Extruder system for forming a folded extrudate with improved organoleptic properties

A method for forming an extrudate from a formulation including cultivated animal cells and plant-based proteins, the method comprising:

• receiving an intermediate extrudate into a flow path of a cooling die, wherein:
• the flow path extends from an inlet with a first cross-sectional area at an upstream end of the cooling die to an outlet with a second cross-sectional area at a downstream end of the cooling die, the second cross-sectional area is larger than the first cross-sectional area, the flow path includes a transition region at the upstream end and a forming region at the downstream end, and
• the intermediate extrudate is received at the inlet at a first mass flux and crosses an interface between the transition region and the forming region at a second mass flux, wherein the first mass flux is at least 4× greater than the second mass flux;
• cooling the intermediate extrudate at a cooling rate, wherein the cooling rate provides a first temperature reduction per unit length of at least 4° C./cm;
• and
• expelling the intermediate extrudate from the cooling die to form the extrudate.

A system for forming an extrudate, the system comprising:

• an extruder barrel housing a set of screws;
• a set of feed streams coupled to one or more inlets of the extruder barrel, wherein the set of feed streams provide feed material processed within the extruder barrel;
• and
• a cooling die fluidically coupled to an outlet of the extruder barrel, the cooling die further comprising a body defining a flow path extending from an inlet at an upstream end of the body to an outlet at a downstream end of the body, wherein:
• the inlet has a first cross-sectional area,
• the outlet has a second cross-sectional area that is larger than the first cross-sectional area, the flow path includes a transitional region at the upstream end of the body with a length L and a minimum cross-sectional expansion ratio of at least 2× for any continuous length L/2 over the length L of the transitional region, and the flow path includes a forming region extending from the transitional region to the outlet.

An apparatus for forming an extrudate, the apparatus comprising:

• a body defining a flow path extending from an inlet at an upstream end of the body to an outlet at a downstream end of the body, wherein:
• the inlet has a first cross-sectional area with a first geometric shape,
• the outlet has a second cross-sectional area with a second geometric shape, and
• the second cross-sectional area is larger than the first cross-sectional area and the second geometric shape is an ellipse, ellipse-like, or tear-drop.