EXTRUSION COOKING-

PRINCIPLE,EXTRUDERS
MITHRALINNI.M.A
II-B.TECH AGE
What is extrusion?
It is a process by which a set of mixed
ingredients are forced through an opening in a
perforated plate or die with a design specific to
the food, and is then cut to a specified 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 consists of a large, rotating screw

tightly fitting within a stationary barrel, at the
end of which is the die.
Extrusion enables mass production of food
via a continuous, efficient system that
ensures uniformity of the final product.

Food products manufactured using extrusion

usually have a high starch content.

These include some pasta, breads (croutons,

bread sticks, and flat breads), many breakfast
cereals and ready-to-eat snacks,
confectionery, pre-made cookie dough, some
baby foods, full-fat soy, textured vegetable
protein, some beverages, and dry and semi-
moist pet foods.
There are two types of extrusion processes:

• Cold extrusion, which mixes and shapes foods such as biscuit

dough and pasta without cooking them.

• Hot extrusion (or extrusion cooking), which is used to produce

a wide range of products, including crisp snack foods, sugar
confectionery and soya-based weaning foods
ELEMENTS OF PROPER EXTRUSION COOKING:
1. THE MATERIAL SHOULD BE PRECONDITIONED WITH
STEAM AT CONTROLLED TEMPERATURE OF 82 – 99
DEGREES.
2. FEEDING OF GRANULAR MATERIAL IN THE
EXTRUDER SHOULD BE CONTINUOUS AT DESIRED
RATE.
3. MOISTURE SHOULD BE UNIFORMLY APPLIED.
4. THE EQUIPMENT TRANSFORMS THE FLOURY
MATERIAL INTO A DOUGH AT 82-110 DEGREES.
5. DOUGH TEMPERATURE ELEVATED TO 115-200
DEGREES DURING LAST 10-30 SECONDS TO EXPAND
THE PRODUCT.
6. FORMATION OF DESIRED SHAPE AND SIZE IS DONE
BY A NOZZLE OR DIE AT THE END OF THE PROCESS.
7. EXTRUDATE IS CUT INTO DESIRED LENGTHS,THEN
DRIED AND COOLED.
 THE EXTRUDER

This equipment has a screw inside a barrel that conveys materials along the barrel and kneads the food into a
semi-solid, plasticized mass.

In cold extruders the material is not heated but simply formed into shapes (including rods, tubes, strips or
shells), when it is forced through openings in a ‘ die’ at the discharge end of the barrel.

In extruder-cookers the material is heated by friction and/or supplementary heaters in the barrel and it
emerges from the dies under pressure. Some snack food products expand rapidly and have a light, crisp
texture, caused by steam being flashed off due to the sudden pressure drop when they emerge from the die.

Cold-extruded products are preserved by chilling, baking or drying, whereas extrusion cooking destroys
contaminating micro-organisms and the dry products have a long shelf life. They are packaged to prevent
them picking up moisture and to prevent oxidation during storage.

Cold extruders are suitable for all scales of operation from household- to small-scale, but extruder-cookers
are much more expensive and are likely to only be affordable by larger-scale producers.
An extruder has three basic components:
1.SCREW
a)Compression zone
b)Metering zone Click icon to add picture

2.BARREL

3.TUBE AND DIE

20XX presentation title 7

SINGLE SCREW EXTRUDERS

SINGLE SCREW EXTRUDER MEANS THAT THERE IS ONLY ONE SCREW IN THE EXTRUDER BARREL.
EXTRUSION SYSTEM
THE MAIN FUNCTION OF THE EXTRUSION SYSTEM IS TO MELT AND PLASTICIZE THE POLYMER MATERIAL TO
FORM A
UNIFORM MELT, AND REALIZE THE TRANSITION FROM THE GLASS STATE TO THE VISCOUS FLUID STATE.
· TRANSMISSION SYSTEM
THE TRANSMISSION SYSTEM IS USUALLY COMPOSED OF A MOTOR, A REDUCER AND A BEARING. ITS FUNCTION
IS MAINLY TO
DRIVE THE SCREW AND SUPPLY THE TORQUE AND TORQUE REQUIRED BY THE SCREW IN THE EXTRUSION
PROCESS.
SPEED 100-400 RPM
· HEATING AND COOLING SYSTEM
THE HEATING AND COOLING SYSTEM OF THE EXTRUDER CONSISTS OF A HEATING DEVICE AND A COOLING
DEVICE, WHICH IS
A NECESSARY CONDITION FOR THE SMOOTH OPERATION OF THE EXTRUSION PROCESS.
THE HEATING DEVICE AND COOLING DEVICE MUST ENSURE THAT THE TEMPERATURE CONDITIONS MEET THE
PROCESS REQUIREMENTS.
 APPLICATIONS:

Pipe extrusion: suitable for PP-R pipes, PE gas pipes,

PEX cross-linked pipes, aluminum-plastic composite
pipes, ABS pipes, PVC pipes, HDPE silicon core pipes
and various co-extruded composite pipes.

Sheet and sheet extrusion: suitable for the extrusion of

PVC, PET, PS, PP, PC and other profiles and sheets.

Profile extrusion: Adjusting the speed of the extruder and

changing the structure of the extruder screw can be used to
produce various plastic profiles such as PVC and
polyolefins.

Modified compounding: It is suitable for compounding,

modifying and enhancing compounding of various
plastics.
TWIN SCREW EXTRUDERS
• The twin-screw extruder is developed on the basis of the
single-screw extruder. Due to its good feeding performance,
mixing and plasticizing performance, exhaust performance,
extrusion stability, etc., it has been widely used in extruded
products. Forming processing.
• Speed : 20-60 rpm (High torque)
• There are two types of twin-screw extruders: intermeshing and
non-intermeshing. And, Intermeshing twin screw extruders
have two types: co-rotating and counter-rotating.
SECTIONS OF TWIN SCREW EXTRUDERS:

•Conveying section: The function is to transport

materials and prevent backing.

•Melting section: In this section, the materials are

fully melted and mixed through heat conduction
and frictional shearing.

•Plasticizing section: further melt and mix the

ingredients of the material, with the function of
distributing and dispersing mixing.

•Discharge section: conveying and pressurizing,

forming a certain pressure, making the materials
more compact, and at the same time further
mixing, to achieve the purpose of extrusion and
granulation.
 APPLICATIONS:

The twin screw extrusion machine is used in the food industry for
the production of breakfast cereals, pasta, snacks, and pet food.
The high degree of mixing and kneading action provided by the machine
helps in enhancing the texture and flavor of the final product.

Used for manufacturing RPVC dual conduit pipes, RPVC pipes, PVC
profiles, and PVC compounding.

They can also be used in the polymer, chemical, and food industries for
mixing a wide variety of consumer products, such as:

1.Adhesives
2.Sealants
3.Mastics
4.Putties
5.Soaps
Effects of extrusion on nutritional quality

The extrusion process results in “chemical reactions that occur within the extruder barrel and at the die”
• Destruction of certain naturally occurring toxins
• Reduction of microorganisms in the final product
• Slight increase of iron-bioavailability
• Creation of insulin-desensitizing starches (a potential risk-factor for developing diabetes)
• Loss of lysine, an essential amino acid necessary for developmental growth and nitrogen
management
• Simplification of complex starches, increasing rates of tooth decay
• Increase of glycemic index of the processed food, as the “extrusion process significantly increased
the availability of carbohydrates for digestion”
• Destruction of Vitamin A (beta-carotene)
• Denaturation of proteins.