Report on Extrusion Line

Subject: Student READY- Experiential Learning Programme-I (FPO- 471)

Semester:
th
7

Submitted to

Dr. R.B. Modi

Assistant Professor
Department of Food Processing Technology

Submitted by

Dhavalsinh Raj (3070920030)

Niyati Shah (3070920035)
Ami Solanki (3070920037)
Jay Chovtiya (5070921001)
Raj Patel (3070919034)

College of Food Processing Technology and Bio –Energy

Anand Agricultural University, Anand – 388110

2023

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 INDEX

Sr. no. Title Page

no.
1 Introduction 3

2 Raw materials 3

3 Principle of extrusion 5

4 Gelatinization of starch 7
5 Equipments in extrusion line 7
6 Machinery of extrusion 11
7 Recipe 14

8 Machine operation 16

9 Observation 17

10 Cost calculation 17

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1. Introduction
Extrusion is a process used to create objects of a fixed cross-sectional profile by pushing
material through a die of the desired cross-section.

Extrusion in food processing consists of forcing soft mixed ingredients through an opening in a
perforated plate or die designed to produce the required shape. The extruded food is then cut to a
specific size by blades. The machine which forces the mix through the die is an extruder, and the
mix is known as the extrudate. The extruder is typically a large, rotating screw tightly fitting
within a stationary barrel, at the end of which is the die.

The first extruder was designed to manufacture sausages in the 1870s. Dry pasta and breakfast
cereals have been produced by extrusion since the 1930s, [and the method has been applied to pet
food production since the 1950s (first extruded dog food: Purina Dog Chow in 1957, and first
extruded cat food: Purina Friskies in 1962).

2. Raw Materials

1. Corn
Cornmeal, corn grits, corn flour, and corn cones are all a different form of dry-milled dent corn
used for extrusion. Mostly, de-germed corn is used in extruded snacks because it expands better
than whole corn. Corn starch granules are medium in size (5–20 mm) and have very good
expansion characteristics. Waxy corn contains very little amylose, whereas the normal corn
contains 25–35% amylose .The function of the starch is to achieve various textural attributes and
characteristics. Changing the amylose/amylopectin ratio in the starch can change these attributes.
High-amylose corn starches are used when crunchiness and strength is required, to increase the
expansion of the snack, high-amylopectin corn starches (waxy starch) can be used.
Extruded snacks are a growing market segment in the corn-based industry. Corn (also known as
maize) is a key component in corn collets and many pellet products. Dry-milled cornmeal is used
in the majority of corn-based extruded snacks. Cornmeal is used in large quantities in the
production of puffed extruded snacks, and some is used in the production of corn chips.
Cornmeal, corn grits, corn flour, and corn cones are all types of dry-milled dent corn that differ
only in particle size distribution. Granulation is determined by the type of snack and the type of
extruder.

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 2. Sorghum

Sorghum (Sorghum bicolour L.) is the fourth most important cereal consumed and cultivated in
India during both rainy (kharif) and post-rainy (rabi) seasons. As sorghum is rich in starch and
protein (kafirin), it can be regarded as substitute for the cereals that are presently used for the
production of ready to eat (RTE) snacks. High temperature, short-time (HTST) extrusion cooking
could be used to produce sorghum-based extruded snacks of high nutritional quality and in a
ready-to-eat form.

In terms of composition, sorghum grains resemble corn but have lower oil content. The grain
comprises 8-12% protein, 65-76% starch, and approximately 2% fiber. The germ, a significant
source of oil, contains high levels of protein (19%) and ash (10%). The distribution of grain
components can vary due to factors like hybrid nature, soil, climate, and crop management
practices. Notably, newer hybrids with increased irrigation exhibit larger grains filled with starch
and lower protein content.

3. Pearl millet

Pearl millet (Pennsisetum typhoides) is one of the important millets of western parts of India.
Owing to high nutritive value and low cost of bajara a simple technology was developed for
making traditional snack products. Pearl millet being a good source protein, fiber and mineral can
prove to be a great source of product addition to healthy and balanced diet, but it is not being used
for consumption on wider scale. The present study was conducted to explore the utilization of
pearl millet for the preparation of extruded flakes as an innovative new product.

4. Rice
Four types of rice are produced in the United States: long, medium, short, and waxy grains.
Broken rice can be used as ingredient in expanded or puffed snack products, since rice has good
expansion qualities. Flours from different rice varieties have major differences in physical and
chemical properties, which can affect the snack cell structure and expansion. Selection of the rice
starch in the snack food formulation will depend on the amylose content of the common rice
varieties. Long grains have 22–23%, medium grains 15–19%, and waxy grains < 1% amylase.
The protein content of rice ranges from 6% to 8%.
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Rice is one of the largest crops grown in the world. Four types of rice are produced in the United
States: long, medium, short, and waxy grains. In the United States, rice ingredients are not
commonly used in snack food formulation. In Japan, most of the snacks are made with rice or
rice flour. One major reason is the cost of rice as compared to that of other snack food
ingredients. Broken rice can be used as ingredient in expanded or puffed snack products, since
rice has good expansion qualities. Rice starch granules are the smallest (2–8 mm) of all grain
starches and can be digested very easily. Its functional properties are very different from corn or
wheat starches. The primary difference is in amylose/amylopectin ratio in the starch. Flours from
different rice varieties have major differences in physical and chemical properties, which can
affect the snack cell structure and expansion.

3. Principle of Extrusion
The raw materials are allowed into the extruder barrel and the screw(s) then convey the food
along it. Further down the barrel, smaller flights restrict the volume and increase the resistance to
movement of the food.

As a result, it fills the barrel and the spaces between the screw flights and becomes compressed.
As it moves further along the barrel, the screw kneads the material into a semi-solid; plasticized
if the food is heated above 100ºC the process is known as extrusion cooking (or hot mass
extrusion).

Here, frictional heat and any additional heating that is used cause the temperature to rise rapidly.
High temperature of operation in presence of water promotes gelatinization of starch components
and stretching of expandable components.

The food is then passed to the section of the barrel having the smallest flights, where pressure
and shearing is further increased. Finally, it is forced through one or more restricted openings
(dies) shearing is further increased. At the discharge end of the barrel as the food emerges under
pressure from the die, it expands to the final shape and cools rapidly as moisture is flashed off as
steam.

 Hot Extrusion
If the food is heated above 100ºC the process is known as extrusion cooking (or hot
extrusion). Here, frictional heat and any additional heating that is used cause the temperature

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to rise rapidly. The food is then passed to the section of the barrel having the smallest flights,
where pressure and shearing is further increased.
Finally, it is forced through one or more restricted openings (dies) at the discharge end of the
barrel as the food emerges under pressure from the die, it expands to the final shape and cools
rapidly as moisture is flashed off as steam. A variety of shapes, including rods, spheres,
doughnuts, tubes, strips, swirls or shells can be formed. Typical products include a wide variety
of low density, expanded snack foods and ready-to-eat (RTE) puffed cereals.

 Cold Extrusion

Cold extrusion is carried out at relatively warm temperatures, often around room temperature. Cold
pressing and cold forging are two other names for it. Using the cold extrusion process, you may
extrude metals including copper, tin, titanium, steel, and aluminum alloys.
High pressure is given to the raw metal as it is fed through the die in the cold extrusion process, and
the metal is then driven through the die’s cross-section. As a result, the material is extremely robust
and stable.
Cylinders, car pistons, fire extinguishers, and aluminum cans are all made using this method. The
mechanism requires minimal energy input and operates in a pristine, environmentally friendly
setting. When compared to the hot extrusion method, no oxidation occurs.

Fig. 1 extruder

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4. Gelatinization of starch

gelatinization is a process of breaking down the intermolecular bonds of starch molecules in

the presence of water and heat, allowing the hydrogen bonding sites to engage more water.
This irreversibly dissolves the starch granule in water. Water acts as a plasticizer. Swelling of
starch granules on heating with water resulting in thickening of starch pastes and leaching out
of amylose from granules into the water. This gives the system a viscous transparent structure.
This process of breaking down the intermolecular bond of starch molecule in presence of
water and heat, allowing the hydrogen bonding sites to engage more water is termed as
gelatinization of starch.

Three main process happening in starch

1) Swelling: During heating water is absorbed in amorphous space of starch

2) Double helical melting: Water then enters amorphous regions, the tightly boundaries of
double helical structure of amylopectin. Heat causes such regions to become diffuse the
amylose chain begin to dissolve.

3) Amylose leaching: The amylose leach out of the starch granules into the surrounding water
and the granule structure disintegrates. Unmodified starch start swell at 55°C while other
starches at 85°C. Gelatinization temperature depends on plant type, amount of water present,
PH, type and concentration of salt, sugar, fat and protein. Gelatinization make the starch
digestible. It is used in pudding, sauces, and creams and give pleasing texture.

Starch granules

Starch occurs as granules in the cytoplasm of the cell. The granules remain essentially intact
during most types of processing, such as milling, separation and purification of starch and
even during most types of chemical modification. Starch granules range in size, shape and can
vary greatly regard to content, structure and organization of the amylose and amylopectin
molecule and branch of amylopectin.

5. Equipments in extrusion Line

5.1 Twin Screw Extruder

Twin screw extruder also known as Double-screw extruder. This equipment useful to
extrude maize, rice, millet, buckwheat, oat, wheat and other grains from its raw material
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which are supplying by the market. After extrusion, items shaping, drying, oil spraying,
flavors spraying and other supplementary technology will be taken place in the food
industries.

Fig 2. Twin extruder

Specification Technica

Power: 22kW l
Paramet
Extrusion Capacity: 5-80Kg/hr
ers:
Dimension of the extruder:
Installed
2500*700*1500mm Dimensions of twin
Capacit
screw:
y: 22
Screw length: 1050mm
kW
Screw diameter: ɸ
5mm Main

Rotational Screw speed: 0-500 rpm

 Function of system parameters:

SLG Series Double-screw Extruder is comprises the following systems

a) Feeding System
b) Extruding System
c) Cutting System
d) Heating System
e) Lubrication System
f) Driving System
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 g) Control System

a) Feeding System: Feeding system is fixed in the distribution box. The raw materials can
feed with the help of screw rotation which is show in Fig.2 and the screw rotation speed is
adjustable one. This system is composed by screw, raw material hopper, mixer, driving
part.

Technical Parameters:

Motor Model : MBK07-YO.75-

CS-D

Screw Diameter:ɸ 65mm,

ɸ70mm, ɸ85mm

Screw speed : 0-150rpm

Fig 3: Feeding system

b) Extruding System

The main part of extruding system is two screws and barrel. The rotation of the two screws
is in the same anti-clock direction. During the process, the two screws scrape the raw
material stick on the other screws and pushed forward. The screws are composed by seven
sections. While the rawmaterial pushing forward through the seven sections, there will be
contact between the raw material and the barrel, and the raw material absorbs the heat
energy from the barrel. While finishing the extrusion, the raw material has an increased in
inner energy. The screws are easily replaceable.

c) Cutting System

Cutting system is composed by motor, knife and belt. The knife frame is fixed on the
moulded part and this will be driven by the motor. The extruded items are cut by the knife.
More than 20 different moulded shapes are available.
Motor Model; Y90S2

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d) Heating System

Heating system is divided in to 3sections. Every section has infra-red heater. The each
heater has 2kw power. The temperature of each section is adjustable.
To maintain the steady temperature, the system has cooling arrangement with water
circulation system controlled by solenoid valves in each heating section. External inlet and
outlet are required for water circulation to the cooling tank.

Fig 4: Heating System

e) Lubrication System

This system consists of geared pump, oil tank, oil pipes. It is used for lubrication and
Cooling for every rotating parts.
Model of gear pump: BBG-6
Motor Model: Y7214

f) Driving System

Attached drawing III is for SLG series double screw extruders. The power starts from main
motor,after one pair of belt and I=9:1 reducer, it is then divided to two screws which rotate
the same direction. Gear Z24 and Z50 are grawed outside; it belongs to belt driving
system. The reducing ration of this driving system is: I= （ Φ270×24/Φ250×50×9=4.67.
The speed adjustment is by frequency inverter, Reliable and wide range for adjustment.

g) Control System

All the extruder is concentrated by console. Easy for operation is achieved by enhanced
self- protection device in all extruders and habitus indication meter.

Protection grade: IP44

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Safety protection: ground (less than 4Ω)

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 Fig 5: Control System

6. Machinery of extrusion

1. Flour Mixer

Technical Parameters:
Power: 3kW
Output: 5-30Kg/Batch
Dimension: 900*500*1100mm
Effective volume of stirring drum: 170lt
Running Speed of stirring wings: 580 rpm

2. Hoister Machi

Technical Parameters:
Model: LXSL-I
Power: 0.75Kw
Production capacity: 300Kg/h
Dimensions: 2500*500*2000mm
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3. Multi-function Shaper

Technical Parameters:
Model: ZXJ-II
Power: 0.55Kw
Production Capacity: 5-50Kg/h
Dimensions: 1200*640*1200mm

4. Core Filler

Technical Parameters:
Power: 0.55Kw
Heating Power: 3Kw
Production Capacity: 0-150Kg/h
Dimensions: 800*550*1600mm

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 5. Three layer dryer

Technical Parameters:
Dimensions: 4800*1200*1650mm
Voltage: 380V
Power: 0.55Kw
Roast time: 30s-6min
Production Capacity: 150Kg/h

6. Conveyor
Technical Parameters:
Model: FSJ-I
Motor Power: 1.1kW
Output: 0-150Kg/h
Dimension: 1100*600*500
Distance of transmission: 5-10m
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prayer

Technical Parameters:
Power: 0.37Kw
Heating Power: 3Kw
Production Capacity: 0-50Kg/h
Dimensions: 1100*660*700mm

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8. Seasoning drum

Technical Parameters:
Power: 0.55Kw
Production capacity: 0-150Kg/h
Dimensions: 2150*650*1500mm

7. Recipe

Sr. No. Ingredient Quantity

1. Corn flour 6 kg
2. Sorghum flour 6 kg
3. Rice Flour 6 kg
4. Pearl millet Flour 4 kg
5. Spice mix 1.5 kg
6. Oil 250 ml
7. Salt 310 g
8. Water 710 ml

7.1 Process Flowchart of Corn Balls

Corn flour, Sorghum flour, Rice flour & Pearl millet flour

Sieving

Mixing using flour mixer + Addition of water

Pouring flour in feeder/hopper

Extruding

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 Cutting

Seasoning

Packaging

Fig. 6: Flour in mixer

Fig. 7 Production of extruded products

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8. Machine Operations:
First, we obtained the necessary raw materials, which included 3 kg of pearl millet flour, 6 kg of rice
flour, 6 kg of maize flour, and 6 kg of sorghum flour. After twice sieving the flour, it was found to
have an initial moisture content of about 11%. After that, we added the raw material to the flour
mixture and added water to bring the mixture's final moisture content to about 17%. The mixing
process took 10 to 15 minutes. The main motor (power) switch (22kw) was then turned on. After
that, turn on the heating button and adjust the settings to T1 (80°C), T2 (95°C), and T3 (150°C).
Oil pump started after temperature reached the intended level. Simultaneously, the feeding motor was
started, its speed was set to 7 rpm, and the flour mix was fed into the extruder's hopper/feeder along
with a small quantity of water. The extruded product was collected after the cutting motor was
started, the cutting speed was adjusted to 15 rpm, and the extruded material had expanded well.
After that, we allowed the extruded product to cool to room temperature while we got prepared to
season it with a mixture of spices (kurkure masala) After that turn on the heating switch of oil
distributer (oil sprayer) and temperature was adjusted as per the requirements. Boiling oil was
manually sprayed after collecting the extruded product, and seasoning was then added and
thoroughly mixed. We collected our product and sealed it in a polythene bag after seasoning.
Initial moisture content of flour: 11%
Mixing Time: 10 – 15 min
Final moisture content: 17%
Heater Temperature: 80°C, 95°C, 150°C
Cutting motor speed: 15 rpm
Feeding motor speed: 7 rpm

8.1 Problems faced during extrusion

 When the material chocked up inside the extruder during extrusion.

 In order to solve the above problem water along with 2-3 drops of oil added was
used which provide lubrication and smooth flowing of materials inside the
extruder.
 During extrusion when the extruded product was coming out, the cut product
was getting stuck in the cutting system.

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  To overcome this problem, speed of cutter was increased.
9. Observation:
Yield = 4 kg
Seasoning of multigrain balls
Spice mix: Kurkure Masala
Oil: Sunflower oil
Manually sprinkling oil drops on the products and then adding spice mix into that.

10. Cost Calculation

Sr. No Raw material Amount Cost per kg Total cost

1 Rice flour 6kg 74 444
2 Maize flour 6kg 80 480
3 Sorghum flour 6kg 110 330
4 Pearl Millet flour 4kg 42 252
5 Oil 250 ml 208 52
6 Spice mix 1.2 kg 100 120
7 Packaging material 135 pouches - 150

Total cost = 1828 rupees

Cost for 1 kg = 77.78 rupees
Amount in 1 pack = 30 gm
No. of pack form = 135 Packets
Price of 1 pack = 2.59 Rupees

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