Food Processing Machinery
The range of Food Processing Machinery
- Soy Protein Processing Extrusion plant - for soya chunk, nuggets,
- Cereal blended food products Extrusion plants - pasta, noodles, vermicelli and many other items.
- Snack food Extrusion plant.
Definition of Extrusion
- The act or process of pushing or thrusting out.
- The act or process of shaping by forcing through die.
- An object or material processed by extruding.
FUNCTIONS OF AN EXTRUDER
- COOKING
- Starch gelatinization.
- Protein denaturation.
- SHAPING / FORMING.
- EXPANSION.
- SHEARING.
- TEXTURE ALTERATION.
- MIXING AND UTILIZING VARIOUS INGREDIENTS.
- PASTEURIZATION AND STERLIZATION.
- DEHYDRATION.
Extrusion Cooking
The process by which moistened expansible, starchy and/or proteinaceous materials are plasticized in a tube by a combination of moisture, pressure, heat and mechanical shear.
The Extruder being manufactured for soya processing is a new development for us in extrusion technology, this extruder is having a special feature of segmented barrel as well as segmented screw which facilitates cleaning of the screw / barrel as well as interchangeability of screw profiles is possible to achieve desired results in the processing of various materials.
The machine is designed to run at a very high speed of about 300 rev. Per minute, and the driving motor is of 150 hp.
By the new concept of introducing Gear box in the drive system we are looking forward to reduce the drive motor power to 150 hp from 300 hp, currently being used in conventional plant.
The material of construction of the screw is Stainless Steel, so also the inner sleeves of the Barrel(cylinder) are made up of SS. The Extruder Die is also made from SS as the material being processed comes in direct contact with these components of the machine.
This machine we are working on presently is meant for Texturized Soy Protein processing (TSP). The same can be adopted for many of other processes from the same category, some of them are listed below-
- Texturized Vegetable Proteins (TVP) - Reorientation and cross linking of vegetable proteins in a high shear and temperature environment (extruder) to form a fibrous matrix that can suppliment or substitute meat products after flavoring and colouring.
Major modifications desired inside the extruder - Protein Denaturation (Shear and Thermal Energy) and unfolding.
- Digestibility increases.
- Destruction of Enzymes and Toxic Proteins.
- Proteins aligned in the direction of flow in screw channels and dies, causes lamination or texturization.
- Cross linking between proteins enhances matrix formation and increases expansion.
- Cereals and Snacks Products - Expanded Cereals, Flaked Cereals, Infant Foods.
- Pasta Products- Allows pasta to be shaped by extrusion through a die. Yield a strong, flexible dry finished product, having good packaging tolerance and good storage stability. Yield a translucent dry finished product with a clear surface free of specks and bright in colours. Yield a firm, resilient, non sticky cooked product with pleasing taste and aroma.
- Rice Analog Products - Precooked , Reformed Rice produced by moderate temperature- low shear extrusion, fully cooked and gelatinized.
Definition of products
Meat extender - Product soaked in water, then mixed with Meat to make it go further or change its properties.
High Protein Snacks - Products eaten in the dry form. Often flavoured externally or incorporated into snacks bar.
Meat Analog - Product that replaces meat. Meat made from vegetable proteins.
Important concepts - Products not fully cooked to prevent protein denaturation, starch degradation and poor cooking quality. Finer particle size(flour) and starch mechanical degradation leads to greater susceptibility to enzymatic ( amylase) action and poor product shelf life.
TSP PRODUCTS
- CHUNK STYLE TSP- Large chunks, steaks, minced small chunks, flaked, soy crisps, strips.
- CHUNK STYLE TEXTURISED WHEAT PROTEINS ( TWP).
- STRUCTURED MEAT ANALOG (SMA).
- FIBROUS SOY PROTEINS (FSP).
- HIGH MOISTURE MEAT ANALOG (HMMA).
- TEXTURED MEAT PROTEINS (TMP).
ADVANTAGES OF EXTRUSION COOKING
Process for production of Precooked Rice
- Utilizes broken/ cracked rice,
- Forms into various shapes and sizes,
- Produce a cooked/ restructured product with rice like Texture.
- Produce fortified rice for improved nutrition.
DAL ANALOG
Provides protein contents of natural dal lentil.
- EXPANDED CEREALS
- ADD STARCH ADD PROTEINS
- TEXTURISED PROTEINS.
PROTEINS
--SOY FLOUR.
-- BEAN FLOUR.
-- PEA FLOUR.
-- DAL LENTILE FLOUR.
STARCH
-- WHEAT FLOUR.
-- CORN FLOUR.
-- RICE FLOUR.
BENEFITS OF EXTRUSION
- Versatile range of final products.
- Ingredient flexibility.
- Continuous process.
- Increased productivity.
- Reduced production costs.
Endless possibilities
Animal feed
- pet food,
- pet treats,
- aquatic food,
- Hygienic animal feeds,
- full fat soy,
- oil seed processing.
Food products
- textured vegetable proteins.
- RTE Breakfast cereals.
- Expanded snacks.
- Infant foods.
- Modified starches.
- Precooked pasta.
- Protein enriched foods.
- other products- limited only by imagination.
HOW IS EXTRUSION AN IMPROVEMENT OVER BATCH PROCESS?
- CONTINOUS.
- LESS LABOUR.
- ONE OR TWO PIECES OF EQUIPMENT- LESS ENERGY, LESS COST.
- BETTER CONTROL.
- MINIMAL EFFLUENTS.
- SHORTER TIME, MORE EFFICIENT.
- WIDER RANGE OF PRODUCTS, NEW FOODS.
The Extrusion lines can also be equipped with downstream equipments such as Die Face Cutter for product formation, dryer belt, inline oven and conveyor facilities, based on customer requirements.
