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The extruder was first developed to make lead pipes in the late 18th century. But the extrusion process technique quickly spread to other manufacturing sectors, including food, feed, and biomass products. An extruder machine presses a fluid or solid material through a die. Depending on your use case, extruders adopt single- or twin-screw systems to push the premixed feed material through a barrel. Thermal pressure applied in this step can chemically modify the mixture, so the screw system must be precisely calibrated to achieve the desired result. Finally, a knife head cuts the extruded material into your designed dimensions. Extrusion machinery produces items of a uniform size, shape, and consistency.

Extrusion

Pellet snacks, or snack pellets, are intermediate products which you can further process and develop into snack products for consumption. Pellet snacks production involves mixing, extrusion, frying, and packing. Since these are intermediate products, final product customization on the production line will depend on your customer’s desired product and flavor profile.

Pellet snacks

Products can be extruded with a variety of shapes and characteristics by controlling the nozzle geometry and pressure and temperature characteristics of substrates as they are propelled through a screw style mixing machine. Precise control of pressure at the point of extrusion is essential to predictable, desirable results.


<h2>Small scale, precisely controlled extrusion of animal feed</h2>
Amandus Kahl’s Extruder OE 8 is a small batch or laboratory extruder that works on the same principal as the successful Annular gap expander design where a conical stop is used to restrict flow out of a tube as materials are driven through it by a rotating shaft. The stop is moved towards and away from the tube creating an adjustable sized gap through which material leaves the tube. Controlling the size of this gap relative to the material throughput determines the pressure under which the material is extruded and influences many of the product’s final characteristics.

These units can be provided with heating or cooling jackets and provisions for monitoring temperature and pressure. Precisely controlled product extrusion is thus achieved by applying Amandus Kahl’s patented gap control technology from the annular gap expanders to this simpler machine.

Laboratory extruder

Products can be extruded with various shapes and characteristics by controlling the nozzle geometry and pressure and temperature characteristics of substrates as they are propelled through a screw-style mixing machine. Precise control of pressure at the point of extrusion is essential to predictable, desirable results.


<h2>Product shaping with easy start-up and less waste</h2>
Amandus Kahl’s Extruder OE series is an extruder line that works on the same principle as the successful annular gap expander design. A conical stop restricts the flow out of a tube as materials are driven through it by a rotating shaft. The stop is moved towards and away from the tube, creating an adjustable-sized gap through which material leaves the line. Controlling the size of this gap relative to the material throughput determines the pressure under which the material is extruded and influences many of the product’s final characteristics.

Heating or cooling jackets can be added to these units for monitoring temperature and pressure. Precisely controlled product extrusion is thus achieved by applying Amandus Kahl’s patented gap control technology from the annular gap expanders to this more straightforward machine.

Extruder with annular gap expander

Pellet-style snacks represent a broad food sector category. They are consumed worldwide and vary according to the market. Popular types include prawn crackers, puffed cheese, pork rinds, and bugles, to name a few. Under the right frying conditions, these snacks expand and acquire the crispy texture that makes them such popular nibbles. However, transferring the pellet snack through the frying line is a delicate process that could compromise the final product.


<h2>Transfer fried pellet snacks gently through the production cycle</h2>
The PP snack pellet frying line from Kuipers combines an efficient transportation system designed for pellet-style snacks. Also, the deep fryer uses gentle heat transfer technology to ensure consistent cooking to preserve the desired flavor and texture as the pieces move to the next production stage.

In addition, a dirt removal system at the pre-frying stage maintains oil quality for longer. Furthermore, the automatic PP system is fully controlled via PLC and handles production of 50 kilograms per hour output to 1,000 kilograms per hour output.

In order to produce different varieties of pellet snacks, you need different temperatures and frying time. Fortunately, this piece of equipment is completely adjustable in terms of frying time and temperature which means it can be used to make a wide array of snack pellets.

Kuipers have created a way to remove dirt from the oil which means that the oil does not need to be changed. This results in higher quality oil which is essential when deep frying these types of food products.

Pellet snacks frying line

Factors such as the increase in disposable income and consumption of small meals facilitated a rapid growth within the snack industry. To capitalise on your local market and beat competition it is important to keep the process natural while maintaining taste, colour, smell and crispiness during the frying of extruded and pelleted snacks. Despite the rise in production volumes, a frying solution must maintain proper care during the processing of each individual pellet snack.


<h2>Always maintain a high product quality</h2>
Kuipers’ complete processing lines for various snacks are capable of processing snacks that have been already pre-dried as well as extruded products. It uses a unique frying technology, wherein snacks are carefully transported through the fryer in a continuous process while being carefully monitored. It allows you to easily control and monitor the process through its main programmable logic controller.

The frying line for extruded snacks is configured to enable gentle heat transfer to heat up the frying oil with a very small fluctuation in temperature of the frying oil. Its low frying oil content in its unique fryer pans help achieve a oil turn over time of less than 3 hours. It is also designed to prevent dust and small particles from entering the fryer maintaining oil quality for longer periods. Production transportation within the fryer is also key in the process. This allows every single piece of the product to have the exact same retention time and no possibility to escape from the flow to stay behind and burn. Customization according to the raw product makes the whole process accurate and the product quality consistent.

The efficiency of our technology combined with the optimal process for the specific product allows uninterrupted production for days or weeks. It does not require an expensive filter system or adding chemicals which eventually have an impact on the quality of the end product and the health of the consumer.

Frying line for extruded snacks and pellets

Kuipers Food Processing Machinery specializes in the technology for the frying and processing of snacks, savouries, nuts, seeds and potato products.

Born during challenging times such as the Industrial Revolution and rooted in the “Waste not, Want not” philosophy, pork rinds are a great example of converting waste materials into useful ones. Made from pigskin leftovers, these pellet snacks are a true specialty, particularly in the north of Europe.

So what does it take to produce a pork rind snack? To find out we set up an interview with Valeria Lucinschi from <a href="https://kuipers.nu/">Kuipers Food Processing Machinery</a>, an expert company in industrial frying systems.


<h4>How is frying pork rinds different from frying other snacks?</h4>
Pork rind frying is considered an easy process because this pellet snack absorbs a lot of oil, meaning that the frying oil is always replenished within the fryer. In general, most pellet snacks absorb over 20% of oil, while other products like nuts absorb only around 2%. The overall process of maintaining oil quality is therefore less challenging in this case.

Frying is essentially taking the moisture out of a product. Since pellet snacks have a relatively low percentage of moisture, the frying process can be quite short. Some of them are even fried for just a few seconds (flash-frying) - this is not the case with pork rinds, however. This special product is usually fried at a higher temperature and for much longer than traditional pellets.
<h4>How can a manufacturer guarantee the uniformity of each pellet as they come out of the fryer?</h4>
It’s essential that the time inside the deep-fryer, called retention time, is the same for each pellet. When the pellet expands to form our crunchy snack, it also starts floating. A good transportation system inside the fryer is necessary to ensure each pellet is evenly fried and expanded while carrying it along towards the defatting stage.

Another critical factor is ensuring the fryer and the transportation system are designed according to the dimensions and properties of the products to be processed. Unlike other fried snacks, pellets can vary significantly in size.



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<a href="https://making.imgix.net/2022/05/shutterstock_1732308994-scaled.jpg"><img class=" wp-image-53679 aligncenter" src="https://making.imgix.net/2022/05/shutterstock_1732308994-300x200.jpg" alt="" width="738" height="492" /></a>
<h4>What oil is good or will lead to a better tasty snack?</h4>
Most producers fry the pork rinds in lard, which is also a part of the animal usually thrown away. The pork rind gets a better, more intense taste when fried in its fat. Unlike traditional oils, lard solidifies if not kept at the right temperature, typically higher than 40 degrees. When using this fat, manufacturers need additional components in the line such as an extra heating system.
<h4>What determines how many snacks we can fry in our fryer?</h4>
Bulk density is one of the most important factors for sure. Pellets expand when frying; this means that the volume of the product that can be fried varies a lot because some can expand more, and some can expand less. This is not usually an issue with other products like nuts, because they don’t change their size during frying. Other factors like moisture content and frying time can also play a vital part in the capacity output from industrial fryers.

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Pork rind frying; from pigskin waste to tasty pellet snack

Food

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

A snack is a small portion of food ready to eat and simple and fast to prepare. People usually consume snacks during the day between traditional meals such as breakfast, lunch, or dinner. Snack foods include simple products such as nuts, dried fruits, peanuts as well as packaged and processed foods. Puffed corn products made by extrusion or flavored potato chips are examples of processed foods.

Snacks

Find production technology for Pellet snacks extrusion, and connect directly with leading machine manufacturers worldwide

Pellet snacks extrusion

Which pellet snacks extrusion equipment do you need?

Laboratory extruder

Extruder with annular gap expander

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