Variable Depth Extrusion Die for Curled Cereal Flakes
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Solution Overview
Problem
Existing processes for producing curled ready-to-eat cereal flakes require multiple equipment and steps, including flaking rolls and intermediate drying, which increase energy consumption and operational complexity.
Innovation Solution
An extrusion die with a variable depth land is used to extrude cooked dough, causing the dough to curl as it exits, eliminating the need for flaking rolls and intermediate drying by creating curled cereal flakes through a streamlined process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional flaking rolls and intermediate drying steps are used to produce curled cereal flakes, then the flakes achieve desired curl and aesthetic appearance, but the process complexity and energy consumption increase
Solution Approach 1:
The patent combines multiple processing functions (extrusion, shaping, and curling) into a single extrusion die operation. The variable depth land within the die performs multiple functions simultaneously, eliminating the need for separate flaking rolls and drying steps while achieving the desired curled flake shape
Solution Approach 2:
The curling action is performed preliminarily during the extrusion process itself, before the flakes undergo final drying and toasting. The variable depth land creates the curled shape during dough extrusion, so the curling action occurs before subsequent processing steps rather than requiring separate post-processing equipment
2Shape
If traditional flaking rolls and intermediate drying steps are used to produce curled cereal flakes, then the flakes achieve desired curl and aesthetic appearance, but the energy consumption increases
Solution Approach 1:
The patent combines multiple processing functions (extrusion, shaping, and curling) into a single extrusion die operation. The variable depth land within the die performs multiple functions simultaneously, eliminating the need for separate flaking rolls and drying steps while achieving the desired curled flake shape
Solution Approach 2:
The curling action is performed preliminarily during the extrusion process itself, before the flakes undergo final drying and toasting. The variable depth land creates the curled shape during dough extrusion, so the curling action occurs before subsequent processing steps rather than requiring separate post-processing equipment
3Device complexity
If flat flakes are produced, then the production process is simpler, but the bulk density is high and aesthetic appeal is reduced
Solution Approach 1:
The patent applies local quality by creating non-uniform depth (variable depth land) within the extrusion die. Different regions of the die have different land depths, causing localized variations in dough flow and pressure that result in curled edges and reduced packing density, while maintaining simplicity in the overall process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The extrusion die efficiently produces aesthetically pleasing, curled cereal flakes with reduced bulk density, simplifying the production process and saving energy and resources.
Implementation Method 1
The present invention relates to an extrusion die and process for forming curled cereal flakes
Data Source
AI summary
An extrusion die for extruding cooked dough includes at least one slot having an inlet, an outlet and a land. The land has a length and a depth, with the depth extending between the inlet and the outlet and the length extending between a first side and a second side of the land. The depth of the land varies along at least a portion of the length. A process for forming cereal flakes using the extrusion die includes the steps of extruding and cutting.