CHAPTER SB "EXTRUDED FOODS INTRODUCTION ske mechanical extrusion of food pastes using,» piston on a . peoyiea in the home to make products like ‘se Mae 20 DRTC Ueerees eT ekecsion ls not Rea eee OAWeIEERNRENRCE TE Vevovaled inthe Foren coRaER ee aston technology ittniciess have baled Gereal procussing teeiustog to trcrease thelr production. Large-scale production of full asaya flour veah enhanced nutsiHanal properties has been made possible by extru- Son cooking process, With'the help of extrusion technology, it has become possible to produce breakfast cereals, weaning foods, snacks and engineered foods like meat substitutes and meat analogues. Until recently extrusion cooking remained more ofan art than a technology. In recent times, it is becoming increasingly popular as it Provides means for nergy’ efficient, economic and continuous processing with little waste, no effluents and high versatility, productivity and product quality. Cooker extruders made their appearance more than 25 years ago and combined the features of expellers, designed to expel oil from cooked cil seeds, or gelatnise starch in animal feeds, and extruders for cooked doughs like pasta, macaroni and vermicelli. Cooking and extrusion in a simple operation resulting in different types of ready to eat foods in a fw minutes using any raw material led to rapid exploration and expansion of this technology Principle of Extruders Dr} ingredients like cereals, oilseeds and pulses are ground to specific sizes, nixed and passed through an extruder at high pressure where the food material gets cooked and comes out through the die in various shapes 3 The raw materials are first preconditioned with moisture to a level of 10 to 35%. The extruder consists of a barrel in which works a threaded serew or worm, just as in an oil expelle heat energy released by friction in the presence of moisture gelatinises the starches, hydrates the proteins and converts the total mass into a plastic dough, while the high shear forces couked dough under high pres end, the sudden release flush off, and the duct 1 1. As the material passes along, the rupture the starch granules. As the uire emerges from the die placed at the of pressure causes the super heated moisture to dough pulfs out in consequence. The form of the pro- determined by the nature of the die and the arrangement torRenerate upty 1 Hand 6 minutes PF a the cooking ale soy abeans ttc t above the Show S alischanged from ww Pestriction and, AO Provision for nd. therefore, any or to charging the wn for adding heat hange and, hence on of mechanical device, making it ous masses. The \ either through canation in shear erature gradients n for replaceable Some of the mer- mple and easy to installed; (c) it is mmoplastic extru- 18 percent mois- gular chips; (e) it zyme present, or "an, and (f) the employs high. ection. It ct. This helps in “ matenal The ble speed motor + provides high liquid form can, @ short period extruders, with of heads, screw h the same raw | | | Extruded p ms meatal its possible to get preci Wot different testy Mouthfonl eh “bitty and se on, Horexample, wheat flout can te truuded su tay Nght as the lightest Snack, oF as dense as the most dense breakfast rot any desired density between these two extremes Weager can mashes, starches and protein blend, 1 et, ve + a wide latitude of ingredient uti ensities. Tean also be trol of growth inhibitor ness. Used! for processing oil seeds arid pulens 1 rs and for substantial elimination of by der technology is being inc raye tilised in the modern processed food. It has ite incrits and demer. 1. Improved utilisation of non-traditional food sources, i Wane (ike soya flour, ol eakes, guar meal, cr.) has become Possible with extrusion cooking. > Efficient processing reduces nutrient damages like destruction of vitamins, or protein damage by carbohydrate binding, that normally occur during cooking. 3 Shelf life inhibitors in raw materials and storibility of the product is improved, ‘4+ Transit losses during intermediate stages of Production are elm nated by process integration, 5. Only 2 few minutes are required for the entire process as the extruder length is just about 6-25 cms. The capacity of even 4 sinall extruder is 0.5 tonnes/hour, and of a large one is 3 tonnes /hour. 6 A single unit can be utilised for a wide Tange of raw materials cereals, pulses and oilseeds, and can produce (by altering the wide range of cooked products in terms of shape and size curls, flakes, chips, cubes, balls, almonds or Powders). Flavour ond iexture can also be varied. For example, a crisp and Puify product is the result of using oil cakes and a chewy elastic texture is Possible by using whole vilseed 7 Sanitary quality of the extruded foods is high. as must bacter and also salmonella are destroyed during extrusion ® The requirement of space, labour and energy are all low, ant the Guibut is very high. Thus, the cost of extrusion proce sing 1s smaller than that of alternative methods of foo Demerits cessing, Unless there is sufficient demand for the product, the h output capacity (due to idleness or insufficient utilisation) may proves vtly- ase Food! Processing and Proservation The unit design is such that power b Causes the unit to jam. Some Prone to become an extromet tion is quite troublesome The very low bulk density of the products (200g/1) and the extra ye peed in handling without fa) crumbling ¢ uring transport, and b) the loss of crispness on exposure to atmospHeric moisture, neces: States special packaging materials and! forme The operation of the machine is affected Substantially due to the high coefficient of friction and back Pressure if defatted flour of over- toasted saya is used. But this Problem is absent if full-fat soya flour is used, failure, even for afew seconds, Taw materials, ¢g., maize are specially 'y tough mass, and the cleaning opera. Use of Extruded Foods: Extrusios, couking technology has limitless applications. Some of them i zs 3. 4 are listed below: Suitable formulations for supplementary feeding can be made from ony Available raw materials in such combinations so es to give final Products of desired composition, The product can be used as ready-to-eat snack. Stabilisation of rice bran can be achieved, Full fat or defatted soya powders can be made ration of soup, or as a mince meat substitute. It can be used as an emergency ratio in case of natural calamities like floods, cyclones, and famine. Special dietary formulations that include high fibre or enriched with Protein, vitamins and/or minerals, can be extrusion cooked ints expanded for use in the prepa- snacks. : Special autogenous low-cost extrusion cookers have opened new possibilities for weaning and protein-enriched foods. Expanded, fortified and enriched cereals serve as breakfast cereals. Convenience products like instant or quick cooking noodles or Pasta not only provide convenience of preparation, but are also of special use for preparing gluten-free products in case of gluten allergy and lic diseases, orate wafers and crisp bread products of extrusion technology re enriched and have high fibre content. Peedicts like chewing gum, certain hard candies, base tubes that may be filled with sweet filling and cereal sugar products that are coated with chocolate after eatrusion can be produced from cereal- lends. ree ‘red foods include textured plant (or milk) proteins. The plant proteins are formed into fibrous or lamellar continuous structures that simulate animal muscle or fish flesh. Animal meat products in combination with cereal-based blends is also possible. 13, fnstant dry » starches can | bles cari also 14 Instant bevey rice meal, ar corn soya mi Factors Affectin Moisture content erably low monst is necessary fo extrusion:cookit material need 1 ers significantly breaking streng with shear rate, Changes Dur Physical ct the die is an a the starch cor sure drop. Ai ture content ¢ Macromolec 1. Starch: The the changes i ucts. There is at 18% mois temperaturesHixtruded Foods — 255 2 Tnstant dry soups and gravy bases made from extrusion modified ogera tarhes can be reconstituted instantly Spices and chopped veget starshes e added les wan also be added os produced by extrusion of e¢ 4 Instant beverages produced shun aris og : ae meal, are siitable for making, either milk thin beverages, like orn soya milk, oF thick beverages like milk shakes or gruel sorghum grits or Factors Affecting Extrusion Performance Moisture content: Twin screw extruders can handle materials of consid- erably low moisture content. However, a certain minimum water activity is necessary for the desired polymer transformation during HTST extrusion cooking, Products from intermediate and low moisture feed material need no drying. The moisture content of the mass in the extrud- ers significantly affects the apparent viscosity, expansion and product breaking strength. The influence of moisture, however, is inter-related with shear rate, temperature and die size. Feed rate: This influences the heat transport characteristics of the mate- nal. High feed rate results in decrease of water absorption and solubility properties of the product. Improper heat transport due to increasing feed rate also affects various other properties of product like specific volume, final moisture, extrusion temperature, etc. Particle size: Non-homogenous mass results in plugging of nozzle and incomplete cooking of large particles. Particle size affects gelatinisation of the product. : : Additives: Addition of sugar increases the degree of gelatinisation and salt improves the expansion and cohesiveness in the extrusion of wheat flour. Addition of 1.5% monoglyceride or 35% sunflower seed oil results in complete cooking. Hydroxypropyl cellulose improves lubricacy and extrudibility of the mix and. thus, increases the output at reduced energy cost Changes During Extrusion Process Physical characteristics: Expansion of the product as it emerges trom the die is an apparent change, and the degree of expansion depends upon the starch content, its gelatinisation and water vapour arising from pres- sure drop. Addition of fat decreases the expansion Temperature, mois- ture content and die geometry also influence the expansion Macromolecular constituents 7 Starch The characteristics of the extruded products are determined by the changes in starch as it is the ma >r component of cerealbased prod ucts, There is no change in corn semolina at temperatures less than 05°C at 16% moisture, while partial gelatinisation and swelling occurs at temperatures of 207°C and above. Both wh Hand potato starch show