Extrusion Product Mastership

Cikupa Factory | 2015

At the End of this Module you will

Module Objectives:

 Participants understand and can explain process of extrusion

 Participants understand key parameters in process and its impact
to product quality

Product
Attributes

Ingredients

2
Chapter Objective

Introduction

Extrusion Process

Raw Materials in Extrusion

Trouble shooting
Chapter Objective

Introduction

Extrusion Process

Raw Materials in Extrusion

Trouble shooting
Which of these Products are made by
Extrusion?

Quiz
Which of these Products are made by Extrusion?

Quiz
 Extrusion history

Cider pressing on Single Screw Extruder Triplex Extrusion to

Keystone apple press dog food produce tires
800-900 1800-1900 1920 1970 2000…. (year)

Double Screw Meat Grinder (USA)

 Extrusion Technology
A continuous process which cooks, chills, shapes and texturizes food ingredients

UP-Stream Equipment Process

- Storage bins
- Mixers for dry ingredients
- Feeders: dry mix, liquids Product
Attributes
- Preconditioning
- ...
Ingredients Equipment

Extruder
Down-Stream Equipment
- Transport systems
- Dryers
- Coating systems
- Frying
The extruder is the HEART of extrusion line
 Pro-con Extrusion Technology
Pro.. Cons..
• High productivity • Low potential for flavor
• Low cost development
• High product quality • Potential unpleasant
• Energy efficiency product texture
• Higher operational
/maintenance cost (e.g
wear)
• Hard to control complexity

*versus traditional technologies (roller drying or biscuit production)

Extrusion in Nestle Worldwide
Worldwide Petfood
X4X Purina: 220
CLX BC160: 5
W&P C170:2
Nestle UNITED KINGDOM Wenger X185/E725: 11
BROMBOROUGH 1 x BC 92
GERMANY
Wenger X235/E925: 8 Hamburg 2 x BC 72
WELWIN GARDEN CITY CLX BC72: 1
CPW R&D 1 x BC 72 CLX BC45: 4
W&P Zsk 58:1 POLAND RUSSIA
Nestle Purina FRANCE W&PC58:1 TORUN 4 x BC 92
PERM
RUMILLY 6 x BC 92 Togum: 1
1 x APV 100 2 x BC 72
Nestle Dreyer’s ITANCOURT 2 x BC 92 CLX EV 68: 1
CLX EV 88: 3

SPAIN
Worldwide Nestlé Dreyer’s LA PENILLA (spare)
GerstenbergSchröder
CHINA
1 x BC 72 TIANJIN 1 x BC 72
KBX: 28 extruders
PORTUGAL
AVANCA 2 x BC 72
Pakistan PHILIPPINES
Taliwa BC 45 LIPA 2 x BC 92
MEXICO
LAGOS DE MORENO 4 x BC 92
INDIA (spare)
MOGA 1 x SCHAAF INDONESIA
OSEM 1 x BC 72 Cikupa BC 72
ECUADOR (spare)
GUAQUIL 1 x BC72 MALAYSIA
CHEMBONG 1 x BC 72
1 x BC45 vacuum
CHILE BRAZIL
CACAPAVA 1 x BC72,
MAIPU 1 x BC 72 2 x BC 92 SOUTH AFRICA AUSTRALIA
1 x BC 92
STANDERTON (Uncle Toby’s)
RIO PARDO 2x BC 92 1 x BC 45 various
Worlwide Pasta extrusion lines
- Buhler line: 12
- Demaco (frozen): 15
Extrusion in Nestle Worldwide
PTC BEAUVAIS
1 Schr!oder KBX65/1000
R&D / PTC 1 Schr!oder KBX130/2000

PTC ORBE
R & D AMIENS PTC Singen
2 x BC 21
1 x BC45 1 W&P C37
1 x BC 45
1 x BC 72 1 W&P C58
1 x BC 72
1 x EV 53 1 BC45
1 Schaaf
R&D Solon 1 X4X Afrem Pasta Extruder
1 Extrutech X525
ALAN line
Gear pumps
PTC York
3 chocolate
R&D Bakerfield extruders
1 Schröder KBX130/2000

PTC LISIEUX
1 x BC 45
ST. JOSEPH
1 x WENGER TX-80

R & D SDEROT
1 x BC 45 R&D Shanghai
PTC St Louis
1 x BC 45
1 x EV68
or 1 x ZSK 70 (WP) Q3 2006
2 X4X Purina
Wenger X115 Optima

R & D SINGAPORE
1 x W&P C58
Extrusion products developed at Nestle

Ice Cream Infant

Cones Cereals
Junior Breakfast
Snacks Extrusion Cereals
Technology
Milo (Powder Savoury
Snack) Snacks

Wafer Confectionery
Products
production
Chapter Objective

Introduction

Extrusion Process

Raw Materials in Extrusion

Trouble shooting
What is an extruder ?

Normally a continuous cooking

and / or chilling machine
which can form materials with
flow properties into a wide
range of shapes and textures F

“Example:
- Noodle press F
- Mincing machine
 Temperature and Pressure are the key parameters for
product characterization
Celcius bar
> 100 °C: Cooking extrusion : 150 120

 Direct expansion:
Breakfast cereals, infant cereals and pet
food
 Indirect expansion:
Snacks and certain breakfast cereals (flakes, 80 50
sheeted products)
20-80 °C: Cold extrusion
Non dairy creamer, MILO, Coffee, Pasta, Chocolate 5

0 0
< 0°C : Freezing extrusion : Ice-cream

15
Extrusion classification : screw configuration

« Extrusion »

Single screw Double screw extrusion

Co-extrusion
Process inside extruder ?
Transport Mixing Shearing/Cooking Forming
Solid Phase Homogeneous phase Solid phase

1 2 3 4

Hydrolysis of
Macromolecules
 Process inside extruder

During extrusion, the ingredients undergo transitions from solid to liquid to solid

Dry Mix
Forming Die

Expanded
Cereal Base

Ingredients
Mixing Melting, Shearing Forming

Solid Liquid Solid

Process inside extruder
Time-temperature relationship for an extruder food product

Muelenaere and Buzzard, 1969 food technology

Process inside extruder
State diagram of the Extrusion process
Main part extruder:
K-tron gravimetric screw feeder - LIW feeder

Weigh-cells measure
the loss-in-weight per
time period, thus
comparing actual versus
set feed rate.
The correct feed rate is
controlled by the speed
of the metering screws.

March 11, 2020 Extrusion training module 25

Main part extruder :
K-tron gravimetric screw feeder

March 11, 2020 Extrusion training module 26

Main part extruder :
Screw
 Effect of screw elements on conveying, mixing and shearin
Element Conveying Mixing Shearing Element ConveyingMixing Shearing

  ---  

100 / 50 C2F 50/-25 CF2C

  ----  

100/33 C2F 100/-25 CF2C

   ----  

100 / 25 C2F 50/-25 CF1C

   - - - - - 
100/33 C1F 100/-25 CF1C

   - - - - - 
100/25 C1F 50/-25 CF1C

- - - - - -  

100/-25 CF1C
BC45EFEC.DRW
Main part extruder :
Screw
Main part extruder :
Screw
Using new and worn-out screw elements together in high pressure zones
will cause uneven barrel wear
Barrel = 115 mm
Worn-out screw elements

New screw elements

(113,9 mm) This will cause
uneven barrel wear

March 11, 2020 Extrusion training module 30

Main part extruder :
Hydraulic system
Main part extruder :
Barrel
• Barrel temperature and wear are two
important parameter to get consistent quality
Main part extruder :
Die Head Assembly
Main part extruder :
Temperature and Pressure Probe
Main part extruder :
Temperature and Pressure Probe
An ALARM will sound if the pressure
at the DIE reaches 200 bar the
system
will be stopped if it exceeds 300 bar

Burnt Product Will Block Probe • Handle sensors with care

• Tighten with torque wrench
• Calibrate pressure sensors
before extruder start-ups
Main part extruder :
liquid injection flow meter
Main part extruder :
Steam
Main part extruder :
Chilled water
Relationship between parameters into the cooker extruder

X=f(X,U)
Dependant var (X)
1 Mass temperature
2 Y=f (X)
Torque
Pressure
SME
Residence time
Independent var (U) etc.
Screw speed
Massfeedrate
Response (Y)
Sensory characteristics
Feed moisture
Physical characteristics
Screw design
Chemical characteristics
Die design
Barrel Temp

Uncontrollable factors Unknown factors

Relative humidity into pilot Not explained
Ambiant temperature etc. Human error
 Independent factors Feed rate - Injector location for steam
- Injector location for water
Steam rate - Ratio steam/water
- Ingredients ratio, origin Feeder Water pump - Total amount of steam&water
- Particle size distribution

Brazilian rice flour 68.2% BULHER

Corn starch: 30% PRECONDITIONER - Paddles set up
Calcium carbonate: 0.9% - Paddles speed 1
Sodium-biposphate: 0.9% - Paddles speed 2

- Die assembly - Screw speed

(preexpansion, dies area, design etc…) - Screw configuration
- Barrel set up
- Barrel T°set up

- Cutter speed
- N° of blades
EXTRUDER BC72

- Ratio water into preconditioner /

N2 into the extruder.
Oil pump Water pump
Inject
- Nitrogen rate
- Injector - oil rate
location - Injector location
- water rate
- Injector location
Example of extrusion set up
- Lecithin concentration
 Dependent factors

- Temperature
- % H2O
- Specific weigth
- Mean residence time

- Temperature
- % H2O
- Head pressure

- Intermediate - Mean residence time

product - Flow rate
- Shear rate - Specific mechanical energy
carateristics - Amps consumption
- Pellet size - Viscosity
- Side pressure - Torque consumption
- Pellet density
etc...
Main effects of extrusion parameters
Downstream equipment:
Cream Filling
Downstream equipment:
Embosser
• Product rope entering crimper to be cut or
shaped
Downstream equipment:
Dryer
 Reduction of surface
moisture
 Remove processing
moisture
 Prepare product for further
processing (flaking,
toasting, coating)
 Improve product shelf life
 Typically single pass with
wire mesh band.
Downstream equipment:
Dryer
Downstream equipment:
Cooling tunnel

 Reduction of surface moisture

 Remove processing moisture
 Conditioning product before packed
Macintyre

52
 Why Should the Maximum Temperature of the Cream be 70°C?
Ingredient Temperature when Temperature Limit Comments
adding
Crystal Sugar Ambient (30-40°C) >100°C

Rework (filled) Ambient (30-40°C) <70°C Temperature sensitivity

comes from milk powder
content
Palm Kernel Stearin 45-55°C >100°C Melting point 40DegC

Cocoa powder Ambient (30-40°C) >100°C

Milk powder Ambient (30-40°C) <60°C develops a burnt flavour

Corn starch Ambient (30-40°C) >100°C

Lecithin Ambient (30-40°C) >100°C

Vanillin crystals Ambient (30-40°C) >100°C

Even though the milk powder has a sensitivity of 60°C, in the mix, the fat offers protection
that allows the cream to endure 70°C before a burnt flavour might start to develop;
If cream has reached temperatures >70°C, a sensory tasting needs to be undertaken to
make a decision whether to use it, to rework it, or to waste it
Cream Making – Impact of Refining Time on Particle Size
and Cream Temperature
Temperature
Schematic! in °C

The longer we refine

500
(speed 6), the lower the
particle size, the higher
the temperature.
There is a cut off point
where more refining does
not deliver enough
150 benefit anymore – and
110 the temperature rise will
continue

0 180 240 Cutting time of dry

60 120
powders in s
Cream Attributes are Linked to the Cream Processing
High Viscosity High book versus High Particle Size Wafer moisture
bar in rework very high (=soggy)
Low particle Low refining
(=high cereal %)
size time
Low High rework
energy
Low High rework Milled sugar
High book (knife
temperature Less versus bar in speed or coarser than
Less fat pressure) normal
lecithin rework

High Tendency to Separate (Cream) High Tendency to Delaminate (Product)

Particle size Particle size Fat content Lack of body
Less lecithin (lack of sugar
high high high
(added or low or rework)
bar to book Less lecithin Low
rework) (added or low temperature at Not enough
High holding High fat bar to book time of layering or too much
temperature content rework) pressing
Chapter Objective

Introduction

Extrusion Process

Raw Materials in Extrusion

Trouble shooting
Main components in food systems

Carbohydrates Proteins Lipids

Starch Fats

Fibre Oils

Sugars Emulsifiers
Minor components in food systems
Minerals

Vitamins

Salts / Buffers

Flavours

Additives
(antioxidants /
stabilizers)
 The role of ingredients in extrusion (1)

Ingredient Main Source(s) Main Function

Starch Cereal flours - Usually the most important ingredient
(whole Starches - Main energy source of breakfast cereals
wheat, corn - Structure forming material
grits) - “Binding agent”
- Texture, cell structure, product density
Fibre Cereal Flours Higher density products
No potential for expansion
Absorption water in preconditioning
Sugar Sugar - Colour and flavour generation (Maillard r.)
Sugar syrup - Texture, cell structure, product density
The role of ingredients in extrusion (2)
Ingredient Main Source(s) Main Function
Fat / Oil Added fat / oil - Texture
Oat flour - “Carrier” for flavour components
Milk powder - Emulsifier -> reduced stickiness
Soya flour - “Lubricating effect” reduces SME
Protein Milk powder - About 1/10 of starch content
Cereal flours - Colour and Flavor generation ( maillard
(wheat flour) reaction)
- improve product stability
Salt Mineral NaCl - Flavour

Others Vitamins - Flavour – effect on pH

Minerals - Nucleating reagents
Buffers - Comply with legislation
 The role of ingredients in extrusion (3)

Ingredient Functionality Side effects Level Remarks

Disodium hydrogen phosphate Reduces risk of fat oxidation, improves Modifies pH, colour / 0.4 – 1.5 % Wet mixing required
shelf life flavour changes possible
(rice)
Dipotassium hydrogen Idem; probably slightly higher amounts Modifies pH, colour / 0.4 – 1.5 % Wet mixing required
phosphate required; good alternative to avoid high flavour changes possible
sodium (Na) levels (rice)
Trisodium phosphate TSP Reduces risk of fat oxidation, improves Idem 0.4 – 1.5 % Wet mixing required
shelf life
Vanillin (methyl-vanillin) Reduces risk of fat oxidation, improves Slight vanilla flavour depends on Dry mix required
shelf life; vanilla flavour category
(Codex)
Covi-ox (mixed tocopherols Reduces risk of fat oxidation, improves Vitamin E activity Powders and pastes
natural extract) shelf life available
Calcium carbonate CaCO3 Calcium source; may modify expansion in may modify viscosity; < 1.0 % wet mix preferred; use
extrudates (finer pores) risk of fat oxidation with natural ground salt
precipitated salt;
Cream Filling Material

64
 3 extruded cereal products of
significantly different composition
Composition (%)
Component
Breakfast Cereal High Fiber Cereal Savoury Snack
Moisture 9 8 10
Starch 70 32 53
Protein 6 10 16.2
Sugar 10 13
Fat 1.3 2.8 3.5
Fibres 2 30 14
Ash 1.8 4 3.2
Total 100 100 100
Chapter Objective

Introduction

Extrusion Process

Raw Materials in Extrusion

Trouble shooting
Trouble-shooting
Issue Possible root cause Actions

Irregular feed Particle size segregation, Verify drymix material and

composition, fat and moisture mixing process
fluctuation of the distribution disparity
extruder performance
and product quality

Barrel temperature / Change in motor torque Verify product pressure is

heating control and die pressure stable. Keep fluctuation in
barel temperature small
Blocking die plates holes Presence of large particle Proper CIL
size ingredient
Worn out sections of the
extruder performance
Improper start up Follow start up procedure
procedure
Trouble-shooting
Issue Possible root cause Actions

Irregular screw speed Barrel and screw wear Regular check

Motor trip recommended 1500
working hours for screw
wear
Nominal clearance
clextral : 0.0052. max
clearance 0.0110
General mechanical Thrust bearing pack and Regular check and fix
problems gearbox
Misalignment between Instrument Handle with care, calibrate
display and actual output before start up
Trouble-shooting
Issue Possible root cause Actions
Product density variation Changes in moisture content – higher Standardize
moisture content produces coarse moisture
structure with thicker cell walls Check dosing
Changes in fat content drymix and
Changes particle size water
Wear of extruder barrels and screw injection
elements Measure gap
Improper install gap value value (diff +-
0.3mm is
acceptable

Product dimension Simultaneous intention of big and small Check speed

variations particles screw
conveyor and
embosser
Trouble-shooting
Trouble-shooting