SCREW CONFIGURATION EFFECTS ON STARCH BREAKDOWN DURING TWIN-SCREW EXTRUSION of RICE FLOUR

Study on the Function of Conveying, Kneading Block and Reversing Elements on the Mixing Efficiency and Dispersion Effect inside the Barrel of an Extruder with Numerical Simulation

In order to better understand the extrusion process mechanism of plant protein inside a barrel, the parameter changes and flow characteristics of fluids under conveying, kneading block and reversing elements were investigated with numerical simulation. The results showed that the shear rate increased obviously with the increase in pitch; the shear rate value of the reversing element was larger, while that of the kneading block was the opposite. The screw combinations of conveying, kneading blocks and reversing elements all have a certain degree of mixing effect on the particles, and the reduction in pitch can effectively increase the mixing effect of the particles. The conveying element can provide a relatively constant acceleration for the particles, due to the pumping capability and pressure buildup as the pitch increases. The kneading block and the reversing element can increase the leakage flow between the discs and backflow, resulting in an extension of the residence time distribution that facilitates fluid interaction in the barrel and improves the dispersion of the particles. The restraint by the reversing element on the particles is obviously weaker than that of the kneading block and shows a higher particle mixing degree. Overall, the influence of different elements on the flow condition, mixing degree and residence time is significantly different, which improves the process controllability and provides references for potential applications to meet multiple demands.

Food extrusion: An advanced process for innovation and novel product development

Extrusion is a versatile process capable of producing a variety of new and novel foods and ingredients, thus increasing manufacturing opportunities. Further, it could provide nutritious, safe, sustainable, and affordable foods, especially directed at individualized consumer needs. In addition to past research efforts, more investigations should be conducted in order to refine, redesign, or develop new extrusion processing technologies. The present review highlights the current advances made in new and novel food product development by considering the extrusion process, the influencing parameters, and product characteristics and properties; the most promising extrusion processes that can be used in novel food product and ingredient development, such as extrusion cooking, hot-melt extrusion, reactive extrusion, and extrusion-based 3D printing; the possibilities of using various raw materials in relation to process and product development; and the needs for product development modeling along with extrusion process design and modeling. In correlation with extruded product development, topics that merit further investigation may include structure formation, plant and animal biopolymers functionalization, biopolymer reactions, process simulation, modeling and control, engineering and mechanical aspects of extruders, analysis of pre-processing treatments, as well as prototyping, risk analysis, safety, sensory and consumer acceptance.

Effects of Extrusion on Starch Molecular Degradation, Order-Disorder Structural Transition and Digestibility-A Review

Extrusion is a thermomechanical technology that has been widely used in the production of various starch-based foods and can transform raw materials into edible products with unique nutritional characteristics. Starch digestibility is a crucial nutritional factor that can largely determine the human postprandial glycemic response, and frequent consumption of foods with rapid starch digestibility is related to the occurrence of type 2 diabetes. The extrusion process involves starch degradation and order-disorder structural transition, which could result in large variance in starch digestibility in these foods depending on the raw material properties and processing conditions. It provides opportunities to modify starch digestibility by selecting a desirable combination of raw food materials and extrusion settings. This review firstly introduces the application of extrusion techniques in starch-based food production, while, more importantly, it discusses the effects of extrusion on the alteration of starch structures and consequentially starch digestibility in various foods. This review contains important information to generate a new generation of foods with slow starch digestibility by the extrusion technique.

Extrusion pretreatment of lignocellulosic biomass: a review

Bioconversion of lignocellulosic biomass to bioethanol has shown environmental, economic and energetic advantages in comparison to bioethanol produced from sugar or starch. However, the pretreatment process for increasing the enzymatic accessibility and improving the digestibility of cellulose is hindered by many physical-chemical, structural and compositional factors, which make these materials difficult to be used as feedstocks for ethanol production. A wide range of pretreatment methods has been developed to alter or remove structural and compositional impediments to (enzymatic) hydrolysis over the last few decades; however, only a few of them can be used at commercial scale due to economic feasibility. This paper will give an overview of extrusion pretreatment for bioethanol production with a special focus on twin-screw extruders. An economic assessment of this pretreatment is also discussed to determine its feasibility for future industrial cellulosic ethanol plant designs.

Validation of a continuous granulation process using a twin-screw extruder

Using twin-screw granulation as particle size enlargement technique, the effect of modifying the screw configuration (number of mixing zones, configuration of kneading block) on granule quality, tablet properties and mixing efficiency was investigated. The amount of oversized agglomerates and yield was significantly influenced by the presence of an extra conveying element at the screw end. Changing the staggering angle of the kneading block significantly affected yield and granule friability. The 90 degrees configuration resulted in a lower yield and granule friability. Disintegration time was the only tablet property significantly influenced by the screw configuration as disintegration was significantly faster when an extra conveying element was placed at the screw end. The influence of tracer addition method (wet vs. dry) on mixing efficiency inside the extruder barrel was investigated by means of different tracers: riboflavin (0.05%) suspended in the granulation liquid and hydrochlorothiazide (2.5%) added separately as powder. Mixing efficiency in function of time and granule size (above and below 1400 microm) was tested using riboflavine sodium phosphate (0.05%) dissolved in the granulation liquid. Since a good mixing efficiency was obtained independent of tracer addition method, tracer solubility, granulation time and granule size, continuous granulation using a twin-screw extruder was identified as a robust process.

Extraction of sunflower oil by twin screw extruder: screw configuration and operating condition effects

The objective of this study was to investigate the screw configuration allowing oil extraction from sunflower seeds with a twin-screw extruder. Experiments were conducted using a co-rotating twin-screw extruder. Five screw profiles were examined to define the best performance (oil extraction yield, specific mechanical energy and oil quality) by studying the influence of operating conditions, barrel temperature, screw speed and feed rate. Generally, the position and spacing between two reversed screw elements affected oil extraction yield. An increase of oil extraction yield was observed as the reversed screw elements were moved with increased spacing between two elements and with smaller pitch elements. In addition, oil extraction yield increased as barrel temperature, screw speed and feed rate were decreased. Highest oil extraction yield (85%) with best cake meal quality (residual oil content lower than 13%) was obtained under operating conditions of 120 degrees C, 75 rpm and 19 kg/h. Furthermore, the operating parameters influenced energy input. A decrease in barrel temperature and feed rate followed by an increase in screw speed increased energy input, particularly specific mechanical energy input. Effect of the operating parameters on oil quality was less important. In all experiments tested, the oil quality was very good. The acid value was below 2 mg of KOH/g of oil and total phosphorus content was low, below 100 mg/kg.