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Extruding plants or meats involves using a meat analogue extruder for textured vegetable protein (TVP) or wheat gluten protein. Extruders can imitate fibrous meat by varying temperature, moisture, die, and pressure. Generally, there are single-screw extruders and double-screw extruders. Single-screw extruder belongs to traditional extruder technology. It extrudes content through a single screw in the cylinder, rotating with shearing and friction to extrude content. It has low power consumption, applicable for small-scale production. However, controlling temperature and pressure precisely is difficult.
Double-screw extruder consists two counter-rotating screws inside a barrel, extruding material through the annular space between the screws, which forces and shear the material. They provide better shearing action, allowing for thorough cooking and interaction with raw material, thereby increasing repeatability and yields. Double-screw extruders have higher driving power, which are suitable for large-scale production. Normally, there are also wet extruder and dry extruder. The wet extruder usually is used for producing pellets for aquatic animals like fish and shrimp. The pellet can hold up to 20 percent moisture and 14 percent fat. The extruder has a die part with a high-temperature, high-pressure section for shaping the pellet. The low-pressure zone mixes the dough, and the slime is stored. The dry extruder is commonly used to produce snacks and floating feed for land animals. The moisture content of the feed is between 8 and 10 percent. The extruder has a die part with a high-temperature, high-pressure section for fluffing and forming the feed.
According to the heating method, extruders can be classified into steam-heated extruders, electric-heated extruders, and others. Steam-heated extruders utilize steam power and pressure to heat the product. The process can increase the product temperature faster. They also have better controlled moisture level. The extruder is more often used in industry, but it needs external boiler to provide steam. Electric-heated extruders use electric current to heat the screw and barrel of extruder. This method provides a direct heating method, which has simpler setup and faster heat-up time. However, electric-heated extruders lack control over the extruding product's moisture level. At present, many extruders in use are electric-heated.
Usually, the meat analogues extruder machines' capacity and model specifications are provided based on the clients' request. Therefore, outcomes may vary depending on the type and species of raw ingredients used and the processing parameters set during the extruding procedure.
Generally, the available models and specifications include a 100-150 kg/h capacity with a 45 kw motor. This is ideal for small to medium-sized businesses. Another model is the 500-1000kg/hr capacity with a 75kw motor, which suits business with large-scale production of meat replacements. The third one is the 1500 kg/h capacity with a 110 kw motor, which is perfect for industrial-scale production.
Additionally, there is a dual-screw extrusion technology for processing textured vegetable protein meat substitutes. It has an adjustable temperature control system, including a feeding, cooking, puffing, and cutting section. The preshears, live screw barrels, and posthears are made of stainless steel, which ensures sanitary processing conditions. Other typical parts include the cutter, die-plates, and heating-cooling jackets. Moreover, some modern meat extrusion machines have touchscreen controllers that monitor and manage the extruding process parameters, such as temperature and time.
On top of that, for proper functioning, the meat analogue extruder machines require routine maintenance. The maintenance schedule demands that the screws be regularly removed and cleaned to eliminate build-up residue and prevent clogging. The feeding system, cutting blades, die plates, and heating-cooling jackets, among other parts, should be cleaned often to ensure hygienic production conditions. Also, the lubricating oil for moving parts should be applied periodically to minimize wear and tear. Further, after cleaning the extruder machine, drying it, and applying rust-proof oil, it should be stored in a dry and cool place away from direct sunlight. Some component parts may require replacement after an indicated period, and the examinations should be done often according to the manufacturers' instruction.
Commercial production of meat substitutes
Extruder machines for processing meat analogs are commonly utilized in the manufacturing sector to create various plant-based protein foods. These include replicas of sausage, hamburgers, poultry, fish, and other products designed to cater to the surging demand for vegetarian and vegan options.
Research and product development
Food innovation labs, GMOs, and other organizations studying food technology may use an extruder for meat substitutes during the research and development phase to invent new meat substitute recipes. Therefore, the food's taste, structure, and nutrition may be improved through the modernization of the machine and technology.
Small-scale food production
Small businesses, such as local restaurants, vegetarian fast food restaurants, and specialized meat substitute workshops, may use small-scale analog meat extruders to produce unique flavors and textures of meat substitutes for local sales or to supply small servings to specific customers.
External service supply
Operators with small meat substitute extruders may furnish external services, such as catering or food stands, at various social gatherings, celebrations, or sporting events. This equipment's mobility and simple setup allow for a quick on-site preparation of meat substitutes for immediate consumption by participants.
Home food supplementation
Small meat analogue extruders may be utilized in the home food supplement preparation in the form of meat analogue powders in capsules. In this case, it would be possible to manufacture personalized meat substitute products in small quantities to meet specific dietary needs.
Teaching and training
Meat analogue extruders may be used for educational and training purposes at specialized educational establishments, such as colleges offering courses in nutrition, culinary arts, or food technology. Students will be familiarized with the process of extruding meat substitutes using these machines, thus acquiring practical skills and enhancing their knowledge.
Consider the following things of the meat extruder machine before purchasing:
Crawler and barrel:
TG meat extruders have a barrel and a crawling structure. The barrel is a complicated metal construction, heated/cooled, with different sections for heating, fermentation, etc. It has controlled rotation, which affects the ingredients' movement, changing the texture and protein structure. TG meat extruders with a crawler consist of a crawler and barrel. The crawler pushes raw materials to the barrel, where the meat analogues are formed, and the expulsion is done by the barrel. This combination allows changing the formula of SST products and reducing energy consumption.
Interchangeable parts:
The Lewco food extruder machine has interchangeable parts, which helps various meat substitutes products. The exclusive screws and barrels formulas change movement and pressure, which changes the texture of the material. Therefore, business buyers will be able to apply different production formulas to meet market requirements.
Modular design:
The STX meat analogue extruder machine, with a modular design, divides easily into different parts. Therefore, the maintenance and cleansing processes are more accessible. Apart from that, the interchangeable and advanced design gives room to vary production lines quickly to meet consumers' changing wants and ideality.
Available in different capacities:
An important aspect while buying a meat extruder is the availability of the machine in different capacities. A mini meat extruder is suitable for small businesses as it takes up less space. Also, a portable meat extruder is good for on-site production and providing customers with fresh products. For large-scale production, a high-capacity extruder is required. This will ensure that a higher quantity will be produced to meet the demand.
Q: Can the extruder be used for anything other than meat substitutes?
A: Yes, a meat analogue extruder can be used to create other food products, such as cereals, snacks, fish food, and poultry feed. However, the die shapes and temperatures will differ to achieve the required texture and shape.
Q: Will the finished product from the extruder have the same nutritional value as meat?
A: It is possible to achieve a similar nutritional profile to meat by including similar protein sources such as peas, beans, and other plant protein. However, not all meat substitutes will have the same nutritional values. It is best to analyze the product before making any claims.
Q: What are some advantages of using an extruder to make meat substitutes?
A: The extruder is one of the machines that can efficiently process large amounts of raw material. It also helps denature protein and create a fibrous structure that resembles meat. The machine is versatile, and different settings can create various textures and shapes. The operation is also automated, which helps reduce labor costs.
Q: How much does a meat analogue extruder cost?
A: Small lab-scale extruders start at around $10,000. Large commercial scale meat analogue extruders cost much more, with prices starting at around $60,000.
