Apparatus and method for producing flake-like cereal without the use of a flaking mill

1. A method comprising:

feeding a food material into a feed section of a cooking extruder;

mixing the food material with water using the cooking extruder;

heating the food material using the cooking extruder;

extruding the food material through a die connected to the cooking extruder comprising one or more orifices, each orifice comprising:

an inlet including a first flow channel configured to accept the food material, wherein the first flow channel is surrounded by a hollow jacket for circulating cooling medium;

a breaker screen connected to the inlet and comprised of one or more holes;

wherein the first flow channel and the hollow jacket for circulating the cooling medium are positioned upstream of the breaker screen;

an expansion chamber connected to the breaker screen, wherein the expansion chamber has an expansion chamber cross-sectional area;

an exit orifice connected to the expansion chamber and configured to output the food material, wherein the exit orifice has an exit orifice cross-sectional area and wherein the food material outputs the exit orifice at a temperature between 250 degrees Fahrenheit and 350 degrees Fahrenheit;

slicing the extruded food material using a cutting knife assembly; and

toasting the sliced extruded food material using a toasting oven.

2. The method of claim 1 , wherein the exit orifice cross-sectional area is less than the expansion chamber cross-sectional area.

3. The method of claim 1 , wherein the one or more holes include a hole cross-sectional area and the hole cross-sectional area is less than the expansion chamber cross-sectional area.

4. The method of claim 1 , wherein the cutting knife assembly slices the extruded food material at a rate such that a slice thickness is less than a diameter of one or more vapor bubbles within the food material.

5. The method of claim 1 , wherein heating the food material using the cooking extruder further comprising heating the food material using the cooking extruder to a temperature greater than 212 degrees Fahrenheit.

6. The method of claim 1 , wherein mixing the food material further comprises mixing liquid food materials with the food material.

7. The method of claim 6 , wherein the liquid food material includes one or more of the following a solution of sugar, malt extract, salt or other flavors.

8. The method of claim 1 , wherein the food material includes a moisture content determined when the food material is within the cooking extruder and before the die.

9. The method of claim 8 , wherein the moisture content is less than 20 percent.

10. The method of claim 8 , wherein the moisture content is between 14 and 17 percent.