摘要:
Methods and apparatus for high-moisture extrusion of starch-bearing grains is disclosed which yield cooked, gelatinized products suitable for short-time enzymatic conversion to sugars, and particularly those subject to fermentation to alcohol; the high production rates afforded through use of extrusion equipment, and the short conversion time of the resultant products, is particularly advantageous for economical alcohol manufacture, both for alcoholic beverages and for use as fuel. Preferably, whole or cracked starch-bearing grain is presoaked in an excess of water to a substantial moisture level, and the resultant slurry is fed to a specialized extruder. In the extruder the water is at least partially separated and carried from the process, and the grain is highly cooked and gelatinized for subsequent conversion. The overall apparatus preferably includes presoak tanks for the grain, a grain-conveying feeder, an extrusion cooker, and enzyme conversion tanks; the apparatus is advantageously sized for batch-continuous operations to produce a continuous flow of sugars. Conversion times for the gelatinized starches are low, less than about 45 minutes, and moisture and extrusion conditions can be altered to further lower sugar conversion time.
摘要:
An improved twin screw extruder device (14) is provided which is capable of producing a wide variety of high quality extrudates having greatly varying final properties, without the need for extensive machine modifications. The extruder (14) includes a barrel (16) together with a co-rotating twin screw assembly (22). The assembly (22) is made up of a pair of screws (50, 52) having central, tapered shafts (54, 56) equipped with outwardly extending helical flighting (58, 60); the screws (50, 52) are non-parallel and are positioned so that the flighting (58, 60) thereof is intercalated along the length of the screws (50,52). The flighting is of specialized configuration and tapers along the length of the screws (50, 52) preferably at an angle of taper different than that of the shafts (54, 56); moreover, the width of the outer flighting surfaces (70, 72) increases along the length of the shafts (54, 56). This screw geometry defines a series of alternating upper and lower close-clearance high-pressure nip areas (78) defined by the flighting (58, 60) which serves to propel an extrudable mixture forwardly towards the outlet end (20) of the barrel (16). However, passageways (80) and kneading zones (82) are also defined between the screws (50, 52), which assures full mixing, shearing and cooking of the material. The extruder device (14) is capable of producing high density sinking aquatic feeds as well as expanded, low density products merely by changing the rotational speed of the screws (50, 52) together with appropriate temperature control. In another embodiment, a fluid extraction extruder (138) is provided having a specialized extruder head (140) including an outer shell (144) and an inner, elongated, slotted sleeve (152).
摘要:
Improved short length extrusion cooking devices (10) are provided which can achieve product throughput and quality characteristics of conventional long-barrel extruders. The short length extruders (10) of the invention include a relatively short barrel (14) having an inlet (18) and an endmost extrusion die (20). An elongated, helically flighted axially, rotatable screw assembly (22) is positioned within the barrel (14) and is coupled to motive means (39, 39a) for rotation of the assembly (22) at a speed of at least about 500 rpm. The device (10) may include an internal, apertured flow-restricting device (60, 110) which defines a mid-barrel choke point for the material being processed. An alternate extruder (120) is configured without a mid-barrel restriction and is designed to operate at essentially atmospheric internal pressure throughout the majority of the length of barrel (122) with a significant pressure rise in the final head (134) adjacent the extrusion die. Preferably, the barrel (14, 122) has an internal bore of generally frustoconical configuration with an effective length to maximum diameter ratio (L/D) of at least about 6. Novel extrusion processes and products are also provided, using extremely short extrusion barrel retention times to give cooked extrudates having essentially no amino acid or vitamin nutrient losses, and/or dense, highly cooked, low moisture feeds.
摘要:
Improved short length extrusion cooking devices (10) are provided which can achieve product throughput and quality characteristics of conventional long-barrel extruders. The short length extruders (10) of the invention include a relatively short barrel (14) having an inlet (18) and an endmost extrusion die (20). An elongated, helically flighted axially, rotatable screw assembly (22) is positioned within the barrel (14) and is coupled to motive structure (39, 39a) for rotation of the assembly (22) at a speed of at least about 500 rpm. The device (10) may include an internal, apertured flow-restricting device (60, 102) which defines a mid-barrel choke point for the material being processed. An alternate extruder (120) is configured without a mid-barrel restriction and is designed to operate at essentially atmospheric internal pressure throughout the majority of the length of barrel (122) with a significant pressure rise in the final head (134) adjacent the extrusion die. Preferably, the barrel (14, 122) has an internal bore of generally frustoconical configuration with an effective length to maximum diameter ratio (L/D) of at least about 6. Novel extrusion processes and products are also provided, using extremely short extrusion barrel retention times to give cooked extrudates having essentially no amino acid or vitamin nutrient losses, and/or dense, highly cooked, low moisture feeds. Twin screw extruders (232, 232a) with and without mid-barrel restriction elements (252-256) can also be provided, and include an internally tapered barrel (237) with correspondingly tapered, flighted, axially rotatable screws (238, 240).
摘要:
A method of producing extrudates such as high protein, high fat sinking aquatic feeds is provided wherein a high protein starting material is initially preconditioned and passed through an extruder; in the extruder barrel a zone of reduced pressure is created upstream of the die for densifying the final extrudate. Fat may be added to the starting mixture at any desired point in the process, and/or may be added as a surface coating to the final extrudate. Preferably, the method further involves measuring a density value of the extrudate such as bulk density, and adjusting the magnitude of the reduced pressure conditions in the barrel in response to such measurement.
摘要:
An apparatus (10) and method for the production of sterile, pelleted feed products is provided which includes an extruder device (12) equipped with a pelleting head (14) adjacent the outlet end of the extruder barrel (17). The pelleting head (14) includes an annular die section (52) having die openings (58) therethrough which is secured to the extruder barrel (17), forming an extension thereof; a rotatable, multiple-vane plate (66) is secured to the screw (42) of the device (12) and cooperates with the die section (52) to form final pellets. A rotatable knife (16) serves to cut emerging extrudate so as to size the pellets. In an alternative embodiment, the plate (66) is separately powered for rotation independent of the extruder screw (17), preferably by means of a prime mover (102) coupled with a short extruder screw section (100) which supports the plate (66). Preferably, the extruder device (12) is equipped with an upstream preconditioner (40) serving to moisturize and uniformly mix dry feed ingredients. The preconditioner also at least partially precooks the mixture and subjects the same to time-temperature conditions for sterilization purposes.
摘要:
Improved, high-capacity processing systems including a processing device such as an extruder (26) or a pellet mill (P) are provided which minimize product losses and permit the user to conduct multiple, segregated short runs with a minimum of down time between runs. The extruder systems (20, 220) include an extruder assembly (21, 221) having a special, multiple-position die assembly (28), as well as an upstream preconditioner (24) and feed bin assembly (22). A variable speed, variable output discharge screw feeder (78) is located between the preconditioner outlet (62) and extruder barrel inlet (90). A PLC-type controller (30) coupled to the extruder assembly components establishes a choke full condition at the discharge feeder (78) so that continuous uninterrupted flow of preconditioned material to the extruder (26) at a uniform mass flow rate is maintained for as long as possible. In preferred forms, load cells (46, 72) are operatively coupled to the bin assembly (22) and preconditioner (24) so as to monitor material flow through the systems (20, 220). A multiple stage cascade-type dryer assembly (29) is provided downstream of extruder (26). The assembly (29) is controlled via the controller (30) in coordination with the extruder assemblies (21, 221) so as to maintain the segregation between separate product runs throughout the drying operation. Pellet mill systems include bin and preconditioner assemblies (22, 24) operatively coupled with a pellet mill (P).
摘要:
Improved, high-capacity processing systems including a processing device such as an extruder (26) or a pellet mill (P) are provided which minimize product losses and permit the user to conduct multiple, segregated short runs with a minimum of down time between runs. The extruder systems (20, 220) include an extruder assembly (21, 221) having a special, multiple-position die assembly (28), as well as an upstream preconditioner (24) and feed bin assembly (22). A variable speed, variable output discharge screw feeder (78) is located between the preconditioner outlet (62) and extruder barrel inlet (90). A PLC-type controller (30) coupled to the extruder assembly components establishes a choke full condition at the discharge feeder (78) so that continuous uninterrupted flow of preconditioned material to the extruder (26) at a uniform mass flow rate is maintained for as long as possible. In preferred forms, load cells (46, 72) are operatively coupled to the bin assembly (22) and preconditioner (24) so as to monitor material flow through the systems (20, 220). A multiple stage cascade-type dryer assembly (29) is provided downstream of extruder (26). The assembly (29) is controlled via the controller (30) in coordination with the extruder assemblies (21, 221) so as to maintain the segregation between separate product runs throughout the drying operation. Pellet mill systems include bin and preconditioner assemblies (22, 24) operatively coupled with a pellet mill (P).
摘要:
Improved short length extrusion cooking devices (10) are provided which can achieve product throughput and quality characteristics of conventional long-barrel extruders. The short length extruders (10) of the invention include a relatively short barrel (14) having an inlet (18) and an endmost extrusion die (20). An elongated, helically flighted axially, rotatable screw assembly (22) is positioned within the barrel (14) and is coupled to motive means (39, 39a) for rotation of the assembly (22) at a speed of at least about 500 rpm. The device (10) includes an internal, apertured flow-restricting device (60, 110) which defines a mid-barrel choke point for the material being processed. Preferably, the barrel (14) has an internal bore of generally frustoconical configuration with an effective length to maximum diameter ratio (L/D) of at least about 6.
摘要:
An improved twin screw extruder device (14) is provided which is capable of producing a wide variety of high quality extrudates having greatly varying final properties, without the need for extensive machine modifications. The extruder (14) includes a barrel (16) together with a co-rotating twin screw assembly (22). The assembly (22) is made up of a pair of screws (50, 52) having central, tapered shafts (54, 56) equipped with outwardly extending helical flighting (58, 60); the screws (50, 52) are non-parallel and are positioned so that the flighting (58, 60) thereof is intercalated along the length of the screws (50, 52). The fighting is of specialized configuration and tapers along the length of the screws (50, 52) preferably at an angle of taper different than that of the shafts (54, 56); moreover, the width of the outer flighting surfaces (70, 72) increases along the length of the shafts (54, 56). This screw geometry defines a series of alternating upper and lower close-clearance high-pressure nip areas (78) defined by the flighting (58, 60) which serves to propel an extrudable mixture forwardly towards the outlet end (20) of the barrel (16). However, passageways (80) and kneading zones (82) are also defined between the screws (50, 52), which assures full mixing, shearing and cooking of the material. The extruder device (14) is capable of producing high density sinking aquatic feeds as well as expanded, low density products merely by changing the rotational speed of the screws (50, 52) together with appropriate temperature control. In another embodiment, a fluid extraction extruder (138) is provided having a specialized extruder head (140) including an outer shell (144) and an inner, elongated, slotted sleeve (152).