Share

Extrusion brings ingredient production cost savings

Extrusion brings ingredient production cost savings

Baker Perkins’ twin-screw extrusion technology can create significant savings in the production of core ingredients for the food industry.

Typical examples include breadcrumbs, croutons, gluten-free bread products, modified and pre-gelatinised flours, rusk for sausage fillings, and ice cream inclusions.

Compared with traditional processes, extrusion can bring significant savings in space, equipment, energy and labour; the process is also extremely flexible, enabling quick and easy switching between different recipes.

Extrusion is hygienic and energy efficient - all the action is in the short barrel: ingredients in, product out seconds later.

If it is possible to make a product with an extruder, it is almost certainly the cheapest, most efficient and most compact method for making it. Conventional processing typically involves a great deal more equipment, time and cost.

Breadcrumb is a typical example. The traditional process involves mixing, forming and baking bread before discarding the crusts and grinding. The same product can be made with no waste using only a twin-screw extruder and dryer.

Similarly for croutons; a bread-like texture can be developed in the extruder and the pieces cut to size at the die or a post-extrusion cutter. Croutons for the ingredients market (such as soups and salads) or a crunchier variant for the snacks market can both be produced by this method with rapid changes between them.

Extrusion is also an excellent way of addressing the market for gluten-free bread products as it can handle with ease the various alternative flours and starches used to make the dough. Screw profiles can be adjusted to achieve the desired characteristics much more readily than conventional processes, and it also overcomes the problems caused by stickiness of the dough.

Extruders also bring a lot of advantages to modified and pre-gelatinised flours used in products such as instant soups, ready meals, bakery pre-mixes and infant nutrition. The wide range of conditions that can be created in an extruder enable characteristics such as rapid and/or cold-water thickening, increased protein or fibre content, improved dispersibility and enhanced texture to be readily developed.

Other examples include soy-based high-protein crispies used in breakfast cereals, chocolate bars and snack/trail mix to add texture and volume, and low-protein versions based on wheat or corn; rusk for sausage fillings; and ice cream inclusions – generally cookie or biscuit based.

As well as the enormous savings in space, equipment, energy and labour the process is also much more flexible, enabling quick and easy switching between different recipes. Extrusion systems can be expanded as a business grows or markets change to move from ingredients into production of foods such as snacks and cereals,

Extrusion is perhaps the most versatile process available to the food industry. It is capable of producing a wide range of end products from a variety of different ingredients and rapidly switching between them. It can replicate products made using other, less flexible, methods and the breadth of process options offers product developers plenty of scope for innovation.

Read more:

Baker Perkins’ Snack Master™ Systems: Overview

Baker Perkins SBX Master™ Extruder

Contact Us

   

Contact Form

Office Locations

Baker Perkins Worldwide

Latest News

REMINDER: our webinar - How to Increase the Throughput of your Powder Coating Extruder - is this Thursday, August 1… twitter.com/i/web/status/1…

10 August 2020

How can you significantly improve the performance of your industrial twin screw extruder? Find out in our webinar o… twitter.com/i/web/status/1…

07 August 2020

Just three years since its launch, the 50th ServoForm Mini depositor has recently been ordered by a North American… twitter.com/i/web/status/1…

04 August 2020

We have new vacancies at our UK facility for a Fabricator, CNC Miller, and CNC Turner. Applications required by Fri… twitter.com/i/web/status/1…

17 July 2020

Baker Perkins has renewed the lease on its headquarters at Peterborough, UK, for a further 17 years:… twitter.com/i/web/status/1…

15 July 2020

Baker Perkins has increased the throughput and durability of its Flake Master range of flaking mills:… twitter.com/i/web/status/1…

29 June 2020