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Extrusion and Other Terminal Agglomeration Technologies by GALEN J Extrusion and other terminal agglomeration technologies BY GALEN J. ROKEY AND BRIAN PLATTNER REVIEWED AND EDITED BY ADAM FAHRENHOLZ, CHARLES STARK, AND CASSANDRA JONES preconditioning step. The initial portion of this ellet mills and many other feed processing P chapter will not revisit the entire subject of technologies result in an agglomerated or pelleted preconditioning; however, it examines the feed. Recognized advantages of pelleted feed are as importance of preconditioners for an extrusion- follows: based pelleting system. While the text may only • Increased bulk density; mention one of these pelleting technologies, such as • Less bridging in bins; extrusion, the reader should understand that the • Less dust; principles apply to all systems. Preconditioning • Reduced ingredient segregation; with steam and water has been associated with • Less feed waste; extrusion cooking of feed products since the • Increased nutrient density; inception of the extrusion cooking process. • Improved palatability; Extrusion-cooked feed products whose production • Increased nutrient availability; and processes successfully employ preconditioning • Decreased microbiological activity. include petfoods, swine starter diets, full-fat soy, aquatic feeds and other specialty animal feeds. An alternative to conventional pelleting is the extrusion process. Extrusion may be used either to The preconditioning step initiates the heating improve upon an existing process, or to process by the addition of steam and water into the manufacture feeds that a conventional pelleting dry mash. Uniform and complete moisture system cannot. As formulated feeds become more penetration of the raw ingredients significantly sophisticated to meet the specific physiological improves the stability of the extruder and enhances needs of the animal and the expectations of the the final product quality. In addition, plasticizing public, extrusion-based processing technologies will the raw material particles prior to extrusion reduces continue to be a factor in this industry. Several the wear on equipment caused by the abrasive raw items key to extrusion such as steam material particles. There are generally two preconditioning, the extrusion process and situations where preconditioning should be equipment, process parameters, and final products considered when producing extrusion-cooked and are discussed in this chapter. Novel technologies, pelleted products. First, it should be used in such as the Universal Pellet Cooker (UPC), and the conjunction with moist extrusion where material is Sphere-izer Agglomeration System (SAS) are also extrusion cooked at in-barrel moisture contents discussed. greater than 18%. Second, one should consider using preconditioning in situations where the raw material particles are difficult to hydrate, such as Preconditioning large particles, or non-uniform particle size Preconditioning is an integral part of any pelleting distributions. In general, any extrusion process that or extrusion system. As one begins to examine would benefit from higher moisture and longer alternatives to the conventional pelleting process, retention time will be enhanced by preconditioning. they quickly realize the added importance of the Feed Pelleting Reference Guide Section 1: Introduction Chapter 2: Extrusion and Other Technologies Feed Pelleting Reference Guide Section 1: Introduction Chapter 2: Extrusion and Other Technologies Because preconditioning is recognized as being preconditioners being used in the extrusion cooking important to producing premium products and industry today are double (DC) preconditioners, operating an efficient extrusion cooking process, it differential diameter/differential speed (DDC) is important that the basic principles of the preconditioners, and high intensity (HIP) preconditioning process are well understood. The preconditioners (see Figure 2-2). The single-shafted three objectives accomplished during the preconditioner, as found in most traditional preconditioning process are: hydration of raw pelleting systems was also utilized to a large extent material particles; heating of raw material particles; in the past in extrustion, but the double-shafted and mixing of materials added to the preconditioner conditioners represent today’s technology. in separate streams. This is accomplished in a preconditioner by holding the materials in a moist, warm environment for sufficient time and with Figure 2-2. Types of atmospheric sufficient mixing. This process results in the raw preconditioners. material particles being plasticized by the steam and water in the environment. In practice, the objective is to completely plasticize the raw material particles in order to eliminate any dry core as illustrated in Figure 2-1. Figure 2-1. The objective of preconditioning is to Double Conditioner eliminate the unplasticized core in the raw material particles. Differential Diameter Conditioner Preconditioning hardware and operation The preconditioners utilized for the extrusion industry are almost exclusively atmospheric preconditioners (i.e., they operate at prevailing atmospheric pressure). Their maximum operating temperature is the boiling point of water at High Intensity Preconditioner When compared to the single preconditioners, input beyond this point will only result in the loss of double preconditioners have improved mixing and moisture as steam. Atmospheric preconditioners are have a longer average retention time of up to 1.5 relatively simple to construct and have lower minutes for a similar throughput. As with single manufacturing and maintenance costs associated preconditioners, they have beaters that are either with them compared to other preconditioner types. permanently fixed to the shaft or that can be The three basic types of atmospheric changed in terms of pitch and direction of Feed Pelleting Reference Guide Section 1: Introduction Chapter 2: Extrusion and Other Technologies conveying. The two shafts of a double Table 2-2. Coefficient of Variation for Moisture preconditioner usually counter-rotate such that Content in Different Preconditioner Designs material is continuously interchanged between the Preconditioner Design CV (%) two intermeshing chambers. HIP 2.65 DDC 4.96 The most recent technology in the industry are the DC (Double Cylinder) 6.66 DDC and HIP preconditioners, which have the best SC (Single Cylinder) 9.36 mixing characteristics combined with the longest average retention times. Retention times of up to 2- The more uniform moisture distribution not only 4 minutes for throughputs comparable to those used improves extrusion stability for recipes that become in double and single preconditioners can be sticky when hydrated, but contributes to more expected. As with a double preconditioner, the two consistent destruction of biological contaminates shafts of a differential diameter/differential speed (salmonella) using thermal critical control points. preconditioner usually counter-rotate such that As in traditional pelleting, preconditioners are material is continuously interchanged between the usually installed above the extruder barrel so that two intermeshing chambers. The HIP gives an the preconditioned material falls directly into the added layer of control as each shaft has an inlet of the extruder as depicted in Figure 2-3. In independent drive. This allows the direction of shaft addition, there are other important installation rotation and speed of the shaft to be varied allowing recommendations for proper functioning of the direct operator control of the residence time and preconditioning hardware and process. mixing intensity (see Table 2-1). Figure 2-3. Preconditioner installed above an Table 2-1. Effect of Speed on Residence Time extruder. Side A Side B Retention Time Speed Speed (minutes) (rpm) (rpm) 100 500 1.00 250 125 1.47 800 50 2.40 When analyzing the various preconditioner designs, one of the most efficient ways is to compare their coefficient of variation. The increased mixing intensity of twin shafted and variable speed preconditioners compared to other designs yields Water and water-based slurry addition improved moisture distribution in the material Perhaps the single largest difference between a discharging the preconditioner. Table 2-2 lists the conventional pellet mill and an extrusion-based average coefficient of variation (CV) of moisture system is the internal addition at the preconditioner content in four different preconditioner designs. To of water and water-based slurries including colors, determine CV after stable conditions were achieved, fresh meats and molasses. Extrusion processes samples were collected off the preconditioner at 15 operate at much higher moisture levels, and thus are second intervals for a 2.5 minute time period and capable of handling these additional process streams analyzed for moisture content. with ease. Water is added to the preconditioner from the top of the preconditioning chamber close to the raw material inlet. For best distribution of Feed Pelleting Reference Guide Section 1: Introduction Chapter 2: Extrusion and Other Technologies water throughout the raw materials, spray nozzles Figure 2-4. Introducing materials to the are used. Other water-based additives such as preconditioner. molasses, digests and fresh meats can be added in conjunction with the water or at any point in the preconditioning process. It is recommended to add these slurries as close to the inlet of the preconditioner as possible to allow for optimal hydration of the dry materials
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