Extrusion-Cooking Techniques

Transcription

1 Edited by Leszek Moscicki Extrusion-Cooking Techniques Applications, Theory and Sustainability

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3 Edited by Leszek Moscicki Extrusion-Cooking Techniques

4 Further Reading Brennan, J. G., Grandison, A. S. (eds.) Food Processing Handbook 2 volumes 2011 Hardcover ISBN: Peinemann, K.-V., Pereira Nunes, S., Giorno, L. (eds.) Membrane Technology Volume 3: Membranes for Food Applications 2010 Hardcover ISBN: Rijk, R., Veraart, R. (eds.) Global Legislation for Food Packaging Materials 2010 Hardcover ISBN: International Food Information Service IFIS Dictionary of Food Science and Technology 2009 Hardcover ISBN: Janssen, L., Moscicki, L. (eds.) Thermoplastic Starch A Green Material for Various Industries 2009 Hardcover ISBN: Piringer, O. G., Baner, A. L. (eds.) Plastic Packaging Interactions with Food and Pharmaceuticals 2008 Hardcover ISBN: Campbell-Platt, G. (ed.) Food Science and Technology 2009 Hardcover ISBN:

5 Edited by Leszek Moscicki Extrusion-Cooking Techniques Applications, Theory and Sustainability

6 The Editor Prof. Dr. Leszek Moscicki Lublin University of Life Sci. Dept. of Food Proc. Engineer. Doswiadczalna Str Lublin Poland All books published by Wiley-VCH are carefully produced. Nevertheless, authors, editors, and publisher do not warrant the information contained in these books, including this book, to be free of errors. Readers are advised to keep in mind that statements, data, illustrations, procedural details or other items may inadvertently be inaccurate. Library of Congress Card No.: applied for British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. Bibliographic information published by the Deutsche Nationalbibliothek The Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data are available on the Internet at # 2011 WILEY-VCH Verlag & Co. KGaA, Boschstr. 12, Weinheim, Germany All rights reserved (including those of translation into other languages). No part of this book may be reproduced in any form by photoprinting, microfilm, or any other means nor transmitted or translated into a machine language without written permission from the publishers. Registered names, trademarks, etc. used in this book, even when not specifically marked as such, are not to be considered unprotected by law. Cover Design Formgeber, Eppelheim Typesetting Thomson Digital, Noida, India Printing and Binding Fabulous Printers Pte Ltd, Singapore Printed in Singapore Printed on acid-free paper ISBN:

7 V Contents Preface XI List of Contributors XIII 1 Extrusion-Cooking and Related Technique 1 and Dick J. van Zuilichem 1.1 Extrusion-Cooking Technology Preparation of Raw Material Extrusion-Cooking Forming, Drying and Packing Quality Parameters Extrusion-Cooking Technique Historical Development Processing of Biopolymers Food Melting Rheological Considerations Modern Food Extruders Single-Screw Extrusion-Cookers Twin-Screw Extrusion-Cookers Concluding Remarks 22 References 23 2 Engineering Aspects of Extrusion 25 Dick J. van Zuilichem, Leon P.B.M. Janssen, and 2.1 Mass Flow and Temperature Distribution in a Single-Screw Extruder The Theory of Mass Flow and Temperature Distribution Residence Time Distribution of the Material in the Extruder Energy Balance 29

8 VI Contents Components of Energy Balance Total Power Input to a Screw Mass and Heat Transfer in a Twin-Screw Extruder Heat Transfer Model by Yacu Solid Conveying Section Melt Pumping Section Model by van Zuilichem 41 References 43 3 Raw Materials in the Production of Extrudates 45 and Agnieszka Wójtowicz 3.1 Introduction Structure-Forming Raw Materials and Additional Components Physical and Chemical Changes in Vegetable Raw Materials During Extrusion-Cooking Changes in Starchy Materials Changes in Protein-Rich Materials Changes in Fibers Changes in Vitamins Nutritional Value of Extrusion-Cooked Foods Concluding Remarks 60 References 60 4 Production of Breakfast Cereals 65 and Andreas Moster 4.1 Introduction Directly Extruded Breakfast Cereals Flaked Cereals Remarks on Operation 77 References 80 5 Snack Pellets Introduction Methods of Snack Pellet Manufacturing Production Stages Initial Phase Extrusion and Forming Production of Short Forms Production of Laminated, Perforated and Spatial Forms Drying, Packing and Storage Toasting or Frying Final Stage of Snack Production 88 References 89

9 Contents VII 6 Crispbread, Bread Crumbs and Baby Food Production of Crispbread Production of Bread Crumbs Production of Precooked Flour, Instant Semolina and Baby Food 94 References 97 7 Precooked Pasta 99 Agnieszka Wójtowicz 7.1 Introduction Raw Materials Used in Pasta Processing Extrusion-Cooked Pasta-Like Products Experimental Results Conclusions 115 References Processing of Full Fat Soybeans and Textured Vegetable Proteins Introduction Extrusion-Cooking of Full-Fat Soybeans and Other Protein-Rich Vegetable Materials Production of Textured Proteins and Meat Analogues 123 References Extrusion Technique in Confectionery Introduction Sweets and Candy Creams and Pastes Gums and Jellies Other Products Concluding Remarks 137 References Pet Food and Aquafeed Introduction Market Development Feed Extruders Technology Raw Materials and their Preparation Extrusion and Drying Concluding Remarks 148 References 149

10 VIII Contents 11 Expanders Introduction Design of Expanders Application Processing Concluding Remarks 157 References Extrusion-Cooking in Waste Management and Paper Pulp Processing 159 and Agnieszka Wójtowicz 12.1 Introduction Processing of Animal Waste Utilization of Non-Meat Waste of the Food Industry Extrusion in Paper Pulp Processing 163 References Process Automation 167 and Andreas Moster 13.1 Introduction Control and Automation 167 References Thermoplastic Starch 177 Marcin Mitrus and 14.1 Introduction Raw Materials Starch Plasticizers Auxiliary Substances Physical and Utility Features Crystallographic Structure Glass Transition Temperature Mechanical Properties Rheological and Viscoelastic Properties Water Absorption Production of Biodegradable Packaging Materials Protective Loose-Fill Foams Film Blowing Production of Shaped-Form Packagings Concluding Remarks 188 References 188

11 Contents IX 15 Scale-Up of Extrusion-Cooking in Single-Screw Extruders 191 Leon P.B.M. Janssen and 15.1 Introduction Basic Analysis Summary of Equations Used Kinematic Similarity Geometrical and Kinetic Similarity Motor Power and Torque Equal Average End Temperature Similar Temperature Profiles Similarity in Residence Times Guidelines for Scaling 199 References Producers of Food Extruders and Expanders 201 Index 215

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13 XI Preface Extrusion-cooking is gaining increasing popularity in the global agro-food processing industry, particularly in the food and feed sectors. In this handbook, we want to share the secrets of this relatively new technology, paying particular attention to the utilitarian aspects, namely discussing the processes associated with the production of various extrudates and describing the machinery and equipment necessary for their manufacture. There are also many comments and recommendations of a purely operational nature. A perusal of the book will give, in my view, not only information concerning the complexities of the production but also a quantum of engineering knowledge helpful in decision making for those who are considering whether or not to implement this technology in their processing plants. Being a promoter of substantial research programs in this field for many years I am 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 the latest achievements in the field, offering readers the best practical knowledge available at the time of publication. The text of the book has been developed together with invited scientists and industrial experts, whose substantial contribution has assured a high level of transferred knowledge. This handbook is intended for researchers, students, engineers and technical staff studying or working in food process engineering, food technology, chemical engineering and/or related disciplines. I do hope that the text will also be of interest for food and feed producers as well as representatives of the various industries benefitting from the processing components and semi-finished goods in the agro-food industry. L. Mościcki - Editor

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15 XIII List of Contributors Leon P.B.M. Janssen University of Groningen Department of Chemical Engineering Nijenborgh AG Groningen The Netherlands Marcin Mitrus Lublin University of Life Sciences Department of Food Process Engineering Doswiadczalna Str Lublin Poland Lublin University of Life Sciences Department of Food Process Engineering Doswiadczalna Str Lublin Poland Andreas Moster Bühler GmbH Ernst-Amme-Str Braunschweig Germany Dick J. van Zuilichem Everlaan DH Wageningen The Netherlands Agnieszka Wójtowicz Lublin University of Life Sciences Department of Food Process Engineering Doswiadczalna Str Lublin Poland