Food item fabricating apparatus and methods

Apparatus (10) is disclosed including first and second forming rollers (18, 21) which rotatably abut with an anvil roller (20). The forming rollers (18, 21) each include a periphery forming a continuous forming surface including a plurality of axially and circumferentially spaced patterns each formed including depressions (196, 198) and/or grooves (24). Food (14) is simultaneously fed by a saddle (36, 36') between a continuous strip of support material (16) and a continuous ribbon of film material (66) as they pass between a first abutment nip of the first forming roller (18) and the anvil roller (20). In a preferred form, the saddle (36') is in the form of a block having a trough (24) supplied by food under pressure. Radially disposed barriers (132) divide the trough (24) into axial portions. Radially disposed dividing walls (136) having lower tapering surfaces (138) and an axially disposed dividing wall (148) having a radially spaced lower end divide the trough (24) into volumes for receiving different foods (14a,14b) to produce food items including integral food zones where the different foods (14a,14b) are not intermixed. An applicator (160) applies a thin layer of edible oil to the film material (66) prior to and on the side opposite of the forming roller (18) to provide more consistent and/or easier separation of the film material (66) from the food (14).