System of ultrasonic processing of pre-baked food product

Abstract

A system and method of ultrasonic processing of pre-baked food product and/or food product rework is provided that includes an ultrasonic horn and a forming member for receiving and forming unprocessed pre-baked food product into a desired shape. The ultrasonic horn is actuated to compress the unprocessed pre-baked food product between the ultrasonic horn and the forming member thereby forming compressed pre-baked food product. The ultrasonic horn ultrasonically energizes the compressed pre-baked food product to form an agglomerated food product. The system also includes an ejection member, such as an ejection piston, for ejecting the formed agglomerated food product away from the forming member. The forming member may be a forming cavity defined by a food product collection chamber. Alternatively, the forming member may include a forming block having a forming chamber. A fill plate having a fill recess may be positioned on the forming block to add more volume for the unprocessed pre-baked food product to accumulate. The ultrasonic horn may include a hemispherical protrusion or indentation; and the forming member may be a forming cylinder having a hemispherical protrusion or indentation that conforms to a contour of the hemispherical indentation or protrusion located on a compressive surface of the ultrasonic horn.