Extrusion-Cooking Techniques

Edited by Leszek Moscicki

Applications, Theory and Sustainability

Moscicki (Ed.)

Extrusion-Cooking Techniques

www.wiley-vch.de

An industrial expert in food and feed sectors and a pioneer of extrusion cooking, Leszek Moscicki is head of the Department of Food Process Engineering, Lublin University of Life Sciences, Poland. After completing his PhD at Lublin Agricultural University, he continued his research at Wageningen Agricultural University, the Netherlands. He has more than 150 scientific publications to his name, is a national delegate to the International Association of Cereal Science and Technology, a committee member of the Polish Academy of Science as well as several other Polish scientific and professional associations, and has coordinated several EU projects on HTST processing of vegetable raw materials.

Offering an engineering perspective and the latest information on the application of this rapidly expanding technique, this practical book covers the technology, engineering, materials and products, as well as economic and ecological aspects. In addition to the theory, it also utilizes case studies that can easily be put into industrial practice.

Each step of the process is discussed in terms of sustainability, and all data complies with the EU and FTA environmental regulations.

Invaluable reading for food chemists and technologists, process engineers, chemists in industry, agricultural scientists, and chemical engineers.

From the Contents:l Engineering Aspects of Extrusionl Raw Materials in the Production of Extrudatesl Production of Breakfast Cereals, Snack Pellets, Baby Food and morel Extrusion Technique in Confectioneryl Pet Food and Aquafeedl Extrusion-Cooking in Waste Management and Paper Pulp Processingl Thermoplastic Starchl Expandersl Process Automationl Scale-Up of Extrusion-Cooking in Single-Screw Extruders

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Edited by

Leszek Moscicki

Extrusion-Cooking

Techniques

Further Reading

Brennan, J. G., Grandison, A. S. (eds.)

Food Processing Handbook

2 volumes

2011

Hardcover

ISBN: 978-3-527-32468-2

Peinemann, K.-V., Pereira Nunes, S.,Giorno, L. (eds.)

Membrane TechnologyVolume 3: Membranes for

Food Applications

2010

Hardcover

ISBN: 978-3-527-31482-9

Rijk, R., Veraart, R. (eds.)

Global Legislation forFood Packaging Materials

2010

Hardcover

ISBN: 978-3-527-31912-1

Campbell-Platt, G. (ed.)

Food Science and Technology

2009

Hardcover

ISBN: 978-0-632-06421-2

International Food Information Service

IFIS Dictionary of Food Scienceand Technology

2009

Hardcover

ISBN: 978-1-4051-8740-4

Janssen, L., Moscicki, L. (eds.)

Thermoplastic StarchA Green Material for Various Industries

2009

Hardcover

ISBN: 978-3-527-32528-3

Piringer, O. G., Baner, A. L. (eds.)

Plastic PackagingInteractions with Food

and Pharmaceuticals

2008

Hardcover

ISBN: 978-3-527-31455-3

Edited byLeszek Moscicki

Extrusion-Cooking Techniques

Applications, Theory and Sustainability

The Editor

Prof. Dr. Leszek MoscickiLublin University of Life Sci.Dept. of Food Proc. Engineer.Doswiadczalna Str. 4420-280 LublinPoland

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# 2011 WILEY-VCH Verlag & Co. KGaA,Boschstr. 12, 69469 Weinheim, Germany

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Printed in SingaporePrinted on acid-free paper

ISBN: 978-3-527-32888-8

Contents

Preface XIList of Contributors XIII

1 Extrusion-Cooking and Related Technique 1Leszek Mościcki and Dick J. van Zuilichem

1.1 Extrusion-Cooking Technology 11.1.1 Preparation of Raw Material 31.1.2 Extrusion-Cooking 41.1.3 Forming, Drying and Packing 51.2 Quality Parameters 61.3 Extrusion-Cooking Technique 71.3.1 Historical Development 81.3.2 Processing of Biopolymers 101.3.3 Food Melting 111.3.4 Rheological Considerations 121.4 Modern Food Extruders 141.4.1 Single-Screw Extrusion-Cookers 141.4.2 Twin-Screw Extrusion-Cookers 171.5 Concluding Remarks 22

References 23

2 Engineering Aspects of Extrusion 25Dick J. van Zuilichem, Leon P.B.M. Janssen, and Leszek Mościcki

2.1 Mass Flow and Temperature Distribution in a Single-ScrewExtruder 25

2.1.1 The Theory of Mass Flow and Temperature Distribution 252.1.2 Residence Time Distribution of the Material

in the Extruder 282.2 Energy Balance 29

V

2.2.1 Components of Energy Balance 292.2.2 Total Power Input to a Screw 302.3 Mass and Heat Transfer in a Twin-Screw Extruder 332.3.1 Heat Transfer 352.3.2 Model by Yacu 382.3.2.1 Solid Conveying Section 392.3.2.2 Melt Pumping Section 392.3.3 Model by van Zuilichem 41

References 43

3 Raw Materials in the Production of Extrudates 45Leszek Mościcki and Agnieszka Wójtowicz

3.1 Introduction 453.2 Structure-Forming Raw Materials and Additional

Components 463.3 Physical and Chemical Changes in Vegetable Raw Materials

During Extrusion-Cooking 503.3.1 Changes in Starchy Materials 513.3.2 Changes in Protein-Rich Materials 553.3.3 Changes in Fibers 563.3.4 Changes in Vitamins 563.4 Nutritional Value of Extrusion-Cooked Foods 583.5 Concluding Remarks 60

References 60

4 Production of Breakfast Cereals 65Leszek Mościcki and Andreas Moster

4.1 Introduction 654.2 Directly Extruded Breakfast Cereals 684.3 Flaked Cereals 684.4 Remarks on Operation 77

References 80

5 Snack Pellets 81Leszek Mościcki

5.1 Introduction 815.2 Methods of Snack Pellet Manufacturing 835.2.1 Production Stages 835.2.1.1 Initial Phase 835.2.1.2 Extrusion and Forming 835.2.1.3 Production of Short Forms 855.2.1.4 Production of Laminated, Perforated and Spatial Forms 855.2.1.5 Drying, Packing and Storage 875.2.1.6 Toasting or Frying – Final Stage of Snack Production 88

References 89

VI Contents

6 Crispbread, Bread Crumbs and Baby Food 91Leszek Mościcki

6.1 Production of Crispbread 916.2 Production of Bread Crumbs 936.3 Production of Precooked Flour, Instant Semolina

and Baby Food 94References 97

7 Precooked Pasta 99Agnieszka Wójtowicz

7.1 Introduction 997.2 Raw Materials Used in Pasta Processing 1007.3 Extrusion-Cooked Pasta-Like Products 1017.3.1 Experimental Results 1027.4 Conclusions 115

References 115

8 Processing of Full Fat Soybeans and Textured Vegetable Proteins 119Leszek Mościcki

8.1 Introduction 1198.2 Extrusion-Cooking of Full-Fat Soybeans and Other Protein-Rich

Vegetable Materials 1208.3 Production of Textured Proteins and Meat Analogues 123

References 126

9 Extrusion Technique in Confectionery 129Leszek Mościcki

9.1 Introduction 1299.2 Sweets and Candy 1309.3 Creams and Pastes 1329.4 Gums and Jellies 1339.5 Other Products 1369.6 Concluding Remarks 137

References 137

10 Pet Food and Aquafeed 139Leszek Mościcki

10.1 Introduction 13910.2 Market Development 14010.3 Feed Extruders 14010.4 Technology 14310.4.1 Raw Materials and their Preparation 14410.4.2 Extrusion and Drying 14610.5 Concluding Remarks 148

References 149

Contents VII

11 Expanders 151Leszek Mościcki

11.1 Introduction 15111.2 Design of Expanders 15211.3 Application 15411.3.1 Processing 15411.4 Concluding Remarks 157

References 158

12 Extrusion-Cooking in Waste Management and PaperPulp Processing 159Leszek Mościcki and Agnieszka Wójtowicz

12.1 Introduction 15912.2 Processing of Animal Waste 16012.3 Utilization of Non-Meat Waste of the Food

Industry 16212.4 Extrusion in Paper Pulp Processing 163

References 165

13 Process Automation 167Leszek Mościcki and Andreas Moster

13.1 Introduction 16713.2 Control and Automation 167

References 175

14 Thermoplastic Starch 177Marcin Mitrus and Leszek Mościcki

14.1 Introduction 17714.2 Raw Materials 17814.2.1 Starch 17814.2.2 Plasticizers 17814.2.3 Auxiliary Substances 17914.3 Physical and Utility Features 18014.3.1 Crystallographic Structure 18014.3.2 Glass Transition Temperature 18114.3.3 Mechanical Properties 18214.3.4 Rheological and Viscoelastic Properties 18314.3.5 Water Absorption 18314.4 Production of Biodegradable Packaging Materials 18414.4.1 Protective Loose-Fill Foams 18414.4.2 Film Blowing 18514.4.3 Production of Shaped-Form Packagings 18514.5 Concluding Remarks 188

References 188

VIII Contents

15 Scale-Up of Extrusion-Cooking in Single-Screw Extruders 191Leon P.B.M. Janssen and Leszek Mościcki

15.1 Introduction 19115.2 Basic Analysis 19315.3 Summary of Equations Used 19415.4 Kinematic Similarity 19515.5 Geometrical and Kinetic Similarity 19615.6 Motor Power and Torque 19615.7 Equal Average End Temperature 19715.8 Similar Temperature Profiles 19715.9 Similarity in Residence Times 19815.10 Guidelines for Scaling 199

References 199

16 Producers of Food Extruders and Expanders 201Leszek Mościcki

Index 215

Contents IX

Preface

Extrusion-cooking is gaining increasing popularity in the global agro-food proces-sing industry, particularly in the food and feed sectors. In this handbook, we want toshare the secrets of this relatively new technology, paying particular attention to theutilitarian aspects, namely discussing the processes associated with the productionof various extrudates and describing the machinery and equipment necessary fortheir manufacture. There are also many comments and recommendations of apurely operational nature. A perusal of the book will give, in my view, not onlyinformation concerning the complexities of the production but also a quantum ofengineering knowledge helpful in decision making for those who are consideringwhether or not to implement this technology in their processing plants.

Being a promoter of substantial research programs in this field for many years Iam a great enthusiast for extrusion-cooking, seeing much room for its application.As an editor my ambition was to collect the contents of this book that represent thelatest achievements in the field, offering readers the best practical knowledgeavailable at the time of publication. The text of the book has been developed togetherwith invited scientists and industrial experts, whose substantial contribution hasassured a high level of transferred knowledge.

This handbook is intended for researchers, students, engineers and technical staffstudying or working in food process engineering, food technology, chemical engi-neering and/or related disciplines. I do hope that the text will also be of interest forfood and feed producers as well as representatives of the various industries benefit-ting from the processing components and semi-finished goods in the agro-foodindustry.

L. Mościcki - Editor

XI

List of Contributors

XIII

Leon P.B.M. JanssenUniversity of GroningenDepartment of Chemical EngineeringNijenborgh 49474 AG GroningenThe Netherlands

Marcin MitrusLublin University of Life SciencesDepartment of Food ProcessEngineeringDoswiadczalna Str. 4420-280 LublinPoland

Leszek MościckiLublin University of Life SciencesDepartment of Food ProcessEngineeringDoswiadczalna Str. 4420-280 LublinPoland

Andreas MosterBühler GmbHErnst-Amme-Str. 1938114 BraunschweigGermany

Dick J. van ZuilichemEverlaan 16705 DH WageningenThe Netherlands

Agnieszka WójtowiczLublin University of Life SciencesDepartment of Food ProcessEngineeringDoswiadczalna Str. 4420-280 LublinPoland