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Extrusion equipment

extrusion-process

Extrusion-process

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

<span style="font-weight: 400">If Popeye needed spinach for his power, you need healthy snacks to boost your energy! From dried fruit chips to nuts and protein bars, healthy snacks have become more popular since the 2000s, and t</span><span style="font-weight: 400">he global healthy snack market will reach USD 98 billion by 2025. </span><span style="font-weight: 400">In the wide range of healthy snacks, raw fruits and vegetables appear as the main ingredient, and these snacks focus on the high protein content and reduced fat or carbohydrate percentages. Also, “less processed” and “less amount of added chemicals” are the primary trend in making healthy snacks as the clean eating movement began after the 2000s. </span>

Healthy snacks

Pet food is a specialty food mostly based on formulated ingredients for various nutritional and dietary requirements. Pet food formulas are becoming more diverse and complex, considering the special health conditions and needs of young and aging pets that live in cities. The production of pet food is similar to processing food in general when it comes to fresh feedstock and flesh products.

Pet food

We continuously talk to suppliers of feed processing technologies that have important know-how on how to create the smarter, better, and greener feed products we need to kickstart a better tomorrow. Are you into making animal feed or pet food and looking for ways to improve your production process? Let’s navigate the world of feed production technologies together!

Feed

There is a pasta type for every mood. Curly, straight, ridged, or smooth, pasta has quickly grown into a staple food. The simple combination of milled wheat and water is transformed by pasta making equipment into a rainbow of shapes, colors, and sizes. But producing pasta with the right firmness, elasticity, and color profile is as intricate a process as preparing an authentic lasagna.

Pasta

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.

Continuous

Industrial

Ensuring a uniform and thorough mix for high-viscosity materials can be challenging. Traditional mixing methods often struggle with agglomerates and uneven torque distribution, compromising the quality and efficiency of the kneading process.
<h2>Achieve uniform mixing and effective torque transfer</h2>
The GUITTARD MX series by HASLER Group offers a robust solution for high-viscosity kneading applications. The double Z-arm kneader, capable of handling up to 10,000 litres, utilizes Z-shaped arms to provide optimal tank coverage, effectively breaking down agglomerates and ensuring an even mix. Its rugged drive mechanism guarantees efficient torque transfer, making it ideal for complex processes in industries such as chemicals, cosmetics, and food production. The modular design allows for customization, while options like an extrusion screw enhance integration into continuous production systems. The equipment meets CODAP, ASME, and TÜV international standards, ensuring reliability and quality.

Double z-arm industrial extrusion kneader for high-viscosity processes

Extrusion

Kneading

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

solid

Producing high volumes of diverse ice cream products quickly and efficiently is a significant challenge in modern ice cream manufacturing. Ensuring consistency in texture and shape while maintaining high hygiene standards and minimizing energy consumption are critical for success.
<h2>Maximize production efficiency with advanced extrusion technology</h2>
The BT extrusion and hardening lines from Gram Equipment offer high-speed production for a variety of ice cream products including sticks, sandwiches, ball top cones, bars, logs, and cakes. This system features a tunnel design that optimizes airflow for increased hardening efficiency, minimizing energy consumption and ensuring high product quality. The integrated worktable layout and anti-freeze chain system facilitate easy maintenance and cleaning, reducing downtime. Advanced electronic synchronization and performance monitoring enhance production control and flexibility. Designed with exceptional hygienic standards, the BT extrusion lines support safe and high-quality ice cream production.

High-speed ice cream extrusion line

In extrusion processes, maintaining product quality and preventing equipment downtime are crucial. Unwanted solid particles can clog the die, leading to production inefficiencies and compromised product quality.
<h2>Ensure consistent quality and safety in extrusion</h2>
The Screen Changer from Extrufood is an essential component designed to enhance the performance and reliability of extrusion lines. It filters out solid particles that could clog the die, ensuring the extruded product remains of high quality. A key feature includes a start-up valve that regulates pressure buildup for added safety. The screen changer can be locked in a central position—without a screen—allowing easy checking and reworking of the extruded mass for texture and consistency. This central position also serves as a quick and secure method to prevent damage to downstream equipment, effectively reducing downtime. Extrufood, under the Extrugroup brand, is recognized for their innovative and customized solutions in extrusion technology, serving the confectionery, pet food, and plastics industries.

Screen changer for extrusion lines

Industrial filtration equipment separates solid matter from liquid by using a filter medium. The filter allows only the fluid to pass through but retains the solid matter. The choice of filtration equipment depends on the particle size, the consistency of the mixture, and the nature of your product.

Filtration

In the confectionery industry, creating visually appealing products with multiple colors often requires complex processes and increased setup times. This can be a significant challenge for manufacturers attempting to stay competitive and meet consumer demands for unique and attractive products.
<h2>Enables easy color switching in extrusion process</h2>
The Dieswitch® from Extrufood is an advanced extrusion system designed to simplify the production of confectionery products with multiple colors. It allows for individually colored strands to be easily switched during the extrusion process, enabling manufacturers to achieve intricate color patterns and effects such as sun downer and natural color ripening. This innovation not only boosts production efficiency but also enhances flexibility, allowing for a multitude of color and shape combinations. The Dieswitch® can significantly increase production volume per line, providing a practical solution for companies in the confectionery, pet food, and plastics industries.

Extrusion system for color changing confectionery strands

Efficiently cooling and conditioning extruded confectionery products to room temperature is crucial for seamless continuous production. Without proper cooling, issues such as irregular cutting, packing challenges, and potential damage to the product can arise, disrupting the production process.
<h2>Cool and condition extruded products effectively.</h2>
The cooling tunnels from Extrufood are designed to efficiently cool and condition extruded products to room temperature. These versatile tunnels come in both single and multi-tier configurations, featuring a retractable infeed belt. This allows for easy adaptation between single and multi-tier operations, making it possible to handle products with high filling ratios of up to 30/70. The belt can be adjusted up or down without extensive line modifications. Extrufood cooling tunnels are tailor-made to meet specific customer requirements, ensuring optimal performance in continuous extrusion production lines.

Cooling tunnel for confectionery extrusion

Conditioning

Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water. Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries.

Cooling

In the production of directly expanded food products or extruded chemical goods, achieving consistent and high-quality pelletization is crucial. Poor pellet quality can lead to product rejection, processing inefficiencies, and increased operational costs.
<h2>Ensures uniform pellet quality</h2>
The ZGF Centric Pelletizer from Coperion is designed for producing directly expanded food stuffs, extruded chemical products, and pharmaceutical applications. It features a centrally arranged knife rotor and die plate, ensuring uniform pellet length which can be adjusted by the number of knives and the rotor speed. The quick release connections and swivellable pelletizer hood allow for easy access during cleaning and die plate changes. The spring-loaded knife rotor maintains consistent contact with the die plate, ensuring high-quality pellet production. It also includes a safety device to prevent the pelletizer hood from opening until the motor is at a standstill. Available in various models, the ZGF 30, ZGF 70, and ZGF 125 accommodate different production needs with motor power ranging from 1.1 to 11 kW.

Centric pelletizer for direct extrusion

Cutting

Pelleting equipment transforms powdered, mashed, or grounded material into a denser cylindrical shape. Pellet processing compresses the fine material against a perforated die, where it will be shaped and cut. Although granulating and extrusion also produce pellet-like products, manufacturing pellets is a distinct process.

Pelleting

In industries like pharmaceuticals and petrochemicals, the need to produce consistent and high-quality pellets or beads is critical. The challenge often lies in minimizing downtime caused by cleaning and changing over between different products.
<h2>Efficient production of pellets and beads with easy cleaning.</h2>
The Caleva Extrusion and Spheronization System 100 kg/hour allows for rapid changeover between different products due to its easy dismantling and cleaning features. This system, invented by Caleva, who named the process of spheronization, integrates both extrusion and spheronization in a compact and mobile design on lockable wheels. Suitable for a variety of industries including pharmaceuticals, catalyst manufacturing, petrochemicals, and ceramics, it focuses on efficient production with minimal downtime. The system is ideal for flexible contract manufacturing and single product production. The small footprint and ease of movement make it practical for facilities with limited space.

Pellet and bead extrusion and spheronization system 100 kg/hour

In the confectionery industry, producing consistent and visually appealing marshmallows requires precise control over the extrusion process. Achieving the correct texture and appearance while efficiently utilizing raw materials is essential for high-quality marshmallow production.
<h2>Extrude colorful, twisted marshmallow strings</h2>
The Mondomix Cable Extruder by Bühler is designed to continuously extrude strings of marshmallow mass onto a starch belt. This equipment allows for color variety and precise control over the extrusion process, with nozzle outlets equipped with regulating valves to balance product flow. The speed of nozzle rotation can be adjusted to create different shapes and dynamic stripes, delivering visually appealing products. Particularly suitable for candy and sugar masses, it ensures efficient raw material usage to produce colorful marshmallows in various configurations, such as twisted strings. The Mondomix Cable Extruder is ideal for confectionery producers looking for consistent and versatile marshmallow production solutions.

Colorful marshmallow extrusion for confectionery production

In the manufacturing of pipes and tubes, the need for precise control over diameter and material thickness is crucial. Achieving consistent and accurate extrusions often requires specialized tools to handle various specifications without the hassle of frequent equipment changes.
<h2>Allows precision control of pipe and tube extrusion</h2>
The Brabender Tubing Die Head is an accessory designed to enable the extrusion of pipes and tubes with different diameters and material strengths. This equipment comes with easily exchangeable die inserts, allowing quick changes to meet various production requirements without the need to replace the entire nozzle head. This feature helps save time and effort while maintaining consistent quality. The Tubing Die Head is suitable for numerous applications, including the chemical industry, education, research, energy, food industry, minerals, mining, and raw materials sectors, as well as the petroleum industry. Supported by Anton Paar's certified service, the die head comes with a 3-year warranty and global technical support, ensuring reliability and longevity in operation.

Tubing die head for pipe extrusion

When extruding various products in industries like chemicals and food, it's crucial to have a versatile die head capable of maintaining specific dimensions and ensuring consistent quality.
<h2>Precision extrusion with adjustable die diameters</h2>
The round strand die head from Brabender is designed for precision extrusion, equipped with a heating collar and compatible with screw-in dies ranging from 1 mm to 7 mm in diameter. This provides flexibility in extruding different products by simply switching the screw-in nozzles. The round strand die head can also be equipped with a cutting device, making it unique among extrusion die heads. This makes it ideal for use in industries such as chemicals, food, and academic research where precision and adaptability are essential.

Round strand die head for precision extrusion

In the food industry, producing quality pasta and similar products often involves the need for precise extrusion heads. Controlling the temperature during extrusion is a common challenge, impacting product quality and consistency.
<h2>Produces uniform pasta with adjustable cooling</h2>
The Pasta Die Head by Brabender is designed to create pasta and similar extruded products. This specialized head is notable for its ability to be cooled by both air and water, offering flexibility depending on production needs. Temperature control during extrusion helps in maintaining the integrity and consistency of the final product. Suitable for industrial-scale production, it integrates seamlessly with Brabender extruders like the Extrudiograph series. The head is built to handle different pasta shapes and sizes, ensuring uniformity and quality across batches. Brabender's Pasta Die Head is also backed by Anton Paar’s certified service, ensuring reliable operation throughout its lifecycle.

Pasta die head for food industry extrusion

Industrial measurement equipment is used as a crucial step before products leave the production line. These measuring instruments check for correct dosage and standards. Equipment for measurement and control employs a wide range of technologies to detect inconsistencies in volumes, sizes, weights, and fill levels as well as to inspect goods for quality against a set of criteria. Specialized measuring tools allow you to minimize the probability for error to its lowest possible, ensuring that both products and packaging meet your benchmarks.

Measurement &amp; Control

Batch

Pilot

In the realm of polymer research and product development, accurately assessing the extrudability of materials is crucial for creating high-quality products. One major challenge is simulating real-world production processes within a controlled laboratory environment.
<h2>Assess and analyze polymer extrudability accurately</h2>
The Brabender measuring extruder and Extrusiograph models 30/25 and 30/32 are advanced, electrically heated measuring heads connected to a Brabender torque rheometer. These devices are essential for testing the extrudability of polymers under realistic conditions. They can precisely measure and record various parameters during the extrusion process, providing reliable and meaningful results for subsequent evaluation. Particularly suited for research and application development, these extruders offer a practical approach to simulating production processes with small sample sizes. This makes them invaluable in not only understanding material behaviors but also in optimizing formulations and processing conditions.

Polymer extrusion testing extruder

Drawing samples and testing them for conformity with preset quality standards allows manufacturing units to produce a consistent quality of the product. In a batch process, sample testing systems ensures that each batch meets the specified standards. In a continuous process, product and materials testing helps in the early identification of quality issues, saving significant time and resources, and preventing a sub-standard product from reaching the market. The selection of industrial testing equipment depends on the identification of key quality parameters. These parameters may include volume, weight, viscosity, hardness, particle size distribution, sterility, gauge and containment, among other parameters. Testing machinery need regular calibration to ensure that the parameters being tested are accurate. Some of the more common testing solutions include thermal imagers, scratch testers, optical inspectors and texture analyzers.

Testing

In the extrusion process, achieving uniform film quality can be challenging. This is especially true when dealing with various polymers and film dimensions. Precision in inflation, cooling, and winding is critical to ensuring high-quality output and operational efficiency.
<h2>Optimize film production and quality control</h2>
The Blown Film Take-Off Unit by Brabender is designed to work with an extruder and film blowing die head for simultaneous inflation, cooling, flattening, and winding of an extruded film tube. This unit stands out due to its wide range of adjustment options, which allow you to optimize production conditions easily. Features like adjustable working height, winding torque, and cooling air help you adapt to different film dimensions and properties. Optional modules are available to measure and control film width and analyze film quality. The unit is integrated with MetaBridge Connect for full control and automated data transfer when used with Brabender MetaBridge extruders, making the entire process streamlined and efficient.

Blown film take-off unit for extrusion

Producing icebox cookies for large-scale distribution involves several challenges, including shaping dough uniformly and efficiently cooling it. Manual production is time-consuming and resource-intensive, making it difficult to maintain consistent output and quality.
<h2>Streamline dough shaping for mass production</h2>
The Icebox Cookies Extruder by ANKO is designed to automate the shaping process of icebox cookie dough, addressing the inefficiencies of manual production. By placing the dough into the hopper, the extruder forms it into uniform bars, ready for sequential refrigerating and slicing. This extruder is equipped with customizable molds, allowing for the production of dough bars in various shapes. With dimensions of 1,080 (L) x 450 (W) x 1,080 (H) mm, a power requirement of 0.4 kW, and a capacity range of 400–4,000 g/min, this tool is suitable for a variety of industrial applications. The maximum diameter for shaping molds is 60 mm, and the extruder weighs 100 kg (net). Manufactured by ANKO, a company with over 46 years of experience in food machinery, the extruder meets ISO certification standards and is equipped with CE and UL inspection approvals. Primary uses include production in the confectionery industry, specifically for icebox cookies, biscuits, and similar baked goods.

Icebox cookies extrusion solution

The process of forming allows you to shape your products homogeneously. Forming machines are fed the manufactured material in bulk and cut it down to specification, so the process takes place between formulation of the mass and the packaging of the final item.

A special class of this equipment – Form, Fill, and Seal Machines (FFS) – creates bags and pouches from flat material such as plastic sheets, fills them with your designated product, and seals them.

Forming

In injection molding and extrusion processes, achieving a precise and consistent blend of materials is paramount. A key challenge is accurately metering color concentrate, regrind, and other additives into the flow of primary materials.
<h2>Precisely meter additives into material flow</h2>
The AF Series Volumetric Additive Feeders by AEC (ACS Group) ensure accurate and reliable metering of various additives, such as color concentrate and regrind. Designed with a modular structure, these feeders can handle one or two materials. Key features include a low-profile throat section and an easy-to-clean, interchangeable stainless steel auger assembly. The feeders introduce a free-flowing additive into the center of the primary materials' flow, ensuring a consistent blend. These feeders can be used in virtually any injection or extrusion process, including as a starve feeder for extruders. Models AF-1, AF-2, and AF-200 offer specific configurations to suit different requirements, with options such as a push-button digital control display, variable speed drive motor, and stainless steel components.

Volumetric additive feeders for injection and extrusion processes

Blending

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

Injection

Metering

In extrusion processes, ensuring a consistent and homogeneous blend of multiple components is crucial for maintaining product quality. Traditional batch-type blenders and mixers often result in variations that can compromise end products.
<h2>Achieve consistent blends for extrusion processes</h2>
The AccuMeter™ Ovation from AEC (ACS Group) is a continuous loss-in-weight blender designed to deliver the most homogeneous blend for extrusion applications. Equipped with precision load cells, this system eliminates the weight and vibration inconsistencies typically associated with metering auger and motor assemblies. The lower mass flow weigh hopper of the AccuMeter™ Ovation learns the exact extruder rate and continuously communicates this to the control system. This adjustment ensures that the upper material feed rates match the learned extruder rate, maintaining a consistent ingredient ratio. It can handle up to 2 to 6 components and process up to 5000 pounds per hour, making it suitable for diverse extrusion tasks. The unit includes an Allen-Bradley Micro850 PLC with a high-resolution 7-inch color touchscreen and a variable frequency drive (VFD) system with inverter duty AC motors for precision auger metering and a broader recipe range.

Continuous loss-in-weight blender for extrusion applications

Weighing

When producing chocolate masses for extrusion, maintaining precise temperature control is critical to ensuring consistent product quality. Without proper cooling, the final chocolate can suffer from incorrect tempering, leading to texture and appearance issues.
<h2>Ensure precise cooling for extrusion processes</h2>
The Cooling Unit from Aasted is an essential component for extensive cooling of chocolate masses during extrusion. This compact unit integrates a small tank with a built-in agitator, providing optimal mixing and cooling. An optional aeration system is available to meet specific production needs. Designed with efficiency and flexibility in mind, the Cooling Unit ensures that the chocolate mass maintains the ideal temperature and consistency throughout the extrusion process. Easily attachable to existing production lines, this unit is ideal for chocolate manufacturers seeking reliable and precise cooling solutions.

Cooling unit for chocolate mass extrusion

Aerators are devices used for mixing air (oxygen transfer) with a liquid such as water or oil to form a homogeneous product. Selecting an industrial aeration system involves choosing a suitable mixing head and considering the desired input and output flows, temperature, level of aeration, properties of the liquid phase, and the degree of automation and pressure control. Aerators are used in the food industry for the production of fat-based center masses and crèmes and in the chemical industry for wastewater treatment. When it comes to water treatment, surface aerators are most commonly used.

Aeration

When blending solids and liquids into highly viscous pastes or plastic masses, achieving uniform consistency can be challenging due to the high material density. Traditional mixing methods may fall short in delivering homogeneous mixtures, especially in continuous production environments.
<h2>Kneads, mixes, and extrudes continuously</h2>
The Extrudomix from Hosokawa Micron is a mixer/extruder that combines high shear mixing and low to medium pressure extrusion in one continuous process. A horizontally aligned shaft with blade segments arranged in a spiral pattern moves material through the chamber. As the material advances, it undergoes continuous kneading and mixing due to stationary anvils positioned between the rotating blades. This results in homogeneous pastes and plastic masses efficiently and cost-effectively. The Extrudomix features heating and cooling jackets and a variety of die shapes and sizes, making it versatile for numerous applications, such as homogenizing filter cakes or mixing base powders with liquids. Available in several models with capacities ranging from 340 kg/h to 4550 kg/h, it caters to both small and large-scale production needs.

Mixer/extruder for viscous pastes and plastic masses

<span style="font-weight: 400">The heating process is a step of raising the temperature of food, pharma, cosmetics, and many other types of products. You may employ different heating solutions for this process, depending on the type of product you intend to manufacture. Selecting the appropriate heater machine for your product is quite important since various products require different ranges of temperatures and different ways of heat transfer using exchangers. Industrial heating equipment varies in two ways - the type of material it can process and the reaction you want to achieve.</span>

Heating

liquid

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

In the chemicals industry, achieving dust-free, uniformly sized granulates is crucial for applications like additive manufacturing and dry flue gas cleaning. Traditional methods often fall short in maintaining consistency and quality, presenting a significant challenge for production lines focused on efficiency.
<h2>Form and round cylindrical stable pellets</h2>
The Gear Pelletizer AGF from Hosokawa Alpine is designed to form cylindrical, stable pellets with uniform length. Utilizing counter rotating hollow toothed rollers, the AGF Gear Pelletizer processes materials into granulates with diameters between 1 to 10 mm. For creating shingled, highly porous granulates, the Bextruder compresses material through an extrusion rotor and perforating die. The Bexroller further refines these granulates, rounding them off in a spheronization process. These pieces of equipment are integral in industries that require precision and reliability, particularly in chemical, food, and pharmaceutical applications. The systems are known for their efficiency and low-maintenance operation, ensuring high-quality end products with minimal dust.

Pelleting and spheronizing equipment for chemical granulates

Purification is the removal of contaminating substances and by-products to increase the level of purity of the desired substance. Considerations for choosing a suitable purification system in the industry, include the physical state of the mixture, the desired product, required level of purity, the type of mixture, heat sensitivity of the product, number of purification steps needed, and the production volume. Industrial purification systems are used for the production of pure water in the food pharmaceutical and biotech industries.

Purification

Refining

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 snack production, precise storage and tempering of cream is critical before it can be used in extrusion processes. Ensuring consistency and optimal temperature of the cream can directly affect the quality and texture of the final product.
<h2>Store and temper cream effectively</h2>
The Intermediate Cream Container CZB from Hebenstreit is designed for storing and tempering finished cream before it is pumped into the extruder. Equipped with two special pumps, it ensures that the cream flows directly into the two product strands at the die plate during the extrusion process. This precise control over cream temperature and flow rate helps maintain the consistency and quality of the product. The system is ideal for processes involving raw material preparation, extrusion, drying, seasoning, cooling, co-extrusion, cutting, embossing, and conveying.

Intermediate cream container for snack production

Almost all manufacturers will require industrial storage systems and solutions at some point during their production process. The raw materials that go into your products need dedicated storage solutions to protect them from spoilage and contamination before they enter the manufacturing cycle. Storage usually refers to particular storage space. For example, having enough warehouse storage. Or clearing out a production facility for more floor space.  However, in this case, we are referring to the equipment and solutions that make storage manageable and easier. Such equipment includes solutions such as storage racks, pallet racks and shelving systems. These are just some of many storage options available to manufacturers. Advanced technology facilitates the management of heavy duty and high density tank and silo systems by automating the delivery system and linking it with the rest of the production line.

Storage

Tempering equipment is most commonly used in manufacturing chocolate products as well as bakery products. However, tempering can also be found in the metals industry for processing alloys. The idea behind the tempering process is to heat two or more items to a certain temperature so that they can be blended together easier. Chocolatiers pass the chocolate through a heating cycle and then a cooling tunnel to give their final products a smooth and glossy finish. Tempering machines automate this process, evenly distributing the crystal structure in melted chocolate across the entire production line. Besides enhancing the look and texture of coatings, denser and consistent crystallization also has the benefit of slowing down fat migration in your chocolate-filled products. A vibrating table is an important component for tempering chocolate. First the chocolate mixture goes through a dispenser into the chocolate mould. After which the vibrating table is used to evenly distribute the mixture in the mould so that there are no air bubbles. Thus, creating a smooth and consistent final product.

Tempering

In snack production, achieving uniform dyeing and precise cutting of extruded products can pose significant challenges. Consistency in color application and precise control of product length are crucial to maintaining product quality and meeting production targets.
<h2>Dyes and cuts up to 12 extruded strands efficiently</h2>
The Inking System SIS by Hebenstreit is designed for the continuous dyeing and cutting of up to 12 endless extruded strands. After extrusion, the system picks up product strands and applies dye in adjustable stripes before cutting them to the desired length. The product length is continuously adjustable, and natural dyes like beetroot juice can be used for coloring. This system enables the consistent application of dye and precise cutting, which are vital for maintaining high-quality output. The adjustable nature of the system allows customization based on production needs, supporting versatile snack product manufacturing.

Continuous extruded snack dyeing system

In high-volume ice cream production environments, achieving consistent product output with minimal downtime is critical. Operations often require a system capable of filling various packaging formats efficiently while meeting stringent hygiene and safety standards.
<h2>Fill up to 40,000 ice cream units per hour</h2>
The Flexline Filler from Gram Equipment is an automated, in-line ice cream filling system designed to meet high capacity, hygiene, and safety demands. With a capacity of up to 40,000 cups or cones per hour and up to 12,000 bulk products per hour, the Flexline Filler offers remarkable flexibility and usability. It features a comfortable working height and dual-side operation for ease of use. The filling process adapts to different packaging volumes and ingredient types through extrusion, volumetric, or time-elapse filling. Additional features include selectable equipment options like chocolate spraying for cone impregnation, multi-flavor fillers, various decoration units, and dosing mechanisms. The system is easy to clean and inspect, ensuring compliance with hygiene standards.

Automated in-line ice cream filling system

Decoration equipment adds the finishing touch to your industrially-prepared foods by depositing ingredients in a specified pattern on the surface of the products. Your items pass individually under a system of nozzles that lay the decorating formula precisely and uniformly. Popular in confectionery, decoration is used to differentiate products in the market.

Decorating

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

In the industrial ice cream production sector, there's a growing demand for diverse and innovative product offerings. Producing ice cream that includes large chunks of ingredients like cookies or fruits requires specialized extrusion technology to maintain product integrity and quality.
<h2>Add large inclusions to extruded ice cream</h2>
The LIFE and LIFE-3D units from Gram Equipment enable the extrusion of ice cream with large inclusions while shaping it in a single unit. Utilizing their patented Cryo-ZAT™ (Zero Adhesion Technology), these units can handle the addition of any inclusion that can run through an ingredient feeder, ensuring that large cookie pieces or other inclusions maintain their integrity through the extrusion process. They support a production capacity of up to 120 pieces per minute for both stick and stickless products, dependent on the downstream handling capabilities. This makes the LIFE unit particularly suitable for creating unique and visually appealing ice cream products that cater to modern consumer preferences.

Extruded ice cream with large inclusions

Shaping

Producing high-quality licorice on a continuous production line requires a consistent slurry. This involves mixing ingredients into a homogeneous mass and ensuring a steady feed to the cooking extruder. Maintaining a continuous feed can be challenging without an appropriate preparation system.
<h2>Ensure consistent slurry feed to extruder</h2>
The slurry preparation system by Extrufood is designed to create a homogeneous mixture of ingredients for licorice production. It features two counter-rotating agitators in the mixing tank, ensuring an even blend. The slurry is then transferred via a pump to the cooking extruder for continuous processing. To address the issue of batch processing versus continuous feeding, a day tank is used. Typically holding twice the volume of the mixing tank, this water-heated, jacketed vessel includes an inspection opening, an agitator, and level indicators. This setup provides a buffer, allowing for uninterrupted supply to the extrusion process. Additionally, a double filter station ensures that the slurry remains contamination-free and can be cleaned easily without stopping operations.

Slurry preparation for licorice production

In the confectionery industry, processing diverse viscous masses such as licorice, fruit gums, and chewy candy can be challenging. Achieving consistent texture and shape while maintaining high production efficiency requires specialized equipment.
<h2>Form and shape various confections with ease</h2>
The Extrufood forming extruders are twin-screw, co-rotating extruders, specifically designed to handle a variety of viscous masses including licorice, fruit gums, fruit snacks, sugar paste, chewy candy, toffees, and caramels. These extruders are built on a robust, single base frame, ensuring stability during operation. The intermeshing screws are self-wiping, simplifying the cleaning process. An optional twin-screw, counter-rotating infeed section allows for a stable, de-aerated mass flow, enhancing consistency. For multi-colored products, Extrufood offers solutions such as the Diemix® for mixing color and flavor directly after extrusion or a twin-forming extruder setup. Every part in contact with the product is made from stainless steel, ensuring hygiene standards are met.

Confectionery forming extruders for viscous masses

In pharmaceutical manufacturing, precise ingredient handling is crucial to ensure product quality and efficacy. Challenges include maintaining high accuracy in feeding systems and meeting rigorous cleaning requirements to prevent contamination.
<h2>Ensure precise and hygienic ingredient handling</h2>
The Coperion K-Tron pharmaceutical design feeders are engineered specifically for use in pharmaceutical applications. These feeders can handle a variety of materials, including active pharmaceutical ingredients (APIs), excipients, and lubricants. The modular design offers flexibility, allowing for quick changes in feeder types and sizes, which aids in process adaptation and simplifies cleaning. All product contact surfaces are made from FDA-approved materials and adhere to cGMP guidelines, ensuring compliance with industry standards. With options for volumetric and gravimetric configurations and capabilities for minimal feed rates as low as 32 g/h, these feeders offer high accuracy and flexibility. They provide complete product containment, suitable for use in hazardous environments (ATEX, NEC) and integration into continuous processes such as blending, granulating, and extrusion. Validation documentation and state-of-the-art controls are available to meet CFR 21 Part 11 compliance.

Pharmaceutical design feeders for precise ingredient handling

Granulation

Powder

In industries where high volume production of materials with low bulk density is crucial, traditional extrusion methods often face challenges. These include difficulties in feeding materials with poor flow properties and achieving high throughput rates without compromising product quality.
<h2>Enhance throughput and efficiency with advanced twin screw technology</h2>
The ZSK Mv PLUS by Coperion is a twin screw extruder optimized for processing materials with low bulk density and high filler content. Its design features a large free screw volume and high screw speeds, allowing for maximum throughput with specific energy requirements below 0.13 kWh/kg. This extruder offers gentle product handling, reducing thermal and shear stress, which is essential for maintaining product quality. The series is capable of speeds up to 1,800 rpm and provides a specific torque of 11.3 Nm/cm3, which boosts productivity by up to 40% compared to previous models. With application-specific solutions such as quick-release features and side devolatilization (ZS-EG), the ZSK Mv PLUS is ideal for industries requiring flexible and efficient processing capabilities. Key applications include polymerization, powder coating, catalyst carriers, adhesives, and food processing.

High throughput twin screw extruder for low bulk density products

In pharmaceutical production, ensuring uniform mixing and minimizing degradation of active pharmaceutical ingredients (APIs) is crucial. Traditional batch processes can lead to inconsistencies and higher degradation rates, leading to inefficiencies and increased costs.
<h2>Continuous mixing and dispersion of Apis</h2>
The ZSK Pharma Extruder from Coperion excels in continuous mixing of pharmaceutical ingredients. Featuring a modular barrel design customizable to product needs, it ensures intensive mixing with minimized product degradation. The extruder utilizes high torque, accommodating high throughput rates while maintaining low product temperatures. Constructed in GMP design, it uses FDA-compliant materials for all product contact parts. With specific torque up to 18 Nm/cm³ and maximum speeds up to 1,200 rpm, the ZSK Pharma Extruder can handle throughputs from 1 to 10 kg/h in laboratory settings. The advanced control system simplifies operations, while the compact design facilitates easy cleaning and maintenance. Ideal for pharmaceutical hot melt extrusion and wet extrusion of APIs, this extruder is a versatile tool for enhancing product bioavailability and creating controlled-release formulations.

Pharmaceutical twin screw extruders

Dispersion

In the production of diverse food and pet food items, ensuring a consistent texture and quality throughout the process can be a challenge. Precise control over ingredient mixing and cooking conditions is essential for achieving the desired product characteristics.
<h2>Enhance food and pet food extrusion processes</h2>
The ZSK Food Extruders by Coperion are designed for the efficient extrusion of various food and pet food products. The extruders feature a series of co-rotating, closely intermeshing screws that eliminate stagnant zones, thereby ensuring a consistently high conveying efficiency and self-cleaning capability. Their modular design allows for configurations tailored to specific applications, leveraging a combination of free screw volume, screw speed, and torque. The extruders come in a range of sizes, suitable for laboratory to full-scale production. The ZSK Mv PLUS series offers speeds up to 1800 rpm with a specific torque of 11.3 Nm/cm3, making it suitable for high throughput and diverse formulations. Typical applications include pet food, cereals, snacks, and texturized proteins. The stainless steel, open-frame design promotes hygiene and easy cleaning, minimizing downtime.

Food extruders for pet food production

Whether it is marmalade or pizza, sauce or hummus, chocolate or fruit puree, most food products undergo a cooking step during their production process. Cooking is nothing more than applying heat to food, but there are different methods to do it. For instance, baking, frying, and roasting involve cooking food without using water, unlike boiling or steaming. Industrial cookers such as vacuum and pressure cookers, industrial fryers, industrial ovens, and industrial roasters focus on specialized applications that meet the different needs of the food industry by helping producers achieve a homogeneous cooking process.

Cooking

When manufacturing food products like snacks or pasta, maintaining high-quality while increasing production volume is essential. Traditional methods can struggle with throughput and process stability, leading to inconsistent results.
<h2>Enhance production with advanced twin-screw technology</h2>
The Evolum+ twin-screw extruder by Clextral offers high levels of throughput, flexibility, and control, ensuring optimal process stability and maximum product quality. With production volume up to 40% higher than standard models, it achieves an improved volume/energy ratio. Advanced Thermal Control (ATC) provides better process stability (up to 70%) and energy savings (up to 20%). Constructed for hygienic processing, the extrusion system is available in stainless steel or stainless/painted steel. Suitable for various food products, the Evolum+ features an ergonomic design and open profiles for easy access and maintenance.

High-performance twin-screw extruder for food production

When producing gelatine, precise cooling and gelling of concentrated extracts are essential to ensure product integrity before extrusion and drying. Efficient processing techniques are required to achieve high-quality gelatine outputs, especially for creating uniform gelatine noodles.
<h2>Cool and gel concentrated gelatine extract</h2>
The Unità Chemetator fissa by Chemtech (Omnia Technologies) provides a range of scraped surface heat exchangers designed for efficient cooling and gelling of concentrated gelatine extract. These heat exchangers can be equipped with inclined extrusion tubes and perforated plates, which are crucial for producing gelatine noodles. The perforated plates allow for optimal drying on a drying belt before the final product grinding, ensuring consistent quality. The extruded noodles break under their own weight and fall onto the drying belt, facilitating even drying. This technology is targeted towards food industries that deal with large-scale gelatine production, balancing both effectiveness and efficiency in processing.

Scraped surface heat exchangers for gelatine processing

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

When preparing high-viscosity products like doughs and rubber compounds, achieving a thorough and efficient mix presents numerous challenges. These include ensuring even distribution of ingredients, maintaining the desired temperature, and preventing leaks during the mixing process.
<h2>Ensure thorough mixing of viscous materials</h2>
The Double Sigma Arm Mixer from Carugil is designed for intensive kneading and mixing of high-viscosity products. Its dual sigma blades deliver consistent, high-capacity performance needed by industries dealing with difficult-to-mix materials. The mixer includes front and rear bowl seals made of high-quality material to prevent leaks and maintain product quality. To accommodate specific process requirements, the bowl is available with a double jacket for heating or cooling and thermal insulation protected by stainless steel hermetically sealed panels. Options such as a Variable Frequency Drive (VFD) for speed control and specialized extrusion spouts enhance the mixer’s versatility. For discharge, the mixer offers tilting bowl or extrusion screw mechanisms. This design ensures efficient processing, reduced maintenance needs, and consistent product quality.

Double sigma kneader for viscous product mixing

In the food and confectionery industry, maintaining consistency and quality during the extrusion process is essential. Traditional methods often struggle to offer flexibility and high throughput, resulting in inefficient operations and potential quality issues for products such as chewing gum, soft candies, and protein bars.
<h2>Ensures stable and precise mass flow</h2>
The Carugil CSTR is a counter-rotating twin-screw extruder designed to meet the specific demands of processing food and confectionery masses. Constructed with heavy-duty materials and featuring stainless steel contact areas, the CSTR ensures durability and safety. The twin-screw infeed section provides stable infeed, resulting in consistent mass flow. With a water-jacketed extrusion barrel and electronic temperature control, the extruder maintains accurate and even temperature throughout the process. The machine also includes an inverter-controlled variable speed drive for the extrusion screws, allowing for precise control. Additionally, the CSTR supports various filling types such as powder, semi-liquids, and granulates, accommodating a wide range of products.

Food and confectionery twin-screw extruder

In the research and development of pharmaceutical and chemical formulations, precise control over mixing, extruding, and spheronization processes is critical. Small batch sizes and customizable parameters are often needed to optimize formulations and reduce waste.
<h2>Mix, granulate, extrude, and spheronize efficiently</h2>
The Caleva Multi Lab, provided by Caleva Process Solutions, is an all-in-one lab scale tool designed for formulation development. The device allows for mixing, granulating, extruding, and spheronizing in batch sizes from 10 grams to 50 grams, making it suitable for small-scale R&D projects. The system includes a standard and high-density die at no extra cost, enabling the exploration of different extrusion parameters. It also has interchangeable mixing bowls (275ml and 71ml) and blades, including a Sigma blade and bowl system for high-viscosity materials. The compact design minimizes bench space, fitting three distinct processes into a single, small footprint machine. This equipment is particularly valuable for pharmaceutical, chemical, and catalyst production, where precise control over pellet size, density, and surface area is essential for successful formulation.

Lab scale mixer, extruder & spheronizer for r&d formulation

Entry level

In pharmaceutical, petrochemical, and ceramics industries, precise pellet formation is essential for ensuring product quality. Rapid changeovers and efficient cleaning between batches can be challenging, often leading to downtime and reduced productivity.
<h2>Efficient spheronization and extrusion for high-quality pellets</h2>
The Spheroid Extruder Spheronizer System from Caleva Process Solutions handles 50 kg per hour and is ideal for product development and contract manufacturing. Its quick cleaning capability allows frequent product changes, optimizing time and resources. This system operates with development batches as small as 250 g, making it versatile for various applications. Trusted by industries such as pharmaceutical, catalyst manufacture, petrochemicals, and ceramics, this equipment is designed for reliability and efficient use of space. The system’s small footprint and ability to pass through standard doors enhance its adaptability across different facility areas.

Spheroid extruder spheronizer 50kg per hour

In industries such as pharmaceuticals, cosmetics, chemicals, and food, efficient and flexible production of uniform pellets is essential. Challenges include managing varied material densities and minimizing downtime due to cleaning or part wear.
<h2>Produces up to 150 kg of pellets per hour</h2>
The Caleva Twin Screw Production Pelletizer Kit combines the Caleva Variable Density Twin Screw Extruder (VD-TSE70) and the Caleva Spheronizer 700 to provide reliable and efficient pellet production. Capable of producing up to 150 kg of pellets per hour, this system supports continuous or intermittent operation. The extruder offers variable density control to tailor extrudates and pellets according to specific product properties. Its compact design and axial extrusion can handle up to 200 kg per hour, offering several die patterns for diverse applications. The Spheronizer 700 utilizes air blast technology for enhanced efficiency and includes a water jacket for precise temperature control. This kit is particularly useful for industries such as pharmaceuticals, cosmetics, chemical engineering, and more. The Caleva VD-TSE70 and Spheronizer 700 systems facilitate easy assembly and disassembly, ensuring effective cleaning and sterilization. Additionally, Caleva's robust engineering reduces the risk of damage across various industrial materials.

Twin screw pelletizer for continuous production 150 kg/h

Laboratories and pilot plants often need precise extrusion processes to simulate production conditions on a smaller scale. Ensuring consistent material handling and quality control during these trials is critical to achieving reliable data that can guide large-scale production decisions.
<h2>Achieve precise, small-scale extrusion</h2>
The Brabender TwinLab twin-screw extruders are designed for lab and pilot-scale extrusion tasks. Their robust construction, featuring nitrided barrels and high-speed capabilities of up to 1200 rpm, ensures long life and flexibility in handling various materials. The patented clam shell design allows for easy cleaning and observation. Supplied with versatile MetaBridge software, it enables complete control and data access through any device. Multiple configurations and sizes make it adaptable for processing liquids, powders, and pellets, delivering throughput rates from 0.05 kg to 100 kg per hour. This modular system is powered by MetaStation drive units and is suitable for both research and small-scale production.

Lab-scale twin screw extruder

In polymer processing, achieving high-quality compound mixtures consistently can be challenging, especially when dealing with varying material viscosities and intricate blending requirements. Ensuring homogeneous mixing while managing high shear forces is crucial for producing reliable feedstock materials.
<h2>Ensures superior compound mixing and processing</h2>
The Brabender Twin Screw Compounder TSC 42/6, provided by Anton Paar, is designed to meet the demanding needs of polymer compounding. It features counter-rotating twin screws that offer high shear forces, forced conveying, and self-cleaning capabilities, enhancing the efficiency and effectiveness of the mixing process. With a throughput of up to 6 kg/h and adjustable mixing times, this compounder is suitable for a range of continuous and batch processing applications. The TSC 42/6 is equipped with a two-strand die head with interchangeable inserts, allowing for versatile operation from mixing to extrusion. The system's design ensures long residence times and excellent cross-flow for optimal mixing, making it ideal for producing feedstock materials for injection molding trials and other polymer processing tasks.

Twin screw compounder for polymer processing

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable industrial conveying system include the nature of the product, its physical state, the desired conveying rate, and sensitivity of the product to heat and mechanical shock. Conveying equipment is used in the food, pharmaceutical, chemical, biomass, and mineral industries to move materials around a warehouse as well as to transport bulk powders, granules, and grains for processing and filling. These types of systems are usually automated and there is a wide variety of solutions to choose when it comes to the type of conveyor. Types include screw, gravity, chain, roller and belt conveyors.

Conveying

When testing materials in the lab or conducting pilot-scale trials, there is a need for precise and versatile extrusion capabilities. It's crucial to handle diverse materials, including liquids, powders, and pellets, while maintaining rigorous data tracking.
<h2>Measure material properties with lab extrusion</h2>
The Brabender TwinLab series is a range of lab- and pilot-scale twin screw extruders designed to deliver detailed material insights through comprehensive measurement parameters. Featuring a powerful MetaBridge software platform, it offers intuitive control and data analytics accessible from any device. The patented clam shell design allows easy access for cleaning and monitoring. The series supports both twin and single-screw extrusion, offering flexibility in material processing. With various models available, such as the B-TSE-A 12/36 and B-TSE-S 20/40, users can handle throughputs from 0.05 kg/h to 100 kg/h. The Nitrided barrel surface ensures maximum lifetime even in abrasive conditions.

Small twin screw extruder

Manual

In polymer and food industries, controlled processing of raw materials into consistent extrusions is crucial for product quality and efficiency. Achieving this requires a versatile and reliable extrusion system capable of handling various materials and processes.
<h2>Versatile and efficient extrusion processing</h2>
The Brabender Stand-Alone Extruder KE 30 is designed for diverse extrusion tasks with a throughput of up to 15 kg per hour. This extruder supports a wide range of nozzles and offers both manual and PC operation. The newly available 32D cylinder enhances material testing capabilities. It is equipped with a CAN bus system for easy configuration of extrusion lines, ensuring high operating comfort and safety. Brabender's extruder is ideal for polymer and food processing industries, providing flexibility and efficiency in a compact design.

Stand-alone extruder for polymer and food processing

In laboratory settings, researchers and developers often face challenges in producing small, yet representative, samples of plastics, food, and feed. Such tasks require equipment that can ensure precision and reliability while operating within limited lab space.
<h2>Compact extrusion of small sample sizes</h2>
The Stand-Alone Extruder KE 19 by Brabender is specifically designed for lab-scale testing in various industries, including plastics, food, and feed. Its space-saving and economical design, combined with an integrated drive, requires minimal lab space. This lab extruder supports grooved tube configurations and is optimized for small sample sizes, making it ideal for producing conclusive test results. The compact setup ensures less material waste and provides precise control over the extrusion process, which is crucial for experiments and product development. Brabender’s KE 19 is acknowledged for its robust design, ensuring durability and consistent performance in demanding research environments.

Stand-alone extruder for lab-scale testing

Developing meat-like textures from plant proteins at a laboratory or pilot scale requires precise control over product dimensions and process parameters. The exact temperature control and modular production capabilities are essential in creating consistent and high-quality products.
<h2>Control cooling and process for plant protein extrusion</h2>
The Modular Cooling Die from Brabender is designed to provide precise control over the extrusion process for texturised plant proteins. This die features three heating/cooling zones with independent temperature control, allowing you to fine-tune the process for different product textures and dimensions. Six accessible openings along the die enable concurrent measurement of pressure and temperature, providing comprehensive data for process optimization. The modular nature of the die allows for easy adaptation to various product sizes and requirements, ensuring it fits perfectly into your specific extrusion setup. Ideal for laboratory and pilot plant applications, this cooling die facilitates effective development and testing of plant-based meat analogs using raw materials such as wheat gluten and soybeans.

Modular cooling die for texturised plant proteins

Complex processes call for continuous tracking and monitoring systems that help you to keep the manufacturing operation under control. The technology analyzes the components in the production phase for divergence in behavior or changes in conditions. Based on advanced software applications, monitoring platforms make sure that your products satisfy the quality criteria while they are being developed.

Monitoring

In research and material development, precise control over experimental conditions is crucial to achieving reliable results. Challenges such as material homogeneity, energy efficiency, and resource optimization demand advanced extruder technology for testing formulations on a laboratory or pilot scale.
<h2>Optimize material processes with twin screw extruders</h2>
The Brabender TwinLab-C 20/40 is a twin screw extruder designed for lab and pilot-scale applications, providing comprehensive control over the extrusion process. It features a modular framework that allows you to tailor components such as screws, die heads, and feeders to your material requirements. This flexibility supports the development and testing of novel formulations with minimal resource consumption. Capable of handling small sample quantities while preserving manufacturing resources, these extruders enable rigorous testing without relying on full-scale production setups. Brabender's live process monitoring ensures continuous oversight of process parameters, allowing for the correlation of process variables with the properties of the extrudate. Suitable for industries including the chemical and food sectors, the TwinLab-C 20/40 is an invaluable tool for innovation in material science.

Lab-scale twin screw extruders for material development

Formulation technologies are an integral process in many industries such as pharma and food. Chemical mixtures require strict handling to combine the separate ingredients into the homogenized recipe that makes your final product. Formulation technology stores, mixes and subjects the elements to a range processing parameters according to your specifications to develop the base material. The resulting formulas are then weighed, formed, packaged, or sent for further formulation.

Formulation

When conducting research on the extrudability of polymers and similar materials, precise control over the melting and homogenization process is critical. Engineers require detailed data to analyze development and application engineering challenges under realistic conditions.
<h2>Control and analyze polymer extrusion parameters</h2>
The Brabender Extrusiograph 19/25 and 19/32 by Brabender are specialized extruders used for investigating the extrudability of polymers and flowable products. These instruments melt the sample in a heated barrel, homogenize it, and transport it from the screw to the die at the discharge. Throughout this process, various parameters are measured and recorded for in-depth analysis. Notably, the Extrusiographs offer a modular measuring head, facilitating small sample volumes and efficient operation. They feature grooves in the cylinder and three measuring points, providing comprehensive data for subsequent evaluations.

Polymer testing extruder

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for the emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving the consistency and uniformity of various products.

Homogenization

In industries focusing on the processing of shear-sensitive materials such as PVC, maintaining product integrity while ensuring effective mixing and kneading is crucial. Traditional methods often fail to provide the precision and control necessary for high-quality results.
<h2>Ensures effective kneading for delicate materials</h2>
The Conical Twin Screw Extruder (CTSE) by Brabender is designed specifically for testing the extrusion behavior of materials typically processed in twin screw extruders. It features gentle and effective kneading properties, making it suitable for shear-sensitive materials like PVC. The nitrided barrel surface extends the equipment's life, even when used with abrasive products. Polished and chrome-plated screws, available in various special steels, further enhance its durability and performance. An integrated degassing system ensures the removal of entrapped air, thereby improving product quality. This extruder is versatile enough to handle different film dimensions and properties, thanks to its accessory compatibility. Users can benefit from its long service life, precise kneading, and reduced material degradation.

Conical twin screw extruder for shear-sensitive materials

Degassing

In extrusion applications, maintaining consistent cooling and alignment of strands is essential. Traditional cooling systems often result in strand misalignment and suboptimal cooling efficiency, leading to product inconsistencies.
<h2>Achieve optimal strand alignment and cooling</h2>
The WBX Series Water Bath by Bay Plastics Machinery is designed for precise strand pelletizing. Custom-built in various dimensions, it accommodates most extrusion processes. The standard adjustable legs facilitate alignment with different pelletizers and extruders, while the locking quick-releasing hold-down bars ensure straight, even strands. These bars feature 2-inch grooved UHMWPE rollers, reducing friction. Models range from 6 to 30 feet in length, with 3 to 5 hold-down bars. Optional water recirculation systems, including a pump, heat exchanger, strainer, and automatic water make-up circuit, maintain optimal operating levels by compensating for evaporation and spillage.

Industrial water bath for pelletizing processes

Developing new pharmaceutical formulations or ensuring consistent quality in complex drug production processes often requires precise and controlled extrusion techniques. High containment is also necessary to protect both the product and operators from exposure to active pharmaceutical ingredients.
<h2>Ensures precise extrusion and high containment</h2>
The twin-screw extruder by Leistritz, represented by Austar, is designed for emerging pharmaceutical applications such as hot-melt extrusion, melting granulation, wet extrusion, and film dosage preparations. A high-torque spline shaft and flexible thread elements allow for various screw configurations, providing a broad process window. The extruder also features a uniquely designed barrel for stable and accurate temperature control. It offers high containment solutions from OEB3 to OEB5, ensuring safe operation. Austar's laboratory in Shijiazhuang is equipped with ZSE 12 HP-PH equipment for material testing and equipment demonstrations. Leistritz, the first to apply this technology in the pharmaceutical sector, partners with numerous reference-listed drug manufacturers, attesting to its reliability and expertise.

Twin-screw extruder for pharmaceutical applications

In large-scale bakeries, optimizing production efficiency while maintaining high quality is a significant challenge. Conventional batch processing often limits output and can introduce inconsistencies. When faced with the demand for mass production of buns and rolls, these hurdles become even more pronounced.
<h2>Boost production efficiency for buns and rolls</h2>
The High-Speed Bun and Roll System by AMF Bakery Systems is a comprehensive solution for large-scale production facilities looking to enhance efficiency and output. This system integrates advanced features like the FLEX extrusion dividers for precise dough handling and consistent product quality. With a capacity to produce up to 96,000 pieces per hour, the system significantly increases throughput while maintaining stringent sanitary standards with open frame designs. Ideal for producing various types of buns and rolls, including hamburger buns and hot dog buns, this system ensures superior product consistency and operational simplicity. The integration with AMFConnect™ allows real-time monitoring and data-driven decision-making, further optimizing bakery performance. Additionally, components such as the BakeTech Continuous Proofer and Oven ensure precise control over fermentation and baking processes, maximizing product quality and minimizing rejects.

High-speed bun and roll production system

Baking

The fermentation process stimulates enzymatic activity in organic substrates to transform their chemical composition. Fermentation is aided by storying the biomaterials in anaerobic environments, allowing the microorganisms to decompose their nutrient structures. The process is integral to some of the most popular products throughout time such as wine, beer, cheese, and kimchi. But besides the food sector, fermentation is also an important stage in the industrial manufacturing of chemicals, pharmaceuticals, and biofuels.