Definition of extrusion

Extrusion is defined as The process by

which moistened, expansible, starch and/or
proteinous materials are plasticized and
cooked in a tube by a combination of
moisture, pressure, temperature and
mechanical shear.
Extrusion of feed is a combination of heat;
shear and pressure build up in the
presence of water.

Extrusion Basics
Thoroughly mixed before entering the pre-bin
The feed here (FrTek are volumetric, not
gravimetric
The feeder needs to be calibrated before
each new material (hazzle)

coater

The bin should be equal filled all time to

ensure constant pressure on material (
constant feeding)
Prebin
I

Wet material has quite another density than

Prebin dry material (you need to calibrate)
II
(Pre)conditioner
extruder

dryer
cooler

mixer

Extrusion Line
surge bin
ingredient feeder

water addition

agitator

to vacuum pump

volumetric feeder

steam to conditioner

conditioner
steam to conditioner
venting

direct steam additon

slurry pump
72 kW at ca. 450 rpm
to suction pneumatic

Pre-conditioner (NOT a mixer)

Raw Material

Steam and
liquids

High
rpm

Mixing unit
Retention unit

Conditioned
Material

Low
rpm

The Screw Elements

1st

2nd

3rd

4th

5th
2: Feeding
4: Pressure generation, heat
transfer high fill
6: Reverse conveying elements

6 10: Forward Polygon:

Kneading effect. High shear,
(Can be both forward and
backward, i.e. Left and right
handed) (interrupted melt flow)

Advantages Extrusion/Expansion
increased temperatures
increased fat addition

(90C to 160C)
(30% or more)

increased molasses addition

gelatinization of starch

(70% to 95%)

pasteurized/sterilised feed
improved pellet durability

(up to 15%)

(90C to 160C)
(up to 20%)

increased production capacity

lower dust quantities
a more flexible process

(up to 50%)

Disadvantages
Bigger energy consumption compared with
other processes.
More expensive than pelleting with regular
conditioning.

Processing parameters: extrusion

Graph provided by Bhler AG

Extrusion processing: SME

Graph provided by Bhler AG

Energy justification: Extrusion

E (total) = SME (specific mechanical E) + STE (specific thermal E)

50
45
40
35

SME

30
25
20
15
10
5
0

Wheat

Oats

Wheat

Oats

Zimonja and Svihus (2008)