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Here are the steps to make snack food using a twin - screw extruder: ### 1. Raw Material Preparation - **Base Ingredients** - **Starchy Materials**: Common choices include corn, wheat, rice, or potato starch. These starches form the main structure of the snack food. For example, corn starch is often used for its ability to expand well during extrusion, creating a light and crispy texture. - **Flours**: Wheat flour can be added to improve the binding properties and add some protein content. It helps hold the ingredients together and contributes to the overall texture of the snack. - **Flavoring Agents** - **Salt**: Enhances the taste of the snack. Different types of salt, such as table salt or sea salt, can be used depending on the desired flavor profile. - **Sugars**: Granulated sugar, brown sugar, or corn syrup can be added to provide sweetness. They also affect the browning and texture of the snack during processing. - **Spices and Seasonings**: A wide variety of spices like chili powder, paprika, cumin, and garlic powder can be used to add different flavors. Cheese powder, onion powder, and various herb blends are also popular for creating unique taste sensations. - **Oil and Fat** - Vegetable oils such as soybean oil, canola oil, or palm oil are commonly used. Oil helps in the extrusion process by reducing friction and also contributes to the flavor and mouthfeel of the snack. It can be added directly to the raw material mixture or sprayed on the finished snack. - **Additives** - **Emulsifiers**: Such as lecithin, which helps to improve the mixing of ingredients and the stability of the final product. - **Stabilizers and Thickeners**: Guar gum, xanthan gum, or carrageenan can be added to improve the texture and shelf - life of the snack. They help to hold moisture and prevent the snack from becoming too dry or stale. ### 2. Mixing the Ingredients - **Dry Mixing** - Combine all the dry ingredients, including starches, flours, salt, sugars, spices, and dry additives, in a large mixer. Mix them thoroughly for about 5 - 10 minutes to ensure an even distribution of flavors and components. - **Wet Mixing** - Slowly add the required amount of water (usually around 15 - 30% of the total mixture weight) and oil to the dry mixture. Continue mixing for another 5 - 10 minutes until the mixture reaches a dough - like consistency. The water softens the starches and helps in the gelatinization process during extrusion, while the oil coats the particles and affects the texture. ### 3. Twin - Screw Extruder Setup and Operation - **Pre - heating and Preparation** - Clean the twin - screw extruder thoroughly to remove any residues from previous batches. Check the screws, barrels, and die for any signs of wear or damage. - Set the temperature zones of the extruder according to the type of snack food you want to make. Generally, the feed zone is set at a relatively lower temperature (around 80 - 120°C), and the temperature gradually increases towards the die end, reaching 150 - 200°C. Pre - heat the extruder for about 15 - 20 minutes to allow the temperatures to stabilize. - **Feeding the Mixture** - Load the well - mixed raw material into the hopper of the twin - screw extruder. The twin - screw design provides better conveying and mixing capabilities compared to a single - screw extruder. The screws rotate in a coordinated manner to push the mixture forward through the barrel. - Adjust the feeding rate to ensure a continuous and stable flow of the mixture into the extruder. This can be controlled using a feeder with variable speed. - **Extrusion and Shaping** - As the mixture moves through the barrel, it is subjected to high pressure and shear forces. The heat generated by the mechanical action of the screws, along with the external heating, causes the starches to gelatinize and the ingredients to fuse together. - The molten mixture is forced through a die of a specific shape. Dies can be designed to produce various shapes such as twists, rings, curls, or flat chips. The shape of the die determines the final appearance of the snack food. ### 4. Post - Extrusion Processing - **Drying (Optional)** - If the extruded snack is too moist, it may need to be dried. Transfer the extruded snack to a drying oven or a conveyor dryer. Set the drying temperature at around 60 - 80°C for a period of time (usually 10 - 30 minutes) to reduce the moisture content and improve the crispness. - **Cooling** - After extrusion or drying, the snack needs to be cooled to room temperature. This can be achieved by allowing it to air - cool on a conveyor belt or in a well - ventilated area. Cooling helps to harden the snack and makes it easier to handle. - **Flavor Coating (Optional)** - To enhance the flavor further, the cooled snack can be coated with additional seasonings or flavorings. This can be done by spraying or tumbling the snack in a mixture of flavor - rich powders or liquids. For example, a cheese - flavored snack can be coated with a cheese - based powder to intensify the flavor. ### 5. Quality Control and Packaging - **Quality Control** - **Appearance**: Check the shape, size, and color of the snack. Ensure that all the pieces are uniform and free from defects such as cracks or uneven shapes. - **Texture**: Evaluate the texture of the snack. It should be crispy, crunchy, or have the desired mouthfeel as per the product design. - **Flavor**: Taste the snack to ensure that the flavors are well - balanced and meet the expected taste profile. - **Moisture Content**: Measure the moisture content of the snack to ensure it is within the acceptable range for proper storage and shelf - life. - **Packaging** - Once the snack passes the quality control tests, it is ready to be packaged. Use appropriate packaging materials such as plastic bags, foil - lined bags, or sealed containers to protect the snack from moisture, air, and light. - Label the packages clearly with information such as the product name, flavor, ingredients, nutritional information, and storage instructions. - **Storage** - Store the packaged snack food in a cool, dry place away from direct sunlight. The storage temperature should be maintained at around 15 - 25°C, and the relative humidity should be kept low (below 60%) to ensure the snack retains its quality and freshness during storage.
| Model | Main motor | Output |
| TSE65 | 22kw | 100kg/h-150kg/h |
| TSE70 | 30kw | 200kg/h-250kg/h |
| TSE85 | 55kw | 300kg/h-500kg/h |
| TSE90 | 75kw | 800kg/h-1000kg/h |
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