Abstract: An improved low shear extrusion and dehydrating apparatus (10) and method is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is at least about 2, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: An improved low shear extrusion and dehydrating apparatus (10) and method is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is at least about 2, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: A continuous mixer (32) is disclosed which can be used for mixing of incoming product streams (22, 24) of different characteristics respectively to yield a final product stream (26) of predetermined, consistent characteristics. The mixer (32) includes an elongated housing (42) having a pair of product input ports (50,52) and an output (64), with a pair of elongated, axially rotatable, mixing screws (44,46) located within the housing (42). The screws (44, 46) include a series of outwardly projecting mixing elements (114) preferably of pyramidal design and arrayed in a helical pattern along the length ofthe screws (44,46). The mixer (32) may be used in a processing system (10) having individual product lines (28, 30) coupled to the mixer (32), and is especially useful for processing of incoming meat streams (22,24) of different fat/lean ratios, to give a final comminuted output stream (26) of an intermediate and essentially constant fat/lean ratio.

Abstract: A continuous mixer (32) is disclosed which can be used for mixing of incoming product streams (22, 24) of different characteristics respectively to yield a final product stream (26) of predetermined, consistent characteristics. The mixer (32) includes an elongated housing (42) having a pair of product input ports (50, 52) and an output (64), with a pair of elongated, axially rotatable, mixing screws (44, 46) located within the housing (42). The screws (44, 46) include a series of outwardly projecting mixing elements (114) preferably of pyramidal design and arrayed in a helical pattern along the length of the screws (44,46). The mixer (32) may be used in a processing system (20,200) having individual product lines (28, 30, 204, 206) coupled to the mixer (32), and is especially useful for processing of incoming meat streams (22,24) of different fat/lean ratios, to give a final comminuted output stream (26) of an intermediate and essentially constant fat/lean ratio.

Abstract: A spreader apparatus (10) designed to evenly spread pellets or the like across an inlet deck (20) of a dryer or cooler is provided which includes a plurality of elongated, telescoping, pivotally supported delivery tubes (12) arranged in side-by-side relationship to form an array (14) extending across the deck (20). A drive assembly (16) is coupled with the tube array (14) so as to sequentially move the array (14) fore and aft to spread product thereon. A distributor (18, 152) is positioned above the array (14) in order to deliver product thereto. The distributor (18) includes a stationary, annular, multiple-pocket tray (76) as well as a spout (98) mounted for 360° rotation about an upright axis. As the spout (98) rotates, successive quantities of product are delivered to each pocket (84) of the tray (76). A ducting assembly (86) is provided between the tray (76) and the upper ends of the tubes (12).

Abstract: An improved low shear extrusion and dehydrating apparatus (10) and method is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is at least about 2, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: Combined extrusion/sonolation apparatus (10) which is designed to continuously and efficiently incorporate components (e.g., liquid lipids or fats or meltable solids) into heterogeneous materials in order to form stable products. The apparatus (10) includes an extruder (12) having a barrel (27) and restricted orifice outlet (38); a sonolation device (14) is directly coupled to the outlet (38). Preferably a monitoring unit (50) is located downstream of the sonolation device (14) and is connected via a controller (18) with the extruder (12) and device (14) so as to control the operation of the latter. In use, starting materials are fed into the extruder (12) and are initially mixed, whereupon a component is injected through a barrel-mounted injector pipe (41). The composite extrudate is treated within device (14) by subjecting it to acoustic vibrations.

Abstract: An improved low shear extrusion and dehydrating apparatus (10) and method is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is at least about 2, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: Improved, high-capacity extrusion systems (20, 220) are provided which minimize product losses and permit the user to conduct multiple, segregated short extrusion runs with a minimum of down time between runs. The systems (20, 220) include an extruder assembly (21, 221) having a special, multiple-position die assembly (28), as well as an upstream preconditioner (24) and feed bin assembly (22). A variable speed, variable output discharge screw feeder (78) is located between the preconditioner outlet (62) and extruder barrel inlet (90). A PLC-type controller (30) coupled to the extruder assembly components establishes a choke full condition at the discharge feeder (78) so that continuous uninterrupted flow of preconditioned material to the extruder (26) at a uniform mass flow rate is maintained for as long as possible. In preferred forms, load cells (46, 72) are operatively coupled to the bin assembly (22) and preconditioner (24) so as to monitor material flow through the systems (20, 220).

Abstract: An vertical dryer (10) is provided having a plurality of individual dryer decks (12-18) including alternating fan and heater decks (14, 16), an air circulation assembly (11), and an upright, common plenum chamber (26) in communication with the decks (12-18). The assembly (11) is operable to create a continuous drying air stream which passes upwardly in countercurrent flow relationship to product on the decks (12-18). Also, the assembly (11) serves to pass the drying air stream into, through and out of the plenum (26) at the level of each heater deck (16); in the plenum (26), the air stream velocity is decreased, causing particulate fines to fall out of the stream for collection. The use of the common plenum (26) also allows independent control of the decks (12-18) in terms of air flows therethrough and recirculation characteristics.

Abstract: Improved, high-capacity processing systems including a processing device such as an extruder (26) or a pellet mill (P) are provided which minimize product losses and permit the user to conduct multiple, segregated short runs with a minimum of down time between runs. The extruder systems (20, 220) include an extruder assembly (21, 221) having a special, multiple-position die assembly (28), as well as an upstream preconditioner (24) and feed bin assembly (22). A variable speed, variable output discharge screw feeder (78) is located between the preconditioner outlet (62) and extruder barrel inlet (90). A PLC-type controller (30) coupled to the extruder assembly components establishes a choke full condition at the discharge feeder (78) so that continuous uninterrupted flow of preconditioned material to the extruder (26) at a uniform mass flow rate is maintained for as long as possible.

Abstract: Combined extrusion/sonolation apparatus (10) which is designed to continuously and efficiently incorporate components (e.g., liquid lipids or fats or meltable solids) into heterogeneous materials in order to form stable products. The apparatus (10) includes an extruder (12) having a barrel (27) and restricted orifice outlet (38); a sonolation device (14) is directly coupled to the outlet (38). Preferably a monitoring unit (50) is located downstream of the sonolation device (14) and is connected via a controller (18) with the extruder (12) and device (14) so as to control the operation of the latter. In use, starting materials are fed into the extruder (12) and are initially mixed, whereupon a component is injected through a barrel-mounted injector pipe (41). The composite extrudate is treated within device (14) by subjecting it to acoustic vibrations.

Abstract: An improved low shear extrusion and dehydrating apparatus (10) is provided for the continuous extrusion of various starting materials (e.g., starch-bearing grains or starch fractions thereof, proteinaceous materials and/or nutraceuticals) to yield improved products, especially cold water swelling or soluble starch products. The invention is also useful for forming pre-gelled starch products and for processing starch-bearing materials using little or no surfactant. The apparatus (10) preferably includes an elongated extruder (18) together with a tubular die assembly (20) coupled to the outlet of the extruder barrel (32), wherein the volumetric ratio of the die assembly (20) to the free volume of the extruder (18) is from about 3-20, and the ratio of die assembly retention time to the extruder retention time is at least about 5.

Abstract: Improved short length extrusion cooking devices (10) are provided which can achieve product throughput and quality characteristics of conventional long-barrel extruders. The short length extruders (10) of the invention include a relatively short barrel (14) having an inlet (18) and an endmost extrusion die (20). An elongated, helically flighted axially, rotatable screw assembly (22) is positioned within the barrel (14) and is coupled to motive structure (39, 39a) for rotation of the assembly (22) at a speed of at least about 500 rpm. The device (10) may include an internal, apertured flow-restricting device (60, 102) which defines a mid-barrel choke point for the material being processed. An alternate extruder (120) is configured without a mid-barrel restriction and is designed to operate at essentially atmospheric internal pressure throughout the majority of the length of barrel (122) with a significant pressure rise in the final head (134) adjacent the extrusion die.

Abstract: An improved short-length, high-speed extrusion device (10) is provided with having increased capacities and the capability of producing high quality extrudates with improved density and pellet integrity properties. The device (10) includes an extruder (14) equipped with a peripheral die (20,118), the latter having die outlet openings (100,120) oriented generally transverse to the longitudinal axis of the extruder barrel (16). The die (20) has a plurality of axially spaced series (92-98) of openings (100), wherein each series (92-98) has a different number of openings (100). Alternately, the die (118) is of radially enlarged design relative to the extruder barrel (16) and has only a single series of openings (120). In both instances, an internal flow-directing bullet (108,140) is positioned within the corresponding die (20,118) in order to smoothly direct flow of product from the outlet (21) of the barrel (16) to the transversely oriented die outlet openings (100,120).

Abstract: A twin screw extruder (10) including an elongated barrel (12), a pair of elongated rotatable screws (14) and (16) positioned within the barrel (12) for moving material therethrough, and a high-speed bearing support assembly (18) for supporting the screws (14, 16) against misalignment and wear. The bearing support assembly (18) includes a pair of rotors (42, 44) each operably coupled with corresponding extruder screws (14, 16) for rotation therewith and a stator member (46) coupled with the extruder barrel (12) for receiving the rotors (42, 44). The stator (46) includes a plurality of injection ports (62) for directing an edible lubricant such as liquid fat into the bearing assembly (18) during operation of extruder (10).

Abstract: Improved short length extrusion cooking devices (10) are provided which can achieve product throughput and quality characteristics of conventional long-barrel extruders. The short length extruders (10) of the invention include a relatively short barrel (14) having an inlet (18) and an endmost extrusion die (20). An elongated, helically flighted axially, rotatable screw assembly (22) is positioned within the barrel (14) and is coupled to motive means (39, 39a) for rotation of the assembly (22) at a speed of at least about 500 rpm. The device (10) may include an internal, apertured flow-restricting device (60, 110) which defines a mid-barrel choke point for the material being processed. An alternate extruder (120) is configured without a mid-barrel restriction and is designed to operate at essentially atmospheric internal pressure throughout the majority of the length of barrel (122) with a significant pressure rise in the final head (134) adjacent the extrusion die.

Abstract: An improved extrusion processing system (10) for sticky extrudates such as candy products is provided which includes an extruder (12) equipped with a die (16) presenting an outlet face (23) and a knife assembly (19) and a knife hood (18). The system (10) further has a particulate delivery unit (20) which serves to direct a stream of particulate substance under positive pressure onto the outlet face (23) of extrusion die (16). The delivery unit (20) includes a container (42) for holding a supply of a particulate substance such as starch or sugar together with conduits (52, 56) adapted for coupling with a source of pressurized air and connected with container (42); a stream of the particulate substance under pressure is created and delivered via conduit (56) to hood (18) where it passes through delivery tube (60) for application onto outlet face (23).

Abstract: A pellet conditioning device (10) for the cooling and/or drying of preformed discrete pellets (148) is provided which includes an upright pellet-receiving bin (12) with a dual grate assembly (18) therein. The assembly (18) includes a stationary first grate comprising a plurality of upright, apertured grate wall members (86), and a shiftable second grate including a plurality of elongated, obliquely oriented plates (106) located between and in spanning relationship to adjacent pairs of the wall members (86). Shifting structure (20) is provided for selective and sequential translational, rectilinear shifting movement of the lower margins (110) of the plates (106) so as to successively open and close a pellet passageway (117) adjacent each lower margin (110). A duct and fan arrangement (38) is also provided with the bin (12) so as to draw cooling air currents through the grate assembly (18) and pellets (148) therein.

Abstract: An improved short-length, high-speed extrusion device (10) is provided with having increased capacities and the capability of producing high quality extrudates with improved density and pellet integrity properties. The device (10) includes an extruder (14) equipped with a peripheral die (20,118), the latter having die outlet openings (100,120) oriented generally transverse to the longitudinal axis of the extruder barrel (16). The die (20) has a plurality of axially spaced series (92-98) of openings (100), wherein each series (92-98) has a different number of openings (100). Alternately, the die (118) is of radially enlarged design relative to the extruder barrel (16) and has only a single series of openings (120). In both instances, an internal flow-directing bullet (108,140) is positioned within the corresponding die (20,118) in order to smoothly direct flow of product from the outlet (21) of the barrel (16) to the transversely oriented die outlet openings (100,120).