Abstract: High meat content extruded pet feeds and methods of preparation thereof, make use of relatively high meat contents which include quantities of previously dewatered meat. In an embodiment, the total meat content of the feeds consists essentially of dewatered emulsified poultry meat or other meat sources commonly used in the pet food industry. In the methods, mixtures containing starch, fat, and meat, the latter including dewatered meat, are passed through an extruder followed by staged drying. The extruder may be of twin screw design having hollow core screws permitting introduction of steam or other heat exchange media into the screws.

Abstract: Food or feed processors (16, 16a) include an elongated processor barrel (38) presenting an inner surface (44) with a central body or tube (60) within the barrel (38) and presenting an outer surface (62). The surfaces (38, 62) define an elongated annular processing region (70). The barrel (38) and tube (60) are steam heated by means of apparatus (52, 66). A rotatable processing element (72) is also located within the region (70). The element (72) has a plurality of vanes (88, 104), which scrape the surfaces (44, 62) to prevent buildup of material on these surfaces.

Abstract: High Specific Mechanical Energy extruder screw assemblies (14, 88, 98) and complete extruders (10, 86, 96) are provided, which include wide-flight intermediate screw sections (104) having axial flight widths greater than the flight widths of the inlet and outlet screw sections (102, 106) on opposite sides of the intermediate sections (104). The intermediate sections (104) provide increased friction and shear serving to enhance the SMEs imparted to comestible food materials during processing thereof.

Abstract: Food or feed processing systems (10, 96) include an extruder (14) and a downstream processor (16, 16a), and are operable to process high meat food or feed formulations. The processors (16, 16a) include an elongated processor barrel (38) presenting an inner surface (44) with a central body or tube (60) within the barrel (38) and presenting an outer surface (62). The surfaces (38, 62) thereby define an elongated annular processing region (70). The barrel (38) and tube (60) are steam heated by means of apparatus (52, 66). A rotatable processing element (72) is also located within the region (70). The element (72) has a plurality of helical vanes (88, 104), which scrape the surfaces (44, 62) to prevent buildup of material on these surfaces.

Abstract: Food or feed processors (16, 16a) include an elongated processor barrel (38) presenting an inner surface (44) with a central body or tube (60) within the barrel (38) and presenting an outer surface (62). The surfaces (38, 62) define an elongated annular processing region (70). The barrel (38) and tube (60) are steam heated by means of apparatus (52, 66). A rotatable processing element (72) is also located within the region (70). The element (72) has a plurality of vanes (88, 104), which scrape the surfaces (44, 62) to prevent buildup of material on these surfaces.

Abstract: Food or feed processing systems (10, 96) include an extruder (14) and a downstream processor (16, 16a), and are operable to process high meat food or feed formulations. The processors (16, 16a) include an elongated processor barrel (38) presenting an inner surface (44) with a central body or tube (60) within the barrel (38) and presenting an outer surface (62). The surfaces (38, 62) thereby define an elongated annular processing region (70). The barrel (38) and tube (60) are steam heated by means of apparatus (52, 66). A rotatable processing element (72) is also located within the region (70). The element (72) has a plurality of helical vanes (88, 104), which scrape the surfaces (44, 62) to prevent buildup of material on these surfaces.

Abstract: A meat dewatering assembly (10) includes a support frame (12), a twin screw dewatering unit (14), a drive assembly (16) coupled with the unit (14), and a perforated housing (60). The unit (14) has a pair of tapered, non-parallel, intermeshed, helically flighted screws (52, 54) presenting nip clearances (59) between the fighting (55). The drive assembly (16) serves to counter-rotate the screws (52, 54). In use, emulsified meat is passed into the housing (60) during counter-rotation of the screws (52, 54), in order to compress the meat within the clearances (59) and thereby express water from the meat. Adjustment collars (38) permit selective size alteration of the nip clearances (59).

Abstract: High thermal transfer, hollow core extrusion screws (50, 52, 124, 126, 190) include elongated hollow core shafts (54, 128, 130, 192) equipped with helical fighting (56, 132, 134, 194) along the lengths thereof. The fighting (132, 134, 194) may also be of hollow construction which communicates with the hollow core shafts (54, 128, 130, 192). Structure (88, 90) is provided for delivery of heat exchange media (e.g., steam) into the hollow core shafts (54, 128, 130, 192) and the hollow fighting (132, 134, 194). The fighting (56, 132, 134, 194) also includes a forward, reverse pitch section (64, 162, 216). The extrusion screws (50, 52, 124, 126, 190) are designed to be used as complemental pairs as a part of twin screw processing devices (20), and are designed to impart high levels of thermal energy into materials being processed in the devices (20), without adding additional moisture.

Abstract: An improved, high-capacity die assembly (10) for a food or feed extruder (12) is provided and is particularly useful for the production of high quality aquatic feeds. The die assembly (10) includes a mount (20), which is secured to the discharge end of an extruder barrel (14), with a plurality of tubular die components (22, 24) coupled with the mount (20). Each component (22, 24) includes wall structure (38) defining an outwardly diverging tubular chamber (40) with a die plate assembly (50) coupled to the outer end of the wall structure (38). A flow diverter element (54) is located within each chamber (40) and has a large diameter end adjacent the assembly (50) and a smaller diameter end closer to the chamber inlet. The assembly (50) has a plurality of openings (52) outboard of the element (54).

Abstract: Food or feed processing systems (10, 96) include an extruder (14) and a downstream processor (16, 16a), and are operable to process high meat food or feed formulations. The processors (16, 16a) include an elongated processor barrel (38) presenting an inner surface (44) with a central body or tube (60) within the barrel (38) and presenting an outer surface (62). The surfaces (38, 62) thereby define an elongated annular processing region (70). The barrel (38) and tube (60) are steam heated by means of apparatus (52, 66). A rotatable processing element (72) is also located within the region (70). The element (72) has a plurality of helical vanes (88, 104), which scrape the surfaces (44, 62) to prevent buildup of material on these surfaces.

Abstract: The present invention provides improved apparatus and methods for the monitoring and control of apparatus designed to remove moisture from an initially wet product, such as a continuous dryer (14). The net rate of water removal from the wet product (16) is determined during drying thereof, preferably on a real-time basis. A control assembly (20) is operatively coupled with the dryer (14) and includes sensors (24, 26, 28, 34), which are operatively coupled with a digital controller (38). The controller (38) has a PID controller operable to continuously determine the average net rate of water removal from the product (16).

Abstract: Apparatus for injection of fluid into an extruder is provided, including a static mixer section with a pipe assembly coupled with the static mixer outlet and leading to the extruder barrel; the pipe assembly outlet and barrel injection opening have diameters less than the maximum internal diameter of the static mixer casing. The invention greatly simplifies the fluid injection apparatus used with extruders, while giving more efficient absorption of thermal energy with a minimum of environmental contamination, and the ability to inject multiple streams into the extruder.

Abstract: Apparatus for injection of fluid into an extruder is provided, including a static mixer section with a pipe assembly coupled with the static mixer outlet and leading to the extruder barrel; the pipe assembly outlet and barrel injection opening have diameters less than the maximum internal diameter of the static mixer casing. The invention greatly simplifies the fluid injection apparatus used with extruders, while giving more efficient absorption of thermal energy with a minimum of environmental contamination, and the ability to inject multiple streams into the extruder.

Abstract: An extruder (20) is specifically designed for the production of animal feed products (e.g., aquatic feeds) containing substantial quantities of low-cost fibrous materials, such as rice byproducts, at high production rates. The extruder (20) includes an elongated barrel (22) with a screw assembly (24) within the barrel and an endmost extrusion die assembly (34). The screw assembly (24) includes an inlet screw assembly (42) and a processing screw assembly (44). The assembly (44) includes screw components (50-56) of differential pitch to present a long pitch inlet section (64) and a tight pitch discharge section (68). Materials passing through the screw assembly (24) are successively subjected to high levels of steam injection (STE) followed by high levels of friction and shear (SME), so that the STE/SME ratio is at least about 6/1.

Abstract: Apparatus (20) for injection of fluid into extrusion system components such as a preconditioner (24) or extruder (100) is provided, preferably as a composite assembly including a fluid injection valve (52) and an interconnected static mixer section (54). Alternately, use may be made of the fluid injection valve (52) or static mixer section (54) alone. The invention greatly simplifies the fluid injection apparatus used in extrusion systems, while giving more efficient absorption of thermal energy with a minimum of environmental contamination, and the ability to inject multiple streams into the extrusion systems.

Abstract: An improved, high-capacity die assembly (10) for a food or feed extruder (12) is provided and is particularly useful for the production of high quality aquatic feeds. The die assembly (10) includes a mount (20), which is secured to the discharge end of an extruder barrel (14), with a plurality of tubular die components (22, 24) coupled with the mount (20). Each component (22,24) includes wall structure (38) defining an outwardly diverging tubular chamber (40) with a die plate assembly (50) coupled to the outer end of the wall structure (38). A flow diverter element (54) is located within each chamber (40) and has a large diameter end adjacent the assembly (50) and a smaller diameter end closer to the chamber inlet. The assembly (50) has a plurality of openings (52) outboard of the element (54).

Abstract: The present invention provides improved apparatus and methods for the monitoring and control of apparatus designed to remove moisture from an initially wet product, such as a continuous dryer (14). The net rate of water removal from the wet product (16) is determined during drying thereof, preferably on a real-time basis. A control assembly (20) is operatively coupled with the dryer (14) and includes sensors (24, 26, 28, 34), which are operatively coupled with a digital controller (38). The controller (38) has a PID controller operable to continuously determine the average net rate of water removal from the product (16).

Abstract: The present invention provides improved apparatus and methods for the monitoring and control of apparatus designed to remove moisture from an initially wet product, such as a continuous dryer (14). The net rate of water removal from the wet product (16) is determined during drying thereof, preferably on a real-time basis. A control assembly (20) is operatively coupled with the dryer (14) and includes sensors (24, 26, 28, 34), which are operatively coupled with a digital controller (38). The controller (38) has a PID controller operable to continuously determine the average net rate of water removal from the product (16).

Abstract: A method for extruding a comestible material comprises the steps of passing comestible material into an extruder (100) with rotation of the extruder screw(s) (120, 122) and delivery of fluid comprising steam and water into an opening (114a) of the extruder barrel (104). The fluid delivery step comprises separately directing individual quantities of steam and water into the casing (72) of a static mixing section (54), and blending the steam and water to create a blended mixture, and then delivering the blended mixture into the barrel (114a). The blended mixture is delivered to the barrel opening (114a) by means of a conveying assembly (84, 86) having a pipe assembly (86) with an outlet in communication with the barrel opening (114a); the pipe assembly (86) and opening (114a) have diameters less than maximum internal diameter of the static mixer casing (72).

Abstract: An extruder (100) for comestible material comprises a tubular barrel (104) and one or more elongated, axially rotatable, helically flighted screws (120, 122) within the barrel (104), where the barrel (104) has a delivery opening (114a). The extruder barrel (104) is equipped with an assembly (22) for delivery of fluid to the interior thereof, including a static mixing section (54) operable to blend the steam and water to create a blended mixture; the blended mixture is delivered to the barrel opening (114a) by means of a conveying assembly (84, 86) having a pipe assembly (86) with an outlet in communication with the barrel opening (114a); the pipe assembly (86) and opening (114a) have diameters less than maximum internal diameter of the static mixer casing (72).