Chapter 01 “Snack Foods Processing: Extruded Snacks and Tortilla Chips” Practical Short Course Chapter 01 fees |PERDC PROCESS ENGINEERING RESEARCH & DEVELOPMENT CENTER ‘TEXAS ABM ENGINEERING EXPERIMENT STATION, Process Engineering Research and Development Center Texas A&M Engineering Experiment Station The Texas A&M University System College Station, TX 77843 Page 1 of 51Chapter 01 Dr. Mian N. Riaz is the Director of the Process Engineering R&D Center, Head of the Extrusion Technology Program, and graduate faculty in the Nutrition and Food Science Department at Texas A&M University, College Station, Texas, USA. Dr. Riaz received his B.Sc (Honors) degree in 1985 from the University of Agriculture, Faisalabad, Pakistan, in agriculture, majoring in Food Technology and M.Sc (Honors) also from the same university in Food Technology In 1987. He was the first Ph. graduate from the University of Maine, Orono, in 1992 in the Department of Food Science. He has published 5 books, 2? chapters, and more than 100 papers on extrusion and other related topics. Three of his books are in the area of extrusion: Extruders in Food Application; Extruders and Expanders in Pet Food, Aquatic and Livestock Feeds; Extrusion Problem Solved. Another of his books is Soy Applications in Foods. Dr. Riaz’s area of research is extrusion of food and feed, extruded snacks, texturization of vegetable protein, utilization of by-products by extrusion, oilseed extrusion, and extrusion expelling of oilseed crops. Dr. Riaz is a frequent speaker at international and national conferences and meetings and, so far, he has delivered more than 300 presentations in 5S countries. Every year he organizes 5 courses in the area of extrusion, He has been with the Texas A&M University System since 1992. He also has a teaching appointment in the Nutrition and Food Science Department. In February 2015, the Nutrition and Food Science Department announced the formation of the Food Diversity Program where Dr. Riaz serves on the advisory board. Page 2 of 51Chapter 01 Extruders in Snack Foods Preparation Ce EEE | Ue eee T E-Mail: mnriaz@tamu.edu http:/foodprotein.tamu.edu/extrusion Pin eonan Coprer ozs? Process Engineering ener nd Cxvlomen Canter he tere a Uno Sew What is Extrusion? Page 3 of 51Chapter 01 What is Extrusion? Page 4 of 51Chapter 01 Definition of Extrusion Cooking are plasticized and coo! ed by a combination of moisture, Pte temperature, and mechanical shear. Definition of Extrusion Cooking ein to oa ee =r physical changes. Meanwhile, | forming a predetermined shape. Page 5 of 51Chapter 01 What is Extrusion? Process Engineering ener nd Cxvlomen Canter he tere a Uno Sew Lace Men career acon ace DC eae th meen ec) emery Shaping Destruction of micro-organisms and Petkernssal taal Page 6 of 51Chapter 01 BUA Cie Lol) Page 7 of 51Chapter 01 arg Page 8 of 51Chapter 01 preconditioning extrusion-cooking (steam, water) eo (shear, temperature) Pin eoten copra zat? Pron nie ing th rv Cre scm a Overy Page 9 of 51Chapter 01 Sonos Cer nay Biaeoten copra at? Pox nga ah arent at Nucleation E¥Pansion Contraction Page 10 of 51Chapter 01 Page 11 of 51Chapter 01 Advantages of Extrusion postal aco} Perr nt aud TSE em mee ml Stet D leeteltia ty Page 12 of 51Chapter 01 Page 13 of 51Chapter 01 Product COAST CS TCU oe ert ae eemett wy Clete Ue eed produced, which is not easily formed using Pelt ig production method Page 14 of 51Chapter 01 Pe asia Extrusion processing also need less space per unit of oye Te- LOM ULM Tame dtl | CU Page 15 of 51Chapter 01 New foods/feeds High Productivity & WU Eom eco Page 16 of 51Chapter 01 High Product Quality Quality -- Continue idases and microorganisms. Page 17 of 51Chapter 01 Pin eonan Coprer ozs? Process Engineering ener nd Cxvlomen Canter he tere a Uno Sew Classification of Extruders Page 18 of 51‘Typical Preduets anasto ‘Sting aun Fe Fong Auto Feet etood eas FatFasoy i Ld oe Chapter 01 Single Serew Extruder Characteristics Gedy: wp 20 meena Sev Spe 30701 Lang Dae an 10-14 Opa rate Speed De Sroved ae Segre Seen, Sle Locks. & Meng aes Pin eonan Coprer ozs? Process Engineering ener nd Cxvlomen Canter he tere a Uno Sew Page 19 of 51Chapter 01 et nae Pin eonan Coprer ozs? Process Engineering ener nd Cxvlomen Canter Shear aii Uns Ssee Dry Recipe Delivery Perron coe Page 20 of 51Chapter 01 Preconditioning Zo ae nt Una Sy Extruding eee a a & een Page 21 of 51Chapter 01 ri) TN Pe Page 22 of 51Chapter 01 Categories of SSE (Pasta-type) (Cereal and Fried Snack Foods) ee te High Shear Cooking Extruders Lote Tt Selo Pia eonon Cop Pct engsing ae an Semen ate resi Unwaty5 Twin Screw Extruder Page 23 of 51Chapter 01 Typical Products ‘Twin Sorew Extruder Characteristics Hi Enory Pet Foes Copaaty ipl mete tour Expand Pat os Sere Spt 300-1200 pr Sang ua Foot Lenght Dae Rao. 13.25 Freon anime Pos ‘ari pees ome Pstrand es Simson Bee! FulFatsoy Sogenid cove and Mung Lab euive(-1E} Pia eonon Cop Pron niente Cte ‘os a Onrty Sy Wet Extrusion Chapter 01 Page 29 of 51Chapter 01 Dry Extrusion tr, he tere a Uno Sew Selection of an Extruder PRO Cau La LOW COST Page 30 of 51Chapter 01 Pin eonan Coprer ozs? Process Engineering ener nd Cxvlomen Canter he tere a Uno Sew Terminology US eT TTT era Page 31 of 51Chapter 01 Majority fall in this category 3-G, Half Products, Puffed later by hot air, frying, or microwave Page 32 of 51Chapter 01 Terminology Feedstock: Terminology Preconditioner: Page 33 of 51Chapter 01 Terminology Terminology Interrupted, cut flight screw Page 34 of 51Chapter 01 Terminology Flight: Page 35 of 51Chapter 01 Terminology Terminology Shearlock, steamlock, shear ring: Page 36 of 51Chapter 01 Elements for generating screw profiles and pressures : nts $ARcowt ARPS yap -Rey 4 Regge 27ts vi i GR oy CT) OQ C7) bea Zin sup-sue —s4P-tunte 18baey 34P-9.units 34P-cone AP cone Twintghe Twig oy Seaeti — Sea ue Disks 075 unts mee loco Paddles 075 unis Pals tt Page 37 of 51Chapter 01 Terminology t= Page 38 of 51Chapter 01 Terminology Terminology MCR Ons’ Page 39 of 51Chapter 01 Extruder Dies DC CUE ae ei eee BRS oer as Page 40 of 51Chapter 01 Page 41 of 51Chapter 01 Factors to Consider in Selecting an Extruder recovery rita Local backup expectations > ETire] fervor elit) of Taree Page 42 of 51Chapter 01 Factors a for sustained usage - Rea fi) oe folic) | sleeves, die inserts Factors + a Page 43 of 51Chapter 01 Extrusion “Rules of Thumb” Formulation: Pin eonan Coprer ozs? Pron niente Cte ‘os a Onrty Sy Rules of Thumb Might be done less expensively in CUCU UMM aL Peel Page 44 of 51Chapter 01 Rules of Thumb Feeding the Extruder: te ie Fi Ganen Cop Pots engine an Semen ate Rules of Thumb Dea ek CN SSeS as aa) preconditioner (5-10 X holding 4. time) Page 45 of 51Chapter 01 Rules of Thumb Coating and Enrobing — Cleaning peeeenn ng Re) Mee Med Tits ston Coprenie at? mg Resch an Gevetnpmet Cte Py aT) = Books = Magazine Page 46 of 51Eee am eore aE) Te eum Unt Se tea EXTRUSION COOKING TECHNOLOGY ae eS temo tile) Technology Chapter 01 Page 47 of 51Chapter 01 tea = Extrusion Cooking 1989 Pin eonan Coprer ozs? Process Engineering ener nd Cxvlomen Canter he tere a Uno Sew Py aT) The Technology of Extrusion lexTRuSION re) COOKING Page 48 of 51Chapter 01 RCT Tet beeatriColtecM aM melee Ne) ) or L Col LES) Srteoten Coy Pct engsing ae an Semen ate So tears Ab Unorey 9 Py aT) cree ts anemic remy es and Applications es Page 49 of 51Chapter 01 tea = Extruders and Expanders in Pet Food, Aquatic and Livestock Feeds. ry Germany, Py aT) = Breakfast Cereals and How Rae Page 50 of 51Chapter 01 tea = Snack Food Processing, Lusas, E. W. and Rooney, eA i Py aT) = Extrusion problems solved: Food, pet food and feed ry Woodhead Publishing, UK Page 51 of 51