Coperion Food Extrusion System in Hybrid Design

For its food extrusion systems, Coperion offers a hybrid solution for manufacturing meat substitute products. With only a minimum of retrofitting effort, Texturized Vegetable Protein (TVP), High Moisture Meat Analogues (HMMA), and numerous other extrudates such as snacks and cereals can be manufactured on the same machine.

When manufacturing TVP, the extruder’s main inlet is continually fed with bulk raw protein material using Coperion K-Tron’s high accuracy loss-in-weight feeders and material handling refill systems. Immediately thereafter, water is injected using Coperion K-Tron liquid feeders. In certain cases, direct steam injection is applied into the process section as well. Within the process section, materials are mixed, kneaded and cooked. The product then moves out of the extruder via a nozzle plate where it is processed such that it achieves a porous structure with oriented fibers or layers. The attached Coperion ZGF pelletizer’s knife rotor then immediately cuts the product. The TVP granules are then dried to ensure long-term product stability.

Alternatively, HMMA is primarily used as a high-quality meat-analogue product in ready-to-eat meals. By adjusting recipe and process parameters, the structures of different meat types can be replicated with striking similarity to the original. HMMA’s moisture content lies between approximately 50-80%, therefore requiring refrigeration. Protein sources used to manufacture high-quality HMMA are primarily legumes such as soy, lupine or pea, or novel sources such as algae. In certain cases, for example when manufacturing meat product extenders, lesser quantities of genuine meat or fish products are added.

For the HMMA process, the bulk raw protein material is fed into the extruder inlet, to which water is then added. Within the ZSK Food Extruder a thermomechanical process takes place. The mass is fully mixed, kneaded and cooked in the extruder’s process section. Discharge takes place using a specialized cooling die that generates a meat-like texture which is “frozen in”. The result is a solid strand with fiber structure similar to flesh; the strand is then conveyed to the next process step.

ZSK Food Extruder in Hybrid Design for Maximum Flexibility

The Coperion Hybrid Design ZSK Extruder allows the manufacture both TVP and HMMA on the same machine with only a minimum of retrofitting. The feeding and process section for both applications are nearly identical, while the discharge units differ significantly. While the aforementioned ZGF Centric Pelletizer is attached to the process section for manufacturing TVP in order to cut the product directly at the nozzle plate, HMMA is discharged using a long specialized cooling nozzle which produces a product strand that exhibits a texture closely resembling that of genuine meat. Using Coperion’s adapter solution, the ZSK Extruder’s discharge can be switched from a pelletizer to a cooling nozzle in no time. The same principle functions just as quickly in reverse when switching from an HMMA process to TVP.

In addition, the extruder twin screws’ combination of self-cleaning action and modular construction allow the processing of numerous other products on the ZSK system such as snacks and cereals.

Stefan Gebhardt, General Manager of Business Unit Food & Pharma at Coperion, is convinced the ZSK Food Extruder hybrid design will offer significant benefits: “The high demand for this hybrid technology shows us that it corresponds exactly to the current market trend. The need for meat substitute products is growing steadily while at the same time undergoing major changes. With this hybrid machine concept that allows production of TVP and HMMA on one and the same extruder, we’re providing meat analogue manufacturers with a solution that gives them a high degree of flexibility to be optimally prepared for rapidly changing market conditions.”