The purpose of our study was to determine if an emulsifier, and particularly “which” emulsifier, monodyglycerides or rice extract, would aid in the production of 3G snack pellets.
Our first formulation included Myvaplex 600P® at .5% addition level. This emulsifier proved successful in reducing stickiness and torque/amps during extrusion. This emulsifier has been used in week-long, 24 hour per day production periods.
We utilize an Extru-Tech, Inc. twin screw cooking extruder and single screw forming extruder for production.
We have had very good results and good expansion in final product. We do notice build up of material on the water-cooled shaft of the former after extended periods of production.
Our next step in the study was to use the same proportions of NU-RICE in the same formulation repeating the same run conditions.
The results in were good. Amp load was reduced 15%, exit temp of product reduced 10 degrees Fahrenheit and moisture addition could be reduced at the cooking extruder. Also, we noticed a more uniform product at the die plate of the former. Due to these factors we believe we can increase production output by perhaps 6%.
Another improvement was the expansion in the final frying of the product. We saw about 4 x expansion rate after frying in the control and a 5 x expansion with Nu-RICE.
Our final testing involved using the same formulation but with .5% Nu-RICE and .25% Myvaplex 600P®. This also yielded good results as the photo below demonstrates. However, I do not believe the addition of .25% Myvaplex 600P® to be of substantial improvement to merit its existence in the formulation.
After dismantling both the cooking extruder and former we found reduced levels of product buildup on both the extruder screws and particularly the former shaft from product run with Nu-RICE. Also, fry checks were performed on the product after three days to allow for moisture migration. Results proved to be identical to previous fry checks.
All testing was performed at Crosswind Foods, the food grade division of Extru-Tech, Inc. in Sabetha, Kansas. 2003