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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.

This label marks technology built with specific processing know-how on how to help their customers move towards plant based production or improve their plant based products. 

making-logo

making logo

Accelerate protein transition

A dedicated food extrusion innovation center for testing on twin-screw extruder to develop meat substitutes and extenders as High Moisture Meat Analogues and dry TVP

Continuous

<span style="font-weight: 400;">Shaped and filled extruded products are extremely popular with consumers, but can be complex and inefficient to manufacture on a large scale whilst maintaining high consistency and quality. A dedicated extrusion solution designed from the ground up for high level production provides consistency while delivering reduced costs.</span>


<h2>Twin screw extruder with enhanced quality and production flexibility</h2>
<span style="font-weight: 400;">The SBX Master Extruder by Baker Perkins has been designed specifically to enable the production of a range of high quality extruded snacks. Its integrated design allows for the easy addition of flavouring and colours, and the SBX Master is capable of producing complex multi-ingredient premium product, as well as more standard designs such as expanded corn balls, multigrain rings and shaped designs.</span>

<span style="font-weight: 400;">The SBX Master is built for flexibility. A modular barrel design allows the perfect length to be chosen to exactly suit the product required, maximising quality, and advanced features are available such as super-cooling to allow the production of fine extruded flakes.</span>

<span style="font-weight: 400;">Set up, recipe selection and full condition monitoring are available through an easy-to-use HMI with graphical representation. The open frame design means all areas of the machine are easily accessible for cleaning and maintenance, and AC motors are used throughout which are maintenance free and consume less power than DC equivalents.</span>

<span style="font-weight: 400;">Another key aspect in reducing costs is the SBX Master’s capability for rapid product changeover. Face-cutter blades are able to be changed quickly, without the need for the extruder to be brought to a complete stop, and fully automatic start-up and shutdown cycles have been designed to minimise waste between production runs.</span>

Extruder for large-scale production of TVP

Extrusion

solid

Soybeans are an essential ingredient in the creation of protein-rich animal feed. To achieve high-quality feed production, extrusion technology is used to facilitate mechanical and heat treatment of soybean seeds. The use of extruders helps to break apart the inner structure of soybean seeds, which makes it easy to transport nutrition in animals’ digestive system.


<h2>Mechanical grinding and heat treatment of soybean feed</h2>
The organic soybean feed extruder designed by Farmet is capable of heating up to very high temperatures and extruding oil seeds under great pressure. Soybean seeds are mixed, kneaded and squeezed into uniform shapes of pellets and granules. Short-time exposure to high temperature helps to alter the natural qualities of protein and reduce anti-nutritional substances from soybean seeds, thus enhancing the digestibility of soybean feed for ruminant livestock.

Farmet’s extruder removes bacteria and other unwanted organisms through sterilization and changes the texture of soybean seeds through expansion and gelatinization of starch. Designed with a hydraulically openable basket, the use of this unit will significantly reduce your downtime losses during maintenance as all parts are easily accessible and replaceable.

Organic soybean feed extruder

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

Batch

Cereal and grain bars are increasingly popular, both as snack foods and as functional foods using natural ingredients. Traditionally, a higher-quality softer bar has been difficult to produce economically in small-to-medium production environments. Additionally, standard machines have only been able to produce either moulded dry-grain based bars or extruded dried fruit paste-based bars, limiting production flexibility. A modern, purpose-designed machine that can address these issues is therefore an attractive proposition.


<h2>Flexible bar machine for grain or fruit paste-based products</h2>
The Bar 2 from DSC is a flexible entry-level machine for the production of extruded or moulded soft cereal bars.

For dry cereal mixes, the product is dosed onto a conveyor which passes it through a laminating roller to assert the initial thickness. A further laminating roller then produces the final product dimension.

For dried fruit pastes, two specially designed rollers shape the pre-mixed product into a fully adjustable extrusion.

For both product types the final stage is to cut to final product size. Cut dimensions can be selected by means of the built-in touchscreen control interface.

The HMI allows the creation and storage of multiple product recipes for easy recall, meaning simple one-person operation.

The whole machine has been designed to be simple to clean, with all product contacting surfaces easily accessible for hot water washdown.

Entry-level cereal bar making machine

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

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

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

<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

<span style="font-weight: 400;">Shaped and filled extruded breakfast and snack products are extremely popular with consumers, but can be complex and inefficient to manufacture on a large scale whilst maintaining high consistency and quality. A dedicated extrusion solution designed from the ground up for high level production provides consistency while delivering reduced costs.</span>


<h2>Twin screw extruder with enhanced quality and production flexibility</h2>
<span style="font-weight: 400;">The SBX Master Extruder by Baker Perkins has been designed specifically to enable the production of a range of high quality extruded breakfast cereals. Its integrated design allows for the easy addition of flavouring and colours, and the SBX Master is capable of producing complex multi-ingredient premium product, as well as more standard designs such as expanded corn balls, multigrain rings and shaped designs.</span>

<span style="font-weight: 400;">The SBX Master is built for flexibility. A modular barrel design allows the perfect length to be chosen to exactly suit the product required, maximising quality, and advanced features are available such as super-cooling to allow the production of fine extruded flakes.</span>

<span style="font-weight: 400;">Set up, recipe selection and full condition monitoring are available through an easy-to-use HMI with graphical representation. The open frame design means all areas of the machine are easily accessible for cleaning and maintenance, and AC motors are used throughout which are maintenance free and consume less power than DC equivalents.</span>

<span style="font-weight: 400;">Another key aspect in reducing costs is the SBX Master’s capability for rapid product changeover. Face-cutter blades are able to be changed quickly, without the need for the extruder to be brought to a complete stop, and fully automatic start-up and shutdown cycles have been designed to minimise waste between production runs.</span>

Extruder for large-scale production of breakfast cereals

If you want to produce the highest quality product using more delicate masses, traditional depositors can be too aggressive and overwork the mass. You need a machine that's been designed specifically for lower scale higher quality work with gentle handling.


<h2>Plug-and-play C-Frame depositor and extruder for small volume production</h2>
The Aasted Alice is an innovation breakthrough for small volume production of high quality confectionary. Able to be used as a standalone unit or as part of a more complex enrobing line, the Alice is able to grow and expand with you.

The modular design means you can start simply with a single head extruder, and yet at a later date add further extrusion modules to produce increasingly intricate and exciting product. The large range of die tools provides a large range of possibilities for output.

Designed with delicate masses in mind, the Aasted Alice ensures gentle handling from input to output stage, applying the absolute minimum of work and shear as it passes through the machine.

Alice has been engineered to handle a vast range of masses including nougat, marzipan and almond pastes, peanut butter, aerated fillings, caramels, praline centre masses and much more. With individual temperature control of hopper and dies you can tailor Alice to give perfect results every time.

For hygienic cleaning or production changeover, the Alice is the first extruder depositor that allows complete hosing down off-line. All parts are easy to handle, lightweight and offer quick release/disassembly features that all combine to minimise downtime.

C-frame extruder for bakery masses

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

Depositing equipment is a very common production line process in the food industry. Whether you want to make muffins or jellies or garnish and decorate cakes, all of this is impossible without the depositing step. Depositing is a form of extrusion used primarily to produce pieces of dough that will be further processed to create several food products. The dough is passed through a depositing machine and poured in equal parts from holes in a die plate with nozzles or a conveyor belt. But that’s not all. Depositors are also used to fill, layer, or cover your food items with other ingredients before proceeding to the next step of the production process which is usually packaging.

Depositing

liquid

Do you need the highest quality single mass products? Traditional machinery can be too aggressive to achieve perfect results, often overworking the mass resulting in lower quality. You need a gentle single-mass solution that has been designed specifically for smaller volume high quality production.


<h2>Compact, gentle single-mass depositor and extruder for small volume production</h2>
The Aasted Alice is an innovation breakthrough for small volume production of high quality confectionary. Designed with delicate masses in mind, the Aasted Alice ensures gentle handling from input to output stage, applying the absolute minimum of work and shear as it passes through the machine.

The modular design means you can start simply with a single head extruder, and yet at a later date add further extrusion modules to produce increasingly intricate and exciting product. The large range of die tools provides a large range of possibilities for output.

Alice has been engineered to handle a vast range of masses including nougat, marzipan and almond pastes, peanut butter, aerated fillings, caramels, praline centre masses and much more. With individual temperature control of hopper and dies you can tailor Alice to give perfect results every time.

For hygienic cleaning or production changeover, the Alice is the first extruder depositor that allows complete hosing down off-line. All parts are easy to handle, lightweight and offer quick release/disassembly features that all combine to minimise downtime.

Compact extruder for bakery masses

Are you looking to produce the widest range of extruded/deposited products possible, but don't want to compromise on quality and flexibility? Traditional solutions been designed to produce excellent results with a narrow range of masses. The compromise for this has been lack of flexibility, meaning a lower rate of return on investment for a "one trick" solution. The latest flexible solutions are able to offer outstanding results across a wide range of masses with the widest range of extrusion and depositing actions.
<h2>Fully modular extruder and depositor for handling the widest variety of masses with the highest quality</h2>
Designed around maximum flexibility and value, the Aasted Alice delivers outstanding results with the widest variety of masses.

The Alice head can be manually adjusted, automated on vertical movement, or fully automated horizontally and vertically. Single, double or triple head options mean the creation of products with up to three different masses.

To minimize downtime for maintenance, cleaning or product changeover Alice features easy removal of the entire deposit unit to allow offline hose down. All parts have been specifically designed to be lightweight, easy to release and easy to handle to maximize your efficiency. Inline cleaning is also possible with specialist tools available for the purpose if required.

Aasted QuickShift tools provide the ability for Alice to produce an astonishing range of products with simple changeover. Options include one-shot, two-colour extrusion and wire cutting, wire cutting for large inclusions, sequence depositing, depositing with pivot and more. In addition a completely customized tool option is available to fit your exact requirements.

Extruder for bakery masses

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

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

An extrusion machine pushes or pulls material through a shaped die to form a continuous length of product with a preset cross-section. The extrusion process is used to produce a large number of commercial products which include plastic tubing, plastic sheets, and many food types.


<h2>Kneading, mixing and extruding in one continuous process</h2>
The Extrud-O-Mix from Hosokawa Micron is an efficient extruder that kneads, mixes, and extrudes in one continuous process; as a standalone unit or in combination with other process equipment. Perfect for mixing solids and liquids into very viscous and homogeneous pastes as well as plastic masses, and moreover it has better particle dispersion in comparison to higher pressure systems, is also less expensive to buy and less expensive to operate. The high shear mixer can be used for a variety of applications like mixing base powders with liquids to form uniform pastes, homogenizing filter cakes, blending wet material with powders or liquids, homogenizing powders with liquids into a plastic mass followed by extrusion and pre-feeding of caked masses.
<h4></h4>

Continuous extruder for mixing solids and liquids

Blending

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

Low pressure extrusion for the production of slightly dispersed dust-free granulates. For shingled, highly porous granulates with good dispersal properties. With the basket extruder the material is compressed with an extrusion rotor with a perforating die.


<h2>Gentle pressure for granulates with a loose structure and large surface area</h2>
With the Bextruder BX from Hosokawa Alpine, the product is gently pressed to granulate with a loose structure and large surface area.

In the product chamber of the Bextruder two rotors operate in counter rotation. The upper rotor ensures good mixture and carries the material downwards. The lower extrusion rotor compresses the material and extrudes it through the screen basket.

The Bextruder is often used in pellets with a porous structure and large surface area, easily dispersible granulate, drinks powder, sauces and soups, detergent, pesticides and so on.

Basket extruder

Industrial separation equipment encapsulates the separation process which is to separate components of a liquid mixture, for recovering dissolved solids from liquids. The choice of a suitable technology depends on the identification of the key physical or chemical property, such as size, mass, density, or boiling point, which sets the product of interest apart from the rest of the components. Separation technology is widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high-purity chemicals. As well as in waste management and recycling industries.

Separation

Dough for speciality breads must first be rolled into sheets of varying thickness, to facilitate forming of rolls, bread sticks, pizza bases, and focaccia. High moisture choux pastry for eclairs and profiteroles requires additional moisture for more flexible dough. The water steams during baking enable the products to expand.


<h2>Automatic sheeter for plain dough</h2>
The Trivi-Z automatic plain dough sheeter is ideal for processing straight dough recipes which do not require grease or fat layers. It incorporates a moisture extruder especially designed for processing product containing over 75% of water. The machine accommodates different dough thicknesses for speciality breads.

This plain dough sheeter adapts to customer requirements, and automatically rolls out sheets suitable for a wide variety of applications at industrial scale. These include bread sticks, pizza, focaccia, ciabatta, baguettes, flat breads, tin breads, snacks and so on.

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Automatic bread dough sheeter

<span style="font-weight: 400">The molding process is often included in bakery products. Utilizing molding equipment guarantees a uniform shape, weight, and size. The molding machine first gently flattens the dough mix by going through a sheeter, where a series of rollers press the thin piece of dough. The sheet is then cut into the specified shape and, depending on your final product, may be rolled by using a curling chain. After the molding, other ingredients may be added before the products are conveyed for baking or freezing.</span>

Moulding

Industrial dough sheeters turn raw dough into sheets that match recipe thickness. This includes making layered dough for croissants and other pastries. The product doubles over several times in the process, at which point the folding angle must match the specifications of the product.


<h2>A continuous dough sheeter for puff pastries</h2>
The Trivi TRI-3 dough sheeter folds dough the number of times the recipe requires. This produces layered dough sheet for longer-lasting croissants, filled puff pastry, and strudel, as well as other products such as pot pies and sausage rolls. The machine incorporates a fat extruder for adding butter / vegetable margarine layers to the product as desired.

This dough sheeter adapts to meet customer recipes at industrial scale. It converts pre-moulded dough blocks into a state suitable for direct feeding into product moulding machines. Using the extruder does not require adjustments to settings.

Automatic pastry dough sheeter

<span style="font-weight: 400;">Small batches of product using high value ingredients are not economical or practical to run on full scale production extruders. Similarly, research and development that requires a higher output is costly if existing line equipment needs to be repurposed for only small batch runs. A dedicated lab-scale extruder that’s also capable of continuous small-batch production provides a lower cost alternative whilst delivering excellent results.</span>


<h2>High quality twin screw extruder for development work and small batch production</h2>
<span style="font-weight: 400;">The Baker Perkins MPF24 Twin Screw Extruder has been designed to offer the flexibility of a lab-scale device for product design and evaluation together with the capacity to operate as a small batch production extruder.</span>

<span style="font-weight: 400;">In lab and R&amp;D work, the MPF24 has been designed to perfectly scale-up results to Baker Perkins’ range of production scale food extruders thanks to using compatible screw geometry. The specially designed clamshell barrel can be opened at any time to allow the status of the process and product to be assessed.</span>

<span style="font-weight: 400;">For maximum flexibility, the MPF24 has been designed use wide range of cutters and dies. A comprehensive touch screen HMI allows for complete control as well as extensive monitoring and data capture, which is perfect for experimental use.</span>

<span style="font-weight: 400;">However the MPF24 is also robust enough to stand on its own as a small batch production extruder. A mobile platform allows the unit to be easily moved into a production environment, and it is particularly useful for making small batches of high premium product using high-value ingredients, or when only small quantities are available.</span>

<span style="font-weight: 400;">Products the MPF24 can produce include standard direct expanded curls, rings and puffs through to complex multi-component premium products. Ingredients are texturized and cooked through a combination of heat, mechanical shear and moisture addition, and flavourings and colours can easily be added.</span>

Pilot extruder for cereals and snacks

<span style="font-weight: 400;">Extruded products are very popular in the breakfast cereal and snack sectors. It is extremely inefficient to design, test and perfect new product ideas and recipes using full-scale production equipment. A high-quality lab-scale extruder is a vital tool both in product research and recipe design, and where results can be accurately scaled in production line design as well.</span>


<h2>Benchtop extruder for research, troubleshooting, and quality assurance needs</h2>
<span style="font-weight: 400;">The Baker Perkins MPF19 Benchtop Extruder is a high-quality twin screw extruder perfect for lab work, product design and process testing duties.</span>

<span style="font-weight: 400;">The MPF19 is equipped with the unique Baker Perkins “clam-shell” barrel. This allows the extruder to be halted at any stage and provides immediate access to check on the processed materials.</span>

<span style="font-weight: 400;">Designed with maximum flexibility for research and development, the MPF19 allows for quick and easy adjustment of formulation, all process settings, and all screw configurations. In addition, the  screw configurations offer identical geometry to full-scale production extruders which makes the MPF19 perfect for recipe formulation and testing. Fully automated start-up and shutdown procedure also perfectly mimics the same systems available on production scale machines.</span>

<span style="font-weight: 400;">An integrated control system provides almost all the controls available in a production scale extruder, and provides storage for up to 50 recipes and full performance data capture. The MPF19 can be connected to a PC to allow data download for analysis and comparison.</span>

Benchtop extruder for cereals and snacks

With a cold oil press, you can optimize the process of extracting oil from a wide variety of oil seeds and boost the production capacity.


<h2>Cutting-edge technology in cold oil pressing and essential oil production</h2>
The TBP series Multi-purpose cold oil press from Toper R&amp;D focuses on achieving the highest quality when extracting oil from any oil seeds by utilizing cutting-edge technology. The presses are mostly used for industrial purposes. Spice oils, cereal and grain oils, cosmetic oils, fruit seeds oils, flower and nuts seeds oils, are among the types of oil the TBP-100 is capable of producing. It comes with an approximate weight of 245 kgs  and a frequency of 50 - 60 Hz.

Cold oil press for seeds

Biscuits are confectionery products that contain mostly flour, which you mix and bake with other ingredients as sweet or savory snacks. Biscuit production involves four primary processes: mixing, forming, baking, and cooling. For you to perform these processes, you need basic biscuit processing equipment, including mixers, molders/cutters, and ovens.

Biscuits

The name Canola comes from ‘Canadian Oil Low Acid’. In the 1970s researchers in Canada developed rapeseed varieties with low erucic acid and glucosinolate. These properties made the seed safe for consumption while improving its palatability. Today, the varieties are grown worldwide and include the rapeseed double-zero, as it is known in Europe. In only a few decades, canola oil and canola meal processing carved out a central role in the global food and feed industry.

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Canola meal

Chewing gum is usually a polymer that you mix with flavorings – which is something most consumers have no clue about. In a survey in Iceland, 85% of people said they didn't know the product contained plastic. While there are non-plastic options more recently available, the gum base is usually natural latex or a synthetic substitute. To decrease the impacts on the environment, some producers are shifting towards more environmental-friendly options.

Chewing gum

Cookies

First developed by Will Kellogg in 1894, corn flakes’ popularity grew exponentially. Made from toasting flakes of corn (maize) and served with cold milk, corn flakes have become a favorite breakfast cereal snack for millions around the world. Corn flakes production begins with milling raw corn, creating cornmeal which is then extruded to create corn flakes.

Corn flakes

Cotton has been used for about five millennia in ancient civilizations in America, Africa, and Asia. But up until the nineteenth century, cottonseed was not considered a product of value. The first cottonseed oil production started in 1833, consequently forming the cottonseed cake. Nowadays, we know cottonseed meal is a useful by-product for the feed industry and the fertilizer sector.

Cottonseed meal

Croutons

Around 1860, American businessman James Spratt made dog biscuits by mixing vegetables, flour, beetroot, and meat. His novel idea came after he noticed dogs eating leftover biscuits from ships in England. Following the commercial success in Britain, he started production in America, and it didn’t take long before others developed their own baked pet food formulas. But the need for more palatability led to experiments beyond the oven. In 1956, extruded dry pet food production made its splash on the market.

Dry pet food

Extruded aquafeed

Children love them, and adults love them too. Extruded cereal is a typical ready-to-eat cereal with different flavors and shapes. You pour cold milk into a bowl of extruded cereal and eat them for breakfast or sometimes as a dessert. These shapes of cereals are refined by thermo-mechanical cereal extruder machines. Typically, extruded cereal can be categorized into three kinds: direct expanded cereal, co-extruded cereal, and extruded flakes. Depending on which kind of extruded cereal you are making among these three kinds, your choice of processing line will differ.

Extruded cereal

In the feed sector, it's common to talk about feed as balanced, compound, or concentrate. Many people use one of these terms to refer to any feed mill product. However, the processing of feed concentrates, only requires grinding and mixing. The further transformation into pellets adds is an added value for the market.

Feed concentrates

Feed premix delivers a quality blend of macro and micronutrients to meet the overall growth and health needs of animals. Although they constitute a small portion of the feed, they provide enormous benefits by adding a balanced, nutrient-rich feed that supports the animal health. Feed premix making equipment ensures a proper combination of important ingredients to generate a perfect blend.

Feed premixes

The fishmeal powder market forecast shows that its global market value will reach USD 10.3 billion by 2025. Expanding since 2019, at an annual growth rate of 6.5%. Fishmeal powder production has strong business potential with the increase of applications in animal feed, pet food, and fortified foods.

Fishmeal powder

There are two misconceptions about floating pellets. The first one is that they are made with a pellet mill, when the proper floating pellets-making machines are extruders. The second misconception is that floating feed is only used for fish. However, many other species consume feed on the water, such as crocodiles and birds.

Floating pellets

Fodder

Instant soup is quite popular due to its ease of use and quick preparation. Products like cup noodles and vegetable soup mixes are some of the examples commonly used by consumers. The instant soup processing equipment is used to dehydrate or dry components of the soup mixture to prolong shelf life and preserve the taste of the vegetables and other components.

Instant soup

Licorice is a glossy candy with firm consistency that can have different flavors, like chocolate, cherry and strawberry. With the right licorice making equipment, start by making a paste from the licorice roots, mixing them with sugar, flour and sweeteners. Extrude it with a nuzzle, allowing to cool, then cut and package it.

Licorice

To make a good marshmallow, you need to get the air straight. With it, proper marshmallow manufacturing equipment and a few ingredients - categorized into sweeteners and emulsifying agents, like gelatin – help you achieve flavor. Popular around the world, the marshmallow market size reached $319.8 million in the US and Canada.

Marshmallows

Also known as color concentrates for plastics, masterbatches are plastic granules that contain additives for coloring plastics. Their major purpose is to bring vibrance and improve the final product's appearance. In the process of making them, masterbatch production equipment is used to combine two major constituents—colorants and polymer-specific carriers.

Masterbatches

Muesli, known as the adults’ cereal, is a loose mixture of rolled oats, whole grains, seeds, nuts, and dried fruits. Unlike granola, the muesli manufacturing process goes through rather simple steps. All of the ingredients are combined in the mixer without any specific cooking or baking process. This loose mixture is then packed individually, either in stand-up pouches, paper bags, paper tube and so on.

Muesli

Toast spread, oatmeal topping or salad dressing - nut butter can be used in various ways. Although in a culinary sense classified as such, peanuts, almonds, cashews and pecans, the popular choices for nut butter are, botanically speaking, not nuts. They are processed in a series of nut butter processing equipment to get the creamy, rich product ready for consumption.

Nut butter

To put into perspective, the average number of peanuts that you use to make a 12-ounce jar of peanut butter is 540 pieces. Peanut butter is widely used as a spread for most bread and biscuits. To make it, use raw peanuts and process them using peanut butter making machines.

Peanut butter

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

With consumerism comes great responsibility. More and more are switching their diet towards vegan and vegetarian alternatives, varying from dairy to meat. As more plant-based meat technologies are being invented, the production is rising in popularity. Ever wondered which challenges come with that?

Plant-based meat

All plastics are polymers, but not all polymers are plastics. Polymer production is a multi-step process that transforms raw materials into products that we use in our day-to-day life with the help of polymer process equipment such as extruders, calenders and injection molding machines.

Polymers

Poultry feed

In NASA's early years, a research program was established on how to provide food for astronauts while in space. In fact, in the 1960s, nutrition bars were launched with a label called "Space Food Sticks" because they were designed to allow astronauts to eat them easily while wearing their helmets. Protein bar manufacturing equipment is used to mix ingredients, extrude the mixture at a set temperature, cool the product before cutting it to size, coating it, and allowing it to cool to prepare it for packaging.

Protein bars

The ubiquitous plastic shopping bag was first designed as a reusable carrier. Its inventor, Sten Gustaf Thulin, will have been appalled to see his creation turn into a single-use object. But this disposable tendency is common to all plastic materials, from screw taps to milk carton lining. With plastic recycling equipment, however, plastic waste can be reprocessed and given a second lease of life.

Recycled plastic

From Asia to America, different forms of puffed rice bars - or as known as Rice Krispies - are enjoyed in diverse forms. Puffed rice bars or popped rice bars are made of puffed rice, sugar (or sweetener that works as a binder), additional flavorings such as vanilla or chocolate, and perhaps different sorts of grains and nuts.

Rice Krispies

Shrimp or prawn crackers are savory snacks common in Asian countries. Believed to have its origins in West Malaysia, this snack is part of daily common cuisines or as a midday snack. Prawn cracker manufacturing has a strong demand, with Indonesia exporting 1.648 million kg as of May 2019.

Shrimp crackers

Despite only one letter difference, silicon and silicone are two different things. While silicon is the 14th chemical element on the periodic table, silicone is a synthetic material that, among other chemical elements, contains silicon. Although commonly observed as plastic, technically silicone is rubber. Among others, silicone processing equipment mainly involves several high-temperature machines, mixers and molds.

Silicone

In aquafeed, you can find three types of pellets: floating pellets, sinking pellets, and slow-sinking pellets, because not all aquatic species eat at the same height of the water column. In the case of bottom feeders such as shrimp, river crab, sea bass, and some species of catfish, they eat sinking pellets. Contrary to tilapia and carp that feeds from the surface with floating pellets. Sinking pellets production must control water stability to preserve the quality and form of the pellets, avoiding nutrients' dissolution in the water.

Sinking pellets

When it comes to aquafeed, you can find three types of pellets: floating pellets, sinking pellets, and slow-sinking pellets. Not all aquatic species eat at the same height of the water column. For example, tilapia and carp eat at the surface (floating pellets) while shrimp and sea bass eat at the bottom (sinking pellets). Slow-sinking pellets are ideal for species that eat along the water column such as salmon and cod.  To get the pellets to sink at the right rate, slow sinking pellets production must control water stability in the products.

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Slow sinking pellets

The inventor of the lithium-ion battery predicted that solid-state batteries would become commercially available by the mid-2020s, making them an attractive option for energy storage in a wide range of applications, including electric vehicles. This battery type promises a marked improvement in safety, power, and environmental impact compared to current battery packs that use a liquid electrolyte. However, recent breakthroughs in the lab don’t automatically translate into mass production. The complex processing requires specially-designed manufacturing technology to make solid-state batteries a real solution, especially for the automotive industry.

Solid-state batteries

Only about 6% of the soy produced globally is directly consumed by humans, typically as edamame beans, tofu, or soy milk.  More than three-fourths of global soy production goes to animal feed. The rest is processed by soybean meal technology into oils or used for biofuels and other industrial processes.

Soybean meal

Stock cubes, also known as bouillon cubes or broth cubes, have been used in cooking for centuries. Think that, the first written version of a stock cube comes from Anne Blencowe’s recipe book from 1694. Made of dehydrated vegetables or meat stock, the bouillon cube production line consists of mixers, homogenizers, cube forming machines and packaging machines.

Stock cubes

Vegan meat alternatives and plant-based foods have rapidly grown in popularity over the last decade. Many people are switching to meat substitute food products. Your body does not discriminate between proteins and calories coming from meats and those coming from plants. From a nutritional point of view, they all have the same value. But chewing on a portion of veggie pumpkin protein does not feel the same as a cut of meat - the texture is completely different.

Textured Vegetable Protein

A toner is a fine powder located in printer and copier cartridges. One peculiar property the product is their ability to act like liquids. Toner manufacturing equipment sees to it that the particle size is between 5 and 30 micrometers to flow through the cartridge.

Toner

Ancient civilizations were using yeast as it naturally occurred in bread-making and brewing. But yeast processing equipment wasn't developed and fully commercialized until the end of the 18th century. Today, this industrialized micro-organism is critical in producing biofuels and other products beyond food and drinks.

Yeast

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