Extrusion technology

this presentation speaks about the extrusion technology and incorporation of fruits and vegetable for enhancing the nutritional of the extruded food product.

1. 1

2. 2

3. 3

4. 4 Mike Adams

5. UNIVERSITY OF HORTICULTURAL SCIENCES BAGALKOT COLLEGE OF HORTICULTURE, BAGALKOT Seminar – I “Extrusion Technology: A potential technique for vegetables and fruits based snack food product” Ms: Ayeeshya Kolhar UHS17PGD223 Ph.D (II yr) Dept of Post Harvest Technology 5

6. Conclusion 6 S E M I N A R O U T L I N E

7. The word “ extrudate ” originates from the Latin word “ex” (out) and “ trudere ” (to thrust). Extrusion is defined as “A process in which material is pushed through an orifice or a die of given shape, the pushing force is applied using a piston or a screw.” 7 Karwe , 1992

8. Extrusion is a process which combines several unit operations including mixing, kneading, cooking, shearing, shaping, forming, conveying, separation, venting, flavor generation, plastification and expansion of the food structure. Fellows, 2000 8

9. 9 Table 1: History INVESTIGATOR YEAR FINDINGS MC.Anelly 1964 First to describe a process for the production of spongy elastic particles from soy flour. Atkinson 1970 Disclosure of a continuous cooking extrusion process EL-Dash 1981 First to process breakfast cereal products Noguchi. 1998 Extrusion cooking of high moisture protein foods Fast 2000 RTE cereals Saalia 2011 Degradation of afflatoxins by extrusion Ryan 2011 Oat based breakfast cereal snack Rao and Thejaswini , 2015

10. PRODUCTION TECHNIQUE Bordoloi and Ganguly , 2014 10

11. Fig. 1: Expansion of the product Bordoloi and Ganguly , 2014 11

12. COMPONENTS OF EXTRUSION SYSTEM Feeding system Pre-conditioning system Screw or worm Barrel Die and the cutting mechanism Rao and Thejaswini , 2015 12 Fig.2 COMPONENTS OF EXTRUSION SYSTEM

13. GENERAL CONDITIONS Temperature : 52-199 ° C Pressure :1500- 70,000 KPa Time :15-19 sec Screw speed :150-600 rpm Rao and Thejaswini , 2015 13

14. FOOD EXTRUDER Fig.3: Food extruder 14 Bordoloi and Ganguly , 2014

15. CLASSIFICATION OF EXTRUDERS 15 Bordoloi and Ganguly , 2014

16. SINGLE-SCREW EXTRUDERS The most common extruders applied in the food industry. The barrels of single-screw extruders usually have helical or axial grooves on inner surfaces. This helps to convey and mix the material more effectively. Fig. 3: Single-screw extruder Caldwell , 2000 16

17. The first major commercial application of the in the food processing industry was conversion of semolina flour into pasta using solid screws. Application 17 Huber, 2000

18. Twin-screw extruder The term ‘twin-screw’ applies to extruder with two screws of equal length placed inside the same barrel. More complicated than single screw extruders, but at the same time, provide more flexibility and better control . Maurya and Said, 2014 18

19. Application Processing plastics Food companies ( sticky caramels and candies) 19 Maurya and Said, 2014

20. RAW MATERIALS USED The most used raw materials- starch and protein based materials, and are used in solid form (Steel et al., 2012 ). Most products such as breakfast cereals, snacks and biscuits–starch (wheat, corn, rice, potato, cassava and pea flour). Protein- meat-like characteristics (soybean). Dehgonshoar et al., 2010 20

21. Physico -chemical changes during extrusion 21

22. Changes in starch Rao and Thejaswini , 2015 22

23. Changes in protien Rao and Thejaswini , 2015 23

24. Changes in lipids Lipids acting as lubricants . They reduce the friction between particles in the mix and also between the screw and barrel surfaces. Rao and Thejaswini , 2015 24

25. Changes in Fibres Rao and Thejaswini , 2015 25

26. Anti-nutrients Extrusion cooking destroys many natural toxins and anti- nutrients , there by improving safety of the food product. Compounds such as allergens and mycotoxins susceptible to extrusion in combination chemical treatments. Rao and Thejaswini , 2015 26

27. Influence of extrusion cooking on various parameters Nutritional quality Microbiological quality Product quality Rao and Thejaswini , 2015 27

28. Fruit or vegetable blended extruded products Cereal Fruits, vegetables, by-products etc. Snacks with different appearance and flavour with improved nutrition. Bordoloi and Ganguly , 2014 28

29. 29

30. Objective : To incorporate cauliflower by-products as a source of dietary fibre into ready to-eat snacks and evaluating it’s effect on nutrition and sensory attributes of ready to-eat expanded snacks 30

31. 31 Table 2: Formulations for extrudate development Ingredients (% w/w) Wheat flour 16.4–36.4 Cauliflower 0–20 Corn starch 20 Oat flour 10 Egg whites 10 Milk powder 10 Onion powder 03 Tomato powder 05 Carrot powder 05 Dill 0.1 Mint 0.1 Salt 0.4 Stojceska et al ., 2008

32. Process conditions Process conditions Solid feed rate : 20-25 kg/ h Water feed : 9-11% Screw speed : 250-350 rpm Temperature : 80°C at the feed entry 120°C at the die exit Stojceska et al ., 2008 32

33. 33 Table 3: Nutritional characterization of raw materials (A) and extruded products (B) Stojceska et al ., 2008

34. Fig. 5: Images of extrudates containing different levels of cauliflower . Stojceska et al ., 2008 34

35. Fig. 6: Influence of cauliflower level on taste panel acceptability score Stojceska et al ., 2008 35

36. 36 Inference Incorporation of cauliflower by-products into ready-to-eat snacks and their effect on nutritional and textural characteristics were positively affected. The taste panel acceptability score showed that cauliflower by-products could be added up to 10%. Stojceska et al ., 2008

37. Objective : To characterize and evaluate the performance of pineapple pomace as an ingredient in extruded products. 37

38. Table 4:Chemical composition of freeze-dried pineapple pomace Component Percentage (% ) Moisture 3.77 ± 0.52 Protein 4.71 ± 0.28 Fat 0.61 ± 0.14 Total Dietery fibre 45.22 ± 3.62 Insoluble Dietery fibre 44.44 ± 3.60 Soluble Dietery fibre 0.78 ± 0.10 Carbohydrates 43.46 Selani et al ., 2014 38

39. Table 5: Physicochemical composition of freeze- dried pineapple pomace Physicochemical parameters Pineapple pomace pH 3.86 ± 0.07 Titratable acidity (g /100 g) 2.01 ± 0.23 Water activity (a w ) 0.14 ± 0.06 Colour: L* 75.63 ± 3.07 a* -0.10 ± 1.79 b* 26.91 ± 2.35 Selani et al ., 2014 39

40. Experimental setup Pineapple pomace : 0%, 10.5%, 21% Moisture : 14%, 15%, 16% Temperature : 140° C & 160° C Single screw extruder with screw speed – 220 rpm Control : 14% moisture + no fibre Selani et al ., 2014 40

41. 28/10/2016 41 Averages followed by different letters are significantly different (p < 0.05) by Tukey’s HSD test. Data with logarithmic transformation (base 10). The comparison among the means was performed with transformed data and the results presented in the original scale. Selani et al ., 2014 Table 6: Effects of the pineapple pomace incorporation on the physical characteristics of the extrudates

42. Fig. 7: Appearance of the extruded products Selani et al ., 2014 42

43. Factors influencing the quality of the product I. Rheological properties of the food Type of feed materials Moisture content Physical state of the materials Chemical composition 43

44. II. Operating characteristics Temperature Pressure Diameter of the die apertures Shear rate. 44

45. Objective: To evaluate physical characteristic and microstructure of extruded product. 45

46. Experiment Control : 100 % corn grits Treatments : Corn grits with pumpkin flour (5, 10,15 and 20 per cent) Screw speed - 250 and 350 rpm Barrel temperature – 160 C Evaluation - physical characteristics of snacks Nor et al ., 2013 46

47. Fig. 9: Effect of screw speed and the proportion of pumpkin flour on the expansion ratio Nor et al ., 2013 47

48. Nor et al ., 2013 Fig.10: Effect of varying pumpkin flour percentage and screw speed on the hardness of extruded product. 48

49. Nor et al ., 2013 Fig. 11: Effect of varying pumpkin flour percentage and screw speed on the bulk density of extruded product . 49

50. Table 7: X-ray tomography cross sectional of 2-D image (radial): changes of bubble size through out the extruded sample at screw speed 250 rpm (scale 1:2) Nor et al ., 2013 50

51. Objective: To develop and evaluate extruded snacks with optimum level of garlic powder. 51

52. Experiment Materials used Rice flour : 50-70% Defatted soy flour : 30% Garlic bulbs & salt Treatments T 1- RF 70% T 2 - RF 65% + G 5% T 3- RF 60% + G 10% T 4 - RF 55% + G15% T 5- RF 50% + G 20% Haritha et al .,2012 52

53. Sensory parameters Treatment ( means) T 1 T 2 T 3 T 4 T 5 RF 70% RF 65% + G 5% RF 60% + G 10% RF 55% + G 15% RF 50% + G 20% Flavour 23.53 23.80 21.80 18.26 15.26 Colour 13.20 12.73 11.00 10.46 9.86 Expansion 13.40 12.60 10.20 10.13 8.26 Texture 13.20 12.46 11.80 9.66 9.13 Odour 8.20 8.00 7.40 7.06 5.86 Overall acceptability 12.66 13.00 11.60 8.93 8.26 Table 8: Effect of substitution of rice flour with garlic powder on sensory analysis Haritha et al .,2012 53

54. 54 The garlic can be incorporated in the form of dehydrated powder in rice and defatted soy based ready-to-eat extruded snacks up to 10 % level with acceptable sensory qualities. Inference

55. Objective : To asses the formulation, development and evaluation of physico -chemical and sensory properties of extruded snacks with different flour blends. 55

56. Methodology Control : Corn + BG (80: 20) Treatments : Corn flour + Black gram flour + Tuber flour (60: 20:20) Preconditioning Spicing and drying Packaging and storage Sensory evaluation and physico chemical analysis Reddy et al ., 2014 56

57. Fig. 10: RTE extruded formulations developed by incorporation of different roots and tuber flour blends Corn flour + Black gram flour Corn flour + Black gram flour + Potato Corn flour + Black gram flour + Taro Corn flour + Black gram flour + Yam Corn flour + Black gram flour + Sweet potato Corn flour + Black gram flour + Beet root Reddy et al ., 2014 57

58. Table 10: Mean physical parameters of the developed extruded products Reddy et al ., 2014 Values are expressed as mean ± standard deviation of ten determinations .Mean values with similar superscripts within a column do not differ significantly (P>0.05). C -corn, BG - black gram 58

59. Table 11: Proximate analysis of extruded snacks (per 100 g) Reddy et al ., 2014 Values are expressed as mean ± standard deviation of ten determinations .Mean values with similar superscripts within a column do not differ significantly (P>0.05) . C - corn, BG - black gram 59

60. Fig. 13: Mean sensory scores of the extruded products Reddy et al ., 2014 60

61. Fig. 14: SEM images of control and most acceptable extruded snack (potato incorporated extruded products). Reddy et al ., 2014 A. External SEM image of control extrudate B. External SEM image of potato incorporated extruded products C . Internal SEM image of control extrudate D.Internal SEM image of potato incorporated extrudate 61

62. Advantages Versatility Cost Nutritional improvement Productivity Product quality Environmentally-friendly 62 Tripathi and Mangaraj , 2013

63. Disadvantages High capital cost Non-availability of spare parts Repairs and maintenance Power failure 63 Tripathi and Mangaraj , 2013

64. 64 Companies involved

65. 65 CONCLUSION…

66. 66 Proper handling and processing of the waste generated by fruits and vegetable processing industry into extrudable form. Commercialization of the fruits and vegetable incorporated extruded snack products. Creating awareness among the consumer about the fruits and vegetable incorporated extruded snack products using extension methodologies. Future line of the work………….

67. 67 Thank you…

68. 68