Edited by Leszek Moscicki Extrusion-Cooking Techniques Applications, Theory and Sustainability
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 Technology Volume 3: Membranes for Food Applications 2010 Hardcover ISBN: 978-3-527-31482-9 Rijk, R., Veraart, R. (eds.) Global Legislation for Food Packaging Materials 2010 Hardcover ISBN: 978-3-527-31912-1 International Food Information Service IFIS Dictionary of Food Science and Technology 2009 Hardcover ISBN: 978-1-4051-8740-4 Janssen, L., Moscicki, L. (eds.) Thermoplastic Starch A Green Material for Various Industries 2009 Hardcover ISBN: 978-3-527-32528-3 Piringer, O. G., Baner, A. L. (eds.) Plastic Packaging Interactions with Food and Pharmaceuticals 2008 Hardcover ISBN: 978-3-527-31455-3 Campbell-Platt, G. (ed.) Food Science and Technology 2009 Hardcover ISBN: 978-0-632-06421-2
Edited by Leszek Moscicki Extrusion-Cooking Techniques Applications, Theory and Sustainability
The Editor Prof. Dr. Leszek Moscicki Lublin University of Life Sci. Dept. of Food Proc. Engineer. Doswiadczalna Str. 44 20-280 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 http://dnb.d-nb.de. # 2011 WILEY-VCH Verlag & Co. KGaA, Boschstr. 12, 69469 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: 978-3-527-32888-8
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 1 1.1.1 Preparation of Raw Material 3 1.1.2 Extrusion-Cooking 4 1.1.3 Forming, Drying and Packing 5 1.2 Quality Parameters 6 1.3 Extrusion-Cooking Technique 7 1.3.1 Historical Development 8 1.3.2 Processing of Biopolymers 10 1.3.3 Food Melting 11 1.3.4 Rheological Considerations 12 1.4 Modern Food Extruders 14 1.4.1 Single-Screw Extrusion-Cookers 14 1.4.2 Twin-Screw Extrusion-Cookers 17 1.5 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 25 2.1.1 The Theory of Mass Flow and Temperature Distribution 25 2.1.2 Residence Time Distribution of the Material in the Extruder 28 2.2 Energy Balance 29
VI Contents 2.2.1 Components of Energy Balance 29 2.2.2 Total Power Input to a Screw 30 2.3 Mass and Heat Transfer in a Twin-Screw Extruder 33 2.3.1 Heat Transfer 35 2.3.2 Model by Yacu 38 2.3.2.1 Solid Conveying Section 39 2.3.2.2 Melt Pumping Section 39 2.3.3 Model by van Zuilichem 41 References 43 3 Raw Materials in the Production of Extrudates 45 and Agnieszka Wójtowicz 3.1 Introduction 45 3.2 Structure-Forming Raw Materials and Additional Components 46 3.3 Physical and Chemical Changes in Vegetable Raw Materials During Extrusion-Cooking 50 3.3.1 Changes in Starchy Materials 51 3.3.2 Changes in Protein-Rich Materials 55 3.3.3 Changes in Fibers 56 3.3.4 Changes in Vitamins 56 3.4 Nutritional Value of Extrusion-Cooked Foods 58 3.5 Concluding Remarks 60 References 60 4 Production of Breakfast Cereals 65 and Andreas Moster 4.1 Introduction 65 4.2 Directly Extruded Breakfast Cereals 68 4.3 Flaked Cereals 68 4.4 Remarks on Operation 77 References 80 5 Snack Pellets 81 5.1 Introduction 81 5.2 Methods of Snack Pellet Manufacturing 83 5.2.1 Production Stages 83 5.2.1.1 Initial Phase 83 5.2.1.2 Extrusion and Forming 83 5.2.1.3 Production of Short Forms 85 5.2.1.4 Production of Laminated, Perforated and Spatial Forms 85 5.2.1.5 Drying, Packing and Storage 87 5.2.1.6 Toasting or Frying Final Stage of Snack Production 88 References 89
Contents VII 6 Crispbread, Bread Crumbs and Baby Food 91 6.1 Production of Crispbread 91 6.2 Production of Bread Crumbs 93 6.3 Production of Precooked Flour, Instant Semolina and Baby Food 94 References 97 7 Precooked Pasta 99 Agnieszka Wójtowicz 7.1 Introduction 99 7.2 Raw Materials Used in Pasta Processing 100 7.3 Extrusion-Cooked Pasta-Like Products 101 7.3.1 Experimental Results 102 7.4 Conclusions 115 References 115 8 Processing of Full Fat Soybeans and Textured Vegetable Proteins 119 8.1 Introduction 119 8.2 Extrusion-Cooking of Full-Fat Soybeans and Other Protein-Rich Vegetable Materials 120 8.3 Production of Textured Proteins and Meat Analogues 123 References 126 9 Extrusion Technique in Confectionery 129 9.1 Introduction 129 9.2 Sweets and Candy 130 9.3 Creams and Pastes 132 9.4 Gums and Jellies 133 9.5 Other Products 136 9.6 Concluding Remarks 137 References 137 10 Pet Food and Aquafeed 139 10.1 Introduction 139 10.2 Market Development 140 10.3 Feed Extruders 140 10.4 Technology 143 10.4.1 Raw Materials and their Preparation 144 10.4.2 Extrusion and Drying 146 10.5 Concluding Remarks 148 References 149
VIII Contents 11 Expanders 151 11.1 Introduction 151 11.2 Design of Expanders 152 11.3 Application 154 11.3.1 Processing 154 11.4 Concluding Remarks 157 References 158 12 Extrusion-Cooking in Waste Management and Paper Pulp Processing 159 and Agnieszka Wójtowicz 12.1 Introduction 159 12.2 Processing of Animal Waste 160 12.3 Utilization of Non-Meat Waste of the Food Industry 162 12.4 Extrusion in Paper Pulp Processing 163 References 165 13 Process Automation 167 and Andreas Moster 13.1 Introduction 167 13.2 Control and Automation 167 References 175 14 Thermoplastic Starch 177 Marcin Mitrus and 14.1 Introduction 177 14.2 Raw Materials 178 14.2.1 Starch 178 14.2.2 Plasticizers 178 14.2.3 Auxiliary Substances 179 14.3 Physical and Utility Features 180 14.3.1 Crystallographic Structure 180 14.3.2 Glass Transition Temperature 181 14.3.3 Mechanical Properties 182 14.3.4 Rheological and Viscoelastic Properties 183 14.3.5 Water Absorption 183 14.4 Production of Biodegradable Packaging Materials 184 14.4.1 Protective Loose-Fill Foams 184 14.4.2 Film Blowing 185 14.4.3 Production of Shaped-Form Packagings 185 14.5 Concluding Remarks 188 References 188
Contents IX 15 Scale-Up of Extrusion-Cooking in Single-Screw Extruders 191 Leon P.B.M. Janssen and 15.1 Introduction 191 15.2 Basic Analysis 193 15.3 Summary of Equations Used 194 15.4 Kinematic Similarity 195 15.5 Geometrical and Kinetic Similarity 196 15.6 Motor Power and Torque 196 15.7 Equal Average End Temperature 197 15.8 Similar Temperature Profiles 197 15.9 Similarity in Residence Times 198 15.10 Guidelines for Scaling 199 References 199 16 Producers of Food Extruders and Expanders 201 Index 215
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
XIII List of Contributors Leon P.B.M. Janssen University of Groningen Department of Chemical Engineering Nijenborgh 4 9474 AG Groningen The Netherlands Marcin Mitrus Lublin University of Life Sciences Department of Food Process Engineering Doswiadczalna Str. 44 20-280 Lublin Poland Lublin University of Life Sciences Department of Food Process Engineering Doswiadczalna Str. 44 20-280 Lublin Poland Andreas Moster Bühler GmbH Ernst-Amme-Str. 19 38114 Braunschweig Germany Dick J. van Zuilichem Everlaan 1 6705 DH Wageningen The Netherlands Agnieszka Wójtowicz Lublin University of Life Sciences Department of Food Process Engineering Doswiadczalna Str. 44 20-280 Lublin Poland