Corn spirals and method of manufacture

Claim 2

A process for producing a cooked snack food product comprising subjecting a ground masa made from dehulled corn kernels to comminution by simultaneously grating and cutting that reduces the size of particles in the masa, passing the comminuted masa through a die to a ribbon-like form, severing said ribbon-like material to form snack-sized pieces, and cooking said pieces.

Claim 3

The process of claim 1 further comprising screening the masa prior to extrusion such that said masa contains particles having a maximum size which does not exceed the largest dimension of the die opening.

Claim 4

The process of claim 1 wherein cooking said pieces comprises frying in hot oil to a final moisture content in the range 0.5% to 1.5% by weight.

Claim 5

The process of claim 1 wherein the die forms a ribbon-like extrudate having a spiral shape.

Claim 6

The process of claim 4 wherein adjacent windings of said spiral shape are separated by gaps of at least 0.10" but not in excess of 2.0", measured axially, and said severed pieces retain their shapes.

Claim 7

The process of claim 5 wherein cooking said spiral pieces comprises frying in hot oil to a final moisture content in the range 0.5% to 1.5% by weight.

Claim 8

The product produced by the process of claim 1.

Claim 9

A process for producing a snack food product comprising the sequential steps of: (a) boiling corn kernels in a water and lime solution and allowing the mixture to stand; (c) washing the corn kernels with water to remove the hulls; (d) grinding the dehulled corn between rotating grinding surfaces to form masa; (e) comminuting the particles in the masa by a simultaneous grating and cutting action to reduce particle size; (f) delivering the ground, comminuted masa into a piston-type extruder which applies pressure on the masa to force said masa through an extruder head and through helix-forming dies that form a helical ribbon of extruded masa, (g) cutting the extruded masa as it passes from the die, and (h) allowing said masa to drop into a fryer to cook it.

Claim 10

A process for producing a snack food product comprising the sequential steps of: (a) boiling corn kernels in a water and lime solution and allowing the mixture to stand; (c) washing the corn kernels with water to remove the hulls; (d) grinding the dehulled corn between rotating grinding surfaces to form masa; (e) comminuting the particles in the masa by a simultaneous grating and cutting action to reduce particle size; (f) delivering the ground, comminuted masa into a piston-type extruder which applies pressure on the masa to force said masa through an extruder head and through helix-forming dies that form a helical ribbon of extruded masa, (g) cutting the extruded masa as it passes from the die, and (h) allowing said masa to drop into a fryer to cook it.

Claim 11

The process of claim 8, wherein said extruder head has a screen of perforated metal through which the masa must pass before reaching the die.

Claim 12

The process of claim 9, wherein the screen passes only particles having diameters less than about 0.05 inch.

Claim 13

The product produced by the process of claim 8.