Extrusion Die Design for Controlled Breakfast Cereal Surface Texture

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Solution Overview

Problem

Conventional extrusion processes for breakfast cereals result in products with uncontrolled surface cracks and a processed appearance, making it difficult to achieve both appealing texture and natural appearance while maintaining high production rates and low material waste.

Innovation Solution

An extrusion die with a transversal cross-section design featuring a circular central opened portion and a peripheral indented opened portion with regularly spaced indentations, creating macro-cracks that mimic a scale structure, allowing for controlled size and shape of scales on the surface, which enhances the natural appearance and texture of the product.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional extrusion processes are used for breakfast cereals, then production rates can be maintained high, but the products develop uncontrolled surface cracks and a processed appearance that consumers find unappealing

Engineering Contradiction:

Improvesurface appearance controlVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The extrusion die is pre-designed with specific geometric features (central opening, peripheral indented opening, and circumferential grooves) that will create the desired scale structure during extrusion. This preliminary design of the die geometry enables controlled surface features without requiring complex post-processing or additional manufacturing steps, thus maintaining ease of manufacture while improving surface appearance control

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the geometric parameters of the extrusion die (opening configuration, groove depth, groove spacing) to control the formation of surface scales. By adjusting these die parameters, the process produces consistent, appealing surface textures while maintaining high production rates and simple manufacturing

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If conventional extrusion dies are used, then the manufacturing process remains simple, but the surface cracks are uncontrolled and the appearance is processed rather than natural

Engineering Contradiction:

Improvesurface uniformityVSAvoidextrusion die structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The extrusion die is segmented into distinct functional zones: a central opening for the main foodstuff flow, a peripheral indented opening for secondary flow or support, and circumferential grooves that segment the surface flow into controlled portions. This segmentation enables precise control over surface scale formation while keeping each individual die element relatively simple in structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The extrusion die geometry is designed to copy or replicate natural surface features (scales) through its groove patterns. By copying the essential characteristics of natural scale structures into the die design, the process produces appealing, natural-looking surfaces without requiring complex additional processing equipment

Inventive Principle:

Principle #26Copying

3Loss of substance

If traditional extrusion processes are used, then material waste remains low, but the texture and appearance do not provide a pleasant consumer experience

Engineering Contradiction:

Improvematerial wasteVSAvoidtexture control

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The invention changes the extrusion parameters through die geometry (opening sizes, groove depths, groove spacing) to control texture formation. These parameter changes achieve pleasant texture and appearance while maintaining efficient material utilization and low waste through the continuous extrusion process

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The extrusion die design produces breakfast cereals with a non-uniform surface and natural appearance, providing a pleasant texture and appealing consumer experience, while maintaining high production efficiency and minimizing material waste.

Implementation Method 1

the pressure drop at the exit of the extruder causes the expansion of gas bubbles of a diameter range of approximately 50 μm to 1.5 mm which results in a random surface porosity of the same range

Methodology Applied

Scientific EffectPressure drop expansion: Pressure Drop

Implementation Method 2

The invention relates to the use of an extrusion die for the manufacture of expanded extruded or co-extruded foodstuff

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentEP3426048B1Use of an extrusion die for extruding a food product and use of a food product manufacturing machine.

Publication Date: 2020.07.01 SOCIETE DES PRODUITS NESTLE SA

Figure 1A~1B
Figure 2A~2B
Figure 3~4

AI summary

The present invention concerns an extrusion die (2) for extruding a food product having a humidity level between 2.5 to 6.5%, the extrusion die (2) being intended to be connected to the end of an extruder (1), said extrusion die presenting in transversal cross-section: a circular central opened portion (28); and a peripheral indented opened portion (29) comprising indentations (30) in which the indentions are in communication with the circular central portion (28). The invention also relates to an extruder (1), process and method utilising said extrusion die (2) and to an extruded or co-extruded individual food item produced using said extrusion die.