An extruder system (100) comprising a cooking extruder (110) configured to extrude a food material, a die (300) connected to the cooking extruder comprised of one or more orifices (200), each orifice (200) comprising an inlet configured to accept the food material, a breaker screen (210) connected to the inlet and comprised of one or more holes, an expansion chamber (220) connected to the breaker screen (220), wherein the expansion chamber (220) has an expansion chamber cross-sectional area and an exit orifice (230) connected to the expansion chamber (220) and configured to output the food material, wherein the exit orifice (230) has an exit orifice cross-sectional area and a cutting knife assembly (120) connected to the exit orifice (230) configured to cut the food material at a rate to create a slice thickness, as well as a method utilising such an extruder system (100) for producing a food product.
