Effect Of Extrusion Process Parameters Research Articles

Effect of Process Variables and Ingredients on Controlled Protein Network Creation in High-Moisture Plant-Based Meat Alternatives.

The market has observed a rapid increase in the demand for plant-based foods as an alternative to animal meat products. Technologies such as high-moisture extrusion (HME) have the potential to develop anisotropic structures using alternative protein ingredients. This article discusses the different possible mechanisms responsible for structure formation and the effect of extrusion process parameters and outlines the recent advances in the long cooling dies (LCDs) used for meat alternative development. The role of different protein ingredients and the impact of combining them with other biopolymers were also evaluated. The underlying mechanism behind anisotropic structure formation during HME is a synergistic effect, with substantial dependence on the source of ingredients and their processing background. Formulation including proteins derived from plants, insects, animals, and microalgae with other biopolymers could pave the way to develop structured meat alternatives and fill nutritional interstices. Dynamic or rotating annular gap cooling dies operating at freely controllable shear and static annular gap dies are recent developments and assist to produce layered or fibrous structures. The complex chemical sites created during the HME of plant protein favour flavour and colour retention. This paper summarises the recent information published in the scientific literature and patents, which could further help researchers to fill the present knowledge gaps.

Development, Characterization and Sensory Evaluation of an Extruded Snack Using Fig Molasses By-Product and Corn Semolina.

The effects of extrusion process parameters on the physicochemical, pasting and technological properties of ready-to-eat snacks were evaluated. The aim was to develop fortified extruded products with fig molasses by-product powder (FMP), which is created as a result of the production of fig molasses, is not currently used in food industry, and may cause environmental problems. The feed humidity was changed to 14-17-20%, the die temperature was 140-160-180 °C and the ratio of FMP was 0-7-14% at a fixed screw speed of 325 rpm. The study showed that adding FMP to extruded products had a significant effect on colour properties, water solubility and water absorption index properties. İncreasing the FMP ratio had a significant reducing effect on dough properties of non-extruded mixtures such as peak viscosity (PV), final viscosity (FV) and setback viscosity (SB). The optimum conditions for the production of snacks were found to be 7% FMP, 155.44 °C die temperature and 14.69% humidity. It was determined that the estimated values of water absorption index (WAI) and water solubility index (WSI) for the products manufactured under ideal extrusion conditions were close to the obtained values, and that there was no significant difference between the estimated values of the other response variables and their actual values.

Effects of extrusion process parameters on cooking characteristics and physicochemical, textural, thermal, pasting, microstructure, and nutritional properties of millet‐based extruded products: A review

AbstractIn the current century, consumers are more concerned about the quality and safety of food. They are focusing more on high nutritional value, tasty, and visually appealing food items which are available at low cost. Food industries are making a consistent effort in developing such food products from nutrition‐rich ingredients such as millet using the new technology of food processing such as extrusion. Millet is rich sources of protein, fiber, antioxidants, polyphenols, and micronutrients which make it an excellent raw material for developing a variety of nutritious and value‐added extruded food products. In food industries extrusion technology is being used to develop a wide range of food products with better product quality. The study of the effects of extrusion processing parameters, namely feed moisture (FM), extruder screw speed (FM), and barrel temperature (BT), and co‐ingredients on product quality characteristics is an important concern for developing a food product with better quality. The review focuses on various studies that have been reported on the development of millet‐based extruded products. Emphasis has been given on effects of co‐ingredients and extrusion processing parameters on extruder operation parameters, namely mass flow rate, specific mechanical energy, average residence time, torque, and die pressure, and the cooking characteristics, physicochemical, pasting, textural, thermal, nutritional properties, and overall acceptability of the millet‐based extruded products. The extrusion process parameters widely influence the product characteristics. During extrusion cooking, starch gelatinization, protein denaturation, modification of lipid, Maillard reactions, and complex formation among starch, protein, and lipids lead to significant changes in chemical and physical characteristics of the extruded products. Extrusion cooking has a significant effect on the inactivation of enzymes, and reduction in anti‐nutritional factors. Extrusion processing at high BT with high FM increases the degree of starch gelatinization which leads to an increase in water absorption index and expansion of the product. An increased degree of starch gelatinization decreases the melt viscosity and thereby decreases the torque and specific mechanical energy. Proper control of extrusion conditions and proportion of co‐ingredients give a product with higher nutritional value, better texture, and better sensory characteristics with high overall consumers' acceptability.Practical ApplicationsReady‐to‐eat (RTE) snacks are in high demand among consumers in recent years, owing to their better texture quality, good sensory characteristics, and easy availability at low cost. Extruded snacks are valuable food products in terms of production, packaging, handling, transportation, storage, and shelf‐life. Food industries are highly capable of improving consumers' acceptability and nutritional value by altering the extrusion process parameters and co‐ingredients. Proper monitoring of extrusion process parameters and the proportion of co‐ingredients plays an important role in obtaining desirable characteristic properties and improving the overall acceptability of extruded snacks. The development of extruded products by the use of locally and easily available raw materials is a good practice for improving the nutritional value of the final products. Millets are highly nutritious crops containing significantly high contents of protein, vitamins, minerals, and fiber. They are also rich sources of polyphenols and antioxidants which have additional health benefits. The information provided in this review can be helpful in analyzing the effects of extrusion process parameters and co‐ingredients on characteristic properties of millet‐based food products and improving their consumers' acceptability.

On-line ATR-MIR for real-time quantification of chemistry kinetics along the barrel in extrusion-based processes

This work deals with the development and validation of an on-line infrared spectroscopic set-up for the real time quantification of the melt extrudate during reactive extrusion based processes. The arrangement consists of an infrared spectrophotometer operating in attenuated total reflectance ATR-FTIR, fitted on-line, along the extruder barrel. The setting helps understand the effects of extrusion process parameters and the reaction conversion during development of polymer blends and compound in-processing. The ATR-FTIR spectroscopic probe has been coupled along with an extruder to analyze/understand the process during operation in the MID region of the infrared spectrum. The ATR-FTIR prototype probe was calibrated and validated using off-line measurements. The probe is interfaced to the extruder through to a probe holder unit (PHU), also described herein. The on-line ATR-FTIR measurements were conducted at various locations (L/D) along the length of the extruder. Polymer blends of PP/PA6 in various compositions were investigated and reactive blend of PP-g-AA/PA6 were used to validate the on-line measurements compared to the standard off-line ATR-FTIR analysis.

Physico-chemical properties of extruded cassava-chia seed instant flour

This study evaluated the effects of extrusion process parameters and blends of chia seed and cassava flours on the nutritional and functional properties of flour blends aiming at improving the nutritive quality of cassava flour and enhancing the use of cassava in the production of extruded products. Extrusion was carried out using a single-screw extruder with constant parameters; screw compression ratio (3:1); die shape (round), die diameter (10 mm), pitch angel 45° screw, screw speed (100 rpm), and feed rate (35 rpm). The effect of feed moisture and amount of chia seed on the proximate composition, and physical and functional properties was determined using standard methods. The protein, fat and ash contents significantly (p < 0.05) increased from 2.39 to 12.23%, 0.79–11.77%, and 2.59–4.04%, respectively, with increasing chia seed incorporation. Increase in chia seed incorporation significantly (p < 0.05) increased Bulk Density (BD) of cassava from 0.45 to 0.63g/cm3 for 60% chia seed substitution ratio and 15% moisture conditioning and the Water Absorption Index (WAI) of cassava from 1.53 to 5.94% for 20% chia seed incorporation and 20% moisture conditioning, while reducing significantly the Water Solubility Index (WSI) from 55.48 to 17.48 g/g for 60% chia seed incorporation and 20% moisture conditioning. On the other hand, solubility and swelling power of the extruded flour blends varied in no particular direction with chia seed incorporation and feed moisture conditioning. The cassava-chia seeds blends exhibited potential for the production of nutritive extruded instant porridge flour (extrudate was milled to flour) with good physical and functional properties.

The effects of extrusion conditions on the properties of Amplang, a traditional fish snack in Borneo

The effects of extrusion process parameters on Amplang fish snack production are investigated in this study using a single-screw extrusion machine. The extrusion parameters are based on two factors, namely the barrel temperature (100 - 140oC) and screw speed (146 - 208 rpm). The central composite design (CCD) is used to produce thirteen experimental combinations and the effects of the extrusion parameters on the physical and functional characteristics (hardness, bulk density, expansion ratio, and water absorption and solubility indexes) of the Amplang fish extrudate were assessed as responses. The fish extrudates investigated in this study varied between 45.57 - 246.33 N (hardness), 0.09 - 0.21 g/cm3 (bulk density), 1.00 - 2.67 (expansion ratio), 2.58 - 4.01 g/g (water absorption index), and 19.25 - 29.8% (water solubility index). The bulk density, expansion ratio, water absorption index, and water solubility index were shown to be significantly (P &lt; 0.05) affected by the barrel temperature and screw speed. In conclusion, barrel temperature and screw speed can influence the physical and functional properties of extruded fish snacks and the extrusion technique demonstrated in this study can be utilised to produce Amplang fish snacks in Sabah.

Effects of extrusion process parameters on the quality properties of ready-to-eat pulse-based snacks

This research work evaluates the effect of extrusion process parameter on the quality of pulse-based ready-to-eat snacks. By applying D-optimal mixture ratios a formulation containing 41.1 g/100 g ...

Effects of Extrusion Process Parameters on a Cereal-Based Ready-to-Eat Expanded Product Formulated with Carrot Pomace

The effects of extrusion process parameters, i.e., screw speed (300–500 rpm), die temperature (120–180°C), feed moisture content (14–20%), and sample formulation (60–80% rice flour/10–30% pulse flour [red lentil]/10% carrot pomace), on the functional (bulk density [BD], expansion ratio [ER], water absorption index [WAI], and water solubility index [WSI]), physical (hardness and overall acceptability [OA]), and system (specific mechanical energy [SME]) properties of an expanded rice-based snack product were investigated. The experiments were planned using a Box-Behnken design, and the extrusion process parameters were optimized for maximum ER, WAI, and OA and minimum BD, WSI, SME, and hardness within the experimental range using response surface methodology. Analysis of variance (ANOVA) revealed the higher significant (P ≤ 0.05) effects of feed moisture content on functional properties and of die temperature on physical properties, followed by the effect of screw speed on system properties, compared with o...

Physicochemical, Phytochemical and Nutrimental Impact of Fortified Cereal Based Extrudate Snacks: Effect of Jackfruit Seed Flour Addition and Extrusion Cooking

Aim of present study was to estimate quantitative changes in nutrimental, physicochemical and phytochemical properties of rice-jackfruit seed flour blend extrudates. Rice-jackfruit seed flour blend was prepared at 70:30 proportions and was subjected to extrusion cooking. Effect of barrel temperature (140-180°C) and screw speed (100-300 rpm) on nutrimental, physicochemical (expansion, density, WSI, WAI and hardness) and phytochemical (TPC and TFC) properties were studied. Rice flour extrudate was found to have 6.63% protein and 0.17% fiber which were further increased to about 8.44 and 0.8%, respectively after addition of jackfruit seed flour at 180°C with 300 rpm. Extrusion cooking at lower barrel temperature resulted in increase in TPC and TFC. Rice- jackfruit seed flour blend extrudate at 180°C with 100 rpm resulted in highest antioxidant capacity and reducing power (208.56 µmol of TE/g and 0.26 mg of AAE/g of dry powder respectively). Practical applications: Although there is increased use of extrusion processing, but still there is no fully developed theory to predict the effects of process variables on various raw materials and their mixtures. Any change in feed composition and process variables can influence extrusion performance as well as product quality. Therefore, it is crucial to study the effect of extrusion process parameters (barrel temperature and screw speed) on extrudate characteristics. Also, the researchers, so far, tried lots of combinations for nutraceutical enrichment of extrudate snacks. To the best of our knowledge, this is first report on extrusion cooking of RF fortified with JFSF. In future, this data could be useful for food processing industries. Originality of this study demonstrates the feasibility of developing value added extrudates with improved nutrimental and nutraceutical appeal. Present study shows potential for utilization of jackfruit seed which is part of the waste generated in large quantities when the fruit is processed or consumed.

Processing–formulation–performance relationships of polypropylene/short flax fiber composites

ABSTRACTThis work is a comprehensive study of the effect of extrusion process parameters and formulation on the properties of polypropylene (PP)/short flax fiber composites. The parameters that were varied during the twin‐screw extrusion process were screw configuration, revolutions per minute (rpm), extrusion temperature, and flow rate. The effect of the feeding zone location of cellulosic fiber was also considered. This study investigates the effect of the formulation, cellulosic fiber content, the presence of a coupling agent, and of a reactive additive on composite performance. The composites were characterized in terms of morphology and microstructure, fiber length, rheological, thermal, and mechanical properties. Sensibility to humidity and recyclability were also considered. When compared with as‐received PP, the tensile strength of injection‐molded parts increased with cellulosic content by up to 40 vol %, and the tensile modulus increased 3.5 times when a combination of coupling and reactive agents was used. Exposed to controlled humidity of 50% during 1 year, these composites exhibited a very low level of humidity uptake around 0.85 wt %. The processability of these materials using a cast film line and the mechanical properties of extruded sheets are also presented. Furthermore, these materials demonstrate a good recyclability using injection molding by keeping the integrality of their mechanical properties after five reprocessing cycles. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015, 132, 41528.

Lüders effect in Al 99.7% extruded via the KoBo method

Abstract The aim was to determine the effect of extrusion process parameters of the KoBo method (initial billet temperature, extrusion rate and die oscillation frequency) on the Lüders phenomenon occurrence in aluminum wires. The material used in the experiment was 99.7% pure Al billet. The extrusion was carried out with the following parameters: extrusion ratio λ = 100, initial billet temperature in the range of 293–493 K, extrusion rate of 0.1–0.5 mm · s−1 and frequencies of 3, 5 and 8 Hz (the die oscillation angle was a constant ± 8°). Output materials were mechanically tested and examined microscopically. Based on the results it was found that: the Lüders phenomenon in aluminum wires extruded by the KoBo method appears only i) in a specific range of the extrusion force, namely 450–650 kN, ii) a specific range of, yielding strength (100–140 MPa), iii) dependent on the combination of process parameters its extent and position can vary over a product's length, iv) tests have also shown that this phenomenon has a continuous propagation nature only at the initial stage of the tensile test.

Numerical and experimental investigation of process parameters in non-isothermal forward extrusion of Ti–6Al–4V

Ti–6Al–4V is the most common Ti alloy that may be worked at supra or subtransus temperatures, conventionally or isothermally. In this article, the effect of extrusion process parameters and die geometry on the extrusion force and adiabatic temperature rise is investigated. The process is considered to be non-isothermal. The results show that the non-uniform effective strain field inside the workpiece generates more elongated grains near the surface of the extrudate. The results also indicate that the ram velocity has the highest effect on both extrusion force and adiabatic temperature rise. The study suggests that in non-isothermal extrusion of Ti–6Al–4V, die and billet temperatures have stronger effect on the extrusion force compared with the die angle. However, effect of the die angle on the adiabatic temperature rise is considerable and cannot be neglected. Effect of the billet temperature on adiabatic temperature rise is more than the effect of die angle. The simulation model and analytical results are verified by experimental investigations that shows good agreement between the corresponding results. The provided insights using the approach and the results presented in this article gives a better understanding of forward extrusion of Ti–6Al–4V material. The results can be used by the tool designers and process planners in developing the tools and the processes that gives better yield and reduces the manufacturing costs.

Effect of extrusion process parameters and pregelatinized rice flour on physicochemical properties of ready-to-eat expanded snacks.

Present study was conducted to investigate effects of pregelatinized rice flour and extrusion process parameters such as feed moisture (16-19%), die temperature (115-145°C) and screw speed (150-250rpm) on physicochemical properties of ready-to-eat expanded snacks by using co-rotating twin-screw extruder. Higher die temperature increased extrudate density and WSI but reduced die pressure, torque and expansion. Increased feed moisture content resulted in extrudates with increased density, WAI and hardness but reduced die pressure, expansion and WSI. Screw speed was found to have no significant effect on expansion and hardness of extrudates, while increase in screw speed resulted in increased WAI of extrudates and reduced torque of extrudates. Effect of pregelatinized rice flour on extrudate expansion and hardness was analysed at 16% feed moisture, 135°C die temperature and 150rpm screw speed. Use of pregelatinized rice flour increased expansion while it reduced hardness of extrudates.

Effect of Extrusion Process Parameters on Physical, Functional and Textural Properties of Broken Rice-Foxtail Millet-Maize based Extrudates

The effect of extrusion on the physical, functional and textural properties of broken rice extrudates blended with foxtail millet and maize flours of various formulations (10:80:10, 20:60:20, 30:40:30, 10:60:30 and 30:60:10) on density, true density, porosity, expansion ratio, water absorption index (WAI), water solubility index (WSI), solubility index, swelling power, colour values, hardness and fracturability by varying the parameters of feed moisture content, screw speed and barrel temperature were investigated. The density of blends ranged from 0.09 to 0.57 g/cm3 , expansion ratio (1.47-2.58), true density (40.08-559.48 kg/m3 ), porosity (22.83-38.18 per cent), WAI (3.52-7.81 g/g), WSI (0.0-6.6 per cent), swelling power (5.03-8.18 g/g) and hardness (1.91-10.44 N). It was observed that the increase in feed moisture content resulted in extrudates with a lower expansion ratio and WAI, higher density, WSI and hardness. Among the various combinations investigated the blend with broken rice (30), foxtail millet (60) and maize (10) yielded good sensory results. The results obtained from the experiments were significantly different at (P≤0.01) all combinations.

Design and experiments of extrusion die for polypropylene five-lumen micro tube

Abstracts Polymeric multi-lumen micro tube is formed by extrusion die with asymmetric flow channels. Due to the flow imbalance of polymer melts, it is difficult to design the extrusion die. In this paper, the extrusion die of a five-lumen micro tube was studied. The relationship between the structural parameters of asymmetric flow channels in right-angle extrusion die was built on the basis of flow balance of polymer melts. In the opposite direction of extrusion die channel, the lengths of the flow channels were calculated by the relationship, and the ends of the lengths were fitted. An objective function for the structural optimization of the flow channel in right-angle extrusion die was established through the fitting deviations. Then, the right-angle extrusion die for five-lumen micro tubes was designed according to the optimization results and manufactured by micro EDM machining technology. The uniform sections of extrusion products obtained by extrusion experiments with the designed and manufactured die verified the correctness of the asymmetric flow channels of extrusion die for five-lumen micro tubes. Finally, effects of extrusion process parameters on the shape accuracy of five-lumen micro tubes, evaluated by the ovality of profiles, were investigated experimentally with polypropylene as extrusion material. The optimal combination of process parameters including air injection velocity 6 ml/min, die temperature 202 °C, screw speed 16 r/min, vacuum degree of the water tank 0 and the pulling speed 10 m/min was concluded, which improved the sectional shape accuracy of the extruded micro tube by 33.6%. The ovality of outside profile, main lumen and secondary lumen in the tube section were optimized by 2.88%, 2.09% and 3.9%, respectively with the optimal combination of process parameters.

Extrusion freeforming of millimeter wave electromagnetic bandgap (EBG) structures

PurposeThe aim of this paper is to provide an easy method of extrusion freeforming to fabricate microwave electromagnetic bandgap (EBG) crystals. EBG crystals are periodic dielectric structures that can block wave propagation and generate a bandgap. These crystals can be used in high capability antennae, electromagnetic wave semiconductors, microresonators, high‐reflectivity mirrors and polarizing beam splitters.Design/methodology/approachThe effects of extrusion process parameters and paste characteristics were investigated. Finally, one‐period and two‐period woodpile EBG crystals with bandgaps in the frequency region of 90‐110 GHz were fabricated and the bandgap was measured.FindingsThe filament diameter is influenced by whether extrusion is carried out with or without a substrate and by the free fall‐distance from the nozzle. The quality of lattice structures is dependent on paste flow and properties. A ceramic paste with 60 vol. % (the fraction of ceramic powder based on solvent‐free polymer) was well suited to fabrication. The solvent content also influenced the fabrication. The experimental results show that under ∼12 per cent solvent mass fraction in the paste and relatively high extrusion ram velocity (more than 0.014 mm/s) at a pressure of 14 MPa, samples with high quality were fabricated.Originality/valueThis paper demonstrates that the rapid prototyping method of extrusion freeforming can be applied for the fabrication of EBG crystals from ceramic powders and the important factors which influence the product quality are identified.

NUMERICAL MODELLING OF EXTRUSION PROCESS IN SUPERPLASTIC FLOW RANGE

The results of numerical modeling of direct and indirect extrusion process of a model alloy of high strain-rate sensitivity at room temperature, Sn38Pb, are presented. The studies were carried out for three values of die angle, three temperatures, four ram speed values, two values of extrusion coefficient and two values of friction factor. Effect of extrusion process parameters on distribution of effective strain, effective strain rate in extruded bar and extrusion load was estimated.

Effect of Extrusion Process Parameters on the Quality of Buckwheat Flour Mixes

ABSTRACTA response surface analysis using a second‐order central composite design was used to study the effect of extrusion process parameters on the extrudate quality of three blends containing buckwheat flour. The extrudates were prepared as three blends. Blend 1 was a 55:40:5 (w/w) mix of light buckwheat flour, wheat flour, and nonfat dry milk (NFDM). Blend 2 was a 40:55:5 mix of light buckwheat flour, corn meal, and NFDM. Blend 3 was a 30:60:10 mix of light buckwheat flour, corn meal, and NFDM. The blends were processed in a twin‐screw extruder with factorial combinations of the parameters including: process temperatures of 95–150°C, dough moisture of 15–22%, and screw speeds of 260–390 rpm. The linear components alone significantly explained most of the variation of expansion index, bulk density, water absorption, and breaking strength. The greatest amount of variability was explained by process temperature for blend 1. Dough moisture accounted for the greatest amount of variation for blends 2 and 3. Maximum predicted expansion index values and high water absorption percentages were obtained at low dough moisture levels. Dough moisture and process temperatures were the most important factors predicting bulk density. Sensory evaluation of texture, color, flavor, and general acceptability scores of selected samples ranked blend 3 &gt; blend 2 &gt; blend 1. The in vitro protein digestibility values ranked blend 1 &gt; blend 2 &gt; blend 3. An increase of up to 9.5% units in the protein digestibility values was observed when compared to the nonextruded raw blends.