METHODS AND DEVICES FOR APPLYING PARTICULATES TO THE SURFACE OF MOLDED PRODUCTS

1 . A molded product comprising an undistorted three-dimensional design and particulates that do not distort the shape of the three-dimensional design.

2 . The molded product of claim 1 comprising the particulates in an amount ranging from about 2% to about 16% by weight.

3 . The molded product of claim 1 wherein the particulates having a size ranging from about 0.5 mm to about 8 mm measured at their longest side.

4 . The molded product of claim 1 wherein the molded product is a food product.

5 . The molded product of claim 1 wherein the molded product comprises one or more edible ingredients selected from the group consisting of grains, starches, meats, meat meals, proteins, fibers, sugars, minerals, aromas, colors, flavors, oils, humectants, preservatives, acids, and combinations thereof.

6 . The molded product of claim 1 wherein the particulates comprise one or more edible ingredients selected from the group consisting of grains, starches, meats, meat meals, proteins, fibers, sugars, minerals, aromas, colors, flavors, oils, humectants, preservatives, acids, and combinations thereof.

7 . A method for making a molded product comprising an undistorted three-dimensional design and particulates that do not distort the shape of the three-dimensional design comprising:

filling a mold in a die roll with one or more particulates;

filling the mold with a dough;

compressing the dough into the mold; and

releasing the compressed dough from the mold to form the molded product.

8 . The method of claim 7 further comprising baking the molded product.

9 . The method of claim 8 further comprising drying the baked molded product.

10 . The method of claim 7 further comprising filling a package with one or more of the molded products.

11 . The method of claim 7 wherein the mold has one or more three-dimensional designs.

12 . The method of claim 7 wherein the molded product comprises the particulates in an amount ranging from about 2% to about 16% by weight.

13 . The method of claim 7 wherein the particulates having a size ranging from about 0.5 mm to about 8 mm.

14 . The method of claim 7 wherein the molded product is a food product.

15 . The method of claim 7 wherein the dough is one or more edible ingredients selected from the group consisting of grains, starches, meats, meat meals, proteins, fibers, sugars, minerals, aromas, colors, flavors, oils, humectants, preservatives, acids, and combinations thereof.

16 . The method of claim 7 wherein the particulates are one or more edible ingredients selected from the group consisting of grains, starches, meats, meat meals, proteins, fibers, sugars, minerals, aromas, colors, flavors, oils, humectants, preservatives, acids, and combinations thereof.

17 . A continuous production line capable of manufacturing a molded product having an undistorted three-dimensional design and particulates that do not distort the shape of the three-dimensional design comprising (1) an apparatus for producing molded products comprising an undistorted three-dimensional design and particulates that do not distort the shape of the three-dimensional design and (2) a means for transporting the molded products for further processing.

18 . A rotary molding apparatus comprising:

a dough hopper;

a particulate hopper;

a die roll having at least one mold in communication with the dough hopper and the particulate hopper; and

a dough feed roll adjacent to the die roll.

19 . The rotary molding apparatus of claim 18 further comprising a rubber roll having a conveying belt positioned between the rubber roll and die roll forming a means to extract molded product and move it away from the die roll.

20 . (canceled)

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30 . A product made using the method of claim 7 .

31 . The continuous production line of claim 17 wherein the apparatus is a rotary molding apparatus comprising:

a dough hopper;

a particulate hopper;

a die roll having at least one mold in communication with the dough hopper and the particulate hopper; and

a dough feed roll adjacent to the die roll.

32 . The continuous production line of claim 17 wherein the means for transporting the molded products is a rubber roll having a conveying belt positioned between the rubber roll and die roll.

33 . The continuous production line of claim 17 wherein the apparatus is a rotary molding apparatus comprising:

a dough hopper;

a particulate hopper;

a die roll having at least one mold in communication with the dough hopper and the particulate hopper; and

a dough feed roll adjacent to the die roll, and

wherein the means for transporting the molded products is a rubber roll having a conveying belt positioned between the rubber roll and die roll.

34 . The molded product of claim 1 wherein the molded product is a companion animal food product.

35 . The molded product of claim 34 wherein the companion animal food product is a dog food product.

36 . The molded product of claim 35 wherein the three-dimensional design on the dog food product is a dog.

37 . The molded product of claim 34 wherein the companion animal food product is a cat food product.

38 . The molded product of claim 37 wherein the three-dimensional design on the cat food product is a cat.

39 . The method of claim 14 wherein the food product is a companion animal food product.

40 . The method of claim 39 wherein the companion animal food product is a dog food product.

41 . The method of claim 40 wherein the three-dimensional design on the dog food product is a dog.

42 . The method of claim 39 wherein the food product is a cat food product.

43 . The method of claim 42 wherein the three-dimensional design on the cat food product is a cat.