UNIVERSIDAD NACIONAL DE SAN CRISTOBAL DE HUAMANGA

FACULTAD DE INGENIERIA QUIMICA Y METALURGIA

ESCUELA DE FORMACIÓN PROFESIONAL DE INGENIERIA EN INDUSTRIAS ALIMENTARIAS

PRESENTADO : SULCA MEDINA ALEJANDRO

 Extrusion
Extrude  “To push or force out a material
through an opening (Die)”
Die
Material

Applications
Breakfast cereals & snacks :
• Directly expanded cereals
• Pellet-to-flakes cereals
• Directly expanded snacks
• Snacks pellets
• Co-filled cereals
• Flat bread
 EXTRUDER APPLICATIONS

PROTEINS

• Texturized Vegetable Protein (TVP)

• Protein fibers (High Moisture Extrusion)
• Caseinates...

OTHER APPLICATIONS :
• Functional ingredients:
• Flavors, flavor encapsulation, precooked
flours, modified starches….
• Oil seed extraction
• Confectionery
FEED EXTRUSION TECHNOLOGIES

ANIMAL FEED

• Aquafeed pellets
• Dry pet food (cat & dog food)
• Pet treats
 TWIN SCREW EXTRUSION
FOR PLASTICS AND CHEMICALS

Specialty compounds
(masterbatches, composites)

Energetic materials :
Air-bags generators

Biodegradable packaging

Plastics recycling and reprocessing

Reactive extrusion
 EXTRUDERS CLASSIFICATION

Twin Screw Extruders (TSE)

Single Screw Extruders (SSE)

 BASICS OF SSE TECHNOLOGY
DESIGN AND PROCESS CHARACTERISTICS
 Screw design = single piece (constant
Feed
pitch, decreasing channel depth) or a
splined shaft that holds screw sections of
varying configuration (pitch)
PRECONDITIONER

PSSE

Transport Compression Metering Shaping

P

Axial distance, z
 BASICS OF SSE TECHNOLOGY
FLOW CHARACTERISTICS IN THE SCREW CHANNEL

Drag flow Velocity profiles in the screw channel

BARREL

SCREW

Pressure flow

FEED DIE
Down channel direction
 BASICS OF SSE TECHNOLOGY
FLOW CHARACTERISTICS IN THE SCREW CHANNEL

• The forward pitch of the screw flight conveys the materials

down the channel by developing a « DRAG FLOW », the velocity of
that flow is directly proportional to the screw speed N.
• Because of the die restriction at the extruder’s discharge, there is a
« PRESSURE FLOW », which is opposite in direction to the drag
flow. Thus, SSE Flow rate = Drag flow rate – Pressure flow rate

K dP
Q = α ⋅N − ⋅
ηa dZ
Operational flow rate is dictated by N, die pressure and melt rheological
properties: the coupling of these variables limits the operating range and
flexibility of SSEs
 BASICS OF SSE TECHNOLOGY
FLUID DYNAMICS IN THE SCREW CHANNEL

Screw channel
(unwound)

Down channel
direction

Fluidynamics in the screw channel shows that fluid

Screw channel
particles have different velocities and do not mix. That
(cross section)
leads to a distribution of residence times and poor
mixing. Consequently, heat transfer and mechanical
energy input in the cooking section are very limited.
Besides, shear rate is not uniform leading to
heterogeneous melt properties, degree of cooking,
Flow pattern in the screw
temperature, and strain, specifically
channel
 BASICS OF SSE TECHNOLOGY
EFFECT OF MELT SLIP AT THE BARREL WALL
Velocity profiles in the screw channel
BARREL

Perfect melt Melt slip

adherence

SCREW

• In SSE, melt adherence at the barrel wall is required to obtain the maximum
throughput of the extruder. Any change in the composition that generates melt
slip at the barrel would lead to decrease of the extruder throughput. Moisture,
fat, protein hydrolisates all induce slip.

• In addition melt slip at the barrel wall decreases mixing as well as the heat
transfer and shear rate (mechanical energy input).
 EXTRUDERS CLASSIFICATION
SINGLE SCREW EXTRUDERS

i. Short Barrel Single Screw “DRY” Extruders

ii. Long Barrel Single Screw “Dry” Extruders

iii. Long Barrel Single Screw “Wet” Extruders

iv. Expanders

v. Pasta Extruders
 BASICS OF COROTATING TSE
DESIGN AND PROCESS CHARACTERISTICS
• Splined shafts that hold screw sections of varying
Feed
configuration (forward pitch, reverse screw,
kneading disks…..)

Venting
PRECONDITIONER

Compression
Disks Transport Melting Degassing Shaping
Compression Shearing

P
Mixing or
Kneading Disks

Axial distance, z
 BASICS OF COROTATING TSE
FLOW CHARACTERISTICS IN THE SCREW CHANNEL

Intermeshing
zone
N

Down channel direction

• Corotating TSE works as a positive displacement pump, due to the

interpenetration of the screws. This allows to handle viscous, oily, sticky or
very wet materials, with the same level of pumping efficiency.

• Unlike SSE, the throughput of corotating TSE is, within the limits of
reasonable operation, independent of die pressure.
 EXTRUSION PROCESSING ADVANTAGES

“Raw” Cereal and other Ingredients

Unit Operations Screw pumps the material
• Feeding Inside the barrel
• Conveying Forming and
• Mixing expansion
• Shearing
• Cooking
• Forming
• Drying and Cooling Water
Cooking by Electrical, Evaporation
Steam jacketed, Induction
“magnetic” heating

Residence Time
10seconds – 1min
GLASS TRANSITION CONCEPT
Glass transition temperature oC
RUBBERY STATE
Increasing temperature

Increasing moisture

GLASSY STATE

Moisture Content (%)

 TRANSFORMATIONS OF RAW
MATERIALS DURING EXTRUSION

LIQUID
(AMORPHOUS)
TEMPERATURE

Heating
Glass Transition
Expansion
Temperature

GLASS

Dry Material Wetting and Mixing

MOISTURE
 Product Expansion and Quality
Bubble

Steam Air Moisture Heat

Puff Collapse Set Harden

Die
P, T

Boiling Pt.
Newtonian
Elastic
0
0 TIME
 EXTRUSION PROCESS MODELING
Flow in the die
Pdie
Pressure Flow
Forces Shear Forces
Q

∆P= Pdie − Pamb = Pdie

Kd
Q= x Pdie Newtonian Fluid
µ
K 'd
Q =
n
x Pdie Non-Newtonian Fluid
k
Summary of equations use for different extrusion dies and assuming non-slip at the
die wall

TYPE OF FLUID
GEOMETRY NEWTONIAN PSEUDOPLASTIC
3 n +1
π R4 π nR n
Circle (pipe) Kd = ( L / R >>1 ) K' d =
8L (2 L )1 / n ( 3n + 1 )
π R4 ( 1 − κ 2 )2 πn 2 n +1
Kd = (1 − κ 4 ) − K ′d = n +1 ( Ra + Ri )( Ra − Ri ) n
8L ln 1κ
2 n
( 2n + 1 )L 1/ n

Circular Slit κ = Ri 2 n +1
Ra π Dn
(Annular Slit) K ′d = .H n
H / R << 1
π RH3 n +1
Kd = H / R << 1 2 n
( 2n + 1 )L1 / n
6L
(considered as slit)
(considered as slit)
3 2 n +1
BH Bn
Rectangular Slit Kd = B >> H K ′d = n +1 H n

12 L 2 n
( 2n + 1 )L1 / n
 Ro   
1/ n
3  − 1÷   Ro  ÷
πr 4  ro  3 n +1
3n − 1÷ ÷
Kd = . πr n n   ro  ÷
K ′d = 1 / n 
3
Conical Section 8L  ro 
1−  ÷ 2 ( 3n + 1 )    ro  3n ÷
 Ro   L1 −  ÷ ÷ ÷÷
÷
   Ro   
2 n +1
A3
Kd = 2A n
2 LU 2 K ′d = n +1
Irregular Section
Approximated formula ( 3n + 1 )U n

Approximated formula
 RHEOLOGICAL BEHAVIOUR
Shear Flow - No Elasticity
Shear Stress
Flow Curves
Newtonian Fluid
Viscosity = Slope of the Flow Curve

Shear Rate

Shear Stress
Shear Stress

Viscosity 2
Viscosity 2
Viscosity 1
Viscosity 1

Shear Rate Shear Rate

Dilatant Fluid n > 1

Shear Thickening
σ = k γ n Pseudoplastic Fluid n < 1
Shear Thinning
 EXTRUSION PROCESS MODELING

• SHEAR RATE ( Non-Newtonian Fluid)

• TEMPERATURE
• MOISTURE CONTENT
• THERMO-MECHANICAL TREATMENT

µapp =ko ⋅ e A/T

⋅e B⋅ M
⋅ γ n −1
ψ
Ψ : This term may include the effect of any reaction
 Table 2. Reported Power Law Parameters in Food Extrudates

Material K n Temperarure Moisture A B

(Pa.sn) (-) Range (0C) Range (%) (K) (% MDB) Source
Cooked cereal dough
(80% corn grits, 20% 785 0.51 67-100 25-30 2500 -7.9a Harper et al.,
oat flour 1971
Pregelatinised corn Cervone and
flour 36 0.36 90-150 22-35 4390 -14 Harper, 1978
Remsen and
Soy Grits 0.79 0.34 35-60 32 3670 - Clark, 1978

Hard Wheat Dough 1885 0.41 35-52 27.5-32.5 1800 -6.8 Levine, 1982
Corn Grits 28000 0.5 177 13 - - Van Zuilichem et
17000 0.5 193 13 - - al., 1974
7600 0.5 207 13 - -
Full Fat Soybeans 3440 0.3 120 15-30 - - Fricke et al, 1977
Pregelatinised corn
flour 17200 0.34 88 32 - - Harmann and
Harper, 1979
Sausage Emulsion 430 0.21 15 63 - - Toledo et al,
1977
110600 0.05 100 25 - -
15900 0.40 130 25 - -
 EXTRUSION PROCESS MODELING

Kd  Q 
Q= x Pdie ⇒ Pdie =   × µapp
µapp  Kd 
µapp =7.5 ⋅ e −7.9 M
⋅e 2500 / T
⋅ γ 0.5−1

• For the same operating conditions

(Screw Speed, Throughput, Temperature, etc)
• A change of 5% in Moisture Content from
30% to 25%)
Pdie / 25% µapp / 25% e −7.9 x 0.25
= = = 1.5
Pdie / 30% µapp / 30% e −7.9 x 30

DIE PRESSURE INCREASES 50%

 MELT VISCOSITY IS AN IMPORTANT
MEASUREMENT TO UNDERSTAND EXPANSION

ON LINE VISCOMETER APPROACH

Shear Stress σ
Shear Rate γ Pressure
Profile
σ
P3 P2 P1
Shear Stress

Flow Q

z
Shear Rate γ
 Conventional On-line Viscometer
Wall shear stress

Apparent Shear rate

 MELT RHEOLOGY
Conventional Approach

On-Line Extrusion Rheological Measurements

Corn Meal

1000

500
Shear Stress (Pa)

300

100

50
30

10
200 250 300 350 400 450 500 550 600
Shear Rate 1/s

25% Moisture - 180oC

45% Moisture - 180oC
25% Moisture - 165oC
 MELT RHEOLOGY
Conventional Approach
On-Line Extrusion Rheological Measurements
Corn Meal

150

148
Shear Stress (Pa)

146

144

142

140
200 250 300 350 400 450
Shear Rate 1/s

25% Moisture - 180oC

 MELT VISCOSITY
An On-line Viscometer Used in the Plastic Industry
TEST HEAD

Pressure Transducers Temperature Sensors Sensor PLC based Data Operator

control Interface
electronics Terminal
Power and
Control
Inlet Pump Purge Line Exit Pump

COMPUTER

4-20mA Signal

Extruder Barrel
Control of Process
 Modified Slit Die Viscometer

Keep Pdie
P5 P4 P3 P2 P1
Constant T Constant
die
T5 T4 T3 T2 T1 SME

Screw
Extruder

Valve Bypass Valve Bypass flow rate

Valve

Flow Rate in Viscometer

T xN
SME: Specific Mechanical Energy SME =
Feed
Modified Slit Die Viscometer
SLIT DIE VISCOMETER
 Modified Slit Die Viscometer
SLIT DIE VISCOMETER
Die Pressure Transducer

Pressure Transducers Extruder

Barrel

Slit Die Block

Adapter
Modified Slit Die Viscometer
Pressure Profile in the Slit Die
Comparison between Melts

1200

1000
Pressure (psi)

800
Die Pressure
600

400

200

0
0 50 100 150 200 250 300 350
Distance from Die Exit (mm)

Colflow 67 - SME = 40 W-h/kg

Crisp Film - SME = 131 W-h/kg
50/50 Mix - SME = 83 W-h/kg
Modified Slit Die Viscometer
Rheological Behaviour of Extrudate Melts

3500

3000
Apparent Viscosity (Pa.s)

2500

2000

1500

1000

500

0
0 20 40 60 80
Shear Rate (1/second)

Colflow 67
Crisp Film
50/50 Mix
 RESEARCH EXTRUSION SYSTEMS
CONICAL – CO-ROTATING SCREW EXTRUDERS

Minilab – Thermo Haake

RESEARCH EXTRUSION SYSTEMS
RHEOLOGICAL STUDIES
 RESEARCH EXTRUSION SYSTEMS
Reactive Extrusion

PD2 PD1

Polymerization of L-lactid to biodegradable polymers

 TRANSFORMATIONS OF RAW
MATERIALS DURING EXTRUSION

LIQUID
TEMPERATURE

Heating
Expansion Glass Transition Temperature

GLASS RUBBER

Dry Material Wetting and Mixing

MOISTURE
 PRODUCT EXPANSION AND QUALITY

Tg Tg

Temperature
Temperature

Moisture
Tg

Shrinkage Region
New Region

Time Moisture
 PRODUCT EXPANSION AND QUALITY

• Shear viscosity resists expansion

• Extensional viscosity and elasticity of the bubble
membrane affect expansion and recovery
Purdue University and the Space Program
 DESIGN OF A MULTIPURPOSE
SMALL EXTRUDER
Motivation
• Mission to Mars
• 6-8 months outbound
• 600 day surface stay
• 6-8 months return

Lift cost to Mars:

~$200,000/kg
Design a multipurpose small extruder
First Extrusion

soybeans soy flour

Extrusion Pressing Drying Grinding
meal

oil

Second Extrusion

soy flour Texturized soy protein

Extrusion Drying
LARGE SCALE “MODEL” EXTRUDER
Triple F - Model RC 2000
 Extrusion of Soybean and
Soybean products
Soy-ingredients”, water,
minor ingredients, etc

• Rheological Model for the product to describe the flow

inside the extruder
• Rheology is a function of temperature, moisture content
type of soybean, oil content, etc
 MODELING AN EXTRUSION PROCESS

Momentum Transfer

∇ ⋅u =0

∇ ⋅τ − ∇p = 0
Pressure

Rheology
Energy Transfer
ρ C p u ⋅∇T = ∇ ⋅ (k ∇T ) + τ : ∇u
Length Rheology
 Technical Challenges – Complex Geometry

Steam locks
Die

4.125” 5.375” 5.625”

0.562” 0.313”

1.625”

Actual geometry with mesh

Cut-away view
 OBJECTIVES
• To determine the rheology of soy flour
using different rheological methods
that can cover a range of shear rates,
moisture content, oil content and
temperature
• Construct a master curve that allow
the prediction of the rheology of soy
flour at different shear rates, moisture
content and temperatures
Relevant literature on rheology
of soy-based materials
• Engineering analysis of soy dough
rheology in extrusion. (Jao, Y. & Chen,
A. 1978).
• Rheological behaviour of different
cereals using capillary rheometry (S.
Singh, & A. Smith, 1999)
• A rheological-based method to
compare filler processing properties.
(Peressini et al., 2002)
Rheology Model function of (T, oil content, shear
rate, moisture content,…)
(1) Constant Temperature (2) To
Log Viscosity
T1

Log aM
Mo
M1 T2
M2
Shifting (aM)

log Shear Rate Moisture Content

(3) (4) Oil content 1
Constant Oil Content

Log Viscosity
Oil content 2
Log Viscosity

Oil content 3
To
Shifting (ao)
T1
Shifting (aT)
T2

log (aM Shear Rate) log (aM aT Shear Rate)

 Rheological Model
Expected “Dream” Results “Real Life” Results

3.5
Temperatures = 50oC - 90oC
Moistures = 30% - 42%
Log Viscosity

3.0 Oil = 0% - 12.2%

2.5

log (Viscosity)
2.0

1.5

1.0

0.5

0.0
2.0 2.5 3.0 3.5 4.0 4.5 5.0

log (aM aT ao Shear Rate) log (aM x aT x ao x Shear Rate)

Rheological Model For Soy Flour
3.5 Temperatures = 50oC - 90oC
Moistures = 30% - 42%
3.0 Oil = 0% - 12.2%

log (Viscosity)
2.5
2.0
1.5
1.0
0.5
0.0
2.0 2.5 3.0 3.5 4.0 4.5 5.0
log (aM x aT x ao x Shear Rate)

logη = − 0.70 log ( aM0.852 ⋅ aT1.373 ⋅ ao0.373 ⋅ γ ) + 5.7

log aM = 12.55(M + b) - 2.13
b = - 0.00034 ⋅ T + 0.0223
log aT = 0.020 T - 1.23
log ao = 9.3 (Oil Content + A) - 0.088
A = - 0.001347 T + 0.06866
 Model prediction versus literature
4.5
T=100, mc=35.5% literature

4 T=100, mc=35.5%, predicted

T=100, mc=28.5%, literature

3.5
T=100, mc=28.5%, predicted

3
log viscosity [Pa-s]

2.5

1.5

0.5

0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5
shear rate
 Experimental Validation Large
Scale Extruder

Extruder geometry:
Db=138.94 mm, L=934 mm,
H=17.08 mm,θ = 6.9◦
Operating conditions:
N = 620 rpm
Mass flow rate:
M = 184.8 g/sec
Material: Soy flour
 Pressure measurements during
soy dough extrusion
450
Port 4
400 Port 5
350 Port 6
Port 7
300
Pressure (Psi)

250
200
150
100
350
50
300
0
0 10 20 30 40 50 60 250

Pressure (Psi)
Time (min) 200

150

100

50

0
3 4 5 6 7 8
Port number
 Final performance comparison
Temperature rise Die pressure (bar) Power consumption
(C) (kW)
Industrial 97.8 19.7 57.4
Extruder
Model 96 17.5 58.9
Prediction

Extrusion temperature validation

250
Experimental data
Simulation
Temperature ( C)

200
o

150

100

50
3 4 5 6 7 8
Port number
 Setting the dimensions of the small extruder
The ratio between the diameter of the screw of large
extruder D2 and the screw diameter of the small extruder
D1 is represented by lower case d.

D2
=d D
D1
The primary scaling variables are channel depth H,
screw length L, helix angle, φ and screw speed N.

H 2 = H1d h L2 = L1d l H

ν
φ2 = φ1d β
N 2 = N1d

L
Setting the dimensions of the small extruder

• Shear rate
• Pumping rate
• Residence time
• Power consumption
• Specific energy consumption
Design of the Small (60 lb/h) extruder
 Pressing and Oil Extraction
Protein Texturization

Screw Press
Slit die Rheometer
 EXTRUSION TECHNOLOGY
• Very versatile technology, it offers many possibilities
for the development of foods and ingredients.
• Advantages of extrusion technology includes the
possibility of continuous process, no effluents, large
throughput, better control, energy efficiency. Investments
could be large, but capital can be paid off quickly.
• For product development and technology design the
rheological and other properties such as Tg,
thermophysical properties must be known or determined.
• Deciding what technology, single or twin screw extruders,
to use requires not only an economical analysis but also
an analysis of the products to be manufactured.
Gracias por la atención