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An extruder in India is a motor-driven machine that pushes or pulls pliable materials at a constant speed through a given outline or shape. Materials can include food, plastic, rubber, and even human tissue, to name a few areas of application. In the food industry, for example, an extruder would process cereals, snacks, pasta, vegetables, meat, fish, dairy, and polymer engineering products.
Based on the feeding system and product features, food extruders can be divided into three main categories:
The main component of a single screw extruder is the helical screw that conveys food to the exit die while also applying heat and pressure to expand the food. The helical screw is placed inside a barrel that has heating elements surrounding it. The combination of friction caused by the moving screw and the heat from the surrounding barrel results in the cooking and expansion of the food. As the food moves through the extruder, it also takes on new shapes and textures and finally comes out as puffed snacks. Single-screw extruders are generally used to make simplified food products of grains, nuts, and legumes. They usually have lower prices and are easier to operate.
This Extruder is usually made up of stainless steel material. Three main parts constitute it: the feeder, the conditioner, and the pelletizer. The fish feed raw materials are fed into the extruder through the feeder section. The motor-driven screws inside the feeder section push the raw material to the next part of the extruder, which is the conditioner. In the conditioner's high-temperature and high-pressure environment, steam, oil, or water is added to let the raw material go through a consolidation process before reaching the pelletizer. Because of the consolidation process in the conditioner's high temperature and high pressure, harmful bacteria in the fish feed raw material are killed, making it safer for human consumption. Finally, the consolidated raw material goes into the pelletizer, which has a die and a rotating knife. The consolidated raw material takes its final shape and is cut into small pieces in the pelletizer. A Floating Fish Feed Extruder is an essential part of processing raw material into fish food.
Unlike single screw extruders, which use one screw to push food through the barrel, double-screw extruders use two intermeshing screws that rotate in a fixed barrel. The two contrasting movements help change the shapes of various types of food. Because of their remarkable flexibility, double-screw extruders can change pressure, temperature, and time, which makes transforming food into distinctive shapes and tastes easier. Additionally, their capacity to grow rapidly makes it possible to transform large quantities of food in one location. For processing complex ingredients and making animal feed like pet food, fish food, and malt extract for beer, double-screw extruders are typically employed.
Size:
Industrial-scale food extruder machines are usually about 3m to 4m long. Smaller lab-scale units are about 1m to 2m in length.
Processing capacity:
Food extruder machines can work with anywhere from 1kg to over 500kg of food material per hour.
Screw diameter:
The diameter of the extruder screws can range from about 30mm to over 150mm. Larger screws are used for industrial machines.
Temperature control:
Food extruders typically have 3 to 5 sections along the barrel where heaters and coolers are located. The heating sections are usually about 60cm long.
Die shapes:
Food extruders can have different types of nozzles that produce grain shapes, star shapes, tubular shapes, etc.
Power:
Extruder motors usually consume between 3HP and 40HP of power depending on the size and processing capacity of the machine.
Material:
An industrial food extruder is usually built with stainless steel grade 304 or 316.
Feeding system:
Food extruder machines can have single-screw pre-conditioners, double-screw pre-conditioners, and steam-based feeding systems as advance methods for feeding raw material into the main extruder.
Maintenance of food extruder machine in India
Daily maintenance tasks
Add lubricant to caged wheels, bushings, bearings, and chains in the feeder, gearbox, and driving assemblies as per the lubrication chart. Wipe and clean all oil cups before adding lubrication.
Weekly maintenance tasks
Check to see that all fasteners are tight. Make special note of the screen area and feed section in the extruder where nuts and bolts often become loose. Check to see that all shields and guards are tightly secured.
Monthly maintenance tasks
All belt slack should be adjusted so that the belts do not drag against any component parts. Clean all mill parts, screens, and energy chambers utilizing a vibrating feeder. Change the oil from gearboxes and bearings after they have been cleaned and thoroughly dried.
Quarterly maintenance tasks
Inspect and replace all components in the die area of the food extruder including o-rings, gaskets, die plates, and bolts. If there are any issues with feeding belts or flights in the extrusion barrel, replace them. Examine all electric components including the contactors and electric junction boxes. Also, examine the lubrication lines in the gearbox and motor. Set the clearances as per the factory specifications.
The Indian food processing industry is large and diverse, creating both demand and supply sides of the extruder machine market. Apart from the food segment, the plastic industry is huge as India is the third-largest producer of plastics in the world. Many industrial sectors use these secondary products that originated with the help of extrusion machines. Given the growing industries in India, the market for extrusion machines continues to flourish.
Following are some key usage areas where India uses extrusion machines:Food Texturization
Extruder machines in India are primarily used in the food industry to make food products such as textured protein, snack foods, breakfast cereals, pasta, etc. These food items typically go through high-temperature, short-time processing (HTST), which retains nutrients.
Pet Food and Feed
Various food products meant for pets and farm animals have occurred thanks to extruder machines. These include feed pellets, canned pet food, and aquatic feed. Extruder machines help improve the food's digestion, nutrition, and palatability.
Plastics and Polymer Processing
The plastic extruder machine is essential for India’s plastic and polymer industry. It creates primary products used in the automotive, construction, packaging, and electrical industries, such as plastic sheets, films, pipes, profiles, and containers. India specializes in blown film extrusion, blown film, injection, and blow molding.
Rubber Extrusion
Though a small segment, the rubber extrusion market in India is expected to cross significant levels. This is because many industries rely on rubber for seals, gaskets, and tires.
3D Printing
3D printing in India is about to explode. Extruder machines play a vital role in the production of 3D printing filaments. The monofilament strands are cooled, coiled, and cut into segments to be used in 3D printers. With the growth of DIY market, desktop 3D printers, and education market, the demand for 3D printing filaments is expected to rise.
Wood Plastic Composites WPCs
Wood plastic composites are hybrid materials that contain wood fibers or wood flour, thermoplastics, and other species. WPC can be extruded into various forms, including decking and other outdoor products, building interior parts, automotive components, and more.
The right selection of a suitable industrial food extruder in India is quite essential. Both quality and performance need to be considered so that they can fulfill the specific requirements of the manufacturing unit.
Initially, it is important to understand the main process the machine will be used for, such as the food product being worked upon, the raw material, and the final product's shape and size. Once these details are sorted, they can further narrow down the choices in industrial food extruder machines in India. Understanding the processing requirements can also help outline the preferred machine type.
Now, more technical aspects of the industrial food extruder in India need to be considered, such as the machine's capacity and output. This will ensure that the chosen machine will meet the production demand of the industry.
>It is also important to choose a machine made from food-grade stainless steel; this ensures product safety and hygiene. The main parts, like the screw, barrel, and die, should also be durable and corrosion-resistant so that they can withstand prolonged use.
Since an extruder machine can be quite an investment for the buyer, it is essential to check the energy efficiency of the machine. This includes the motor power and the heating system of the unit. Understand the energy consumption to ensure it is not excessive so that it can help the end user save on costs.
The final adjustment and control of the settings in the extruder are required to process different materials and food items. This flexibility shows the machine's versatility. It's best to go for automatic or semi-automatic machines with programmable control systems, as this will ensure precise control over the extrusion process and ease of operation.
Q1. What is the future of plastic extrusion in India?
A1. The future of plastic extrusion in India looks promising. The increasing demand for plastic products in various industries such as packaging, automotive, construction, and consumer goods is driving the growth of the plastic extrusion market.
Q2. What are the trends in the global extrusion market?
A2. The global extrusion market is witnessing several trends. The adoption of advanced extrusion technologies such as co-extrusion,Multi-screw extrusion and micro-extrusion is increasing.
Q3. What is the impact of extrusion on the environment?
A3. The plastic extrusion process has a negative impact on the environment. However, its environmental impact can be mitigated with proper waste management, recycling, and sustainable practices.
Q4. What are the limitations of plastic extrusion?
A4. Complex shapes variation, tight tolerances, and quality control requirements are limits to the ability of plastic extrusion. Some geometries may be difficult to extrude, particularly those involving deep cavities or sharp angles.
Q5. What are the advantages of using an extruder machine?
A5. The advantages of using an extruder machine include high-dimensional accuracy, low-cost production, and efficient operations. It also hasMass production capability, flexibility to use various materials, and rapid return on investment.
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