Extrusion Processing Conditions Research Articles

Application of genetic algorithm to optimize extrusion condition for soy-based meat analogue texturization.

The aim of this study was to find the optimum extrusion process conditions for texturized soybean meal as a meat analogue for food formulations using genetic algorithm. The defatted soybean meal was replaced with whole soybean meal at 10% and extruded in the temperature range of 150-200°C, screw speed of 270-300rpm and 20-25% feed moisture content based on the Box-Behnken design. The barrel temperature effect was markedly greater than those of the feed moisture content and screw speed on the product functional properties and appearance. Higher temperatures led to a higher rehydration capacity, water and oil absorption capacity, however, it had a negative effect on the product brightness. It was found that the extrusion at lower moisture content improved soy protein functionality. Genetic algorithm technique was applied to find the best process conditions. The optimized process conditions were found to be the temperature of 198.8°C, screw speed of 291rpm and feed moisture content of 20.2%. Overall, the whole soybean treatment was applicable to overcome the oil separation issue during extrusion and the process was optimized to produce texturized soy protein with the maximum attainable functionality.

Optimization of hot melt extrusion parameters for sphericity and hardness of polymeric face-cut pellets

The aim of this study was to formulate face-cut, melt-extruded pellets, and to optimize hot melt process parameters to obtain maximized sphericity and hardness by utilizing Soluplus® as a polymeric carrier and carbamazepine (CBZ) as a model drug. Thermal gravimetric analysis (TGA) was used to detect thermal stability of CBZ. The Box–Behnken design for response surface methodology was developed using three factors, processing temperature ( °C), feeding rate (%), and screw speed (rpm), which resulted in 17 experimental runs. The influence of these factors on pellet sphericity and mechanical characteristics was assessed and evaluated for each experimental run. Pellets with optimal sphericity and mechanical properties were chosen for further characterization. This included differential scanning calorimetry, drug release, hardness friability index (HFI), flowability, bulk density, tapped density, Carr’s index, and fourier transform infrared radiation (FTIR) spectroscopy. TGA data showed no drug degradation upon heating to 190 °C. Hot melt extrusion processing conditions were found to have a significant effect on the pellet shape and hardness profile. Pellets with maximum sphericity and hardness exhibited no crystalline peak after extrusion. The rate of drug release was affected mainly by pellet size, where smaller pellets released the drug faster. All optimized formulations were found to be of superior hardness and not friable. The flow properties of optimized pellets were excellent with high bulk and tapped density.

Rheological study of copovidone and solid dispersion blend used for hot melt extrusion

ABSTRACTThe focus of this work is to generate rheological parameters using AR 2000EX rheometer for PVP VA64 and Compound A – PVP VA64 blend at different temperatures, which can then be subsequently used to identify hot melt extrusion process conditions. Addition of Compound A to the neat PVP VA64 shows a drop in storage modulus and loss modulus as compared to the neat PVP VA64. It appears that Compound A is acting as a plasticizer by increasing the separation of the polymer chains and thus results in reduction of viscosity of Compound A blends compared to polymer only samples. For both systems, based on low standard error of fit, Cross model was chosen as the best fit for the rheological data and temperature dependency of viscosity was assessed by Williams–Landel–Ferry (WLF) model. This approach can be applied to screen formulations with new chemical entities (NCEs) and generate rheological information with various extruding polymers at fixed/variable drug loading in polymer matrix to determine suitability for hot melt extrusion process and appropriate temperature for conducting hot melt extrusion. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016, 133, 43278.

To investigate the Effect of extrusion process conditions on the functional characteristics of expanded products Based on corn- almond

In recent years, the demand for snacks with optimal functional and nutritional properties has a dramatic increased; hence researching in this regard is considered as an essential task. Almond, is one of the nuts kernel and an important source of nutrients, especially fats, fiber, antioxidants, vitamins and minerals such as iron and calcium. Using this seeds nut in expanded products not only improves the nutritional properties but also it causes to produce a product with optimal functional features. As the screw rate and humidity level have a great effect on the properties of extruded products. In this study, defatted almond flour –corn flour blends (20 - 80) were extruded in a co-rotating twin-screw extruder. Response surface methodology using a central composite design was used to evaluate the effects of independent variables, namely screw rate (120–220 rpm) and humidity level (12–16%) on functional properties (water absorption index, water solubility index and oil absorption index). Based on the process optimization maximum water absorption is 6.54085, water solubility is 25.6472 and oil absorption is 3.09778 that was belong to the production of screw rate 209.17 rpm and the 14% humidity.

Design of a process material independent conical coat-hanger die by analytical approach

An analytical approach is applied in order to optimize the geometric parameters of conical coat-hanger dies in the current study. Then, a conical coat-hanger die performance of which is independent from extrusion process material and process conditions (flow rate and temperature) based on flow balance at the die exit was designed by use of this analytical method. The performance of designed conical coat-hanger die was evaluated by Computational Fluid Dynamics (CFD) analyses. Various values of the power law indices were used in viscosity model in order to test the die performance in terms of process material rheology. The CFD analyses validated the efficiency of the analytical method. The velocity distributions are satisfactorily uniform at the exit of the designed coat-hanger die for materials of different power-law indices.

Impact of extrusion processing conditions on lipid peroxidation and storage stability of full-fat flaxseed meal.

BackgroundThe full-fat flaxseed (Linum usitatissimum L.) meal has obtained relatively new flourished concept as food or feedstuff for the development of healthier products. It provides favorable balance of polyunsaturated, monounsaturated and saturated fatty acids. However, flaxseed meal may be susceptible to oxidation by exposure to various storage conditions which is extremely undesirable and produces toxic compounds to human health. Another consideration in the application of flaxseed meal relates to the presence of anti-nutritional compounds that need to be minimized using appropriate processing method. The present research work was conducted to evaluate the impact of extrusion processing conditions and storage of full-fat flaxseed meal on functional characteristics such as α-linolenic acid content, lipid peroxidation and sensory attributes.MethodsThe raw flaxseed meal was analyzed for cyanogenic glycosides, tannin and mucilage anti-nutritional compounds. Fatty acids composition was quantified by gas chromatography. The meal was extruded at barrel exit temperature (100–140 °C), screw speed (50–150 rpm), feed rate (30–90 kg/h) and feed moisture (10–30 %) for reduction of anti-nutritional compounds. The raw and extruded meals were stored for a ninety-day period under room conditions (20–25 °C). Lipid peroxidation was analyzed by peroxide, free fatty acids, conjugated dienes, total volatiles and malondialdehyde assay. Color, aroma and overall acceptability attributes were evaluated by sensory multiple comparison tests.ResultsThe raw flaxseed meal possessed significant amount of anti-nutritional compounds, lipid and α-linolenic acid contents. The extrusion processing at high barrel exit temperature (140 °C) significantly reduced the cyanogenic compounds (84 %), tannin (73 %) and mucilage (27 %) in the flaxseed meal. The α-linolenic acid content and lipid peroxidation did not significantly change after extrusion processing or during storage at the end of 60 days. Fluctuations in sensory attributes occurred during storage, but at the end of 90 days, only the extruded samples presented negative effect and showed lowest consumer acceptability.ConclusionsThe present study suggested that extrusion of flaxseed meal at optimum conditions and stored for 60 days did not change the stability of full-fat flaxseed meal and can be used as supplement or ingredient for the production of various healthier products.

Polyamide‐6 composites reinforced with cellulose fibers and fabricated by extrusion: Effect of fiber bleaching on mechanical properties and stability

We prepared polyamide‐6 (PA‐6) composites using bleached and semibleached cellulose fibers from Eucalyptus species by processing in a corotating interpenetrating twin‐screw extruder. PA‐6 is a challenging matrix because of its high processing temperature, which overlaps the thermodegradation temperature of the fibers. The selection of the processing conditions for extrusion and the use of the lubricant ethylene bis (stearamide) permitted the production of composites with 20, 30, and 40 wt% of bleached fibers, which are lighter than the corresponding glass fiber composites. Composites with 30 wt% of bleached fibers yield the best mechanical properties and good fiber/matrix interaction, as demonstrated by mechanical tests and scanning electron microscopy. X‐ray photoelectron spectroscopy studies showed that the natural moisture in the fibers promotes the fiber/matrix interaction through the formation of ester bonds. We assessed the effect caused by the presence of lignin in the fibers. Composites containing 30 wt% of semibleached fibers maintained the flexural properties and showed small improvements in thermal stability when compared with bleached fiber composites; however, there is a slight decrease in the tensile properties. Through accelerated aging tests, we observed that increased lignin concentration in the fibers reduced the formation of carbonyl compounds on sample surfaces, indicating a stabilization effect. POLYM. COMPOS., 38:299–308, 2017. © 2015 Society of Plastics Engineers

Investigation of Naturally Occurring Fumonisin B1 and Glycated Fumonisin B1 in Korean Feedstuffs

Mycotoxins are potentially dangerous contaminants of livestock feeds. In this study, we measured the levels of fumonisin B1 and glycated fumonisin B1 in feedstuffs and then investigated the ability of the extrusion heating regimen to convert the most prevalent mycotoxin contaminant, fumonisin B1, to a less toxic glycated form. All feed samples were analyzed with fully validated methods. All measured concentrations of fumonisin B1 were below harmful thresholds, including European Union-recommended levels or US Food and Drug Administration action levels. Because fumonisin B1 was highly contaminated mycotoxin in our present investigation and fumonisin B1 has been shown to be less toxic following Maillard type reaction with reducing sugar, we examined the formation of fumonisin B1 derivatives by Maillard reaction under extrusion process conditions. We employed a variety of tandem mass spectrometric methodologies to selectively detect fumonisin B1 derivatives and to elucidate their structures partially. We found that compounds of m/z 736 were more likely artifacts or side reaction products rather than glycation products. N-(carboxymethyl) fumonisin B1 of m/z 780 and other major glycation products of m/z 794 and 810 were not detected, and only negligible amounts of methylene fumonisin B1 was found in 10 extruded feed samples. Therefore, either the tested extrusion conditions did not induce fumonisin B1 glycation or the glycation products simply could not be detected by the method employed in this study.

A Comparative Study of the Effects of Non-starch Polysaccharide Gums on Physical Properties of Single-screw Extruded Aquafeed

A factorial experimental design (5×3×2) was used to investigate the effects of non-starch polysaccharide binding agents on physical properties of single-screw extrusion. Extrusion cooking trials were performed with an ingredient blend for yellow perch, fortified with five non-starch polysaccharide binding agents including three plant-origin gums (guar, wheat gluten, carboxymethyl cellulose (CMC)) and two microbial-origin exopolysaccharide gums (xanthan and pullulan), with three levels of gum inclusion (3, 6, and 10%), and two levels of screw speed (100 and 150 rpm). Effects of the independent variables on extrudate characteristics were extensively analyzed and included density, expansion ratio, water absorption and solubility indices, pellet durability, and color. Increasing gum level from 3 to 10% led to a considerable increase in unit density of extrudates for xanthan, guar, wheat gluten, CMC, and pullulan by 39.6%, 21%, 11.4%, 30%, and 19.7%, respectively. The minimum (357 kg m-3) and maximum (607 kg m-3) bulk densities were observed for the diets produced with 6% guar at 150 rpm and 10% xanthan at 100 rpm, respectively. The mean values of expansion ratio for the diets containing exopolysaccharide gums were slightly smaller than those of the other diets. Increasing gum inclusion level increased the expansion ratio of the extrudates using xanthan, wheat gluten and pullulan but reduced the expandability of diets used guar gum; increased levels did not change the expansion ratio of extrudates containing CMC. At the highest levels of gum inclusion and screw speed, both pullulan and wheat gluten gums provided better expandability of the feed extrudate. Exopolysaccharide gums resulted in extrudates with significantly higher pellet durability and water solubility indices. Overall, the addition of 6 to 10% non-starch exopolysaccharides could improve the pellet durability of aqua feed extrudates. A future study investigating the effects of feed composition and additional extrusion processing conditions on the physical parameters of these products in aquafeeds would be appropriate.

Optimization of Extrusion Process Parameters for Red Lentil-carrot Pomace Incorporated Ready-to-eat Expanded Product Using Response Surface

For optimization of extrusion process for development of red lentil-carrot pomace incorporated ready- to-eat rice based expanded product, experiments were planned in Box-Behnken design using response surface methodology. The independent process variables for extrusion were feed moisture content (14-20%), die temperature (120-180℃), screw speed (300-500 rpm) and formulation (rice flour: pulse flour; 60-80%: 10-30%) with constant proportion of carrot pomace powder (10%). Second order polynomials were used to model the extruder responses, functional and physical properties as a function of extrusion process variables. The extrusion process was optimized for maximum expansion ratio, water absorption index, overall acceptability and minimum bulk density, water solubility index, specific mechanical energy and hardness with in experimental range. The optimum extrusion process conditions obtained were 80:10:10 (rice flour: pulse flour: carrot pomace powder), 14% feed moisture content, 394 rpm screw speed and 120℃ die temperature. An analysis of variance (ANOVA) revealed that among the process variables, feed moisture content followed by screw speed had the most significant effect on all the responses; screw speed had the significantly higher effect on specific mechanical energy. The proportion of red lentil and carrot pomace in rice based expanded product was observed to have significantly lower effect on the selected responses.

Effect of carbamazepine on viscoelastic properties and hot melt extrudability of Soluplus®

The purpose of this study was to apply viscoelastic properties of polymer and drug-polymer mixtures to determine processing conditions for the preparation of amorphous solid dispersion by melt extrusion. A poorly water-soluble drug, carbamazepine (CBZ), was mixed with Soluplus® as the carrier. Torque analysis using a melt extruder was performed at 10, 20 and 30% w/w drug concentrations and the effect of barrel temperature was studied. Viscosity of the mixtures either at fixed temperatures with different angular frequencies or as a function of temperature with the same frequency was studied using a rheometer. The viscosity of Soluplus® and the torque exerted on the twin screws decreased with the increase in CBZ concentration. The viscosity versus temperature plots for different CBZ concentrations were parallel to each other, without the drug melting transition, indicating complete drug-polymer miscibility. Thus, the drug-polymer mixtures could be extruded at temperature as low as 140°C with 10% w/w drug load, 135°C with 20% w/w drug and 125°C with 30% w/w drug, which were, respectively, ∼50°C, 55°C and 65°C below the melting point of 191°C for CBZ. The differential scanning calorimetry (DSC) and powder X-ray diffraction (XRD) analyses of the binary mixtures extruded at 125–150°C showed absence of crystalline drug. A systematic study of miscibility and extrudability of drug-polymer mixtures by rheological and torque analysis as a function of temperature will help formulators select optimal melt extrusion processing conditions to develop solid dispersions.

Reduction of scattering loss in fluoroindate glass fibers

The current fluoroindate glass optical fiber loss is dominated by extrinsic absorption and scattering loss. Attempts were made to reduce fluoroindate glass fiber loss by optimizing glass melting conditions, preform extrusion process and fiber drawing conditions. Our results show that fluorination of the glass batches (with 99.99% InF3) at 450 °C by addition of ammonium bifluoride reduced un-dissolved particles (potential scattering losses) in the glass. Glass flow analysis was carried out to provide insights into the glass temperature-viscosity behavior and the relationship between preform surface roughness and extrusion temperature, which enabled fabrication of preforms with low surface roughnesses and eventually reduced the fiber scattering loss. Fiber surface crystallization was reduced via conducting chemical etching and polishing (with colloidal silica) on both glass billets and preforms, extending the heating zone for fiber drawing, and applying additional weight at the bottom of preforms. As a consequence, the fiber surface roughness decreased, resulting in decreased fiber scattering loss and enhanced fiber strength.

Klucel™ EF and ELF polymers for immediate-release oral dosage forms prepared by melt extrusion technology

The objective of this research work was to evaluate Klucel™ hydroxypropylcellulose (HPC) EF and ELF polymers, for solubility enhancement as well as to address some of the disadvantages associated with solid dispersions. Ketoprofen (KPR), a Biopharmaceutics Classification System class II drug with poor solubility, was utilized as a model compound. Preliminary thermal studies were performed to confirm formation of a solid solution/dispersion of KPR in HPC matrix and also to establish processing conditions for hot-melt extrusion. Extrudates pelletized and filled into capsules exhibited a carrier-dependent release with ELF polymer exhibiting a faster release. Tablets compressed from milled extrudates exhibited rapid release owing to the increased surface area of the milled extrudate. Addition of mannitol (MNT) further enhanced the release by forming micro-pores and increasing the porosity of the extrudates. An optimized tablet formulation constituting KPR, MNT, and ELF in a 1:1:1 ratio exhibited 90% release in 15min similar to a commercial capsule formulation. HPC polymers are non-ionic hydrophilic polymers that undergo polymer-chain-length-dependent solubilization and can be used to enhance solubility or dissolution rate of poorly soluble drugs. Dissolution/release rate could be tailored for rapid-release applications by selecting a suitable HPC polymer and altering the final dosage form. The release obtained from pellets was carrier-dependent and not drug-dependent, and hence, such a system can be effectively utilized to address solubility or precipitation issues with poorly soluble drugs in the gastrointestinal environment.

Synthesis and characterizations of poly(ethylene-co-vinylalcohol)-grafted-poly(3-hydroxybutyrate-co-hydroxyvalerate) copolymers

Poly(ethylene-co-vinylalcohol)-grafted-poly(3-hydroxybutyrate-co-hydroxyvalerate) (EVOH-g-PHBV) was prepared by a catalyzed grafting of PHBV onto immiscible EVOH. These reactions were performed at high temperature in the molten state. The choices of Tin(II) bis(2-ethylhexanoate) (Sn(Oct)2) and 1,5,7-Triazabicyclo[4.4.0]dec-5-ene (TBD), as catalyst, were justified by a first study in an internal mixer. The catalyst quantity, reaction temperature and reaction time were optimized to apply them in the conditions of a reactive extrusion process with a co-rotating twin screw extruder. High reaction temperature, from 180 °C to 220 °C, associated to intensive mixing led to efficient grafting of PHBV onto EVOH, compatible with short residence times required.Rheological, thermal and morphological analyses were conducted to characterize the obtained copolymers. Molecular weights were determined by SEC. SEM imaging were made on cryo-fractured surfaces of blends extruded with and without catalyst. In most of reaction conditions, a compatible blend was obtained with a fine micro phase separation. Grafted copolymers were only obtained when well defined and controlled conditions are applied.

Twin-screw Extrusion Processing of Vegetable-based Protein Feeds for Yellow Perch (Perca flavescens) Containing Distillers Dried Grains, Soy Protein Concentrate, and Fermented High Protein Soybean Meal

<span style="color: #800000; font-family: Times New Roman; font-size: small;"> </span><p class="MsoNormal" style="margin: 0in 0in 4pt; line-height: 12pt; mso-line-height-rule: exactly;">Changing to alternative protein sources supports production of more economic aquafeeds. Two isocaloric (3.06 kcal/g) and isonitrogenous (40% db) experimental feeds for juvenile yellow perch were formulated with incorporation of fermented soybean meal (FSBM) and soy protein concentrate (SPC), each of which were at two levels (0 and 20% db), along with constant amounts of high protein distillers dried grains (DDG) (~30% db), and appropriate amounts of other ingredients. Using a pilot scale twin-screw extruder, feed production was performed in two replications for each diet at conditioner steam levels of 0.11 to 0.16 kg/min, extruder water of 0.11 to 0.19 kg/min, and screw speeds of 230 to 300 rpm. The effects of SPC and FSBM<ins datetime="2012-07-09T13:59" cite="mailto:k"> </ins>inclusion on extrudate physical properties were compared with those of a control diet (which contained 20% fishmeal and ~30% DDG). Inclusion of 20% FSBM and 20%SPC resulted in a substantial decrease in unit density by 9.2 and 24%, but an increase in lightness, greenness, yellowness, and expansion ratio of the extrudates by 7, 27, 14, 7, 17, 34, 15, and 16.5%, respectively. SPC inclusion led to a considerable increase in water absorption, thermal resistivity, and thermal diffusivity by 17.5, 6.3, and 17.6%, respectively, whereas no significant change was observed for these properties with incorporation of 20% FSBM. Additionally, all extruded products had high durability. Taken together, using ~30% DDG with20% FSBM or20% SPC as alternative protein sources resulted in viable extrudates with properties appropriate for yellow perch production. A future study investigating the effect of extrusion processing conditions on the production of complete vegetable-based protein feeds for yellow perch species would be appropriate.</p><span style="color: #800000; font-family: Times New Roman; font-size: small;"> </span>

Ethanol Extraction of Flavonoids from Mungbean Skin after Twin-Screw Extrusion Process

In order to increase the extraction rate of flavonoids from mungbean skin, twin-screw extrusion process was used as a pretreatment method. After optimizing conditions of twin-screw extrusion process, effects on ethanol extracting flavonoids were studied. Results revealed that the best extrusion conditions were: screw speed at 268r/min, extrusion temperature at 115~120°C, feed moisture at 17% and feeding rate at 726g/min. Under these conditions, the optimum condition for ethanol extraction of flavonoids was: using 38% ethanol solution at a material-liquid ratio of 1:20 at 77.5 °C with 2.5 h. The average extraction rate of flavonoids from mungbean skin was 3.14%, comparing to rate of un-extruded material 2.07%, extraction rate raised by 51.5%. This pretreatment can destroy the density structure of mungbean skin which has great effect on the increase of extraction rate of flavonoids.

Extrusion processing and characterization of edible starch films with different amylose contents

Various edible starch films were prepared via extrusion, with a particular focus on the effects of the amylose content of starches from the same resource (corn) on film processibility and performances. Four corn starches with different amylose contents (4.3–77.4%) were used as model materials. The effects of various extrusion processing conditions, such as temperature, screw speed, feeding rate, and water content were systematically investigated. It was found that, while a higher amylose content increased the difficulty of extrusion processing, this could be overcome by increasing the processing temperature, moisture content, and equilibration time. On the other hand, mechanical testing, differential scanning calorimetry, dynamic mechanical analysis, and microscopy showed that films based on higher amylose starch had better mechanical and thermal properties. The reasons include not only the easy entanglement of long linear amylose chains, but also the retained granular structure in high-amylose films, which may act as self-reinforcement.

Quality Attributes of Soy-pasta During Storage Period

The influence of Full Fat Soy Flour (FFSF) and different extrusion conditions on the acidity content and color characteristics of spaghetti during 7-month storage were evaluated. The spaghetti was produced by laboratory pasta maker and was dried at 50 C. Treatments were packed in polyethylene bags and were o kept in room temperature during storage. Addition of FFSF and extrusion processing conditions influenced the acidity content of spaghetti. This enrichment resulted in significant increases (p<0.05) in the acidity during storage. On the other hand, color characteristics of dry spaghetti showed significant changes after seven months of storage. So, the shelf life of this new product was lesser than traditional spaghetti.

Thermal characterisation of corn–lentil extruded snacks

The phase transitions of extruded corn–lentil snacks were investigated using different extrusion process conditions, which were feed rate (2.52–6.84 kg/h), extrusion temperature (170–230 °C) and feed moisture content (13–19% wb). Lentil flour–corn flour mixtures were used at ratios ranging from 10–50%. Extrusion temperature, feed rate and feed moisture content decreased the specific mechanical energy during extrusion cooking. The sorption isotherm at room temperature of corn–lentil snacks was described successfully by the GAB model. The glass transition temperature of extrudates (midpoint of the specific heat shift) increased with feed rate, extrusion temperature, and lentil to corn ratio. Water acts as a plasticiser on extrudates, depressing their glass transition temperature. The Gordon-Taylor equation was used for the plasticisation description and had a good fit with the experimental data. Generally, as the moisture content decreased, the sharpness of glass transition also decreased. The formation of amylose–lipid complexes was confirmed by the presence of an endothermic peak.

Thermal balance between viscous heating and inlet thermal condition in non stationary polymer flow through a cylindrical die

During the forming of polymer materials under extrusion or injection moulding process conditions, the heat source resulting from the high viscous dissipation within the flow in the die channel plays an important role on the thermal field within the polymer and the experimental device. One difficulty to simulate numerically this kind of flow, besides the accurate knowledge of the actual rheological parameters of the materials, consists in fixing the boundary conditions of the spatial domain of integration. Indeed, for non stationary conditions, they are varying both in space and time. In this paper, experimental data (temperature and flow rate) measured in a specific instrumented die are compared to the solutions predicted by a set of coupled equations which models the heat source release, the heat conduction process and the polymer flow, under non stationary conditions. This analysis leads to evaluate the thermal balance between the viscous heating and the inlet thermal condition.