Guy R. Extrusion Cooking - Technologies and Applications
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Extrusion cooking
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Extrusion cooking
Technologies and applications
Edited by
Robin Guy
Published by Woodhead Publishing Limited
Abington Hall, Abington
Cambridge CB1 6AH
England
www.woodhead-publishing.com
Published in North and South America by CRC Press LLC
2000 Corporate Blvd, NW
Boca Raton FL 33431
USA
First published 2001, Woodhead Publishing Limited and CRC Press LLC
ß 2001, Woodhead Publishing Limited
The authors have asserted their moral rights.
This book contains information obtained from authentic and highly regarded sources.
Reprinted material is quoted with permission, and sources are indicated. Reasonable
efforts have been made to publish reliable data and information, but the authors and
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British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.
Library of Congress Cataloging-in-Publication Data
A catalog record for this book is available from the Library of Congress.
Woodhead Publishing Limited ISBN 1 85573 559 8
CRC Press ISBN 0-8493-1207-8
CRC Press order number: WP1207
Cover design by The ColourStudio
Project managed by Macfarlane Production Services, Markyate, Hertfordshire
(macfarl@aol.com)
Typeset by MHL Typesetting Limited, Coventry, Warwickshire
Printed by TJ International, Padstow, Cornwall, England
List of contributors ..................................................... ix
1 Introduction ...................................................... 1
R. Guy, Campden and Chorleywood Food Research Association,
Chipping Campden
Part I General influences on quality ................................. 3
2 Raw materials for extrusion cooking ............................ 5
R. Guy, Campden and Chorleywood Food Research Association,
Chipping Campden
2.1 Introduction . . ................................................ 5
2.2 Examples from Group 1: structure-forming materials based
on starch . . . . . ................................................ 11
2.3 Examples from Group 1: structure-forming materials based
on protein . . . . ................................................ 20
2.4 Examples from Group 2: dispersed-phase filling materials . . . 21
2.5 Examples from Group 3: ingredients that act as plasticisers
and lubricants ................................................ 22
2.6 Examples from Group 4: soluble solids . . . . . ................. 24
2.7 Examples from Group 5: nucleating substances . . . . .......... 25
2.8 Examples from Group 6: colouring substances . . . . . .......... 25
2.9 Examples from Group 7: flavouring substances . . . . .......... 26
2.10 References . . . ................................................ 27
Contents
3 Selecting the right extruder ..................................... 29
M. N. Riaz, Texas A&M University, College Station
3.1 Introduction and terminology . . . ............................. 29
3.2 Function and advantages of extruder technology . . . . . . . ..... 29
3.3 Selecting an extruder . . . . .................................... 30
3.4 General design features . . .................................... 31
3.5 Segmented screw/barrel single-scr ew ‘wet’ extruders . . . ..... 32
3.6 Dry extruders . . . . . ........................................... 36
3.7 Interrupted flight extruders . . . . . ............................. 38
3.8 Twin-screw extruder . . . . . .................................... 42
3.9 Single- vs. twin-screw extruder . ............................. 46
3.10 Sources of further information and recommended reading . . . 48
3.11 References . . . . . . . . ........................................... 49
4 Optimised thermal performance in extru sion ................... 51
J. Mottaz and L. Bruyas, Clextral, Firminy
4.1 Introduction . . . . . . ........................................... 51
4.2 Heat transfer in extrusion processing . . ...................... 52
4.3 Experimental analysis . . . .................................... 58
4.4 Thermal modelling . . . . . . .................................... 67
4.5 Sizing an extruder and future trends . . . ...................... 73
4.6 Conclusions . . . . . . . ........................................... 77
4.7 Acknowledgements . . . . . . .................................... 78
4.8 References . . . . . . . . ........................................... 78
5 Effective process control ......................................... 83
C. J. Chessari and J. N. Sellahewa, Food Science Australia, North Ryde
5.1 Introduction . . . . . . ........................................... 83
5.2 Product requirements . . . . .................................... 88
5.3 Key control points in meeting product requirements . . . . ..... 90
5.4 Instrumentation . . . ........................................... 93
5.5 Process monitoring . . . . . . .................................... 97
5.6 Process control in action . .................................... 100
5.7 Summary . . . . . . . . . ........................................... 104
5.8 Sources of further information and advice . . . . ............... 105
5.9 References . . . . . . . . ........................................... 105
6 Extrusion and nutritional quality ............................... 108
M. E. Camire, University of Maine
6.1 Introduction . . . . . . ........................................... 108
6.2 Macronutri ents . . . . ........................................... 110
6.3 Vitamins ..................................................... 116
6.4 Minerals ..................................................... 118
6.5 Non-nutrient healthful components of foods . . ............... 119
6.6 Future trends . . . . . ........................................... 120
vi Contents
6.7 Sources of further information and advice . . ................. 121
6.8 References and further reading ............................... 122
Part II Specific extruded products ................................... 131
7 Breakfast cereals ................................................. 133
J-M. Bouvier, Clextral, Firminy
7.1 Introduction . . ................................................ 133
7.2 The range of products . . ...................................... 136
7.3 Key process issues of the product range . . . . ................. 139
7.4 Main unit operations and technologies . . . . . . ................. 146
7.5 Future trends . ................................................ 159
7.6 Sources of further information and advice . . ................. 159
7.7 References . . . ................................................ 160
8 Snack foods ....................................................... 161
R. Guy, Campden and Chorleywood Food Research Association,
Chipping Campden
8.1 Introduction . . ................................................ 161
8.2 Formed dough products: potato . . . . . . ........................ 166
8.3 Formed dough products: maize and other materials .......... 169
8.4 Half-product or pellet snacks . ............................... 170
8.5 Directly expanded snacks . . . . . ............................... 173
8.6 Co-extruded snacks . . . . ...................................... 177
8.7 Future snack processes . ...................................... 180
8.8 References . . . ................................................ 181
9 Baby foods ........................................................ 182
M. Kazemzadeh, Buh ler Inc., Bloomington
9.1 Introduction . . ................................................ 182
9.2 Traditional batch processing . . ............................... 183
9.3 Extrusion system for baby foods . . . . . ........................ 184
9.4 The market for baby foods . . . . ............................... 193
9.5 Baby food products . . . . . ...................................... 194
9.6 Processing benefits of twin-screw extrusion . ................. 196
9.7 Socio-economical future of baby food production . .......... 197
9.8 Conclusion . . . ................................................ 198
9.9 References . . . ................................................ 198
Index . . . . ....................................................... 200
Contents vii
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Chapter 1, 2 and 8
Dr Robin Guy
Campden and Chorleywood Food
Research Association
Chipping Campden
Glos GL55 6LD
Tel: +44 (0)1386 842136
Fax: +44 (0)1386 842100
E-mail: r.guy@campden.co.uk
Chapter 3
Professor Mian N. Riaz
Head – Extrusion Technology
Program
Food Protein R & D Center
Texas A&M University
College Station
TX 77843-2476
USA
Tel: (1) 979 845 2774
Fax: (1) 979 845 2744
E-mail: mnriaz@tamu.edu
Chapter 4
Dr Je´ro
ˆ
me Mottaz
Clextral
B.P.10 – ZI de Chazeau
F-42702 Firminy Cedex
France
Tel: +33 (0) 4 77 40 31 31
Fax: +33 (0) 4 77 40 31 00
E-mail: clextralig@aol.com
Chapter 5
Dr Jay Sellahewa
Food Engineering Group
Food Science Australia
PO Box 52
North Ryde
NSW 1670
Australia
Fax: +61(0) 2 9490 8310
E-mail: Jay.Sellahewa@foodscience.
afisc.csiro.au
Contributors