Food Extrusion Efficiency Technology

Food extrusion entails the mixing and molding of low moisture food materials, and more recently, high moisture food materials, by passing them through a specifically designed opening or die. Subsequently, the resultant extruded material undergoes precision cutting using blades.

Extrusion cooking stands out as an exceptionally versatile and efficient technology in the field of food processing. Employing a high-temperature short-time (HTST) process, it deactivates enzymes and minimizes microbial contamination, gaining popularity for its heightened productivity and significant retention of nutrients compared to traditional cooking methods.

Throughout the extrusion process, as the food progresses through the extruder, thermomechanical cooking occurs at elevated temperatures (typically ranging from 100°C to 180°C), subjecting the food mix to pressure and shear stress generated in the screw-barrel assembly.

The laminar flow within the channels of the extrusion screw and die aligns the molecules in the direction of flow, resulting in the creation of a crunchy or chewy texture in the fabricated food.

Upon exiting the die, the extruded material undergoes a transition from high pressure to atmospheric pressure in the extrusion-cooked melts. Generally, minimal additional processing is required for the extrudates, often limited to slight drying.

The entire extrusion process is continuous and can be completed in under a minute. In the food industry, single-screw and twin-screw systems are the most commonly employed extruders, with twin-screw systems being more prevalent due to their versatility.

Extrusion induces various processes such as the gelatinization of starch, protein denaturation, and reduction of lipid oxidation and anti-nutritional factors. Furthermore, it is acknowledged as a versatile, cost-effective, and highly efficient technology in the realm of food processing.
Food Extrusion Efficiency Technology

Processing of Honey

Processing of Honey
The processing of honey may be very simple e.g. in the case of a hobby operation, or extremely complex involving a great deal of technology tailored to each individual honey type.

Most processing however is concerned with liquefying and straining (or filtering) honey.

Both of these operations usually require some application of heat to the honey. The heat has the dual effect of removing crystallization in natural honey, and to reduce the viscosity.

Both of these things are required to provide a product that can be cleaned and further processed for creamed honey or just filled into jars as liquid honey.
Processing of Honey

Bread baking process

The function of baking is to present cereal flours in an attractive, palatable and digestible form.

Most bakery products are made of the same few ingredients – flour, shortening, sugar, eggs, water or milk and leavenings.

The dough is kneaded by hand or machine. After the dough rests for some time (about 2 hours) it is manipulated to push out the gas that has been evolved.

Three process are commence when the ingredients for bread making are mixed.
*The protein in the flour begin to hydrate and to combine with some water , to form gluten.
*Air bubbles are folded into dough. During the subsequent handling of the dough these bubbles divide or coalesce.
*Enzyme in the yeast start to ferment the sugars present in the flour and later sugar released by diastatic action of the amylases on damaged starch in the flour, breaking them down to alcohol and carbon dioxide.

The dough is then moulded into loaf shape and allowed to rest in the baking pan for 45 to 60 minutes at 38° – 48° C for final proof and is then baked for about 30 minutes with steam injected into the oven to produce a glaze on the crust.

Loaf sized are breads is baked in an oven pre-heated to 204° C. After the first 15 minutes of baking, the temperature is reduced if the crusts become to brown. Baking is continued until the bread is fully baked.

There are four major changes to the dough piece which can be seen as it is baked:
*A large reduction in product density – the dough gets thicker, associated with development of an open porous or flaky structure
*A change of shape associated with shrinkage or spread and increase on thickness
*A reduction in moisture level, to between 1-4%
*A change in surface coloration
Bread baking process

Cereal Extrusion Processing

Breakfast cereal manufacturing was one of the earliest commercial applications of extrusion cooking and remains one of the most widespread.

The application of extrusion technology is one of the most economic processes, being used increasingly in the food industry for the development of new products such as breakfast cereals and modified starch from cereals.

Cereals flour and other starchy materials are widely used as raw materials in the production of many extruded product. The physical of cereals fluids developed within an extruder and their extrudates are predominantly due to the starch component present, which usually represents between 50% and 80% of the dry solids.

The extrusion-cooking unit thermo-mechanically cooks breakfast cereal mixes to generate the right functional properties of the resulting melt according to the quality profile of the final products.

Chemical and structural transformation in foods during extrusion cooking determine the quality of the extruded products.

A few studies have been reported in extrusion cooking increased the availability of protein and other nutrients in the grain.

Extrusions processes are typically high temperature and high pressure for short time durations. This results in products with limited heat treatments that have nearly all the nutritional attributes of the raw materials remaining in the final products.
Cereal Extrusion Processing

Processing technology development of fruit juice

A freshly squeezed orange or fresh pulped and strained apple would supply a fruit juice drink for immediate consumption, but to expect it to maintain its quality for even a day or two was tempting providence.

Actually the technology to produce high quality fruit juice concentrate has been improved considerably over the years.

With the technology benefits of ultra-high temperature pasteurization, aseptic packaging techniques and system, pressed juices can be stored for extended periods with very little deterioration in quality.

There has also been a range of developments leading to the removal of acidity, color and minerals from clear juices such as apple.

Previously reliance had to be places upon the use of preservatives and classical pasteurization at lower temperature and longer holding times. The traditional process of hot filling juice in containers to produce shelf stable precuts is now being replaced by newer technologies.

Enzymes and finishing treatments are widely used in the processing of fruit juices to obtain products of particular specification. It is more oriented towards flavor orientation, nutrition protection and product stabilization though enzyme control and pasteurization.

During the second half of the twentieth century, apart from the continues move towards more efficient means of production and marketing of bottles or canned soft drink products, there was much progress of knowledge about flavor technology.

Further advanced techniques include the use of membrane technology to achieve cold sterilization, freeze concentration, combination of cold and hot processes, accompanied by aseptic filling technology and irradiation technology.

Pulsed electric field technology also has a potential to replace traditional thermal processes for the pasteurization of fruit juice.
Processing technology development of fruit juice

Process of Fermentation

Fermentation technology is one of the oldest technologies employed in the food processing industry.

The term fermentation is derived from the Latin verb ‘fervere’, to boil, which describes the appearance of the action of yeast on extracts of fruits or malted grain during the production of alcoholic beverages.

In general it can be defined as the process of growing a culture of microorganisms in a nutrient medium at maintained physic-chemical conditions and thereby converting feed into desired end product.

Fermentation involves the breaking down of complex organic substance into smaller ones.

The microbial or animal cell obtains energy through glycolysis, splitting a sugar molecule and removing electrons from the molecules.

Fermented products encompass, but are not limited to wine, beer, vinegar, bread, soy sauce, sauerkraut, kimchi, pickled, olive, different fermented milk products, a large number of cheeses and a variety of sausages.

Many species of microorganisms are used for carrying out the process of fermentation to produce useful products. They include bacteria, fungi, algae and actinomycetes.

Several advantage of fermentation technology included:
*Produces value added and add variety to the human being’s diets.
*Preservation of the food.
*Food quality improvement through flavor development, nutrient enrichments.
*The food more nutritious.
*Detoxifies of foods

Today large numbers of chemicals are produced by fermentation technology with the advent genetic engineering and the developments in computer technology.
Process of Fermentation

The Goals of Modern Food processing

The Goals of Modern Food processing
Formulation
A logical basic sequence of steps to produce an acceptable and quality food product from raw materials.

Easy production procedure
Develop methods that can facilitate the various steps of production.

Time economy
A cohesive plan that combines the science of production and manual labor to reduce the time needed to produce the product.

Consistency
Application of modern science and technology to assure the consistency of each batch of products.

Product and worker safety
The government and the manufacturers work closely to make sure that the product is wholesome for public consumption and the workers work in a safe environment.

Buyer friendliness
Assuming the buyer dislikes the product, the manufacturer must do everything humanly possible to ensure that the product is user friendly (size, cooking instructions, keeping quality, convenience, etc).

Obviously, to achieve all these goals is not a simple matter. The first question is why do we want to process food?

At present, there are many modern reasons why foods are processed, for example, adding value to a food, improving visual appeal and convenience.

However, traditionally the single most important reason we wish to process food is to make last longer without spoiling.

Probably the oldest methods of achieving this goal are the salting of meat and fish, the fermenting of milk and the pickling of vegetable.
The Goals of Modern Food processing