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Extrusion technology
- 1. 1
- 2. 2
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- 4. 4Mike Adams
- 5. UNIVERSITY OF HORTICULTURAL SCIENCES BAGALKOT COLLEGE OF HORTICULTURE, BAGALKOT Seminar – I “Extrusion Technology: A potential technique for vegetables and fruits based snack food product” Ms: Ayeeshya Kolhar UHS17PGD223 Ph.D (II yr) Dept of Post Harvest Technology 5
- 6. Introduction Production technique and it’s components Food extruders- Types & application Physico- chemical changes Factors affecting extrusion process Advantages & Limitations Case studies Conclusion 6 S E M I N A R O U T L I N E
- 7. The word “extrudate” originates from the Latin word “ex” (out) and “trudere” (to thrust). Extrusion is defined as “A process in which material is pushed through an orifice or a die of given shape, the pushing force is applied using a piston or a screw.” 7 Karwe, 1992
- 8. Extrusion is a process which combines several unit operations including mixing, kneading, cooking, shearing, shaping, forming, conveying, separation, venting, flavor generation, plastification and expansion of the food structure. Fellows, 2000 8
- 9. 9 Table 1: History INVESTIGATOR YEAR FINDINGS MC.Anelly 1964 First to describe a process for the production of spongy elastic particles from soy flour. Atkinson 1970 Disclosure of a continuous cooking extrusion process EL-Dash 1981 First to process breakfast cereal products Noguchi. 1998 Extrusion cooking of high moisture protein foods Fast 2000 RTE cereals Saalia 2011 Degradation of afflatoxins by extrusion Ryan 2011 Oat based breakfast cereal snack Rao and Thejaswini, 2015
- 10. PRODUCTION TECHNIQUE As a result, it fills the barrel and the spaces between the screw flights and becomes compressed Further down the barrel, smaller flights restrict the volume and increase the resistance to movement of the food Raw materials are fed into the extruder barrel and the screw(s) then convey the food along it. Bordoloi and Ganguly, 2014 10
- 11. 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 As it moves further along the barrel, the screw kneads the material into a semi-solid, plasticized mass. Fig. 1: Expansion of the product Bordoloi and Ganguly, 2014 11
- 12. COMPONENTS OF EXTRUSION SYSTEM Feeding system Pre-conditioning system Screw or worm Barrel Die and the cutting mechanism Rao and Thejaswini, 2015 12 Fig.2 COMPONENTS OF EXTRUSION SYSTEM
- 13. GENERAL CONDITIONS Temperature : 52-199 ° C Pressure :1500- 70,000 KPa Time :15-19 sec Screw speed :150-600 rpm Rao and Thejaswini, 2015 13
- 14. FOOD EXTRUDER Fig.3: Food extruder 14Bordoloi and Ganguly, 2014
- 15. CLASSIFICATION OF EXTRUDERS BASED ON OPERATION HOT COLD BASED ON CONSTRUCTION SINGLE SCREW TWIN SCREW 15Bordoloi and Ganguly, 2014
- 16. SINGLE-SCREW EXTRUDERS The most common extruders applied in the food industry. The barrels of single-screw extruders usually have helical or axial grooves on inner surfaces. This helps to convey and mix the material more effectively. Fig. 3: Single-screw extruder Caldwell , 200016
- 17. The first major commercial application of the in the food processing industry was conversion of semolina flour into pasta using solid screws. Application 17 Huber, 2000
- 18. Twin-screw extruder The term ‘twin-screw’ applies to extruder with two screws of equal length placed inside the same barrel. More complicated than single screw extruders, but at the same time, provide more flexibility and better control. Maurya and Said, 2014 18
- 19. Application Processing plastics Food companies (sticky caramels and candies) 19 Maurya and Said, 2014
- 20. RAW MATERIALS USED The most used raw materials- starch and protein based materials, and are used in solid form (Steel et al., 2012). Most products such as breakfast cereals, snacks and biscuits– starch (wheat, corn, rice, potato, cassava and pea flour). Protein- meat-like characteristics (soybean). Dehgonshoar et al., 2010 20
- 21. Physico-chemical changes during extrusion 21
- 22. The starch polymer becomes glassy as moisture is removed, forming a hard brittle texture Dispersed and degraded to form a continuous fluid melt Heat & the action of shear destroy the organized molecular structure, also resulting in molecular hydrolysis of the material At relatively high temperatures, the starch granules melt and become compressed to a flattened formChangesinstarch Rao and Thejaswini, 2015 22
- 23. Enzymes lose their activity after being submitted to high temperatures and shear High molecular weight proteins can dissociate into smaller subunits During extrusion, disulfide bonds are broken and may re- form Proteins are more reactive and undergo many changes during the extrusion process, most important being denaturation Changesinprotien Rao and Thejaswini, 2015 23
- 24. Changes in lipids Lipids acting as lubricants. They reduce the friction between particles in the mix and also between the screw and barrel surfaces. Rao and Thejaswini, 2015 24
- 25. Changes in Fibres Rao and Thejaswini, 2015 25
- 26. Anti-nutrients Extrusion cooking destroys many natural toxins and anti- nutrients, there by improving safety of the food product. Compounds such as allergens and mycotoxins susceptible to extrusion in combination chemical treatments. Rao and Thejaswini, 2015 26
- 27. Influence of extrusion cooking on various parameters Nutritional quality Microbiological quality Product quality Rao and Thejaswini, 2015 27
- 28. Fruit or vegetable blended extruded products Cereal Fruits, vegetables, by-products etc. Snacks with different appearance and flavour with improved nutrition. Bordoloi and Ganguly, 2014 28
- 29. 29
- 30. Objective: To incorporate cauliflower by-products as a source of dietary fibre into ready to- eat snacks and evaluating it’s effect on nutrition and sensory attributes of ready to-eat expanded snacks 30
- 31. 31 Table 2: Formulations for extrudate development Ingredients (% w/w) Wheat flour 16.4–36.4 Cauliflower 0–20 Corn starch 20 Oat flour 10 Egg whites 10 Milk powder 10 Onion powder 03 Tomato powder 05 Carrot powder 05 Dill 0.1 Mint 0.1 Salt 0.4 Stojceska et al., 2008
- 32. Process conditions Process conditions Solid feed rate : 20-25 kg/ h Water feed : 9-11% Screw speed : 250-350 rpm Temperature : 80°C at the feed entry 120°C at the die exit Stojceska et al., 2008 32
- 33. 33 Table 3: Nutritional characterization of raw materials (A) and extruded products (B) Stojceska et al., 2008
- 34. Fig. 5: Images of extrudates containing different levels of cauliflower. Stojceska et al., 2008 34
- 35. Fig. 6: Influence of cauliflower level on taste panel acceptability score Stojceska et al., 2008 35
- 36. 36 Inference •Incorporation of cauliflower by-products into ready-to-eat snacks and their effect on nutritional and textural characteristics were positively affected. •The taste panel acceptability score showed that cauliflower by- products could be added up to 10%. Stojceska et al., 2008
- 37. Objective: To characterize and evaluate the performance of pineapple pomace as an ingredient in extruded products. 37
- 38. Table 4:Chemical composition of freeze-dried pineapple pomace Component Percentage (% ) Moisture 3.77 ± 0.52 Protein 4.71 ± 0.28 Fat 0.61 ± 0.14 Total Dietery fibre 45.22 ± 3.62 Insoluble Dietery fibre 44.44 ± 3.60 Soluble Dietery fibre 0.78 ± 0.10 Carbohydrates 43.46 Selani et al., 2014 38
- 39. Table 5: Physicochemical composition of freeze-dried pineapple pomace Physicochemical parameters Pineapple pomace pH 3.86 ± 0.07 Titratable acidity (g /100 g) 2.01 ± 0.23 Water activity (aw) 0.14 ± 0.06 Colour: L* 75.63 ± 3.07 a* -0.10 ± 1.79 b* 26.91 ± 2.35 Selani et al., 2014 39
- 40. Experimental setup Pineapple pomace : 0%, 10.5%, 21% Moisture : 14%, 15%, 16% Temperature : 140° C & 160° C Single screw extruder with screw speed – 220 rpm Control : 14% moisture + no fibre Selani et al., 2014 40
- 41. 28/10/2016 41 Averages followed by different letters are significantly different (p < 0.05) by Tukey’s HSD test. Data with logarithmic transformation (base 10). The comparison among the means was performed with transformed data and the results presented in the original scale. Selani et al., 2014 Table 6: Effects of the pineapple pomace incorporation on the physical characteristics of the extrudates
- 42. Fig. 7: Appearance of the extruded products Selani et al., 2014 42
- 43. Factors influencing the quality of the product I. Rheological properties of the food Type of feed materials Moisture content Physical state of the materials Chemical composition 43
- 44. II. Operating characteristics Temperature Pressure Diameter of the die apertures Shear rate. 44
- 45. Objective: To evaluate physical characteristic and microstructure of extruded product. 45
- 46. Experiment Control : 100 % corn grits Treatments : Corn grits with pumpkin flour (5, 10,15 and 20 per cent) Screw speed - 250 and 350 rpm Barrel temperature – 1600C Evaluation - physical characteristics of snacks Nor et al., 2013 46
- 47. Fig. 9: Effect of screw speed and the proportion of pumpkin flour on the expansion ratio Nor et al., 2013 47
- 48. Nor et al., 2013 Fig.10: Effect of varying pumpkin flour percentage and screw speed on the hardness of extruded product. 48
- 49. Nor et al., 2013 Fig. 11: Effect of varying pumpkin flour percentage and screw speed on the bulk density of extruded product. 49
- 50. Table 7: X-ray tomography cross sectional of 2-D image (radial): changes of bubble size through out the extruded sample at screw speed 250 rpm (scale 1:2) Nor et al., 2013 50
- 51. Objective: To develop and evaluate extruded snacks with optimum level of garlic powder. 51
- 52. Experiment Materials used Rice flour : 50-70% Defatted soy flour : 30% Garlic bulbs & salt Treatments T1- RF 70% T2- RF 65% + G 5% T3- RF 60% + G 10% T4 - RF 55% + G15% T5- RF 50% + G 20% 52
- 53. Sensory parameters Treatment ( means) T1 T2 T3 T4 T5 RF 70% RF 65% + G 5% RF 60% + G 10% RF 55% + G15% RF 50% + G 20% Flavour 23.53 23.80 21.80 18.26 15.26 Colour 13.20 12.73 11.00 10.46 9.86 Expansion 13.40 12.60 10.20 10.13 8.26 Texture 13.20 12.46 11.80 9.66 9.13 Odour 8.20 8.00 7.40 7.06 5.86 Overall acceptability 12.66 13.00 11.60 8.93 8.26 Table 8: Effect of substitution of rice flour with garlic powder on sensory analysis 53
- 54. 54 The garlic can be incorporated in the form of dehydrated powder in rice and defatted soy based ready-to-eat extruded snacks up to 10 % level with acceptable sensory qualities. Inference
- 55. Objective: To asses the formulation, development and evaluation of physico-chemical and sensory properties of extruded snacks with different flour blends. 55
- 56. Control : Corn + BG (80: 20) Treatments : Corn flour + Black gram flour + Tuber flour (60: 20:20) Preconditioning Spicing and drying Packaging and storage Sensory evaluation and physico chemical analysis Reddy et al., 2014 56
- 57. Fig. 10: RTE extruded formulations developed by incorporation of different roots and tuber flour blends 1. Corn flour + Black gram flour 2. Corn flour + Black gram flour + Potato 3. Corn flour + Black gram flour + Taro 4. Corn flour + Black gram flour + Yam 5. Corn flour + Black gram flour + Sweet potato 6. Corn flour + Black gram flour + Beet root Reddy et al., 2014 57
- 58. Table 10: Mean physical parameters of the developed extruded products Reddy et al., 2014 Values are expressed as mean ± standard deviation of ten determinations .Mean values with similar superscripts within a column do not differ significantly (P>0.05). C -corn, BG - black gram 58
- 59. Table 11: Proximate analysis of extruded snacks (per 100 g) Reddy et al., 2014 Values are expressed as mean ± standard deviation of ten determinations .Mean values with similar superscripts within a column do not differ significantly (P>0.05) . C - corn, BG - black gram 59
- 60. Fig. 13: Mean sensory scores of the extruded products Reddy et al., 2014 60
- 61. Fig. 14: SEM images of control and most acceptable extruded snack (potato incorporated extruded products). Reddy et al., 2014 A. External SEM image of control extrudate B. External SEM image of potato incorporated extruded products C. Internal SEM image of control extrudate D.Internal SEM image of potato incorporated extrudate 61
- 62. Advantages Versatility Cost Nutritional improvement Productivity Product quality Environmentally-friendly 62 Tripathi and Mangaraj, 2013
- 63. Disadvantages High capital cost Non-availability of spare parts Repairs and maintenance Power failure 63 Tripathi and Mangaraj, 2013
- 65. 65 CONCLUSION…
- 66. 66 Proper handling and processing of the waste generated by fruits and vegetable processing industry into extrudable form. Commercialization of the fruits and vegetable incorporated extruded snack products. Creating awareness among the consumer about the fruits and vegetable incorporated extruded snack products using extension methodologies. Future line of the work………….
- 67. 67 Thank you…
- 68. 68
Editor's Notes
- Wecome to all, before getting into the seminar lets consider two different problems
- Processing of fruits and vegetables leads to genaration of great quantum of waste, which is difficult to expose and again it causes the environmental pollution. It is well known about nutraceutical value of fruit and vegetable from seed to peel they possess the nutraceutical value as the waste is also a componet of fruit and vegetable then it also possess the nutraceutical value instead of exploring this we are wasting it and causing environment pollution which really not adviceable….
- Today in the name of urbanization/globalisation our food habit is completely changing And again there is an increase in working women population and all of us were busy and there is no time for us to cook our own food, then automatically we are moving towards junk snacks which are neither nutritious nor healthy
- By observing the lifestyle of human The medical scietist mike adams drawn a line that this second problem force to search a healthy snack food product. By observing these two problems clearly the first problem can be solution for the second i.e we can explore the nutracetical value of the fruit and vegetable and their components for preparation of healthy snack food products for this we are in need of technology and it is extrusion technology using this we can achive our goal of reducing the waste and producing the healthy snack food product………
- With this brief background I’m here to through light on the topic i.e
- And today we willl discuss about extr
- There are 5 diff components of extruder to achive the efficent prtoduction syste it is desired to have constant non interpted feeding of the raw material……. Preconditioning of the dough is must for easy processing of the material, which is achived by using steam or water….this facilitaets homogity of the particle in the raw material and reduces the friction between the screw surface and the barrel thus prevent deprition of the machines Screw: an important component of the extruder plays vital role in producing the quality end product. It helps for genrtn of pressure, shear forced reuired for bringing out the necessary physicochemical changes……. Barrel another important component of the extruder is barrel which gold the screw and provides varied range of temperture and facilitate the cooking process…... Die an important components performance two different function 1….it provides shape for the product and helps for increasing the force and the cutting mechanism helps for achiving the uniform sized product which is horizontally or vertical….this is a typical extruder
- Hot extruder works using more than 100 C the process is also known as extrusion cooking leads to production of food products with low water activity…..and prolongend shelf life ex expanded snack food products inaddition they also destroy the mycotoxin and antinutritional factor Whereas the cold extruder works using low tempr i.e at ambient condition it simply mix the material and convey it ex meat and pasta food products….
- As the name suggest single screw extruders contain single screw which placed inside the barrel……. The rotating screw provides required shearing force, helps in metering of the material ex
- Change the content
- Twin screw extruders were widely used in food processing, here 2 screws of equall length were placed inside the rootating barrel they are complicated when compared to the single screw extruder but offers flexibility in functioning Inaddition to this twin screw extruder also helps for easy handling of oily, sticky wet material and material with wide range of particle size are used for processing The only limitaion is high cost of the machine…….
- change
- Changes in Fibres
- the brassica family member cauliflower is well known for its nutrion and antioxidant property along with this it has hugh waste index...... to exploit the nutrion and anti oxidant propety of this vegetable and to reduce the waste index.......
- Increasing the proportion of pumpkin flour from 0% to 10% for the 350 rpm treatment decreased the expansion ratio of the extruded pellets by about 15%, but no further change occurred as the proportion of pumpkin flour was increased to 15% and 20%. At a screw speed of 250 rpm the expansion ratio did not change significantly with the proportion of pumpkin flour (Figure 4).
- As expected, the hardness of the extruded products (Figure 5) varied inversely with respect to expansion ratio with harder products tending to be less expanded although this was less evident for the product extruded at 250 rpm.
- Urbanization and lack of time