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Food extruder REF-45
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Extruders and food equipment > Food extruders
REF-45 food extruder with grooved cylinder and cutting at the head

REF-45 food extruder with grooved cylinder and cutting at the head

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REF-45 food extruder with grooved cylinder and cutting at the head
REF-45 food extruder with grooved cylinder and cutting at the head
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Food extruder REF-45

Extruded food products have gained popularity among consumers as a way to consume nutrient-dense foods. Consumers want different ways to increase the amount of protein in their diet. Thus, there is a need for new high-protein food products to meet the growing consumer demand for protein. The development of products based on the extrusion of vegetable proteins helps in the creation of various food products. The REF 45 mm-Food single-screw extruders for food extrusion Zamak Mercator are perfect for conducting research on the extrusion of vegetable proteins. The use of a grooved extruder cylinder made of stainless or acid-proof steel ensures an appropriate level of cleanliness. High torques of the screws ensure the ability to process highly resistant products and expand the possibilities of conducting research. The equipment necessary to conduct food research is a water-cooled and heated matrix. The extruder enables research on the production of food, including gluten-free food, pasta, instant products, instant porridges and gruels, fodder, and animal food. Nowadays, food producers make sure that their products are tasty, safe and convenient to use. Among the new food processing technologies, extrusion can be distinguished. The product obtained in this way is characterized by a varied texture, shape and color. The REF-45 laboratory extruder for food has been designed to conduct research or production in areas related to the possibility of using the extrusion technique in agri-food processing.
Technical data of the device
Extruder screw diameter:45 mmTemperature measurement and control for each cylinder zone and head:Yes
Grooved acid-resistant cylinder [hardened]:Yes Measurement of the torque of the extruder screws:Yes
Extruder cylinder length-1:12 L/DPressure and temperature measurement of the mixture:Yes
Cylinder extension-2:4 L/DMeasurement of the drive load:Yes
Cylinder extension-3:4 L/DRecording and archiving of measurement data and recipes:Yes
Extruder screw -1:12 L/DZonal heating system, cooling the cylinder:Yes
Extruder screw -2:16 L/DProfessional geared motors:Yes
Extruder screw -3:20 L/DEasy change of the length of the plasticizing system:Yes
Cylinder heating - 1 electric / air cooling:Yes Professional wedge closure:Yes
Cylinder 1 and 2 - water thermostating:Yes Water heating and cooling units up to 150 ℃:Yes
Maximum torque per extruder screw:1300 NmHeating and cooling units programmed from the touch screen:Yes
Maximum rotation of the extruder screws:80 obr/minReal-time PLC:Yes
Main drive power:18.5 kWHMI-Ethernet touch screen:Yes
Maximum working temperature:150 ℃Wifi and tablet control:[option]
Cutting system at the head:Yes Remote supervision and service diagnosis:[option]
Technical description

Laboratory single screw extruders for food extrusion REF 45 mm-Food.

Laboratory food extruders are small versions of production extruders. However, there are many differences between laboratory and production extruders. Laboratory food extruders are more extensively equipped with functions that allow testing many food ingredients, which makes them very versatile devices. They have functionalities that facilitate and accelerate the food testing process. Laboratory food extruders are equipped with a rich a set of precise measuring sensors.

Product scalability from labs to food production.

Laboratory food extruders are a valuable research and development tool for performing research that is ultimately to be scaled up to industrial production. In addition to preventing the use of valuable production resources, significant material cost savings can be achieved by making small batches of product. The key to applying scale of operation is the flexibility of laboratory extruders for extruding products Versatile lab extruder allows you to test and modify processes for best results before scaling up to production.

A key factor in successful scaling is ensuring that food products have exactly the same experience on production equipment as they do on lab food extrusion lines Zamak Mercator lab extruders are fully customizable and can be equipped with specialized process control instrumentation to continuously measure and record parameters in order to accurately reproduce the food extrusion processThe technical parameters of food extruders are highCompact and versatile, and at the same time stable and precise, Zamak Mercator laboratory extruders turn out to be a very profitable investment in equipment intended for research.

Zamak Mercator is a manufacturer of laboratory twin-screw extruders for food with screw diameters: 45 mm or other on request

Factors affecting food extrusion using single-screw extruders.

Food extruders have a very long history, and meat extruders were used to make sausages as far back as the 1870s. In the 1930s, dry pasta and breakfast cereals were massively extruded, and many bakeries also started using extruders for food production. Since then, food extrusion technology has crept into the everyday kitchen appliances such as herb and coffee grinders, meat grinders and pasta machines.

The beneficial properties of the food extrusion process lead to consistent and repeatable quality, uniformity and efficiency in the mass production of food products. Food can be profiled into cooked or cold-formed products or semi-finished products of any size, color, shape and consistency.
Starchy foods extrude well, such as pasta, breads, cereals, snacks and candy The food extruder mixes the ingredients evenly, utilizing the heat generated by the friction of the process, as well as additional heating during cooking, before passing the material through the die to form the product final.
Reactions and changes in the state of the food material in the extruder plasticizing system and at the die face contribute to different food processing results Some foods, such as cereals and snack chips, are formed using rapid expansion or swelling that occurs when the material is released by the matrix into the environment.

Custom-made extrusion dies can impart additional properties to the final product, for example, a long die gives vegetable protein the fibrous appearance of real meat, or bronze casting gives pasta a rougher surface for better sauce retention.
As with any extrusion process, the determining factors are material composition and flow properties, screw speed, barrel length, temperature, pressure, humidity, die shape and product cutting speed, all of which must be closely monitored and controlled to ensure that the final food product has required features of appearance, touch and taste.
Most extruder food production takes place at fairly low humidity levels, i.e. below 40%, as moisture reduces the viscosity of the mix and plasticizes the processed material. The increased density of the wet mix lowers the torque and lowers the die pressure.Wet extrusion requires feeding and mixing in a twin screw extruder and requires better process temperature control.

Another factor affecting the texture of the final products is the salt content, which affects the product's aeration and consequent expansion after extrusion Salt also affects the color of the food as the resulting water absorption affects the browning ability of the material However, it is a useful carrier that helps distribute colors evenly and flavors throughout the product.

Division of food extruders into single-screw and twin-screw extruders.

Textured proteins can be processed in single and twin screw extruders There are differences between the two designs Single screw extruders are machines that have produced and continue to produce the world's largest tonnage of textured soy protein products For textured proteins, the limiting factor in the use of single screw extruders is the ability to use a narrow range of raw materials Their use requires good uniform ingredients.
The plasticizing system of the twin-screw extruder consists of two cooperating, interlocking, self-cleaning sets of screws. The screws are divided into segments, thanks to which their arrangement can be modified, thus affecting the processing properties of the extruder to a large extent. more positive product pick-up characteristics compared to a single auger As a result, the twin auger design allows for a greater variety of product processing.

Generally speaking, food extruders can be divided into single screw and twin screw extruders. Raw materials with high coefficient of friction, such as corn grits, rice cones, whole grains, extrude well in single screw extruders. For this reason, they are widely used to extrude snacks and breakfast cereals.
Twin screw extruders are classified as co-rotating and counter-rotating depending on the relative motion of the extruder screws relative to each other.
Co-rotating twin-screw extruders offer better conveying, mixing than single-screw extruders. Compared to a counter-rotating twin-screw extruder, a co-rotating extruder can run at much higher rotational speeds, thus providing higher throughput and better mixing.

The die is a key element in the design of the extruderThe die area is the section of the extruder that occurs after the food material leaves the extruder barrelThe die is usually made up of three parts, which are the transition, distribution and die plate sections When the dough leaves the die, the temperature and pressure drop rapidly and the product it expands when released into the environment.

Food extruder die and food product expansion.

The die is one of the main components of the extruder configuration The die allows the extruded dough to expand rapidly into various shapes and sizes depending on the configuration of the die section Understanding the material properties and flow pattern of the extruder die is fundamental in controlling extruder performance, shape and product quality.
It has been observed that the die entry pressure drop for a viscoelastic fluid is much greater than the entry pressure for a Newtonian fluid of nearly the same viscosity. The inlet pressure drop of the extruder dies increases with the decrease of the extruder barrel diameter ratio. matrix.These factors are very important in the design of food extruder dies.

Process conditions combined with die parameters can have a significant impact on extrusion quality The die diameter and length play a very important role in the extrusion process The flow rate decreases proportionally as the length of the die is increased Typically when cooking with extrusion, reducing the size of the die opening increases the pressure in the die The role of the die in defining texture in extruded products is often overlooked and underestimated The shape of the die will affect the shape and texture of the finished item Tapered die opening will create a smoother surface of the product and cause less mechanical damage to the extruded ingredients A die insert with a sudden change in cross-section and short length will cause more mechanical damage to food ingredients and a finer cellular structureThe shear environment of laminar flow through the matrix influences the textureHigher shear rate matrices have the potential to influence the texture more The product's high shear rate in the matrix causes more shear damage and reduces molecular size, creating softer products with smaller pores, increased solubility and lower mechanical strength. The matrix can also greatly affect textured soy protein.

Important features of single screw food extruders:

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We have made every effort to ensure that the information about our products is factually correct. Please treat the technical data of the devices as indicative, because we constantly improve our products, adapting them to changing technologies. The presented offer is informative and does not constitute an offer within the meaning of the Civil Code

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