The convenience factor, and the straightforward nature of the extrusion process, has been key to the steady growth of the breakfast cereal industry in recent years. For companies considering entry to the market, simple, cost-effective extrusion technology is a logical first production step. It is also a technology widely used by established multi-nationals around the world.
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
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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
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• 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
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agricultural products
•
animal diet
formulation
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