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Extrusion Lecture

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Shakthi Lakmal
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22 views30 pages

Extrusion Lecture

Uploaded by

Shakthi Lakmal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Extrusion

Food processing & Product Development


Breakfast cereal products

Breakfast cereal can be defined as friable

products consisting primary grains,

transformed in to edible & digestible form

by cooking & dehydration


Cereal content ranges from 35.5 – 100 % in
the final products

Main ingredient is the cereal but various

compositions of other ingredients are added

to diversify the products


Breakfast cereal composition (miller 1990)

Component Range

Protein 3.5 – 14.1 (21.1*)

Fat 0 – 17.5

Total carbohydrates 63.5 – 91.7

Sugars ** <1.8 – 49.4

Complex (CHO) 35.3 – 81.1

Dietary fiber 3.5 – 35.3

Sodium 0.02 – 1.13 +/- 0.02

Cereal grains 35.5 – 100


* Higher figure for protein enriched products (Ex. Soy

products

** Includes sugars from fruit and malted barley


Ingredients – Breakfast Cereals
Cereal: Barley, Corn, Oats, Rice, Wheat

Sugars: Brown sugar, Brown sugar syrup, Cereal malt


syrup, Dextrose, Fructose

Fats: Coconut oil, Partially hydrolyzed oil, cottonseed,


soybean,

Fruits, : apple, dates, dried apple, strawberry

Preservatives & Stabilizers : BHA, BHT, Sulfur dioxide, citric


acid,
Ingredients – Breakfast Cereals

Colors: Artificial colours,


Natural : caramel colour, beet powder

Flavors: Malt flavor, cinnamon, salt, cocoa,


malic acid

Vitamins and minerals : Vit, A, B, C, D ,E

Structural additives: Gelatin, Corn starch, Pectin


Basically breakfast cereals are divided

into three types

1. Plain cereal

2. Pre-sweeten cereal

3. Mixture
Plain cereal is the simple cereal formula used in
breakfast cereal extrusion

It is modified and made more palatable by adding


various ingredient and produce pre-sweeten &
mixture

-Pre-sweeten : flavor improvement

-mixture : mineral fortification


: nutrient addition
Extrusion of breakfast cereal
Definition
Extrusion is defined as forcing a product
through a small opening to shape
materials in a designed.

Extrusion principle is not a novel principle.


It has been used from many years ago
Ex: String hopper mold
Extruders are the equipment, used in extrusion

Extruders are used in many industries

Ex: Rubber industry, plastic industry, food industry

In food industry, it is used to produce ready to eat

products
Extrusion basically 3 unit operations
1. Mixing
2. Cooking
3. Puffing
Extruders and extruder operation
Fundamentally, extruder contains a barrel, closely
rotating screw, driving motor, feeding device and
an outlet (die)

The screw rotates inside the barrel with a very close


gap.
Size of the equipment is given as the ratio of
length to width (L/D)
Ex . 8: 1, 24:1

Basically there are two types of extruders

1. Single extruder (single screw extruder

2. Twine extruder (Double screw extruder)


Configuration of the screw & barrel, flights
depths & gaps in the screw vary according
to types of products going to be produced

• EX: flaked, puffed etc


Feed Product Screw speed Products
moisture Temperature (rpm)
% C

11 – 35 80 – 200 200 – 500 Puff snacks


RTE cereal
Function of the extruder

Feeding section
1. Raw material feeding
2. Quick raw material transportation to the transition section
3. Flight distance is high and decreases towards the die
4. Flight dept is high
Transition section

1. Flight gap and depth is low


2. compress the raw material
3. Mixing and cooking is done
• Metering section

1. Flight gap and depth is very low


2. Material is pressurized
3. Products get cool

• Processed product goes through the die faces to


pressure different and get puff.
Single extruder Double extruder
Consist a single Consist two screws
screw
Simple Complex

Use for simple Use for multiple


operations operations
No intermixing It may be intermixing or
non intermixing
Effect of extrusion on starch degradation

- Changes of starch in extrusion


- Cooking of raw materials
-Cooking raises temperature of cereal above the
gelatinized temperature

Temp. is generated from different sources

1. Direct heat
2. Steam
3. Shear stress
Cookers used, in breakfast cereal extrusion
1. Boiling water cooker – low shear & pressure
2. Steam cooker – low shear & pressure
3. Adiabatic extruder – higher shear & pressure
4. High shear cooker – high shear & pressure
5. Low shear high pressure cooker
6. High shear cooker with steam
Breakfast cereal processing
plain breakfast cereal is categorized into different
Categories according to the process, to be used.

Flaked (whole grain, grit & extruded grit)

Extrusion puffed (direct expanded)

Oven puffed (whole grain & extruded)

Gun puffed (whole grain & extruded)

Hot cereal (regular & pre-cooked)


Flaked cereal
Traditionally flake roles were used.
Cooking Flaking Toasting

Ex corn flakes

Flake roles were replaced by extruders

Single screw (L/D <8:1), Deep channel, slightly


grooved barrel, Create high shear, high pressure low
shear

Twine extrudes (L/D >18:1) produces high quality


products
Extrusion puffed breakfast cereal
This technology is used to snacks production
supper gelatinization is done , Puffing occurs due to
pressure difference earlier short adiabatic extruders were
used Ex: snakes
now high shear single extruders are used

oven puffed cereals


Cause sudden expansion
rapid heating in the oven results the expansion
(post extrusion foaming) Ex. Crisp ride.
Raw material extrusion oven puff
Gun puffed cereal
Suddenly product is allowed to disequilibrium
Ex. Puffed wheat

Condition : 200 – 260 oC at 1.4 x 10 Pa , 1 ½ -


12 minutes

Shredded products
previously shredding roles were used

feed shredding roles oven


Positive & negative points in extrusion
positive points
1. Versatility
2. High output
3. It does three unit operations as a one unit
4. Low cost
5. Energy saving
6. Good product quality
7. Environmental concerns – no process effluents
Positive & negative points in extrusion

Negative points

1.High Initial cost


2.Raw materials should be free from hard
materials
Extrusion
• Extrusion is multivariable unit operation such as
mixing, shearing, cooking, puffing & drying in
one energy efficient rapid continuous process.

• This process of HTST , extrusion bring


gelatinization of starch, denaturation of
proteins, modification of lipids & inactivation of
enzymes, microbes , & many antinational
factors

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