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Pellet snacks extrusion Equipment

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

In industrial snack production, consistent and even seasoning application on extruded products is essential. Conventional seasoning methods often result in uneven coverage and potential damage to delicate snacks, affecting quality and consumer satisfaction.
<h2>Ensures even seasoning and minimal product damage</h2>
The Flavour Drum SWT by Hebenstreit is a precision-engineered solution for seasoning extruded snack products. The drum's special profile guarantees optimal mixing, ensuring uniform application of seasoning across all extrudates. The rotation speed and adjustable inclination angle (0-4.4°) control dwell time and degree of filling, thus minimizing product handling and potential damage. With a drum diameter of 1000 mm and a length of 2500 mm, this system is designed to handle high-volume operations, making it suitable for various types of snack production. Its robust construction ensures durability and efficient performance under industrial conditions.

Seasoning drum for extruded snack products

Producing high-quality savoury and sweet snacks like curls, balls, and rings requires precise extrusion to ensure consistent shapes and textures. Challenges include controlling the temperature and mixing of raw materials effectively to achieve uniform product quality.
<h2>Processes raw materials into various snack shapes.</h2>
The Single-Screw Cooking Extruder SE by Hebenstreit is pivotal for snack production, designed to process a wide array of raw materials into high-quality extrudates efficiently. It can produce both sweet and savoury snacks, with the ability to form simple shapes such as curls, balls, wheels, sticks, and rings, as well as complex 3D shapes. The SE70 model handles an output of 100 to 250 kg/h, while the SE110 model processes 200 to 450 kg/h of dried, unseasoned extrudates. Equipped with an inline mixer for homogeneous raw material blending and an inline humidifier for automatic water injection, the extruder ensures optimal consistency. Accurate temperature regulation of the stator and die helps in maintaining the desired product quality. The rotating cutter head can be fitted with up to six blades, offering flexibility in cutting simple and complex shapes. A patented process guarantees even feeding of challenging raw material mixtures.

Single-screw cooking extruder for snack production

In industrial processes where transformation of powders or particles into uniform pellets is required, achieving consistency and stability in the final product can be challenging. The need to minimize dust and ensure uniform pellet size is crucial for optimizing downstream applications.
<h2>Create uniform, dust-free cylindrical pellets</h2>
The Gear Pelletizer AGF, offered by Hosokawa Alpine, is designed to form stable cylindrical pellets with a smooth surface through low-pressure extrusion. This pelletizing process utilizes a pair of counter-rotating hollow toothed rollers. The product is drawn in by the rollers and pressed into nozzle bores, forming cylindrical pellets as it exits the inner side of the rollers. The compression ratio is adjusted by varying the nozzle diameter and length, which can range from 1 to 10 mm. This equipment can operate dust and gas-tight and can handle operations with inert gas or solvents. The Gear Pelletizer AGF is suitable for applications such as extruding stable cylinder pellets, improving usability and regulation properties, and achieving high-stability granulate.

Gear pelletizer for stable cylindrical pellets

Fried peanuts are a very popular snack around the world. If you are looking to start a nut processing plant to capitalise on this market, maintenance of product quality and taste is key. When frying nuts, optimal heat distribution and oil quality are the most crucial factors. A state-of-the-art fryer and process are needed to deliver the exact heat load needed to fry your product efficiently while maintaining its taste.


<h2>Save time, frying oil and labour costs</h2>
Kuipers’ production line for nuts and seeds is configured for optimal frying-oil handling and heat treatment resulting in the lowest possible development of Free Fatty Acids as well as lowest frying oil turnover time in the industry.  It is a frying oil heating system with an innovative design that uses circulating thermal oil as a heat carrier. This allows the reduction of the amount of frying oil required to its lowest .

The <a href="https://making.com/peanuts/">peanut processing machine</a> and frying line keeps in mind the importance of oil quality as it not only acts as the heat transfer medium but is also absorbed by your product. It is thus equipped with a unique filtration system where constant removal of the dirt allows the quality of the frying oil to remain adequate much longer than other conventional systems. It is an automatic and continuously operating filtration system.

All Kuipers lines allow the option to heat the frying oil in the fryer with either thermal oil or electrical elements. With a few additions, the plant can also be upgraded to produce coated and <a href="https://making.com/battered-nuts/">battered nuts</a>. It can be applied for the frying of peanuts, <a href="https://making.com/cashews/">cashew nuts</a>, almonds, macadamias and other nuts or seeds.

Peanut frying line

The key to making a flavorful and crispy bag of potato chips is the frying temperature within the frying machine. Uniform cooking conditions ensure a consistent taste, bite, and color when it comes to potato chips processing. But maintaining steady temperatures across the entire processing line can be challenging, particularly when frying potato chips at high capacities.


<h2>Distribute the frying temperature evenly with multiple oil injection points</h2>
The semi automatic Potato chips production line frying plant from Kuipers uses multiple fully automatic oil injection points to deliver even temperature distribution within the potato chips machine. Manufacturers can manage heat across the width and length of the system to maintain optimum frying conditions throughout the whole process. Distinct oil injection zones facilitate temperature control which needs to be optimal for quality, tasty products.

A full turnkey system for producing potato chips is included in this production line. The machine includes washing, peeling machine, cutting potato slices, blanching, packing machine and most importantly, fries potato chips. For a small scale or full scale potato chips plant, this stainless steel production line does it all so you can successfully make potato chips from start to finish including packaging.

The chip fryer is designed for processing all styles of potato-based fried snacks, including chips, sticks, and hard-bite-style crisps. As well as sweet potato chips, banana chips and french fry style crisps. Capacities are offered from 250 kilograms per hour output to 1000 kilograms per hour output depending on oil volume. The best oil will produce the best final product.

Potato chips production line

Manufacturing potato chips is a farm-to-fork process from raw material to the final product. From washing and peeling to processing and frying and more in between. Freshly harvested potatoes are first washed, peeled, and sliced into thin potato slices. After washing them again to remove the starch, potatoes are then blanched, fried, seasoned, packed, and served, ready for your consumer’s enjoyment.

Potato chips

<span style="font-weight: 400;">From cassava to sweet potatoes, various types of vegetables are processed to make one mixed bag of vegetable chips. Mainly consisting root vegetables like taro and parsnip, vegetable chips are often introduced as a healthy alternative to potato chips. To make these chips, you first need to slice the vegetables and cook them depending on your product; you can simply bake them or fry them, deep fry them, or dry them. After this process, flavorings are added to the chips. </span>

Vegetable chips

Peanuts, also known as groundnuts are one of the most popular edible seeds in the world. You can eat them as-is or process them further into on-the-shelf products like peanut butter, oil, snacks, and soups. Depending on what you want to make, some peanut manufacturing processes include roasting, frying, boiling, grinding, pressing, and coating the peanuts.

Peanuts

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

Fast plant startups require well-defined roadmaps for scope, time, cost, and quality, to facilitate decision-making when purchasing and installing industrial technology. We spoke to Valeria Lucinschi, General Operations at Kuipers Food Processing Machinery, to learn how they ensure an efficient buying and installation cycle and align their fryers with producers’ goals.


<h2>The buying cycle from product testing to FAT</h2>
Valeria explains that when you contact Kuipers to choose a frying technology for your snack, the food engineering team will observe the product's behavior, document it, collect data, and perform computer simulations considering oil efficiency and turnover times. Product testing will help to determine the ideal fryer, size, oil amount, processing time, and other product-specific parameters. “Many new products need further testing to ensure the target outcome can be achieved,” Valeria states.

The buying cycle described by Valeria begins once the parameters are agreed upon. “The engineering department creates the drawings and sends a work order to manufacturing. When the fryer is built and assembled, Kuipers’ service team takes over with electrical pre-wiring and automation. Then the plant is fully pre-tested to ensure that all the main parts are functional. You are invited to attend the factory acceptance test (FAT) and may request alterations at this stage if needed,” Valeria indicates.

“After your agreement, the fryer is packed in Lego-like blocks and shipped. In the best-case scenario, a small standard fryer can be ready within 36 weeks. However, delivery times may be longer depending on the waiting list,” Valeria concludes.
<h2>Site preparation and modular design: the key to quick startup</h2>
Site preparation is crucial for a quick startup. Ensure your facility has the required electrical connection, automation cables, and piping in place beforehand. Kuipers’s modular design makes installation nearly plug-and-play. “The plant can be assembled like Lego blocks and plugged into the utilities,” Valeria says. Kuipers will run an acceptance test on your site and train your operators before finalizing the handover.

According to Valeria, “Kuipers' modular design allows small standard frying plants to be operational within one week of delivery, compared to most equipment suppliers, which take about a month to install and start up a plant. This can save you a significant amount of time and money, considering that an average engineer day costs more than 1000 euros.”

When choosing industrial technology, consider the operation and maintenance requirements as well. Valeria highlights that “With Kuipers' frying systems you can operate for many days without having to change your oil’’. These efficient systems allow you to produce continuously while not compromising your product quality.

Modular plant designs are a way to go if you want to start and run your production, saving time, and hence, money.

Modular design for a fast fryer plant startup

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 fresh salad with a walnut oil dressing or a peanut butter sandwich? A bag of roasted cashews or a pack of almond cookies? The common thread among these tasty treats is nut processing equipment. Not all nut ingredients are indeed nuts, botanically speaking. But the machinery that transforms shelled fruits, legumes, and drupes into fried snacks or a paste is similar. As for the food products, there is a nut recipe for every mood and occasion.

Nuts

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

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 (redirected)

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

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Pellet snacks extrusion Equipment

Which pellet snacks extrusion technology do you need?

Laboratory extruder

Extruder with annular gap expander

Seasoning drum for extruded snack products

Single-screw cooking extruder for snack production

Gear pelletizer for stable cylindrical pellets

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