Abstract: Methods of preparing fresh animal protein products of consistent composition and specification useful as ingredients in extrusion systems are provided, wherein one or more aqueous streams (10, 54, 56) of fresh, uncooked animal protein and fat are initially blended (12, 60) and emulsified (14, 62). The emulsified and blended streams (10, 54, 56) include solid particles having a maximum dimension of up to about 2 mm. These materials are analyzed preferably using near infrared and microwave analyzers (16, 64, 68) and an output stream (18, 70) is created. The analyzers (16, 64, 68) create product signatures for the analyzed materials which is used to adjust the specification of the materials via recirculation (42), addition of fresh animal protein (10) or other ingredients (30) in a batch system; or by appropriate mixing of individual streams (54, 56) in a continuous mixer (66).

Abstract: An extrusion system (10) is provided having an extruder (12), raw material input apparatus (14), dryer (16) and controller (18). The system (10) is equipped with strategically placed analyzers (22-26) designed to measure important parameters of the material input and the final extrudates; the analyzers (22-26) are coupled to controller (18), the latter also being operatively connected to the system components (12-16) for real-time operational control thereof. The analyzers (22-26) are preferably designed to generate analysis signals which pass through a cross-section of the material or extrudate, such as ultrasound, NIR or microwave analyzers.

Abstract: Methods of controlling waste streams and products in extrusion systems are provided in order to create from such materials consistent-quality recyclable waste streams which can be directly fed to an extruder without creating upset conditions or production of out of specification extrudates. In the methods of the invention, an incoming stream (10) of waste material including fat, protein, starch and moisture is blended to increase the homogeneity thereof whereupon the material is analyzed using one or more analyzers (16), especially microwave and near infrared analyzers. Such analysis creates a product signature for the material which is stored in a control microprocessor (28). The analyzed stream (10) can be modified as necessary by recirculation and/or addition of extra ingredients to create a final output stream (18) suitable for extrusion along with a primary stream (48) of extrudable material.