EP0476001A1

EP0476001A1 - Production of cookies with extrusion and post extrusion baking

Info

Publication number: EP0476001A1
Application number: EP90908878A
Authority: EP
Inventors: Bernhard Van Lengerich; Cathryn Clark Warren
Original assignee: Nabisco Brands Inc; Nabisco Inc
Current assignee: Intercontinental Great Brands LLC
Priority date: 1989-06-07
Filing date: 1990-06-07
Publication date: 1992-03-25
Also published as: WO1990014769A1; EP0476001A4

Abstract

L'invention concerne la production de biscuits présentant une structure analogue à celle de la mie d'un biscuit, ainsi qu'une intégrité structurelle. L'extrudeuse (10) est divisée en une zone de mélange, une zone de traitement thermique, une zone d'acheminement et une zone de mélange. Les ingrédients comprenant de la farine et de l'huile, acheminés par le premier orifice (30) d'acheminement d'ingrédients secs, et par le premier orifice (32) de liquides, sont mélangés intimement puis traités thermiquement par l'action d'ensemble d'acheminement, de brassage et de mélange des vis raccordées au moteur (28) se trouvant dans le cylindre. En amont, d'autres ingrédients secs tels que du sucre en cristaux et des agents levants sont acheminés dans l'orifice (31), par l'orifice (33) on ajoute également de l'eau auxdits ingrédients, lesquels sont à nouveau mélangés. On procède ensuite à l'extrusion d'une masse analogue à une pâte de biscuit homogène, partiellement cuite et mélangée uniformément, à l'aide de la plaque matricielle d'extrusion (79). On fait lever et dorer davantage le mélange analogue à une pâte, à l'aide d'une cuisson par post-extrusion, telle qu'une cuisson à micro-ondes, hautes fréquences diélectriques, infrarouges, par conduction, ou à convexion, par friture, ou par une combinaison de ces méthodes.The invention relates to the production of cookies having a structure similar to that of a cookie crumb, as well as structural integrity. The extruder (10) is divided into a mixing zone, a heat treatment zone, a conveying zone and a mixing zone. The ingredients comprising flour and oil, conveyed by the first orifice (30) for conveying dry ingredients, and by the first orifice (32) for liquids, are intimately mixed and then heat treated by the action of routing, mixing and mixing assembly of the screws connected to the engine (28) located in the cylinder. Upstream, other dry ingredients such as crystal sugar and leavening agents are conveyed in the orifice (31), by the orifice (33) water is also added to said ingredients, which are mixed again. . Next, a mass similar to a homogeneous cookie dough, partially baked and uniformly mixed, is extruded using the matrix extrusion plate (79). The dough-like mixture is made to rise and brown further, using post-extrusion cooking, such as microwave, high dielectric, infrared, conduction, or convection cooking, by frying, or a combination of these methods.

Description

PRODUCTION OF COOKIES WITH EXTRUSION AND POST EXTRUSION BAKING

FIELD OF THE INVENTION The present invention relates to the production of cookies having a crumb-like structure using extrusion heat treatment and post extrusion baking.

BACKGROUND OF THE INVENTION In the production of a high oil content farinaceous composition by extrusion cooking, mobility and immiscibility of the water and oil phases generally increase with increasing temperature. Additionally, the mechanical action of extruder screws tends to increase separation of oil from the remaining mass. The tendency for the oil to separate is at locations within the extruder at which the components are subjected to the highest pressure. Exemplary of high pressure locations in a twin screw extruder are: 1) the space between the extruder screw tips and the die orifice, and 2) the narrowest or more restricted passageways between the left and right hand screw elements.

Oil separation under system pressure (screw or die pressure) can be manifested in extruder surging or uneven mass flow rates from the die. Upon extrusion from the die, separated oil may: 1) appear as a coating on the remaining dough mass, or 2) periodically discharge separately from the remaining dough mass. Non- homogeneous dough production and discontinuous extruder operation may thus result from oil separation. The problem of oil separation increases with increasing oil levels.

Water separation from flour, up to the boiling point of- water, is generally not a problem because of the more hydrophilic properties of flour components such as gluten and starch. As flour and water temperatures are raised, increased migration of water into starch granules, protein (e.g. gluten) denaturization, and starch gelatinization tend to occur. The binding or reaction of water with flour components may promote separation of oil: a) by making the flour components more polar or hydrophilic and b) by creating a greater mass of hydrophilic components. Conventional cookie production involves forming cookie dough preforms or pieces followed by baking of the pieces. Low temperatures, typically at about room temperature, are used to form thfe dough. The low temperature mixing generally avoids separation of shortening or fat from hydrophilic dough components. While baking temperatures in a conventional oven, such as a band oven, may promote oil separation, there is no mixing or pressing action performed at the baking temperatures. Any oil separation which may occur in such ovens does not generally interfere with continuous operability of the cookie production process as it would in a continuous cooker/ xtruder process. In addition to high temperature mixing and high system pressure, the presence of sugar in a cookie dough may also increase oil and water separation. Solubilization of sugars in water increases the relative amount of the hydrophilic mass. This in turn may tend to promote oil separation.

In the process of the present invention, cookie products are produced using an extrusion cooker to promote Maillard browning and flavor development without the problems caused by the separation of oil from the remaining cookie dough mass. The extruded cookies or cookie-like products of the present invention have a cookie crumb or crumb-like structure and texture and exhibit structural integrity.

SUMMARY OF THE INVENTION

The present invention provides a continuous process for the production of cookies which exhibit a cookie crumb-like structure and structural integrity using a cooker extruder and post extrusion heating, such as dielectric radio frequency baking, microwave baking, conductive baking, hot air baking, infra red heating, frying or combinations thereof. A cookie crumb-like structure is achieved by avoiding substantial starch gelatinization. Ingredients comprising flour and shortening or fat are admixed and heated in a cooker extruder. Preferably, the starch carrying ingredients are coated with the oil, and then water is added to the hot flour and oil mass during and/or after heat treatment. Using an amount of water such that the water content of the dough-like mixture is sufficiently low so as to avoid substantial starch gelatinization further assures that no or substantially no starch gelatinization occurs. The use of low water contents also tends to reduce oil separation from hydrophilic cookie dough components at elevated temperatures.

In embodiments of the present invention the ingredients are heated in the cooker extruder to a high temperature, for example at least about 150°F, to reduce post extrusion baking time, and promote Maillard browning and flavor development. Preferably, the ingredients are heated to a temperature of at least about 200'F, more preferably at least about 250°F, most preferably from about 300°F to about 500°F, to obtain a heat-treated mass. The heat treated mass is formed at a relatively low pressure within the cooker extruder, generally less than about 20 bars absolute, preferably less than about 10 bars absolute.

Preferably, the heat treated mass temperature upon addition of or during admixing with water or a liquid source of water is from about 100°F to about 300°F, more preferably from about 110° to about 212°F. If the heat treated mass temperature is too low, viscosity may deleteriously increase, mixing may be more difficult, pressure may increase and substantial oil separation or surging may occur. Also, higher temperatures in the cooker extruder reduce post extrusion heating times. In embodiments of the present invention, the heat treated mass is cooled and admixed at low pressures with liquid water or a source of water and optional sugar to obtain a substantially homogeneous dough-like mixture. The heat treated mass is cooled to a sufficiently low temperature so that upon its encountering of points of high pressure, the added water does not cause substantial oil separation and extruder surging. Cooling of the heat treated mass is preferably initiated prior to and continues after addition of the water. The temperature of the dough-like mixture which is formed is most preferably less than about 150°F but above about 100^βF at the exit end of the extruder. The added shortening or fat content of the dough¬ like mixture may, for example, be from about 12% by weight to about 40% by weight, preferably from about 20% by weight to about 30% by weight, based upon the weight of the dough-like mixture.

The elimination or significant reduction of added water or a source of added water in a cooker extruder tends to reduce oil separation from hydrophilic cookie dough components at elevated temperatures. It also reduces post extrusion heating time. However, added water or a source of water is needed in cookie production for formability or machinability of cookie doughs into sheets or pieces at high production rates. Water also helps to disperse cookie ingredients and to promote flavor and color development.

In the present invention, preferably the amount of water added is less than the amount needed to reach a threshold or maximum consistency. In preferred embodiments of the present invention, the amount of water added to the heat treated mass may range from about 0.5% by weight to about 10% by weight, based upon the weight of the dough-like mixture. It may, for example, be from about 2% by weight to about 6% by weight, based upon the weight of the dough-like mixture, depending upon the heat treatment temperatures and the desired consistency for shaping or forming.

The water content of the dough-like mixture is preferably as low as possible to reduce post extrusion heating time and to reduce the risk of substantial oil separation and extruder surging. It is generally less than about 20% by weight, preferably less than about 15% by weight, more preferably less than about 10% by weight, based upon the weight of the dough-like mixture. Process compatible ingredients can be added to adjust the texture of the products produced by the process of the present invention. For example, the relative amount of at least one solid, crystalline, or granulated sugar, such as sucrose, which is subjected to the heat treatment can be used to control the tenderness and crunchiness of the final product. Addition of a solid, or crystalline or granulated sugar, such as sucrose, and subjecting it to high extrusion temperatures tends to melt and/or dissolve the sugar crystals and thus promote a crunchy texture in the final product. Addition of all or a portion of the solid sugar to the cooled mass rather than subjecting it to high extrusion temperatures tends to avoid sugar melting and/or dissolution, and promotes a tender texture in the final product. In embodiments of this invention the sugar component may be added in an amount to provide, for example, from about 10% by weight to about 40% by weight, preferably from about 20% by weight to about 30% by weight total sugar solids, based upon the total weight of the dough-like mixture. Crystalline or granulated sucrose alone or used with other sugars is preferred. Dough-like mixtures of the present invention are extrudable through a die into a continuous rope or sheet. The pressure drop upon extrusion or across the extruder die is generally less than about 20 bars absolute, preferably less than about 10 bars absolute. The work done on the dough-like mixture, defined as the specific mechanical energy is generally low, for example less than about 40 watt-hrs/kg (or 18 watt-hrs/lb) . Preferably, substantial frictional heating does not occur in the cooker extruder with substantially all of the heating being provided by external or jacketed heaters.

Puffing or expansion due to moisture or steam release upon exiting of the dough-like mass from the extruder typically does not occur. The extrudate is formed into pieces and the pieces are leavened and further browned by subjecting them to at least one other heating source, such as a microwave oven, infrared oven, convection oven, dielectric radio frequency oven, a fryer, or conductive heater, to obtain cookie products which exhibit structural integrity and a crumb-like structure and texture. Generally, the volume increase upon post extrusion heating ranges from about 20% to about 200%. Leavening agents are optional and may be included in amounts up to about 5% by weight, based upon the weight of the dough-like mixture. Dough-like mixtures of the present invention having a shelf-stable water activity of less than about 0.7, preferably less than about 0.6 may be packaged as shelf stable products in moisture and oxygen impermeable packaging materials for subsequent leavening and browning in conventional home microwave or convection ovens.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a side view of an extruder of the present invention.

Fig. 2 is an end cross-section of the extruder taken along line 2-2 of Fig. 1.

Fig. 3 is a top view, partially broken away, of the extruder of Fig. 1.

Fig. 4 is a schematic representation of the screw configuration of the extruder of Fig. 1.

DETAILED DESCRIPTION OF THE INVENTION In the present invention cookies are continuously produced using an extrusion cooker to continuously mix ingredients, to reduce post extrusion heating time, and to promote browning and flavor development. The dough¬ like mixture continuously produced in the extrusion cooker is leavened using at least one other energy source to obtain baked goods having a crumb-like structure or cookie crumb. The post extrusion leavening may be by microwave energy, dielectric radio frequency energy, infrared energy, conductive heating, frying, or heated air, such as from a convection oven or fluidized bed heater. In addition to leavening the composition, the post extrusion heating further browns the dough-like mixture.

Separation of oil from the remaining mass and extruder surging are avoided preferably by admixing water into heat-treated ingredients comprising flour and oil which are at a temperature of about 100^βF to about 300^βF, more preferably from about 110°F to about 212^βF. In embodiments of the present invention, water addition may be after and/or during substantial cooling of the heat treated ingredients. After the cooling of the heat treated ingredients, the post extrusion heating leavens the substantially unleavened extrudate. The volume increase resulting from the post extrusion heating or leavening step generally ranges from about 20% to about 200%, based upon the volume of the extrudate. The flour component may be any comminuted cereal grain or edible seed meal, derivatives thereof and mixtures thereof. Exemplary of the flour components which may be used are wheat flour, corn flour, oat flour, barley flour, rye flour, rice flour, potato flour, grain sorghum flour, corn starch, physically and/or chemically modified flours or starches, such as pregelatinized starches, and mixtures thereof. The flour may be bleached or unbleached. Wheat flour or mixtures of wheat flour with other grain flours are preferred. The amount of flour used in the compositions of the present invention ranges, for example, from about 30% by weight to about 70% by weight, preferably from about 45% by weight to about 55% by weight. Unless otherwise indicated, all weight percentages are based upon the total weight of all ingredients forming the dough-like mixtures or formulations of the present invention except for inclusions such as flavor chips, nuts, raisins, and the like. Thus, "the weight of the dough-like mixture" does not include the weight of inclusions.

The flour may be replaced in whole or in part by flour substitutes or bulking agents such as, polydextrose, hollocellulose, microcrystalline cellulose, mixtures thereof, and the like. Corn bran, wheat bran, oat bran, rice bran, mixtures thereof, and the like, may also be substituted in whole or in part for the flour for making a fiber enriched product, to enhance color, or to affect texture.

Corn flour and/or wheat bran may be used, for example, to enhance color and affect texture. Exemplary amounts range up to about 15% by weight corn flour and up to about 20% by weight wheat bran, the percentages being based upon the total weight of ingredients forming the dough-like mixture. Preferably, the corn flour and wheat bran will each comprise from about 1 to about 10% by weight, more preferably from about 2% by weight to about 5% by weight, based upon the weight of the dough¬ like mixture.

The shortening or fat used in the present invention may be any edible fat or oil or mixture thereof suitable for baking applications and may include conventional food-grade emulsifiers. Vegetable oils, lard, marine oils, and mixtures thereof which are fractionated, partially hydrogenated, and/or interesterified are exemplary of the shortenings or fats which may be used in the present invention. Edible reduced or low calorie, or non-digestible fats, fat substitutes, or synthetic fats, such as sucrose polyesters which are process compatible may also be used. The shortenings or fats may be solid or fluid at room temperatures of from about 75^βF to about 90°F. The use of components which are solid or semi-solid at room temperatures are preferred so as to avoid possible oil seepage from the final product during storage. The shortening or fat component is preferably added to the extruder in the form of a heated oil to facilitate metering, mixing, and a fast heat up of the added ingredients.

Generally, the amount of the shortening or fat component admixed with the flour component is, for example, at least about 12% by weight, and may, for example, go up to about 40% by weight, based upon the weight of the dough-like mixture. It preferably ranges from about 20% by weight to about 30% by weight, based upon the weight of the dough-like mixture.

Exemplary emulsifiers which can be used include lecithin, sorbitan monostearate, mono- and/or di- glycerides, polyoxyethylene sorbitan fatty acid esters, such as polysorbates (e.g., polyoxyethylene (20) sorbitan monostearate) , and sodium stearoyl-2-lactate. Exemplary amounts are up to about 3% by weight of one or more emulsifiers based upon the weight of the flour.

Process compatible ingredients which can be used to modify the texture of the products produced in the present invention include sugars such as sucrose, fructose, lactose, dextrose, galactose, maltodextrins, corn syrup solids, hydrogenated starch hydrolysates, protein hydrolysates, mixtures thereof, and the like. Reducing sugars, such as fructose, maltose, lactose, and dextrose or mixtures of reducing sugars may be used to promote browning. Fructose is the preferred reducing sugar, because of its ready availability and its generally more enhanced browning and flavor development effects. Exemplary sources of fructose include invert syrup, corn syrup, high fructose corn syrup, molasses, brown sugar, maple syrup, mixtures thereof, and the like. The texturizing ingredient, such as sugar may be admixed with the other ingredients in either solid or crystalline form, such as crystalline or granulated sucrose, granulated brown sugar, or crystalline fructose, or in liquid form, such as sucrose syrup or high fructose corn syrup. Humectant sugars, such as high fructose corn syrup, may be used to promote chewiness in the post-extrusion baked product.

In embodiments of the present invention, the total sugar solids content, or the texturizing ingredient content, of the dough-like mixtures of the present invention is, for example, at least about 10% by weight, and may, for example, go up to about 40% by weight, based upon the weight of the dough-like mixture. It preferably ranges from about 20% by weight to about 30% by weight, based upon the weight of the dough-like mixture.

Crystalline or granulated sucrose alone or with other sugars is preferred in the present invention. The sucrose content may, for example, be at least about 80% by weight, based upon the total sugar solids content of the dough-like mixture. The balance of the sugar solids may comprise fructose, dextrose, lactose, or mixtures thereof, for example. Sugar granulations which may be used range, for example, from about 4X to about 12X.

The moisture contents of the dough-like mixtures of the present invention should be sufficient to provide the desired consistency to enable proper forming, machining, and cutting of the dough. The total moisture content of the dough-like compositions of the present invention will include any water included as a separately added ingredient, as well as the moisture provided by flour (which usually contains about 12% to about 14% by weight moisture) , and the moisture content of other dough additives included in the formulation, such as high fructose corn syrup, invert syrups, or other liquid humectants. Taking into account all sources of moisture in the dough-like mixture including separately added water, the total moisture content of the dough-like mixtures of the present invention is generally less than about 20% by weight, preferably less than about 15% by weight, more preferably less than about 10% by weight, based upon the weight of the dough-like mixture. The dough-like compositions of the present invention generally have a water or moisture content of at least about 5% by weight, based upon the weight of the dough-like composition.

Generally, if the amount of added water is too low, the extrudate will tend to be slurry-like and cannot be cut into pieces. As the amount of water is increased the extrudate consistency increases, until a threshold level is reached. At this level, additional water reduces the consistency. However, as the amount of water is increased to reduce the consistency, there is an increased risk of substantial oil separation and extruder surging. The lower the pressure and/or temperature to which the heat treated mass is subjected to after water addition: the lower is the risk. Thus, adding an extrusion die to the extruder: a) increases the pressures encountered by the ingredients in the extruder which, b) increases the risk that the addition of water beyond the amount needed to reach the threshold level of consistency will result in oil separation which can reduce machinability. The consistency of the extrudate can be determined by measuring the force needed to penetrate a sample at a constant rate of penetration. An Instron Texture Analyzer Model 4202 can be used to determine the modulus of the sample, which is a measurement of the consistency of the sample. The modulus is the slope, in the linear region, of a plot of the strain or deformation (x-axis) versus the stress (y-axis) . The strain can be measured in inches and the stress can be measured in lbs force. A cylindrical shaped probe having a diameter of 4 mm can be used for the measurement of the consistency. The probe can be set to penetrate the sample at a constant speed of 0.2 inches/min. The sample dimensions can be about 1 inch square and 1/4 inch high, or thick. The sample temperature can be room temperature (about 70 - 75^βF) or higher. The more force required to penetrate the sample, the greater is its modulus and the greater is its consistency. Consistencies suitable for forming or cutting operations depend upon the particular operation and particular equipment utilized. For example, a consistency which is too high for wire cutting may be suitable for sheeting or rotary molding. For rotary molding, the consistency at about the threshold level is suitable. For extrusion through a die, for producing a sheet for example, or for wire cutting, the consistency should be less than the threshold value. However, to reduce the risk of substantial oil separation in the extruder or in post extrusion forming operations and to reduce post extrusion baking times, it is generally preferred that the amount of water added be less than the amount needed to reach the threshold or maximum consistency. Thus, it is generally preferred that the water content of the dough-like mixture is such that additional water will increase the consistency of the dough-like mixture.

If the ratios of the amounts of the other ingredients are kept constant then: the amount of water added which is needed to reach the threshold level of consistency will depend upon the heat treatment of the ingredients. Generally, the longer the heating, or the higher the temperature of heating, the lower is the amount of water needed to reach the threshold level of consistency.

In preferred embodiments of the present invention, the amount of water admixed with the heat treated mass may range, for example, from about 0.5% by weight to about 10% by weight, based upon the weight of the dough¬ like mixture. Depending upon the time and intensity of heat treatment and the consistency needed for shaping or forming,, and the pressures involved, it may be more preferably from about 2% by weight to about 6% by weight, based upon the weight of the dough-like mixture.

The added water may be in the form of pure or tap water, a liquid source of water, such as sucrose syrup, corn syrup, high fructose corn syrup, eggs, honey, molasses, mixtures thereof, and the like, alone or in combination with a dry source of water, such as the moisture content of dried eggs, corn syrup solids, and the like. Water, in the form of tap water or a liquid source of water, such as high fructose corn syrup, for example, may also be added in the heat treating stage. It may be added with the flour for example, in low amounts (e.g. less than about 2% by weight, based upon the weight of the dough-like mixture) which do not result in: a) substantial oil separation or extruder surging or, b) substantial starch gelatinization.

In addition to the foregoing, the dough-like mixtures of the invention may include other additives conventionally employed in cookies. Such additives may include, for example, milk by-products, egg or egg by-products, cocoa, vanilla or other flavorings, as well as inclusions such as nuts, raisins, coconut, flavored chips such as chocolate chips, butterscotch chips and caramel chips, and the like.

A source of protein which is suitable for inclusion in baked goods may be included in the dough-like compositions of the present invention to promote Maillard browning. The source of protein includes non- fat dry milk solids, dried or powdered eggs, mixtures thereof, and the like. The amount of the proteinaceous source may, for example, range up to about 5% by weight, based upon the weight of the dough-like mixture.

The dough-like cookie compositions of the present invention may contain up to about 5% by weight of a leavening system, based upon the weight of the dough¬ like mixture. Chemical leavening agents or injected gases such as carbon dioxide can be 'used, but are not necessary for leavening the dough-like compositions of the present invention. Leavening action may be achieved by post extrusion heating of the composition which is sufficient to vaporize water in the dough-like cookie composition. However, the leavening agents may be used to adjust or control the degree of leavening and/or to control the pH of the cookie products.

The inclusion of a leavening agent or other edible pH-adjusting agents may promote browning of the cookie mixture during processing within the extruder or during post-extrusion heating. A desired pH for the cookies or the dough-like mass is from about 5 to about 9.5, preferably from about 7 to 8.5. Generally, the more alkaline the composition, the greater the degree of browning. However, the pH should be adjusted so as not to adversely affect taste of the final product. A higher pH may be used to promote browning when forming the heat treated mass of the present invention, followed by adjustment of the pH after and/or during cooling of the heat treated mass. Exemplary of chemical leavening agents or pH adjusting agents which may be used include alkaline materials and acidic materials such as sodium bicarbonate, ammonium bicarbonate, sodium acid pyrophosphate, tartaric acid, mixtures thereof, and the like.

In the process of the present invention, the flour component and shortening or fat are continuously and separately fed into the upstream portion of a cooker extruder. One or more crystalline or granulated sugars may be continuously added or preblended with the flour. However, continuous separate addition of the crystalline sugar to the upstream end of the extruder is preferred to avoid particle separation in the dry blend. The flour component, the shortening or fat, and the sugar components are generally initially conveyed in the extruder with cooling or without the application of external heat. They are conveyed and admixed while being heated to obtain a heat treated mass. In the present invention, the ingredients may be heated to temperatures above the minimum gelatinization temperature of the starch (assuming that a sufficient amount of water was available for reaction with the starch) but no or substantially no gelatinization (measured by differential scanning calorimetry) occurs. It is desireable that the oil sufficiently coats the starch containing flour particles to prevent substantial penetration of moisture into the starch granules so as to avoid substantial gelatinization.

A cookie crumb-like structure is obtained by avoiding substantial starch gelatinization. Generally, starch gelatinization occurs when: a) water in a sufficient amount, generally at least about 30% by weight, based upon the weight of the starch, is added to and mixed with starch and, b) the temperature of the starch is raised to at least about 80°C (176°F), preferably 100°C (212°F) or more. The gelatinization temperature may depend upon the amount of water available for reaction with the starch. The lower the amount of available water, generally, the higher the gelatinization temperature. Gelatinization may be defined as the collapse (disruption) of molecular orders within the starch granule manifested in irreversible changes in property such as granular swelling, native crystallite melting, loss of birefringence, and starch solubilization. The point of initial gelatinization and the range over which it occurs is governed by starch concentration, method of observation, granule type, and heterogeneities within the granule population under observation. Pasting is the phenomenon following gelatinization in the dissolution of starch. It involves granular swelling, exudation of molecular components from the granule, and eventually, total disruption of the granules. See Atwell et al, "The Terminology And Methodology Associated With Basic Starch Phenomenon," Cereal Foods World. Vol. 33, No. 3, Pgs. 306-311 (March 1988) .

In the present invention, conditions under which no or substantially no gelatinization is preferably achieved are by embedding or coating the starch carrying ingredients, such as wheat flour, within the oil and then adding the water to the flour and oil mass. No or substantially no gelatinization may also be further assured by: a) reducing or substantially eliminating the addition of water, and/or b) admixing the water with the heat treated mass below the minimum temperature at which starch gelatinization can occur.

In the process of the present invention, heating of the flour, shortening or fat, and sugar at as high a temperature as possible and for as long as possible for a maximum throughput rate without burning or other deleterious effects, is generally desirable for the development of browning and flavor. Maillard browning and flavor development involve the reaction between a reactive carbonyl group of a carbohydrate and a primary amino acid of the composition. The reaction proceeds through a series of intermediate reactions to finally produce the brown nitrogenous polymers. The heat treating step is believed to at least develop precursors to the polymeric nitrogen containing compounds. During the post-extrusion baking step, the colors develop faster than an uncooked dough under similar baking conditions.

The flour component, shortening or fat component, and optionally the sugar or other texturizing components are heated in the cooker extruder generally to a temperature of at least about 150°F, preferably at least about 200°F, more preferably at least about 250°F, and most preferably from about 300°F to about 500°F. The average residence time for the flour, shortening or fat, and optional sugar components at these elevated temperatures is, for example, from about 15 seconds to about 90 seconds.

The heat treated mass is formed at a relatively low pressure within the cooker extruder. Pressures during the heat treating stage are generally less than about 20 bars absolute, preferably less than about 10 bars absolute. It is believed that the use of low pressures in the cooker extruder reduces the tendency for oil to separate from the remaining cookie ingredients. Preferably, substantially no frictional heating occurs in the cooker extruder. Substantially all of the heating is preferably supplied by external or jacketed heating means. Generally, the work done in the production of the dough-like mixture is low, for example, less than about 40 watt hrs/kg (or less than about 18 watt hrs/lb) . The heat treated mass temperature before and/or during admixing with water or a liquid source of water should be sufficiently low so that the added water does not result in substantial separation of oil and extruder surging. The reduction of the temperature of the heat treated mass substantially reduces mobility and immiscibility of the water and oil phases. Also, it has been observed that the oil is most likely to separate from the remaining mass at the points of highest pressure, such as at the extruder die. Generally, the lower the pressures encountered by the heat treated mass upon or subsequent to the addition of the water, the less the heat treated mass needs to be cooled to avoid substantial oil separation and extruder surging.

If the heat treated mass temperature is too low upon and/or during admixing it with the water or liquid source of water, viscosity may deleteriously increase. This may result in mixing difficulties, pressure increases, and substantial oil separation and extruder surging. Additionally, the less cooling performed within the extruder, the less is the amount of post extrusion heating needed for leavening.

If pressures are sufficiently low (such as when an extruder die is not utilized) and if the mass temperature during heat treatment is sufficiently low, no or substantially no cooling may be needed to avoid substantial oil separation or extruder surging. However, higher heat treated mass temperatures are preferred for: 1) the promotion of browning and flavor development, and 2) reduced post extrusion heating times. Thus, it is generally preferred that the heat treated mass be heated to a high temperature, for example about 300°F to about 500°F, and that the heat treated mass temperature be reduced, as needed to avoid substantial oil separation or extruder surging, before and/or during admixing it with water or a liquid source of water. Cooling of the heat treated mass is preferably initiated prior to and continues during admixing it with water or a liquid source of water to reduce the risk of substantial oil separation upon mixing or extrusion.

Preferably, the heat treated mass temperature upon ad., ition of water or a liquid source of water is from about 100°F to about 300^βF, more preferably from about HOT to about 212°F. Generally, the heat treated mass undergoes a temperature drop of at least about 35°F, preferably at least about 50°F before and/or during admixing it with the water or liquid source of water. The heat treated mass is preferably cooled to a temperature below the boiling point of water (212°F) , more preferably to a temperature lower than about 200°F, most preferably less than about 150^βF before or during admixing it with the water or liquid source of water to reduce the risk of substantial steam generation, and substantial oil separation and extruder surging. Admixing- the water or liquid source of water with the heat treated mass at a mass temperature which is lower than the minimum gelatinization temperature of the sta^'rches included in the formulation may further assure that no or substantially no starch gelatinization occurs, particularly as the amount of water is increased.

At the exit end prior to or at the optional extruder die, which is generally the point of maximum pressure, the temperature of the dough-like mixture which is formed in the extruder should be less than the boiling point of water (212^βF) , more preferably less than about 200^βF, most preferably less than about 150"F. Generally, the temperature of the heat treated mass and dough-like mixture in the extruder should not be reduced to below about 100^βF, for example, to avoid mixing difficulties, increased pressure, or increased risk of substantial oil separation or extruder surging due, for example, to increased viscosity or oil solidification. Also, excessively low extrudate temperatures may impair post extrusion forming, shaping, and cutting operations. Increased post extrusion heating times and/or temperatures for leavening purposes also result from excessive cooling. In producing the dough-like mixtures in accordance with the present invention it is preferred that substantially no moisture content reduction occurs and that the dough-like mixture retains a sufficient amount of water for proper leavening during post extrusion heating.

All or a portion of the texturizing ingredient, such as solid, crystalline or granulated sugar, may be admixed with the cooled heat treated mass at the same or at a different location from addition of the water or other aqueous source to control the texture of the final baked product.

Addition of a solid, crystalline or granulated sugar, such as sucrose, and subjecting it to high extrusion temperatures tends to promote sugar melting and/or dissolution and thus a crunchy texture in the final product. Addition of all or a portion of the crystalline sugar to the cooled mass rather than subjecting it to high extrusion temperatures tends to avoid excessive sugar melting, and/or solubilization and promotes a tender texture in the final product. Thus, all, a portion (e.g. about 15% to about 85% by weight, based upon the total amount of solid, crystalline or granulated sugars) , or none of the solid or crystalline sugars may be subjected to the heat treating stage to control texture in the final, post extrusion baked product. Also, the greater the degree, or portion of sugar melting and/or dissolving, the less the viscosity of the extrudate. Accordingly, the relative amounts of solid or crystalline sugar: a) subjected to heat treatment upstream, and b) subjected only to the downstream cooling stage may be used to control the extrudate viscosity for subsequent forming or machining, and/or to control the texture of the final baked good.

The downstream addition of a texturizing ingredient, such as sugar, reduces the mass subjected to heat treatment which permits heating of the upstream ingredients to a higher temperature at a given throughput rate. Also, the downstream addition of the texturizing ingredient such as sugar, which is at a relatively low temperature (e.g. about room temperature) helps to cool the heat treated mass.

Various granulations may also be used to control the degree of sugar melting and/or dissolving, with larger sizes tending to result in less melting or dissolving. The addition of liquid sugar, such as sucrose syrup, may additionally promote crunchiness of the final product.

The residence time of the added liquid water or added liquid source of water, as well as the residence time of the texturizing ingredient, such as sugar, added downstream after initiation of the reduction of the heat treated mass temperature should be sufficient to enable the attainment of a substantially homogeneous dough-like mixture. The residence time in the cooling or reduced temperature stage should also be sufficiently long to reduce the mass temperature so as to avoid substantial expansion or puffing of the dough-like mass upon extrusion. The average residence time in the cooker extruder of the water and crystalline sugar added to the heat treated mass may, for example, be from about 10 seconds to about 60 seconds.

Just prior to extrusion, or upon extrusion through an extruder die, the dough-like mixture may be heated, for example, by about 5°F to about 30°F. This heating may be used to adjust dough consistency or viscosity provided that adverse oil separation or extruder surging does not occur. The post cooling heating may be used, for example, for controlling flow in the die, particularly at low moisture contents.

The pressure in the cooling stage is generally less than about 20 bars absolute, preferably less than about 10 bars absolute. The pressure drop across the extrusion die is generally less than about 20 bars and preferably less than about 10 bars. Low pressures are preferred to avoid separation of oil from the remaining mass and to avoid surging.

The leavening agents or pH adjusters may be added to the cooled mass in the cooling stage or they may be added prior to the cooling stage. They may be added in dry form either separately or as a pre-blend with the flour or solid or crystalline sugar, for example. They may also be added in aqueous form separately or as part of the added water. Emulsifiers may suitably be added with the shortening or fat in the heating stage or with the water in the cooling stage of the process of the present invention. Ingredients which promote Maillard browning, such as proteinaceous materials and reducing sugars are preferably added in the heat treating stage. The dry ingredients may, for example, be preblended with the flour or added separately. The proteinaceous materials and the reducing sugars may also be added in the cooling stage depending upon the degree of browning desired, and the water content of the ingredients. These ingredients, as well as any other additives in dry form may be preblended with the upstream or downstream sugar, for example, or added separately therefrom. Likewise, additives which are in liquid form may be preblended with the added water or liquid source of water or they may be separately added to the extruder. Generally, preblending of minor ingredients for addition to the extruder is preferred for achieving homogeneity.

Heat labile ingredients, such as various vitamins, minerals, flavorings, coloring agents, sweeteners, such as aspartame, and the like, are preferably added in the cooling stage so as to reduce the possibility of thermal decomposition or degradation. The heat labile ingredients may, for example, be preblended with sugar added downstream in the cooling stage or with the added water. They may also be added separately, for instance downstream of the sugar or water addition.

Shear sensitive ingredients, such as chocolate chips or other flavored chips, raisins, nuts, fruit pieces or other inclusions or particulates are preferably added to the cooling stage. The shear sensitive ingredients are most preferably added downstream of the downstream sugar and water addition. Adding the shear sensitive ingredients near the exit or in the last barrel section of the extruder serves to maintain particle integrity by reducing their exposure to the mechanical action of the screw elements. Flavor chips, such as chocolate chips may be added at temperatures below room temperature, for example at about 20°F to about 65°F so as to reduce melting of the chips in the dough-like mixture.

The dough-like mixture is extruded from the cooker extruder to obtain an extrudate without substantial moisture loss or flashing because the temperature of the dough-like mixture exiting the extruder is less than about 212°F. The extruded dough-like mixtures of the present invention will preferably have a shelf-stable water activity of less than about 0.7, preferably less than about 0.6. The shelf-stable compositions of the present invention may be packaged as shelf stable products in moisture and oxygen impermeable packaging materials for subsequent leavening and browning in a post extrusion oven such as a conventional home microwave or convection oven. The dough-like mixture may exit the extruder through a die having various shapes, such as animal shapes, circles, squares, triangles, star-shapes, and the like.

The extrudate may be cut at the die by a rotating knife for example, or by a wire cutting device.

The dough-like mixture may be formed into a continuous rope by the use of a round shaped die orifice. It may also be formed into a ribbon or sheet by the use of a horizontally oriented slit or elongated sheet shaped die orifice. The continuous ropes, ribbons, or sheets may be cut into pieces using known reciprocating cutters.

The dough-like mixtures of the present invention may be extruded without the use of a die plate. The thus obtained extrudate, or even die-extruded extrudat.es, may be formed into pieces using conventional dough-shaping and forming equipment, such as rotary molders, wire cutting machines, sheeting rolls and reciprocating cutters, and the like. Unlike conventional cookie production, the extruded dough-like mixtures of the present invention are generally formed into pieces when hot. Excessive cooling of the extrudate may result in crumbling of the pieces upon wire cutting or other cutting or shaping operations. Preferably, the extrudates are formed into pieces at temperatures of from about 100"F to about 150°F. Consistency, viscosity and plasticity of the extrudates for proper machining may be adjusted, for example, by water or oil addition or reduction in the extruder, or by heating prior to the die, at the die, or after exiting from the die.

Cookie bits or cookie crumb-like products may be produced by extruding the dough-like mixture under very low pressure drops, e.g. without passing it through an extruder die, or at low die flow rates so that the extrudate spontaneously forms into pieces upon falling, onto a moving belt for example. Pieces or drops may also be produced by passing the dough-like mixture through a horizontal or vertical extruder die with a multitude of holes of a size of about 1/8" to about 1/2". The extrudate strands may then be cut at the die by a rotating knife into cylindrically shaped preheated dough bits.

The pieces may then be leavened by post extrusion heating to form cookie-like pieces or bits. The bits may be screened or sized to obtain cookie bits or

"cookie chips" having a substantially uniform size distribution.

The cookie bits or cookie chips may be incorporated into other products, such as "granola type" bars. They may be used to produce a "cookie chip chocolate" product: a) by incorporating the cookie chips or bits into molten chocolate in a mold and then solidifying the chocolate, b) by poi ^*ing molten chocolate over the bits in a mold, or c) by enrobing individual or a plurality of bits with melted chocolate. The cookie chips may, for example, have a maximum dimension of about 1/8" to about 1/2". The amount of the cookie bits incorporated into the product may, for example, be from about 10% by weight to about 90% by weight, based upon the weight of the cookie chip chocolate product. The leavened cookie¬ like pieces or bits also may be: a) ground into crumbs for-use in pie crusts, for example or, b) compacted, in a mold for example, to produce unitary cookie products.

The unleavened dough bits may also be compacted in a mold to obtain a unitary product which may be subsequently leavened. Bits having different sizes and/or compositions may be combined in the mold to produce the unitary products.

Filled products may be produced in accordance with the present invention by coextruding the dough-like mixture with filler materials. The coextrudate may be formed by the use of a concentric die or a tube inserted within the die orifice. Filled products may also be produced by transporting the dough-like mixture extrudate to a conventional enrobing or encrusting machine, such as produced by the Rheon Manufacturing Company for post extrusion filling with a filler material.

Examples of fillers which may be used include chocolate, vanilla, butterscotch, fruit, peanut butter, and cheese-flavored fillings. The filling material may also be a separately produced dough-like mixture for the production of multi-flavored, multi-colored, or multi- textured cookie products.

The extrudate pieces are leavened and further browned using: a) electromagnetic radiation or electronic heating, such as dielectric radio frequency heating, microwave heating, or infrared heating, b) heated air, such as from a convection oven or fluidized bed heater, c) frying, or d) combinations thereof. For example, a combination may comprise microwave heating or dielectric radio frequency heating for internal heating and infrared heating for more intense surface heating. The microwave, infrared, and radio frequency energy may be applied at pressures of from about 0.2 bars to about 6 bars.

When applying dielectric heating, the low conductive food product to be heated is placed between electrodes, which act as capacitor plates, and forms the dielectric of one or more capacitors. A high frequency voltage is applied across the electrodes. Alternating of the electrostatic field or of the polarity of the voltage results in heating of the product.

The frequencies generally used for dielectric heating are about 2 to 90 MHz, e.g. about 13-14 MHz, about 27 MHz, or about 40-41 MHz. The frequencies generally used for microwave heating are, for example, about 2,450 MHz for domestic ovens and about 896 to 915 MHz for industrial ovens. The heating of the pieces in the dielectric or radio frequency oven, microwave oven, or combinations thereof, or in a fryer is generally performed so that proper leavening and browning is achieved, for example, within about 90 seconds, preferably within about 60 seconds, depending upon the thickness and diameter of the pieces. Infrared heating, conductive heating, and hot air heating are generally conducted within about two to three minutes. Infrared heating should generally be performed subsequent to another form of post extrusion heating. It tends to heat the surface and form a skin which prevents leavening gases from escaping. Generally, the heating of the pieces or cookie preforms in the post extrusion oven should be sufficient to result in an internal temperature of at least about 160^βF, preferably at least about 190^βF in the cookie.

Dielectric radio frequency ovens, microwave ovens, infrared ovens, hot air ovens, and the like which may be used are conventional, industrial scale continuous throughput ovens. Continuous, conventional fryers may also be used in embodiments of the present invention. Conductive heating devices which may be used include waffle-type conductive heaters.

The post extrusion heated leavened products of the present invention have a water activity of less than about 0.7, preferably less than about 0.6. The water content of the products is generally less than about 6% by weight, suitably from about 2% by weight to about 4% by weight, based upon the weight of the post extrusion baked product, exclusive of inclusions. The products exhibit a cookie crumb-like structure appearance, and texture and structural integrity. Starch gelatinization (measured by differential scanning calorimetry) for the cookie products of the present invention is generally less than about 5%.

In the process of the present invention, a cooker extruder having two screws is preferably utilized. Preferably the screws of the extruder will be co- rotating, i.e., rotate in the same direction. Co- rotating twin screw elements, generally provide thorough mixing and conveying of the components, with the elements of one screw continuously wiping the other screw. This is particularly advantageous when the composition being mixed has a relatively high viscosity. Suitable extruders which may be used in the present invention include: (1) WENGER model series TX by Wenger of Sabetha, Kansas, (2) model series MPF by Baker Perkins, (3) model series BC by Creusot Loire of Paris, France, and preferably 4) model series ZSK or Continua by Werner and Pfleiderer. Single screw extruders including those with a horizontally oscillating screw during rotation (i.e. a Buss kneader by Buss of Pratteln, Switzerland) may also be used in accordance with the present invention.

A preferred screw configuration which may be used in the present invention with a Werner and Pfleiderer model ZSK-57 twin screw cooker extruder is disclosed in copending U.S. patent application serial no. 362,375 entitled "Extruder Apparatus For Producing An At Least Partially Baked Product Having A Cookie-Like Crumb Structure," filed in the name of Bernhard Van Lengerich on June 7, 1989. The disclosure of the latter application is incorporated herein by reference in its entirety.

The extruder throughput or mass flow rates utilized in the present invention with a Werner and Pfleiderer ZSK 57 twin screw cooker extruder are generally from about 150 lbs/hr to about 850 lbs/hr of extrudate. Higher rates may be achieved with other models. For example, a throughput rate of 6000 lbs/hr may be achieved using a Werner and Pfleiderer model Continua 120 cooker extruder.

Referring now to the drawings and initially to Fig. 1, there is illustrated a side view of an extruder 10 arranged according to the present invention. The extruder 10 comprises a plurality of barrel sections, e.g., twelve barrel sections 11-22 (See Fig. 4), each of which includes a figure eight cross-section bore or screw channel 23 formed therethrough (see Fig. 2) . The sections 11-22 are fastened end-to-end, to one another with the respective bore sections 23 axially aligned, as is well known, to provide the extruder barrel of the extruder 10. In this manner, twin screws 24, 25 can be arranged in an intermeshing arrangement, to extend through communicating screw channels 26, 27 of the figure eight cross-section bore 23 from one end of the extruder barrel formed by the barrel sections to the other end thereof. The twin screws 24, 25 are coupled to an electric motor 28, arranged adjacent the upstream end of the extruder for rotation within the screw channels 26, 27. A first dry ingredient feed port 30 is provided in barrel section 11 and a second dry ingredient feed port 31 is provided in barrel section 18. In addition, a first liquid feed 32 is arranged between barrel sections 11 and 12 and a second liquid feed 33 is provided in barrel element 18.

As illustrated in Fig. 1, the extruder is divided into a blending zone, a heat treatment zone, a conveyance zone and a mixing zone.

Referring now to Fig. 4, there is illustrated, in schematic form, a specific screw configuration for each of the twin screws 24, 25. The illustrated screw configuration is now described as a representative embodiment of the present invention. Each of the screws 24, 25 comprises a series of elements intermeshing with an adjacent identical series of elements of the other screw 24, 25. Screw elements 34, 35, the upstream most elements, are arranged directly beneath the first dry ingredient feed port 30. The screw elements 34, 35 each include a continuous screw-like thread 36 to rapidly convey dry ingredients such as flour and a portion of the crystalline sugar into the screw channel 23. Each of the elements 34, 35 comprises an 80/80/SK screw element which indicates that the screw-like thread has a pitch of 80 and that each element is 80 mm in length. The SK designation indicates a shuffle kneader which includes an undercut thread to catch and convey dry ingredients as they are input through the dry ingredient feed port 30. The first liquid feed port 32 is arranged adjacent the first dry ingredient feed port 30 for input of oil. The screw elements 34, 35 generally comprise the blending zone of the extruder.

A screw element 37 is arranged immediately downstream from the 80/80/SK elements 34, 35 and comprises an 80/40 screw element (i.e., a pitch of 80 and a length of 40 mm) . The screw element 37 is followed immediately by a 60/60 screw element 38 and a 40/40 screw element 39. The progressively shorter, lower pitch screw elements 37, 38, 39 decrease the speed of conveyance to thereby increase the degree of fill of the input oil and flour ingredients within the bore 23. Degree of fill refers to the percentage of the free volume of the bore 23 occupied by ingredients being conveyed by the screw elements 24, 25.

An igel element 40, which is 40 mm in length, is arranged immediately downstream from the screw element 39. An igel element includes churning projections 41 to provide a chopping action to the ingredients within the bore 23. The igel element 40 does not itself substantially convey material which causes a further increase in the degree of fill. The through put flow of ingredients through the igel element 40 is caused by the pushing action on the ingredients by the screw elements 34, 35 37, 38 and 39 upstream from the igel element 40. Two 40/40 screw elements 42, 43 are arranged immediately downstream from the igel element 40 to continue the conveyance of the ingredients. Two additional 40 mm igel elements 44, 45 are provided downstream from the screw element 43. These igel elements 44, 45 are spaced from one another by a 40/40 screw element 46. Moreover, an additional 40/40 screw element 47 is arranged immediately downstream from the igel element 45. The igel elements 44, 45 and screw elements 46, 47 thereby provide alternating elements to chop, convey, chop and convey the ingredients. This sequence gradually increases the degree of fill and churns the ingredients to afford a better mixing of the ingredients.

A first kneading block element 48 is positioned directly downstream from the screw element 47. The kneading block element is used to mix the ingredients and comprises a KB/45/5/20 element. This indicates that it is a kneading block having 45° right hand angle staggered kneading discs, relative to one another around the axis of rotation of the screw, 5 total kneading discs in the element and the element is 20 mm long.

The kneading element 48 is followed by a 40/40 screw element 49. Thereafter, there is an alternating sequence of kneading block elements 50-56 and interposed screw elements 57-63. Each of the intermediate screw elements 57-63 comprises a 40/40 screw element while the kneading block elements 50-56 comprise, in downstream order, a KB/45/5/20 element (kneading block 50) , four KB/45/5/40 elements (kneading blocks 51-54) and two KB/45/5/60 elements (kneading blocks 55-56) .

The gradual increase in size of the kneading block elements 50-56 and relatively short, low pitch screw elements 57-63 in-between the successive kneading block elements causes a continuing increase in degree of fill and a vigorous mixing of the ingredients.

Each of the barrel elements 11-22 includes electrical heating elements 500 and cooling water flow tubing 501 to control the temperature of the barrel element. Such a temperature controlled barrel element comprises, for example, a model ZSK-57 extruder barrel element manufactured by Werner & Pfleiderer. The viscosity of the ingredients comprising flour and oil is not sufficient for friction heating due to the vigorous mixing action of the kneading block elements 50-56. Accordingly, the electrical heating elements of barrel elements 12-16 are operated to raise the temperature of the ingredients. The electric heating of the barrel elements 12-16 are operated to raise the temperature of the barrels to as high as possible, e.g., at least 350"F, for a given throughput rate to promote Maillard browning and flavor development and to reduce the amount of post extrusion heat treatment required for final baking.

Thus, the ingredients comprising flour and oil fed through the first dry ingredient feed port 30 and first liquid feed port 32 are thoroughly mixed and heat- treated by the overall conveying, churning and mixing action of the screws 24, 25 and heating effect of the barrel sections 12-16 upstream from the second dry ingredient feed port 31 and the second liquid feed port 33. The barrel sections 12-16 generally comprise the heat treatment zone of the extruder. The term "vigorous" as used herein means a mixing action which is sufficient to thoroughly mix the ingredients input through the first dry ingredient feed port 30, including the flour, oil, and, optionally, crystalline sugar, and to facilitate distribution of the heat applied by the heating coils throughout the ingredients. In addition, the term relates to increasing the degree of fill to a level accommodating heat conduction from the heating elements through the screw channel 23 and into the ingredients.

The second liquid feed 33 is provided in barrel section 18 for the introduction of added water or a source of added water. As noted above, the added water modifies the consistency of the heat treated ingredients comprising flour and oil to provide a mass having sufficient formability and machinability for post extrusion processing. Moreover, a cooling water flow is provided in the barrel sections 17 and 18 to reduce the temperature of the ingredients within the barrel sections by conduction and thereby reduce the tendency toward oil separation.

Immediately downstream from the last screw element 63 of the alternating screw and kneading block elements is a high speed conveyance zone comprising a series of screw elements 64-68 of generally increasing length and screw pitch. As illustrated in Fig. 4, the series of screw elements 64-68 are located immediately upstream, directly beneath and immediately downstream from the second dry ingredient feed port 31, in barrel sections 17, 18 and 19.

The screw elements 64-68 comprise 60/60, 80/80/SK, 80/80/SK, 80/40 and 80/80 screw elements, respectively, which increases the speed of conveyance of the heat treated ingredients and thereby reduce the compressive pressure on the ingredients as well as the degree of fill within the bore 23 immediately below the second dry ingredient feed port 31. Accordingly, a relatively large quantity of a dry ingredient, e.g. , crystalline sugar, can be added to the material flow through the second dry ingredient feed port 31 inasmuch as the degree of fill has been reduced by the action of the screw elements 64-68 to provide sufficient free volume within the screw channel 23. In addition, the increased speed of conveyance caused by the screw elements 64-68 rapidly moves the added crystalline sugar downstream from the second feed port 31 to prevent back fill flow out of the second feed port 31.

The crystalline sugar and water are added after the high temperature mixing of the ingredients 30, which occurs in barrel sections 11-16, and are, therefore, not exposed to processing conditions which can cause oil separation and excessive dissolution of the sugar.

Screw elements 69-71 are arranged downstream from the screw elements 64-68 and comprise one 60/60 and two 30/30 elements, respectively, to reduce the speed of conveyance and again gradually increase the degree of fill. A kneading block element 72, which comprises a KB/45/5/20 element, is provided downstream from the screw elements 69-71 to mix the added sugar and added water into the other heat-treated ingredients.

Two additional screw elements 73, 74, which comprise a 40/40 and 80/160 element, respectively, convey the ingredients to a final kneading block element 75, which comprises a KB/45/5/60 element for final mixing of the ingredients. The kneading block elements 72, 75 provide the final mixing zone of the extruder.

The final elements of the twin screws 24, 25 comprise screw elements 76-78, which include an 80/80, a 60/60 and a 60/120 element, respectively. These elements convey the ingredients to an extrusion die plate 79 and develop sufficient pressure within the ingredients to force the ingredients through the extrusion die, without moisture flashing and without oil separation, as a partially baked and uniformly mixed, homogeneous cookie dough-like mass which can thereafter be shaped, formed and cut before final baking.

The present invention is further illustrated in the following examples where all parts, ratios, and percentages are by weight and all temperatures are in 'F, unless otherwise stated:

EXAMPLE 1 The ingredients, their feed placement, and their relative amounts used to prepare an extruded, partially baked cookie preform suitable for leavening into a cookie having a crumb-like structure and texture using dielectric radio frequency heating in accordance with the present invention were:

INGREDIENT AND PLACEMENT WEIGHT

Component 1: first dry feed port Wheat flour, bleached

(about 12% by weight water) 49.88

Non-fat dry milk (about 52% by weight lactose) 1.50

Salt 0.75 Component 2: first dry feed port

White sugar (sucrose), granulated 14.72

Brown sugar (about 89% sucrose, 3% invert, 4% non-sugar solids, 3% water) 6.86 Vanilla 1.23

Sodium bicarbonate 0.25

Component 3: first liquid feed port

Soybean spray oil 22.56

Component 4: second liquid feed port Tap water 2.25

Total 100.00 The co-rotating twin screw cooker extruder used to prepare the cookie products of the present invention was a Werner and Pfleiderer ZSK-57 equipped with a screw configuration as shown and described in copending U.S. patent application serial no. 362,375 entitled "Extruder Apparatus For Producing An At Least Partially Baked Product Having A Cookie-Like Crumb Structure," filed in the name of Bernhard Van Lengerich on June 7, 1989. The extruder had twelve barrels, each provided with external, jacketed heating and cooling means. First and second dry feed ports were set up at barrels 1 and 8, respectively. These two dry feed ports were open to the atmosphere. The first liquid feed port was set up between barrels 1 and 2. The second liquid feed port was the same as the second dry feed port at barrel 8. The second liquid feed inlet pipe was inserted into the open port at barrel 8 so that optional second dry feed ingredients and the second liquid feed ingredients could be separately fed into the same port. Dry ingredients were not fed to the second dry feed port in this example.

The first barrel, which contained the first dry feed port, was set on constant cool. The remaining eleven barrels were divided into 7 separately measured barrel temperature zones. The first through the twelfth barrels are hereafter also referred to in the Examples as "barrel 1," "barrel 2," "barrel 3," etc. Barrels 2 and 3 corresponded to temperature zone 1, barrel 4 corresponded to zone 2, barrels 5 and 6 corresponded to zone 3, barrels 7 and 8 corresponded to zones 4, and 5, respectively, barrels 9 and 10 corresponded to temperature zone 6, and barrels 11 and 12 corresponded to temperature zone 7. The thermocouples for measuring actual barrel temperatures were located in barrels 2 , 4, 5, 7, 8, 10, and 12.

Barrels 2 through 6 were set to heat to 350°F, barrel seven to 200°F, barrel eight was set on constant cool (less than 100^βF) , barrels 9 and 10 were set at 100°F and barrels 11 and 12 were set at 110°F.

Paddles and screw elements were arranged on the screw shafts from upstream to downstream to provide: a) rapid conveying of the added dry ingredients in barrel 1, b) conveying of the dry ingredients and added oil and gradually increasing the degree of fill in barrel 2, c) chopping or mixing action for admixing the oil and dry ingredients, conveying to gradually increase the degree of fill, and mixing in barrel 3, d) repeated conveying and an increased degree of mixing in barrel 4, e) increased mixing, conveying and increased mixing to gradually increase the degree of fill in each of barrels 5 and 6, f) increased mixing, conveying, and increased mixing to provide the highest degree of mixing in barrel 7, g) fast conveying of the ingredients fed to the port in barrel 8, h) conveying with a gradual increase in degree of fill in barrel 9, i) conveying and mixing with a gradual increase in degree of fill in barrel 10, j) conveying and mixing in barrel 11, and k) conveying with a buildup in pressure sufficient to extrude the dough¬ like mixture through the extruder die. Gradually increasing the degree of fill tends to reduce points of high pressure which may cause oil separation.

The screws were rotated at about 125 rpm at about 3% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 201 lbs/hr.

Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed to the first dry feed port, but separate from component 1. Component 3 was prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder was about 8.5% by weight, based upon the total weight of the dough-like mixture. At steady state, the barrel set temperatures and the actual barrel temperatures were:

Barrel Set Actual Barrel

Barrel # Temperature, °F Temperature. ^βF

1 cool —

2 350 247

3 350 —

4 350 302

5 350 333

6 350 —

7 200 198

8 <100 98

9 100 —

10 100 105

11 110 —

12 110 113

The pressure in the extruder was less than about 10 bars. The material temperatures in the extruder were about 231°F at barrel 7, and about 137°F at barrel 12. The average or median residence time of the ingredients heated prior to addition of component 4 at the second feed port was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed port was about 10 to 20 seconds. The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was about 151°F. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4".

The pieces were subjected to heating in a continuous

12 kw dielectric radio frequency (27 MHz) oven set at about 81% power for about 45 seconds to produce distinctly leavened, surface browned cookies having a crumb-like structure and crumb-like texture.

EXAMPLE 2 The ingredients, their feed placement, and their relative amounts which may be used to prepare an extruded, partially baked cookie preform suitable for leavening into a cookie having a crumb-like structure and texture using dielectric radio frequency heating in accordance with the present invention are:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 55.00 Non-fat dry milk (about 52% by weight lactose) 1.65

Salt 0.83

White sugar (sucrose), granulated 8.80

Component 2: second dry feed port Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 3.85

Aspartame 0.06

Component 3: first liquid feed port Soybean spray oil 24.75

Component 4: second liquid feed port

Tap water 5.06

Total 100.00

The co-rotating twin screw cooker extruder system of Example 1 may be used to prepare the cookie products of the present invention.

The screws may be rotated at about 225 rpm at about

8% of maximum torque. The ingredients may be fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about

181 lbs/hr. Component 1 may be prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend may be continuously fed to the first dry feed port. Component 2 may be prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which may be continuously fed downstream to the second dry feed port.

Component 3 may be prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which may be continuously fed to the first liquid feed port.

Component 4 may be continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder is about 11.8% by weight, based upon the total weight of the dough-like mixture.

The barrel set temperatures, pressures, and residence times may be the same as in Example 1.

The substantially homogeneous dough-like mixture formed in the extruder may be extruded through a horizontally oriented slit die (about 5mm high by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon having a temperature upon exiting the extruder of less than about 150°F. The ribbon may be cut into cylindrical pieces having a diameter of about 1 and 1/4".

The pieces having an average weight of about 4.2 gm/piece may be subjected to heating in a continuous 12 kw dielectric radio frequency (27 MHz) oven set at about 81% power for 45 seconds to produce distinctly leavened, surface browned cookies having a crumb-like structure and crumb-like texture.

EXAMPLE 3

The ingredients, their feed placement, and their relative amounts which may be used to prepare an extruded, partially baked cookie preform suitable for leavening into a cookie having a crumb-like structure and texture using dielectric radio frequency heating in accordance with the present invention are:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 24 . . 67

Oat bran (about 12% by weight water) 24 . . 67

Non-fat dry milk (about 52% by weight lactose) 1. . 48

Salt 0. .74

White sugar (sucrose) , granulated 14 . . 80

Component 2: second dry feed port

Brown sugar (about 89% sucrose, 3% invert, 4% non-sugar solids, 3% water) 6.91

Component 3: first liquid feed port

Soybean spray oil 22.20 Component 4: second liquid feed port

Tap water 4.53

Total 100.00

The screws may be rotated at about 225 rpm at about

5% of maximum torque. The ingredients may be fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about

203 lbs/hr. Component 1 may be prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend may be continuously fed to the first dry feed port. Component 2 may be prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which may be continuously fed downstream to the second dry feed port.

Component 4 may be continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder is about 10.7% by weight, based upon the total weight of the dough-like mixture.

The barrel set temperatures, pressures, and residence times may be the same as in Example l.

EXAMPLE 4

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 45.72 Non-fat dry milk (about 52% by weight lactose) 1.37

Salt 0.69

White sugar (sucrose), granulated 13.72

Component 2: second dry feed port Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.40

Nut pieces (walnut fluff) 7.31

Component 3: first liquid feed port Soybean spray oil 20.58

Component 4: second liquid feed port

Tap water 4.21

Total 100.00

The screws may be rotated at about 225 rpm at about

218 lbs/hr. Component 1 may be prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend may be continuously fed to the first dry feed port. Component 2 may be prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which may be continuously fed downstream to the second dry feed port.

Component 4 may be continuously fed to the second liquid feed port.

The substantially homogeneous dough-like mixture formed in the extruder may be extruded through a horizontally oriented slit die (about 5mm high by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon having a temperature upon exiting the extruder of less than about 150"F. The ribbon may be cut into cylindrical pieces having a diameter of about 1 and 1/4".

EXAMPLE 5

The ingredients, their feed placement, and their relative amounts used to prepare an extruded, partially baked cookie preform suitable for leavening into a cookie having a crumb-like structure and texture using dielectric radio frequency heating in accordance with the present invention were:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 49.88 Non-fat dry milk (about 52% by weight lactose) 1.50

Salt 0.75

Component 2: first dry feed port

White sugar (sucrose), granulated 15.64 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 7.29

Vitamin mix 0.13

Component 3: first liquid feed port Soybean spray oil 22.56

Component 4: second liquid feed port

Tap water 2.25

Total 100.00

The co-rotating twin screw cooker extruder system of Example 1 was used to prepare the cookie products of the present invention.

The screws were rotated at about 125 rpm at about 3% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 203 lbs/hr. Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed to the first dry feed port. Component 3 was prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder was about 8.5% by weight, based upon the total weight of the dough-like mixture.

At steady state, the barrel set temperatures and the actual barrel temperatures were:

Barrel Set Actual Barrel Barrel # Temperature. Temperature, *F

1 cool

2 350 235

3 350

4 350 281

5 350 341

6 350

7 200 199

8 <100 92

9 100

10 100 104

11 110

12 110 125

The pressure in the extruder was less than about 10 bars. The material temperatures in the extruder were about 231^βF at barrel 7, and about 143°F at barrel 12. The average or median residence time of the ingredients heated prior to addition of component 4 at the second feed port was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed port was about 10 to 20 seconds.

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was about 142^βF. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4". The pieces were subjected to heating in a continuous 12 kw dielectric radio frequency (27 MHz) oven set at about 81% power for about 45 seconds to produce distinctly leavened, surface browned cookies having a crumb-like structure arid crumb-like texture.

EXAMPLE 6

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 48.43

Non-fat dry milk (about 52% by weight lactose) 1.45

Salt 0.73

Component 2: first dry feed port

White sugar (sucrose), granulated 14.53

Brown sugar (about 89% sucrose, 3% invert, 4% non-sugar solids, 3% water) 6.78

Component 3: first liquid feed port

Soybean spray oil 24.21 Component 4: second liquid feed port

Tap water 3.87

Total 100.00

The screws may rotated at about 125 rpm at about 2% of maximum torque. The ingredients may be fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 405 lbs/hr.

Component 1 may be prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend may be continuously fed to the first dry feed port. Component 2 may be prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which may be continuously fed to the first dry feed port, but separate from component 1. Component 3 may be prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which may be continuously fed to the first liquid feed port. Component 4 may be continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder is about 10.7% by weight, based upon the total weight of the dough-like mixture. The barrel set temperatures, pressures, and residence times may be the same as in Example 1:

The substantially homogeneous dough-like mixture formed in the extruder may be extruded without a die to obtain a substantially unleavened extrudate dough having a temperature upon exiting the extruder of less than about 150°F. The extrudate may be transferred or drop into the hopper of a conventional cookie wire-cutting machine. The wire-cutting machine may be equipped with a screw-type or auger feed or counter-rotating grooved rollers for feeding the extrudate through nozzles. Upon emerging through the nozzles, the extrudate is cut into cylindrical pieces by the wire. The pieces may be subjected to heating in a continuous 12 kw dielectric radio frequency (27 MHz) oven set at about 81% power for 45 seconds to produce distinctly leavened, surface browned cookies having a crumb-like structure and crumb¬ like texture.

EXAMPLE 7

INGREDIENT AND PLACEMENT WEIGHT %

Component l: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 48.09

Non-fat dry milk (about 52% by weight lactose) 1.44

Salt 0.74

Component 2: first dry feed port

White sugar (sucrose) , granulated 14.47

Brown sugar (about 89% sucrose, 3% invert, 4% non-sugar solids, 3% water) 6.76

Sodium bicarbonate 1.21 Component 3: first liquid feed port

Soybean spray oil 24.15 Component 4: second liquid feed port

Tap water 3.14

Total 100.00

The screws were rotated at about 125 rpm at about 3% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 414 lbs/hr. Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed to the first dry feed port but separate from component 1. Component 3 was prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder was about 9.1% by weight, based upon the total weight of the dough-like mixture.

Barrel Set Actual Barrel

Barrel # Temperature. °F Temperature. °F

1 cool —

2 350 209

3 350 —

4 350 265

5 350 274

6 350 —

7 200 198

8 cool 98

9 100 —

10 100 99

11 120 —

12 120 124

The pressure in the extruder was less than about 10 bars. The average or median residence time of the ingredients heated prior to addition of component 4 at the second feed port was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed port was about 10 to 20 seconds. The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was less than about 150°F. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4".

The pieces may be subjected to heating in a continuous 12 kw dielectric radio frequency (27 MHz) oven set at about 81% power for about 45 seconds to produce distinctly leavened surface browned cookies having a crumb-like structure and crumb-like texture.

EXAMPLE 8 The ingredients, their feed placement, and their relative amounts which may be used to prepare an extruded, partially baked cookie preform suitable for leavening into a cookie having a crumb-like structure and texture using dielectric radio frequency heating in accordance with the present invention are:

INGREDIENT AND PLACEMENT WEIGHT %

Component l: first dry feed port

Oat Bran

(about 12% by weight water) 48.31

White sugar (sucrose) , granulated 14.02

Component 2: second dry feed port

Brown sugar (about 89% sucrose, 3% invert, 4% non-sugar solids, 3% water) 6.56

Component 3: first liquid feed port

Soybean spray oil 21.73

Component 4: second liquid feed port

Sodium Bicarbonate 1.17

Tap water 8.21

Total 100.00

The screws may be rotated at about 145 rpm at about 1% of maximum torque. The ingredients may be fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about

207 lbs/hr.

Component 1 may be prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend may be continuously fed to the first dry feed port. Component 2 may be continuously fed downstream to the second dry feed port. Component 3 may be prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which may be continuously fed to the first liquid feed port. Component 4 may be prepared by dissolving the sodium bicarbonate in the water to form a solution which may be continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder is about 14.2% by weight, based upon the total weight of the dough-like mixture.

The pieces may be subjected to heating in a continuous 12 kw dielectric radio frequency (27 MHz) oven set at about 81% power for 45 seconds to produce distinctly leavened, surface browned cookies having a crumb-like structure and crumb-like texture.

EXAMPLE 9

The ingredients, their feed placement, and their relative amounts used to prepare a cookie having a crumb-like structure and texture using extrusion heating and dielectric radio frequency baking in accordance with the present invention were:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 49.08 Non-fat dry milk (about 52% by weight lactose) 1.48

Salt 0.74

Component 2: second dry feed port

White sugar (sucrose), granulated 15.13 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 7.06

Component 3: first liquid feed port

Soybean spray oil 24.66 Component 4: second liquid feed port

Sodium bicarbonate 0.17

Tap water 1.68

Total 100.00

The co-rotating twin screw cooker extruder used to prepare the cookie products of the present invention was a Werner and Pfleiderer ZSK-57 equipped with a screw configuration as shown and described in copending U.S. patent application serial no. 362,375 entitled "Extruder Apparatus For Producing An At Least Partially Baked Product Having A Cookie-Like Crumb Structure," filed in the name of Bernhard Van Lengerich on June 7, 1989. The extruder had twelve barrels, each provided with external, jacketed heating and cooling means. The first and second dry feed ports were set up at barrels 1 and 8, respectively. These two dry feed ports were open to the atmosphere. The first liquid feed port was set up between barrels 1 and 2. The second liquid feed port was the same as the second dry feed port at barrel 8. The second liquid feed inlet pipe was inserted into the open port at barrel 8 so that the second dry feed ingredients and the second liquid feed incjredients were separately fed into the same port.

The first barrel, which contained the first dry feed port, was set on constant cool. The remaining eleven barrels were divided into 7 separately measured barrel temperature zones. Barrels 2 and 3 corresponded to temperature zone 1, barrel 4 corresponded to zone 2, barrels 5 and 6 corresponded to zone 3, barrels 7 and 8 corresponded to zones 4, and 5, respectively, barrels 9 and 10 corresponded to temperature zone 6, and barrels 11 and 12 corresponded to temperature zone 7. The thermocouples for measuring actual barrel temperatures were located in barrels 2, 4, 5, 7, 8, 10, and 12.

Barrels 2 through 6 were set to heat to 350°F, barrel seven to 200"F, barrel eight was set on constant cool, barrels 9 and 10 were set at 100°F and barrels 11 and 12 were set at 120°F.

Paddles and screw elements were arranged on the screw shafts from upstream to downstream to provide: a) rapid conveying of the added dry ingredients in barrel 1, b) conveying of the dry ingredients and added oil and gradually increasing the degree of fill in barrel 2, c) chopping or mixing action for admixing the oil and dry ingredients, conveying to gradually increase the degree of fill, and mixing in barrel 3, d) repeated conveying and an increased degree of mixing in barrel 4, e) increased mixing, conveying and increased mixing to gradually increase the degree of fill in each of barrels 5 and 6, f) increased mixing, conveying, and increased mixing to provide the highest degree of mixing in barrel 7, g) fast conveying of the dry and liquid ingredients fed to the port in barrel 8, h) conveying with a gradual increase in degree of fill in barrel 9, i) conveying and mixing with a gradual increase in degree of fill in barrel 10, j) conveying and mixing in barrel 11, and k) conveying with a buildup in pressure sufficient to extrude the dough-like mixture through the extruder die. Gradually increasing the degree of fill tends to reduce points of high pressure which may cause oil separation.

The screws were rotated at about 125 rpm at about 2% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 405 lbs/hr.

Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed downstream to the second dry feed port. Component 3 was prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was prepared by dissolving the sodium bicarbonate in the water to form a solution which was continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder was about 7.8% by weight, based upon the total weight of the dough-like mixture. At steady state, the barrel set temperatures and the actual barrel temperatures were:

Barrel Set Actual Barrel Barrel # Temperature, "F Temperature, *F

1 cool

2 350 206

3 350

4 350 245

5 350 324

6 350

7 200 201

8 cool <100

9 100

10 100 <100

11 120

12 120 115

The pressure in the extruder was less than about 10 bars. The average or median residence time of the ingredients heated prior to addition of components 2 and 4 at the second feed ports was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed ports was about 10 to 20 seconds.

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high) by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was less than about 150°F. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4". The pieces were subjected to radio frequency energy (27 MHz) in a 12 kw dielectric oven set at 81% power for about 45 seconds to produce distinctly leavened cookies. The cookies were surface browned and had a crumb-like structure and crumb-like texture.

EXAMPLE 10

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

Salt 0.75

Component 2: second dry feed port

White sugar (sucrose), granulated 14.72 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.86

Vanilla 1.23

Sodium bicarbonate 0.25 Component 3: first liquid feed port

Soybean spray oil 22.56

Component 4: second liquid feed port

Tap water 2.25

Total 100.00

The co-rotating twin screw cooker extruder system of

Example 9 was used to prepare the cookie products of the present invention.

The screws were rotated at about 125 rpm at about 2% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 200 lbs/hr. Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed downstream to the second dry feed port. Component 3 was prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

Barrel Set Actual Barrel

Barrel # Temperature. ^βF Temperature, "F

1 cool —

2 350 247

3 350 —

4 350 307

5 350 309

6 350 —

7 200 201

8 <100 122

9 100 —

10 100 99

11 110 —

12 110 112

The pressure in the extruder was less than about 10 bars. The material temperatures in the extruder were about 230^βF at barrel 7, and about 131^βF at barrel 12. The average or median residence time of the ingredients heated prior to addition of components 2 and 4 at the second feed ports was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed ports was about 10 to 20 seconds.

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high) by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was about 125^βF. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4".

The pieces may be subjected to heating in a continuous 12 kw dielectric radio frequency (27 MHz) oven set at about 81% power for about 45 seconds to produce distinctly leavened, surface browned cookies having a crumb-like structure and crumb-like texture.

EXAMPLE 11 The ingredients, their feed placement, and their relative amounts used to prepare an extruded, partially baked cookie preform suitable for leavening into a cookie having a crumb-like structure and texture using dielectric radio frequency heating in accordance with the present invention were:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 48.66 Non-fat dry milk (about 52% by weight lactose) 1.46

Salt 0.73

Component 2: second dry feed port

White sugar (sucrose), granulated 14.60 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.81

Sodium bicarbonate 1.22

Component 3: first liquid feed port Soybean spray oil 24.33

Component 4: second liquid feed port

Tap water 2.19

Total 100.00

The co-rotating twin screw cooker extruder system of Example 9 was used to prepare the cookie products of the present invention.

The screws were rotated at about 125 rpm at about 2% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 405 lbs/hr. Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed downstream to the second dry feed port. Component 3 was prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder was about 8.2% by weight, based upon the total weight of the dough-like mixture.

Barrel Set Actual Barrel

Barrel # Temperature, ^βF Temperature, *F

1 cool —

2 350 206

3 350 —

4 350 245

5 350 324

6 350 .—

7 200 201

8 cool <100

9 100 —

10 100 <100

11 120 —

12 120 115

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high) by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was less than about 150°F. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4".

EXAMPLE 12 The ingredients, their feed placement, and their relative amounts used to prepare an extruded, partially baked cookie preform suitable for leavening into a cookie having a crumb-like structure and texture using dielectric radio frequency heating in accordance with the present invention were:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

. Wheat flour, bleached

Salt 0.83

Component 2: second dry feed port

White sugar (sucrose), granulated 8.80 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 3.85

Asparta e 0.06

Component 3: first liquid feed port Clarified butter 24.75

Component 4: second liquid feed port

Tap water 5.06

Total 100.00

The screws were rotated at about 225 rpm at about 8% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 181 lbs/hr. Component l was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed downstream to the second dry feed port. Component 3 was prepared by melting the semi-solid clarified butter to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder was about 11.8% by weight, based upon the total weight of the dough-like mixture.

92

Barrel Set Actual Barrel

Barrel # Temperature. ^βF Temperature. °F

1 cool —

2 350 298

3 350 —

4 350 335

5 350 290

6 350 —

7 200 195

8 cool 100

9 100 —

10 100 100

11 120 —

12 120 119

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high) by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was less than about 150°F. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4". The pieces may be subjected to heating in a continuous 12 kw dielectric radio frequency (27 MHz) oven set at about 81% power for about 45 seconds to produce distinctly leavened, surface browned cookies having a crumb-like structure and crumb-like texture.

EXAMPLE 13

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first drv feed port

Wheat flour, bleached

(about 12% by weight water) 24.67

Oat bran (about 12% by weight water) 24.67

Non-fat dry milk (about 52% by weight lactose) 1.48

Salt 0.74

Component 2: second dry feed port

White sugar (sucrose), granulated 14.80

Brown sugar (about 89% sucrose, 3% invert, 4% non-sugar solids, 3% water) 6.91

Component 3: first liquid feed port

Clarified butter 22.20

Component 4: second liquid feed port

Sodium bicarbonate 0.41

„ Tap water 4.12

Total 100.00

The co-rotating twin screw cooker extruder system of

Example 9 was used to prepare the cookie products of the present invention.

The screws were rotated at about 225 rpm at about 5% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 203 lbs/hr. Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed downstream to the second dry feed port. Component 3 was prepared by melting the semi-solid clarified butter to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was prepared by dissolving the sodium bicarbonate in the water to form a solution which was continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder was about 10.2% by weight, based upon the total weight of the dough-like mixture.

Barrel Set Actual Barrel Barrel # Temperature, Temperature. "F

1 cool

2 350 276

3 350

4 350 311

5 350 289

6 350

7 200 198

8 cool 100

9 100

10 100 100

11 120

12 120 122

The pressure in the extruder was less than about 10

I bars. The average or median residence time of the ingredients heated prior to addition of components 2 and 4 at the second feed ports was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed ports was about 10 to 20 seconds.

EXAMPLE 14 The ingredients, their feed placement, and their relative amounts used to prepare an extruded, partially baked cookie preform suitable for leavening into a cookie having a crumb-like structure and texture using dielectric radio frequency heating in accordance with the present invention were:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first drv feed port

Wheat flour, bleached

Salt 0.69

Component 2: second dry feed port

White sugar (sucrose), granulated 13.72 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.40

Nut pieces (walnut fluff) 7.31

Component 3: first liquid feed port Clarified butter 20.58

Component 4: second liquid feed port

Sodium bicarbonate 0.38

Tap water 3.83

Total 100.00

The co-rotating twin screw cooker extruder system of

Example 9 was used to prepare the cookie products of the present invention.

The screws were rotated at about 225 rpm at about 5% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 218 lbs/hr. Component l was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed downstream to the second dry feed port. Component 3 was prepared by melting the semi-solid clarified butter to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was prepared by dissolving the sodium bicarbonate in the water to form a solution which was continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder was about 10.3% by weight, based upon the total weight of the dough-like mixture.

Barrel Set Actual Barrel

Barrel # Temperature. ^βF Temperature, ^βF

1 cool —

2 350 276

3 350 —

4 350 311

5 350 289

6 350 —

7 200 198

8 cool 100

9 100 —

10 100 100

11 120 —

12 120 122

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high) by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was less than about 150^βF. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4". The pieces may be subjected to heating in a continuous 12 kw dielectric radio frequency (27 MHz) oven set at about 81% power for 45 seconds to produce distinctly leavened, surface browned cookies having a crumb-like structure and crumb-like texture.

EXAMPLE 15

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

Salt 0.75

Component 2: second dry feed port

White sugar (sucrose), granulated 15.64 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 7.29

Vitamin mix 0.13

Component 3: first liquid feed port Soybean spray oil 22.56

Component 4: second liquid feed port

Tap water 2.25

Total 100.00

The screws were rotated at about 125 rpm at about 2% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 203 lbs/hr. Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed downstream to the second dry feed port. Component 3 was prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

Barrel Set Actual Barrel

Barrel # Temperature. °F Temperature. ^βF

1 cool —

2 350 228

3 350 —

4 350 283

5 350 340

6 350 —

7 200 200

8 <100 138

9 100 —

10 100 98

11 110 —

12 110 Ill

The pressure in the extruder was less than about 10 bars. The material temperatures in the extruder were about 236^βF at barrel 7, and about 135°F at barrel 12. The average or median residence time of the ingredients heated prior to addition of components 2 and 4 at the second feed ports was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed ports was about 10 to 20 seconds.

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high) by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was about 143°F. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4".

The pieces were subjected to heating in a continuous

EXAMPLE 16 The ingredients, their feed placement, and their relative amounts which may be used to prepare an extruded, partially baked cookie preform suitable for leavening into a cookie having a crumb-like structure and texture using dielectric radio frequency heating in accordance with the present invention are:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 48.43 Non-fat dry milk (about 52% by weight lactose) 1.45

Salt 0.73

Component 2: second dry feed port

White sugar (sucrose), granulated 14.53 Brown sugar ^-bout 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.78

Component 3: first liquid feed port

Soybean spray oil 24.21 Component 4: second liquid feed port

Tap water 3.87

Total 100.00

The co-rotating twin screw cooker extruder system of Example 9 may be used to prepare the cookie products of the present invention.

Component 1 may be prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend may be continuously fed to the first dry feed port. Component 2 may be prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which may be continuously fed downstream to the second dry feed port. Component 3 may be prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which may be continuously fed to the first liquid feed port. Component 4 may be continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder is about 10.7% by weight, based upon the total weight of the dough-like mixture. The barrel set temperatures, pressures, and residence times may be the same as in Example 9.

The substantially homogeneous dough-like mixture formed in the extruder may be extruded without a die to obtain a substantially unleavened extrudate dough having a temperature upon exiting the extruder of less than about 150°F. The extrudate may be transferred or drop into the hopper of a conventional cookie wire-cutting machine. The wire-cutting machine may be equipped with a screw-type or auger feed or counter-rotating grooved rollers for feeding the extrudate through nozzles. Upon emerging through the nozzles, the extrudate is cut into cylindrical pieces by the wire. The pieces may be subjected to heating in a continuous 12 kw dielectric 108 radio frequency (27 MHz) oven set at about 81% power for about 45 seconds to produce distinctly leavened, surface browned cookies having a crumb-like structure and crumb¬ like texture.

EXAMPLE 17

The ingredients, their feed placement, and their relative amounts used to prepare a cookie having a crumb-like structure and texture using extrusion heating and microwave baking in accordance with the present invention were:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 48.09 Non-fat dry milk (about 52% by weight lactose) 1.44

Salt 0.74

Component 2: first dry feed port

White sugar (sucrose), granulated 14.47 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.76

Sodium bicarbonate 1.21

Component 3: first liquid feed port Soybean spray oil 24.15

Component 4: second liquid feed port

Tap water 3.14

Total 100.00

The co-rotating twin screw cooker extruder used to prepare the cookie products of the present invention was a Werner and Pfleiderer ZSK-57 equipped with a screw configuration as shown and described in copending U.S. patent application serial no. 362,375 entitled "Extruder Apparatus For Producing An At Least Partially Baked Product Having A Cookie-Like Crumb Structure," filed in the name of Bernhard Van Lengerich on June 7, 1989. The extruder had twelve barrels, each provided with external, jacketed heating and cooling means. First and second dry feed ports were set up at barrels 1 and 8, respectively. These two dry feed ports were open to the atmosphere. The first liquid feed port was set up between barrels 1 and 2. The second liquid feed port was the same as the second dry feed port at barrel 8. The second liquid feed inlet pipe was inserted into the open port at barrel 8 so that optional second dry feed ingredients and the second liquid feed ingredients could be separately fed into the same port. Dry ingredients were not fed to the second dry feed port in this example.

The first barrel, which contained the first dry feed port, was set on constant cool. The remaining eleven barrels were divided into 7 separately measured barrel temperature zones. Barrels 2 and 3 corresponded to temperature zone 1, barrel 4 corresponded to zone 2, barrels 5 and 6 corresponded to zone 3, barrels 7 and 8 corresponded to zones 4, and 5, respectively, barrels 9 and 10 corresponded to temperature zone 6, and barrels 11 and 12 corresponded to temperature zone 7. The thermocouples for measuring actual barrel temperatures were located in barrels 2, 4, 5, 7, 8, 10, and 12. Barrels 2 through 6 were set to heat to 350°F, barrel seven to 200^βF, barrel eight was set on constant cool, barrels 9 and 10 were set at 100"F and barrels 11 and 12 were set at 120^βF. Paddles and screw elements were arranged on the screw shafts from upstream to downstream to provide: a) rapid conveying of the added dry ingredients in barrel 1, b) conveying of the dry ingredients and added oil and gradually increasing the degree of fill in barrel 2, c) chopping or mixing action for admixing the oil and dry ingredients, conveying to gradually increase the degree of fill, and mixing in barrel 3, d) repeated conveying and an increased degree of mixing in barrel 4, e) increased mixing, conveying and increased mixing to gradually increase the degree of fill in each of barrels 5 and 6, f) increased mixing, conveying, and increased mixing to provide the highest degree of mixing in barrel 7, g) fast conveying of the ingredients fed to the port in barrel 8, h) conveying with a gradual increase in degree of fill in barrel 9, i) conveying and mixing with a gradual increase in degree of fill in barrel 10, j) conveying and mixing in barrel 11, and k) conveying with a buildup in pressure sufficient to extrude the dough- like mixture through the extruder die. Gradually increasing the degree of fill tends to reduce points of high pressure which may cause oil separation.

Barrel Set Actual Barrel

Barrel # Temperature. ^βF Temperature, °F

1 cool —

2 350 209

3 350 —

4 350 265

5 350 274

6 350 —

7 200 198

8 cool 98

9 100 —

10 100 99

11 120 —

12 120 124

The pressure in the extruder was less than about 10 bars. The average or median residence time of the ingredients heated prior to addition of component 4 at the second feed port was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed port was about 10 to 20 seconds.

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was less than about 150^βF. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 and 1/4". Six pieces were subjected to microwaving in a microwave oven for about 50 seconds to produce distinctly leavened cookies. The cookies were surface browned and had a crumb-like structure and crumb-like texture.

EXAMPLE 18

The ingredients, their feed placement, and their relative amounts used to prepare a cookie having a crumb-like structure and texture using extrusion heating and microwave baking in accordance with the present invention were: ■

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

Salt 0.75

Component 2: first dry feed port

White sugar (sucrose), granulated 14.72 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.86

Vanilla 1.23

Sodium bicarbonate 0.25 Component 3: first liquid feed port

Soybean spray oil 22.56

Component 4: second liquid feed port

Tap water 2.25

Total 100.00

The co-rotating twin screw cooker extruder system of

Example 17 was used to prepare the cookie products of the present invention.

The screws were rotated at about 125 rpm at about 3% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 201 lbs/hr. Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed to the first dry feed port but separate from component 1. Component 3 was prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

Barrel Set Actual Barrel

Barrel # Temperature. ^βF Temperature, °F

1 cool —

2 350 247

3 350 —

4 350 302

5 350 333

6 350 —

7 200 198

8 <100 98

9 100 —

10 100 105

11 110 —

12 110 113

The pressure in the extruder was less than about 10 bars. The material temperatures in the extruder were about 231°F at barrel 7, and about 137°F at barrel 12. The average or median residence time of the ingredients heated prior to addition of component 4 at the second feed port was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed port was about 10 to 20 seconds.

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was about 151°F. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4". Six pieces were subjected to microwaving in a microwave oven for about 50 seconds to produce distinctly leavened cookies. A cookie sample had an internal temperature of about 226°F upon microwaving. The cookies were surface browned and had a crumb-like structure and crumb-like texture.

EXAMPLE 19

The ingredients, their feed placement, and their relative amounts which may be used to prepare a cookie having a crumb-like structure and texture using extrusion heating and microwave baking in accordance with the present invention are:

INGREDIENT AND PLACEMENT WEIGHTS

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 48.66

Non-fat dry milk (about 52% by weight lactose) 1.46

Salt 0.73

White sugar (sucrose) , granulated 14.60

Component 2: second dry feed port

Brown sugar (about 89% sucrose, 3% invert, 4% non-sugar solids, 3% water) 6.81

Sodium bicarbonate 1.22 Component 3: first liquid feed port

Soybean spray oil 24.33 Component 4: second liquid feed port

Tap water 2.19

Total 100.00

The co-rotating twin screw cooker extruder system of Example 17 may be used to prepare the cookie products of the present invention.

The screws may be rotated at about 125 rpm at about

2% of maximum torque. The ingredients may be fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about

405 lbs/hr. Component 1 may be prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend may be continuously fed to the first dry feed port. Component 2 may be prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which may be continuously fed downstream to the second dry feed port. Component 3 may be prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which may be continuously fed to the first liquid feed port. Component 4 may be continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder is about 8.2% by weight, based upon the total weight of the dough-like mixture.

The barrel set temperatures, pressures, and residence times may be the same as in Example 17.

The substantially homogeneous dough-like mixture formed in the extruder may be extruded through a horizontally oriented slit die (about 5mm high by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon having a temperature upon exiting the extruder- of less than about 150°F. The ribbon may be cut into cylindrical pieces having a diameter of about 1 1/4".

Six pieces having an average weight of about 4.2 gm/piece may be subjected to microwaving in a microwave oven for about 50 seconds to produce distinctly leavened surface browned cookies having a crumb-like structure and crumb-like texture.

EXAMPLE 20 The ingredients, their feed placement, and their relative amounts which may be used to prepare a cookie having a crumb-like structure and texture using extrusion heating and microwave baking in accordance with the present invention are:

INGREDIENT AND PLACEMENT WEIGHT%

Component 1: first dry feed port

Wheat flour, bleached

Salt 0.83

White sugar (sucrose), granulated 8.80

Component 2: second dry feed port Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 3.85

Aspartame 0.06

Component 3: first liquid feed port Soybean spray oil 24.75

Component 4: second liquid feed port

Tap water 5.06

Total 100.00

The screws may be rotated at about 225 rpm at about

Component 4 may be continuously fed to the second liquid feed port.

The substantially homogeneous dough-like mixture formed in the extruder may be extruded through a horizontally oriented slit die (about 5mm high by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon having a temperature upon exiting the extruder of less than about 150°F. The ribbon may be cut into cylindrical pieces having a diameter of about 1 1/4".

EXAMPLE 21 The ingredients, their feed placement, and their relative amounts which may be used to prepare a cookie having a crumb-like structure and texture using extrusion heating and microwave baking in accordance with the present invention are:

INGREDIENT AND PLACEMENT WEIGHT%

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 24.67 Oat bran (about 12% by weight water) 24.67

Non-fat dry milk (about 52% by weight lactose) 1.48

Salt 0.74

White sugar (sucrose), granulated 14.80 Component 2: second dry feed port

Brown sugar (about 89% sucrose, 3% invert, 4% non-sugar solids, 3% water) 6.91

Component 3: first liquid feed port Soybean spray oil 22.20

Component 4: second liquid feed port

Tap water 4.53

Total 100.00

The screws may be rotated at about 225 rpm at about

203 lbs/hr. 126

Component 1 may be prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend may be continuously fed to the first dry feed port. Component 2 may be prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which may be continuously fed downstream to the second dry feed port.

Component 4 may be continuously fed to the second liquid feed port.

EXAMPLE 22 The ingredients, their feed placement, and their relative amounts which may be used to prepare a cookie having a crumb-like structure and texture using extrusion heating and microwave baking in accordance with the present invention are:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

Salt 0.69

White sugar (sucrose), granulated 13.72

Component 2: second dry feed port Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.40

Nut pieces (walnut fluff) 7.31

Component 3: first liquid feed port Soybean spray oil 20.58

Component 4: second liquid feed port

Tap water 4.21

Total 100.00

The screws may be rotated at about 225 rpm at about

Component 4 may be continuously fed to the second liquid feed port.

The substantially homogeneous dough-like mixture formed in the extruder may be extruded through a horizontally oriented slit die (about 5mm high by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon having a temperature upon exiting the extruder of less than about 150"F. The ribbon may be cut into cylindrical pieces having a diameter of about 1 1/4".

EXAMPLE 23 The ingredients, their feed placement, and their relative amounts used to prepare a cookie having a crumb-like structure and texture using extrusion heating and microwave baking in accordance with the present invention were:

INGREDIENT AND PLACEMENT WEIGHT %

Component l: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 49.88

Non-fat dry milk (about 52% by weight lactose) 1.50

Salt 0.75

Component 2: first dry feed port

White sugar (sucrose) , granulated 15.64

Brown sugar (about 89% sucrose, 3% invert, 4% non-sugar solids, 3% water) 7.29

Vitamin mix 0.13 Component 3: first liquid feed port

Soybean spray oil 22.56 Component 4: second liquid feed port

Tap water 2.25

Total 100.00

The co-rotating twin screw cooker extruder system of Example 17 was used to prepare the cookie products of the present invention.

The screws were rotated at about 125 rpm at about 3% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 203 lbs/hr. Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed to the first dry feed port but separate from component 1. Component 3 was prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

Barrel Set Actual Barrel

Barrel # Temperature, "F Temperature. °F

1 cool —

2 350 235

3 350 —

4 350 281

5 350 341

6 350 —

7 200 199

8 <100 92

9 100 —

10 100 104

11 110 —

12 110 125

The pressure in the extruder was less than about 10 bars. The material temperatures in the extruder were about 231°F at barrel 7, and about 143°F at barrel 12. The average or median residence time of the ingredients heated prior to addition of component 4 at the second feed port was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed port was about 10 to 20 seconds.

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was about 142^βF. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4". Six pieces were subjected to microwaving in a microwave oven for about 50 seconds to produce distinctly leavened cookies. The cookies were surface browned and had a crumb-like structure and crumb-like texture.

EXAMPLE 24

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

Salt 0.73

Component 2: first dry feed port

White sugar (sucrose), granulated 14.53 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.78

Component 3: first liquid feed port

Soybean spray oil 24.21 Component 4: second liquid feed port

Tap water 3.87

Total 100.00

Component 1 may be prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend may be continuously fed to the first dry feed port. Component 2 may be prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which may be continuously fed to the first dry feed port but separate from component 1. Component 3 may be prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which may be continuously fed to the first liquid feed port. Component 4 may be continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder is about 10.7% by weight, based upon the total weight of the dough-like mixture. The barrel set temperatures, pressures, and residence times may be the same as in Example 17.

The substantially homogeneous dough-like mixture formed in the extruder may be extruded without a die to obtain a substantially unleavened extrudate dough having a temperature upon exiting the extruder of less than about 150^βF. The extrudate may be transferred or drop into the hopper of a conventional cookie wire-cutting machine. The wire-cutting machine may be equipped with a screw-type or auger feed or counter-rotating grooved rollers for feeding the extrudate through nozzles. Upon emerging through the nozzles, the extrudate is cut into cylindrical pieces by the wire. Six of the pieces may be subjected to microwaving in a microwave oven for about 60 seconds to produce distinctly leavened, surface browned cookies having a crumb-like structure and crumb¬ like texture.

EXAMPLE 25 The ingredients, their feed placement, and their relative amounts used to prepare a cookie having a crumb-like structure and texture using extrusion heating and microwave baking in accordance with the present invention were:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

Salt 0.74

Component 2: second dry feed port

White sugar (sucrose), granulated 15.13 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 7.06

Component 3: first liquid feed port

Soybean spray oil 24.66 Component 4: second liquid feed port

Sodium bicarbonate 0.17

Tap water 1.68

Total 100.00

The co-rotating twin screw cooker extruder used to prepare the cookie products of the present invention was a Werner and Pfleiderer ZSK-57 equipped with a screw configuration as shown and described in copending U.S. patent application serial no. 362,375 entitled "Extruder Apparatus For Producing An At Least Partially Baked Product Having A Cookie-Like Crumb Structure," filed in the name of Bernhard Van Lengerich on June 7, 1989. The extruder had twelve barrels, each provided with external, jacketed heating and cooling means. The first and second dry feed ports were set up at barrels 1 and 8, respectively. These two dry feed ports were open to the atmosphere. The first liquid feed port was set up between barrels 1 and 2. The second liquid feed port was the same as the second dry feed port at barrel 8. The second liquid feed inlet pipe was inserted into the open port at barrel 8 so that the second dry feed ingredients and the second liquid feed ingredients were separately fed into the same port. The first barrel, which contained the first dry feed port, was set on constant cool. The remaining eleven barrels were divided into 7 separately measured barrel temperature zones. Barrels 2 and 3 corresponded to temperature zone 1, barrel 4 corresponded to zone 2, barrels 5 and 6 corresponded to zone 3, barrels 7 and 8 corresponded to zones 4, and 5, respectively, barrels 9 and 10 corresponded to temperature zone 6, and barrels 11 and 12 corresponded to temperature zone 7. The thermocouples for measuring actual barrel temperatures were located in barrels 2, 4, 5, 7, 8, 10, and 12.

Barrels 2 through 6 were set to heat to 350°F, barrel seven to 200"F, barrel eight was set on constant cool, barrels 9 and 10 were set at 100"F and barrels 11 and 12 were set at 120°F.

Barrel Set Actual Barrel Barrel # Temperature. ⁸F Temperature, "F

1 cool

2 350 206

3 350

4 350 245

5 350 324

6 350

7 200 201

8 cool <100

9 100

10 100 <100

11 120

12 120 115

The pressure in the extruder was less than about 10

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high) by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was less than about 150"F. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4". Six pieces were subjected to microwaving in a microwave oven for about 50 seconds to produce distinctly leavened cookies. The cookies were surface browned and had a crumb-like structure and crumb-like texture.

EXAMPLE 26

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

Salt 0.75

Component 2: second dry feed port

White sugar (sucrose), granulated 14.72 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.86

Vanilla 1.23

Sodium bicarbonate 0.25 Component 3: first liquid feed port

Soybean spray oil 22.56

Component 4: second liquid feed port

Tap water 2.25

Total 100.00

The co-rotating twin screw cooker extruder system of

Example 25 was used to prepare the cookie products of the present invention.

Barrel Set Actual Barrel Barrel # Temperature. Temperature, *F

1 cool

2 350 247

3 350

4 350 307

5 350 309

6 350

7 200 201

8 <100 122

9 100

10 100 99

11 110

12 110 112

Six pieces were subjected to microwaving in a microwave oven for about 50 seconds to produce distinctly leavened cookies. A cookie sample had an internal temperature of about 217°F upon microwaving. The cookies were surface browned and had a crumb-like structure and crumb-like texture.

EXAMPLE 27

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

Salt 0.73

Component 2: second dry feed port

White sugar (sucrose), granulated 14.60 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.81

Sodium bicarbonate 1.22

Component 3: first liquid feed port Soybean spray oil 24.33

Component 4: second liquid feed port

Tap water 2.19

Total 100.00

The co-rotating twin screw cooker extruder system of Example 25 was used to prepare the cookie products of the present invention.

Barrel Set Actual Barrel

Barrel # Temperature. ^βF Temperature, "F

1 cool —

2 350 206

3 350 —

4 350 245

5 350 324

6 350 —

7 200 201

8 cool <100

9 100 —

10 100 <100

11 120 —

12 120 115

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high) by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was less than about 150°F. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4". Six pieces were subjected to microwaving in a microwave oven for about 50 seconds to produce distinctly leavened cookies. The cookies were surface browned and had a crumb-like structure and crumb-like texture.

EXAMPLE 28

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first drv feed port

Wheat flour, bleached

Salt 0.83

Component 2: second dry feed port

White sugar (sucrose), granulated 8.80 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 3.85

Aspartame 0.06

Component 3: first liquid feed port Clarified butter 24.75

Component 4: second liquid feed port

Tap water 5.06

Total 100.00

The screws were rotated at about 225 rpm at about 8% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 181 lbs/hr. Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component l dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed downstream to the second dry feed port. Component 3 was prepared by melting the semi-solid clarified butter to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

Barrel Set Actual Barrel Barrel ■# Temperature. *F Temperature. °F

1 cool

2 350 298

3 350

4 350 335

5 350 290

6 350

7 200 195

8 cool 100

9 100

10 100 100

11 120

12 120 119

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high) by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was less than about 150^βF. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4". Six pieces were subjected to microwaving in a microwave oven for about 50 seconds to produce distinctly leavened cookies. The cookies were surface browned and had a crumb-like structure and crumb-like texture.

EXAMPLE 29

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first drv feed port

Wheat flour, bleached

(about 12% by weight water) 24.67

Oat bran (about 12% by weight water) 24.67

Non-fat dry milk (about 52% by weight lactose) 1.48

Salt 0.74

Component 2: second dry feed port

White sugar (sucrose), granulated 14.80

Brown sugar (about 89% sucrose, 3% invert, 4% non-sugar solids, 3% water) 6.91

Component 3: first liquid feed port

Clarified butter 22.20

Component 4: second liquid feed port

Sodium bicarbonate 0.41

Tap-water 4.12

Total 100.00

The co-rotating twin screw cooker extruder system of

Example 25 was used to prepare the cookie products of the present invention.

Barrel Set Actual Barrel

Barrel # Temperature. ^βF Temperature. "F

1 cool —

2 350 276

3 350 —

4 350 311

5 350 289

6 350 —

7 200 198

8 cool 100

9 100 —

10 100 100

11 120 —

12 120 122

EXAMPLE 30

The ingredients, their feed placement, and their relative amounts used to prepare a cookie having a crumb-like structure and texture using extrusion heating a d microwave baking in accordance with the present invention were: ι

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

. Salt 0.69

Component 2: second drv feed port

White sugar (sucrose), granulated 13.72 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.40

Nut pieces (walnut fluff) 7.31

Component 3: first liquid feed port Clarified butter 20.58

Component 4: second liquid feed port

Sodium bicarbonate 0.38

Tap water 3.83

Total 100.00

The co-rotating twin screw cooker extruder system of

Example 25 was used to prepare the cookie products of the present invention.

The screws were rotated at about 225 rpm at about 5% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 218 lbs/hr. Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed downstream to the second dry feed port. Component 3 was prepared by melting the semi-solid clarified butter to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was prepared by dissolving the sodium bicarbonate in the water to form a solution which was continuously fed to the second liquid feed port.

Barrel Set Actual Barrel

Barrel # Temperature. ^βF Temperature, °F

1 cool —

2 350 276

3 350 —

4 350 311

5 350 289

6 350 —

7 200 198

8 cool 100

9 100 —

10 100 100

11 120 —

12 120 122

EXAMPLE 31

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

Salt 0.75

Component 2: second dry feed port

White sugar (sucrose), granulated 15.64 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 7.29

Vitamin mix 0.13

Component 3: first liquid feed port ^■ Soybean spray oil 22.56

Component 4: second liquid feed port

Tap water 2.25

Total 100.00

Barrel Set Actual Barrel

Barrel # Temperature, "F Temperature. ^•F

1 cool —

2 350 228

3 350 —

4 350 283

5 350 340

6 350 —

7 200 200

8 <100 138

9 100 —

10 100 98

11 110 —

12 110 Ill

The pressure in the extruder was less than about 10 bars. The material temperatures in the extruder were about 236°F at barrel 7, and about 135^βF at barrel 12. The average or median residence time of the ingredients heated prior to addition of components 2 and 4 at the second feed ports was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed ports was about 10 to 20 seconds.

Six pieces were subjected to microwaving in a microwave oven for about 50 seconds to produce distinctly leavened cookies. A cookie sample had an internal temperature of about 227°F upon microwaving. The cookies were surface browned and had a crumb-like structure and crumb-like texture.

EXAMPLE 32

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Wheat flour, bleached

Salt 0.73

Component 2: second dry feed port

White sugar (sucrose), granulated 14.53 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.78

Component 3: first liquid feed port

Soybean spray oil 24.21 Component 4: second liquid feed port

Tap water 3.87

Total 100.00

The co-rotating twin screw cooker extruder system of Example 25 may be used to prepare the cookie products of the present invention.

On a calculated basis, the water content of the dough-like mixture formed in the extruder is about 10.7% by weight, based upon the total weight of the dough-like mixture. The barrel set temperatures, pressures, and residence times may be the same as in Example 25.

The substantially homogeneous dough-like mixture formed in the extruder may be extruded without a die to obtain a substantially unleavened extrudate dough having a temperature upon exiting the extruder of less than about 150°F. The extrudate may be transferred or drop into the hopper of a conventional cookie wire-cutting machine. The wire-cutting machine may be equipped with a screw-type or auger feed or counter-rotating grooved rollers for feeding the extrudate through nozzles. Upon emerging through the nozzles, the extrudate is cut into cylindrical pieces by the wire. Six of the pieces may be subjected to microwaving in a microwave oven for 60 seconds to produce distinctly leavened, surface browned cookies having a crumb-like structure and crumb-like texture.

EXAMPLE 33 The ingredients, their feed placement, and their relative amounts used to prepare a cookie having a crumb-like structure and texture using extrusion heating and microwave baking in accordance with the present invention were:

INGREDIENT AND PLACEMENT WEIGHT %

Component 1: first dry feed port

Oat bran (about 12% by weight water) 48.31

Component 2: second dry feed port White sugar (sucrose), granulated 14.02

Brown sugar (about 89% sucrose, 3% invert, 4% non-sugar solids, 3% water) 6.56

Sodium bicarbonate 1.17 Component 3: first liquid feed port

Soybean spray oil 21.73

Component 4: second liquid feed port

Tap water 8.21

Total 100.00

The co-rotating twin screw cooker extruder system of

Example 25 was used to prepare the cookie products of the present invention.

The screws were rotated at about 145 rpm at about 1% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 207 lbs/hr.

Component 1 was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a substantially homogenous dry blend which was continuously fed downstream to the second dry feed port. Component 3 was prepared by melting the semi-solid clarified butter to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder was about 14.2% by weight, based upon the total weight of the dough-like mixture. At steady state, the barrel set temperatures and the actual barrel temperatures were:

Barrel Set Actual Barrel

Barrel # Temperature, °F Temperature. °F

1 cool —

2 heater not working 117

3 heater not working —

4 350 235

5 350 335

6 350 —

7 200 195

8 100 115

9 100 —

10 100 100

11 120 —

12 120 120

The pressure in the extruder was less than about 10 bars. The material temperatures in the extruder were about 229°F at barrel 7 and about 137°F at barrel 12. The average or median residence time of the ingredients heated prior to addition of components 2 and 4 at the second feed ports was about 40-50 seconds. The average or median residence time of the ingredients in the extruder from the second feed ports was about 10 to 20 seconds.

The substantially homogeneous dough-like mixture formed in the extruder was extruded through a horizontally oriented slit die (about 5mm high) by about 50 mm wide) to obtain a continuous, substantially unleavened ribbon. The extrudate temperature upon exiting the extruder was about 138°F. The ribbon was cut into cylindrical pieces by hand, using a cookie cutter. The diameter of the pieces was about 1 1/4".

Six pieces were subjected to microwaving in a microwave oven for about 50 seconds to produce distinctly leavened cookies. The cookies were surface browned and had a crumb-like structure and crumb-like texture.

EXAMPLE 34

The ingredients, their feed placement, and their relative amounts used to prepare a cookie bit or cookie chip product having a crumb-like structure and texture using extrusion heating and convection baking in accordance with the present invention were:

INGREDIENT AND PLACEMENT WEIGHT ■ '

Component 1: first dry feed port

Wheat flour, bleached

(about 12% by weight water) 49.03 Non-fat dry milk (about 52% by weight lactose) 1.47

Salt 0.74

Component 2: second dry feed port

White sugar (sucrose), granulated 14.30 Brown sugar (about 89% sucrose,

3% invert, 4% non-sugar solids, 3% water) 6.67

Sodium bicarbonate 1.19

Component 3: first liquid feed port Soybean spray oil 22.17

Component 4: second liquid feed port

Tap water 4.43

Total 100.00

The screws were rotated at about 145 rpm at about 1% of maximum torque. The ingredients were fed in their relative amounts to provide a throughput or mass flow rate of the dough-like mixture extrudate of about 207 lbs/hr. Component 1 was prepared by mixing the ingredients to obtain a substantially homogeneous dry blend. The component 1 dry blend was continuously fed to the first dry feed port. Component 2 was prepared by mixing the ingredients to obtain a second substantially homogenous dry blend which was continuously fed downstream to the second dry feed port. Component 3 was prepared by melting the semi-solid soybean spray oil to obtain a liquid oil which was continuously fed to the first liquid feed port. Component 4 was continuously fed to the second liquid feed port.

On a calculated basis, the water content of the dough-like mixture formed in the extruder was about 10.5% by weight, based upon the total weight of the dough-like mixture.

Barrel Set Actual Barrel

Barrel # Temperature. °F Temperature, °F

1 cool —

2 heater not working 118

3 heater not working —

4 350 237

5 350 334

6 350 —

7 200 196

8 100 117

9 100 —

10 100 106

11 120 —

12 120 121

The substantially homogeneous dough-like mixture formed in the extruder was extruded without a die and the extrudate fell and formed into substantially unleavened pieces. The extrudate temperature upon exiting the extruder was less than about 150°F. The extrudate pieces were subjected to heating in a convection oven at about 350"F for about six minutes to produce distinctly leavened, surface browned cookie pieces having a crumb-like structure and crumb-like texture. The cookie pieces were screened to obtain

"chocolate chip size" pieces. A "reverse chocolate chip cookie" product or "cookie chip chocolate" product may be produced by incorporating the cookie chips or cookie bits into melted chocolate in a cookie-shaped mold followed by solidification of the chocolate by cooling it. The amount of cookie chips used may be about 25% by weight, based upon the total weight of the chocolate and the cookie chips.

Claims

What is claimed is:

1. A method for producing cookies comprising: a. forming a substantially homogeneous dough¬ like mixture in a cooker extruder by heating ingredients comprising at least one flour and shortening or fat to a temperature of at least about 150"F under conditions to prevent substantial starch gelatinization, the amount of shortening or fat being at least about 12% by weight, based upon the weight of the dough-like mixture, b. extruding the dough-like mixture, c. forming the extrudate into pieces, and d. leavening the pieces by subjecting them to post extrusion heating to obtain a crumb-like structure.

2. A method as claimed in claim 1 wherein said ingredients are heated in said cooker extruder to a temperature of at least about 200"F to form a heat treated mass and water is admixed with the heat treated mass to obtain said dough-like mixture.

3. A method as claimed in claim 2 wherein said heat treated mass is cooled to a temperature of less than about 150°F.

4. A method as claimed in claim 1 wherein the water content of said dough-like mixture is less than about 15% by weight, based upon the weight of the dough¬ like mixture.

5. A method as claimed in claim 1 wherein the shortening or fat content of said dough-like mixture is at least about 12% by weight, based upon the weight of the dough-like mixture.

6. A method as claimed in claim 1 wherein at least one crystalline sugar is admixed with the ingredients comprising flour and shortening or fat in an amount of at least about 10% by weight crystalline sugar on a sugar solids basis, said percentage being based upon the weight of the dough-like mixture.

7. A method as claimed in claim 6 wherein said crystalline sugar comprises sucrose.

8. A method as claimed in claim 7 wherein at least one reducing sugar is admixed with said ingredients comprising flour in an amount which promotes Maillard browning.

9. A method as claimed in claim 1 wherein at least one protein source is admixed with said ingredients comprising flour in an amount which promotes Maillard browning. >

10. A method as claimed in claim 2 wherein said dough-like mixture comprises: a. less than about 20% by weight water, b. from about 12% by weight to about 40% by weight shortening or fat, c. from about 10% by weight to about 40% by weight of at least one sugar, on a sugar solids basis, and d. from about 30% by weight to about 70% by weight of at least one flour, said percentages being based upon the weight of said dough-like mixture.

11. A method as claimed in claim 2 wherein said heat treated mass is formed at a pressure within the cooker extruder of less than about 10 bars absolute.

12. A method as claimed in claim 11 wherein the average residence time of said ingredients comprising flour at a temperature of at least about 200°F is from about 15 seconds to about 90 seconds.

13. A method as claimed in claim 12 wherein the average residence time of the ingredients in the cooker extruder from the point of addition of the added water to the heat treated mass is from about 10 seconds to about 60 seconds.

14. A method as claimed in claim 3 wherein said heat treated mass is cooled to a temperature of less than about 150^βF prior to addition of said water.

15. A method as claimed in claim 2 wherein the temperature of said heat treated mass is reduced by at least about 35°F prior to said addition of the water to the heat treated mass.

16. A method as claimed in claim 10 wherein at least a portion of said sugar is admixed with the flour and shortening or fat prior to said addition of the water to the heat treated mass.

17. A method as claimed in claim 10 wherein at least a portion of said sugar is subjected to said heating for forming said heat treated mass.

18. A method as claimed in claim 10 wherein at least a portion of said sugar is admixed with the heat treated mass after reducing the temperature of the heat treated mass.

19. A method as claimed in claim 10 wherein at least a portion of said sugar and the water are admixed with said heat-treated mass.

20. A method as claimed in claim 2 wherein the amount of water admixed with said heat treated mass is from about 0.5% by weight to about 10% by weight, based upon the weight of the dough-like mixture.

21. A method as claimed in claim 20 wherein the water admixed with the heat treated mass comprises a liquid source of water selected from the group consisting of high fructose corn syrup, corn syrup, sucrose syrup, and mixtures thereof.

22. A method as claimed in claim 2 wherein the water content of the dough-like mixture is sufficiently low so as to avoid substantial starch gelatinization.

23. A method as claimed in claim 1 wherein the water content of the dough-like mixture is such that additional water will increase the consistency of the dough-like mixture.

24. A method as claimed in claim 3 wherein after cooling said heat treated mass, it is heated to control its flow through an extrusion die.

25. A method as claimed in claim 1 where said dough-like mixture is coextruded with a filler material and the coextrudate is formed into pieces.

26. A method as claimed in claim 1 wherein the dough-like mixture is extruded at a temperature of from about 100°F to about 212°F.

27. A method for the production of cookies comprising: a. heating ingredients comprising flour, at least one sugar and shortening or fat, in a cooker extruder to a temperature of at least about 150°F to form a heat treated mass, b. admixing water with the heat treated mass in said extruder to obtain a substantially homogeneous dough-like mixture, c. forming the dough-like mixture into pieces, and d. leavening the pieces by subjecting them to microwave energy.

28. A method as claimed in claim 27 wherein said ingredients are heated in said cooker extruder to a temperature of at least about 200°F to form said heat treated mass.

29. A method as claimed in claim 28 wherein said heat treated mass is cooled to a temperature of less than about 150°F so as to avoid substantial separation of oil and to avoid extruder surging.

30. A method as claimed in claim 27 wherein the water content of said dough-like mixture is less than about 15% by weight, based upon the weight of the dough¬ like mixture.

31. A method as claimed in claim 27 wherein at least one sugar and water are admixed with said heat treated mass in said extrudewr to obtain a substantially homogeneous dough-like mixture.

32. A method for the production of cookies comprising: a. heating ingredients comprising flour, at least one sugar and shortening or fat, in a cooker extruder to a temperature of at least about 150°F to form a heat treated mass, b. admixing water with the heat treated mass in said extruder to obtain a substantially homogeneous dough-like mixture,

* c. forming the dough-like mixture into pieces, and d. leavening the pieces by subjecting them to dielectric radio frequency energy.

33. A method as claimed in claim 32 wherein said ingredients are heated in said cooker extruder to a temperature of at least about 200"F to form said heat treated mass.

34. A method as claimed in claim 33 wherein said heat treated mass is cooled to a temperature of less than about 150°F so as to avoid substantial separation of oil and to avoid extruder surging.

35. A method as claimed in claim 32 wherein the water content of said dough-like mixture is less than about 15% by weight, based upon the weight of the dough¬ like mixture.

36. A method as claimed in claim 32 wherein at least one sugar and water are admixed with said heat treated mass in said extrudewr to obtain a substantially homogeneous dough-like mixture.

37. A method for producing leavened products using a cooker extruder comprising: a. forming a heat treated mass in a cooker extruder by heating ingredients comprising at least one flour and shortening or fat to promote browning and flavor development, b. admixing water with the heat treated mass in said cooker extruder to form a dough-like mixture, the amount of shortening or fat being at least about 12% by weight, based upon the weight of the dough-like mixture , and c. leavening the dough-like mixture by subjecting it to post extrusion heating.

38. A method as claimed in claim 37 wherein said ingredients comprising said flour and shortening or fat are heated in said cooker extruder to a temperature of at least about 200°F.

39. A method as claimed in claim 38 wherein said heat treated mass is cooled to a temperature of less than about 150^βF prior to extrusion.

40. A method as claimed in claim 37 wherein the water content of said dough-like mixture is less than about 15% by weight, based upon the weight of the dough¬ like mixture.

41. A method as claimed in claim 37 wherein the shortening or fat content of said dough-like mixture is from about 20% by weight to about 30% by weight, based upon the weight of the dough-like mixture.

42. A method as claimed in claim 37 wherein at least one crystalline sugar is admixed with the ingredients comprising flour and shortening or fat in an amount of at least about 10% by weight crystalline sugar on a sugar solids basis, said percentage being based upon the weight of the dough-like mixture.

43. A method for the production of leavened products comprising: a. forming a dough-like mixture in a cooker extruder from ingredients comprising flour, water, at least one sugar, and shortening or fat, the amount of shortening or fat being at least about 12% by weight, based upon the weight of the dough-like mixture, wherein at least the flour and shortening or fat are heated to a temperature of at least about 150°F in said cooker extruder, b. extruding the dough-like mixture from said cooker extruder at a temperature of from about 100°F to about 212^βF, and c. leavening the pieces in a post extrusion heater.

44. A method as claimed in claim 43 wherein the water content of the dough-like mixture is such that additional water will increase the consistency of the dough-like mixture.

45. A method as claimed in claim 43 wherein said ingredients are heated in said cooker extruder to a temperature of at least about 250°F.

46. A method for the continuous production of a shelf stable, cookie mixture comprising: a. admixing ingredients comprising flour, at least one sugar, and shortening or fat in a cooker extruder, b. heating ingredients comprising flour and shortening or fat in the extruder while continuously mixing at a temperature sufficient to promote browning and to form a cookie mixture, and c. extruding the cookie mixture, wherein the cookie mixture includes a pH-adjusting agent and has a pH of about pH 5 to about pH 9.5 and a water activity of less than 0.7, and wherein the cookie mixture is leavenable by heating.

47. A method as claimed in claim 46 wherein the water content of said mixture is sufficiently low such that further water addition increases the consistency of the mixture.

48. A method as claimed in claim 46 wherein at least one reducing sugar is admixed with said ingredients comprising flour in an amount to promote Maillard browning during heating.

49. A method as claimed in claim 46 wherein at least one protein source is admixed with said ingredients comprising flour in an amount to promote Maillard browning during heating.

50. A method as claimed in claim 46 wherein at least one heat-labile or shear sensitive additive is admixed with sufficient mixing to uniformly disperse the additive in the heat-treated mass and to form said cookie mixture.

51. The method of claim 50 wherein at least one sugar is admixed with the flpur and fat mass and heated to form said heat treated mass.

52. A shelf stable dough-like mixture prepared according to claim 46 wherein said mixture has a water activity of less than about 0.7 and is substantially unleavened and leavenable to a crumb-like structure by heating.

53. A shelf stable, cookie dough-like composition comprising, a. 30% to 70% flour, b. 12% to 40% fat or shortening, c. 10% to 40% sugar solids, and d. up to about 5% chemical leavening agent, wherein said percentages are based on the total weight of the composition, said composition being substantially unleavened and having a water activity of less than about 0.7 and being leavenable to a cookie product having a crumb-like structure by the application of heat, wherein at least said flour and fat and at least a portion of the sugar solids are heat treated by heating to a temperature of at least about 200°F to promote browning and flavor development and wherein said composition has a substantially uniform consistency.

54. The shelf stable composition of claim 53 having a water content sufficiently low such that further addition of water increases the consistency of the mixture.

55. The shelf stable composition of claim 53 wherein said leavening agent is at least one selected from the group consisting of sodium bicarbonate, calcium carbonate, ammonium bicarbonate, and tartaric acid.

56. The shelf stable composition of claim 53 wherein said composition includes at least one heat labile or shear sensitive additive.

57. A shelf stable, cookie dough-like composition comprising, a. 30% to 70% flour, b. 12% to 40% fat or shortening, c. 10% to 40% sugar, and d. at least one pH-adjusting agent, wherein said percentages are based on the total weight of the composition, said composition being substantially unleavened and having a water activity of less than about 0.7 and being leavenable to a cookie product having crumb-like structure by the application of heat, wherein at least said flour and fat are heat treated by heating to a temperature of at least 200°F to promote browning and flavor development and wherein said composition has substantially uniform consistency and a pH of about pH 5 to about pH 9.5.

58. The composition of claim 57 wherein said pH adjusting agent is a chemical leavening agent.

59. The shelf stable composition of claim 57 wherein said composition includes at least one heat labile or shear sensitive additive.

60. A method for the continuous production of fiber-containing cookies having a leavened, crumb-like structure, which comprises: a. admixing ingredients comprising a fiber source and oil in a cooker extruder, b. heating ingredients comprising the oil and at least a first portion of the fiber source in the extruder to form a heat treated mass, c. extruding and forming the dough-like mixture to obtain dough pieces, and d. leavening the pieces by subjecting them to post extrusion heating to obtain a crumb-like structure.

61. An extruder, which comprises: a. a housing including a screw channel formed along the longitudinal axis of the housing; b. at least one screw-type element rotatably received within the screw channel to convey and mix ingredients; c. a feed port means arranged in the housing adjacent the upstream end thereof to input ingredients into the screw channel for conveyance and mixing by the screw-type element; d. means for inputting at least certain ingredients of a cookie-like dough formulation, including oil and flour, with less than a preselected total water content, by weight, of the ingredients; e. the means for inputting being coupled to the feed port means; f. an added water inlet port arranged in the housing downstream from the feed port means to input water into the screw channel; g. a vigorous mixing zone formed by the screw channel and screw-type element intermediate the feed port means and the added water inlet port to vigorously mix and convey the ingredients input into the feed port means; h. a temperature control means operating to elevate the temperature of the screw channel for heat treatment of the ingredients input into the feed port means in a heat treatment zone of the housing extending intermediate the feed port means and the added water inlet port; i. a source of water coupled to the added water inlet port to add a preselected amount of water through the added water inlet port to increase the water content and modify the consistency of the ingredients input into the feed ports means at a location in the screw channel downstream from the vigorous mixing and heat treatment zones; j. a mixing zone formed by the screw channel and screw-type element downstream from the added water inlet port and operating to mix the added water throughout the heat treated ingredients under pressure and temperature conditions to avoid substantial oil separation from the heat treated ingredients and added water; and k. an output means at the downstream most end of the housing.

62. The extruder of claim 61 further comprising a downstream dry ingredient feed port arranged adjacent to the added water inlet port.

63. The extruder of claim 62 further comprising a means for inputting crystalline sugar coupled to the downstream dry ingredient feed port.

64. The extruder of claim 63 wherein the screw-type element forms a high speed conveyance zone beneath the downstream dry ingredient inlet port for rapid intake of the crystalline sugar into the screw channel.

65. The extruder of claim 61 wherein the screw-type element comprises a sequence of elements upstream from the added water inlet port including, in downstream order, a shuffle kneader, an alternating sequence of screw elements and igel elements followed by an alternating sequence of screw elements and kneading block elements, the sequence of elements operating to vigorously mix and convey the ingredients input through the feed port means prior to input of the added water, the sequence of elements upstream from the added water inlet port together with the screw channel comprising the vigorous mixing zone.

66. The extruder of claim 65, wherein the screw- type element comprises a sequence of elements downstream from the added water inlet port, including, in downstream order, an alternating sequence of screw elements and kneading elements to mix and convey the ingredients input through the feed port means and added water input through the added water inlet port at low pressure and low temperature, relative to the vigorous mixing and heat treatment zones, the sequence of elements downstream from the added water inlet port together with the screw channel comprising the mixing zone.

67. The extruder of claim 66 further comprising at least one high speed conveyance screw element arranged at the upstream end of the sequence of elements downstream from the added water inlet port.

68. The extruder of claim 67 further comprising a downstream dry ingredient inlet port formed in the housing above the at least one high speed conveyance screw element and adjacent the added water inlet port.

69. The extruder of claim 61 wherein the feed port means comprises a dry ingredient feed port adjacent to a liquid feed port.

70. The extruder of claim 61 wherein the extruder comprises a twin screw extruder.

71. The extruder of claim 61 wherein the temperature control means comprises an electric heating means arranged in the housing to apply heat to the screw channel_*.

72. The extruder of claim 71 wherein the temperature control means further comprises a cooling water flow means arranged around the screw channel to reduce the temperature of the screw channel.

73. The extruder of claim 72 wherein the temperature control means includes a thermostat control to selectively activate the electric heating means and cooling water flow means to control the temperature of the screw channel.

74. The extruder of claim 61 further comprising a cooling means arranged on the housing adjacent the added water inlet port on the upstream side thereof to cool the screw channel immediately upstream from the added water inlet port.

75. An extruder, which comprises: a. a housing including a screw channel formed along the longitudinal axis of the housing; b. at least one screw-type shaft rotatably received within the screw channel; c. the housing including a first dry ingredient feed port arranged adjacent the upstream end of the housing and a second dry ingredient feed port spaced downstream from the first dry ingredient feed port; d. a temperature control means operating to elevate the temperature of the screw channel in a heat treatment zone intermediate the first and second dry ingredient feed ports; e. the screw-type shaft being arranged and configured upstream from the second dry ingredient feed port to convey and vigorously mix dry ingredients input at the first dry ingredient feed port; f. means to input dry ingredients through the first and second dry ingredient feed ports. g. the screw-type shaft being arranged to provide a high speed conveyance element directly below the second, dry ingredient feed port, and h. a mixing zone formed by the screw channel and screw-type element downstream from the second dry ingredient feed port and operating to provide low pressure and low temperature mixing and conveying, relative to the vigorous mixing by the screw-type shaft upstream from the second dry ingredient feed port, of the ingredients input through the first and second dry ingredient feed ports.

76. The extruder of claim 75 further including a liquid feed port adjacent to the second downstream dry ingredient feed port.

77. An extruder which comprises: a. a housing including a screw channel formed along the longitudinal axis of the housing; b. at least one screw-type element rotatably received in the screw channel for conveyance and mixing of ingredients; c. a feed port means arranged in the housing at the upstream end thereof to input ingredients into the screw channel for conveying and mixing by the screw- type element; d. an added water inlet port arranged in the housing intermediate the upstream most and downstream most ends of the housing; e. the screw-type element being configured to provide a vigorous mixing and conveying action on ingredients input through the feed port means upstream from the added water inlet port and a gentle mixing and conveying action on the ingredients downstream from the added water inlet port; f. a source of water coupled to the added water inlet port; and g. a temperature control means operating to elevate the temperature of the screw channel along the length of the screw channel adjacent the screw-type element upstream from the added water inlet port.

78. The extruder of claim 61 further comprising a heat treatment device coupled to the output means to the extruder to receive and further heat treat the ingredients output by the output means.

79. The extruder of claim 78 wherein the heat treatment device comprises a microwave device.

80. The extruder of claim 78 wherein the heat treatment device comprises a radio frequency device.