GB2525621A - Snack food chips - Google Patents

Abstract

A method of manufacturing three-dimensionally shaped snack food chips comprises : providing a plurality of dough sheets 2; providing a belt assembly 20 having an array of three-dimensionally curved shaping elements 30, 34 extending from an upper surface thereof; depositing an array of the dough sheets 2 onto the upper surface of the belt assembly 20 so that the array of dough sheets 2 and the array of shaping elements 30, 34 have a non-indexed relationship; causing the dough sheets to slump so that each dough sheet 2 assumes an irregular three dimensional shape, and cooking the dough sheets 2. The non-indexed relationship between the dough sheets 2 and the curved shaping elements 30, 34 results in a population of differently shaped dough sheets 2. Each chip has at least one three-dimensionally curved portion suitable for scooping up dips, and preferably also a flat portion (where the dough slumped to contact the belt 20) which functions as a handle for holding the chip. Also disclosed is a belt 20 having a first array of shaping elements (28, fig.2) and a second array of partially overlapping shaping elements (32, fig.2) of a different size and shape.

Description

Snack Food Chips The present invention relates to a method of manufacturing a plurality ofthree-dirnensionaty shaped snack food chips. The present invention also rel&Ues to a Dolt assembly tbr use in the manufaclurir.ig method, the present invention thsther r.elates to a snack food comnrising a plurality of non-identically shaped and three-dimensionally shaped snack food chips.

The manufacture of snack food chips well known. A variety of different snack food. chips is known having various shapes and configurations, and compositions.

There is a general need in the snack food art to provide consumers with new taste experiences associated with snack Ibods, and new ways to consume snack foods.

It is known to provide tortifla chips, which are composed of a naizcbased composition which has been formed as a masa dough and then fried. It is also known to market tortilla chips in conjunction with various dips, tbr example a salsa dip, to enable the consumer to dip the tortilla chip into the dip to provide a. portion of the dip on the tortilla chip.

It is known to provide variously shaped snack food chips. for example which have been three-dimensionally shaped for carrying a portion of a dip thereon.

There is a riced in the art to provide a method of manufacturing three-dimensionally shaped snack food chips that can provide a product of highly acceptable morphology to the consumer, which can he used for dipping and which can be produced in acosteffective manner The present invention aims at kast partially to meet those needs.

The present invention accordingly provides a method of manufacturing a plurality of three-dimensionally shaped snack food chips, the method comprising the steps of: i. providing a plurality of dough sheets; ii. providing a belt assembly having an array of a plurality of three-dimensionally curved shaping elements extending from an upper surface of a belt; iii. depositing an array of the dough sheets onto the upper surthee of the belt assembly so that the array of dough sheets and the array of shaping elements have a non-indexed relationship;

I

iv. in a shaping step causing the dough sheets to slump at least partially under the action of gravity so that each dough sheet assumes an irregular three-dimensional shape including at least one three-climensionaEly curved portion formed by a respective shaping efement, the nonindexed relationship forming a population of differently shaped dough sheets from the plurality of dough sheets; and v, cooking the shaped dough sheets to fonu a popthation of differently shaped rigid snack thod chips each having the respective irregular three-dimcnsionai shape. each snack food chip having at least one three-dimensionaliy curved portion.

The present invention further provides a belt assembly for shaping dough sheets in a method of manuf' cturing three-dimensionally shaped snack food chips. the belt assembly comprising an array of a plurality of shaping elements extending from an upper surface of a belt, wherein the shaping elements comprise a first array of first shaping elements and a second array of second shaping elements, the first and second shaping elements having at least one of a.

different size and shape. the first and second arrays at least partially overlapping.

The present invention finther provides an oven comprising a belt assembly according to the uresent invention, the belt assembly being arranged for conveying a. plurality of three-* dimensionally shaped dough sheets through the oven in the manufacture of snack thod chips.

The present invention further provides a snack food comprising a plurality of non-identically shaped and thee-dimensionally shaped snack food chips, the snack food chips being substantially rigid, each chip including at least one concavity which is shaped and dimensioned so as to he able to hol.d in a spoon-like manner a portion. of a dip and each snack food chip including at least on.e substantially flat portion shaped and dimensioned so as to be able to function as a manually-engageabie handle portion for the snack food chip.

Prefizrred features of all of thesc aspects of the present invention are defined in the dependent d aims, The preferred embodiments of the present invention can provide a novel three-dimensionally shaped snack ibod chip product in which the chips within a given population of the chips are essentially individually different in shape and configuration. yet each chip is specifically shaped with at least one concavity which may act as a spoon for picking up and holding a portion of a dip, such as a satsa dip, and wrth a substantially flat portion that can ftinction as a manually engageahie handk portion.

The preferred embodiments of the present invention can farther provide a low cost method for manufacturing such threedimensionai1y shaped snack food chips which has low production costs as svell as low capital expenditure. The aüparatus for shaping the snack thod chips, in particular the belt assembly for shaping dough pieces. may be retrofitted to an existing snack thod chip production line, Although the invention has particular application to the manufacture of shaped tortilla chips.

the method or the present invention may be used to produce a variety of different snack food chip compositions, as well and shapes. For example, the snack food chip may comprise any cereal-based composition. and may comprise any of, any mixture of or all of. maize, wheat, barley, rice or any other grain-derived product, as well as any seasoning, either within the cereai-based composition and/or applied as a topical seasoning.

The present invention is at least parfly predicated on the finding by the present inventors that by essentially non-unitormly applying dough pieces onto a specially shaped moulding device in the form of a belt carrying a plurality of shaping elements, so that there is no indexing between the dough pieces and the shaping elements, a substantially randomised population. of non4dentical threedimensionaily shaped chips is provided, yet with each chip including at least one concavity shaped and dimensioned so as to he able securely to hold, in a spooniike manner, a given minimum portion of a dip. Furthermore, each chip includes a substantially flat portion shaped and dimensioned so as to be able to function as a handle portion.

The snack food chips may be provided with other product design features to improve eating quality, for example particular tiavourings or texturizing components. The snack food chips may be provided in a consumer acceptable retail fonnat, for example a packaging such as a bag or carton, typically hermetically sealed, which is compatible with a retail sales environment, Embodiments of the present invention will now be described by way of exampke only with reference to the accompanying drawings, in which: Figure 1 schematically illustrates an apparatus for use in a method for manufacturing snack ibod chips in accordance with an embodiment of the present invention; Figure 2 schematically illustrates a plan view of a belt assembly used in the apparatus illustrated in Figure 1; Figure 3 schematically illustrates a side view of a part of the belt assemhiy of Figure 2; Figure 4 schematically illustrates a side view of a plurality of dough sheets in the irocess of being shaped on one embodiment of the belt assembly used in the apparatus illustrated in Figure 1; Figure 5 schematically illustrates a plan view of a plurality of dough sheets in the process of being shaped on a portion of another embodiment of the belt assembly used in the apparatus illustrated in Figure 1; and Figure 6 schematically illustrates a perspective view of a plurality of snack thod chips.

forming a population produced by a method fbr manufacturing snack food chips in accordance with an embodiment of the present invention, Referring to Figure 1 of the accompanying drawings, there is shown an apparatus ibr use in a method for manufacturing snack food chips, in particular tortilla chips, in accordance with an embodimern of (he present invention.

In the method, a plurality of dough sheets 2 is provided. The dough sheets 2 may have any desired composition, and may include any cereai-hased composition suitable for making a snack fOod dough which may be subsequently cooked, for exampie by frying, baking.

toasting, microwave cooking, or any other suitable cooking process. or any combination of cooking processes, to produce the desired taste and texture, for example a crispy texture, in the resultant chip. The dough may typically comprise a maize-based dough for the manufacture of snack food chips in the form of tortilla chips.

The dough heets.2 are two-dimensionally pro-shaped, and cut into desired two-dimensional shape and dimensions. Initially the dough sheets 2 are typically substantially planar and flexible, The dough sheets 2 are fed by a feeder conveyor 4 to a toaster oven 6, The toaster oven 6 includes an upper belt assembly 8 anda series of lower endless conveyor belts 10, 12 14.

The belt assembly S has an array of a plurality of three-dimensionally curved shaping elements 16 extending from an upper surface 18 of a belt 20. Since the belt 20 is an. endless belt in the illustrated embodiment, the shaping elements 1 6 extending from the outer surface 22 of the belt 1$. Typically, the belt 18 is an endless belt mounted between two laterally separated support rollers 24, 26.

in the illustrated embodiment, at least some, typically all, of the shaping elements 16 are convex and extend upwardly from the upper surface 18 of the belt 20.

In an alternative embodiment, not illustrated, some or all of the shapin.g elements are concave recesses which extend downwardly from the upper surface of the belt.

In this embodiment, the array of shaping elements 16 is a regular array. The shaping elements 16 are mutually spaced on the tipper surface 18 of the belt 20.

In the illustrated embodiment, as shown in greater detail in Figures 2, 3 and 4, the shaping elements 16 comprise a first array 28 of first shaping elements 30 and a second array 32 of second. shaping elements 34. Preferably, the first array 28 and the second array 32 are regular.

However, alternatively either or both of the first array 28 and the second array 32 may he irregular.

The first and second arrays 28, 32 at least partially overlap, and typically thily overlap with each first shaping element 30 being adjacent to at least one second shaping element 34.

Typically, each first shaping element 30 is adjacent to a plurality of second shaping elements 34' The first and second shaping elements 30, 34 have at least one of a different size and shape.

Typically, the first shaping elements 30 have a larger area and a larger curvature than the area and curvature of the second shaping elements 34.

As shown in Figures 2 and 3, the first shaping elements 30 may have a substantially circular shape with a central peak 36 whereas the second shaping elements 34 may have substantially elliptical shape with a central peak 38, lower than the central peak 36 of the first shaping elements 30.

The belt 20 comprises a plurality of interiiik.ed metal links 40, fbi example of stainless steel.

The shaping elements 30. 34 are fitted to the belt 20. and preferably are removably fitted to the belt 20. in some preferred embodiments, at least sonic of the shaping elements 30, 34 comprise a shaped wire 42. Typically. the shaped wire 42 is in the form of a coil, forming a compressed dome or conical spring. The shaped wire 42 may have a central looped end 44 which is clipped to at least one of the metal links 40. thereby retaining the coil in compression and removably securing the shaped wire 42 to the belt 20. However, runny other shaping element configurations and structures may be employed in accordance with other embodiments of' the present invention.

An array of the dough sheets 2 is deposited from the feeder conveyor 4 onto the upper surface 44 of the belt assembly 8 so that the array of dough sheets 2 and the array of shaping elements 16 have a nonindexcd relationship, the nonindexed relationship may apply entirely to both the transverse and longitudinal relationship between the dough sheets 2 and the shaping demerits 16. Alternatively, the nonindexed relationship may apply partly to either the transverse or the longitudinal relationship between the dough sheets 2 and the shaping elements 16. with there being some degree of indexing in. respectively, either the longitudinal or transverse relationship between the dough sheets 2 and the shaping elements 16 so that the overall relationship is nonindexecI.

For example, to provide the noni.ndexed relationship, the dough sheets 2 are deposited in nlura rows, each row extending along the belt assembly 8, and the longitudinal location of the dough sheets 2 along the rows may be non4ndexed with the longitudinal position of the shaping elements 16 along the belt assembly 8. Optionally, the rows of dough sheets 2 are indexed with. corresponding rows of shaping elements 16 extending along the belt assembly 8. In other words, there may he some indexing across rows of the dough sheets 2 and rows of shaping elements 16 but, as in the embodiment described above, in conjunction therewith there is no indexing in a longitudinal direction, so that the. overall relationship between the dough sheets 2 and the shaping elements 16 is non4ndexed, Optionally, to provide the non=indexed relationship, the dough sheets 2 are deposited from the feeder conveyor 4 having a higher longitudinal speed than a longitudinal speed of the belt assembly 8.

Optionally, the dough sheets 2 are deposited onto the belt assembly S to provide the population of differently shaped dough sheets 2 over a particular production, period cycle or for a particular production cycle to produce a particular number of snack food chips, Typically. the dough sheets 2 are mutually spaced after deposition onto the upper surface 44 of the belt assembly 8.

Typically, the dough sheets 2 each have an area which is greater than the area of an individual shaping element 16. The dough sheets 2 may be. regularly shaped. tbr example being triangular. square. rectangular, elliptical, etc.. or be irregularly shaped. Typically, the dough sheets 2 have a surface area of from 1000 o 2500 nrni2 and a maximum dimension of from 30 to 100 mm.

Then, as shown in Figures 4 and 5, the dough sheets 2 are caused to slump at least partially under the action of gavity so that each dough sheet 2 assumes an irregular three-dimensional shape including at least one three-dimensionally curved portion 46 formed by a respective shaping element 16. The curved portion 46 typically includes at least one concave portion 48 ihrmed by a respective convex shaping eLement 16.

Figures 4 and 5 show dough sheets 2 being shaped by the shaping elements 16 on the belt assembly 8 within the toaster oven 6. In Figure 4 in one embodiment the dough sheets 2 arc disposed on a particular embodiment of shaping elements 16 whereas in Figure.5 in another embodiment the dough sheets 2 are disposed on a different embodiment of shaping elements 1.6. in each of Figures 4 and 5 the dough sheets 2 are a conventional triangular shape as used for tortilla chips.

The non-indexed relationship between the array of dough sheets 2 and the array of shaping elements 16 forms a population of differently shaped dough. sheets 2 from the plurality oi initia.I substantially fiat dough sheets 2.

Tn an optional modification, a portion 56 of the dough sheet 2 located above an uppermost regmn 52 of the convex shaping element 16 is pressed by a pressing device 54 downwardly against the convex shaping element 16 so that the dough sheet 2 is additionally urged downwardly against the convex shaping element by an external force. This assists the dough sheet 2 more rapidly assuming the shape and configuration of the underlying shaping element(s) 1 6. The pressing device 54 may comprise a plurality of endless chains mounted for rotation about a rotatable driver. In another embodiment, the external force is applied by an air blower which applies at least one downward air jet against an upper surface of the dough sheet 2. In an alternative embodiment, the external three is applied by a vacuum suction device which applie.s a negative suction. pressure against a lower surface of the dough sheet 2.

Typically, at least 95% of the dough sheets 2 slump to contact a portion 56 of the belt 20 adjacent to one of the shaping elements 16, thereby ibmting a substantially flat portion 58 of the dough sheet 2, which is then substantially present in the resultant snack chip.

I'vpicaliv, during at least a part of the shaping step when the dough sheets 2 are caused to slump, the dough sheets 2 are subjected to infrared radiation, emitted from infrared larri.ps 62 located in the toaster oven 69 on at least one of the upper or lower surfaces of the dough sheets 2. The incident infrared radiation can act to accelerate rigid itication.. and moisture reduction, of the dough sheets 2 prior to the subsequent cooking step. Optionally, the dough sheets 2 are also subjected to convective heating during at least a part of the shaping step to accelerate rigiditication of the dough sheets prior to the cooking step, for example by a convector heater 64 in the toaster oven 6. After the shaping step the shaped dough sheets 66 are substantially rigid.

The shaped dough sheets 66 are deposited from a downstream end of the belt assembly 8 onto a succession of conveyors 10, 12, 14 within, the toaster oven 6. These additional conveyors 10, 12 14 ftmction to control the time period of the shaped dough sheets 66 within the toaster oven 6 so that the shaped dough sheets 66 exit the toaster oven 6 with the desired rigid three-dimensional shape and moisture content.

For the manufacture of tortilla chips, it is known to prove the dough prior to frying. In the embodiment of Figure i therefore, the shaped dough sheets 66 are conveyed by a. transfer conveyor 68 to a proving chamber 70, in the proving chamber 70, the shaped dough sheets 66 are subjected to controlled temperature and humidity to prove the dough prior to cooking, as is generally known to those skilled in the art of making tortilla chips. The shaped dough sheets 66 are conveyed through the proving chamber 70 by a series of conveyors 60.

Subsequent to the shaping step, and in the illustrated embodii.nent downstream of the proving chamber 70, the shaped dough sheets 66 are deposited onto a conveyor mechanism 72 which conveys the shaped dough through a cooking apparatus 74, in the illustrated embodiment. in the form of a fryer 74. during the cooking step. Akernativel.y, other cooking techniques apart front frying, such as baking. toasting, microwaving, etc. maybe used instead of frying.

in the fryer 74, the shaped dough sheets 66 are cooked to form a population of differently shaped rigid snack food chips 76, each having the respective irregular threedimensionai shape. Each snack food chip 76 has at least one three-dimensionally curved portion. A typical population of snack food chips 76 produced on a common belt assembly B is illustrated in Figure 6.

After the snack food chips 76 have been cooked, they are delivered from the cooking apparatus 74. The final shape of the snack food chips 76 is substantially determined by the preliminary shaping step, which shapes and then rigidities the initial, flexible dough to ihrm a substantially final shape and configuration.lhr the tins] snack chip 76.

The snack food chips 76 made according to the present invention are thre&dimensionaliy shaped snack food chips 76, and in particular are shaped and dimensioned so as to be suitable for use together with a dip, such as a salsa composition, cream cheese, avocado composition.

etc. which are sveil known in the snack food art.

in preferred embodiments, the array of dough sheets 2 is irregular, the dough sheets 2 being irregularly deposited onto the upper surface of the belt assembly 8, whereas the array of shaping elements 16 is regular. This establishes a substantially nonuniform, even substantially randomised in some embodiments, relationship between the location of the dough sheets 2 and the underlying shaping elements 16. This provides that the initial identical dough sheets 2 are mouidcd threedimensionaliy into substantially randomly shaped snack chips 76, yet with each snack chip 76 including a concave portion of controlled curvature and area, as shown in Figure 6.

Typically, at least 95% of the resultant snack chips 76 have a major surface portion 78 (i.e. more than 50% of the surface area) which is concave and thrmed by at least one shaping element and a minor surface portion 80 (i.e. less than 50% of the surface area) which is substantially flat and formed by a surface of the bek. Optionally, the major surface portion comprises at least 60% of the surface area of the snack food chip and the minor surface portion comprises at most 40% of the surface area of the snack food chip.

Preferahy. at least one substantially fiat portion extends to an edge of the respective snack food chip.

Typically, the concave portion 78 has a radius of curvature of from 15 to 40 mm, a depth of from 10 to 30 mm. a width of fiDm 25 to 55 mm, and/or a volume of from 0,5 to 10 ml.

Typically, at least 95% of the plurality of snack food chips include at least one concave portion which has a volume of from 0,5 to 10 ml. Typically, the snack food chips have a surface area of from 1000 to 2500 mm2.

The thre&dirnensionaliy shaped snack food chips produced in accordance with embodiments of the present invention can have a high* iy acceptable morphology to the consumer, which can be used for dipping and which can be produced in a costeffective manner. The novel threeS dimensionally shaped snack food chip product comprises that chips witliin a given popuhution of the chips are essentially individually diffrent in shape and configuration, yet each chip is specifically shaped with at least one concavttv 78 which may act as a spoon for pkking up and holding a portion of a dip, such as a salsa dip, and. with a substantiafly fiat portion 80 that extends to an edge of the chip and can function as a manually-engageable handle portion.

Various other modifications to the present invention will be readily apparent to those skilled in the art,

Claims (1)

1. Claims 1. A method of manufacturing a plurality of three-dimensionally shaped snack food chips, the method comprising the steps of: i. providing a plurality of dough sheets; ii. providing a belt assembly having an array of a plurality of three-dimensionally curved shaping elements extending from an upper surface of a belt; iii, depositing an array of the dough sheets onto the upper surface of the belt assembly so that the array of dough sheets and the array of shaping elements have a non-indexed relationship; iv. in a shaping step causing the dough sheets to slump at least partially under the action of gravity so that each dough sheet assumes an irregular three-dimensional shape including at least one three-dimensionally cured portion formed by a respective shaping element, th.e non-indexed relationship tbrrning a population of differently shaped dough sheets from the plurality of dough sheets; and cooking the shaped dough sheets to form a population of differently shaped rigid snack food chips each having the respective irregular three-dimensional shape, each snack food chip having at least one three-dimensionally curved portion.

   2. A method according o claim I wherein at least some of the shaping elements are convex and extend upwardly from the upper surface of the belt and the at least one three-dimensionally curved portion includes at least one concave portion formed by a respective convex shaping element.

   3. A method according to claim 2 wherein aU of the shaping elements are convex and extend upwardly from the upper surface of the belt.

   4. A method according to claim 2 or claim 3 wherein in step iv a portion of the dough sheet located above an uppermost region of the convex shaping element is additionally urged downwardly against the convex shaping element by an external force.

   A method according to claim 4 wherein the external force is apphed by a pressing device which applies a pressing force against an upper surface of the portion of the dough sheet. I. i

   6. A method according to claim 5 wherein the pressing device comprises a plurality of endless chains mounted for rotation about a rotatable driver.

   7. A method accordin.g to claim 4 wherein the external force is applied by an air blower which applies at least one downward air jet against an upper surface of the dough sheet, 8. A method according to claim 4 herein the extenal force is applied by a vacuum suction device whicli applies a negative suction pressure against a lower surface of the dough sheet.9. A method according to any foregoing claim wherein the array of shaping elements is a regular array and the array of dough sheets is irregular, the dough sheets being irregularly deposited onto the upper surface of the belt.10. A method according to any foregoing claim wherein the dough sheets each have an area'hicl is greater than the area of an individual shaping element.11. A method according to any foregoing claim wherein the dough sheets are mutually spaced after deposition onto the tipper surf ace of the belt assembly.12, A method according to any foregoing claim wherein the shaping elements are mutually spaced on the upper surface of the belt.13. A method according to any foregoing daim wherein at kast 95% of the dough sheets slump to contact a portion of the belt adjacent to one of the shaping elements, thereby forming a substantially flat portion of the resultant snack chip.14. .A method according to any foregoing claim wherein at least 95% of the resultant snack chips have a nwjor surface portion which is concave and formed by at least one shaping element and a minor surface portion which is substantially flat and formed by a surface of the belt, 15. A method according to any foregoing claim wherein the concave portion has a radius of cun'attire of from 15 to 40 mm, a. depth of from 10 to 30 mm, and/or a width of from 25 to 55 mm, andlor a volume of from 0,5 to 0 ml, or any combination of these dimensions.16. A method according to any foregoing claim wherein the dough sheets have a surface area of from 1000 to 2500 nun2 and a maximum dimension of from 30 to 100 mm.17. A method according to any foregoing claim wherein in step iv the dough sheets are subjected to infrared radiation on at least one of the upper or lower surfaces thereof to accelerate rigidilleation of the dough sheets prior to the cooking step. *i 218, A method according to claim 17 wherein in step iv the dough sheets are also subjected to convective heating to accelerate rigidification of the dough sheets prior to the cooking step.19. A method according to any foregoing claim wherein after step iv the shaped dough sheets are substantially rigid.20. A method according to any thregoing claim wherein after step iv the shaped dough sheets are deposited onto a conveyor mechanism which conveys the shaped dough through a cooking apparatus during the cooking step v.21. A method according to any foregoing claim wherein the dough sheets comprise a maize-based dough.22. A method according to any foregoing claim wherein the snack food chips comprise tortilla chips.23. A method according to any foregoing claim wherein the shaping elements comprise a first array of first shaping elements and a second array of second shaping elements, the irst and second shaping elements having at least one of a different size and shape, the first and second arrays at beast partially overlapping.24. A. method according to claim 23 wherein the first and second arrays filly overlap with each first shaping element, being adjacent to at least one second shaping element.25. A method according to claim 24 wherein the each first shaping element is adjacent to a piurabity of second shaping elements.25. A method according to any of claims 23 to 25 wherein the first array and the second array are regular.27. A method according to any one of claims 23 to 26 wherein the first shaping elements have a larger area and a larger curvature than the area and curvature of the second shaping elements.28. A method according to any foregoing claim wherein the belt comprises a plurality of interlinked metal links and the shaping elements are fitted to the belt.29, A method according to claim 28 wherein the shaping elements are removably fitted to the belt, 30. A method according to claim 28 or claim 29 wherein at least some of the shaping elements comprise a shaped wire.31. A method according to claim 30 wherein the shaped wire is in the form of a coil, 32, A method according to any fbregoing claim wherein, to provide the non-indexed relationship, in step iii the dough sheets are deposited in plural rows, each row extending along the belt assembly, and the longitudinal location of the dough sheets along the rows is noni.ndexed with the longitudinal position of the shaping elements along the belt assembly, 33. A method according to claim 32 wherein the rows of dough sheets are indexed with corresponding rows of shaping elements extending aong the belt assembly.34. A method according to any foregoing claim wherein in step iii the dough sheets are deposited from a feeder conveyor having a higher longitudinal speed than a longitudinal speed of the belt assembly.35. A method according to any foregoing claim wherein in step iii the dough sheets are deposited onto the belt assembly to provide the population of differently shaped dough sheets over a particular production period cycle or for a particular production cycle to produce a particular number of snack tbod chips.36. A belt assembly or shaping dough sheets in a method of manufacturing three dimensionally shaped snack food chips, the belt assembly comprising an array of a plurality of shaping elements extending from an upper surface of a belt, wherein the shaping elements comprise a first array of first shaping elements and a second array of second shaping elements, the first and secon.d shaping elements having at least one of a different size and shape. the first and second arrays at least partially overEapping.37. A belt assembly according to claim 36 wherein the first and second arrays fblly overlap with each first shaping etement being acUacent to at least one second shaping element, 38. A belt assembly according to claim 37 wherein the each first shaping element is adiacent to a plurality of second shaping elements.39. A belt assembly according to any of claims 36 to 38 wherein the first array and the second array are regular.40. A belt assembly according to any one of claims 36 to 39 wherein the first shaping elements have a larger area and a larger cu.n'aturc than the area and curvature of the second shaping elements.41. A belt assembly according to any one of claims 36 to 40 wherein at least some of the shaping elements are convex and extend upwardly from the upper surihee of the belt, 42. A hell assembly according to claim 41 wherein all of the shaping elements are convex and extend upwardly from the upper surthee of the belt.43. A belt assembly according to any one of claims 36 to 42 wherein the belt comprises a plurality of interlinked metal links and the shaping elemcnts are fitted to the belt.44. A belt assembly according to claim 43 wherein the convex shaping elements are removably fitted to the belt.45. A belt assembly according to claim 43 or claim 44 wherein at least some of the convex shaping elements comprise a shaped wire.46. A belt assembly according to claim 45 wherein the shaped wire is in the form of a coil.47. An oven comprising a belt assembly according to any one of claims 36 to 46, the belt assembly being arranged for conveying a plurality of three-dimensionally shaped dough sheets through the oven in the manufacture of snack food chips.48. A snack food comprising a plurality of non-identically shaped and three-dimensionally shaped snack food chips, the snack food chips being substantially rigid, each chip including at least one concavity which is shaped and dimensioned so as to be able to hold in a spoon-like manner a portion of a dip and each snack food chip including at least one substantially flat portion shaped and dimensioned so as to be able to function as a manually-engageable handle portion for the snack fbod chip.49. A snack food according to claim 48 wherein the plurality of snack food chips fbrm a substantially randomised population with the snack food chips having mutually different three-dimensional shape.50. A snack food according to claim 48 or claim 49 wherein at least 95% of the snack food chips have a major surface portion which is concave and a minor surface portion which is substantially flat.51. A snack food according to claim 50 wherein the major suthce portion comprises at least 60% of the suthce area of the snack food chip and the minor swtce portion comprises at most 40% of the surface area of the snack food chip.52. A snack food according to any one of claims 48 to 51 wherein at least one substantially flat portion extends to an edge of the respective snack food chip.53. A snack food according to any one of claims 48 to 52 wherein at least one concave portion has a radius of curvature of from 15 to 40 mm.54. A snack food according to any one of claims 48 to 53 wherein at least one the concave portion has a depth of from 10 to 30mm.55. A snack food according to any one of claims 48 to 54 wherein at least one concave portion has a width of from 25 toSS mm.56. A snack thod according io any one of claims 48 to 55 wherein at least 95% of the plurality of snack food chips indude at least one concave portion which has a volume of from 0,5 to 10 ml.57. A snack ibod according to any one of claims 48 to 56 wherein the snack food. chips have a surface area of from 1000 to 2500 mm2.58. A. snack food according to any one of claims 48 to 57 wherein the snack food chips comprise tortilla chips formed and comprise a niaizeJbased composition.59. A packaged snack food comprising a portion of the snack food according to any one of claims 48 to 58 in a sealed package Il 6 Amendments to the claims have been filed as follows.Churns 1, A method of manufacturing a plurality of three-dimensionally shaped snack food chips, the method comprising the steps of: i. providing a plurality of dough sheets; ii. providing a belt assembly having an array of a plurality of three4imensionally curved shaping elements extending from an upper surface of a belt; iii. depositing an array of the dough sheets onto the upper surface of the belt assembly so that the array of dough sheets and the array of shaping elements have a non-indexed relationship; iv, in a shaping step causing the dough sheets to slump at kast partially under the action of gravity so that each dough sheet assumes an irregular three-dimensional shape inehiding at least one three-dimensionally curved portion formed by a respective shaping element and at least 95% of the dough sheets slump to contact a portioT.t of the belt adjacent to one Of the shaping elements IC) thereby forming a substantially fiat portion of the resultant snack chip, the non-indexed relationship forming a population of differently shaped dough sheets from the plurality of dough sheets; and v cookin.g the shaped dough sheets to form. a population of differently shaped rigid snack food chips each having the respective irregular three-dimensional shape, each snack food chip having at least one three-dimensionally curved portion.2, A method according to claim I wherein at least some of the shaping elements are convex and extend upwardly from the upper surface of the belt and the at least one three-dimensionally curved portion includes at least one concave portion fbrmed by a respective convex shaping element.3. A method according to claim 2 wherein all of the shaping elements are convex and extend upwardly front the upper surface of the belt.4. A method according to claim 2 or claim 3 wherein in step iv a portion of the dough sheet located above an uppermost region of the convex shaping elemen.t is additionally urged downwardy against the convex shaping element by an externai force.5. A method according to claim 4 wherein the external force is applied by a pressing device which applies a pressing force against an upper surface of the portion of the dough sheet.6. A method according to claim 5 wherein the pressing device comprises a plurality of endless chains mounted fix rotation about a rotatable driver.7. A method according to claim 4 wherein the external force is applied by an air blower which applies at least one dowarrl air jet against an upper surface of the dough sheet.8. A method according to claim 4 wherein the external force is applied by a vacuum suction device which applies a negative suction pressure against a lower surface of the dough sheet.9. A method according to any foregoing claim wherein the array of shaping elements js a regular array and the array of dough sheets i.s irregular, the dough sheets being irregularly deposited onto the upper surface of the belt.10. A method according to any foregoing claim wherein the dough sheets each have an area Which is greater than the area of an individual shaping element.11. A method according to any foregoing claim wherein the dough sheets are mutually 0 spaced after deposition onto the upper surface of the belt assembly.12. A method according to any tbregoing claim wherein the shaping elements are mutually spaced on the upper surface of the belt.13 A method according to any foregoing claim wherein at least 95% of the resultant snack chips have a major surface portion which is concave and formed by at least one shaping element and a minor surface portion which is substantially fiat and lormed by a surface of the belt, 14. A method according to any foregoing, claim wherein the concave portion has a radius of curvature of from 15 to 40 rnm a depth of from 10 to 30 mm, and/or a width of from 25 to 55 mm, and/or a volume of from 05 to 10 ml, or any combination of these dimensions.15. A method according to any foregoing claim wherein the dough sheets have a surface area of from 1000 to 2500 mm2 and a maximum dimension of from 30 to 100 mm.16. A method according to any foregoing claim wherein in step iv the dough sheets are subjected to infrared radiation on at least one of the upper or ower surfaces thereof to accelerate rigidification of the dough sheets prior to the cooking step.17. A method according to claim 16 wherein in step iv the dough sheets are also sujected to convective heating to accelerate rigidification of the dough sheets prior to the cooking step.1 8. A method according to any foregoing claim wherein sitter step iv the shaped dough sheets are substantially rigid.19 A method according to any foregoing claim wherein afler step iv the shaped dough sheets are deposited onto a conveyor mechanism which conveys the shaped dough through a cooking apparatus during the cooking step v, 20. A method. according to any foregoing claim wherein the dough sheets comprise a m aizehased dough.21. A method according to any foregoing claim wherein the snack food chips comprise tortilla chips.22. A method according to any foregoing claim wherein the shaping eements comprise a first array of first shaping elements and a second array of second shaping elements, LID the first and second shaping elements having at least one of a different size and shape, the first and second arrays at least partially overlapping.23 A method according to claim 22 wherein the first and second ar.ays thlly overlap with 0 each first shaping clement being adjacent to at least one second shaping &ement, 24. A method according to claim 23 wherein the each first shaping element is adjacent to a plurality of second shaping elements.25. A method according to any of claims 22 to 24 wherein the first array and the second array are regulan 26. A method according to any one of claims 22 to 25 wherein the first shaping elements have a larger area and a larger curvature than the area and curvature of the secor.id shaping elements.27. A method according to any foregoing claim wherein the belt comprises a plurality of interlinked metal links and the shaping elements are fitted to the belt.28. A method according to claim 27 wherein the shaping elements are removably fitted to the belt.29. A method according to claim 27 or claim 2 wherein at least some of the shaping elements comprise a shaped wire.30. A method according to claim 29 wherein the shaped wire is in the form of a coil, 3 1, A method aecord.in.g to any thregoing claim wherein to provide the non-indexed relationship, in step iii the dough sheets are deposited in. plural rows, each row extending aorig the belt assemb'y, and the longitudinal location of the dough sheets al.oi.ig the rows is non-tndexed with the longitudinal position of the shaping elements along the belt assenthly.32. A method according to claim 31 wherein the rows of dough sheets are indexed with corresponding rows of shaping elements extending along the belt assembly.33. A method according to any foregoing claim wherein in step iii the dough sheets are deposited from a feeder conveyor having a higher longitudinal speed than a longitudinal speed of the belt assembly.34. A method according to any foregoing claim wherein in step iii the dough sheets are deposited onto th.e belt assembly to provide the population. of differently shaped dough sheets over a particular production period cycle or for a particular production cycle to produce a particular number of snack food chips. IC) (4