the extrusion process in relation to snack foods,...
TRANSCRIPT
The Extrusion Process in Relation to Snack Foods, Healthy Bars and other Soy Products
Mian N. Riaz, Ph D.Head – Extrusion Technology Program
Food Protein Research & Development CenterTexas A&M University, USA
Tel: 979/845-2741; Fax: 979/845-2744E-mail: [email protected]; https:foodprotein.tamu.edu/extrusion
Fundamentals of Snack, Bars and Soy Based Extrusion Processing
Formulation (Recipe)
Hardware
Software
Product Specifications
Genes
Conditio
ns
Prot
iens
Sta
rche
s
Oligomers
Lipids
Polypeptides
Sto
rage
Consu
mer A
cceptan
ce
Minerals
Vitam
ins
Process
Quality
Enzymes
Genes
Conditions
Protiens
Starches
Oligomers
Lipids
Polypeptides
Storage
Consumer Acceptance
MineralsVitamins
ProcessQuality
Enzymes
Raw Material
Final Product
Know Your Raw Materials!
They may be
your best friend,OR BECOME
YOUR WORST NIGHTMARE!!
Formulation
Carbohydrate
Protein
Lipids
Minor Ingredients
Starch Gelatinization
Requires
– Moisture
– Elevated temperature
– Retention Time
Proteins
Denature when heat treated– Lose solubility
– Lose enzymatic activity
– Improves digestion
Level of heat treatment– Affects “functionality”
– Affects processing characteristics
Lipids
Level of indigenous or added lipids affects:
– binding and texture of product
– quantity of energy mechanically added to product
Minor Ingredients
Minerals
Vitamins
Pigments
Flavors
Processing Aids
Note: Vitamin, Pigment, and Flavor Potency is effected by energy (in the form of heat), moisture, and retention time in the process.
Extrusion Processing Technologies for Snack
Dry Extruders (Short Time / High-Temperature Extruders)
Expander/Cooker Extruders
Single Screw Extrusion Cookers
Twin Screw Extrusion Cookers
Types of Extruder Single screw
– Simpler and cheaper
– Limited mixing and flexibility
– Range of raw materials limited
– Low tolerance to lipids in raw materials and moisture variations
– Low tolerance to moisture variations in raw materials
Twin-screw
– Flexible, wide range of raw materials
– High level of micro-mixing
Extruder Die Provides resistance at discharge of extruder
Shapes product
Ist Generation Snacks
Nuts, dried fruit, cracker,potato chips, tortilla chips
2nd Generation Snacks
Majority fall in this category
Puffed collets,
Baked or Fry
Expanded snacks (2nd generation)
3rd Generation Snacks
3-G , half products
Puffed later by hot air, frying, ormicrowave
Snack pellets (3rd generation)
Extrusion: A Novel Food Processing Tool
– Confections
– Bread Crumbs
– Breakfast Cereal
– Snacks
– Precooked Pasta
– Precooked, Reformed Rice
– Precooked Pulse Analog
– Viscosity Controlled Flour
– Textured Protein
Extrusion: A Novel Food Processing Tool Confectionery Products
Extrusion: A Novel Food Processing Tool Confectionery Products
Extrusion: A Novel Food Processing Tool Confectionery Products
Extrusion: A Novel Food Processing Tool Extruded Bread Crumb Products
Expanded Bread Crumb process
Nontraditional Bread Products(Dough Balls)
Extruded Dough Balls
Baked “Bread” Balls
Milled Bread Crumbs
Extrusion: A Novel Food Processing ToolNontraditional” Bread Products
(Breadsticks)
Extrusion: A Novel Food Processing Tool Nontraditional Bread Products
(Flat Breads / Crisp Breads)
Alternative Breading
Gluten-free breading
– Corn
– Rice
Extruder
– Mixed with high shear (to cook starch)
– Cut, Cooled, Shredded, Dried
– Cut, Dried, Roller-milled
Extrusion: A Novel Food Processing Tool Breakfast Cereals
Direct expanded
Protein Enhanced Cereals and Snacks
PROTEIN CRISPS PROTEIN FORTIFIEDCORN SNACKS
Cooking
Forming
Shaping
Preconditioning
Generic Flaked Cereal Process
Generic Flaked Cereal Process
Extruded Infant Food
Extrusion: A Novel Food Processing ToolDirect Expanded Snacks
• Simple shapes
• Simple raw materials
• Simple process
• Externally coated/seasoned
Extruded and Fried Snacks
Fried Cheetos Curls Multi-Grain Chips
Extruded and Fried Snacks
What are half-products?
• Dense, dry, shelf-stable, cooked pellets that are expanded some time after formation into crunchy or crispy snack products
• They are “half” or partially made, then finished later
Other names for half-products…
• Third generation snacks (3G snacks)
• Snack pellets
• Indirect expanded snacks
1st Generation 2nd Generation 3rd Generation
Benefits of the half-product production method
• Good shape definition not possible with direct expansion
• Product textures not possible with direct expansion
• Can use raw materials not compatible with the direct expansion process
• Can process in one location, then ship dense pellets to a location closer to the market for puffing, coating, and packaging
Disadvantages of the Half-product Production Method
• Much greater equipment cost
• More complex operations
• Final product result not seen for at least one hour later making it difficult to provide real-time feedback
• More flexibility = greater complexity!!
Generic half-product process
Cook Shape Dry
Store
PuffCoatPackage
Different Cooking Methods
1. Use of pre-gelatinized materials and cold former
2. Batch cooking followed by sheeting
3. Single screw cooker with single screw former
4. Twin screw cooker with single screw former
5. Twin screw cooking/forming combination process
Snack Pellets
• More complex shapes
• More complex raw material blends
• More complex process•
• Stable, shelf stable pellet that is puffed later
Snack Pellets
Cooking
Venting (Vacuum)
Extrusion Cooking Process
FinalProduct
Forming
Shaping
Preconditioning
Extrusion: A Novel Food Processing ToolCo-Extruded / Filled Products
Co-Extruded Snacks
Filled Snacks
Production ofFilled Tubes or Pillows
Traditional Pasta
Produced by low temperature extrusion
Not cooked or gelatinized
Must be boiled for reparation
• Produced by moderate temperature extrusion
• Fully cooked or gelatinized
• Not necessary to boil for preparation
• Hot water hydration -- 5 to 10 minutes
• Cold water hydration -- 20 to 60 minutes
• Microwaveable
Extrusion: A Novel Food Processing ToolExtrusion Precooked Pasta
Precooked Pasta
Pasta Noodles
Crouton and Couscous
Extrusion: A Novel Food Processing Tool
Precooked, Reformed Rice
Advantages of the Extrusion Cooking Process for Production of Precooked Rice
Utilization of cracked and broken kernels Cooking / Preparation
– ½ Cooking time of regular rice– Easily stored and reheated after cooking– Hydrates in cold water
Fortification– Vitamins and Minerals
Uniqueness– Flavors– Pigments and Colors– Shapes
Add ProteinExpanded Cereals
Add StarchTexturized Proteins
Extrusion: A Novel Food Processing Tool Precooked “Pulse” Analogs
Products based on Texturized Protein Technology– Provides protein content of natural dal lentil
Products based on Cereal Technology– Provides starch for binding as well as
additional protein
Lentil Analog
Proteins– Soy Flour
– Bean Flour
– Pea Flour
– Dal Lentil Flour
Starch– Wheat Flour
– Corn Flour
– Rice Flour
Bean Analog
Proteins– Soy Flour
– Bean Flour
– Pea Flour
– Lentil Flour
Starch– Wheat Flour
– Corn Flour
– Rice Flour
Bean Analog
Precooked Bean Analog (non-hydrated)
Precooked Bean Analog (hydrated)
Natural Bean(non-cooked)
Extrusion: A Novel Food Processing Tool Textured Protein Products
TVP
FSP
SMA
HMMATMP
LMMA
Extrusion: A Novel Pet Food Processing Tool