided in the die at the transition area, where the smallest area of the passageway increases to a larger area that defines the final size of the product. The width or diameter  159  of the die tubing  156  is configured in a generally circular area having a diameter in a range of about of about 0.50 inches to 1.00 inches or an area in a range of about 0.25 square inches to 0.75 square inches. 
     Thus, as shown in  FIGS. 3E and 3G , the passageway extending through the die head  108  is defined by orifices  122 , funnel section  123 , die tubing  125  and relief surface  127 . In  FIG. 3G , the total area of reduction from the area of the grain entering the orifices  122  to the area exiting the die tubing  125  is in the range of about 55% to about 75%. The area of reduction between the inlet width or diameter  129  of the orifice  122  and the inlet width or diameter  139  of the funnel-shaped member  123  is approximately 45%. The area of reduction between the inlet width or diameter  139  of the funnel-shaped member  123  and the width or diameter  149  of the die tubing  153  is approximately 40%. From the die tubing  125  to the relief  127 , an area of increase of approximately 25% occurs. 
     The relief surface  127  extends downstream of the die tubing  125  and flares outward to an enlarged surface area (best shown in  FIG. 3E ), which defines the final product size. Namely, the width of the relief gap is substantially the same as the thickness of the extruded final product. Preferably, the enlarged relief section extends completely to the outlet side of the die head  108 . This is a significant factor in providing great structural strength of the die head  108 . As a result, the die head is particularly well-suited for the production of extruded articles having substantial long lengths. 
     The relief surface  127  in the die allows for the pressure of the process to be maintained upstream of the die head  108  and prevents the upstream pressure from being applied downstream past the relief surface  127  of the die head. The relief surface  127  serves as a buffer against downstream pressure, thereby reducing the excessive pressure that can fracture the die assembly. Thus, the relief surface  127  in the die enables the use of long cooling tubes  156  in the cooling chamber  150  to allow the process to produce a high volume output. The configuration of the relief surface can also mitigate the occurrence of die swell of the material after exiting the die. 
     Without the relief surface  127  in the die, the pressure applied upstream of the die head would also be applied to the cooling tubes. However, the cooling tubes  156  have been designed to be long in length to assure a long residence time of the dense grain while advancing through the cooling tubes in order to substantially cool the product. If the upstream pressure is applied downstream to the long cooling tubes, then the process would require significantly more energy and pressure to push the product through the long cooling tubes. Without the relief in the die, such a configuration would not be practical in some conventional devices, and in some conventional applications would be impossible. 
     The die assembly is made of a robust material, because it is subjected to a great amount of pressure and extremely high forces. Therefore, the die must be designed with sufficient strength to withstand such pressure and force without cracking or failing. The die constructed according to the present teachings permits it to withstand the great pressures developed in forcing the material therethrough with the result that such die has greater die life than previous dies and require fewer repairs. 
     When using the die assembly  110  illustrated in  FIGS. 1-3G , the die body  102  receives the dense hot grain from the bulk densification process (not shown) under pressure that is created by the continuous forward motion of the conveyance of material from the tip of the screws (not shown) through the bulk densifier adapter (not shown) to the die adapter  146  located at the second end  144 . Then, through the use of lateral pressure, the densified material is pushed passed the nose cone member  126  which directs the flow of the grain to the die head  108  via a direct passageway  124  which flows from the bulk densifier (not shown) to the die head  108 . 
     At the die head  108 , the material is split and forced laterally through multiple orifices  122 , which functions as an entrance of multiple passageways to the outlet of the die head. In certain embodiments, the orifices  122  are shaped, for example, like funnels such that the material enters the inlet of each orifice  122  evenly under pressure. As best shown in  FIGS. 2A, 2B, and 3E , the passageway extending through the die head  108  is defined by orifices  122 , funnel section  123 , die tubing  125  and relief surface  127 . Thus, the orifices  122 , funnel section  123 , die tubing  125  and relief surface  127  define flow paths for passage of the material from the die assembly downwardly in the direction of extrusion by pressure and force into the cooling chamber  150 . In such embodiments, the largest area of the orifice  122  is located at the inlet (best shown in  FIGS. 3B-3D ). At the funnel section  123 , the passage formed by the through-hole may taper inwardly from the inlet to a relatively small opening at the die tubing  125 . Therefore, due to the funnel shape of the orifice  122 , the material is compressed laterally and perpendicularly in a direction traverse to the direction of transport as the material advances forward. The internal structure of the die can be configured to produce a product that upon exiting the die the product is completely formed having the final desired shaped and the final desired high density. Thus, the die assembly may be configured such that flowing the grain material through the die head may generate sufficient lateral and perpendicular pressure on the grain material to produce the desired final density and shape of the product. After the material flows out of the relief of the die orifice  122  toward the cooling chamber, the material enters into the cooling tubes having its final shape and density. Therefore, upon completion of the die process, no additional steps such as applying additional pressure, or no additional additives are needed or required to achieve the desired high density or consistency. 
     In various embodiments, the die head  108  can be product specific such that the configuration of the orifices  122  can be selected based upon the desired characteristics of the final product.  FIGS. 9A-9D , similar to  FIG. 3A , also depict various embodiments of the die head having an array of die tubing.  FIG. 9A  depicts a die head  108   a  having a circular cross-section shape including 46 die tubes.  FIG. 9B  illustrates a die head  108   b  having a circular cross-section shape including 32 die tubes.  FIG. 9C  depicts a die head  108   c  having a circular cross-section shape including 48 die tubes.  FIG. 9D  illustrates a die head  108   d  having an octagon shape including 98 die tubes or channels. 
     Mechanisms other than the funnel members  123  of the orifices  122  may be used to introduce the grain material into the die head  108 . The funnel  123  may be of any particular shape other than conical or funnel-shaped, as long as the configuration compresses the material laterally and perpendicularly, such as, for example, triangular, pyramid, any configuration having inwardly sloping sides, etc.; the shape of the orifices  122  is exemplary and nonlimiting. Furthermore, the outflow end at the relief  127  of the funnel die tubing may be configured having a cross-sectional shape other than circular, such as, for example, square, rectangular, triangular, oval, etc. Those skilled in the art would recognize a variety of techniques and devices that may be used to introduce the grain material into the die head  108  and the cooling chamber  150 . 
       FIG. 4A  is a side perspective view of an exemplary embodiment of the cooling assembly  104  of  FIG. 1  shown in an opposite direction. When using the cooling assembly  104 , the apparatus  100  advances the densified grain in the form of a hot, dense, stable product from the die head  108  to the cooling assembly  104  for cooling the product. The cooling assembly  104  can be mounted in a face-to-face engagement with the second plate part of the die head  114 , as illustrated in  FIGS. 1, 2B and 2C . 
     The cooling assembly  104  may include a cooling chamber  150  having a first end  152 , a second end  154 , at least one cooling tube  156 , an outlet end  160 , a coolant passage  162 , a first coolant opening  164  and a second coolant opening  166 . The first end  152  may include a first plate member  186  ( FIGS. 2, 4A and 4B ) with a plurality of fourth set of holes  190  ( FIG. 4A ). The second end  154  may include a second plate member  188  ( FIG. 4A ) with a plurality of exit ports  184  ( FIG. 5 ). The at least one cooling tube  156  may include an inlet end  158  connected to the at least one connector  192  ( FIG. 4B ) as a passageway to the outlet end  160 . The outlet end  160  can be connected to at least one exit port  184  ( FIG. 5 ). A break-off assembly  106  ( FIG. 1 ) may be attached to the second plate member  188  at the second end  154  of the cooling chamber  150  ( FIGS. 1, 4A, and 5 ). 
       FIG. 4B  is a perspective view of the second plate member  186  as shown in  FIG. 4A . The second plate member  186  includes a first portion  128  having the plurality of second set of holes  190 . As illustrated in  FIG. 2C , the first plate member  186  of the cooling chamber  150  is in face to face engagement with the die plate  108  in such a way that they are aligned to each other and connected through the plurality of fourth set of holes  190  with the at least one fastening means, when assembled. The plurality of connectors  192  extend outwardly for connecting the passageway from the die head  108  with the cooling tubes  156 . One end of the plurality of connectors  192  mates with relief sections  127  of the die head  108 , and the other end of the plurality of connectors  192  mates with the cooling tubes  156 . Namely, the plurality of connectors  192  are configured to connect the die assembly  102  in fluid communication with the cooling chamber  150 . 
     In some embodiments, the cooling chamber may be manufactured from carbon steel including pressure rated individual cooling tubes made of stainless steel. In some embodiments, the cooling section may be 18 feet long and include 8 die tubes, each having a ⅞-inch diameter. In some embodiments, the cooling section may be 20 feet long and include 20 die tubes, each having a ⅞-inch diameter. In some embodiments, the cooling section may be 6½ feet long and include 48 die tubes, each having a 7/16-inch diameter. All of the above embodiments are exemplary and non-limiting. 
     Various embodiments of the cooling assembly  104  may further include some or all of the following additional components: a temperature gauge  170  for measuring surface temperature in the cooling chamber  150 , at least one valve drain  172  and at least one pressure relief valve  168  configured to regulate the amount of moisture added to the cooling chamber  150 . A coolant (not shown) can be supplied to the coolant passage  162  (See  FIG. 1 ) inside the cooling chamber  150  through the at least one coolant opening  164 ,  166  in order to remove heat from the densified grain. In various embodiments, the coolant opening  164 ,  166  can function as either an inlet or an outlet depending upon the configuration and application of the apparatus  100 . The coolant (not shown) can be, for example, water, water mixed with glycol, oil, refrigerants gas or gases and/or any cooling medium. 
     The coolant passage  162  (See  FIG. 1 ) maintains a low coolant temperature inside the cooling chamber  150  thereby removing a substantial amount of heat from the at least one cooling tube  156  during the process. In various embodiments, the at least one cooling tube  156  can include heat sink fins attached thereto to maximize cooling rates and efficiencies. Various embodiments of the cooling chamber may include a temperature gage  170  for measuring surface temperature in the cooling chamber  150 , at least one valve drain  172  and at least one pressure relief valve  168  adapted to regulate the amount of moisture added to the cooling chamber  150 . In some embodiments, the coolant (not shown) can be pumped through the coolant passage  162  in a re-circulatory manner with a pump or series of pumps (not shown). The coolant passage  162  inside the cooling chamber  150  can be managed by a central chilling system (not shown) to maintain a low coolant temperature thereby a substantial amount of heat is removed from the at least one cooling tube  156 . 
       FIG. 5  is a perspective view of the break-off assembly  106  embodied within the grain processing apparatus  100  shown in  FIG. 1  in accordance with the present teachings. The break-off assembly  106  can be attached to the second plate member  188  at the second end of the cooling chamber  154  (See  FIG. 5 ). The break-off assembly  106  can include at least one cone breaker  180  threaded to at least one stud member  178 . The at least one cone breaker  180  can be configured having a conical funnel shape. The at least one cone breaker  180  can be adjustable to twist or rotate in a clockwise or a counterclockwise direction and to move outward or away from the plurality of exit ports  184  of the cooling chamber  150  (See  FIG. 5 ). 
     At the completion of the cooling process, the densified and shaped grain material  182  may emerge from the grain processing apparatus  100  through the plurality of exit ports  184 . When exiting the plurality of exit ports  184  as shown in  FIG. 5 , the grain material  182  encounters the at least one cone breaker  180 , which breaks off a portion of the grain material  182  thereby producing a final product of a predetermined length, shape, size having a high density. The position of the at least one cone breaker  180  may be adjusted longitudinally to adjust the break-off length of the exiting grain material  182 . 
       FIG. 6  is a flow chart illustrating an exemplary method  600  for processing densified grain and for producing a highly densified grain material having a desired length, shape and size. In step  602 , the densified grain feeds into the die adapter  146  at the second end of the die body  110 . In step  604 , the densified grain is passed through the extrusion passageway  124  along the sides of the substantially triangular nose cone member  126 . Then in step  606 , the densified grain is pushed to the plurality of orifices  122  of the die head  108  under a constant pressure. 
     After the grain pushing process, the densified grain is conveyed through the plurality of orifices  122  in step  608 . In step  610 , the densified grain is transferred to the plurality of orifices  122  that extend out through the die head towards the second portion of the second plate part  114  thereby producing a high density shaped grain. In step  612 , the shaped grain is transferred to the inlet end  158  of the at least one cooling tube  156  of the cooling chamber. Each inlet end  158  connects to an outlet of the at least one orifice  122  of the die head. In step  614 , the shaped grain is directed along the inlet end  158  to the outlet end  160  of the at least one cooling tube  156 . During this transportation in step  616 , the heat present in the shaped grain can be removed by supplying the coolant in the coolant passage  162  inside the cooling chamber  150  through the at least one first and second coolant opening. 
     Then, the shaped grain  182  exits at the outlet end  160  of the at least one cooling tube. Thereafter, the shaped grain  182  emerges from the plurality of exit ports  184  of the second plate member in the cooling chamber in step  618 . Finally, the shaped grain  182  is broken off into the desired length utilizing the at least one cone breaker  180  in step  620 . The final product of the grains will be produced having sufficient density for effective transportation, handling and storage practices. 
       FIG. 7  illustrates another exemplary embodiment of the break-off assembly  106  shown in  FIG. 5 . In lieu of a single breaker  180 , in some embodiments, the break-off assembly  300  may include a plurality of cone breakers  302  attached to the second plate  306  having a plurality of exit openings  304  for the densified grain product. The plurality of cone breakers  302  can be threaded to a plurality of stud adapter  310 . This embodiment of the break-off assembly  300  including a plurality of cone breakers  302  allows the process to increase the productivity and produce a greater quantity of densified grain product within less time. 
       FIG. 8  illustrates yet another embodiment of the break-off assembly  106  shown in  FIG. 5 . In  FIG. 8 , the exemplary break-off assembly  400  includes a breaking mechanism  404  configured to provide a linear length of sliding movement for the densified grain, thereby efficiently adjusting the length of the densified grain product. The densified grain product exits from a plurality of tubes  402  which is adaptable to adjust the length of the densified grain product. Similar to the embodiments shown in  FIG. 7 , the break-off assembly  300 ,  400  effectively increases the productivity of the process and produces densified grain product having a desired length, shape and size. 
     By way of example only, the break-off assemblies  180  and  300  are depicted as having a conical shape. However, the break-off assemblies  180  and  300  may be of any particular shape other than conical or funnel-shaped, as long as the configuration breaks off the exiting final grain product, such as, for example, triangular, pyramid, any configuration having inwardly sloping sides, etc. Thus, the shape of the break-off assemblies  180  and  300  is exemplary and nonlimiting. 
     In an embodiment comprising a plurality of break-off assemblies  300 , multiple cooling tubes having multiple break-off assemblies  300  may be utilized to emit several continuous stream of densified grain product and break off the densified grain product having the desired length, shape, and size. In such an embodiment, some or all of the break-off assemblies  300  may have similar or different shaped configurations. In some embodiments, two or more of the cone breakers and the breaking mechanisms can be adjusted to produce grain having the same length. In other embodiments, some of the cone breakers and the breaking mechanisms can be individually adjusted to produce grain having different lengths. The adjustment of the breaker  180 , the plurality of breakers  302 , and the breaking mechanisms  404  can be performed individually or collectively through either manual or automatically controlled means. 
     In lieu of the triangular nose cone member  126  being centrally located, in some embodiments the triangular nose cone member may be positioned at a location offset from the center of the die. As shown in the example of  FIG. 11 , the offset configuration may be configured to enable different amounts of grain to flow through specific orifices to produce grain products having specific characteristics, such as smaller diameters  122   a  or larger diameters  122   b,  or different consistency. In some embodiment, the triangular nose cone may be configured such that the offset position is stationary. In other embodiments, the triangular nose cone may be rotated and locked in various positions to partially or completely block the inlet of the orifices to control the amount of grain inserted into specific orifices. This arrangement may enable selective use of one or more of specific orifices. Furthermore, in lieu of the uniform rectangular orifices depicted in  FIGS. 3A and 3B  in some embodiments, the orifices may have various sizes, as shown in  FIG. 11 , or various cross-sectional shapes configurations, such as, without limitations, circular, semi-circular (one-half of a circle), elliptical, oval, or polygonal cross-sections. 
     In general, according to various embodiments, the densified grain processing  100  apparatus enables the formation of highly densified grain material having a desired length, shape and size with greater ease and economy. The extrusion passageway  124  encloses the substantially triangular nose cone member  126  which is, centrally located, inwardly extending and acts as a flow-directing mechanism inside the die body  110 . The die head  108  and the die adapter  146  can be made, for example, of 4140PH and plated with an electroless nickel with Teflon impregnation along with a hardness bake. In some embodiments, the die head  108  and the die body  110  can be removably coupled to each other. 
     The die head  108  of the die assembly  102  may include a plurality of orifices  122 . Each orifice  122  may have an enlarged area at the inlet of the orifice and a narrowed area at the outlet of the orifice such that each orifice forms a funnel shape configuration. The funnel shape of the orifice compresses the densified grain laterally and perpendicularly according to the forward motion of the densified grain as it advances forward along the die head  108  towards the second plate part  114 . 
     The grain processing apparatus  100  provides the desired removal of heat content from the at least one cooling tube  156  by maintaining a low coolant temperature inside the cooling chamber  150  during the process. Various embodiments provide a grain processing apparatus and method for processing densified grain into higher densities without necessarily supplying any extra pressure. The grain processing apparatus  100  provides the desired features of reduced cost of energy and operation, as well as reduced maintenance, while maintaining a high output of grain product from the apparatus  100 . 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the device and method of the present disclosure without departing from the scope of its teaching. By way of example, the design of the various components of the apparatus, such as the die assembly, cooling, and the break-off assembly, can be configured based on the rheological characteristics of a specific material. 
     The rheological data can be used to determine the flow and deformation properties of a specific material under applied pressure as the material flows through the device. Some examples of rheological characteristics that may be considered in the system design are: temperature, pressure, flow rate, mechanical properties, flow properties, and viscosity. 
     CONCLUSION 
     Various embodiments of the present disclosure are disclosed herein. The disclosed embodiments are merely examples that may be embodied in various and alternative forms, and combinations thereof. 
     The law does not require and it is economically prohibitive to illustrate and teach every possible embodiment of the present claims. Hence, the above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the disclosure. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. All such variations, modifications and combinations are included herein by the scope of this disclosure and the following claims. 
     The foregoing description of the preferred embodiment of the present invention has been presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teachings. It is intended that the scope of the present invention not be limited by this detailed description, but by the claims and the equivalents to the claims appended hereto.