RU2792993C1 - Method for producing pellets for chips - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: method for production of pellets for the manufacture of chips is proposed, in which the previously obtained ready-made dough for pellets is thoroughly mixed in a mixer and fed into an extruder, with which the finished dough is squeezed out through a matrix, while the dough is cooked in the extruder, and a layer of dough is extruded through the extruder matrix into a continuous form, which is fed to the corrugation installation, consisting of corrugated rolls rotating in opposite directions, pressed against each other with the possibility of adjusting the distance between them, and the dough coming out of the corrugated rolls is continuously cooled and fed in layers to the stamping installation, which consists of two rotating opposite sides of the stamping rolls, with one stamping roll being smooth, and on the surface of the second roll, oval rings, pointed at the ends, are fixed, which with their top touch the reciprocal smooth roll end-to-end, at the exit from the stamping installation, a finished oval-shaped pellet and the remains of the formation are obtained, where the pellet is then sent to the storage or production of chips, and the rest of the dough layer is re-placed in the extruder. In this case, oval rings are welded to the washers, and the washers are attached to the stamping roll. The layer of dough is fed from the corrugation plant to the stamping installation through a round roller bar, which is positioned and fixed higher than the rolls of the installations. The extruder, the corrugation installation and the stamping installation are fixed on the same frame so that the axes of the rolls of the units are perpendicular to the imaginary projection of the plane of the extruder nozzle intersecting these axes, and in order to be able to adjust the position of the units relative to each other on the bed, each unit is equipped with wheels, and the top of the bed is equipped with rails under these wheels. Bristle is installed in the lower part of the roll with oval rings.

EFFECT: expanding the arsenal of methods for production of wheat-potato pellets for making chips, which uses more compact and simple equipment, and the pellets are obtained in a single thickness that can be adjusted, the pellets are then used to make chips.

6 cl, 16 dwg

Description

The invention relates to the food industry, and in particular to a method for the production of pellets from potato, wheat, corn and multi-grain raw materials. The pellets are then used to make chips.

The process of preparing chips from semi-finished products - pellets (pellets are called semi-finished products obtained by molding, drying, which after frying becomes chips) is carried out according to the following scheme: preparation of the dry components of the mixture -> mixing the components -> feeding into the extruder -> kneading the dough and pressing through the matrix ( see [https://bstudy.net/619317/estestvoznanie/tehnologiya_prigotovleniya_realizatsiya_chipsov]).

At the same time, it is possible to obtain both flat chips of classic, round or oval shapes, as well as new, original configurations such as "shells", "clouds", "spirals", etc.

Thus, both products prepared in the traditional way (“crisps”) and those made from powdered potato raw materials (“reconstituted”) can be called chips if they are obtained by slicing or imitating it. Other products obtained by a similar extrusion technology, but having volumetric forms, are snacks, and not only potato derivatives, but also cereal derivatives (additional gelatinization is required) or their mixtures can serve as raw materials for them.

Known technology for the preparation of chips [https://bstudy.net/619317/estestvoznanie/tehnologiya_prigotovleniya_realizatsiya_chipsov], which describes the production process of potato chips obtained by molding:

1) Dry mashed potatoes, starch and food additives are mixed for 2 to 4 minutes, and then water or saline is added with continuous stirring. The mixture is thoroughly mixed in the mixer and fed into the extruder.

2) The extruder extrudes the semi-finished product of snacks (pellets) through the matrix (die), the size and shape of the pellets depend on the shape of the holes in the matrix. Forming by rolling into a strip with a thickness of not more than 0.8 mm is also possible.

3) The extruded products then go to the dryer.

4) After drying, this semi-finished product is stored.

5) As needed, the semi-finished product is fried.

6) Excess oil is removed (the process is carried out on a mesh vibro-conveyor).

7) Additives are added using a continuous coating machine.

8) Ready snacks are cooled and packaged.

The above process is typical for the bulk of the equipment for the production of wheat-potato pellets.

Such production lines are usually very cumbersome, for example, in the line https://www.tronka.com.ua/pellets.html (published: 04/18/2022) the equipment at the stage after receiving the dough consists of: press extruder, cutting device, instrumentation and PU, forming matrix.

All known technologies for the production of pellets are based on the fact that the finished dough leaves the matrix immediately corrugated and it is difficult to control the thickness of the dough from the matrix.

The objective of the invention is to eliminate the above problems.

The technical result of the invention is the expansion of the arsenal of methods for the production of wheat-potato pellets for the manufacture of chips, which uses more compact and simple equipment, and the pellets are obtained with a single thickness that can be adjusted.

The specified technical result is achieved due to the fact that the claimed method for the production of pellets for the manufacture of chips, in which the pre-obtained finished dough for pellets is thoroughly mixed in a mixer and fed into an extruder, with which the finished dough is squeezed out through a matrix, characterized in that the extruder is used dough cooking, and through the extruder matrix, a dough layer is extruded in a continuous form, which is fed to the corrugation installation, consisting of corrugated rolls rotating in opposite directions, pressed against each other with the possibility of adjusting the distance between them; and the dough coming out of the corrugated rolls is continuously cooled and fed in layers to a bran installation, which consists of two bran rolls rotating in opposite directions, with one bran roll being smooth, and oval rings, pointed at the ends, are fixed on the surface of the second roll, which with their top touch the reciprocal smooth one. butt roll; at the exit from the bran plant, a finished oval-shaped pellet and the remains of the layer are obtained, where the pellet is then sent to storage or the production of chips, and the remains of the dough layer are re-placed in the extruder.

Preferably, the oval rings are welded to the washers and the washers are attached to the cut roll.

Preferably, the sheet of dough is fed from the corrugator into the bran machine via a circular roller bar which is positioned and fixed higher than the rollers of the machines.

Preferably, the extruder, corrugator and cutter are mounted on the same frame so that the axes of the rolls of the machines are perpendicular to an imaginary projection of the plane of the extruder nozzle intersecting these axes.

In order to be able to adjust the position of the installations relative to each other on the frame, each installation is equipped with wheels, and the top of the frame is equipped with rails for these wheels.

Preferably, bristles are placed at the bottom of the oval-ring roll.

Brief description of the drawings

Figure 1 shows the device of the system with all the elements of the equipment installed on the frame.

Figure 2 shows a close-up of the area A highlighted in figure 1

Figure 3 shows a close-up of the roll with rings.

Figure 4 shows the installation device corrugation (view in volume).

Figure 5 shows the corrugation setting device (side view).

Figure 6 shows a section of the corrugation installation (front view), where A is the position at the closest approach between the rolls (pellet of minimum thickness), B is the position of maximum distance between the rolls (pellet of maximum thickness).

Figure 7 shows an example of an extruder device.

8 shows an example of extrusion of a sheet of dough from an extruder.

Figure 9 shows an example of a prototype corrugation installation.

Figure 10 shows an example of pellet production and stretching dough layers between plants.

FIG. 11 shows an example of cooling a dough sheet by pulling it through a roller bar.

Figure 12 shows an example of the use of bristles to better detach the pellets from the rings.

13 shows a ring roll in operation.

Figure 14 shows the finished pellet.

15 shows an example of a roll ring.

FIG. 16 shows an example of welding a ring to a washer.

On the drawings: 1 - bed, 2 - extruder, 3 - extruder motor, 4 - screw, 5 - hopper, 6 - corrugation unit, 7 - unit motor, 8 - bran unit, 9 - adjusting screw, 10 - gear, 11 - roll shaft, 12 - smooth roll of the bran plant, 13 - roll with ovals of the bran plant, 14 - ovals, 15 - wheels, 16 - rail, 17 - lower roll of the corrugation plant, 18 - upper roll of the corrugation plant, 19 - gear transmission, 20 - corrugation installation frame, 21 - extruder matrix nozzle.

Implementation of the invention

The production of wheat-potato pellets for making chips is carried out as follows.

Prepare the dough. The dough can be made from potato, wheat, corn and multi-grain raw materials.

For example, for the production of potato pellets, dry mashed potatoes, starch and food additives are mixed for 2-4 minutes, and then water or saline is added with continuous stirring. The mixture is thoroughly mixed in the mixer and fed into the extruder.

From the extruder, the finished dough is squeezed out through the matrix.

What is new is that in the extruder 2 (see Fig.7) the dough is boiled, and a layer of dough is squeezed out through the extruder matrix (see Fig.8) in a continuous form, which is fed to the corrugation unit 6.

Installation corrugation (see Fig.4-Fig.5) consists of corrugated rolls 17 and 18 rotating in opposite directions, pressed against each other with the possibility of adjusting the distance between them. Rolls 17 and 18 can be 300 to 400 mm wide.

The rotation of the rolls 17 and 18 is provided by the electric motor 7, which rotates one of the rolls 18 with its shaft through a gear transmission 19, and the shaft 10 of this roll 18 through the gear system in the form of two connected sprockets 11 transmits the torque to the second roll 17 so that their rotation is ensured in opposite directions. The distance between the rolls 17 and 18 is adjusted from the minimum (see Fig.6(A)) to the maximum (see Fig.6(B)) by raising the upper roll relative to the lower one using the adjusting screws 9.

The dough emerging from the corrugated rolls is continuously cooled. The process of cooling the dough consists in the fact that before it is fed in layers to the bran installation 8, the dough is in the open air and is blown (see Fig.10-Fig.11).

The bran installation 8 is arranged by analogy with the corrugation installation 6 and consists of two bran rolls rotating in opposite directions. The only difference from the installation of corrugation 6 is that in it one bran roll 12 is smooth, and on the surface of the second roll 13 oval rings 14, pointed at the ends, are fixed, which with their top touch the reciprocal smooth roll 12 butt.

At the outlet of the bran plant 8, with the help of these rings 14, an oval-shaped pellet is obtained (see Fig. 14) and the remains of the formation (with holes from the pellets) (see Fig. 13).

The corrugated layer of dough, passing through these rollers 12 and 13 with the help of rings 14, cuts off an oval semi-finished product in the form of a corrugated oval from the dough. To facilitate dumping the dough from the mold, bristles can be installed on the rings 14 in the lower part of the roll 13 with oval rings. Figure 12 shows how the bristles contribute to a more efficient removal of the pellets from the ovals.

The finished pellet is then sent to the production of chips or storage, and the rest of the dough layer is re-placed in the extruder 2, which ensures waste-free production.

If it is necessary to change the thickness of the dough on the corrugation installation, the distance between the rolls is changed (see Fig.6).

The extruder 2 can be made consisting of an electric motor 3, the shaft of which is connected to the screw 4, which has an open cavity at the top, connected to the hopper 5 in the form of a funnel. At the end of the screw 4 there is a matrix in the form of a rectangular nozzle 21 (see Fig.7).

Oval rings can be made by stamping or bending into an oval (see example in Fig.15). For the convenience of attaching the ovals 14 to the roll 13, the ovals 14 are welded to the washer (see Fig.16), which has a mounting hole. The washers themselves are then attached to the bran roll with screws through the hole in the washer.

In order to ensure more efficient cooling of the dough, the dough layer is fed from the corrugation unit to the bran unit through a round roller bar (see the example in Fig. 11), which is positioned and fixed higher than the rolls 12 and 18 of the units are located.

The optimal and accurate process of transferring the layer of dough from the extruder 2 to the corrugation plant 6, and then from it to the bran plant 8 occurs when the extruder, the corrugation plant and the bran plant are fixed on the same frame 1 so that the axes of the rolls 12, 13, 17, 18 installations are placed so that they are perpendicular to the imaginary projection of the plane of the nozzle 21 of the extruder 2, which intersects these axes.

To be able to adjust the position of the installations relative to each other on the frame 1, the body 20 of the installation is placed on wheels 15, and the top of the frame 1 is equipped with rails 16.

The pellet can be made from potato, wheat, corn and multi-grain raw materials. The pellet has a long shelf life of 1.5 years or more.

The main technological process in the production of chips from pellets is frying, i.e. short-term treatment of pellets in oil heated to 170-200°C. The water contained in the pellet quickly turns into steam. Going outside, the steam destroys the fabric of the pellets, forming a swelling and many voids and increasing the volume by 2-4 times.

The formation of blisters is closely related to the thickness of the pellet and its moisture content. That is why it is important to regulate the thickness of the pellets according to the claimed method.

At the same time, a process of rapid and intensive dehydration is carried out, in which 2-3% moisture remains in the manufactured products. The presence of voids determines the crispy texture of the chips. In their absence, the pellet becomes hard after roasting. However, when frying, for example, corn pellets, the rigidity of the product after frying is maintained and this is not a disadvantage of the product and is even liked by consumers.

During frying, the chips pellets absorb oil in such an amount that its concentration in the final product can range from 16 - 30% and depends on the type of pellets, therefore, fat is an essential component that largely determines the taste of chips.

The process of making pellets, as well as their thickness, roasting modes (temperature and time) depend on the raw material. Thus, the maximum productivity is achieved when frying potato pellets, the lowest when frying corn and multi-grain pellets. For example, if the productivity of the potato pellet fryer is 500 kg/h, the productivity for corn pellets can reach no more than 100 kg/h.

But if you provide a given thickness of the pellets during their manufacture, then this will allow you to fry potato and corn pellets in the same performance mode.

The method has been successfully tested. The photo of Fig.7-Fig.14 shows all stages of the production cycle for obtaining pellets according to the claimed method. The claimed method was able to regulate the thickness of the pellets.

Claims (6)

1. A method for the production of pellets for making chips, in which the previously obtained ready-made dough for pellets is thoroughly mixed in a mixer and fed into an extruder, with which the finished dough is squeezed out through a matrix, characterized in that the dough is boiled in the extruder, and extruded through the extruder matrix a layer of dough in a continuous form, which is fed to the corrugation installation, consisting of corrugated rolls rotating in opposite directions, pressed against each other with the possibility of adjusting the distance between them, and the dough coming out of the corrugated rolls is continuously cooled and fed in layers to the bran installation, which consists of two bran rolls rotating in opposite directions, with one bran roll being smooth, and on the surface of the second roll oval rings, pointed at the ends, are fixed, which with their top touch the reciprocal smooth roll end-to-end; the pellet is then sent to the storage or production of chips, and the rest of the dough layer is re-entered into the extruder. 2. The method according to claim 1, characterized in that the oval rings are welded to the washers, and the washers are attached to the bran roll. 3. The method according to claim 1, characterized in that the layer of dough is fed from the corrugation plant to the bran plant through a round roller bar, which is positioned and fixed higher than the rolls of the installations are located. 4. The method according to claim 1, characterized in that the extruder, the corrugation unit and the bran unit are fixed on the same bed so that the axes of the rolls of the units are perpendicular to the imaginary projection of the plane of the extruder nozzle intersecting these axes. 5. The method according to claim 4, characterized in that in order to be able to adjust the position of the units relative to each other on the bed, each unit is equipped with wheels, and the top of the bed is equipped with rails for these wheels. 6. The method according to claim 1, characterized in that bristles are installed in the lower part of the roll with oval rings.

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