Twin-Screw Maize Extruder With Large Die to Prevent Clogging
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Solution Overview
Problem
Existing extrusion processes for nixtamalized maize flour production face challenges such as clogging, high energy consumption, and inefficiencies in producing nejayote, which leads to environmental pollution and operational downtime.
Innovation Solution
An extruder with twin screws featuring uniform thread thickness and varying thread spacing and angle, combined with a large die orifice and sectioned barrel, facilitates efficient nixtamalization of maize fractions, reducing friction and pressure, and minimizing material expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional single worm drive extruder configuration is used, then the equipment structure is simple, but the material flow time is long, cutting force and pressure on the die are high, and the output temperature is high causing material expansion
Solution Approach 1:
The barrel is divided into multiple sections (feeding section, transition section, die section) that can be quickly disassembled and reassembled. This segmentation allows for reduced cleaning time and improved maintenance efficiency while maintaining the overall extrusion process continuity
Solution Approach 2:
The invention extracts and eliminates the production of nejayote (alkaline broth) from the traditional nixtamalization process by using extrusion technology. The extruder processes maize fractions directly to produce nixtamalized flour without generating the problematic liquid waste that requires treatment and disposal
2Use of energy by stationary object
If traditional extrusion process is used for nixtamalized maize flour production, then the equipment is compact and energy efficient, but clogging occurs inside the cylinder requiring frequent stopping and cleaning
Solution Approach 1:
The twin screws feature variable pitch and angle along their length, creating dynamic zones for transport, mixing, and compression. This dynamic configuration prevents material stagnation and clogging by continuously varying the mechanical action on the material throughout the extrusion process
Solution Approach 2:
The screw thread spacing and angle are varied along the length of the screws to create different functional zones. The feeding section has larger spacing for material intake, while the die section has tighter spacing for compression, optimizing material flow and preventing clogging throughout the process
3Device complexity
If traditional die configuration is used, then the equipment is simple, but the material expansion is high and the output temperature is high
Solution Approach 1:
The die section features a large circular orifice (40-50% of barrel discharge area) that provides a specific local geometry for material extrusion. This localized design change allows the material to expand controlled amounts and reduces the pressure drop, thereby lowering the output temperature while maintaining equipment simplicity
4Adaptability or versatility
If nejayote is produced during nixtamalization, then the traditional process is followed, but environmental pollution occurs due to high pH and organic matter concentrations
Solution Approach 1:
The invention converts the harmful nejayote waste product into a beneficial outcome by eliminating its production entirely. The extrusion process directly transforms maize fractions into nixtamalized flour without generating the alkaline broth that causes environmental pollution, turning a harmful process into a clean technology solution
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 extruder achieves rapid material flow, lowers operational friction and temperature, and enhances the quality of nixtamalized maize flour production by reducing clogging and cleaning times, while eliminating nejayote production.
Implementation Method 1
the screws in the present invention features a thread uniform in width and depth, but the spacing between the threads is different in longitude and angle, this differences in the screws generate sections of transport, mixing and compression in the barrel
Implementation Method 2
Extrusion is a continuous process that combines heat and mechanical stress to provoke the gelatinization of the starch granules
Implementation Method 3
provoke the gelatinization of the starch granules
Implementation Method 4
The last advantage to be mentioned is that the die of the present invention has a large orifice which helps the material to flow in a short amount of time, reducing the cutting force (friction) and the pressure on the back of the die
Data Source
AI summary
The present utility model “Extruder to nixtamalize maize fractions” aims to provide and extruder to nixtamalize maize fractions previously conditioned with water and food grade lime, eliminating he production of nejayote in the production of nixtamalized maize flour, as well as the reduction of clogging of the extruded material. In addition to the aforementioned, it's easy to assemble for cleaning.