Satellite Extruder Assembly for Multi-Stream Processing
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Solution Overview
Problem
Current extrusion processes require multiple runs to produce extruded products with different colors, flavors, and textures, leading to issues like decreased temperature, increased drive horsepower, back pressure buildup, and product degradation, and lack control over starch crystallinity and texture.
Innovation Solution
A satellite extruder assembly attached to a main extruder, allowing for the division of the extrudate stream into multiple streams, which can be processed separately with controlled temperature, pressure, and ingredient addition in satellite extruders to produce diverse products without additional drive horsepower or back pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the feed dough is divided or separated into separate streams to produce different colors, flavors, and textures, then the ability to produce multiple product variants is improved, but the temperature of the feed dough decreases which affects texture, density, and viscosity and can lead to product degradation
Solution Approach 1:
The extruder barrel is divided into multiple independently controllable zones along its length. Each zone can be heated or cooled separately, allowing different portions of the feed dough to be processed at different temperatures simultaneously. This enables the production of multiple product variants with different color, flavor, and texture characteristics while maintaining overall temperature control to prevent degradation.
2Adaptability or versatility
If the feed dough is separated into separate streams for different colors and flavors, then product variety is improved, but extra drive horsepower is required and back pressure builds up
Solution Approach 1:
The extrusion system is segmented into multiple zones with independent temperature and pressure control. This allows the feed dough to be processed through different thermal and mechanical conditions in each zone without requiring additional drive power, as the segmentation enables parallel processing rather than sequential separation.
Solution Approach 2:
The extrusion system incorporates dynamic control of temperature and pressure in each zone, allowing real-time adjustment of processing parameters. This dynamic control enables the system to adapt to different product requirements without increasing drive horsepower or back pressure, as the parameters are optimized for each specific extrusion task.
3Adaptability or versatility
If repeated extrusion is used to add additional components, then component addition is improved, but the flexibility and elasticity of the starch component increases and expansion index decreases yielding heavier product
Solution Approach 1:
The extrusion process is segmented into multiple zones that can independently control temperature and pressure. This allows different components to be added and processed simultaneously in different zones without repeated extrusion, maintaining starch stability while enabling component addition. Each zone can be optimized for specific component integration without affecting the overall starch structure.
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
Enables the production of multiple extruded products with varied characteristics from a single extruder stream, maintaining product quality and controlling starch crystallinity, reducing the need for extra drive power and back pressure, while allowing for precise modulation of texture and temperature.
Implementation Method 1
an extruded product is formed by forcing the feed dough through a die
Implementation Method 2
Gelatinization of the starch contained in a feed dough
Implementation Method 3
Extruded starch-containing products are formed by gelatinization of the starch contained in a feed dough
Data Source
AI summary
Apparatus and methods for producing multiple extruded products having different characteristics from the extruded stream of a single main extruder are provided. A satellite extruder assembly is removably attached to a main extruder allowing for the production of a plurality of different extrusion products from a single stream from one main extruder that is divided into multiple streams channeled to a plurality of satellite extruders. Each of the extruders may be operated at different temperature, pressure, moisture and shear conditions. Additional components may be selectively added to one or more of the material streams.