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Maker - Product Challenge

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TVP extrusion Equipment

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

Extrusion

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

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

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

Laboratory extruder

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

Extruder with annular gap expander

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

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

<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

What does a $300,000 burger taste like? Meat. The first lab-grown burger took two years and 20,000 strands of muscle tissue to produce. But with rapid advances in cultivated meat processing technology, non-animal meat alternative products can now take a lot shorter to prepare. And cost much less.

Cultivated meat

Making.com is a new online platform that helps makers find production technology quicker by grouping it around the products they make.

With the protein transition, both more sustainable plant- and animal-based solutions are advancing. We excitingly met Tobias Gaiser and John Sheehy from <a href="https://www.coperion.com/en/home">Coperion</a> who have <span class="ui-provider a b c d e f g h i j k l m n o p q r s t u v w x y z ab ac ae af ag ah ai aj ak" dir="ltr">key technology and know-how for the protein transition. We had a very insightful talk at</span> <a href="https://anugafoodtec.com">Anuga FoodTec</a> about the future of protein.



Among other processes, Coperion specializes in industrial extruders with their expertise in making texturized vegetable proteins (TVP) and high-moisture meat analogs (HMMA). They also have know-how in <span class="ui-provider a b c d e f g h i j k l m n o p q r s t u v w x y z ab ac ae af ag ah ai aj ak" dir="ltr">precision fermentation and other key processes for making cultivated meat</span>.

John, who is the Global Key Account Manager for Alternative Proteins, took the time to detail all the varieties and making processes of <span class="ui-provider a b c d e f g h i j k l m n o p q r s t u v w x y z ab ac ae af ag ah ai aj ak" dir="ltr"> plant-based and insect protein in addition to cultivated meat. He </span>explained that cultivated meat can not always compete with real meat in terms of texture and flavor. Therefore it is now being mixed with TVP, which has a special very meat-like texture. "The extrusion process creates these specific fibers within the TVP," adds John. These products should reach the market within a few months.

Tobias explained that TVP can be made from soy, pea, or wheat protein, but the list of alternatives is growing over time. Therefore the possibilities are endless. He emphasized that being plant-based is not just a statement, but many of their employees actually follow that course.

We're grateful for this talk with Coperion and are enthusiastic to see what innovations are coming our way in the protein revolution!

#Changemaker: how about a cultivated TVP fish or meat burger?

Food

Protein

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

I’m high in fiber, proteins, and minerals. What are your superpowers?

Lentils are one of the oldest crops ever, and you’ll be surprised how versatile this humble legume can be. They are higher in proteins than beef and have other essential nutrients. That’s why they are the new "old" superhero or, more accurately, superfood.



Martin Jager and Cassandra Winter know it well. Martin and Cassandra are the founder of <a href="https://www.easyvegan.at/en/easyvegan-is-loved-by-everyone/" target="_blank" rel="noopener">EasyVegan</a>, ready-made frozen products relying on the power of lentils.

The Making.com team met them at Free From Amsterdam 2022 where Cassandra shared how everything started. Cassandra is a <em>burger lover</em> but wanted to create something tastier than the tofu and veggie burgers already on the market. So after many experiments in the kitchen with lentils, she found the right combination for a burger that - we assure you - is a wonderful explosion of flavors. So she bought a sales trailer and traveled through Austria and Bavaria, selling her vegan products at city festivals, culinary events, sporting events and concerts. EasyVegan was then founded in April 2017 with the life partner Martin to make the lentil products accessible to a broad mass.

EasyVegan products such as lentil sliders, lentil sticks, lentil balls, and lentil patties are sustainable, purely natural, lactose-free, gluten-free, GMO-free, preservative-free, and palm oil-free products. Moreover, they are SUPER tasty!

<a href="https://making-tst.imgix.net/2022/11/WhatsApp-Image-2022-11-23-at-10.55.28-3.jpeg"><img class=" wp-image-60450 aligncenter" src="https://making-tst.imgix.net/2022/11/WhatsApp-Image-2022-11-23-at-10.55.28-3-225x300.jpeg" alt="" width="366" height="488" /></a>

&nbsp;

#Changemaker: The plant-based burger made of lentils you didn't know you needed!

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

Baker Perkins supplies technology for the bakery, biscuit, confectionery, supplements, snack and breakfast cereal sectors, The company's production machines are based on over 100 years of experience in the field.

Soya, peas, beans or cereals are low in fat, high in fibre and protein content, and therefore a nutritious and healthy base for new meat analogues. The global shift away from meat leads to an increased demand for these TVP textured vegetable proteins (TVP) that can be often purchased in the form of dry chunks or flakes.


<h2>Higher moisture content for a meaty result</h2>
How is TVP made? Vegetable protein isolate from for example beans or peas is passed through an extruder. In this <a href="https://making.com/plant-based-meat">plant-based meat process</a> it is steamed, heated and – still hot – squeezed out of the machine nozzle. As soon as the substance cools, it changes into the desired form.

To achieve fibrous, chewy and meat-like TVP for veggie burgers it needs to be extruded at far higher moisture content of 50-70% . For sausages and for example nuggets only 20-30% is required. The moisture level facilitates forming, enabling a fibrous structure which can look and taste like natural meat.
<h2>Extrusion equipment for meatless meat</h2>
So the extrusion process begins with making a premix from soy beans, wheat, peas, lentils, etc. This mass is then transferred into a <a href="https://www.bakerperkins.com/news/developing-new-technology-for-commercial-production-of-meat-substitutes">double screw extruder,</a> where by the means of steam heating, shear, as well as presence of water, the meat-like structure is formed. When the material exits the extruder die, the structure is ready and can be further processed with different dyes or flavours, depending on the final product. The dye shape plays a significant role here, as it determines the final product - e.g., a circular cross-section tool for sausage-like products or a square cross-section for chicken analogues. Below a video of a TVP extruder from Baker Perkins. They have a cool R&amp;D centre to help their customers fine tune new recipes with for example seaweed and algae and further improve their meat-like taste and appearance.

[embed]https://www.youtube.com/watch?v=0B5RiyxijDI[/embed]

How to produce textured vegetable protein TVP?

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

TVP extrusion

TVP extrusion - Making.com

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