Abstract: An extruder system (10, 124) for the processing of feed materials is provided including an extruder (12), adjustable back pressure valve assembly (14) and a superatmospheric post-extrusion product treatment assembly (16, 124). The back pressure valve assembly (14) includes an adjustable valve member (48) which can be shifted to alter the effective cross-sectional open area of a product passageway (36), and alternately can be shifted to a product diverting position wherein the product is diverted from downstream processing. The treatment assembly (16) includes a sealed housing (78) directly coupled to the assembly (14) so that product emerging from the assembly (14) passes into housing (78) without experiencing atmospheric pressure. The treatment assembly (124) includes a product-guiding cowling (128) which is open to the atmosphere, together with a sealed housing (134) for effecting above atmospheric pressure treatment of extruded product.

Abstract: Material processing apparatus (10) is provided for the simultaneous production of different characterized final products using a single, initially processed product stream. The apparatus (10) includes a barrel assembly (12) having an elongated, tubular barrel (16) with a flighted, axially rotatable screw (26) within the barrel, and an additive incorporation assembly (14) coupled with the barrel (16) and having a plurality of individual mixing chambers (34, 36) configured to receive and process individual, separate streams of product from the barrel assembly (12). Individual additive injectors (52, 54) are also provided for injection of additives such as colorants or the like into the respective product streams for mixing with the chambers (34, 36). Preferably, the assembly (14) includes a flow divider (32) having plural separate passageways (46, 48), which are in communication with the corresponding mixing chambers (34, 36).

Abstract: An extruder system (10, 124) for the processing of feed materials is provided including an extruder (12), adjustable back pressure valve assembly (14) and a superatmospheric post-extrusion product treatment assembly (16, 124). The back pressure valve assembly (14) includes an adjustable valve member (48) which can be shifted to alter the effective cross-sectional open area of a product passageway (36), and alternately can be shifted to a product diverting position wherein the product is diverted from downstream processing. The treatment assembly (16) includes a sealed housing (78) directly coupled to the assembly (14) so that product emerging from the assembly (14) passes into housing (78) without experiencing atmospheric pressure. The treatment assembly (124) includes a product-guiding cowlijng (128) which is open to the atmosphere, together with a sealed housing (134) for effecting above atmospheric pressure treatment of extruded product.

Abstract: An improved twin screw extruder device (14) is provided which is capable of producing a wide variety of high quality extrudates having greatly varying final properties, without the need for extensive machine modifications. The extruder (14) includes a barrel (16) together with a co-rotating twin screw assembly (22). The assembly (22) is made up of a pair of screws (50, 52) having central, tapered shafts (54, 56) equipped with outwardly extending helical flighting (58, 60); the screws (50, 52) are non-parallel and are positioned so that the flighting (58, 60) thereof is intercalated along the length of the screws (50, 52). The fighting is of specialized configuration and tapers along the length of the screws (50, 52) preferably at an angle of taper different than that of the shafts (54, 56); moreover, the width of the outer flighting surfaces (70, 72) increases along the length of the shafts (54, 56).

Abstract: Material processing apparatus (10) is provided for the simultaneous production of different characterized final products using a single, initially processed product stream. The apparatus (10) includes a barrel assembly (12) having an elongated, tubular barrel (16) with a flighted, axially rotatable screw (26) within the barrel, and an additive incorporation assembly (14) coupled with the barrel (16) and having a plurality of individual mixing chambers (34, 36) configured to receive and process individual, separate streams of product from the barrel assembly (12). Individual additive injectors (52, 54) are also provided for injection of additives such as colorants or the like into the respective product streams for mixing with the chambers (34, 36). Preferably, the assembly (14) includes a flow divider (32) having plural separate passageways (46, 48), which are in communication with the corresponding mixing chambers (34, 36).

Abstract: An improved twin screw extruder device (14) is provided which is capable of producing a wide variety of high quality extrudates having greatly varying final properties, without the need for extensive machine modifications. The extruder (14) includes a barrel (16) together with a co-rotating twin screw assembly (22). The assembly (22) is made up of a pair of screws (50, 52) having central, tapered shafts (54, 56) equipped with outwardly extending helical flighting (58, 60); the screws (50, 52) are non-parallel and are positioned so that the flighting (58, 60) thereof is intercalated along the length of the screws (50, 52). The flighting is of specialized configuration and tapers along the length of the screws (50, 52) preferably at an angle of taper different than that of the shafts (54, 56); moreover, the width of the outer flighting surfaces (70, 72) increases along the length of the shafts (54, 56).

Abstract: An improved twin screw extruder device (14) is provided which is capable of producing a wide variety of high quality extrudates having greatly varying final properties, without the need for extensive machine modifications. The extruder (14) includes a barrel (16) together with a co-rotating twin screw assembly (22). The assembly (22) is made up of a pair of screws (50, 52) having central, tapered shafts (54, 56) equipped with outwardly extending helical flighting (58, 60); the screws (50, 52) are non-parallel and are positioned so that the flighting (58, 60) thereof is intercalated along the length of the screws (50,52). The flighting is of specialized configuration and tapers along the length of the screws (50, 52) preferably at an angle of taper different than that of the shafts (54, 56); moreover, the width of the outer flighting surfaces (70, 72) increases along the length of the shafts (54, 56).

Abstract: An improved twin screw extruder device (14) is provided which is capable of producing a wide variety of high quality extrudates having greatly varying final properties, without the need for extensive machine modifications. The extruder (14) includes a barrel (16) together with a co-rotating twin screw assembly (22). The assembly (22) is made up of a pair of screws (50, 52) having central, tapered shafts (54, 56) equipped with outwardly extending helical flighting (58, 60); the screws (50, 52) are non-parallel and are positioned so that the flighting (58, 60) thereof is intercalated along the length of the screws (50, 52). The flighting is of specialized configuration and tapers along the length of the screws (50, 52) preferably at an angle of taper different than that of the shafts (54, 56); moreover, the width of the outer flighting surfaces (70, 72) increases along the length of the shafts (54, 56).

Abstract: An improved twin screw extruder device (14) is provided which is capable of producing a wide variety of high quality extrudates having greatly varying final properties, without the need for extensive machine modifications. The extruder (14) includes a barrel (16) together with a co-rotating twin screw assembly (22). The assembly (22) is made up of a pair of screws (50, 52) having central, tapered shafts (54, 56) equipped with outwardly extending helical flighting (58, 60); the screws (50, 52) are non-parallel and are positioned so that the flighting (58, 60) thereof is intercalated along the length of the screws (50,52). The flighting is of specialized configuration and tapers along the length of the screws (50, 52) preferably at an angle of taper different than that of the shafts (54, 56); moreover, the width of the outer flighting surfaces (70, 72) increases along the length of the shafts (54, 56).

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: 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: 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: 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: 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: 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: A method of producing extrudates such as high protein, high fat sinking aquatic feeds is provided wherein a high protein starting material is initially preconditioned and passed through an extruder; in the extruder barrel a zone of reduced pressure is created upstream of the die for densifying the final extrudate. Fat may be added to the starting mixture at any desired point in the process, and/or may be added as a surface coating to the final extrudate. Preferably, the method further involves measuring a density value of the extrudate such as bulk density, and adjusting the magnitude of the reduced pressure conditions in the barrel in response to such measurement.

Abstract: An extrusion die apparatus adapted for coupling to the outlet end of an extruder barrel and corresponding methods of use are described. The die apparatus, when so coupled to the extruder barrel, has 1) an inlet-end chamber downstream of and in communication with the interior of the extruder barrel, 2) a secondary chamber downstream of and in communication with the inlet-end chamber, and 3) a plurality of individual, spaced die-outlet orifices downstream of and in communication with the secondary chamber. The die apparatus includes manually or automatically controllable inserts for controlling the operating pressures within the chambers and outlet orifices. These operating pressures are adjusted so that the pressure within the inlet-end chamber, which controls cooking, is greater than the pressure within the secondary chamber, and the pressure within the secondary chamber is greater than the pressure within each outlet orifice. In operation, the die apparatus receives product from the extruder barrel.

Abstract: A preferred preconditioning device for use with an extruder includes two juxtaposed, frustocylindrical, intercommunicated chambers one of which presents a greater cross-sectional area than the other. A respective pair of rotatably driven mixing shafts extend axially through corresponding chambers with each mixing shaft having a plurality of mixing elements coupled therewith. The mixing elements are arranged, in order to present in cooperation with the chambers, a plurality of conditioning zones preferably including a mixing zone for initially mixing the material, an intermediate retention zone providing increased retention time for enhancing equilibration between solid and liquid portions of the material, and a final tertiary zone for comminuting clumps of material.

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).