The benefits of extrusion cooking

NEXT PAGE

Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom.All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. ©Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872

Digital Re-print - September | October 2010 The benefits of extrusion cooking

www.gfmt.co.uk

The convenience factor, and the straightforward nature of the extrusion process, has

been key to the steady growth of the breakfast cereal industry in recent years. For companies considering entry to the market, simple, cost-effective extrusion technology is a logical first production step. It is also a technol-ogy widely used by established multi-nationals around the world.

Twin-screw extrusion is a proven and versatile technology for cereal processing: it is the basis for products involving corn, rice, bran, wheat, barley and oats. It is a straight-forward process - the extruder cooks the ingredients using a combination of heat, mechanical shear and moisture addition; flavours and colours can be added either directly into the barrel, or afterwards.

Profitable businessesExtrusion gives milling companies the

opportunity to widen their business strat-egy by processing their own grain, adding significant value and escaping the confines of commodity pricing at the mercy of influences that cannot be controlled, including weather and speculators.

It is possible to enter the breakfast cereal market without the expense of mar-keting your own brands. The practice of independent cereal manufacturers supplying supermarkets on a contract basis, or ‘co-packing’ – acting as a sub-contractor to major producers – is widely accepted.

Baker Perkins has helped milling com-panies develop profitable breakfast cereal businesses in a number of European markets – and in another sector, supplies equipment to major UK bread bakers owned by milling organisations.

The Cereal Master EX concept Baker Perkins’ ability to extend and adapt

existing extruder based cereal lines utilising a wide choice of units, with minimal invest-ment, is a key feature of the its service to breakfast cereal producers.

The ability to incorporate additional units into a line to extend end product capability is fundamental to the decision of many manu-facturers to select the extrusion process – a modular approach to process design allows the system to expand as the producer’s business grows.

A Cereal Master EX line producing direct expanded cereals such as corn balls, multi-grain rings, alphabet shapes, and cocoa balls

can be extended with additional units and, using Baker Perkins’ process expertise, make a range of high added-value flakes, multigrain flakes and filled pillows.

Co-extrusion equipment, flaking rolls, toasters, cereal cookers, syrup coating units, shredders and dryers can be added to form versatile plants suitable for a wide range of high-specification cereals produced in volume.

Typical end products include a wide selection of filled pillows and a broad range of flakes, including corn and bran flakes.

Innovation Centre Manufacturers from around the world

visit the company’s Food Innovation Centre at Peterborough, UK, which contains a range of production and laboratory scale equip-ment, including a twin-screw extruder that can be configured for a wide range of products.

Customers use these facilities to develop new products and processes, produce sam-ples for test marketing, or conduct feasibility trials – all in a confidential environment.

Services include creating complete product portfolios for new producers. Customers can conduct equipment tri-

Extruded ready-to-eat breakfast cereals have all the qualities today’s demanding consumers expect of a convenience food. They offer nutrition, taste, value and variety and are instantly available. Significantly, many breakfast cereals also benefit from a positive reputation in health terms – a growing issue in consumer choice.

The benefits of

extrusion cooking

Grain&feed millinG technoloGy12 | September - october 2010

FeatureExtrusion

als, develop products, train staff and produce samples for test marketing in conditions of complete confidentiality.

Extruded breakfast cereals – a healthy option

Extrusion provides the ability to develop a broad spread of cereal products, and the versatility of the twin-screw extrusion process means that new products are continually being added to the portfolio.

For example, breakfast cereals are the perfect vehicles for the nutritious whole and multi grain servings recommended as part of a healthy lifestyle. They are established favourites with consumers aware of the implication of diet in a healthy lifestyle.

Wholegrain products retain, after process-ing, all three parts of the original grain – the germ, bran and endosperm – in their original proportions: refining normally removes the

bran and germ, losing about 25

percent of a grain’s protein along with at least 17 key nutrients.

With 48 grams of wholegrain recommended daily by the Whole Grain Council, and 32 grams in a typical serving, breakfast cereals are a key part of a healthy lifestyle.

Multigrain products feature a combination of grains such as wheat, rye, corn, barley or rice, and offer the opportunity for cereal manufacturers to develop products with an imaginative appearance featuring new tex-

Grain&feed millinG technoloGy September - october 2010 | 13

Feature

Breakfast Cereal -a low cost market opportunity

Multi-nationals around the world use Baker Perkins process technology to produce a vast range of market leading breakfast cereal products. But it also has the technology and expertise that is ideally suited for a business that wants to move into this market - as a small start up, own brand manufacturer for instance. With a low capital cost start that is totally flexible and scaleable Baker Perkins has the equipment and know-how to get you started in this rapidly expanding market. Make the most of this exciting business opportunity....

Call Baker Perkins today +44 1733 283000 or email [email protected]

www.bakerperkinsgroup.com

Extrusion

als, develop products, train staff and produce samples for test marketing in conditions of complete confidentiality.

Extruded breakfast cereals – a healthy option

Extrusion provides the ability to develop a broad spread of cereal products, and the versatility of the twin-screw extrusion process means that new products are continually being added to the portfolio.

For example, breakfast cereals are the perfect vehicles for the nutritious whole and multi grain servings recommended as part of a healthy lifestyle. They are established favourites with consumers aware of the implication of diet in a healthy lifestyle.

Wholegrain products retain, after process-ing, all three parts of the original grain – the germ, bran and endosperm – in their original proportions: refining normally removes the

bran and germ, losing about 25

percent of a grain’s protein along with at least 17 key nutrients.

With 48 grams of wholegrain recommended daily by the Whole Grain Council, and 32 grams in a typical serving, breakfast cereals are a key part of a healthy lifestyle.

Multigrain products feature a combination of grains such as wheat, rye, corn, barley or rice, and offer the opportunity for cereal manufacturers to develop products with an imaginative appearance featuring new tex-


Feature

Breakfast Cereal -a low cost market opportunity

Multi-nationals around the world use Baker Perkins process technology to produce a vast range of market leading breakfast cereal products. But it also has the technology and expertise that is ideally suited for a business that wants to move into this market - as a small start up, own brand manufacturer for instance. With a low capital cost start that is totally flexible and scaleable Baker Perkins has the equipment and know-how to get you started in this rapidly expanding market. Make the most of this exciting business opportunity....

Call Baker Perkins today +44 1733 283000 or email [email protected]

www.bakerperkinsgroup.com

Extrusion

http://www.intelscan.is

http://www.bakerperkinsgroup.com

down by design features that cut maintenance.

An AC drive system is virtually maintenance free, and innovative open-frame design maximises access for cleaning and main-tenance. The newly introduced splined shafts and high torque capacity of the gearbox are designed for optimum reliability and durability.

Processes that require a face cutter benefit from a new design of this unit. Changing the cutter blade can be achieved in 15 min-utes without stopping production.

The SBX extruder is par-ticularly easy to use, with PLC touch-screen control, and time-

saving automatic start and stop sequences as standard.

Co-extrusion equipment Co-extrusion is a recent Baker Perkins

innovation for the cereal industry, and provides a simple, cost-effective means of extending a product range beyond standard direct expanded cereals.

It involves the simultaneous extrusion of a cereal outer shell and a filling, and extends capability through the ability to make added-value products with contrasting textures and colours, with innovative flavours and fillings, and with out of the ordinary shapes that catch the eye.

The Baker Perkins co-extrusion system can be added to an existing twin-screw line supplied by virtually any manufacturer. The essential elements of the system are a die, pillow crimper and cream feed system. The fillings can be of virtually any colour or flavour – creams, fruit pastes or chocolate praline are typical. The product range is limited only by the imagination.

Co-extrusion die Die design is crucial in controlling shape,

expansion and shell structure, and providing end products of differing formulations and shapes from a single extruder. Baker Perkins has a modular die format, which allows shapes to be altered easily and cost-effec-tively by changing a product-specific insert.

Pilllow-crimperThe pillow-crimper provides co-extruded

pillow cereals in attractive new patterns such as hexagons, ‘cats face’, chevrons and waves. ‘Standard’ shapes such as squares can also be

SBX twin-screw extruderThe latest generation of twin-screw extrud-

ers can produce standard, direct expanded cereals such as fruit rings, corn puffs, alphabet letters, rings, cocoa curls, oat loops and crisp rice with no further processing, except sugar coating and drying. The SBX extruder can respond to market demand for rapid changeo-ver between products and has the inbuilt flex-ibility to bring new products to market quickly.

The modular barrel of the SBX Master enables the length of each machine to be matched precisely to the customer’s process application, and enables extension later as production needs change.

To further increase flexibility, the range of end products that can be made has been increased by incorporating a motor and gear-box able to handle twice as much torque as the previous generation of extruder.

The flexible Baker Perkins die design and segmented agitator configuration - allow-ing quick product change-over with few change parts - has been retained, together

with the high free volume agi-tator geometry that enables

high outputs to be achieved, even on low density

materials such as bran and

fine milled flours.

A new, high out-

put model has been introduced, to

give a capacity range from 225 - 2000kg/hour of direct expanded product.

Cost of ownership is driven

tures and colours, with a beneficial nutritional profile.

Elsewhere, Baker Perkins development of new, modular dies has led to the introduc-tion of a range of products with a distinctive surface texture. These consist of a number of individual strands, with a sweet centre.

Downstream, coating with sugar can provide additional options for added-value product development. These dies can be retrofitted to virtually any make of extruder.

Shaping productsProducts are shaped by being forced

through the die, and Baker Perkins’ ‘library’ of shapes is continually being expanded; it ranges from rings or squares to stars and letters of the alphabet.

Retrofitting new dies during the mid-life cycle of an extruder can freshen a product portfolio with new and attractive brands.

Grain&feed millinG technoloGy14 | September - october 2010

FeatureExtrusion

vides accurate metering of fillings for products handled on the cutter-crimper. The system features one pump per product stream, allowing each to be adjusted independently for precise weight control.

The cutter-crimper and cream feed system were developed to process the higher out-puts now available from twin-screw extrud-ers. Baker Perkins has introduced 12-stream dies with an output potential twice the previ-ous maximums, maximising the robust power of the latest solid-barrel extruders.

produced, with outline definition much improved compared to previous generation equipment.

The pillow-crimper can handle up to 12 lanes of product simultaneously, form-ing filled tubes into individual pillows. Easily interchangeable cutting roll sets allow pillows to be made in a wide range of shapes and sizes. The pillow crimper can be retrofitted into lines including any make of extruder.

Cream feed system The Baker Perkins cream feed system pro-

More inforMation:Keith Graham Baker Perkins LtdManor Drive Paston ParkwayPeterborough, PE4 7AP United Kingdom

Tel: +44 1733 283469Fax: +44 1733 283004Email: [email protected]: www.bakerperkinsgroup.com


Feature Extrusion

SABETHA, KANSAS USA 785-284-2133 [email protected] WWW.WENGER.COM

USA BELGIUM TAIWAN BRASIL CHINA TURKEY

Since 1935, we've been help-ing customers solve problemsand capitalize on opportuni-ties faced by their businesses.

Seventy-five years ago, a keyanswer was a molasses mixer.Today, the solutions tend tobe more technologically com-plex – but our foundingpledge remains unchanged.

At Wenger, we innovate tosolve customer challenges.

And then we do it again.

Inventing the new original since 1935.

innovation is our enduring legacy.

Wenger_Ad_2010_210x147mm 5/24/10 9:37 AM Page 1

http://www.wenger.com

The exclusive UK-supplier o f w o r l d - l e a d i n g component protection

lubricants has issued a warning to feed mills across the country that increasing pressure from animal feed companies may mean a move to only H1 approved greases.

I n d u s t r i a l S p e c i a l i t y Lubricants, the UK distributor of Whitmore’s r ange of p roduc t s , h a s re ce n t l y introduced a new-generation H1 approved product to meet this demand and is in talks with a number of mills across the UK and Ireland to begin supply.

“Many mills have chosen to use non-food-approved greases for their bearings because they feel that the old-generation H1 products didn’t provide adequate component protection, but increasing pressure from animal food manufacturers is seeing the market changing” explained Leanne Combrinck from ISL.

“The new-generation of products provides even more protection under pressure than non-food-grade lubricants – in fact our Medallion Extreme™ range offers protection under the most severe conditions, tripling the life of bearings even when compared to traditional favourites” she added. As well as being registered with the NSF as food grade H1 for incidental contact with food, the range of greases resist pound-out, provide extra protection, and offer a very significant reduction in product consumption.

By providing appropriate protection under pressure, particularly where components are subjected to high load or

shock values, mills can also make signif icant savings on their bottom line according to the results of an in-depth positive cost analysis project and efficiency audit recently conducted by ISL. “A lack of protection means that bearings need replac ing f ar more frequently and the amount of product used is often also significantly higher than we’d expect” explained Leanne. “This lack of efficiency has huge cost implications, an impact on production with down-time caused by maintenance and component replacement, and an impact on energy costs because more is required to work the machinery.”

“Taking into account product costs, quantity of use, and the cost of replacing bearings – which our new lubricant reduces from an average of three times per year to just one – our positive cost analysis project has proven that many feed mills could spend just 59 percent of their current budget which is obviously a huge saving” explained Leanne. “Plus they are able to assure their customers that they only use food-grade lubricants which, while a bonus at the moment, may well become mandatory in the near future so it’s a case of acting now and making a change for the better” she added.

T h e M e d a l l i o n Extreme™ range is water resistant, so stays in place even during frequent wash

downs and is suitable for use up to 350˚F (177˚C). “Ideal for lubricating bearings, bushings and slides, and rollers, Medallion Extreme™ also includes the anti-bacterial agent, Lubristat, to limit the growth of bacteria on, and within, the body of the grease” Leanne explained. Whitmore’s point to a recent test conducted by a major Japanese brewery specifically looking at E-coli, which showed that the Lubristat additive not only controlled the growth of bacteria but can actually exterminate an existing colony.

Perfect for use across the

plant, and kosher-pareve for year-round use, the product range is already causing a stir in the feed mill sector and ISL is offering free audits of current provision for anyone interested in a no-obligation cost saving audit.

More inforMation: Industrial Speciality LubricantsCastle Foregate,ShrewsburyShropshireSY1 2ELUnited Kingdom

Tel: +44 1782 710012Email: [email protected]: www.islubricants.co.uk

Product warning issued for UK Feed Mills

News September - October 2010


Simple pushbuttonfor digital results!

RIDA®QUICK SCAN

New

R-Biopharm Rhône Ltd.Block 10 Todd CampusWest of Scotland Science ParkAcre Road, GlasgowScotland G20 0XA

Phone: +44 (0) 141 945 2924Fax: +44 (0) 141 945 [email protected]

Fax: +44 (0) 141 945 [email protected]

R-Biopharm Rhône Ltd.

mod.indd 1 06/10/2010 08:50

– Thermal loading cut by half– Reduced grain damage for all types

of grain, including paddy rice– No loss of germination properties

among seeds and malting barley– No loss of baking proper-

ties among bread grainsFollowing Schmidt-Seeger's commit-

ment to lower operating costs as one of its main goals, even grain producers in areas with high levels of harvest moisture are now able to compete on the market

ConclusionAl l the

innovations incorporated in the Eco Dry and the Eco Cool have

contributed to achieving the following main goals:– Lower energy requirement– Uniform final moisture level

in all product sub-flows

the product to overheat. It must be certain that every grain spends the same amount of time in the drier regardless of whether it passes through along the edge or in the center.

Eco Dry plus Eco Cool at a site in Kirchham, Germany, output 11 tonnes/hour (maize, 35 percent moisture reduced to 15 percent);

total storage capacity 60 tonnes, installed heating capacity 3.5MW – performance improved by Eco Cool to 13 tonnes/hour, additional storage capacity of the continuous-flow cooler 55 tonnes


Feature

Eco Dry – The new Generation of Cereal Dryers

Your benefits:● Energy saving potential of up to 20 % (drying maize using our continuous cooling column)

● gentle drying process● uniform drying temperatures reducing hotspots● minimized discharge of fines (canola, flax)Contact us. We would like to discuss our dryer innovations and new developments with you.

Schmidt-Seeger GmbH Eichstaetter Strasse 49, 92339 Beilngries – Germany Telephone: +49 8461 701-0, Fax: +49 8461 701-133 [email protected], www.schmidt-seeger.com

Grain

general principle that is true for xylanase cannot be transferred to phytase.

Thus, when the effect of phytase on ileal amino acid digestibility is plotted as a propor-tion of the undigested fraction the conclu-sions are quite different to that of xylanase (see Figure 4). Indeed, those amino acids which benefit most from phytase addition are those amino acids which are present at high concentrations in endogenous proteins such as mucins and pepsin.

The net effect of this is that when phytase is present in a diet it improves the digest-ibility of some nutrients more than others. As the response to xylanase is largely driven by the digestibility of the diet to which it is added the efficacy of xylanase will be reduced in the presence of phytase, but not to the same extent for all nutrients.

The law of diminishing returnDue to upwards pressure on the price of

many commonly used feed ingredients such as corn, fat and protein sources, the use of several feed additives can be, at least at face value, attractive for poultry producers.

The difficulty with simply adding various supplements to a ration and ascribing them the suppliers recommen-dations is that in most instances the magnitude of effect on for exam-ple, energetic efficiency has been assessed inde-pendent from other additives. The matrix values for phytases and xylanases (see Table 1), for example, are gener-ally established by feeding diets containing these enzymes independent of other feed additives and measuring some response criteria such as weight gain, conversion, bone ash, or digestibility (total tract or ileal).

One practical illustration of this is in the application of amino acid matrices for feed enzymes used in combination.

Taking lysine as an example and applying real published nutrient release values for vari-ous commercially available products:

Total lysine = 1.23% Digestible lysine = 1.15% Undigested lysine = 0.08% Phytase: 0.017% Xylanase: 0.024% Protease: 0.048%

Using phytase, xylanase and protease in combination = 0.089% improvement in digestible lysine (i.e. from 1.15% to 1.24%).

In the above example the use of sup-plier’s recommendations for lysine results in

Figure 2: The effect of xylanase on ileal amino acid digestibility (IAAD) coefficients from 19 peer-

reviewed papers published between 1998 and 2009


Feature Enzyme

http://www.satake-group.com

http://www.r-biopharm.com

http://www.consergra.com

http://www.abvista.com

PREVIOUS PAGEwww.gfmt.co.uk

LINKS• Seethefullissue• VisittheGFMTwebsite

• ContacttheGFMTTeam

• SubscribetoGFMTA subscription magazine for the global flour & feed milling industries - first published in 1891

September 2010

• Thebenefitsofextrusioncooking

In this issue:

• The law of diminishing

returns: - consequences

for feed enzyme strategy

• An innovative approach to animal diet formulation

• Global grain & feed markets

• Cutoperatingcosts!

- Energy savings in drying technology for agricultural products

• Theinfluenceoftemperature,humidityandairflowonthegraindryingprocess

ThisdigitalRe-printispartoftheSeptember|October2010editionofGrain&FeedMillingTechnologymagazine.Contentfromthemagazineisavailabletoviewfree-of-charge,bothasafullonlinemagazineonourwebsite,andasanarchiveofindividualfeaturesonthedocstocwebsite.Pleaseclickheretoviewourotherpublicationsonwww.docstoc.com.

Topurchaseapapercopyofthemagazine,ortosubscribetothepapereditionpleasecontactourCirculationandSubscriptionsManageronthelinkadove.

INFORMATIONFORADVERTISERS-CLICKHERE

Article reprintsAll Grain & Feed Milling Tecchnology feature articles can be re-printed as a 4 or 8 page booklets (these have been used as point of sale materials, promotional materials for shows and exhibitions etc).

If you are interested in getting this article re-printed please contact the GFMT team for more information on - Tel: +44 1242 267707 - Email: [email protected] or visit www.gfmt.co.uk/reprints

http://www.gfmt.co.uk

http://www.gfmt.co.uk/archive.php

http://www.gfmt.co.uk

http://www.gfmt.co.uk/contact.php

http://www.gfmt.co.uk/subscriptions.php

http://www.docstoc.com/profile/Perendale

http://www.gfmt.co.uk/advertising.php

mailto:[email protected]

http://www.gfmt.co.uk/reprints

The benefits of extrusion cooking

Documents

Transcript of The benefits of extrusion cooking