Extrusion Processing

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Extrusion Processing Short Course
(Direct Expanded Starch Products and Plant-Based Protein Products)

 

*Tentative Program

Day 1

7.30 a.m. to 8.00 a.m.     Check-in

8.00 a.m. to 8.15 a.m.     Introductions and Kick-off

8.15 a.m. to 9.50 a.m.    Overview of Extrusion Processing – Girish Ganjyal, Washington State University

9.50 a.m. to 10.00 a.m.   Break (10 min)

10.00 a.m. to 11.30 a.m. Biopolymers and Product Development with Extrusion Processing – Jana Richter and Girish Ganjyal, Washington State University

11.30 p.m. to 12.30 p.m. Lunch (Provided) – FSHN 155 Kitchen

12.30 p.m. to 2.00 p.m.   Lab Session: Extruder and Extruder Parts in FSHN 283 and 289A – Jana Richter, Caleb Wagner, Preston Watanabe, Marina Ikuse, and Josh Bernin, Washington State University

2.00 p.m. to 3.00 p.m.    Extruder Screws and Dies – Caleb Wagner and Girish Ganjyal, Washington State University   

3.00 p.m. to 3.10 p.m.    Break (10 min)

3.10 p.m. to 4.00 p.m.    Physico-chemical Characteristics of Raw Materials and Extrusion – Debomitra Dey, CW Brabender, Inc.

4.00 a.m. to 5.00 p.m.     Ingredients in Extrusion Processing: Starches and Fibers – Jana Richter, Marina Ikuse, and Girish Ganjyal, Washington State University

Day 2 –

8.00 a.m. to 9.00 a.m.    Ingredients in Extrusion Processing: Proteins – Caleb Wagner and Girish Ganjyal, Washington State University

9.00 a.m. to 11.30 p.m.  Lab Sessions: Direct Expansion Process

• Extrusion Demo in FSHN 289A – Jana Richter, Caleb Wagner, and Marina Ikuse
• Product Analysis Demo in FSHN 212 – Preston Watanabe and Josh Bernin

11.30 p.m. to 12.30 p.m. Lunch (Provided) – FSHN 155 Kitchen

12.30 p.m. to 1.00 p.m.   Discuss Data from Lab Session – Marina Ikuse and Girish Ganjyal, Washington State University

1.00 p.m. to 2.00 p.m.    Post Extrusion Drying/Dehydration Processes – Dave Reynolds, Buhler, Inc.

2.00 p.m. to 2.10 p.m.     Break (10 min)

2.10 p.m. to 3.10 p.m.    Sensory Analysis of Extruded Products – Carolyn Ross, Olivia Chaffee, Washington State University

3.10 p.m. to 4.10 p.m.     Colors in Extruded Food Products – Marty Gill, GNT USA.

4.10 p.m. to 5.00 p.m.     Texturization of Plant Proteins: Low and High Moisture – Girish Ganjyal and Jana Richter, Washington State University

Day 3

8.00 a.m. to 9.00 a.m.    Overview of Products and Practical Sessions

9.00 a.m. to 12.00 p.m.  Lab Session: Texturization Process in FSHN 289A and FSHN 155

• FSHN 289A – Lab Team
• FSHN 155 – Sarah Fischer, MGP Ingredients, Inc.

12.00 p.m. to 1.00 p.m.   Lunch (Provided) – FSHN 155 Kitchen

1.00 p.m. to 2.00 p.m.    Twin-Screw Extruders and Scale-up – Elizabeth Drantch, Buhler, Inc.

2.00 p.m. to 2.15 p.m.     Break (15 min)

2.15 p.m. to 3.30 p.m.    Overview and Demo: Preparation of Plant Based Protein Analogs – Sarah Fischer, MGP Ingredients, Inc.

3.30 p.m. to 4.30 p.m.     Final Discussions, Q&A with all speakers, Evaluations.

*There may be minor changes in the schedule.

Extrusion is a very common processing technology used in the food industry to produce direct expanded snack foods, cereals, and pet foods, among other products. Extruded products are typically made by utilizing a raw material, often flour, and subjecting it to high temperatures while also creating a high shear and high pressure environment using rotating screws.

This introductory course will provide information about the extrusion processing systems, extruder parts, basic heat and mass transfer, extruder screws and dies, food ingredient functionality and food product development with extrusion. The course will provide practical examples of product development with extrusion using ingredients.

Extrusion is a very widely used technology in the food industry. Some of the common food products made with extrusion technology include snacks, breakfast cereals, flat breads, bread crumbs, pellet products, textured vegetable proteins and many others.

It is a complex process with multiple inputs variables. Extrusion can be viewed as a reactor with a short residence time and with numerous options to control the energy inputs. The food ingredients in extrusion undergo physico-chemical changes as they are subjected to mechanical shear and heat. These physico-chemical changes transform them into the products with different eating characteristics.

Our research focuses on two different aspects of extrusion processing:

• Physico-chemical changes in various food ingredients during extrusion processing and their effects on the extruded products.
• Fundamental aspects of extrusion processing.

Current projects:

• Waxy and Partial Waxy Wheats processing.
• Quinoa processing.
• Barley processing.
• Pea and Lentil processing.
• New technique for evaluating the cross-sectional density profiles of extruded foods.
• Expansion phenomenon in extrusion.
• Super Critical and High Pressure CO2 extrusion processing.