EXTRUDER

Feeder Heating system Cooling system Cutter Die Hopper Feeding barrel Motor

Water pump

Clextral EVOLUM 53 Extruder

Extruder

Extruder development in the food industry

Mid-1930s Single screw continuous pasta press
1940 1950 1960s 1980s Oil extraction Pet foods RTE cereals Aquatic feeds

In 1998 Retail value of extruded products: $3.62 billion or 3.7 million tons of production

Extruder Classification

Heat Generation
Extruders
Adiabatic Isothermal Polytropic

Continuous screw extruders

Single screw extruders

Twin screw extruders

Counter rotating

Co-rotating

Intermeshed

Non intermeshined

Intermeshed

non Intermeshed

Self-wiping

Partially self-wiping

Feed Moisture (%) Twin-screw cooking extruder High-shear cooking extruder Low-shear cooking extruder High-pressure forming extruder Pasta press 11-35

Product Temperature (oC) 80-200

Screw Speed (rpm) 200-500

Typical Products Puffed snacks RTE cereals Modified starch Puffed snacks

15-20

120-180

350-500

11-16

170-200

300

25

65-80

40

Cereal pellets Half-product snacks Pasta

32

30-52

30

Basic extruder components

Screw(s)

Die

SCREWS and SHAFTS

Shaft

Conical screw caps

Screw elements

Elements for generating screw profiles and pressures

1/2 P - 9 units Twin-flight

Twin-flight

1/2 P - 6 units

9 units Twin-flight

3/4 P - cut

1/2 P -cut

6 units Twin-flight

1/2 P
0.75 units

1/2 P - Rev 1/2 P - Rev

1.5 units 0.75 units

3/4 P - 9 units Twin-flight

3/4 P - 6 units 4.5 units

Twin-flight Twin-flight

3/4 P

3/4 P - 9 units
Single-flight

3/4 P - cone
9 units - cut

3/4 P - cone
9 units

1/1 P - 9 units
Twin-flight

Disks 0.75 units

6 units Twin-flight

1/2 P - Rev

Shaft Collar 3 units

Paddles 0.75 units

Paddles 1 unit

Cone-screw Washer

D= screw diameter
h= channel depth t= pitch e= axial flight tip thickness n= number of screw threads, d= clearance between flight tips and barrel
-1 t / 2

N= screw speed

screw helix angle (a function of diameter and pitch) tan

Advantages of Extrusion Process

Adaptability Product variety Energy efficiency Low cost Unique products Increased throughput Product quality Minimal waste Minimum labor Combine several steps in conventional process

Enzyme inactivation

Material exchange

Product group

Product example

Conventional process

Processing steps with conventional process

Maillard reaction

Mixing, kneading

Caramelizing

Precipitation

Crystallizing

Gelatinizing

Sterilization

Modified flours Texturized proteins Animal feeds

Baby food Meat substitutes Aquaculture Pet food

Drum dryer Spinning system Presses Oven Roasting kettle Baking oven Puffing-gun Cooker Cooker Roaster Cooker Cooker Press Crystallizer

Flavors Baked goods Breakfast cereals Pasta Drinks

Meat flavors Caramel Flat bread, bread crumbs Puffed grains Cereal flakes Oriental noodles Coffee Instant powders Liquorice Chocolate Sugar

Confections

Denaturing

Expanding

Dispersing

Alkalizing

Roasting

Reaction

Cooking

Shaping

Heating

Cooling

Baking

Drying

PROCESSING STEPS IN A EXTRUDER

Feeder Die

Feeding zone

Single screw extruder

Twin screw extruder (Corotating)

Twin screw extruder (Counterrotating)