Test extruder and pilot plant
Since 2021, a small but very flexible twin-screw extruder has been available to me for trials, product and process development and training. It is possible to carry out small sample productions on this extruder system in addition to these principle and development trials. I offer a wide range of process and product options based on renewable raw materials here.
The extruder is located in a production building of a well-known milling company, which has advantages, but also some limitations.
Feel free to contact me for a non-binding discussion about your application wishes and ideas. I will then give you a realistic estimation of your desired process on this extruder as well as a possible quotation. (Contact, Email)
Current product options:
• Cereals
• Modified flours and starches
• Indirectly expanded products
• Fortification of products
• Encapsulation of flavours etc.
• Texturized proteins
• Milling by-products
• Compounds of renewable raw materials
• Recipe optimisation
• New developments from renewable raw materials
etc.
The extruder is a co-rotating twin screw extruder (BCTM) from Bühler. He has a screw diameter of 30mm. The process length of 32 L/D (8 barrels + end plate) corresponds to a screw length of ~1024mm.
The concept of the system was also designed with regard to the widest possible range of applications. Thus, there are 3 external temperature control units (Regloplas300), which can temper 3 enclosure zones independently of each other in the range of 20-250°C. The large process length also enables two-stage or reactive processes. After prior consultation, certain quantities of product can also be dried, ground or otherwise further processed and analysed.
The availability of a large selection and number of screw elements also allows the desired broad and flexible application of the extruder to be able to implement almost all of your application requirements.
The inserts with one or more die holes corresponding to the process are inserted into the die holding plate. A large number of die options are available, from a die hole diameter of 0.5mm, which can also be adapted and remanufactured as required.
The exiting extrudate strand(s) can be granulated by a permanently installed rotating cutter head. The cutter head can be equipped with one, 2, 3 or 6 cutter blades and rotate at up to 3000 rpm.
5 temperature sensors and a pressure cell enable very precise process control, which is an optimal basis for possible further scale-up processes.
Other external elements include gravimetric dosing for powdery solids or mixtures. With a drum mixer, solid mixtures can be produced very flexible on site. By means of two regulated gear pumps, water or other liquids such as syrup, flavours, colours, acids, alkalis, etc. can be metered to the desired locations in the process. A drying oven (up to 80°C) is available for drying the various samples.
During the tests, all relevant test parameters for further processing can be checked, visually displayed and saved via the extruder control. Of course, the system is constantly being improved and expanded with regard to further application possibilities. I will try to provide missing elements and equipment (new purchase or loan) that are necessary for your desired application. Just talk to me about your wishes and ideas (Contact, Email).
I look forward to supporting and advising you with my know-how.
Your Thomas Brümmer