Product Description
Bugles are cone - shaped, hollow snack foods with a crispy texture. Here's how you can make them using a twin - screw extruder: ### 1. Raw Material Preparation - **Starches and Flours** - **Corn Starch**: A primary ingredient, it provides the base structure. Use high - quality corn starch for better results. - **Wheat Flour**: Adds flavor and helps with the binding of ingredients. It also contributes to the overall texture of the snack. - **Other Starches (Optional)**: Tapioca starch or potato starch can be added in small amounts to enhance the crispness and mouthfeel. - **Protein Sources** - **Soy Protein Isolate or Concentrate**: Increases the nutritional value and can improve the texture of the bugles. It helps the snack hold its shape during processing. - **Seasonings and Flavorings** - **Salt**: Enhances the flavor. The amount can be adjusted according to taste preferences, usually around 1 - 3% of the total dry ingredients. - **Spices**: Such as paprika, chili powder, or garlic powder, to add a desired flavor profile. You can create different flavor variations like barbecue, cheese, or spicy. - **Flavor Enhancers**: Monosodium glutamate (MSG) or natural flavor extracts can be used to boost the taste. - **Fats and Oils** - **Vegetable Oil**: Adds moisture, improves the texture, and helps in the extrusion process. Canola oil or soybean oil are commonly used. The amount is typically around 5 - 10% of the total mixture. - **Leavening Agents (Optional)** - **Baking Powder or Sodium Bicarbonate**: These can be added to create a light and airy texture. They release gases during the extrusion process, contributing to the hollow nature of the bugles. ### 2. Mixing the Ingredients - **Dry Mixing**: Combine all the dry ingredients - starches, flours, protein sources, seasonings, and leavening agents (if using) in a large mixer. Mix them thoroughly until well - blended. This ensures an even distribution of flavors and proper interaction of ingredients during extrusion. - **Wet Mixing**: Gradually add the vegetable oil and water to the dry mixture. The water content is crucial and usually ranges from 20 - 30% of the total weight of the ingredients. Mix until a homogeneous dough - like consistency is achieved. The mixture should be moist enough to be extruded but not too wet to cause problems during processing. ### 3. Twin - Screw Extruder Setup - **Temperature Profile** - **Feed Zone**: Set the temperature relatively low, around 40 - 60°C. This allows the mixture to be fed smoothly into the extruder without premature cooking or reaction. - **Compression and Mixing Zones**: As the mixture moves through these zones, the temperature gradually increases. Temperatures in these zones can range from 60 - 100°C. The heat helps in the initial gelatinization of starches and better mixing of ingredients. - **Cooking and Shaping Zone**: The temperature in this zone is set higher, typically between 120 - 160°C. This high temperature fully cooks the mixture, gelatinizes the starches, and helps in the formation of the bugle shape as it exits the die. - **Screw Speed** - A screw speed of 100 - 300 revolutions per minute (RPM) is commonly used. For a more viscous mixture, a slower speed (100 - 150 RPM) may be required to ensure proper mixing and shaping. A faster speed (200 - 300 RPM) can be used for a less viscous mixture to increase the production rate. ### 4. Extrusion Process - **Feeding the Mixture**: Load the prepared dough - like mixture into the hopper of the twin - screw extruder. The twin - screws rotate, conveying the mixture through the barrel. The screws also apply shear and pressure, which further mix and cook the ingredients. - **Die Selection and Extrusion**: Use a die with a cone - shaped orifice to create the bugle shape. As the mixture is forced through the die, the high pressure and temperature cause the dough to expand and form the hollow cone shape. The shape and size of the die can be adjusted to produce bugles of different dimensions. - **Cutting**: After extrusion, use a cutter attached to the extruder to cut the continuous extruded product into individual bugles. The cutting speed can be adjusted to control the length of the bugles. ### 5. Post - Extrusion Processing - **Drying**: The freshly extruded bugles may have a relatively high moisture content. Place them in a drying oven at a temperature of around 80 - 100°C for 10 - 20 minutes. Drying helps to remove the excess moisture and makes the bugles crispy. - **Seasoning (Optional)**: If additional flavor is desired, you can coat the dried bugles with more seasonings. This can be done by spraying or tumbling the bugles in a container with the seasoning powder. - **Cooling**: Allow the bugles to cool to room temperature. This helps to set the texture and makes them ready for packaging. ### 6. Packaging - Once the bugles have cooled and any additional seasoning has been applied, package them in airtight containers or bags. This helps to maintain their freshness and crispness. Label the packaging with product information, including ingredients, flavor, and nutritional facts. ### 7. Quality Control - **Appearance Inspection**: Check the bugles for uniformity in shape, size, and color. They should be free from cracks, misshapen cones, or discoloration. - **Texture Evaluation**: The bugles should be crispy and have a hollow interior. They should break easily when bitten into, providing a satisfying crunch. - **Flavor Testing**: Ensure that the flavor is well - balanced and meets the desired taste profile. Adjust the seasoning levels if necessary. - **Moisture Content Analysis**: Measure the moisture content of the bugles to ensure it is within the appropriate range (usually around 2 - 5%) to maintain crispness.
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Company Profile:
Jinan Sunward Machinery Company is founded in 2009 .It is an industry and trade integrated enterprise. The company is committed to R & D extrusion machinery and related ancillary equipments. It is covering mainly machinery and equipment for puffed snack food machine, fried snack food machine ,corn flakes/breakfast cereal system, baby food system, pellets system, artificial rice system,soy nuggets system; as well as pet food/fish food system.
Jinan sunward machine after- sales department are always available for you.
| Model |
Capacity |
Main Motor power |
Price |
| TSE65 |
100KG/H-150KG/H |
22KW |
$7000-$9000 |
| TSE70 |
200KG/H-250KG/H |
37kw |
$9500-$11000 |
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