Foodstuff extrusion apparatus

Abstract

There is provided a food extrusion apparatus (1) for producing a continuous extruded layer of foodstuff, the apparatus (1) comprising a die (2), the die (2) comprising a main body (3), a core (4) comprising a first portion located within the main body (3), the core (4) comprising an elongate axis and a second coaxial portion extending outside of the main body (3) and further comprising a distal end to which a support (5) is attached, a flow path (7), wherein the flow path (7) comprises an annular radial space extending between the core (4) and the main body (3) and terminating at a distal end of the first portion of the core (4), said support (5)being moveable with respect to the main body (3), and a positioning means (6), wherein the positioning means (6) is configured to move the support (5) with respect to the main body (3) in a direction substantially perpendicular to the elongate axis of the core (4).

Description

FOODSTUFF EXTRUSION APPARATUSFIELD AND BACKGROUND

[0001] The present invention relates particularly, but not exclusively, to a foodstuff extrusion apparatus including a die arrangement for forming a continuous layer of food product. An invention described herein is particularly suitable for forming a layer having a plant protein constituent. This is known in the art as a 'meat analogue'. This layer is often referred to in the art as a "carpet". The foodstuff is often referred to as a "dough".

[0002] The food market is regularly launching plant-based products to cater for vegetarian and vegan consumers demand and more recently for that of flexitarians. There is also a desire from consumers to eat plant-based food products which replicate, in appearance, taste and texture, meat based products.

[0003] Meat analogue products made using conventional dies, for example flat coat hanger dies, have the disadvantage that the geometry does not allow a perfect flow of the dough in the die, particularly when the protein transition results in an elastic solid phase. This transition above a critical temperature is necessary in order to achieve a meat look alike structure made with plant protein.

[0004] This problem is mainly due to the planar distribution in the die geometry because of edge effects and difficulty in achieving a proper flow of solid dough at each side of the planar channel. Walling effects are often seen in conventional flat coat hanger dies whereby the dough exits the die much faster in the middle of the planar channel compared with at the edges of the channel, particularly at higher flow rates.

[0005] These manufacturing issues have been solved in the art using specific extruding dies which comprise rigid rods holding the die relative to an extrusion core. This has allowed extrudate to be formed into a layer or carpet. However, problems can be seen in the continuity of the extrudate in existing dies. A tilt is caused of the core by the pressure imposed by the dough at the entrance of the die and by the gravitational force acting on the inner core. This tilt leads to an uneven distribution of the dough across the cross section of the die leading to waves or discontinuities in the surface of the continuous layer.

[0006] Thus, the present inventors have established an improved apparatus and method of manufacturing a continuous layer of a dough comprising a plant protein in order to obtain symmetrical and homogeneous flow all along the die exit, particularly at higher flow rates. The layer or extrudateformed by the present invention has improved continuity and waves in the surface of the layer produced are reduced or eliminated entirely.

[0007] It will be recognised from the disclosure herein that the apparatus could also be used for the forming of non-plant-based food products or for non-food products. For example, the apparatus could be used for producing a layer or "carpet" of food products using, for example, minced meat. Alternatively, the apparatus could be used for forming a sheet of plastic.SUMMARY

[0008] Particular aspects and embodiments are set out in the appended claims.

[0009] Viewed from a first aspect, there is provided a food extrusion apparatus for producing a continuous extruded layer of foodstuff. The apparatus comprises a die. The die comprises a main body, a core comprising a first portion located within the main body, the core comprising an elongate axis, and a flow path, wherein the flow path comprises an annular radial space extending between the core and the main body and terminating at a distal end of the first portion of the core. The die additionally comprises a support, wherein the support is attached to the core and wherein the support is moveable with respect to the main body, and a positioning means, wherein the positioning means is configured to move the support with respect to the main body in a direction substantially perpendicular to the elongate axis of the core.

[0001] The apparatus may be used to extrude a "meat analogue". The term "meat analogue" is intended to mean a meat emulsion product that resembles meat that has been derived from an animal source, in terms of appearance, texture, and physical structure. The meat derived from an animal source can be, for example, red meat, white meat, and fish. As used herein, a meat analogue does not include meat derived from an animal source; for example, a meat analogue that lacks meat derived from an animal source may instead use vegetable protein to achieve the appearance, texture, and physical structure of meat derived from an animal source. The meat analogue of the first aspect may comprise fibres which are formed in a substantially perpendicular direction to the flow path of the die.

[0002] The term "elongate axis of the core" is intended to mean the axis of the core extending from the point of the core along its length when the core is located in the main body with its outer surfaces parallel with the inner surfaces of the main body. Since the core moves as the support moves, movement with respect to the elongate axis of the core is intended to be with respect to the original position of the core when it is located coaxially in the main body. For example, the support may movevertically or horizontally in a perpendicular direction with respect to the original position of an axis of the core in the main body.

[0003] Thus, according to the invention, a layer of foodstuff such as meat analogue is produced with improved continuity compared to that produced by existing dies used for the same purpose. For example, the positioning means allows readjustment of the core to counterbalance uneven forces acting on it due to inhomogeneous flow or gravitation due to the die's own weight. This enables the apparatus to maintain uniform flow distribution in the cone, thus leading to continuous and consistent flow of material to produce a stable and uniform thickness layer of meat-analogue. For example, when the dough is entering the die and causing tilting of the die with respect to the main body, the positioning of the core can be adjusted. Alternatively, the positioning of the core can be pre-adjusted based on the type of dough to be used. Adjustment of the position of the core in the main body enables an even spread of dough around the core and prevents waves being formed on the surface of the carpet.

[0004] The core may comprise a second coaxial portion extending outside of the main body and further comprising a distal end to which the support is attached.

[0005] The core may be attached to the second coaxial portion by an attachment means arranged around the second portion and wherein the attachment means may be attached to the support by a single connecting arm.

[0006] Thus, according to the invention, a 'monorail' die is provided; the core is supported by a single arm. By using a single arm to support the core at the top of the die, multiple advantages are provided compared to existing dies in the industry. The majority of the product exit area is without any obstruction, except at the singular (thus the name monorail) arm. As a result of the monorail design, significant improvement in free exit area is achieved, leading to unobstructed flow of the layer of foodstuff out of the die exit. This improves the continuity and stability of the layer produced.

[0007] Furthermore, this single arm design also allows more hygienic production of foodstuff such as meat analogue as there is less interaction of the final product with the die external parts. The monorail design also enables deploying of the product directly onto a conveyor belt after the exit from the die.

[0008] The single connecting arm may extend radially away from the distal end and towards the main body. This increases the extrusion outlet space and prevents the extruded layer coming into contact with the connecting arm.

[0009] The attachment means may be spaced from the first portion of the core to provide an extrusion outlet space surrounding the core. This allows space for the extrudate to be sliced by a cutting portion before falling onto the conveyer belt and prevents the extruded layer coming into contact with the connecting arm.

[0010] The attachment means may be a coaxial cylinder arranged around the second portion of the core. The coaxial cylinder enables an even distribution of force around its circumference. The second axial portion may have a generally cylindrical cross-section. Thus a strong connection is achieved between the cylindrical attachment means and the second axial portion of the core.

[0011] The connecting arm may comprise a portion with a tapered cross-section attached to the coaxial cylinder. In this way, the obstructed portion of the flow area from the die is reduced. For example, the connection of the tapered portion to the coaxial cylinder may only block about 16% of the projected area around the circumference of the die.

[0012] The positioning means may comprise an adjustment means and an insert with an inclined plane. The adjustment means may be usable to cause the insert to move into and retract from a gap between the support and the main body. When the insert moves into the gap between the support and the main body, a distance between an inner surface of the support and an outer surface of the main body may increase and when the insert retracts from the gap between the support and the main body, the distance between the inner surface of the support and the outer surface of the main body may decrease.

[0013] Thus, as discussed above, the positioning of the core in the main body can be adjusted. The adjustment means may be automated or manual.

[0014] The adjustment means may comprise a screw. When the screw is turned in a first direction, the insert may forced into the gap between the support and the main body. When the screw is turned in a second direction, the insert may retract from the gap between the support and the main body.

[0015] The inclined plane of the insert may be at an angle of about 1 to 5 degrees, for example about 3 degrees, to a base of the insert. Thus, the movement of the core with respect to the main body can be controlled to a high level of granularity. Movement of the insert by 1 mm into / out of the gap will cause movement of the core in an upwards / downwards direction of about 0.05 mm. Thus, this enables a smooth extruded layer of food product to be formed without there being sudden changes in thickness of the extruded layer.

[0016] The insert may be moveable by about 5 to about 10 mm, for example about 8 mm into / out of the gap between the support and the main body. In some examples, movement of the insert may cause movement of the support up / down by up to about 0.5 mm.

[0017] The insert may be located vertically above the support when the apparatus is in use. When the insert moves into the gap between the support and the main body, the core may be configured to move upwards in the main body. When the insert retracts from the gap between the support and the main body, the core may be configured to move downwards in the main body.

[0018] The first portion of the core may comprise a conical end and a cylindrical body. By using a conic core, the simplicity of the die is improved. Furthermore, by using a die with circular symmetry, a uniform flow of dough through the die can be achieved.

[0019] The die may be a coat-hanger type die. Furthermore, the die may be a short coat-hanger type die. A "short" die is a term used in the art and is determined by the ratio between the perimeter of the core and the length of the core between the tip of the cone to the die exit.

[0020] The die may comprise a die exit, wherein the die exit may be circular and formed by a gap between the core and the main body. Thus, an annular extrudate may be formed and cut along its length to form a carpet.

[0021] The die may additionally comprise a heat circulation system, wherein the heat circulation system may comprise heating units on an outer surface of the core and on an inner surface of the main body. In this way, the temperature of the dough can be controlled throughout its thickness.

[0022] The outer surface of the core and the inner surface of the main body may each comprise two separate heating circuits. In this way, the internal and external parts of the die can be controlled at different temperatures in order to maintain a uniform dough temperature across the cross section of the die.

[0023] According to a second aspect, a method of producing a continuous extruded layer of foodstuff is provided. The method comprises applying heat and / or pressure to a dough in an extruder, passing the dough through a die that is part of and / or is connected to the extruder. The die comprises a main body, a core comprising a first portion located within the main body, the core comprising an elongate axis, and a flow path, wherein the flow path comprises an annular radial space extending between the core and the main body and terminating at a distal end of the first portion of the core. The die additionally comprises a support, wherein the support is attached to the core and wherein thesupport is moveable with respect to the main body, and a positioning means, wherein the positioning means is configured to move the support with respect to the main body in a direction perpendicular to the elongate axis of the core. The method further comprises adjusting the positioning means to move the support with respect to the main body.

[0024] The term 'dough' is intended to mean the meat analogue food product which is input into the die.

[0025] The dough may be directed through the flow path at a massic flow rate of between about 100 and about 1000 kg / h. For example, the massic flow rate may be between about 450 and about 500 kg / h. It can be seen that massic flow rates such as these combined with the adjustment means of the invention enables a more stable carpet of meat analogue to be produced with no visible waves.

[0026] The meat analogue may comprise fibres which are formed in a substantially perpendicular direction to the flow path of the die.

[0027] The positioning means may be adjusted while the dough is passing through the die. This prevents waves being formed in the carpet created from the meat analogue as the positioning of the core with respect to the main body can be controlled.

[0028] The positioning means may be adjusted before the dough is passed through the die. Thus, the positioning of the core with respect to the main body can be controlled based on the dough to be used.

[0029] Other aspects will also become apparent upon review of the present disclosure, in particular upon review of the Brief Description of the Drawings, Detailed Description and Claims sections.BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Examples of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

[0031] Figure 1 shows an isometric view of an apparatus for producing a food product such as a meat analogue;

[0032] Figure 2 shows a cross-sectional view of the apparatus of figure 1;

[0033] Figure 3 shows a distal end-on view of the apparatus of figure 1;

[0034] Figures 4A and 4B show the support raised from the main body of the die (figure 4A) and lowered with respect to the main body of the die (figure 4B); and

[0035] Figures 5 to 10 show an extruded layer of food stuff formed by a prior art apparatus (figure 5) and the apparatus according to the invention (figures 6 to 10).

[0036] While the disclosure is susceptible to various modifications and alternative forms, specific example approaches are shown by way of example in the drawings and are herein described in detail. It should be understood however that the drawings and detailed description attached hereto are not intended to limit the disclosure to the particular form disclosed but rather the disclosure is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the claimed invention.

[0037] As used in this specification, the words "comprises", "comprising", and similar words, are not to be interpreted in an exclusive or exhaustive sense. In other words, they are intended to mean "including, but not limited to".

[0038] It will be recognised that the features of the above-described examples of the disclosure can conveniently and interchangeably be used in any suitable combination. It will also be recognised that the invention covers not only individual embodiments but also combinations of the embodiments that have been discussed herein.DETAILED DESCRIPTION

[0039] The present teaching relates generally to an apparatus and a method for producing a carpet of a food product such as meat analogue.

[0040] Figure 1 shows an isometric view of an apparatus 1 for producing a continuous extruded layer or carpet of a food product such as meat analogue. Figure 2 shows a cross-sectional view of the apparatus 1. Foodstuff or dough enters the left side of the apparatus shown in figure 2 and exits from the right side. Figure 3 shows a distal end-on view of the apparatus 1. The apparatus 1 comprises a die 2. The die 2 comprises a main body 3, a core 4, a support 5, and a positioning means 6. The die 2 of the present example is a coat-hanger type die.

[0041] The core 4 comprises a first portion located within the main body 3 and comprises an elongate axis. A flow path 7 is defined between the main body 3 and the core 4. The flow path 7comprises an annular radial space extending between the core and the main body and terminating at a distal end of the first portion of the core 4. A gap between the core 4 and the main body 3 at a distal end of the main body 3 forms a die exit 10. Typically, the die exit 10 is circular and has a defined gap size. For example, the die exit 10 may have a gap size of between about 4 to about 5 mm, for example 4.8 mm. In other examples, the gap may be between about 1 to about 2 mm, for example 1.5 mm. The die exit may have an external perimeter of greater than 400 mm. For example, the die exit may have an external perimeter of between 400 mm and 500 mm, for example 450 mm. The main body 3 and the core 4 have a concentric spatial relationship. Due to the shape of the dye exit 10, food product or 'dough' entering the die 2 leaves the die exit 10 in an annular shape.

[0042] Adjacent to the die exit 10, a cutting portion 11 is attached to the core. As the dough leaves the die exit 10, the cutting portion 11 cuts along the length of the annular shape so that the dough is formed into a flat layer or carpet.

[0043] The core 4 comprises a second coaxial portion extending outside the main body 3. In the present example this second portion is cylindrical however it may be a different shape. A coaxial cylinder 14 is arranged around the second portion. The coaxial cylinder 14 is attached to the support 5 by a single connecting arm 15. The coaxial cylinder 14 is spaced from the first portion of the core to provide an extrusion outlet space surrounding the core. This is best seen in figure 2 where a gap can be seen between the coaxial cylinder 14 and the die exit 10. The connecting arm 15 is attached to the coaxial cylinder by a portion with a tapered cross-section 16. In other examples, rather than a coaxial cylinder 14, a differently shaped attachment means may be used to attach the tapered portion 16 of the arm 15 to the second portion of the core 4.

[0044] The positioning means 6 is configured to move the support 5 with respect to the main body 3 in a direction substantially perpendicular to the elongate axis of the core. The movement of the support 5 with respect to the main body 3 causes the core 4 to move within the main body 3 thus altering the shape of the annular radial space extending between the main body 3 and the core 4.

[0045] The positioning means 6 comprises an adjustment means 8 and an insert 9 located in a gap between the support 5 and the main body 3. The insert comprises an inclined plane and thus is formed in a 'wedge' shape when viewed in cross-section as in figure 2. The angle of the pointed end of the wedge is between about 1 and about 5 degrees. For example, the angle is about 3 degrees.

[0046] The support 5 additionally comprises two centering pins 12. The centering pins 12 extend through the support 5, through slots 13 in the insert 9 and into the main body 3. The centeringpins 12 prevent movement of the support with respect to the main body in the axial direction of the core.

[0047] In the present example, the adjustment means 8 is a screw. The positioning means 6 additionally comprises a closing plate 18. The closing plate 18 prevents movement of the screw out of the support 5. The screw is threaded and interacts with a threaded hole in the insert 9. Rotation of the screw is thus able to force the insert away from the screw further into the gap between the support 5 and the main body 3 and also draw the insert out of this gap as it is threaded onto the screw.

[0048] For example, when the screw is turned in a first direction (for example clockwise), the insert 9 is forced into the gap between the support 5 and the main body 3. This is due to the rotation of the screw undoing the threaded connection between the screw and the insert 9. This causes the insert 9 to be driven away from the screw into the gap. When the screw is turned in a second direction (for example anti-clockwise), the insert 9 is retracted from the gap between the support and the main body due to the interaction between the threads on the screw and within the insert. Essentially, the screw is screwed further into the insert 9. Since the closing plate 8 prevents movement of the screw out of the gap, the insert is pulled further onto the screw. One complete revolution of the screw may move the insert 9 into / out of the gap by 1 mm.

[0049] When the insert 9 moves into the gap between the support 5 and the main body 3, a distance between an inner surface of the support 5 and an outer surface of the main body 3 increases due to the inclined edge of the insert 9. Specifically, the support 5 shown in figure 1 will move in the upwards direction. Since the support 5 is attached to the core 4, as the support 5 moves upwards, the core 4 will also move upwards. Thus the location of the core 4 inside the main body 3 will change. As the support 5 moves upwards, the centering pins 12 remain stationary with respect to the main body 3.

[0050] When the insert 9 retracts from the gap between the support and the main body, the distance between an inner surface of the support 5 and an outer surface of the main body 3 decreases. Specifically, the support 5 shown in figure 1 will move in the downwards direction. Since the support 5 is attached to the core 4, as the support 5 moves downwards, the core 4 will also move downwards. Thus the location of the core 4 inside the main body 3 will change. Due to the angle of the inclined plane, movement of the insert 9 into or out of the gap by 1 mm causes the support 5 and thus the core 4 to move up or down by about 0.05 mm respectively. The insert is moveable by about 8 mm in the gap between the support and the main body.

[0051] Figure 4A shows the insert 9 fully inserted into the gap between the support 5 and the main body 3 and the support 5 lifted from the main body 3. Figure 4B shows the insert 9 retracted from the gap between the support 5 and the main body 3 and the support 5 abutting the main body 3.

[0052] In other examples, other forms of manual adjustment means 8 other than screws may be used. In other examples, the adjustment means 8 may be automated.

[0053] The support 5 further comprises holding screws 25 (shown in figures 1, 3 and 4A). In the present example, six holding screws 25 are used on either side of the support 5. However, fewer than this could be used. The holding screws 25 attach to the main body 3. This prevents movement of the core 4 (which is attached to the support) in the axial direction within the main body 3 due to the dough being forced onto the pointed end of the core. Specifically, these holding screws 25 prevent the core 4 being pushed out of the main body 3 with the dough. When the vertical location of the core 4 needs to be altered within the main body 3 as a result of tiling / to pre-empt tilting, the holding screws 25 are loosened, the insert 9 inserted or retracted then the holding screws 25 are tightened again with the core 4 is in the desired position.

[0054] The die 2 additionally comprises a heat circulation system 17. The heat circulation system 17 comprises four inlets and four outlets to circulate heated water around the die. The first portion of the core 4 is split into two parts where the first half is cooled by a first helical internal cooling system 21 and a first helical external cooling system 22 and the second half is cooled by a second helical internal cooling system 23 and a second helical external cooling system 24.

[0055] With this heat circulation system 17, the internal surface of the two halves of the first portion of the core can be cooled separately to the outer surface of the two halves of the first portion of the core.

[0056] The cooling water enters in through inlet 19 for the second internal cooling system 23 and leaves at outlet 20. Similarly, there are inlets and outlets for the first internal cooling system 21 and the first and second external cooling systems 22, 24. By having multiple cooling systems, the internal and external parts of the die can be maintained at different temperatures in order to ensure the dough temperature remains uniform across the cross section of the die. Furthermore, by having both internal and external cooling systems, the temperature of the dough can be maintained throughout its depth.

[0057] The apparatus 1 additionally comprises a conveyer belt (not shown) to carry the extruded dough layer from the die exit 10.

[0058] A method of using the apparatus will now be discussed. Heat and / or pressure is applied to a dough in an extruder. The dough enters into the die 2 of the apparatus 1 through the left hand side of figure 2. The dough passes into the annular radial space extending between the main body 3 and the core 4 and travels along this space and out of the die exit 10 in an annular shape where it is cut by the cutting portion 11. The formed continuous layer then falls onto the conveyer belt (not shown) and is carried away from the die 2.

[0059] As a result of flow non-homogeneity and / or the gravitational forces acting on the core 4 as a result of the dough, the conical end of the core 4 is forced to tilt downwards inside the main body 3. This causes discontinuities such as wave-like shapes in the layer of extruded food stuff.

[0060] In order to counteract this tilting, the screw 9 is turned in order to force the insert 9 into the gap between the support and the main body 3. This forces the support 5 and consequently the core 4 upwards. In some examples, the core 4 may be moved downwards in the main body 3. This may be to correct an error of alignment.

[0061] This adjustment in the positioning of the core 4 within the main body 3 may occur whilst the dough is passing through the die. This can be carried out due to an operator noticing discontinuities in the continuous layer leaving the die. Alternatively, the tilt may be detected by measuring the thickness of the extruded layer in the middle and on its edges. In another example in which an automated adjustment means 8 is used, a sensor may detect changes in the gap between the core 4 and the main body 3 around its circumference and adjust the position of the core accordingly. Alternatively, this change in gap size may be monitored manually.

[0062] In other examples, a test dough with the same material properties as the actual dough to be extruded may be run through the die and the deformation in the core 4 monitored. Based on this monitored deformation using the test dough, the core 4 is offset within the main body 3 to preempt the deformation when the dough to be extruded is fed into the system. Thus, the core 4 may be pre-offset to differing amounts based on the dough to be used.

[0001] The invention will now be described, by way of example only, with reference to the following Examples.

[0002] Example 1: Production of extruded layer of foodstuff with a die according to the art. The extruded layer formed with this apparatus is shown in figure 5.

[0003] Example 2: Production of extruded layer of foodstuff with the food extrusion apparatus of the present invention. The core is offset by 0.5 mm and the massic flow rate of the dough is 450 kg / h. The extruded layer formed with this apparatus and these parameters is shown in figure 6.

[0004] Example 3: Production of extruded layer of foodstuff with the food extrusion apparatus of the present invention. The core is offset by 0.25 mm and the massic flow rate of the dough is 450 kg / h. The extruded layer formed with this apparatus and these parameters is shown in figure 7.

[0005] Example 4: Production of extruded layer of foodstuff with the food extrusion apparatus of the present invention. The core is not offset within the main body. The massic flow rate of the dough is 450 kg / h. The extruded layer formed with this apparatus and these parameters is shown in figure 8.

[0006] Example 5: Production of extruded layer of foodstuff with the food extrusion apparatus of the present invention. The core is offset by 0.25 mm and the massic flow rate of the dough is 500 kg / h. The extruded layer formed with this apparatus and these parameters is shown in figure 9.

[0007] Example 6: Production of extruded layer of foodstuff with the food extrusion apparatus of the present invention. The core is offset by 0.5 mm and the massic flow rate of the dough is 500 kg / h. The extruded layer formed with this apparatus and these parameters is shown in figure 10.

[0008] As can be seen from these examples, the extruded layer formed with a die according to the art (figure 5) has significant discontinuities. The layer is broken in some locations and waves are formed along its length. In figures 5 and 6 and 8 and 9, the layers produced with apparatus having throughputs of 450 and 500 kg / h and having preset offsets in the core within the main body, it can be seen that the surface of the layer has a smoother surface than the layer in figure 7 where no offset is implemented. Thus, these examples show the improvements achieved by the apparatus of the present invention when the offset of the core is implemented.

[0009] The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and / or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the spirit and scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

CLAIMS:

1. A food extrusion apparatus (1) for producing a continuous extruded layer of foodstuff, the apparatus (1) comprising a die (2), the die (2) comprising: a main body (3); a core (4) comprising a first portion located within the main body (3), the core (4) comprising an elongate axis and a second coaxial portion extending outside of the main body (3) and further comprising a distal end to which the support (5) is attached; a flow path (7), wherein the flow path (7) comprises an annular radial space extending between the core (4) and the main body (3) and terminating at a distal end of the first portion of the core (4); a support (5), wherein the support (5) is attached to the core (4) and wherein the support (5) is moveable with respect to the main body (3); and a positioning means (6), wherein the positioning means (6) is configured to move the support (5) with respect to the main body (3) in a direction substantially perpendicular to the elongate axis of the core (4).

2. The apparatus (1) of claim 1, wherein the support (5) is attached to the second coaxial portion (14) by an attachment means arranged around the second portion and wherein the attachment means is attached to the support (5) by a single connecting arm (15).

3. The apparatus (1) of claim 2, wherein the single connecting arm (15) extends radially away from the distal end and towards the main body (3).

4. The apparatus (1) of claims 2 or 3, wherein the attachment means is spaced from the first portion of the core (4) to provide an extrusion outlet space surrounding the core (4).

5. The apparatus (1) of any of claims 2 to 4, wherein the attachment means is a coaxial cylinder (14) arranged around the second portion of the core (4).

6. The apparatus (1) of any of claims 2 to 5, wherein the second axial portion has a generally cylindrical cross-section.

7. The apparatus (1) of any of claims 2 to 6, wherein the connecting arm (15) comprises a portion with a tapered cross-section (16) attached to the coaxial cylinder (14).

8. The apparatus (1) as claimed in any of claims 1 to 7, wherein the positioning means (6) comprises an adjustment means (8) and an insert (9) with an inclined plane, wherein the adjustmentmeans (8) is usable to cause the insert (9) to move into and retract from a gap between the support (5) and the main body (3), wherein: when the insert (9) moves into the gap between the support (5) and the main body (3), a distance between an inner surface of the support (5) and an outer surface of the main body (3) increases; and when the insert (9) retracts from the gap between the support (5) and the main body (3), the distance between the inner surface of the support (5) and the outer surface of the main (3) body decreases.

9. The apparatus (1) as claimed in claim 8, wherein the adjustment means (8) comprises a screw, wherein: when the screw is turned in a first direction, the insert (9) is forced into the gap between the support (5) and the main body (3); and when the screw is turned in a second direction, the insert (9) retracts from the gap between the support (5) and the main body (3).

10. The apparatus (1) as claimed in claim 8, wherein the adjustment means (8) is automated.

11. The apparatus (1) as claimed in any of claims 8 to 10, wherein the inclined plane of the insert (9) is at an angle of 1 to 5 degrees to a base of the insert.

12. The apparatus (1) as claimed in any of claims 8 to 11, wherein the insert (9) is moveable by 5 to 10 mm in the gap between the support (5) and the main body (3).

13. The apparatus (1) as claimed in any of claims 8 to 12, wherein the insert (9) is located vertically above the support (5) when the apparatus is in use, wherein: when the insert (9) moves into the gap between the support (5) and the main body (3), the core (4) is configured to move upwards in the main body (3); and when the insert (9) retracts from the gap between the support (5) and the main body (3), the core (4) is configured to move downwards in the main body (3).

14. The apparatus (1) according to claims 1 to 13, wherein the die (2) additionally comprises a heat circulation system (17), wherein the heat circulation system (17) comprises heating units on an outer surface of the core (4) and on an inner surface of the main body (3).

15. The apparatus (1) according to claim 14, wherein the outer surface of the core (4) and the inner surface of the main body (3) each comprise two separate heating circuits.

16. A method of producing a continuous extruded layer of foodstuff, the method comprising: applying heat and / or pressure to a dough in an extruder; passing the dough through a die (2) that is part of and / or is connected to the extruder, the die(2) comprising: a main body (3); a core (4) comprising a first portion located within the main body (3), the core (4) comprising an elongate axis and a second coaxial portion extending outside of the main body (3) and further comprising a distal end to which the support (5) is attached; a flow path (7), wherein the flow path (7) comprises an annular radial space extending between the core (4) and the main body (3) and terminating at a distal end of the first portion of the core (4); a support (5), wherein the support (5) is attached to the core (4) and wherein the support (5) is moveable with respect to the main body (3); and a positioning means (6), wherein the positioning means (6) is configured to move the support (5) with respect to the main body (3) in a direction perpendicular to the elongate axis of the core (4), the method further comprising: adjusting the positioning means (6) to move the support (5) with respect to the main body (3).

17. The method according to claim 16, wherein the positioning means (6) is adjusted while the dough is passing through the die (2) or before the dough is passed through the die (2).

Images