RESUMEN

Herein, we report on the translation of a small scale ball-milled amidation protocol into a large scale continuous reactive extrusion process. Critical components to the successful translation were: a) understanding how the different operating parameters of a twin-screw extruder should be harnessed to control prolonged continuous operation, and b) consideration of the physical form of the input materials. The amidation reaction is applied to 36 amides spanning a variety of physical form combinations (liquid-liquid, solid-liquid and solid-solid). Following this learning process, we have developed an understanding for the translation of each physical form combination and demonstrated a 7-hour reactive extrusion process for the synthesis of an amide on 500 gram scale (1.3 mols of product).

RESUMEN

Twin-screw extrusion pretreatment has great potential for the development of three-dimensional (3D) printed food as dysphagia diets. This study aimed to investigate the effect of twin-screw extrusion pretreatment on starch structure, rheological properties and 3D printing accuracy of whole potato flour and its application in dysphagia diets. The results indicated that twin-screw extrusion pretreatment was found to change chain length distributions, short-range ordered structure and relative crystallinity of whole potato flour (WPF), thereby improving its 3D printing performance. With the increasing proportion of long linear chains (DP > 12), the intensity of hydrogen bonds, linear viscoelastic region, storage modulus (G'), loss modulus (G″), viscosity and n of whole potato flour paste were increased, enhancing high printing accuracy and shape retention of 3D printed samples with a denser microstructure and smaller pore diameter distribution. The whole potato flour paste extruded with a peristaltic pump speed at 5.25 mL/min (WPF-4) displayed the highest printing accuracy with excellent rheological properties, good water distribution state and dense network structure, which classified as class 5 level dysphagia diets. This research provides an effective guidance for the modification of whole potato flour using twin-screw extrusion pretreatment as 3D printed food inks for dysphagia patients.

Asunto(s)

RESUMEN

The synergistic effects of plasma-activated water (PAW) and twin-screw extrusion (TSE) on the structural, physicochemical, antioxidant, and digestive properties of yam flour (YF) were studied. Compared to common TSE, PAW-TSE reduced the protein, starch, and polyphenol contents, swelling power, and gel property of YF, while PAW-TSE enhanced the flavonoid content, whiteness index, solubility, and antioxidant property of YF. Moreover, the results of structural characterization and differential scanning calorimetry indicated that the long-range or short-range ordering, and gelatinization enthalpy of starch in YF were reduced after PAW-TSE, while the structure ordering of proteins in YF increased. Furthermore, the in vitro digestibility results demonstrated a reduction in the rate of enzymatic hydrolysis, coupled with an increase in total contents of slowly digestible and resistant starch after PAW-TSE. It should be noted that TSE using PAW prepared by a longer plasma treatment resulted in a more significant improvement effect on YF.

Asunto(s)

RESUMEN

This study was carried out to investigate the continuous aqueous pretreatment of sugarcane bagasse (SCB) through twin-screw extrusion for a new integrated full valorization, where the solid residue (extrudate) was used for the production of bio-based materials by thermocompression and the filtrate for the production of high-value-added molecules. Two configurations, with and without a filtration module, were tested and the influence of the SCB composition and structure on the properties of the materials were determined. The impact of the liquid-to-solid (L/S) ratio was studied (0.65-6.00) in relation to the material properties and the biomolecule extraction yield in the filtrate (with the filtration configuration). An L/S ratio of at least 1.25 was required to obtain a liquid filtrate, and increasing the L/S ratio to 2 increased the extraction yield to 11.5 g/kg of the inlet SCB. The extrudate obtained without filtration yielded materials with properties equivalent to those obtained with filtration for L/S ratios of at least 1.25. Since the molecule extraction process was limited, a configuration without filtration would make it possible to reduce water consumption in the process while obtaining high material properties. Under the filtration configuration, an L/S ratio of 2 was the best tradeoff between water consumption, extraction yield, and the material properties, which included 1485 kg/m3 density, 6.2 GPa flexural modulus, 51.2 MPa flexural strength, and a water absorption (WA) and thickness swelling (TS) of 37% and 44%, respectively, after 24 h of water immersion. The aqueous pretreatment by twin-screw extrusion allowed for the overall valorization of SCB, resulting in materials with significantly improved properties compared to those obtained with raw SCB due to fiber deconstruction.

RESUMEN

We developed and applied 4 extrusion regimens (moisture content between 30 % and 60 % and temperature from 110 °C to 120 °C) with twin-screw extruder for valorising soy press cakes, byproduct of soy drink (Soyd) and tofu (Soyt) manufacturing processes, by varying physical conditions of extrusion for improving their morphological, functional, and sensory parameters. The valorised soy press cakes were compared to their respective control samples (Soyd or Soyt) both before and after extrusion. Two quantities (3%-6%) of untreated and extruded soy press cakes were utilised to develop meat analogues. Extrusion introduced striations and reduced flakiness on the surface of extruded press cake samples. Press cakes extruded at higher moisture indicated improved water holding and oil holding capacity. Interestingly, the same press cake samples also scored higher for positive indicators (e.g., juiciness) during sensory assessment. Compared with meat analogue control matrix, all meat analogue samples containing varying amounts of extruded press cake exhibited reduced chewiness, with other parameters relatively unchanged. Our results indicate that extrusion of soy press cakes of both Soyd and Soyt origin at 120 °C with 60 % moisture results in improving the morphological, functional, and sensory properties of press cakes, making them suitable for development of meat analogues.

RESUMEN

This study investigates the impact of dry heat pretreatment on the functionality of soy, chickpea, and pea protein ingredients for use in texturized vegetable protein (TVP) production via low moisture extrusion. The protein powders were heat-treated at temperatures ranging from 80 °C to 160 °C to modulate the extent of protein denaturation and assess their effects on RVA pasting behavior, water absorption capacity (WAC), and color attributes. The results indicate that the pretreatment temperature significantly influenced the proteins' functional properties, with an optimal temperature of 120 °C enhancing pasting properties and maintaining WAC, while a higher pretreatment temperature of 160 °C led to diminished ingredient functionality. Different protein sources exhibited distinct responses to heat pretreatment. The subsequent extrusion processing revealed significant changes in extrudate density and color, with increased density and darkness observed at higher pretreatment temperatures. This research provides insights into the interplay between protein sources, pretreatment conditions, and extrusion outcomes, highlighting the importance of controlled protein denaturation for developing high-quality, plant-based meat analogues. The findings have broad implications for the optimization of meat analogue manufacturing, with the aim of enhancing the sensory experience and sustainability of plant-based foods.

RESUMEN

Cellulosic fibers obtained from Barley straw were utilized to reinforce PHB. Four different processed fibers were employed as reinforcing material: sawdust (SW), defibered (DFBF), delignified (DBF), and bleached (BBF) fibers. The composite was processed from two different perspectives: a discontinuous (bach) and an intensification process (extrusion). Once processed and transformed into final shape specimens, the materials were characterized by mechanical testing (tensile mode), scanning electron microscopy, and theoretical simulations by finite elements analysis (FEA). In terms of mechanical properties, only the elastic moduli (Et) exhibited results ranging from 37% to 170%, depending on the reinforcement composition. Conversely, strengths at break, under both tensile and bending tests, tended to decrease, indicating poor affinity between the components. Due to the mechanical treatment applied on the fiber, DFBF emerged as the most promising filler, with mechanical properties closest to those of neat PHB. DFBF-based composites were subsequently produced through process intensification using a twin-screw extruder, and molded into flowerpots. Mechanical results showed almost identical properties between the discontinuous and intensification processes. The suitability of the material for agriculture flowerpots was demonstrated through finite analysis simulation (FEA), which revealed that the maximum von Mises stresses (5.38 × 105 N/m2) and deformations (0.048 mm) were well below the limits of the composite materials.

RESUMEN

Extrusion is typically employed to prepare resistant starch (RS). However, the process is complicated. In this study, the effects of twin-screw extrusion on the crystallinity, thermal properties, and functional properties of starch formed in different extrusion zones were investigated. The effects of this process on the rheological properties and microstructure of RS-added skimmed yogurt were also studied. According to the results, the RS content increased from 7.40 % in the raw material to 33.79 % in the extrudate. The A-type crystal structure of the starch was not observed. The dissociation temperature of the extruded starch ranged from 87.76 °C to 100.94 °C. The glycemic index (GI) of skimmed yogurt fortified with 0.4 % RS was 48.7, and the viscosity was also improved. The microstructure exhibited a uniform network of the starch-protein structure. The findings may serve as a theoretical basis for the application of RS in the food industry.

Asunto(s)

RESUMEN

Thermoplastic starch (TPS) is considered as alternative material for substitute petroleum-based materials for single-use packaging material applications. The main weakness of TPS is sensitive to water and humidity which causes low mechanical properties and low thermal resistance. To address this limitation, one can enhance the strength is by incorporating cellulose nanofiber as a reinforcing agent. Cellulose nanofiber used in this study is bacterial cellulose, synthesized from tapioca liquid waste media, namely Nata de Cassava (NDCass). The effect of NDCass addition to TPS on chemical characteristics, physical properties, crystallinity, mechanical properties, and thermal properties was investigated. As the results, NDCass incorporation has no significant effect on the chemical structure and crystal structure of composites as observed by FTIR and XRD analysis. Incorporating of NDCass improved the mechanical properties by 37.3 %, the thermal stability, and the viscosity, however reduced the elongation at break by 65.6 %, the density, the melt flow and shear rate of TPS biocomposite. This study evidently that starch from Arenga pinnata trunk and bacterial cellulose from tapioca liquid waste can be manufactured into biocomposites using in-situ twin screw extrusion which beneficial for large-scale applications.

Asunto(s)

RESUMEN

Vitamin D3 (VD3) and iron-blend granules were blended with corn and lentil composite flour (75/25, w/w) and fed into a pilot-scale twin-screw extruder to produce ready-to-eat snacks. The morphology and microstructure of extruded snacks were examined using scanning electron microscopy with energy-dispersive X-ray (SEM-EDX), X-ray powder diffraction, and FT-IR. Differential scanning calorimetry and thermogravimetric analysis measured the melting temperature and thermal stability of the extrudates. SEM and FT-IR analysis demonstrate that micronutrients are mixed well in formulations used in extrudates at high shear and high temperatures. The SEM-EDX exhibited the presence of iron, whereas high performance liquid chromatography measurements confirmed the significant retention of VD3 in the extruded snacks. The interaction between VD3 and human osteoblast cells was studied using live imaging and the MMT assay. Overall, for the first time, VD3 and Fe2+ blend granules have been used in an extrusion platform, which has significant potential for the intervention of VD3 and iron deficiencies. PRACTICAL APPLICATION: For the first time, we reported the use of VD3/iron-blend granules in extruded products. The findings of this work demonstrated the thermal stability and capability of providing adequate quantities of VD3 and iron in corn flour/lentil flour/VD3-iron blend extruded snacks. Furthermore, the interaction of VD3 with osteoblast cells highlights the potential health benefits of the extrudates.

Asunto(s)

RESUMEN

In this study, the synergistic effect of plasma-activated water (PAW) combined with twin-screw extrusion (TSE) on multi-scale structure, physicochemical and digestive properties of yam starch (YS) was studied. PAW-TSE resulted in higher amylose content in YS than TSE alone. Compared with single TSE, the relative crystallinity, short-range ordered degree, and gelatinization enthalpy of YS were increased by PAW-TSE according to the results of X-ray diffraction, Fourier transform infrared, Raman spectroscopy, and differential scanning calorimetry. Furthermore, rapid viscosity and dynamic rheological analysis showed that the peak and breakdown viscosity of PAW-TSE treated YS paste were considerably reduced, and the storage modulus and loss modulus were significantly increased, indicating that the gel strength and thermal stability were improved. In addition, the resistant starch (RS) content of YS treated by PAW-TSE increased from 6.04 % to 21.21 %. Notably, the effect of PAW-TSE on YS enhanced with the preparation time of PAW increased. Finally, correlation analysis indicated that the characteristic indexes of PAW had a significant impact on the long or short-range ordered structure, thermal properties, and in vitro digestibility of YS during extrusion. Therefore, PAW-TSE, as an emerging dual modification technology, will greatly expand the application of extrusion technology.

Asunto(s)

RESUMEN

In this study, starch ferulate was synthesized employing a mechanoenzymatic method, specifically based on the twin screw extrusion technique and lipase catalysis. The research then primarily centered on optimizing process parameters and conducting structural analysis. Optimal conditions were determined to be 8.2% ferulic acid addition, 66 °C extrusion temperature, and 3.2% lipase (N435) addition. The enzyme-catalyzed time was 30 s. The degree of substitution for starch ferulate was quantified at 0.005581 under these specific conditions. The presence of C=O bonds in the synthesized starch ferulate proved that the synthesis process was efficient. Additionally, the crystal structure underwent reconstruction. Observations through Scanning Electron Microscopy (SEM) and Confocal Laser Scanning Microscopy (CLSM) demonstrated that the mechanoenzymatic method led to an augmentation in the specific surface area of starch molecules, thereby facilitating the exposure of active sites. This breakthrough underscores the vast potential of mechanoenzymatic techniques to revolutionize the rapid and sustainable synthesis of starch ferulate, marking a pioneering stride in ester synthesis. The insights garnered from this study transcend theory, offering a visionary roadmap for the development and real-world deployment of advanced modified starch esters.

RESUMEN

Twin-screw extrusion is one of the major technologies for solid dispersion in the pharmaceutical industry. However, the thermal exposure to the drug during extrusion can easily trigger and exacerbate drug degradation. A conventional method for investigating drug degradation in extrusion is trial-and-error, which can consume much time and material. We propose to model drug degradation kinetics and combine it with thermal history simulation to predict drug degradation. Ritonavir and copovidone were used as a model system of solid dispersion. Hydantoin aminoalchol was the major degradant of RTV in extrudate. In studying the RTV degradation kinetics, only in nitrogen atmosphere, RTV degradation pathway in TGA or DSC was like the degradation pathway in extrusion. The mixing and solubilization of RTV in copovidone also prevented RTV from degrading to oxazolidine derivative. The degradation samples were collected at various temperatures and at different times. The data was fitted into first-order kinetics model to get degradation rates constant at each temperature. The degradation rate constants were fitted into the Arrhenius equation with an activation energy of 159.3 kJ/mol, and a pre-exponential of 1.23 × 1017. An array of extrusion conditions was developed and analyzed via design of experiment (DOE). Relying on the measured melt temperature and residence time after kneading element and die, we simulated the thermal history in the section between kneading element and die. The RTV degradation kinetics in conjunction with simulated thermal history predicted degradation and achieved a 78% regression.

Asunto(s)

RESUMEN

Highly filled plastics may offer a suitable solution within the production process for bipolar plates. However, the compounding of conductive additives and the homogeneous mixing of the plastic melt, as well as the accurate prediction of the material behavior, pose a major challenge for polymer engineers. To support the engineering design process of compounding by twin-screw extruders, this present study offers a method to evaluate the achievable mixing quality based on numerical flow simulations. For this purpose, graphite compounds with a filling content of up to 87 wt.-% were successfully produced and characterized rheologically. Based on a particle tracking method, improved element configurations were found for twin-screw compounding. Furthermore, a method to characterize the wall slip ratios of the compounded material system with different filler content is presented, since highly filled material systems often tend to wall slip during processing, which could have a very large influence on accurate prediction. Numerical simulations of the high capillary rheometer were conducted to predict the pressure loss in the capillary. The simulation results show a good agreement and were experimentally validated. In contrast to the expectation, higher filler grades showed only a lower wall slip than compounds with a low graphite content. Despite occurring wall slip effects, the developed flow simulation for the design of slit dies can provide a good prediction for both low and high filling ratios of the graphite compounds.

RESUMEN

Nowadays, usable plastic materials with defined properties are created by blending additives into the base polymer. This is the main task of compounding on co-rotating twin-screw extruders. The thermal and mechanical stress occurring in the process leads to a mostly irreversible damage to the material. Consequently, the properties of the polymer melt and the subsequent product are affected. The material degradation of polypropylene (PP) on a 28 mm twin-screw extruder has already been studied and modeled at Kunststofftechnik Paderborn. In this work, the transferability of the previous results to other machine sizes and polypropylene compounds were investigated experimentally. Therefore, pure polypropylene was processed with screw diameters of 25 mm and 45 mm. Furthermore, polypropylene compounds with titanium dioxide as well as carbon fibers were considered on a 28 mm extruder. In the course of the evaluation of the pure polypropylene, the melt flow rates of the samples were measured and the molar masses were calculated on this basis. The compounds were analyzed by gel permeation chromatography. As in the previous investigations, high rotational speeds, low throughputs and high melt temperatures lead to a higher material degradation. In addition, it is illustrated that the previously developed model for the calculation of material degradation is generally able to predict the degradation even for different machine sizes by adjusting the process coefficients. In summary, this article shows that compounders can use the recommendations for action and the calculation model for the material degradation of polypropylene, irrespective of the machine size, to design processes that are gentle on the material.

RESUMEN

A novel computer optimization system for the contrary-rotating double-screw extrusion of plastics was developed in this study. The optimization was based on the process simulation performed with the use of the global contrary-rotating double-screw extrusion software TSEM. The process was optimized using the GASEOTWIN software developed for this purpose using genetic algorithms. Several examples of optimization of the contrary-rotating double screw extrusion process parameters, i.e., the extrusion throughput, and minimize the plastic melt temperature and the plastic melting length.

RESUMEN

The plastication of pellets in a co-rotating twin-screw extruder is a significant concern for product homogeneity and stability in the plastic industry. We developed a sensing technology for pellet plastication in a plastication and melting zone in a self-wiping co-rotating twin-screw extruder. The collapse of the solid part of the pellets emits an elastic wave as an acoustic emission (AE) that is measured on the kneading section of the twin-screw extruder using homo polypropylene pellets. The recorded power of the AE signal was used as an indicator of the molten volume fraction (MVF) in the range of zero (fully solid) to unity (fully melted). MVF decreased with increasing feed rate monotonically in the range of 2-9 kg/h at a screw rotation speed of 150 rotations per minute (rpm) because of the reduction in the residence time of pellets in the extruder. However, the increase in feed rate from 9 to 23 kg/h at 150 rpm resulted in an increase in the MVF as the friction and compaction of pellets caused their melting. The AE sensor could elucidate the pellet's plastication phenomena caused by friction, compaction of pellets, and melt removal in the twin-screw extruder.

RESUMEN

Starch/polyvinyl alcohol (PVA) degradable straws with different PVA contents were prepared by the twin-screw extrusion method. The results showed that the starch/PVA straws with 40 % PVA (PS4) had the highest dispersion uniformity of starch and PVA to achieve the best compatibility, and the compatibility size was below the micron level. Molecular interactions between starch and 40 % polyvinyl alcohol reached the highest due to the highest strength of hydrogen bonds, hence resulting in the highest texture densities. Consequently, the largest compatibility and molecular interactions significantly improved the mechanical properties and water resistance of PS4. Compared to the starch/PVA straw with 0 % PVA (PS0), swelling volume of PS4 decreased by 45.5 % (4 °C) and 65.2 % (70 °C), respectively. After soaking, the diameter strength increased by 540.1 % (4 °C, 1 h) and 638.7 % (70 °C, 15 min), respectively. Water absorption decreased by 45.3 % (4 °C, 30 min) and 27.6 % (70 °C, 30 min).

Asunto(s)

RESUMEN

As protein-based therapeutics often exhibit a limited stability in liquid formulations, there is a growing interest in the development of solid protein formulations due to improved protein stability in the solid state. We used small-scale (<3 g) ram and twin-screw extrusion for the solid stabilization of proteins (Lysozyme, BSA, and human insulin) in PEG-matrices. Protein stability after extrusion was systematically investigated using ss-DSC, ss-FTIR, CD spectroscopy, SEM-EDX, SEC, RP-HPLC, and in case of Lysozyme an activity assay. The applied analytical methods offered an accurate assessment of protein stability in extrudates, enabling the comparison of different melt extrusion formulations and process parameters (e.g., shear stress levels, screw configurations, residence times). Lysozyme was implemented as a model protein and was completely recovered in its active form after extrusion. Differences seen between Lysozyme- and BSA- or human insulin-loaded extrudates indicated that melt extrusion could have an impact on the conformational stability. In particular, BSA and human insulin were more susceptible to heat exposure and shear stress compared to Lysozyme, where shear stress was the dominant parameter. Consequently, ram extrusion led to less conformational changes compared to TSE. Ram extrusion showed good protein particle distribution resulting in the preferred method to prepare highly-loaded solid protein formulations.

RESUMEN

Plant protein technology is a core area of biotechnology to ease the problem of human protein demand. Plant-based meat based on plant protein technology is a growing concern by global consumers in alleviating environmental pollution, cutting down resources consumption, and improving animal welfare. Plant-based meat simulates the texture, taste, and appearance of animal meat by using protein, lipid, carbohydrate, and other plant nutrients as the main substances. This review summarizes the main components of plant-based meat, processing technology, standard formula, market competition, and formula and texture of future research directions. According to the existing methods of plant-based meat fiber forming, the development process and characteristics of four production processes and equipment of plant-based meat spinning, extrusion, shearing, and 3D printing are emphatically expounded. The processing principles and methods of different processing technologies in plant-based meat production are summarized. The production process and equipment of plant-based meat will pay more attention to the joint production of various processes to improve the defects of plant-based meat production process.

Asunto(s)