EP4561374A1

EP4561374A1 - Extruder and roller apparatus

Info

Publication number: EP4561374A1
Application number: EP23742211.8A
Authority: EP
Inventors: Kevin KURZ; Reinhold Willy Betz
Original assignee: Societe des Produits Nestle SA; Nestle SA
Current assignee: Societe des Produits Nestle SA; Nestle SA
Priority date: 2022-07-26
Filing date: 2023-07-11
Publication date: 2025-06-04
Also published as: WO2024022799A1; IL318596A

Abstract

Extrusion is used in the production of foodstuffs. There is provided herein an apparatus for the extrusion of protein-based material, comprising: an extruder comprising an extruding slot; and a roller support adjacent the extruding slot, comprising: a plurality of rollers arranged around a tubular structure with an increasing radius along the longitudinal axis, with first radius R1 at a first end adjacent the extruding slot, and a second radius R2 at a second end, where R2 > R1.

Description

EXTRUDER AND ROLLER APPARATUS

[0001] The process of extrusion is used in the production of foodstuffs. Pliable, mixed ingredients are forced through a plate containing a recess, the recess defining the shape of the extruded material once it has passed through the plate. The pliable material forced through the plate must be of sufficient durability to endure the extrusion process itself, and maintain its shape after passing through the plate. The extruded material is then conventionally cut to a predetermined size using a blade adjacent the plate.

[0002] Extrusion can provide a rapid, uniform, continuous, and cost-effective means of mass-producing foodstuffs. Commonly extruded foodstuffs include pasta, bread products, breakfast cereals, animal feed, and other high-starch items. The high starch content allows for extruded products to endure the forces inherent during conventional extruding processes, without breaking or otherwise deforming. Meat analogue products are also often produced by extrusion and the characteristics of plant protein-based materials relative to high starch materials pose unique challenges for achieving successful extrusion.

[0003] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0004] A first aspect provides an apparatus for the extrusion of protein-based material, comprising: an extruder comprising an extruding slot; and a roller support adjacent the extruding slot, comprising: a plurality of rollers arranged around a tubular structure with an increasing radius along the longitudinal axis, with first radius R1 at a first end adjacent the extruding slot, and a second radius R2 at a second end, where R2 > R1 .

[0005] The preferred features may be combined as appropriate, as would be apparent to a skilled person, and may be combined with any of the aspects of the invention.

Brief Description of the Drawings

[0006] Examples of the invention will be described, by way of example, with reference to the following drawings, in which:

[0007] Figure 1 shows an extruder and roller apparatus; [0008] Figure 2 shows a front view of the extruder and roller apparatus;

[0009] Figure 3 shows a side view of the extruder and roller apparatus;

[0010] Figure 4 shows an alternative roller apparatus;

[0011] Figure 5 shows an exemplary dimensioned plan view of the extruder and roller apparatus;

[0012] Figure 6 shows an exemplary dimensioned side view of the extruder and roller apparatus; and

[0013] Figure 7 shows an exemplary dimensioned front view of the extruder and roller apparatus.

[0014] Common reference numerals are used throughout the figures to indicate similar features.

Detailed Description

[0015] Embodiments of the present invention are described below by way of example only. These examples represent the best ways of putting the invention into practice that are currently known to the Applicant although they are not the only ways in which this could be achieved. The description sets forth the functions of the example and the sequence of steps for constructing and operating the example. However, the same or equivalent functions and sequences may be accomplished by different examples.

[0016] Figure 1 shows an extruder and roller apparatus 100. The part referred to as the “extruder” comprises at least two parts: an extrusion arrangement (not shown), and a cooling die 105. The extrudate is a protein-based material. The extrusion arrangement may comprise at least one screw within a confined cylindrical container, which forces the protein-based material to be extruded longitudinally along the cylindrical container. The protein-based material may also be subjected to high temperatures, pressures, and/or shearing forces within the cylindrical container of the extrusion arrangement, depending on the pre-treatment requirements of that particular protein-based material. In such a way, protein-based material is transformed from its original state to a state suitable for extrusion.

[0017] As the protein-based material is extruded longitudinally along the cylindrical container, it arrives at the cooling die 105. The cooling die 105 receives the protein-based material, and cools the protein-based material to a predetermined temperature as the material passes through.

[0018] At one end of the cooling die 105, remote from the extrusion arrangement, is a plate 110. The plate 110 completely covers a recess of the cooling die 105, with the exception of an extruding slot 115. As the protein-based material passes through the cooling die 105, it is forced through the extruding slot 115, thereby being extruded and so forming an extruded laminar sheet. In one example, the plate 110 is fixed to the cooling die 105.

[0019] The extruding slot 115 of this example is a horseshoe shape. A horseshoe shape may be considered to be any arc shape with at least one break or discontinuity between the two ends of the arc. In another example, the extruding slot 115 is a rectangular shape. In another example, the extruding slot 115 is a circular shape. There may be provided a cutting means (not shown) adjacent the extruding slot 115, arranged to slice the extrusion resulting from the extruding slot 115. For example, a circular extrusion resulting from a circular extruding slot 115 can thereby be formed into a laminar sheet. The cutting means may be in the form of a bladed implement.

[0020] In one example, a cutting means cuts the extrudate as it exits the cooling die 105 at one point to obtain a single piece of extrudate. In one example, the cutting means is located downstream of the cooling component that is itself located downstream of the cooling die 105 end and can cut the extrudate in the same direction as the flow path, such that the cylinder shape opens to form one flat piece of extrudate. In one example, the cutting means cuts the extrudate as it exits the cooling die 105 at more than one point to obtain more than one piece of extrudate.

[0021] Having passed through the extruding slot 1 15, the extruded material is supported by a plurality of rollers 120 arranged around a tubular structure 125 (also referred to as a roller support 125). The rollers 120 may comprise convex rollers. The plurality of rollers comprise rollers of at least two different lengths and/or widths. The tubular structure 125 comprises a first end 125’ adjacent the extruding slot 115, and a second end 125” remote from the extruding slot 115.

[0022] The radius of the tubular structure 125 increases from the first end 125’ to the second end 125”. At the first end 125’ the radius is R1 , and at the second end 125” the radius is R2, where R2 is greater than R1 . In one example, R2 tends to infinity, such that the second end 125” is substantially flat. The radius of the tubular structure 125 may be arranged to increase linearly between R1 and R2. [0023] At least part of the tubular structure 125 may have an arc-shaped cross section, optionally wherein the arc-shaped cross section is of a constant length throughout at least a portion of the longitudinal axis of the tubular structure 125. In such a way, the total width of the extruded material, whether in the form of the length of a curved arc or straight across in a flat sheet, remains constant. An “arc” may be considered any curved shape, for example part of a circumference of a circle, a parabola, a catenary curve, and/or a U-shape.

[0024] As the extruded material passes through the extruding slot 1 15, and is supported by the plurality of rollers 120 arranged around the tubular structure 125, gravitational forces act on the extruded material so as to pull it from the first end 125’ to the second end 125”. In use, this may be performed by having the second end 125” be positioned lower than the first end 125’. This reduces the forces acting on the extruded material, now in the form of a laminar sheet, and which may be very vulnerable to damage.

[0025] Figures 2 and 3 show a front view and a side view of the extruder and roller apparatus 100 respectively. In this example, at least some of the rollers 120’ adjacent the first end 125’ of the tubular structure 125 may be, in use, aligned with an uppermost portion of the extruding slot 115. In this example, at least a portion of the second end 125” of the tubular structure 125 is, in use, aligned with a lowermost portion of the extruding slot 1 15. The vertical distance 205 between at least a portion of the first end 125’ of the tubular structure 125 and the abovementioned portion of the second end 125” of the tubular structure 125 is approximately twice the value of the radius R1 of the first end 125’ of the tubular structure 125.

[0026] Figure 4 shows an alternative tubular structure 125. In this example, the rollers 120 are smaller and are more evenly dispersed throughout the body of the tubular structure 125. The rollers 120 of this and other examples may be distributed in a number of different ways. In this example, some of the rollers 120 are aligned along the longitudinal axis of the tubular structure 125. One or more of the rollers 120 may be removeable, to assist with cleaning after they have been used to transport the extruded material along the tubular structure 125.

[0027] Figure 5 shows an exemplary dimensioned plan view of the extruder and roller apparatus 100. As in relation to the other figures, the part referred to as the “extruder” comprises at least two parts: an extrusion arrangement 505, and a cooling die 105. The protein-based material (not shown) enters the extrusion arrangement 505 via an entry passage 510. The extrusion arrangement 505, using a screw and/or other conveyancing mechanism, passes the protein-based material to the cooling die 105. The cooling die 105 cools and structures the protein-based material, so that it can be extruded through the extruding slot 115.

[0028] Once extruded through the extruding slot 115, the extruded material is supported by the plurality of rollers 120 arranged around the tubular structure 125. In the case of proteinbased material, the extruded material may be extremely fragile. By allowing gravity to gently pull the extruded material from the first end 125’ to the second end 125”, and maintaining a constant width of the extruded material, tension forces acting upon the extruded material can be reduced. Therefore, the extruded material can remain in a complete, unbroken sheet. An unbroken sheet allows for the stamping out of bigger pieces of the extruded material, for example to obtain a plant-based Schnitzel. The volume of material lost is reduced by using the apparatus and method of this invention, by achieving an unbroken sheet. Fewer rollers 120 allow for quicker cleaning and maintenance of the tubular structure 125.

[0029] Once the extruded material has passed along the tubular structure 125, the radius of which is increasing from the first end 125’ to the second end 125”, it is in the form of a flat, laminar sheet. The flat, laminar sheet is optionally passed over one or more supporting trays 515 and onto a collection table 520. From the collection table 520 the flat, laminar sheet can be collected and/or further processed as required.

[0030] In one example, the apparatus 100 has the following dimensions: The distance 525 between the supporting trays 515 and the collection table 520 is between 44-66mm, preferably between 50-60mm, optionally 55.3mm. The distance 530 between the plate 110 and the collection table 520 is between 840-1260mm, preferably between 1000-1100mm, optionally 1050mm. The width 535 of the table on which the tubular structure 125 is supported, substantially representing the maximum width of the tubular structure 125 itself, is between 994-1416mm, preferably between 1050-1250mm, optionally 1180mm.

[0031] Figure 6 shows an exemplary dimensioned side view of the extruder and roller apparatus 100. In one example, the apparatus 100 has the following dimensions: In use, the vertical distance 605 between the collection table 520 and the mid-point of the tubular structure 125 is between 183-275mm, preferably between 200-250mm, optionally 229mm. In use, the vertical distance between the uppermost surface of the collection table 520 and the ground on which the collection table 520 is supported is between 720-1080mm, preferably between 850-959mm, optionally 900mm. In use, the vertical distance between the uppermost surface of the support on which the tubular structure 125 is resting and the ground is between 695-1042mm, preferably between 800-900mm, optionally 868.5mm. In use, the vertical distance 620 between the mid-point of the tubular structure 125 and the ground is between 903-1355mm, preferably between 1050-1250mm, optionally 1 129mm.

[0032] Figure 7 shows an exemplary dimensioned front view of the extruder and roller apparatus 100. This figure shows that width 535 of the support on which the tubular structure 125 is resting substantially includes the total width of the tubular structure 125. Optionally, one or more components of the extruder and roller apparatus 100 are positioned on moveable tables, such as those equipped with wheels, rollers, or other suitable apparatus.

[0033] A protein-based material may be considered a material comprising at least 15wt% protein (weight percent of the total composition), preferably 15-40wt%, preferably 20-40wt%, preferably 25-40wt%, preferably 15-35wt%, preferably 15-30wt%, preferably 15-25wt%, preferably 20-35wt%, preferably 25-35wt%, preferably 20-30wt%.

[0034] The protein-based material of any example given herein is preferably a non-animal protein substance. Non-limiting examples of suitable non-animal protein substances include: pea protein, wheat gluten such as vital wheat gluten, corn protein, for example ground corn or corn gluten, soy protein, for example soybean meal, soy concentrate, or soy isolate, rice protein, for example ground rice or rice gluten, rice protein for example ground rice or rice gluten, barley protein, algae protein, hemp protein, oat protein, canola protein, fava protein, cottonseed, peanut meal, and mixtures thereof. Preferably, the non-meat protein substances are pea protein, wheat gluten, and/or soy protein, and mixtures thereof.

[0035] In any given example, the protein-based material comprises a moisture content of between 50% and 75%, preferably between 50% and 70%, further preferably between 55% and 65%, and further preferably between 55% and 65%.

[0036] In any given example, any raw material used in respect of the protein-based material does not comprise a meat product and comprises gluten, for example wheat gluten. In one example, the raw material does not comprise a meat and does not comprise any gluten. The raw material may include other components in addition to proteins and flours, for example one or more of a vitamin, a mineral, a preservative, a colorant and a palatant.

[0037] The raw material may optionally comprise a flour. If a flour is used, the raw material may include protein. Therefore, an ingredient may be used that is both a vegetable protein and a flour. Non-limiting examples of a suitable flour are a starch flour, such as cereal flours, including flours from rice, wheat, corn, barley, and sorghum; root vegetable flours, including flours from potato, cassava, sweet potato, arrowroot, yam, and taro; and other flours, including sago, banana, plantain, breadfruit flours, and mixtures thereof. A further non- limiting example of a suitable flour is a legume flour, including flours from beans such as favas, lentils, mung beans, peas, chickpeas, soybeans, and mixtures thereof.

[0038] In some examples, the raw material may comprise a fat such as a vegetable fat. A vegetable oil, such as corn oil, sunflower oil, safflower oil, rape seed oil, soybean oil, olive oil and other oils rich in monounsaturated and polyunsaturated fatty acids, may be used additionally or alternatively.

[0039] In at least one example, a dry mix of plant protein of 22wt% soy protein concentrate and 18wt% of wheat gluten and 3wt% of flavor (based on total amount of high moisture extrudate) is used in the apparatus for the extrusion of protein-based material. The dry mix is added through a hopper into an extruder barrel, and 57wt% water (based on the total amount of high moisture extrudate) is separately injected into an extruder 505. The extruder barrels are heated within a curve between 80-180 degrees C. The cooling die 105 is cooling the extruded mixture to an exit temperature of 80°C. The extrudate may be made on a Buhler B93 twin screw extruder. The obtained extrudate is allowed to pass over the roller support 125 and spread from the horseshoe-shaped extruding slot 115 to form a laminar sheet. The laminar sheet produced using this arrangement may be unbroken and used to stamp out individual pieces of material, for example to make plant-based Schnitzel.

[0040] Any range or device value given herein may be extended or altered without losing the effect sought, as will be apparent to the skilled person.

[0041] Any example given may be used additionally or alternatively with any part of any other example given.

[0042] It will be understood that the benefits and advantages described above may relate to one example or may relate to several examples. The examples are not limited to those that solve any or all of the stated problems or those that have any or all of the stated benefits and advantages.

[0043] Any reference to “an” item refers to one or more of those items. The term “comprising” is used herein to mean including the method blocks or elements identified, but that such blocks or elements do not comprise an exclusive list and a method or apparatus may contain additional blocks or elements.

[0044] The steps of the methods described herein may be carried out in any suitable order, or simultaneously where appropriate. Additionally, individual blocks may be deleted from any of the methods without departing from the spirit and scope of the subject matter described herein. Aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples without losing the effect sought.

[0045] It will be understood that the above description of a preferred example is given by way of example only and that various modifications may be made by those skilled in the art. Although various examples have been described above with a certain degree of particularity, or with reference to one or more individual examples, those skilled in the art could make numerous alterations to the disclosed examples without departing from the spirit or scope of this invention.

Claims

1 . An apparatus for the extrusion of protein-based material, comprising: an extruder comprising an extruding slot; and a roller support adjacent the extruding slot, comprising: a plurality of rollers arranged around a tubular structure with an increasing radius along the longitudinal axis, with first radius R1 at a first end adjacent the extruding slot, and a second radius R2 at a second end, where R2 > R1 .

2. The apparatus of claim 1 , wherein the extruding slot is a horseshoe-shaped extruding slot.

3. The apparatus of any preceding claim, further comprising a cutting means adjacent the extruding slot.

4. The apparatus of any preceding claim, wherein, in use, the rollers adjacent the first end are positioned in relation to the rollers adjacent the second end such that the laminar sheet is gravitationally pulled from the first end to the second end.

5. The apparatus of any preceding claim, wherein at least a first portion of the roller support adjacent the first end is aligned with a first region of the extruding slot and at least a second portion of the roller support adjacent the second end is aligned with a second region of the extruding slot, and further wherein the distance between the first region and the second region is double R1 .

6. The apparatus of any preceding claim, wherein R2 tends to infinity.

7. The apparatus of any preceding claim, wherein at least a portion of the roller support has an arc-shaped cross-section.

8. The apparatus of claim 7, wherein the arc-shaped cross-section is of a constant length across at least a portion of the longitudinal axis of the tubular structure.

9. The apparatus of any preceding claim, comprising a linearly increasing radius between R1 and R2.

10. The apparatus of any preceding claim, wherein, in use, the rollers adjacent the first end are positioned vertically higher than the rollers adjacent the second end.

11 . The apparatus of any preceding claim, wherein at least one of the plurality of rollers is removeable.

12. The apparatus of any preceding claim, wherein the roller support is fixed to the extruder.

13. The apparatus of any preceding claim, wherein at least one of the plurality of rollers is aligned longitudinal axis of the tubular structure with at least another of the plurality of rollers.

14. The apparatus of any preceding claim, wherein the plurality of rollers comprises at least one convex roller.

15. A method of producing a sheet of a protein-based material, comprising the steps of: extruding the protein-based material through an extruding slot to form a laminar sheet; and supporting the laminar sheet on a roller support adjacent the extruding slot, the roller support comprising: a plurality of rollers arranged around a tubular structure with an increasing radius along the longitudinal axis, with first radius R1 at a first end adjacent the extruding slot, and a second radius R2 at a second end, where R2 > R1 , and wherein, in use, the rollers adjacent the first end are positioned in relation to the rollers adjacent the second end such that the laminar sheet is gravitationally pulled from the first end to the second end.