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Digital Re-print - September | October 2010
                The benefits of extrusion cooking



     Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom.
     All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies,
     the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of
     information published.
     ©Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form
     or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872




                             www.gfmt.co.uk                                                                                       NEXT PAGE
Extrusion              Feature             Feature               Extrusion



                                                                                                                                                        als, develop
                                                                                                                                                        products,
                                                                                                                                                        train staff
                                                                                                                                                        and produce
                                                                                                                                                        samples       for
                                                                                                                                                        test marketing in
                                                                                                                                                        conditions of complete
                                                                                                                                                        confidentiality.

                                                                                                                                                         Extruded breakfast
                                                                                                                                                         cereals – a healthy
                                                                                                                                                         option
                                                                                                                                                            Extrusion provides the
                                                                                                                                                        ability to develop a broad                                                                                                        bran and germ,

 The benefits of                                                                                                                                        spread of cereal products,                                                                                                   losing about 25




 extrusion cooking
                                                                                                                                                        and the versatility of the                                                                                          percent of a grain’s protein
                                                                                                                                                        twin-screw extrusion                                                                                       along with at least 17 key nutrients.
                                                                                                                                                        process means that new                                                                             With 48 grams of wholegrain recommended
                                                                                                                                                        products are continually                                                                           daily by the Whole Grain Council, and 32
                                                                                                                                                        being added to the portfolio.                                                                      grams in a typical serving, breakfast cereals
                                                                                                                                                            For example, breakfast cereals are the                                                         are a key part of a healthy lifestyle.
                                                                                                                                                        perfect vehicles for the nutritious whole and                                                          Multigrain products feature a combination
  Extruded ready-to-eat breakfast cereals have all the qualities today’s demanding consumers expect of a                                                multi grain servings recommended as part            Wholegrain products retain, after process-     of grains such as wheat, rye, corn, barley or
  convenience food. They offer nutrition, taste, value and variety and are instantly available. Significantly, many                                     of a healthy lifestyle. They are established    ing, all three parts of the original grain – the   rice, and offer the opportunity for cereal
  breakfast cereals also benefit from a positive reputation in health terms – a growing issue in consumer choice.                                       favourites with consumers aware of the          germ, bran and endosperm – in their original       manufacturers to develop products with an
                                                                                                                                                        implication of diet in a healthy lifestyle.     proportions: refining normally removes the         imaginative appearance featuring new tex-




T
       he convenience factor, and                    It is possible to enter the breakfast          can be extended with additional units and,
       the straightforward nature                 cereal market without the expense of mar-         using Baker Perkins’ process expertise, make      Breakfast Cereal -
       of the extrusion process, has              keting your own brands. The practice of           a range of high added-value flakes, multigrain
been key to the steady growth of the              independent cereal manufacturers supplying        flakes and filled pillows.
                                                                                                                                                      a low cost market
breakfast cereal industry in recent               supermarkets on a contract basis, or ‘co-             Co-extrusion equipment, flaking rolls,        opportunity
years. For companies considering entry            packing’ – acting as a sub-contractor to major    toasters, cereal cookers, syrup coating units,
to the market, simple, cost-effective             producers – is widely accepted.                   shredders and dryers can be added to form
                                                                                                                                                      Multi-nationals around the world
extrusion technology is a logical first              Baker Perkins has helped milling com-          versatile plants suitable for a wide range        use Baker Perkins process
production step. It is also a technol-            panies develop profitable breakfast cereal        of high-specification cereals produced in         technology to produce a vast range
                                                                                                                                                      of market leading breakfast cereal
ogy widely used by established                    businesses in a number of European markets        volume.                                           products. But it also has the
multi-nationals around the world.                 – and in another sector, supplies equipment           Typical end products include a wide           technology and expertise that is
                                                  to major UK bread bakers owned by milling         selection of filled pillows and a broad           ideally suited for a business that
                                                                                                                                                      wants to move into this market - as
    Twin-screw extrusion is a proven and          organisations.                                    range of flakes, including corn and bran          a small start up, own brand
versatile technology for cereal processing: it                                                      flakes.                                           manufacturer for instance.
is the basis for products involving corn, rice,    The Cereal Master EX concept
                                                                                                                                                      With a low capital cost start that is
bran, wheat, barley and oats. It is a straight-       Baker Perkins’ ability to extend and adapt     Innovation Centre                                totally flexible and scaleable Baker
forward process - the extruder cooks the          existing extruder based cereal lines utilising        Manufacturers from around the world           Perkins has the equipment and
                                                                                                                                                      know-how to get you started in this
ingredients using a combination of heat,          a wide choice of units, with minimal invest-      visit the company’s Food Innovation Centre        rapidly expanding market.
mechanical shear and moisture addition;           ment, is a key feature of the its service to      at Peterborough, UK, which contains a range
                                                                                                                                                      Make the most of this exciting
flavours and colours can be added either          breakfast cereal producers.                       of production and laboratory scale equip-         business opportunity....
directly into the barrel, or afterwards.              The ability to incorporate additional units   ment, including a twin-screw extruder that
                                                  into a line to extend end product capability is   can be configured for a wide range of             Call Baker Perkins today
                                                                                                                                                      +44 1733 283000 or email
 Profitable businesses                            fundamental to the decision of many manu-         products.                                         bpltd@bakerperkinsgroup.com
    Extrusion gives milling companies the         facturers to select the extrusion process – a         Customers use these facilities to develop
opportunity to widen their business strat-        modular approach to process design allows         new products and processes, produce sam-
egy by processing their own grain, adding         the system to expand as the producer’s            ples for test marketing, or conduct feasibility
significant value and escaping the confines of    business grows.                                   trials – all in a confidential environment.
commodity pricing at the mercy of influences          A Cereal Master EX line producing direct          Services include creating complete
that cannot be controlled, including weather      expanded cereals such as corn balls, multi-       product portfolios for new producers.
                                                                                                                                                      www.bakerperkinsgroup.com
and speculators.                                  grain rings, alphabet shapes, and cocoa balls     Customers can conduct equipment tri-


12 | September - october 2010                                                                                 Grain &feed millinG technoloGy            Grain
                                                                                                                                                        Grain &feed millinG technoloGy
                                                                                                                                                               feed millinG technoloGy                                                                                     September - october 2010 || 13
                                                                                                                                                                                                                                                                           September - october 2010 13
Extrusion              Feature               Feature                 Extrusion



                                                                                                                  down by design features that cut
                                                                                                                  maintenance.
                                                                                                                      An AC drive system is virtually
                                                                                                                  maintenance free, and innovative
                                                                                                                  open-frame design maximises
                                                                                                                  access for cleaning and main-
                                                                                                                  tenance. The newly introduced
                                                                                                                  splined shafts and high torque
                                                                                                                  capacity of the gearbox are
                                                                                                                  designed for optimum reliability
                                                                                                                  and durability.
                                                                                                                      Processes that require a face
                                                                                                                  cutter benefit from a new design
                                                                                                                  of this unit. Changing the cutter
                                                                                                                  blade can be achieved in 15 min-           produced, with outline definition much improved    vides accurate metering of fillings for products
                                                                                                                  utes without stopping production.          compared to previous generation equipment.         handled on the cutter-crimper. The system
                                                                                                                        The SBX extruder is par-                 The pillow-crimper can handle up to            features one pump per product stream,              More   inforMation:

                                                                                                                  ticularly easy to use, with PLC            12 lanes of product simultaneously, form-          allowing each to be adjusted independently         Keith Graham
                                                                                                                  touch-screen control, and time-            ing filled tubes into individual pillows. Easily   for precise weight control.                        Baker Perkins Ltd
tures and colours, with a beneficial nutritional    SBX twin-screw extruder                            saving automatic start and stop sequences as          interchangeable cutting roll sets allow pillows        The cutter-crimper and cream feed system       Manor Drive Paston Parkway
                                                                                                                                                                                                                                                                   Peterborough, PE4 7AP
profile.                                                The latest generation of twin-screw extrud-    standard.                                             to be made in a wide range of shapes and           were developed to process the higher out-
                                                                                                                                                                                                                                                                   United Kingdom
   Elsewhere, Baker Perkins development of         ers can produce standard, direct expanded                                                                 sizes. The pillow crimper can be retrofitted       puts now available from twin-screw extrud-          Tel: +44 1733 283469
new, modular dies has led to the introduc-         cereals such as fruit rings, corn puffs, alphabet    Co-extrusion equipment                               into lines including any make of extruder.         ers. Baker Perkins has introduced 12-stream         Fax: +44 1733 283004
tion of a range of products with a distinctive     letters, rings, cocoa curls, oat loops and crisp        Co-extrusion is a recent Baker Perkins                                                               dies with an output potential twice the previ-      Email: keith.graham@bakerperkinsgroup.com
surface texture. These consist of a number of      rice with no further processing, except sugar       innovation for the cereal industry, and                 Cream feed system                                ous maximums, maximising the robust power           Website: www.bakerperkinsgroup.com
individual strands, with a sweet centre.           coating and drying. The SBX extruder can            provides a simple, cost-effective means of               The Baker Perkins cream feed system pro-        of the latest solid-barrel extruders.
   Downstream, coating with sugar can              respond to market demand for rapid changeo-         extending a product range beyond standard         Wenger_Ad_2010_210x147mm       5/24/10     9:37 AM     Page 1
provide additional options for added-value         ver between products and has the inbuilt flex-      direct expanded cereals.
product development. These dies can be             ibility to bring new products to market quickly.        It involves the simultaneous extrusion of
retrofitted to virtually any make of extruder.          The modular barrel of the SBX Master           a cereal outer shell and a filling, and extends
                                                   enables the length of each machine to be            capability through the ability to make added-
 Shaping products                                  matched precisely to the customer’s process         value products with contrasting textures and
    Products are shaped by being forced            application, and enables extension later as         colours, with innovative flavours and fillings,                                                                    innovation is our enduring legacy.
through the die, and Baker Perkins’ ‘library’      production needs change.                            and with out of the ordinary shapes that
of shapes is continually being expanded; it             To further increase flexibility, the range     catch the eye.
                                                                                                                                                                                                                                                                        Since 1935, we've been help-
ranges from rings or squares to stars and          of end products that can be made has been               The Baker Perkins co-extrusion system
                                                                                                                                                                                                                                                                        ing customers solve problems
letters of the alphabet.                           increased by incorporating a motor and gear-        can be added to an existing twin-screw
                                                                                                                                                                                                                                                                        and capitalize on opportuni-
    Retrofitting new dies during the mid-life      box able to handle twice as much torque as          line supplied by virtually any manufacturer.                                                                                                                     ties faced by their businesses.
cycle of an extruder can freshen a product         the previous generation of extruder.                The essential elements of the system are a
portfolio with new and attractive brands.               The flexible Baker Perkins die design and      die, pillow crimper and cream feed system.                                                                                                                       Seventy-five years ago, a key
                                                   segmented agitator configuration - allow-           The fillings can be of virtually any colour or                                                                                                                   answer was a molasses mixer.
                                                   ing quick product change-over with few              flavour – creams, fruit pastes or chocolate                                                                                                                      Today, the solutions tend to
                                                   change parts - has been retained, together          praline are typical. The product range is                                                                                                                        be more technologically com-
                                                                 with the high free volume agi-        limited only by the imagination.                                                                                                                                 plex – but our founding
                                                                                                                                                                                                                                                                        pledge remains unchanged.
                                                                    tator geometry that enables
                                                                       high outputs to be achieved,     Co-extrusion die
                                                                                                                                                                                                                                                                        At Wenger, we innovate to
                                                                               even on low density         Die design is crucial in controlling shape,                                                                                                                  solve customer challenges.
                                                                                     materials such    expansion and shell structure, and providing
                                                                                       as bran and     end products of differing formulations and                                                                                                                       And then we do it again.
                                                                                         fine milled   shapes from a single extruder. Baker Perkins
                                                                                          flours.      has a modular die format, which allows
                                                                                              A new,   shapes to be altered easily and cost-effec-
                                                                                          high out-    tively by changing a product-specific insert.
                                                                                      put model
                                                                                                        Pilllow-crimper
                                                                                                                                                                                             Inventing the new original since 1935.
                                                                           has been introduced, to
                                                                   give a capacity range from 225 -         The pillow-crimper provides co-extruded
                                                                   2000kg/hour of direct expanded      pillow cereals in attractive new patterns such                       SABETHA, KANSAS               USA      785-284-2133        INFO@WENGER.COM              WWW.WENGER.COM
                                                                   product.                            as hexagons, ‘cats face’, chevrons and waves.                                         USA        BELGIUM          TAIWAN           BRASIL         CHINA      TURKEY
                                                                       Cost of ownership is driven     ‘Standard’ shapes such as squares can also be


14 | September - october 2010                                                                                    Grain &feed millinG technoloGy               Grain&feed millinG technoloGy                                                                                       September - october 2010 | 15
and Ireland to begin supply.        and an impact on energy
         “Many mills have chosen costs because more is
F                         Enzyme
   eature non-food-approved required to work the
      to use
      greases for their bearings machinery.”
      because they feel that the old-         “Taking into account
                                                                                    Eco Dry – The new
      generation H1 products didn’t product costs, quantity                     Generation of Cereal Dryers
      provide adequate component of use, and the cost of                                                                    New
                                          replacingThe arings – with
general principle that isincreasingxylanase
      protection, but true for                          be difficulty           Simple pushbutton
                          animal food which our newadding various
      pressure from to phytase.
cannot be transferred                             simply lubricant              for digital results!
      manufacturers is seeing the onreducessupplements to a ration
     Thus, when the effect of phytase      ileal    from an average
      market changing” plotted as a propor- and ascribing year the
amino acid digestibility is  explained of three times per them                  RIDA®QUICK SCAN
tion Leanne Combrinck fraction the conclu- one – our positive
       of the undigested from ISL.        to just suppliers recommen-
         “The new-generation of xylanase analysis project hasmost
sions are quite different to that     of cost dations is that in
        Figure 4). Indeed, those amino proven that many feed
(seeproducts provides even more acids instances the magnitude
which benefit under pressure than mills of spend just exam-
      protectionmost from phytase addition couldeffect on for59
are those amino acids which are present at ple, their current
      non-food-grade lubricants – in percent of energetic efficiency
high fact our Medallion Extreme™proteins which is obviously inde-
       concentrations in endogenous       budget has been assessed
                                                                                        Your benefits:
      range offers protection under a huge saving” explained
such as mucins and pepsin.                        pendent from other
                                                                                        ● Energy2: The effect of xylanase to 20 %amino
                                                                                             Figure saving potential of up on ileal
     The net effect of this conditions, phytase additives. they are
      the most severe is that when Leanne. “Plus The matrix
                                                                                            (drying maize using our continuous cooling column)
                                                                                        acid digestibility (IAAD) coefficients from 19 peer-
is present in a dietof bearings even digest- to assurephytases and
      tripling the life it improves the able values for their
                                                                                        ● gentle drying process
                                                                                    reviewed papers published between 1998 and 2009
ibility of some nutrients traditional others. xylanases they only 1),
      when compared to more than customers that (see Table
As the response shexylanase Aslargely drivenfood-grade lubricants
      favourites” to added. is well use           for example, are gener-               ● uniform drying temperatures reducing
by the digestibility of    with the to    which, while a bonus feeding diets containing hotspots Total lysine = 1.23%
      as being registered the diet NSFwhich it ally established byat                        these
                                             be enzymes independent of other feed ● minimized Digestible lysine = 1.15%
is added the efficacy for incidental willthe moment, may well
      as food grade H1 of xylanase                                                      additives            discharge of fines (canola, flax)
      contact with food, of phytase, butbecomeand measuring some response criteriaContact us. We would like to discuss= 0.08%
reduced in the presence      the range      not    mandatory in the                       such as            Undigested lysine our dryer
      of greases resist pound-out, near future so it’s conversion, bone ash, or digestibility and Phytase: 0.017% with you.
to the same extent for all nutrients.             weight gain, a case                   innovations          new developments
      provide extra protection, and of acting now andor ileal).
                                                  (total tract making                                        Xylanase: 0.024%
Theoffer a verydiminishing return a change for the better”illustration of this is in the
        law of significant reduction                  One practical
                                                                            R-Biopharm Rhône Ltd.
                                                                                                             Protease: 0.048%
     Due to upwards pressure on the price ofadded.
      in product consumption.             she     application of amino acid matrices for feed
                                                                            Block 10 Todd Campus           Using phytase, 141 945 2924 and protease
                                                                                                                 Phone: +44 (0) xylanase
many commonly used appropriate suchh e enzymesdusedi in n
         By providing feed ingredients T                                                Schmidt-Seeger GmbH +44 (0) 0.089% improvement in
                                                       M e a l l o combination. of Scotland Science Park combination = 141 945 2925
                                                                            West
                                                                                                       in        Fax:
                                                                            Acre Road, Glasgow                   info@r-biopharmrhone.com
      protection under pressure, Extreme™Taking is water an example and Eichstaetter digestible lysine (i.e. from 1.15% to 1.24%).
as corn, fat and protein sources, the use of           range lysine as                  applying Strasse www.r-biopharm.com – Germany
                                                                            Scotland G20 0XA                      49, 92339 Beilngries
      particularly where components at resistant, sopublished nutrient release values Telephone: +49In the 701-0, Fax: +49 8461 701-133 sup-
several feed additives can be, at least face real       stays in place                   for vari-
                                                                                                             8461
                                                                                                                      above example the use of
                                                                                        info@schmidt-seeger.com, www.schmidt-seeger.com
value, attractive for poultry producers. even during frequent washavailable products:
      are subjected to high load or               ous commercially                                     plier’s recommendations for lysine results in


        &&
   Grain feed millinG technoloGy
 Grain feed millinG technoloGy                                                                                         September - october 2010 | 27 | 9
                                                                                                                           September - october 2010

                                                                   mod.indd 1                                                                    06/10/2010 08:50




Grain &feed millinG technoloGy                                                                                        September - october 2010 | 17
d       R        i p o t S                |O        2    e       o G      &F     M       T
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 September                  2010                                                                    •	 See	the	full	issue
                        •	 The	benefits	
                           of	extrusion	
                           cooking                                                                  •	   Visit	the	GFMT	website
                                                                           In this issue:
                        •	 	The	influence	
                                                                   •               The law of

                                                                                                    •	   Contact	the	GFMT	Team
                           of	temperature,	
                           humidity	and	                                           diminishing
                           airflow	on	the	                                            returns:
                           grain	drying	                                         - consequences
                           process                                             for feed enzyme
                                                                                        strategy
                        •	 Cut	operating	                          •          An innovative
                           costs!                                              approach to
                        	 - Energy savings in
                           drying technology for
                           agricultural products
                                                                   •
                                                                                animal diet
                                                                                formulation
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The benefits of extrusion cooking

  • 1. Digital Re-print - September | October 2010 The benefits of extrusion cooking Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. ©Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872 www.gfmt.co.uk NEXT PAGE
  • 2. Extrusion Feature Feature Extrusion als, develop products, train staff and produce samples for test marketing in conditions of complete confidentiality. Extruded breakfast cereals – a healthy option Extrusion provides the ability to develop a broad bran and germ, The benefits of spread of cereal products, losing about 25 extrusion cooking and the versatility of the percent of a grain’s protein twin-screw extrusion along with at least 17 key nutrients. process means that new With 48 grams of wholegrain recommended products are continually daily by the Whole Grain Council, and 32 being added to the portfolio. grams in a typical serving, breakfast cereals For example, breakfast cereals are the are a key part of a healthy lifestyle. perfect vehicles for the nutritious whole and Multigrain products feature a combination Extruded ready-to-eat breakfast cereals have all the qualities today’s demanding consumers expect of a multi grain servings recommended as part Wholegrain products retain, after process- of grains such as wheat, rye, corn, barley or convenience food. They offer nutrition, taste, value and variety and are instantly available. Significantly, many of a healthy lifestyle. They are established ing, all three parts of the original grain – the rice, and offer the opportunity for cereal breakfast cereals also benefit from a positive reputation in health terms – a growing issue in consumer choice. favourites with consumers aware of the germ, bran and endosperm – in their original manufacturers to develop products with an implication of diet in a healthy lifestyle. proportions: refining normally removes the imaginative appearance featuring new tex- T he convenience factor, and It is possible to enter the breakfast can be extended with additional units and, the straightforward nature cereal market without the expense of mar- using Baker Perkins’ process expertise, make Breakfast Cereal - of the extrusion process, has keting your own brands. The practice of a range of high added-value flakes, multigrain been key to the steady growth of the independent cereal manufacturers supplying flakes and filled pillows. a low cost market breakfast cereal industry in recent supermarkets on a contract basis, or ‘co- Co-extrusion equipment, flaking rolls, opportunity years. For companies considering entry packing’ – acting as a sub-contractor to major toasters, cereal cookers, syrup coating units, to the market, simple, cost-effective producers – is widely accepted. shredders and dryers can be added to form Multi-nationals around the world extrusion technology is a logical first Baker Perkins has helped milling com- versatile plants suitable for a wide range use Baker Perkins process production step. It is also a technol- panies develop profitable breakfast cereal of high-specification cereals produced in technology to produce a vast range of market leading breakfast cereal ogy widely used by established businesses in a number of European markets volume. products. But it also has the multi-nationals around the world. – and in another sector, supplies equipment Typical end products include a wide technology and expertise that is to major UK bread bakers owned by milling selection of filled pillows and a broad ideally suited for a business that wants to move into this market - as Twin-screw extrusion is a proven and organisations. range of flakes, including corn and bran a small start up, own brand versatile technology for cereal processing: it flakes. manufacturer for instance. is the basis for products involving corn, rice, The Cereal Master EX concept With a low capital cost start that is bran, wheat, barley and oats. It is a straight- Baker Perkins’ ability to extend and adapt Innovation Centre totally flexible and scaleable Baker forward process - the extruder cooks the existing extruder based cereal lines utilising Manufacturers from around the world Perkins has the equipment and know-how to get you started in this ingredients using a combination of heat, a wide choice of units, with minimal invest- visit the company’s Food Innovation Centre rapidly expanding market. mechanical shear and moisture addition; ment, is a key feature of the its service to at Peterborough, UK, which contains a range Make the most of this exciting flavours and colours can be added either breakfast cereal producers. of production and laboratory scale equip- business opportunity.... directly into the barrel, or afterwards. The ability to incorporate additional units ment, including a twin-screw extruder that into a line to extend end product capability is can be configured for a wide range of Call Baker Perkins today +44 1733 283000 or email Profitable businesses fundamental to the decision of many manu- products. bpltd@bakerperkinsgroup.com Extrusion gives milling companies the facturers to select the extrusion process – a Customers use these facilities to develop opportunity to widen their business strat- modular approach to process design allows new products and processes, produce sam- egy by processing their own grain, adding the system to expand as the producer’s ples for test marketing, or conduct feasibility significant value and escaping the confines of business grows. trials – all in a confidential environment. commodity pricing at the mercy of influences A Cereal Master EX line producing direct Services include creating complete that cannot be controlled, including weather expanded cereals such as corn balls, multi- product portfolios for new producers. www.bakerperkinsgroup.com and speculators. grain rings, alphabet shapes, and cocoa balls Customers can conduct equipment tri- 12 | September - october 2010 Grain &feed millinG technoloGy Grain Grain &feed millinG technoloGy feed millinG technoloGy September - october 2010 || 13 September - october 2010 13
  • 3. Extrusion Feature Feature Extrusion down by design features that cut maintenance. An AC drive system is virtually maintenance free, and innovative open-frame design maximises access for cleaning and main- tenance. The newly introduced splined shafts and high torque capacity of the gearbox are designed for optimum reliability and durability. Processes that require a face cutter benefit from a new design of this unit. Changing the cutter blade can be achieved in 15 min- produced, with outline definition much improved vides accurate metering of fillings for products utes without stopping production. compared to previous generation equipment. handled on the cutter-crimper. The system The SBX extruder is par- The pillow-crimper can handle up to features one pump per product stream, More inforMation: ticularly easy to use, with PLC 12 lanes of product simultaneously, form- allowing each to be adjusted independently Keith Graham touch-screen control, and time- ing filled tubes into individual pillows. Easily for precise weight control. Baker Perkins Ltd tures and colours, with a beneficial nutritional SBX twin-screw extruder saving automatic start and stop sequences as interchangeable cutting roll sets allow pillows The cutter-crimper and cream feed system Manor Drive Paston Parkway Peterborough, PE4 7AP profile. The latest generation of twin-screw extrud- standard. to be made in a wide range of shapes and were developed to process the higher out- United Kingdom Elsewhere, Baker Perkins development of ers can produce standard, direct expanded sizes. The pillow crimper can be retrofitted puts now available from twin-screw extrud- Tel: +44 1733 283469 new, modular dies has led to the introduc- cereals such as fruit rings, corn puffs, alphabet Co-extrusion equipment into lines including any make of extruder. ers. Baker Perkins has introduced 12-stream Fax: +44 1733 283004 tion of a range of products with a distinctive letters, rings, cocoa curls, oat loops and crisp Co-extrusion is a recent Baker Perkins dies with an output potential twice the previ- Email: keith.graham@bakerperkinsgroup.com surface texture. These consist of a number of rice with no further processing, except sugar innovation for the cereal industry, and Cream feed system ous maximums, maximising the robust power Website: www.bakerperkinsgroup.com individual strands, with a sweet centre. coating and drying. The SBX extruder can provides a simple, cost-effective means of The Baker Perkins cream feed system pro- of the latest solid-barrel extruders. Downstream, coating with sugar can respond to market demand for rapid changeo- extending a product range beyond standard Wenger_Ad_2010_210x147mm 5/24/10 9:37 AM Page 1 provide additional options for added-value ver between products and has the inbuilt flex- direct expanded cereals. product development. These dies can be ibility to bring new products to market quickly. It involves the simultaneous extrusion of retrofitted to virtually any make of extruder. The modular barrel of the SBX Master a cereal outer shell and a filling, and extends enables the length of each machine to be capability through the ability to make added- Shaping products matched precisely to the customer’s process value products with contrasting textures and Products are shaped by being forced application, and enables extension later as colours, with innovative flavours and fillings, innovation is our enduring legacy. through the die, and Baker Perkins’ ‘library’ production needs change. and with out of the ordinary shapes that of shapes is continually being expanded; it To further increase flexibility, the range catch the eye. Since 1935, we've been help- ranges from rings or squares to stars and of end products that can be made has been The Baker Perkins co-extrusion system ing customers solve problems letters of the alphabet. increased by incorporating a motor and gear- can be added to an existing twin-screw and capitalize on opportuni- Retrofitting new dies during the mid-life box able to handle twice as much torque as line supplied by virtually any manufacturer. ties faced by their businesses. cycle of an extruder can freshen a product the previous generation of extruder. The essential elements of the system are a portfolio with new and attractive brands. The flexible Baker Perkins die design and die, pillow crimper and cream feed system. Seventy-five years ago, a key segmented agitator configuration - allow- The fillings can be of virtually any colour or answer was a molasses mixer. ing quick product change-over with few flavour – creams, fruit pastes or chocolate Today, the solutions tend to change parts - has been retained, together praline are typical. The product range is be more technologically com- with the high free volume agi- limited only by the imagination. plex – but our founding pledge remains unchanged. tator geometry that enables high outputs to be achieved, Co-extrusion die At Wenger, we innovate to even on low density Die design is crucial in controlling shape, solve customer challenges. materials such expansion and shell structure, and providing as bran and end products of differing formulations and And then we do it again. fine milled shapes from a single extruder. Baker Perkins flours. has a modular die format, which allows A new, shapes to be altered easily and cost-effec- high out- tively by changing a product-specific insert. put model Pilllow-crimper Inventing the new original since 1935. has been introduced, to give a capacity range from 225 - The pillow-crimper provides co-extruded 2000kg/hour of direct expanded pillow cereals in attractive new patterns such SABETHA, KANSAS USA 785-284-2133 INFO@WENGER.COM WWW.WENGER.COM product. as hexagons, ‘cats face’, chevrons and waves. USA BELGIUM TAIWAN BRASIL CHINA TURKEY Cost of ownership is driven ‘Standard’ shapes such as squares can also be 14 | September - october 2010 Grain &feed millinG technoloGy Grain&feed millinG technoloGy September - october 2010 | 15
  • 4. and Ireland to begin supply. and an impact on energy “Many mills have chosen costs because more is F Enzyme eature non-food-approved required to work the to use greases for their bearings machinery.” because they feel that the old- “Taking into account Eco Dry – The new generation H1 products didn’t product costs, quantity Generation of Cereal Dryers provide adequate component of use, and the cost of New replacingThe arings – with general principle that isincreasingxylanase protection, but true for be difficulty Simple pushbutton animal food which our newadding various pressure from to phytase. cannot be transferred simply lubricant for digital results! manufacturers is seeing the onreducessupplements to a ration Thus, when the effect of phytase ileal from an average market changing” plotted as a propor- and ascribing year the amino acid digestibility is explained of three times per them RIDA®QUICK SCAN tion Leanne Combrinck fraction the conclu- one – our positive of the undigested from ISL. to just suppliers recommen- “The new-generation of xylanase analysis project hasmost sions are quite different to that of cost dations is that in Figure 4). Indeed, those amino proven that many feed (seeproducts provides even more acids instances the magnitude which benefit under pressure than mills of spend just exam- protectionmost from phytase addition couldeffect on for59 are those amino acids which are present at ple, their current non-food-grade lubricants – in percent of energetic efficiency high fact our Medallion Extreme™proteins which is obviously inde- concentrations in endogenous budget has been assessed Your benefits: range offers protection under a huge saving” explained such as mucins and pepsin. pendent from other ● Energy2: The effect of xylanase to 20 %amino Figure saving potential of up on ileal The net effect of this conditions, phytase additives. they are the most severe is that when Leanne. “Plus The matrix (drying maize using our continuous cooling column) acid digestibility (IAAD) coefficients from 19 peer- is present in a dietof bearings even digest- to assurephytases and tripling the life it improves the able values for their ● gentle drying process reviewed papers published between 1998 and 2009 ibility of some nutrients traditional others. xylanases they only 1), when compared to more than customers that (see Table As the response shexylanase Aslargely drivenfood-grade lubricants favourites” to added. is well use for example, are gener- ● uniform drying temperatures reducing by the digestibility of with the to which, while a bonus feeding diets containing hotspots Total lysine = 1.23% as being registered the diet NSFwhich it ally established byat these be enzymes independent of other feed ● minimized Digestible lysine = 1.15% is added the efficacy for incidental willthe moment, may well as food grade H1 of xylanase additives discharge of fines (canola, flax) contact with food, of phytase, butbecomeand measuring some response criteriaContact us. We would like to discuss= 0.08% reduced in the presence the range not mandatory in the such as Undigested lysine our dryer of greases resist pound-out, near future so it’s conversion, bone ash, or digestibility and Phytase: 0.017% with you. to the same extent for all nutrients. weight gain, a case innovations new developments provide extra protection, and of acting now andor ileal). (total tract making Xylanase: 0.024% Theoffer a verydiminishing return a change for the better”illustration of this is in the law of significant reduction One practical R-Biopharm Rhône Ltd. Protease: 0.048% Due to upwards pressure on the price ofadded. in product consumption. she application of amino acid matrices for feed Block 10 Todd Campus Using phytase, 141 945 2924 and protease Phone: +44 (0) xylanase many commonly used appropriate suchh e enzymesdusedi in n By providing feed ingredients T Schmidt-Seeger GmbH +44 (0) 0.089% improvement in M e a l l o combination. of Scotland Science Park combination = 141 945 2925 West in Fax: Acre Road, Glasgow info@r-biopharmrhone.com protection under pressure, Extreme™Taking is water an example and Eichstaetter digestible lysine (i.e. from 1.15% to 1.24%). as corn, fat and protein sources, the use of range lysine as applying Strasse www.r-biopharm.com – Germany Scotland G20 0XA 49, 92339 Beilngries particularly where components at resistant, sopublished nutrient release values Telephone: +49In the 701-0, Fax: +49 8461 701-133 sup- several feed additives can be, at least face real stays in place for vari- 8461 above example the use of info@schmidt-seeger.com, www.schmidt-seeger.com value, attractive for poultry producers. even during frequent washavailable products: are subjected to high load or ous commercially plier’s recommendations for lysine results in && Grain feed millinG technoloGy Grain feed millinG technoloGy September - october 2010 | 27 | 9 September - october 2010 mod.indd 1 06/10/2010 08:50 Grain &feed millinG technoloGy September - october 2010 | 17
  • 5. d R i p o t S |O 2 e o G &F M T Content from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. m LINKS This igital e-print s art f he eptember ctober 010 dition f rain eed illing echnology agazine. Please click here to view our other publications on www.docstoc.com. September 2010 • See the full issue • The benefits of extrusion cooking • Visit the GFMT website In this issue: • The influence • The law of • Contact the GFMT Team of temperature, humidity and diminishing airflow on the returns: grain drying - consequences process for feed enzyme strategy • Cut operating • An innovative costs! approach to - Energy savings in drying technology for agricultural products • animal diet formulation Global grain & • Subscribe to GFMT feed markets A subscription magazine for the global flour & feed milling industries - first published in 1891 To purchase a paper copy of the magazine, or to subscribe to the paper edition please contact our Circulation and Subscriptions Manager on the link adove. INFORMATION FOR ADVERTISERS - CLICK HERE Article reprints All Grain & Feed Milling Tecchnology feature articles can be re-printed as a 4 or 8 page booklets (these have been used as point of sale materials, promotional materials for shows and exhibitions etc). If you are interested in getting this article re-printed please contact the GFMT team for more information on - Tel: +44 1242 267707 - Email: jamest@gfmt.co.uk or visit www.gfmt.co.uk/reprints www.gfmt.co.uk PREVIOUS PAGE