Systems and methods for a dairy-based shell

Abstract

Systems, methods, and devices for producing a dairy -based shell are described herein. A method of producing the dairy-based shell includes receiving a slice of cheese having a first moisture content. The method includes baking the slice of cheese until the slice of cheese reaches a second moisture content. The second moisture content is less than the first moisture content. The baked slice of cheese has a first shape. The method includes frying the baked slice of cheese in a second shape until the slice of cheese reaches a third moisture content. The third moisture content is less than the second moisture content, and the second shape is different from the first shape.

Description

Atty. Dkt. No.: 137677-0410SYSTEMS AND METHODS FOR A DAIRY-BASED SHELL CROSS-REFERENCE TO RELATED APPLICATION

[0001] This PCT Application claims the benefit of and priority to U.S. Provisional Application No. 63 / 755,314, filed February 7, 2025, which is incorporated herein by reference in its entirety and for all purposes.TECHNICAL FIELD

[0002] The present disclosure relates generally to the field of food preparation. More specifically, the present disclosure relates to systems and methods of producing edible shells from dairy or dairy-based ingredients.BACKGROUND[000 | Dairy is a common ingredient for food preparation. One common type of dairy product is cheese. Cheese is a general category of dairy products that includes numerous types. Each type of cheese has a variety of different attributes, such as a flavor profile, a texture, being hard or soft, and having a distinct aroma. Cheese is commonly used with or in a variety of foods, such as pizzas.SUMMARY

[0004] One embodiment relates to a method for producing a shell. The method includes receiving a slice of cheese, baking the slice of cheese, frying the baked slice of cheese, and shaping the fried slice of cheese via a shaping tool so that the fried slice of cheese assumes a different shape relative to the received slice of cheese.

[0005] Another embodiment relates to a method for producing a shell formed from cheese. The method includes baking a slice of cheese, receiving the baked slice of cheese in a fryer having a fry basket, and providing a lid within the fry basket such that the slice of cheese rests against the lid while frying. The method further includes shaping the fried slice of cheese via a shaping tool so that the fried slice of cheese assumes a different shape relative to the baked slice of cheese.-1- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410

[0006] Yet another embodiment relates to a method of producing a dairy product and, particularly, a shelf-stable cheese product. The method includes providing a slice of cheese having a fat content within a first range and a first moisture content within a second range. The method further includes baking the slice of cheese at a predetermined temperature for a first duration until the slice of cheese reaches a second moisture content within a third range, the second moisture content being lower than the first moisture content.

[0007] A further embodiment relates to a method of producing a shell. The method includes receiving a slice of cheese having a first moisture content. The method includes baking the slice of cheese until the slice of cheese reaches a second moisture content. The second moisture content is less than the first moisture content. The baked slice of cheese has a first shape. The method includes frying the baked slice of cheese in a second shape until the slice of cheese reaches a third moisture content. The third moisture content is less than the second moisture content, and the second shape is different from the first shape.

[0008] Yet a further embodiment relates to a method of producing a shell. The method includes baking a slice of cheese. The baked slice of cheese has a first shape. The method includes providing a shaping basket having a basket and an insert. The basket defines at least one U-shaped cavity. The insert defines at least one concave and convex section. The method includes positioning the baked slice of cheese in the at least one U-shaped cavity of the basket. The method includes lowering the insert into the basket such that a concave portion of the at least one concave and convex section extends into the at least one U-shaped cavity to hold the baked cheese slice in a second shape. The method includes frying the baked slice of cheese in the second shape and cooling the fried slice of cheese in the second shape to form the shell.

[0009] Numerous specific details are provided to impart a thorough understanding of embodiments of the subject matter of the present disclosure. The described features of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments and / or implementations. In this regard, one or more features of an aspect of the invention may be combined with one or more features of a different aspect of the-2- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410invention. Moreover, additional features may be recognized in certain embodiments and / or implementations that may not be present in all embodiments or implementations.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 A is a perspective view of a food product having a shell made from or mostly from a dairy product, such as cheese, according to an embodiment.|0011] FIG. IB is a perspective view of a food product having a shell made from or mostly from a dairy product, such as cheese, according to an embodiment.

[0012] FIG. 2A is a front view of a round slice of a dairy product, shown as cheese, used to produce a food product, such as shell made of the cheese, according to an embodiment.

[0013] FIG. 2B is a front view of a rectangular slice of a dairy product, shown as cheese, used to produce a food product, such as shell made of the cheese, according to an embodiment.

[0014] FIG. 3 is a flow diagram of a process for producing a food product, such as the shell of FIGS. 1 A and IB, according to an embodiment.

[0015] FIG. 4 is a perspective view of a lid for frying a food product, such as the shell of FIGS. 1 A and IB, according to an embodiment.

[0016] FIG. 5A is a perspective view of a shaping tool for a food product, such as the shell of FIGS. 1 A and IB, according to an embodiment.

[0017] FIG. 5B is a side view of the shaping tool of FIG. 5A.

[0018] FIG. 6 is a perspective view of a shaping basket for a food product, such as the shell of FIGS. 1 A and IB, according to an embodiment.[0019[ FIG. 7 is a perspective view of the shaping basket of FIG. 6.

[0020] FIG. 8 is a perspective view of the shaping basket of FIG. 6 in a condition of use.-3- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410[00211 FIG. 9 is a perspective view of the shaping basket of FIG. 6 in an assembled condition.

[0022] FIG. 10 is a flow diagram of a process for producing a food product, such as the shell of FIGS. 1 A and IB, according to an embodiment.DETAILED DESCRIPTION

[0023] Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.

[0024] Referring generally to the Figures, the various embodiments disclosed herein relate to systems, methods, and assemblies for producing non-conventional food products. In particular, the systems, methods, and assemblies relate to producing a shell made of or primarily of a dairy product, such as cheese. In one embodiment, the shell may be used to hold other food items or products. In this regard, the shell may be used to form a taco. In other embodiments, the shell may be a standalone food product.

[0025] As described herein, the shell is produced by baking a slice of cheese in a flat or substantially flat position. In some embodiments, the baked slice of cheese is then fried in a flat position. After baking and / or frying, the cheese slice is placed on a shaping tool and allowed to cool. Once cooled on the shaping tool, the cheese slice forms the shell.Advantageously, the shell produced herein is made entirely of cheese and is structurally stable enough to receive other food items therein. For example and with the taco use case above, the shell of the present disclosure may receive a protein product (e.g., ground beef, chicken, shrimp, etc.), salad, olives, salsa, other cheese, another shell (e.g., a conventional flour-based shell may be disposed within or outside of the cheese shell), and / or other food items. Traditionally, shells incorporating cheese use other ingredients, such as flour-based dough, for structural stability. For example, some cheese shells are tortillas having cheese cooked onto one or more surfaces of the tortilla. In contrast, the cheese shell described herein-4- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410utilizes fewer ingredients than these conventional shells, and therefore, may be less costly to produce.

[0026] Technically and beneficially, the systems and methods described below produce a relatively crispier cheese shell than other methods. Further, the systems and methods described herein provide a non-conventional way to produce structurally stable shells formed of entirely or substantially entirely cheese. This may be appealing to consumers who desire fewer ingredients in their food products. These and other features and benefits are described more fully herein below.

[0027] Referring now to FIGS. 1 A-2B, views of a food product, particularly a shell 10 made of a dairy product, namely cheese, and cheese slices 5 are shown, according to an embodiment. As referred to herein, “shell” refers to a structural component of a food product, namely a taco, that is structured to at least partially enclose one or more ingredients positioned on or within the shell. As used herein, “cheese” refers to a dairy based product having a particular moisture and / or fat content that allows the cheese to hold its shape while being cut into portions, and namely sliced into slices.

[0028] The cheese slices 5 may be processed and particularly cooked to form the shell 10 food product. The cooking may include at least one of baking or frying to form the shell 10, as shown in FIGS. 1 A and IB. This process is described in greater detail with respect to FIG.3. The cheese slices 5 may have a variety of initial shapes before processing / cooking. For example, the cheese slices 5 may be round, as shown in FIG. 2A, or relatively rectangular, as shown in FIG. 2B. In other embodiments, the cheese slices 5 may have a different starting shape (e.g., square shaped, trapezoidal, etc.). In the examples shown, a single cheese slice is depicted in FIGS. 2A and 2B. It is to be appreciated that the plural is referenced to indicate the capability of producing multiple shells from multiple slices (i.e., for mass production). In some embodiments, a single slice of cheese is used to make a single shell. In some other embodiments, more than one slice of cheese is used to make a single shell. The desired shell size relative to the slice size may dictate whether one slice is sufficient for one shell or multiple slices are needed to make one shell. The present disclosure encompasses all such variations.-5- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410[0029| The cheese slices 5 may be any suitable type of cheese or a combination of cheeses. In some embodiments, the cheese slices 5 are natural cheddar cheese. More specifically, the cheese slices 5 are a mild cheddar cheese with a fat content of 29-33% and a moisture content of 35-38%, both measured as percentages of the cheese’s total weight. In some examples, the fat content of the cheese slices 5 is expressed as a fat-to-dry basis, wherein the fat content is expressed as a percentage of the total dry matter of a cheese rather than as a percentage of the cheese’s total weight (e.g., the weight of the cheese slice 5 including moisture). For example, the cheese slices 5 may be a mild cheddar cheese with a fat-to-dry basis of 50-60%.Additionally or alternatively, the cheese slices 5 may have a potential of hydrogen (pH) in a range between 4.9 and 5.4. In some examples, the cheese slices 5 are a type of cheese, other than cheddar, having a reduced fat content relative to a standard fat content (e.g., 19-24% fat as a percentage of the cheese’s total weight). For example, the cheese slices 5 may be a reduced fat pasteurized process cheese. A reduced fat pasteurized process cheese may be or include one type or multiple types of cheese mixed with an emulsifying agent, among other ingredients. In some examples, the cheese slices 5 may be processed cheese products. A processed cheese product is a food produce made by blending natural cheeses with one or more other ingredients, such as emulsifiers, water, dairy solids, or stabilizers, among other ingredients. A processed cheese product comprises at least 51% cheese. The particular fat content of the cheese slices 5 may prevent or mitigate stretching in a shell making process described with respect to FIG. 3. An example of various reduced fat natural cheeses that the cheese slice 5 may be made of and the associated nutritional contents are shown in the table below:[0030| An example of various natural regular / standard fat cheddar cheeses that the cheese slice 5 may be made of and the associated nutritional contents, chemical specifications, and microbiological specifications are shown in the table below:-6- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410<> < << < << < < < <<< < <4919-7543-3093.1Atty. Dkt. No.: 137677-0410[00311 An example of a reduced fat pasteurized process cheese that the cheese slice 5 may be made of and the associated nutritional contents, chemical specifications, and microbiological specifications are shown in the table below:<<<-8- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410

[0032] In some examples, the cheese slices 5 are cut from a log, block, horn, loaf, or wheel of cheese into slices of a predetermined thickness. For example, the cheese slices 5 may have a thickness in a range of approximately 1 millimeter and 3 millimeters. The cheese slices 5 may have a relatively uniform thickness, according to exemplary embodiments. In other embodiments, the cheese slices 5 may be cut from a log, block, horn, loaf, or wheel of cheese in a non-uniform manner such that a single cheese slice 5 comprises various thicknesses that differ by more than a predefined amount. For example, a relatively uniform thickness may be achieved when the cross-sectional thickness of the slice is within a predefined amount of desired cut thickness (e.g., 1 millimeter ±0.3 millimeter), while the non-uniform thickness is realized when the cross-sectional thickness of the slice in at least one region has a thickness outside of the predefined tolerance (e.g., outside of the ±0.3 millimeters with the example above). In the non-uniform embodiment and as a specific example, the cheese slice 5 of FIG.2A may be cut such that the circumferential edges of the cheese slice 5 are thicker than the central portion of the cheese slice 5. As another example, the cheese slice 5 of FIGS. 2 A and 2B may be cut such that a central line of the cheese slice 5 has a greater thickness than the surrounding portions of the cheese slice 5. In either example, the cheese slice 5 may be cut to satisfy a predefined weight threshold (e.g., a predetermined range of acceptable weights) for the subsequent shell formation of the cheese slice.10033] Referring specifically to FIG. 2A, the cheese slice 5 defines or has a surface diameter D. In some embodiments, the diameter D may be in a range of approximately 5-7 inches and, more specifically, approximately 6 inches. Referring specifically to FIG. 2B, the cheese slice 5 defines or has a surface length L and a surface height H. In some examples, the length L and height H are the same or nearly the same. In this way, the cheese slice 5 may be substantially square in shape. In other examples, the length L and height H are different, such -9- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410that the cheese slice 5 is substantially rectangular in shape. In some examples, the length L and / or the height H are in a range of approximately 4-6 inches. More specifically, the length L and / or height H are 4.25 inches or 5.5 inches. Although the cheese slices 5 are illustrated as round and rectangular, these illustrations are not meant to be limiting as the present disclosure contemplates other embodiments where the cheese slices 5 are other shapes, such as semicircles, trapezoids, or any other polygonal shape. All such combinations and variations are intended to fall within the scope of the present disclosure.

[0034] Referring now to FIG. 3, a flow diagram of a process 100 for producing a cheese shell (i.e., the cheese shell 10 of FIGS. 1 A and IB) is shown, according to an embodiment.

[0035] At process 110, one or more cheese slices 5 are provided. The one or more cheese slices 5 may be cut or otherwise formed and then provided to a user. In other embodiments, the one or more cheese slices 5 are cut, refrigerated, and then shipped to an end user for subsequent processing (e.g., cooking, baking, frying, etc.).

[0036] At process 120, the cheese slices 5 are cooked, and particularly baked or partially baked (par-baked) in an oven (e.g., a natural gas, electric, or convection oven). Cheese slices 5 may be par-baked, for example, when the cheese slices 5 are intended to undergo an additional baking, frying, or other cooking process after the cheese slices 5 are par-baked. In the process 100, the cheese slice(s) 5 are baked in a flat or relatively flat position (i.e., a two-dimensional shape primarily). For example, the cheese slice(s) 5 may be baked on a baking sheet to maintain a relatively flat position. Multiple cheese slices 5 may be baked simultaneously at process 120. The cheese slices 5 are baked for a predetermined duration at a predetermined temperature (e.g., for 7 minutes at 400°F, for 3 minutes at 450°F, 2 minutes at 500°F, etc.). In one embodiment, the cheese slice 5 is deposited onto parchment paper and baked in a tunnel oven at the predetermined duration and temperature. The predetermined duration and predetermined temperature may be determined based on testing. As an example, the cheese slices 5 may be deposited onto parchment paper and baked in a tunnel or linear oven for 2-2.4 minutes at 450-500°F. More particularly, the cheese slices 5 may be deposited onto parchment paper with a first side facing upwards (e.g., away from a baking surface) and baked in a first tunnel oven for 1-1.2 minutes at 450-500°F, then baked in a second tunnel-10- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410oven for 1-1.2 minutes at 450-500°F. In some examples, the cheese slices 5 are flipped after exiting the first tunnel oven and before being positioned within the second tunnel oven, such that a second side of the cheese slices 5 are facing upwards (e.g., away from a baking surface).

[0037] In some examples, the bake time is determined based on a moisture threshold. For example, the cheese slice 5 has a first moisture content before the cheese slice 5 is baked. The cheese slice 5 is baked until the cheese slice 5 has a second moisture content, which is lower than the first moisture content and satisfies the moisture threshold. As a specific example, the cheese slice 5 may be comprised of a natural cheese (e.g., cheddar, pepper jack, marble jack, etc.) having a first moisture content of 35-38% of the total weight of the cheese slice 5. As another specific example, the cheese slice 5 may be comprised of a pasteurized process cheese (e.g., pasteurized process reduced fat cheddar) having a first moisture content of 42-46%. The cheese slice 5 may then be baked until the cheese slice 5 reaches the second moisture content. For example, the cheese slice 5 comprised of natural cheese (e.g., cheddar, pepper jack, marble jack, etc.) may be baked until the cheese slice 5 has a second moisture content of approximately 10-23%. As another example, the cheese slice 5 comprised of pasteurized process cheese (e.g., pasteurized process reduced fat cheddar) may be baked until the cheese slice 5 has a second moisture content of approximately 22-26%.

[0038] Additionally or alternatively, the bake time may be determined based on a weight threshold for the cheese slice 5. For example, the cheese slice 5 has a first weight before baking. The cheese slice 5 is baked until the cheese slice 5 has a second weight, less than the first weight, which satisfies the weight threshold. As a specific example, the cheese slice 5 comprised of natural cheese may have a first weight of 1 ounce and may be baked until the cheese slice 5 has a weight of .85 oz. As another example, the cheese slice 5 comprised of pasteurized process cheese may have a first weight of 18-22 grams and may be baked until the cheese slide 5 has a weight of 14-21 grams.

[0039] After baking, the plurality of cheese slices 5 may be stored. The baked cheese slices 5 may be stored at room temperature, refrigerated, or frozen. In this way, the cheese slices 5 may be baked at a first location and shipped to a second location, where the remaining-11- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410process of the process 100 may be performed. In particular, once the cheese slices 5 are baked, they are cooled, stacked, and packaged in corrugate cases with a plastic liner. The cases are then frozen and distributed to a second location for the remaining of process 100 to occur. Alternatively, the process 100 may occur at a single location.

[0040] Technically and beneficially, after baking the plurality of cheese slices 5 for the predetermined duration at the predetermined temperature and / or from an initial moisture content to a second moisture content may make the baked cheese slices 5 generally shelfstable. As referred to herein, “shelf-stable” refers to food and other perishable items that can be stored at room temperature for a particular amount of time without spoiling or requiring refrigeration. During baking, the cheese slices 5 lose moisture which may reduce the opportunity for future bacterial growth. Additionally, baking can serve as a pasteurization type process which kills, substantially kills, or reduces certain bacteria that may have been present in the cheese slices 5. Baking may also cause fats within the cheese slices 5 to solidify or restructure in a manner that makes the cheese slices 5 more shelf stable relative to unbaked cheese slices 5. The baked cheese slices 5 may have a “crust” on their exterior, which can act as a protective barrier against oxidation. In some examples, various preservatives are added to the cheese slices 5 before or after baking to extend shelflife (e.g., sorbic acid, natamycin, nitrates, nitrites, calcium propionate, etc.).

[0041] In some examples, the baked cheese slices 5 may serve as a standalone product. For example, multiple baked cheese slices 5 may be packaged and distributed for later use, such as consumption. The baked cheese slices 5 may be, for example, vacuum sealed, positioned within sealed flexible packaging, such as a plastic bag, boxed, etc. In some examples, paper, such as wax paper or parchment paper, may be positioned between each baked cheese slice 5 in a package. Additionally or alternatively, the baked cheese slices 5 may be coated in an anti-stick agent, such as cellulose, before packaging the backed cheese slices 5. As a standalone product, the baked cheese slices 5 may be baked to a predetermined moisture threshold that differs from the predetermined moisture threshold for cheese slices 5 intended to be formed into shells.-12- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410[00421 Subsequent to the baking, and specifically par-baking, and freezing of the cheese slices 5 (in the multiple location processing example above), the case containing the cheese slices 5 (from the example above) may be de-thawed. The de-thawing may occur in a refrigerated environment or in an ambient environment.

[0043] At process 130 and after de-thawing (if the cheese slices 5 were frozen for, e.g., transport or later usage), the cheese slices 5 par-baked at process 120 are fried. Particularly, at least one of the baked cheese slices 5 is placed in a fryer, such as fry basket of a deep fryer (e.g., an oil fryer)to fry in a desired position, such as a flat or relatively flat position. Multiple cheese slices 5 may be fried simultaneously at process 120. In some examples, a plurality of cheese slices 5 are stacked on top of one another, then placed into the fry basket. The cheese slices 5 are fried for a predetermined time at a predetermined fry oil temperature. In some examples, the fry time is determined based on a moisture threshold. For example, the cheese slice 5 has a second moisture content after the cheese slice 5 is par-baked and before the cheese slice 5 is fried. The cheese slice 5 is fried until the cheese slice 5 has a third moisture content that satisfies the moisture threshold. As a specific example, the cheese slice 5 comprised of a natural cheese may have a second moisture content of 10-23% of the total weight of the cheese slice 5. The cheese slice 5 may then be fried until the cheese slice 5 reaches a moisture content of 5-9%. As another example, the cheese slice 5 comprised of pasteurized process cheese (e.g., pasteurized process reduced fat cheddar) may be fried until the cheese slice 5 has a second moisture content of approximately 4- 10%. Additionally or alternatively, the bake time may be determined based on a weight threshold for the cheese slice 5. For example, the cheese slice 5 has a second weight after baking but before frying. The cheese slice 5 is fried until the cheese slice 5 has a third weight that satisfies the weight threshold. Although described above as being deep fried in a fry basket, the cheese slices 5 may be fried by any suitable means, such as pan frying, air frying, oven frying, wok frying, and / or the like.

[0044] In some examples, a lid 20 is positioned in the fry basket while the cheese slice 5 is in the fryer oil. The cheese slices 5 may float within the oil to rest against a surface of the lid 20. In this way, the cheese slices 5 fry in a flat or substantially flat position for the predetermined fry time. The lid 20 is described in greater detail with respect to FIG. 4.-13- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410

[0045] At process 140, the cheese slice 5 is placed on a shaping tool (e.g., the shaping tool 40 shown in FIGS. 5A and 5B). In some examples, the cheese slice 5 is placed on the shaping tool 40 immediately after removal from the fryer or shortly thereafter (e.g., within a predefined short period of time, such as five seconds). In other examples, the cheese slice 5 is placed on the shaping tool after removing the cheese slice 5 from the oven. Prior to being placed on the shaping tool 40, the cheese slice 5 may define a first shape. The first shape may be a relatively flat shape / primarily two-dimensional shape. The cheese slice 5 may be positioned on the shaping tool by a user / attendant while the cheese slice 5 satisfies a predetermined temperature threshold. While the cheese slice 5 satisfies the predetermined temperature threshold, the cheese slice 5 is relatively flexible or malleable such that the cheese slice 5 assumes the shape of the shaping tool. The shape the cheese slice 5 assumes when positioned on the shaping tool 40 may be a second shape different from the first shape. In some embodiments, the shaping tool is parabolic in shape (e.g., a U-shaped curve). In this way, when the cheese slice 5 is positioned on the shaping tool while the cheese slice is at the predetermined temperature threshold, the cheese slice 5 assumes the parabolic shape of the shaping tool (i.e., the second shape is parabolic / U-shaped). The cheese slice 5 is cooled on the shaping tool until the cheese slice 5 hardens and / or is relatively stiff (i.e., brittle, crunchy, etc.).

[0046] At process 150, the cheese slice 5 is removed from the shaping tool (e.g., by an attendant or user). As mentioned above, once cooled, the cheese slice 5 solidifies into a relatively stiff material. Upon removal from the shaping tool, the cheese slice 5 forms the shell 10 as shown in FIGS. 1 A and IB. The shell 10 may be structurally stable such that it may be filled with one or more various food items. In particular and in an example implementation, the shell 10 may be a taco shell. In some examples, the shell 10 may be combined with other shells for additional structural stability. For example, a tortilla may be positioned inside the shell 10 (or vice versa). As another example, a hard taco shell may be positioned inside the shell 10 (or vice versa).

[0047] The aforementioned process for producing the shell 10 are not necessarily chronological. Conversely, the process may be performed in any order and some processes may be omitted. Accordingly, the described process is not meant to be limiting as many other-14- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410processes may be used with such variations intended to fall within the present disclosure. For example, the cheese slices 5 may be fried until they reach a predetermined moisture threshold from an initial / uncooked state, without the intermediate process of baking the cheese slices 5. As a specific example, a cheese slice 5 comprised of a processed cheese product may be fried until they reach a predetermined moisture threshold from an initial / uncooked state, without the intermediate process of baking the cheese slices 5.

[0048] As another example, the cheese slices 5 may be baked in an oven until they reach a predetermined moisture threshold (e.g., 5-9% of the total weight of the cheese slice 5) and shaped using a shaping tool (e.g., the shaping tool 40 shown in FIGS. 5A and 5B) without the intermediate process of frying the baked cheese slice. In such an example, the cheese slices 5 may be baking in a single bake session or multiple bake sessions. In this way, the cheese slices 5 may be baked to a predetermined moisture threshold in one bake session and shaped on a shaping tool after the single bake session (e.g., while the baked slice of cheese satisfies a predetermined temperature threshold). In some examples, cheese slices 5 subjected to a single bake session are baked at a predetermined temperature (e.g., 500°F) for a predetermined time. For example, the cheese slices 5 may be baked to a first moisture content threshold, then stored (e.g., frozen, refrigerated, in a container at room temperature) and / or shipped for a second bake session. During the second bake session the cheese slices 5 may be baked from the first moisture content threshold to a second, lower, moisture threshold. After the second bake session the cheese slice 5 may be shaped on the shaping tool (e.g., while the baked slice of cheese satisfies a predetermined temperature threshold).

[0049] Referring now to FIG. 4, a perspective view of the lid 20 is shown, according to an example embodiment. The lid 20 (e.g., cover, top, etc.) is shown to include a base 28, a handle 24 extending from a first end of the base 28 upward and away from the base 28, and a hook 22 extending from a second end of the base 28 opposite the first end and away from the handle 24.

[0050] A shape of the base 28 may correspond to a shape of a fry basket. For example, as shown in FIG. 4, the base 28 may have a generally rectangular shape. The base 28 is sized such that the base 28 may be positioned within the fry basket without the base 28 touching or-15- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410a low likelihood that the base 28 touches the sides of the basket. Additionally, the base 28 may include rounded or cut comers 30 such that the base 28 forms an irregular octagon shape. The shape of the corners 30 may allow the lid 20 to be more easily inserted into a fry basket than, for example, a generally rectangular base 28 with sharp corners (e.g., which may snag on the wires or mesh of the fry basket while the lid 20 is being inserted).[00511 The base 28 includes or defines one or more apertures 26 that allow oil to pass through the base. In this way, the base 28 may suspend itself below the oil rather than floating to the top of the oil. The size, shape, and number of apertures 26 is highly configurable. As shown, the number of apertures 26 cover substantially an entire surface area of the base 28. In other embodiments, the number of apertures 26 cover only a portion of the surface area of the base 28. In the example shown, the apertures have a substantially circular shape. In other embodiments, a different shape may be used. In still other embodiments, a shape and / or size of at least aperture may differ from that of at least one other aperture.

[0052] In some examples, a bottom side (e.g., the side of the base 28 opposite the handle and the hook) of the base 28 includes a non-stick coating (e.g., Teflon™, silicone, ceramic, etc.). The non-stick coating allows the cheese slices 5 to rest flat against the base 28 of the lid 20 while the cheese slices 5 fry, without sticking to the base 28. In some embodiments, the nonstick coating is applied to the top surface of the base 28 as well. In some examples, the nonstick coating is integral with the lid 20 and, particularly, the base 28. In other embodiments, the non-stick coating is selectively applied (e.g., via a spray applicator). The non-stick coating may also be applied to other parts and / or surfaces of parts of the lid 20 as well, in some embodiments (e.g., applied to a surface of the hook 22 and to the handle 24).

[0053] As shown in FIG. 4, the handle 24 is coupled to the base 28 proximate an edge of the base 28. The handle 24 may be coupled to a top side of the base, the bottom side of the base, or a side wall of the base (on a thickness or height portion of the base 28). The coupling may be via a slide in rail disposed along the base, a detachable clip or bracket, a magnet, welding, a fastener, a combination thereof, etc.[0054J The handle 24 is shown to include an elongated portion 34 configured to extend along an interior side of a fry basket. In this way, the elongated portion 34 may be oriented-16- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410substantially vertically relative to the base 28. In some embodiments, the elongated portion 34 is oriented at an angle that follows a slope of an interior side of the fry basket (i.e., a complementary shape). The handle 24 is also shown to include a grip portion 36 that extends away from the elongated portion 34 (and the fry basket, in operation). In some examples, the grip portion 36 extends relatively perpendicularly away from the elongated portion 34. In some examples, the grip portion 36 includes a holder 32 that a user may hold during operating. The holder 32 may be removable or may be a coating on the grip portion 36. In exemplary embodiments, the holder 32 is an insulative material (e.g., silicone, rubber, plastic, cork, etc.) that provides a relatively cooler surface for a user to hold while the lid 20 is in use.

[0055] The lid 20 further includes a hook 22 configured to engage with an upper edge of the fry basket while the lid 20 is in use. The hook 22 is coupled to the base 28 proximate an edge of the base 28. The hook 22 may be coupled to the top side of the base, the bottom side of the base, and / or a side wall of the base. The coupling may be via one or more of: a slide in rail disposed along the base, detachable clips or brackets, magnets, welding, fasteners (e.g., screws), etc. In the example shown, the hook 22 is shown to extend relatively perpendicularly from the base 28. Similar to the elongated portion 34 of the handle 24, the hook 22 may be oriented substantially vertically or at an angle that follows a slope of the interior side of the fry basket. Technically and beneficially, the hook 22 may serve to keep the lid 20 relatively stable during frying by latching onto an upper rail of the basket and sustaining the lid 20 in a substantially stationary position when in use with the fry basket. Although the hook 22 is shown to be positioned near an edge opposite the handle 24, the hook 22 may be positioned near an edge adjacent to the handle 24, on the same edge as the handle 24, and / or in another location with all such variations are intended to fall within the spirit and scope of the present disclosure. Similarly, although one hook 22 is shown in FIG. 4, multiple hooks 22 may extend from the base 28.

[0056] Referring now to FIGS. 5A and 5B, the shaping tool 40 is shown, according to an embodiment. The shaping tool 40 (e.g., tool, forming or molding structure, etc.) is shown to have a wave-like shape designed for shaping the cheese slices 5 after baking and / or frying into a preferred shell shape. The shaping tool 40 includes a series of relatively evenly spaced concave and convex sections 44. These sections resemble an “M” or “W” shape when viewed-17- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410from the side, as shown in FIG. 5B. Thus, in this embodiment, the preferred shape is a V-or U-shape for the shell. In other embodiments, a different shape may be utilized (e.g., a flat bottom with two vertically extending sides). The cheese slices 5 may be placed over the peaks 46 of the concave and convex sections 44 to cool. For example, a centerline of the cheese slices 5 may be aligned with the peaks of the concave and convex sections 44 while the side portions of the cheese slices 5 drape down the sides 48 of the concave and convex sections 44. In other examples, the centerline of the cheese slices 5 may be aligned with the valleys 50 of the concave and convex sections 44 such that the side portions of the cheese slices 5 extend up the sides 48 of the concave and convex sections 44. As shown in FIG. 5A, the concave and convex sections 44 create a plurality of adjacent valleys 50 and peaks 46, allowing the tool to hold multiple cheese slices 5 simultaneously.

[0057] As shown in FIG. 5A, the shaping tool 40 includes a plurality of drain holes 42. The drain holes 42 allow for excess liquids (e.g., oil from the cheese slice 5 cooking process, condensation, etc.) to drain off the cheese slice 5 after baking and / or frying. This may prevent or mitigate the cooled cheese slices 5 from becoming soggy. Advantageously, the drain holes 42 serve as venting for airflow to the cheese slices 5 as the cheese slices 5 cool after baking and / or frying. This may allow for quicker cooling relative to a shaping tool 40 without drain holes. The shaping tool 40 is made of a relatively rigid material, such as stainless steel, plastic, or aluminum. The surface of the shaping tool 40 is smooth and may include a nonstick coating to reduce the likelihood of the cheese slices 5 from sticking to the surface of the shaping tool 40. Technically and beneficially, the shaping tool 40 has a stackable design that allows for efficient storage.

[0058] Although described above with reference to shaping the cheese slices 5, the shaping tool 40 is suitable for other culinary applications, such as shaping taco shells, pastries, or other food products that benefit from a curved or upright shape. Such uses are intended to fall within the spirit and scope of the present disclosure. Although the shaping tool 40 described above and shown in FIGS. 5A and 5B have a “wave-like shape,” any suitable shaping tool may be used to cool the cheese slices 5 after baking / frying. For example, the shaping tool 40 may be a bowl, a flat sheet, a mold, tin, tart pan, ramekin, wire rack, shaped foil, cookie cutter, or any other suitable shaping device. For example, the cheese slice 5 may be placed-18- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410over a dome shaped tool (e.g., the underside of a bowl, a hemispherical mold, etc.) after baking / frying to create a dome-shaped shell (e.g., a relatively hemispherical shell). Such a dome-shaped shell may serve as a lid (e.g., cover, etc.) to a bowl, plate, or other serving dish. For example, the dome-shaped shell may serve as a lid to a particular food item positioned within a bowl, such as a salad or soup, and a user may break the shell into a topping for the food item (e.g., by cracking the shell with a utensil, with their hands, etc.). Similarly, the cheese slice 5 may be placed within a bowl, tin, or ramekin, for example, to form a shell 10 having bowl-like shape. In other examples, the cheese slice 5 may be rolled over a relatively cylindrical or conical device to form a shell having a relatively cylindrical or conical shape. In this way, the shell 10 may be formed in various shapes to accommodate various quantities and types of filings.Referring now to FIGS. 6-9, a shaping basket 60 for frying the cheese slices 5 into a shell shape is shown, according to an example embodiment. The shaping basket 60 may serve as an alternative tool to the lid 20 and the shaping tool 40. For example, the shaping basket 60 may allow a user to fry and shape the cheese slices 5 into shells 10 simultaneously, rather than requiring a fry process followed by a shaping process.

[0060] The shaping basket 60 (e.g., shaper, shaping container, shaping receptacle, molding device, etc.) is shown to include an insert 62 and a basket 64. The insert 62 may be positioned basket 64 within the basket to assemble the shaping basket 60. The insert 62 is shown to have a wave-like body 78 designed for shaping the cheese slices 5 after baking and / or frying into a preferred shell shape. The body 78 includes a series of relatively evenly spaced concave and convex sections 94. These sections may resemble an “M” or “W” shape when viewed from the side, as shown in FIG. 8. The body 78 is shown to be supported by a frame 82. The frame 82 may include a perimeter and one or more frame members configured to receive the convex portions of the body 78. In some examples, the body 78 is removably coupled with the frame 82. For example, the body 78 may be removed from the frame 82 for cleaning. In other examples the body 78 and the frame 82 are a unitary body. The body 78 is shown to include at least one opening 80. The opening 80 may allow gasses released by the cheese slice 5 during frying to escape from the surfaces of the cheese slice 5. The openings 80 may serve as venting for airflow to the cheese slices 5 as the cheese slices 5 cool after baking and / or-19- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410frying. This may allow for quicker cooling relative to a body 78 without openings 80. In one example, the shaping basket is made from a metal material (e.g., food grade metal). In another example, the shaping basket is made from a different material or a combination of materials.

[0061] The insert 62 is shown to include a handle 66. The handle 66 is shown to include an elongated portion 70 configured to extend along an interior side of a handle 68 of the basket 64. In this way, the elongated portion 70 may be oriented substantially vertically relative to the perimeter of the frame 82. In some embodiments, the elongated portion 70 is oriented at an angle that follows a slope of an interior side of the basket 64 (i.e., a complementary shape). The handle 66 is also shown to include a grip portion 72 that extends away from the elongated portion 70 (and the fry basket, in operation). A user may maneuver the insert 62 via holding the grip portion 72, for example.

[0062] The basket 64 is shown to have a wave-like body 99 that is configured to receive the insert 62. For example, the basket 64 is shown to include at least one curved bottom portion 84 extending between sidewalls 98. The curved bottom portion 84 and the sidewalls 98 extending therefrom create a U-shaped cavity. Each U-shaped cavity defines a section 92 of the body 99. Each section 92 of the basket 64 is configured to receive a concave and convex section 94 of the insert 62. In this way, the concave and convex sections 94 of the insert 62 extend into the U-shaped cavities defining the sections 92 of the body 99 of the basket 64. The body 99 is shown to be supported by a frame 90. The frame 90 may include frame members that extend along the perimeter of the body 99 and frame members that extend vertically between other frame members. In some examples, the body 99 is removably coupled with the frame 90, such that the body 99 may be removed for cleaning. In other examples, the body 78 and frame 90 are a unitary component. The body 99 is shown to include at least one opening 88. The openings 88 may allow fry oil to engage with the surfaces of the cheese slices 5 during frying. The openings 88 may function as drain holes. For example, the openings 88 allow for excess liquids (e.g., oil from the cheese slice 5 cooking process, condensation, etc.) to drain off the cheese slices 5 after baking and / or frying. This may prevent or mitigate the shells 10 formed by the cooled, fried cheese slices 5 from becoming soggy. Advantageously, the openings 88 may serve as venting for airflow to-20- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410the cheese slices 5 as the cheese slices 5 cool after baking and / or frying. This may allow for quicker cooling relative to a body 99 without openings 88.

[0063] The basket 64 is shown to include a handle 68. The handle 68 is shown to include an elongated portion 74 oriented substantially vertically relative to the perimeter of the frame 90. The handle 66 is also shown to include a grip portion 76 (e.g., interface element, user interface portion, etc.) that extends away from the elongated portion 74. The handle 68 is shown to have a complimentary shape to the handle 66. In operation, the insert 62 is positioned within the basket 64, as shown in FIG. 9. At least a portion of the handle 66 of the insert 62 may abut, interface with, or otherwise contact the handle 68. A user may maneuver the shaping basket 60 as a whole by the grip portion 76 of the basket 64. For example, a user may insert and remove the shaping basket 60 from a fryer by moving the shaping basket 60 by the grip portion 76 of the basket 64.

[0064] In some embodiments, the basket 64 may further include a hook 96 extending from the frame 90. The hook 96 is shown to be positioned on a side of the basket 64 opposite the handle 68. The hook 96 may allow for attachment to a fryer and / or engagement with a fryer frame during frying. The hook 96 may be variously configured depending on the configuration of the fryer where the shaping basket 60 is employed. While only one hook 96 is shown, more hooks may be included and may be positioned variously on or around the basket 64.

[0065] In operation, the cheese slices 5 are positioned between the body 99 of the basket 64 and the body 78 of the insert 62. In this way, the cheese slices 5 are held against a curved bottom portion 84 and the sidewalls 98 extending therefrom of the basket 64 by the concave and convex sections 94 of the body 78 of the insert 62. In this way, the cheese slices 5 are held in a U-shape or substantially parabolic shape while frying. Similarly, the cheese slices 5 may cool into shells 10 while positioned between the body 99 of the basket 64 and the body 78 of the insert 62. In this way, the cheese slices 5 cool into U-shaped or a substantially parabolic shape upon the shaping basket 60 being removed from a fryer. As shown in FIG. 8, the shaping basket 60 advantageously allows for simultaneous frying and shaping of multiple cheese slices 5 into shells 10.-21- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410

[0066] Referring now to FIG. 10, a flow diagram of a process 1000 for producing a cheese shell (i.e., the cheese shell 10 of FIGS. 1A and IB) is shown, according to an embodiment.

[0067] At process 1002, one or more cheese slices 5 are provided. The one or more cheese slices 5 may be cut or otherwise formed and then provided to a user. In other embodiments, the one or more cheese slices 5 are cut, refrigerated, and then shipped to an end user for subsequent processing (e.g., cooking, baking, frying, etc.). The process 1002 may be the same as, or substantially similar to the process 110.

[0068] At process 1004, the one or more cheese slices 5 are baked. Baking the cheese slice 5 can include positioning the cheese slice 5 on a baking surface, such as a baking sheet. In some examples, an intermediate layer, such as parchment paper or a silicon baking mat, is positioned in between the baking surface and the cheese slice 5. The baking surface and cheese slice 5 thereon are positioned in an oven for baking. The baking process includes a predefined bake time and at least one predefined bake temperature. For example, the predefined bake time and predefined bake temperature may be 500°F for 1.5 minutes. The predefined bake time and bake temperature(s) may vary based on the type of cheese the cheese slice 5 comprises. For example, a cheese slice 5 comprising a natural cheese (e.g., cheddar, reduced fat cheddar, etc.) may have a first predefined bake time and at least one first predefined bake temperature, and a cheese slice 5 comprising a reduced fat pasteurized process cheese may have a second predefined bake time and at least one second predefined bake temperature different from the first predefined bake time and the first predefined bake temperature.[00691 At process 1006, the baked cheese slice 5 is fried in the shaping basket 60. In this way, the cheese slices 5 are fried while being held in a relatively U-shape to form the shell 10. For example, at process 1006, the baked cheese slice 5 may be positioned within the basket 64 in a U-shape orientation (in other examples, a different shape may be utilized, such as a flat-bottom shape and not a curved bottom shape, or a triangular-shaped bottom, etc.). For example, the baked cheese slice 5 may be positioned such that a centerline of the baked cheese slice 5 rests along the curved bottom portion 84 and the sides of the baked cheese slice 5 extend up along the inner faces of the sidewalls 98 extending from the curved bottom-22- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410portion 84. The insert 62 may then be lowered into the basket 64, such that the concave portion of the concave and convex sections 94 extend into a corresponding section 92 of the body 99 of the insert 62. In this way, the insert 62 holds the baked cheese slices 5 in a U-shape or substantially parabolic shape. A user may then maneuver the insert 62 by the handle 68 of the basket 64 to position the shaping basket 60 in a fryer. The baked cheese slices 5 may be submerged (in one embodiment, fully; in another embodiment, at least partly) in the frying oil for a predefined frying duration at a predefined frying temperature. The predefined frying duration and predefined frying temperature may be, for example, 5-40 seconds at 350°F, 10-30 seconds at 350°F, or 15-25 seconds at 350°F. While submerged in frying oil, the cheese slice 5 may lose moisture. For example, the baked cheese slice 5 may have a second moisture content, and the fried cheese slice 5 may have a third moisture content that is less than the second moisture content. Upon expiration of the predefined frying duration, the shaping basket 60, and the cheese slices 5 therein, may be removed from the frying oil. The shaping basket 60 may remain assembled (e.g., with the insert 62 positioned within the basket 64) while the fried cheese slice 5 cool. In this way, the fried cheese slices 5 may cool while still positioned between the basket 64 and the insert 62 to hold the fried cheese slices 5 in a U-shape or substantially parabolic shape. The cheese slice 5 is cooled within the shaping basket 60 until the cheese slice 5 hardens into a shell 10 and / or is relatively stiff (i.e., brittle, crunchy, etc.).[0070| At process 1008, the shaping basket 60 may be disassembled by removing the insert 62 from the basket 64. A user may, for example, de-nest the insert 62 from the basket 64 (i.e., when the insert and basket are engaged for forming the shells, they may be considered nested or assembled into a forming arrangement) by maneuvering the insert 62 by its handle 66. To remove the shells 10 formed from the cooled, friend cheese slices 5, a user may, for example, invert the basket 64 by maneuvering the basket 64 by its handle 68. In other examples, the shells 10 may be individually removed by a user picking them up by their hands, or by a tool, such as tongs. In some examples, the shell 10 has similar material characteristics to a traditional tostada or hard shell taco. For example, the shell may have a rigid, crisp structure that retains its shape under the weight of various fillings. When bitten or otherwise deconstructed (e.g., broken apart), the shell produces an audible crunch, similar to that of a-23- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410fried corn tortilla. The shell 10 may resist cracking or splitting during handling, and may fracture substantially cleanly under bite pressure, similar a conventional hard shell taco.

[0071] As utilized herein with respect to structural features (e.g., to describe shape, size, orientation, direction, relative position, etc.), the terms “approximately,” “about,” “substantially,” and similar terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.[00721 It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0073] The term “coupled” and variations thereof, as used herein, mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.-24- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410[0O74| References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the figures. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.[0075| Although the figures and description may illustrate a specific order of method process, the order of such process may differ from what is depicted and described, unless specified differently above. Also, two or more process may be performed concurrently or with partial concurrence, unless specified differently above.

[0076] It is important to note that any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Although only one example of an element from one embodiment that can be incorporated or utilized in another embodiment has been described above, it should be appreciated that other elements of the various embodiments may be incorporated or utilized with any of the other embodiments disclosed herein.-25- 4919-7543-3093.1

Claims

1. Atty. Dkt. No.: 137677-0410WHAT IS CLAIMED IS:

1. A method of producing a shell, comprising:receiving a slice of cheese having a first moisture content;baking the slice of cheese until the slice of cheese reaches a second moisture content, the second moisture content being less than the first moisture content, the baked slice of cheese having a first shape; andfrying the baked slice of cheese in a second shape until the slice of cheese reaches a third moisture content, the third moisture content being less than the second moisture content, wherein the second shape is different from the first shape.

2. The method of claim 1, wherein the first moisture content is between approximately 35% and 46% of a total weight of the slice of cheese prior to baking the slice of cheese and prior to frying the slice of cheese.

3. The method of claim 1, wherein the second moisture content is between approximately 10% and 26% of a total weight of the slice of cheese after baking the slice of cheese.

4. The method of claim 1, wherein the third moisture content is between approximately 4% and 10% of a total weight of the slice of cheese after baking the slice of cheese and after frying the slice of cheese.

5. The method of claim 1, wherein frying the baked slice of cheese in the second shape includes:providing a shaping basket having a basket, the basket defining at least one U-shaped cavity, and an insert defining at least one concave and convex section;receiving the baked slice of cheese in the at least one U-shaped cavity of the basket; andreceiving the insert into the basket such that a concave portion of the at least one concave and convex section extends into the at least one U-shaped cavity to hold the baked cheese slice in the second shape.-26- 4919-7543-3093.1Atty. Dkt. No.: 137677-04106. The method of claim 1, wherein baking the slice of cheese includes baking the slice of cheese in a substantially flat position, such that the first shape is a relatively flat shape.

7. The method of claim 1, wherein the slice of cheese defines a thickness in a range between approximately 1 millimeter and 3 millimeters.

8. The method of claim 1, wherein baking the slice of cheese includes baking the slice of cheese at a temperature between 400°F and 500°F for a time between 1 minute and 2 minutes.

9. The method of claim 1, wherein the slice of cheese prior to baking is a reduced fat pasteurized process cheese having a fat-to-dry basis between approximately 20.5% and 24%.

10. The method of claim 1, wherein the slice of cheese is a mild cheddar cheese having a fat content between approximately 29% and 33% of a total weight of the slice of cheese prior to baking.

11. A method of producing a shell, comprising:baking a slice of cheese, the baked slice of cheese having a first shape; providing a shaping basket having a basket, the basket defining at least one U-shaped cavity, and an insert defining at least one concave and convex section;receiving the baked cheese slice by the shaping basket, such that the baked cheese slice is in the at least one U-shaped cavity of the basket and a concave portion of the at least one concave and convex section of the insert extends into the at least one U-shaped cavity to hold the baked cheese slice in a second shape;frying the baked slice of cheese in the second shape; andcooling the fried slice of cheese in the second shape to form the shell.

12. The method of claim 11, wherein baking the slice of cheese includes baking the slice of cheese in a substantially flat position, such that the first shape is a relatively flat shape.-27- 4919-7543-3093.1Atty. Dkt. No.: 137677-041013. The method of claim 11, wherein the slice of cheese defines a thickness in a range between approximately 1 millimeter and 3 millimeters.

14. The method of claim 11, wherein baking the slice of cheese includes baking the slice of cheese at a temperature between 400°F and 500°F for a time between 1 minute and 2 minutes.

15. The method of claim 11, wherein the slice of cheese prior to baking is a reduced fat pasteurized process cheese having a fat-to-dry basis between approximately 20.5% and 24%.

16. The method of claim 11, wherein the slice of cheese is a mild cheddar cheese having a fat content between approximately 29% and 33% of a total weight of the slice of cheese prior to baking.

17. A method of producing a shelf-stable cheese product, comprising:providing a slice of cheese having a fat content within a first range and a first moisture content within a second range; andbaking the slice of cheese at a predetermined temperature for a first duration until the slice of cheese reaches a second moisture content within a third range, the second moisture content being lower than the first moisture content.

18. The method of claim 17, further comprising baking the slice of cheese for a second duration until the slice of cheese reaches a third moisture content within a fourth range, the third moisture content being lower than the second moisture content.

19. The method of claim 18, further comprising flipping the slice from a first position to a second position of cheese after the slice of cheese bakes at the predetermined temperature for the first duration and before the slice of cheese bakes at the predetermined temperature for the second duration.

20. The method of claim 17, wherein the first moisture content within the second range is between approximately 35% and 46% of a total weight of the slice of cheese and the-28- 4919-7543-3093.1Atty. Dkt. No.: 137677-0410second moisture content within the third range is between approximately 10% and 26% of the total weight of the slice of cheese.4919-7543-3093.1

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